NFE 2923 Q CE 001 - A Instruments and Valves Certificates

No.
PO PO15298
SAN JUAN LNG FACILITY
No. DOCUMENT NFE-2923-Q-CE-001
REV. DATE 2023-07-13

METERING SKID
REV. A PAGE 1 OF 1163
INSTRUMENTS AND VALVES CERTIFICATES
DOCUMENT N°:
NFE-2923-Q-CE-001
METERING SKID
A 2023-07-13 Issued for Review / Emitido para Revisión DRS ERM MVG
REV. DATE REVISION ISSUED BY CHECKED BY APPROVED BY

No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
INDEX
1. ULTRASONIC FLOWMETER AND FLOW ALIGNER........................................................................... 3
2. RTD AND TERMOWELL ................................................................................................................... 683
3. VALVES – 3/4" .................................................................................................................................. 690
4. VALVES – 8” 600# ............................................................................................................................ 694
5. VALVE WITH ACTUATOR – 8” 600# ................................................................................................ 742
6. FLOW COMPUTER .......................................................................................................................... 932
No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
1. ULTRASONIC FLOWMETER AND FLOW ALIGNER

Sigma Sensor S.A. de C.V.
Colima 49, Valle Ceylán Tlalnepantla
Edo de México C.P. 54150
Tel: 55 53658200, 63645537
www.sigmasensor.com.mx
INDICE
1. MEDIDOR ULTRASÓNICO
1.1 Ficha técnica y dibujos dimensionales
1.2 Reportes de pruebas
1.3 Certificados de conformidad y calidad del equipo
1.4 Carta garantía
1.5 Catálogo
1.6 Manuales del USM GT400
1.6.1 Manual Modbus
1.6.2 Manual de Operaciones
1.6.3 Manual de Software
1.6.4 Manual de Servicio
1.7 Certificado de calibración
2. ACONDICIONADOR DE FLUJO
2.1 Hoja de datos y certificado de material
2.2 Dibujo dimensional
2.3 Certificado de conformidad
2.4 Certificado de inspección / Reporte dimensional
2.5 Carta garantía
2.6 Catálogo
2.7 Manual de instalación y operación
Tel: 55 53658200, 63645537
1. MEDIDOR ULTRASÓNICO
1.1 Ficha técnica y dibujos

dimensionales
13 Technical specifications
Approved measuring range according to MID 181

13.4 Type plate 182
13.4.1 Type plate ATEX / IECEx 183
178
13.4.2 Type plate NEC (CSA) 184
13.5 Weights and dimensions 184
13.5.1 NEC (CSA) 185
13.5.2 ATEX / IECEx 186
Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle
konnte nicht gefunden werden. Fehler! Textmarke nicht definiert.
13.6 Inner diameter of connecting spool pieces 189
13.7 Official seal diagram 192
13.7.1 Type plate 192
13.7.2 Ultrasonic electronics 193
13.7.3 Ultrasonic gas meter 195
13.8 Transducer types 197
13.1 Performance data

Power supply Measuring element: 24 VDC
Power consumption Measuring element: typical 7-9 W;

with heated display, typically 12 W;
max. 15 W
Protection class IP 66
Interfaces RS 485 0 (for RMGViewUSM): 9600 / 19200 / 38400 / 57600 Baud
RS 485 1 9600 / 19200 / 38400 / 57600 Baud

(for Modbus ASCII, RTU or Flow
Computer)
RS 485 2 9600 / 19200 / 38400 / 57600 Baud

Computer)
Manual USM GT400 · EN10 · May 2021

Current output Umax= 16 V Load resistance: max. 400 Ω
Pulse output Umax= 30 V fmax= 5 kHz

179
Sensor frequency 200 kHz (DN100 / 4“ and DN150 /
6“) or 120 kHz (DN200 / 8“ and
larger)
Flow velocity -40 to + 40 m/s
Gas temperature range -40 C to +80 C

(-40 F to 176 F)
Maximum operating observe the details on the type

pressure plate.
Ambient conditions -40 C to +55 C

(-40 F to 131 F)

13.2 Approved gas types

The device must only be operated with the following gas types.
180 Safe operation is only guaranteed with the gas types specified:
• gases of class 1
The components of the gases must be within the concentration limits for test
gases according to EN 437:2009 or similar national standards.
The national standards of other countries demand similar gas type specifications.
Notice
In general, the gas to be measured must not build any condensates in the
operating range of the USM (flow, pressure and temperature range) and
must be free of corrosive and aggressive components, liquids and solids.
In case of deviating conditions a suitable operation has to be agreed with
the RMG service.
13.2.1 Suitability and safety for natural gas containing H2

The USM GT400 can be used in hydrogen-containing natural gas. There are no
safety-related concerns for this use.
Notice
In accordance with the German TR-G19 – the USM GT400 is suitable and
approved for use in custody transfer applications –
in natural gases with a maximum hydrogen content of 10 mol-% without a
loss of the accuracy.
Since there are currently no certified test rigs in Germany to calibrate meters with
higher hydrogen-containing gases, an accuracy above 10 mol-% cannot be tested
or certified.
Not custody transfer measurements are of course possible in natural gases with a
hydrogen content above 10 mol%. However, a reduced measuring range must be
taken into account if applicable. Please contact RMG for further information.

13.3 Approved measuring range according to MID

Nominal diameter Measuring range (m³/h) / (acfh) Extended measuring range (m³/h) /
(acfh) *1 181
mm inches Qmax Qmin Qmin
l780 3 77650 / 23000 5 / 175 (2,5 / 88) abi in preparation
100 4 1000 / 35320 8 / 208 (4 / 140) abcd in preparation
150 6 2400 / 84760 20 / 700 (10 / 350) bci in preparation
200 8 4200 / 148350 32 / 1130 16 / 560
250 10 6600 / 233100 50 / 1750 25 / 880
300 12 9400 / 332000 70 / 2450 35 / 1240
350 12 11400 / 403000 I90 / 3180 45 / 1590
400 16 15000 / 530000 120 / 4230 60 / 2120
450 12 19000 / 670700 150 / 1750 75 / 2650
500 20 23500 / 830000 180 / 6350 90 / 3180
600 24 34000 / 1201000 260 / 9175 130 / 4590
650 26 45000 / 1588000 340 / 12010 170 / 6000
700 28 52000 / 1834800 420 / 14335 210 / 7400
750 30 60000 / 2115000 460 / 16230 320 / 8100
800 32 68000 / 2399000 550 / 19250 550 / 19250
900 36 86000 / 3030000 700 / 24500 700 / 24500
1000 40 108000 / 3800000 850 / 29750 850 / 29750
*1 The extended measuring range only effects Qmin. It can be

used at pressures above p ≥ 4 bar / p ≥ 60 psi.
For meters with a full bore inner diameter according to Di-2 in the table at the end of chapter 13.5,
the table values for Qmin and Qmax are to be increased by a factor of 1.1.
The number of acoustic paths is 6 for all variants.

13.4 Type plate
182
1 Type plate
Fig. 13.1: Position of the type plate
The following details can be found on the type plate:

13.4.1 Type plate ATEX / IECEx
183
Fig. 13.2: Type plate ATEX / IECEx

13.4.2 Type plate NEC (CSA)
184
Fig. 13.3: Type plate NEC (CSA / FM)
13.5 Weights and dimensions
In this chapter you will receive information on the dimensions for the versions NEC
and ATEX /IECEx.
ANSI pressure stages: The flange connecting dimensions comply with the
standard ASME B 16.5.
DIN pressure stages: The flange connecting dimensions comply with the
standard DIN EN 1092.

13.5.1 NEC (CSA)
185
1 Front view
2 Side view
3 Top view
Space requirements for sensor exchange
S0: at non pressure flowmeter
S1: Flowmeter under pressure (with special tool)
Fig. 13.4: Weights and dimensions NEC
The version NEC and version ATEX / IECEx have identical dimensions. The table
of the versions can be found on the following location:
Fehler! Verweisquelle konnte nicht gefunden werden.188

13.5.2 ATEX / IECEx
186
1 Front view
2 Side view
3 Top view

187
1 Threaded blind hole

Fig. 13.6: Weights and dimensions DN80
Due to the different sizes of the individual components, the device in DN80 is
shown separately.

Dimensions - Version NEC and ATEX / IECEx

DN L L Di-1 Di-2 T1 H2 B2 B2 SO2 S12 Weight3 Weight3
ANSI900 ANSI 900 ANSI 900
188 80 240 - 73.7 77.9 82.5 450 450 - 225 - 75 -

(3) (9.5) (2.9) (3.07) (3.25) (17.72) (17.72) (8.86) (165)
100 300 400 97.2 102.3 107.1 330 595 415 250 - 100 125
(4) (11.81) (15.75) (3.83) (4.03) (4.22) (12.99) (23.43) (16.34) (9.84) (220) (276)
150 450 450 146.4 154.1 159.3 340 470 470 300 - 160 180
(6) (17.72) (17.72) (5.76) (6.07) (6.27) (13.39) (18.5) (18.5) (11.81) (353) (397)
200 600 800 193.7 202.7 207.3 360 530 565 375 1520 300 380
(8) (23.62) (31.5) (7.63) (7.98) (8.16) (14.17) (20.87) (22.24) (14.76) (59.84) (661) (838)
250 750 1000 242.8 254.5 260.4 380 650 615 400 1550 450 560
(10) (29.53) (39.37) (9.56) (10.02) (10.25) (14.96) (25.59) (24.21) (15.75) (61.02) (992) (1235)
300 900 900 288.8 303.2 309.7 395 700 660 425 1575 550 670
(12) (35.43) (35.42) (11.37) (11.94) (12.19) (15.55) (27.56) (25.98) (16.73) (62.01) (1213) (1477)
350 1050 - 284-348 333.5 - 420 730 - 450 1600 700 -

(11.2-13.7)
(14) (41.34) (14.31) (16.54) (28.74) (17.72) (62.99) (1543)
400 1200 1200 363.5 381.0 292.2 500 750 750 475 1620 950 1050
(16) (47.24) (47.24) (14.31) (15.0) (11.50) (19.69) (29.53) (29.53) (18.70) (63.78) (2094) (2315)
450 1350 - 367-449 428.7 - 530 820 - 500 1650 1000 -

(16) (53.15) (14.4-17.7) (16.88) (20.87) (32.28) (19.69) (64.96) (2205)
500 1500 1500 455.6 477.8 493.8 550 900 860 525 1670 1500 1650
(20) (59.06) (59.06) (17.94) (18.81) (19.44) (21.65) (35.43) (31.5) (20.67) (65.75) (3307) (3638)
600 1200 1500 547.7 574.7 595.8 550 1000 1045 600 1725 1550 2500
(24) (47.24) (59.06) (21.56) (22.63) (23.46) (21.65) (39.37) (41.14) (23.62) (67.91) (3417) (5512)
650 1200 - 632-648 - 680 1040 - 610 1740 1650 -

(24.9-25-5)
(26) (47.24) (26.77) (40.94) (24.02) (68.5) (3638)
700 1200 - 679-699 - 700 1050 - 615 1750 1800 -

(26.8-27.5)
(28) (47.24) (27.56) (41.34) (24.21) (68.9) (3968)
750 1500 - 730-749 - 800 1100 - 650 1780 1900 -

(28.8-29.5)
(30) (59.06) (31.5) (43.31) (25.59) (70.08) (4189)
800 1500 - 778-800 - 850 1150 - 675 1800 2200 -

(30.6-31.5)
(32) (59.06) (33.46) (45.28) (26.57) (70.87) (4850)
900 1500 - 876-902 - 1000 1300 - 750 1875 2600 -

(34.5-35.5)
(36) (59.06) (39.37) (51.18) (29.53) (73.82) (5732)
1000 1500 - 978-1000 - 1200 1400 - 800 1930 3000 -

(38.5-39.4)
(40) (59.06) (47.24) (55.12) (31.5) (75.98) (6614)
Dimensions are in mm (inch); weight in kg (lbs)

The given values are for pressure level ANSI 600, respectively ANSI900 (speci-
fied).

Di-1 = inner diameter (tapered, schedule 80)

Di-2 = inner diameter full bore (schedule 40)
1 189
Maximum diameter at the flange, depending on tapering.
2
Approximate dimension.
3
Approximate values. Weights can vary due to casting tolerances.
An angle of 7° is used for tapering.
13.6 Inner diameter of connecting spool pieces

Connection diameter at tapering of the USM GT400
(= inner diameter for inlet and outlet spool pieces)
Maximum deviation from meter to piping:
+/- 1% acc. MID
For calibrated spool pieces belonging to the measuring instrument, the deviation
may be up to +/- 3%. For the full-bore version, generally +5% / -2% are allowed re-
gardless of the use during calibration.
The blue marked inner diameters for every ANSI pressure rating are to be under-
stood as a recommendation if no inner diameter is specified by the customer.
Meter Pressure Inner Min. ID Max. ID Schedule

size class Diameter of spools of spools
in DN
/ Inch
80 ANSI150 73,7 73 74,4 80
80 ANSI150 77,9 77,2 78,7 40
80 ANSI300 73,7 73 74,4 80
80 ANSI300 77,9 77,2 78,7 40
80 ANSI600 73,7 73 74,4 80
80 ANSI600 77,9 77,2 78,7 40
100 ANSI150RF 97.2 96.2 98.2 80
100 ANSI150RF 102.3 101.3 103.3 40
100 ANSI300RF 97.2 96.2 98.2 80
100 ANSI300RF 102.3 101.3 103.3 40
100 ANSI600RF 97.2 96.2 98.2 80
100 ANSI600RF 102.3 101.3 103.3 40
100 ANSI600RTJ 97.2 96.2 98.2 80
100 ANSI600RTJ 102.3 101.3 103.3 40
150 ANSI150RF 146.4 144.9 147.9 80
150 ANSI150RF 154.1 152.6 155.6 40


in DN
/ Inch
190 150 ANSI300RF 146.4 144.9 147.9 80
150 ANSI300RF 154.1 152.6 155.6 40
150 ANSI600RF 146.4 144.9 147.9 80
150 ANSI600RF 154.1 152.6 155.6 40
150 ANSI600RTJ 146.4 144.9 147.9 80
150 ANSI600RTJ 154.1 152.6 155.6 40
200 ANSI150RF 193.7 191.8 195.6 80
200 ANSI150RF 198.5 196.5 200.5 60
200 ANSI150RF 202.7 200.7 204.7 40
200 ANSI300RF 193.7 191.8 195.6 80
200 ANSI300RF 198.5 196.5 200.5 60
200 ANSI300RF 202.7 200.7 204.7 40
200 ANSI600RF 193.7 191.8 195.6 80
200 ANSI600RF 198.5 196.5 200.5 60
200 ANSI600RF 202.7 200.7 204.7 40
200 ANSI600RTJ 193.7 191.8 195.6 80
200 ANSI600RTJ 198.5 196.5 200.5 60
200 ANSI600RTJ 202.7 200.7 204.7 40
250 ANSI150RF 242.8 240.4 245.2 80
250 ANSI150RF 247.6 245.1 250.1 60
250 ANSI150RF 254.4 251.9 256.9 40
250 ANSI300RF 242.8 240.4 245.2 80
250 ANSI300RF 247.6 245.1 250.1 60
250 ANSI300RF 254.4 251.9 256.9 40
250 ANSI600RF 242.8 240.4 245.2 80
250 ANSI600RF 247.6 245.1 250.1 60
250 ANSI600RF 254.4 251.9 256.9 40
250 ANSI600RTJ 242.8 240.4 245.2 80
250 ANSI600RTJ 247.6 245.1 250.1 60
250 ANSI600RTJ 254.4 251.9 256.9 40
300 ANSI150RF 288.8 285.9 291.7 80
300 ANSI150RF 295.3 292.3 298.3 60
300 ANSI150RF 303.2 300.2 306.2 40
300 ANSI300RF 288.8 285.9 291.7 80
300 ANSI300RF 295.3 292.3 298.3 60
300 ANSI300RF 303.2 300.2 306.2 40
300 ANSI600RF 288.8 285.9 291.7 80
300 ANSI600RF 295.3 292.3 298.3 60
300 ANSI600RF 303.2 300.2 306.2 40
300 ANSI600RTJ 288.8 285.9 291.7 80


in DN
/ Inch
300 ANSI600RTJ 295.3 292.3 298.3 60 191
300 ANSI600RTJ 303.2 300.2 306.2 40
400 ANSI150RF 363.5 359.9 367.1 80
400 ANSI150RF 373.1 369.4 376.8 60
400 ANSI150RF 381 377.2 384.8 40
400 ANSI300RF 363.5 359.9 367.1 80
400 ANSI300RF 373.1 369.4 376.8 60
400 ANSI300RF 381 377.2 384.8 40
400 ANSI600RF 363.5 359.9 367.1 80
400 ANSI600RF 373.1 369.4 376.8 60
400 ANSI600RF 381 377.2 384.8 40
400 ANSI600RTJ 363.5 359.9 367.1 80
400 ANSI600RTJ 373.1 369.4 376.8 60
400 ANSI600RTJ 381 377.2 384.8 40
500 ANSI150RF 455.6 451.0 460.2 80
500 ANSI150RF 466.8 462.1 471.5 60
500 ANSI150RF 477.8 473.0 482.6 40
500 ANSI300RF 455.6 451.0 460.2 80
500 ANSI300RF 466.8 462.1 471.5 60
500 ANSI300RF 477.8 473.0 482.6 40
500 ANSI600RF 455.6 451.0 460.2 80
500 ANSI600RF 466.8 462.1 471.5 60
500 ANSI600RF 477.8 473.0 482.6 40
500 ANSI600RTJ 455.6 451.0 460.2 80
500 ANSI600RTJ 466.8 462.1 471.5 60
500 ANSI600RTJ 477.8 473.0 482.6 40
600 ANSI300RF 547.7 542.2 553.2 80
600 ANSI300RF 560.4 554.8 566.0 60
600 ANSI300RF 574.6 568.9 580.3 40
600 ANSI600RF 547.7 542.2 553.2 80
600 ANSI600RF 560.4 554.8 566.0 60
600 ANSI600RF 574.6 568.9 580.3 40

13.7 Official seal diagram

In this chapter you will receive information at which location the official seals are
attached to the device.
192
The device must not be used for a calibrated operation if the official seal is
broken.
13.7.1 Type plate
1 Seal
Fig. 13.7: Position of the official seal on the type plate

13.7.2 Ultrasonic electronics
193
Representation of the device with DN 150 (6“)

1 Side view
2 Top view
3 Seal
Fig. 13.8: Official seal diagram according to AEX / IECEx

194

1 Side view
2 Top view
3 Seal
Fig. 13.9: Official seal diagram according to NEC

13.7.3 Ultrasonic gas meter
195
Fig. 13.10: Devices DN 80 (3”), DN 100 (4“) and DN 150 (6“)

196
1 Front view 2 Side view

3 Top view 4 View without cover
5 Seal 6 Type plate
Fig. 13.11: Devices DN 200 (8 ") and larger
Seals of the measuring element of type USM-GT-400
Valid for sizes DN 200 upwards
Representation: DN 200

13.8 Transducer types

Danger
197
Mortal danger from incorrect replacement of the transducer
If transducers of a device under pressure are not changed correctly, this may
cause an explosion. Escaping gas mixtures may lead to intoxication.
• Change the transducer only if you have obtained a training from RMG for
this activity.
• Observe the separate service instruction for changing the transducer.
1 TNG 10-CP / -CHP

Fig. 13.12: Trancducer type TNG 10-CP / -CHP
1 TNG 20-SP / -SHP

Fig. 13.13: Trancducer type TNG 20-SP / -SHP

Transducer Operating fre- Operating pressure Ambient temperature Gas temper-

type quency (kHz) range bar (psi) °C (°F) ature °C (°F)
198
TNG 10-CP 120 1–150 -40 to +55 °C to +80 °C
(14,5 to 2175.57) (55 to 131 °F) (176 °F)
TNG 10-CHP 120 1–300 -40 to +55 °C to +80 °C

(14,5 to 4351.13) (55 to 131 °F) (176 °F)
TNG 20-SP 200 1–150 -40 to +55 °C to +80 °C

(14,5 to 2175.57) (55 to 131 °F) (176 °F)
TNG 20-SHP 200 1–300 -40 to +55 °C to +80 °C

(14,5 to 4351.13) (55 to 131 °F) (176 °F)

Tel: 55 53658200, 63645537
1.2 Reportes de pruebas

Tel: 55 53658200, 63645537
1.3 Certificados de conformidad y

calidad del equipo
18 USM GT400 Attachment
251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

APPROVAL No. - N° D’APPROBATION
AG-0622
NOTICE OF APPROVAL AVIS D’APPROBATION
Issued by statutory authority of the Minister of Émis en vertu du pouvoir statutaire du ministre de
Industry for: l’Industrie pour:
TYPE OF DEVICE TYPE D’APPAREIL
Flow Meter - Ultrasonic Compteurs de débit - Ultrasonore
APPLICANT REQUÉRANT
RMG Messtechnik GmbH

Otto-Hahn-Strasse 5
Butzbach, Hessen, Germany
35510
MANUFACTURER FABRICANT

Otto-Hahn-Strasse 5
Butzbach, Hessen, Germany
35510
MODEL(S) / MODÈLE(S) RATING / CLASSEMENT
USM-GT-400 Meter Size \ Taille Maximum Flow Rate [m³/h]

du compteur \ Débit maximum [m³/h]
DN 100/4" 1000
DN 150/6" 2400
DN 200/8" 4200
DN 250/10" 6600
DN 300/12" 9400
DN 350/14" 11 400
DN 400/16" 15 000
DN450/18" 19 000
DN 500/20" 23 500
DN 600/24" 34 000
DN650/26" 45 000
DN700/28" 52 000
DN750/30" 60 000
DN800/32" 68 000
DN900/36" 86 000
DN1000/40" 108 000
Page 1 of/de 12 Project/Projet: AP-AG-13-0045

AG-0622
NOTE: This approval applies only to meters, the REMARQUE: Cette approbation ne vise que les
design, composition, construction and performance compteurs dont la conception, la composition, la
of which are, in every material respect, identical to construction et le rendement sont identiques, en
that described in the material submitted, and that tout point, à ceux qui sont décrits dans la
are typified by samples submitted by the applicant documentation reçue et pour lesquels des
for evaluation for approval in accordance with échantillons représentatifs ont été fournis par le
sections 13 and 14 of the Electricity and Gas requérant aux fins d’évaluation, conformément aux
Inspection Regulations. The following is a articles 13 et 14 du Règlement sur l’inspection de
summary of the principal features only. l’électricité et du gaz. Ce qui suit est une brève
description de leurs principales caractéristiques.
SUMMARY DESCRIPTION : DESCRIPTION SOMMAIRE :
The USM-GT-400 is a six-path ultrasonic meter. Le compteur USM-GT-400 est un compteur à

ultrasons à six trajets.
Main Components Éléments principaux
Spool Piece Bobine

The spool piece consists of a pressure containing La bobine est composée d’une section centrale sous
spool containing 12 transducer ports and a pressure pression dotée de 12 ports de transducteur et d’une
tap. prise de pression.
Transducers Transducteurs
The transducers are aligned in pairs that alternately Les transducteurs sont alignés en paires qui, en
transmit and receive ultrasonic pulses. The alternance, transmettent et reçoivent des
following transducer models are approved: impulsions d’ultrasons. Les modèles de
Transducer Operating Operating transducteurs suivants sont approuvés :
Type Frequency Pressure Range Type de Fréquence Plage de pression
TNG 10-CP 1 to 150 bar transducteur de service de service
120 kHz
TNG 10-CHP 1 to 300 bar TNG 10-CP 1 à 150 bars
120 kHz
TNG 20-LP 1 to 150 bar TNG 10-CHP 1 à 300 bars
TNG 20-LHP 1 to 300 bar TNG 20-LP 1 à 150 bars
200 kHz
TNG 20-SP 1 to 150 bar TNG 20-LHP 1 à 300 bars
200 kHz
TNG 20-SHP 1 to 300 bar TNG 20-SP 1 à 150 bars
TNG 20-SHP 1 à 300 bars
Signal Processing Unit (SPU) Unité de traitement des signaux (UTS)

The SPU is installed in an encapsulated housing L’UTS est installée dans un boîtier encapsulé
mounted on the spool piece. The SPU also contains monté sur la bobine. L’UTS contient également un
a display. affichage.

AG-0622
Approved Metrological Functions Fonctions métrologiques approuvées
The following functions are approved; additional Les fonctions ci-dessous sont approuvées; toute
functions that are present on the device but not autre fonction du dispositif ne figurant pas dans la
listed are NOT approved and may only be used for liste N’est PAS autorisée et ne peut être utilisée
informational purposes, diagnostics and/or process qu’à titre informatif, et qu’à des fins de diagnostic
control. et/ou de contrôle de processus.
Bi-Directional Flow Measurement Mesure de l’écoulement bidirectionnel

The meters can be used for bidirectional volume Les compteurs peuvent être utilisés pour mesurer
flow measurement. There are separate correction l’écoulement bidirectionnel. Il y a des facteurs de
factors for each direction. correction distincts pour chaque sens.
Approved Outputs Sorties approuvées
Frequency Outputs, Flow Rate Sorties de fréquence, débit

Two frequency outputs are available for the flow Il y a deux sorties de fréquence pour l’écoulement
and two digital outputs are available for flow et deux sorties numériques pour le sens de
direction. l’écoulement.
Digital communication, Cumulative Volume Communication numérique, volume cumulatif

The meters also provide independent volume Les compteurs fournissent aussi des totalisateurs de
counters for each direction which can be read, by volume indépendants pour chaque sens qui peuvent
an approved and compatible flow computer, using être lus par un débitmètre-ordinateur compatible et
the MODBUS protocol (ASCII or RTU) through a approuvé, à l’aide du protocole MODBUS (ASCII
RS-485 serial port. ou RTU) par un port série RS-485.
Interchangeable Transducers Transducteurs interchangeables

The following transducers are approved to be Les transducteurs suivants sont approuvés pour être
exchanged without requiring reverification: interchangés sans revérification :
• TNG 10-CP • TNG 10-CP
• TNG 10-CHP • TNG 10-CHP
• TNG 20-SP • TNG 20-SP
• TNG 20-SHP • TNG 20-SHP
Interchangeable Electronics Composants électroniques interchangeables

The circuit boards in the SPU are approved to be Les cartes de circuits imprimés dans l’UTS sont
exchanged without requiring reverification. approuvées pour être interchangées sans
revérification.

AG-0622
Meter Correction Correction du compteur

The meter curve can be corrected using one of two La courbe du compteur peut être corrigée au
linearization methods: moyen de l’une des deux méthodes de linéarisation
suivantes :
Polynomial Correction Based on Flow Rate
The following equation is used to correct the meter Correction polynomiale fondée sur le débit
curve, where F2 is the deviation from the error L’équation suivante est utilisée pour corriger la
curve. courbe du compteur lorsque F2 est l’écart par
rapport à la courbe d’erreur.
The meter allows for constants in each direction.

The constants for the forward direction are stored Le compteur permet d’enregistrer des constantes
in coordinates G-02 though G-06 and constants for dans chaque sens. Les constantes pour le sens
the reverse direction in coordinates G-10 through normal sont les coordonnées G-02 à G-06 et celles
G-14. pour le sens inverse sont les coordonnées G-10 à
G-14.
Linear Interpolation Flow Rate Correction Correction du débit par interpolation linéaire
This method linearly interpolates between flow rate Cette méthode permet d’effectuer une interpolation
points entered into independent tables for each linéaire entre les points de débit entrés dans les
flow direction. Each table can contain up to 12 tableaux correspondant à chaque sens
interpolation points consisting of meter error d’écoulement. Chaque tableau peut contenir
versus flow rate. The forward direction table is jusqu’à 12 points d’interpolation, soit l’erreur du
stored in coordinates G-20 through G-43 and the compteur par rapport au débit. Les coordonnées du
reverse direction table is stored in coordinates G-44 tableau pour le sens normal sont les coordonnées
through G-67. G-20 à G-43 et celles pour le sens inverse sont les
coordonnées G-44 à G-67.
Software/Firmware Logiciel/Micrologiciel
The following software versions are approved: Les versions des logiciels suivants sont
approuvées :
M32 1.520
Matrix \ Matrix 146
DSP \ DSP 1.520
FPGA \ FPGA 1.520
Combined M32 and Matrix \ M32 et Matrix combinés 1.520-146
Specifications Caractéristiques
Operating temperature range Plage de températures de service

• Manufacturer specified (-40 to +55) °C • Prescrite par le fabricant (-40 à +55) °C
• Approved (-40 to +55) °C • Approuvée (-40 à +55) °C

AG-0622
Power Supply Alimentation électrique

• Input Voltage 19.2 to 26.4 Vdc • Tension d’entrée 19,2 à 26,4 V (c.c.)
• Typical Current 0.5 A • Courant d'entrée 0,5 A
• Typical Power Consumption 12 W • Consommation d’électricité 12 W
Frequency Outputs Sorties de fréquence

• Type Namur or Open Collector • Type Namur ou collecteur
• Maximum Frequency 5 kHz ouvert
• Fréquence maximale 5 kHz
Marking Requirements Exigences relatives au marquage
The USM GT 400 is marked with the following Les renseignements suivants sont inscrits sur la
information on the nameplate: plaque signalétique du modèle USM GT 400 :
• manufacturer’s name, • nom du fabricant;
• model designation, • désignation du modèle;
• serial number, • numéro de série;
• departmental approval number, • numéro d’approbation du Ministère;
• nominal input voltage, • tension d’entrée nominale;
• nominal power consumption and input • consommation d’énergie nominale et
current, courant d’entrée;
• maximum flow rate (at line conditions), • débit maximal (aux conditions ambiantes);
• inside meter diameter, • diamètre intérieur du compteur;
• maximum operating pressure, • pression de service maximale;
• pulse weight • poids d’impulsion.
The direction of positive flow is designated by an Le sens de l’écoulement vers l’avant est désigné
arrow on the electronics housing. par une flèche sur le boîtier des composants
électroniques.
All other markings are accessible through the Tous les autres renseignements sont accessibles par
USE-09 user interface. l’interface de l’utilisateur USE-09.
Sealing Provisions Dispositifs de scellage
The calibration and service switches must be set to Les interrupteurs d’étalonnage et de service
the closed position. Figure 3 depicts the calibration doivent être réglés en position fermée. La Figure 3
switch in the open position and the service switch montre l’interrupteur d’étalonnage en position
in the closed position. ouverte et l’interrupteur de service en position
fermée.

AG-0622
The access cover of the electronics housing is Le couvercle d’accès du boîtier des composants
sealed using a conventional seal though a capstan électroniques est scellé à l’aide d’un sceau
screw securing the access cover and through two classique constitué d’une vis à tête percée pour
holes in the mounting bracket for the electronics maintenir en place le couvercle d’accès et de deux
housing. Refer to Figure 4. trous dans le support de fixation pour le boîtier des
composants électroniques. Se reporter à la Figure
4.
The transducers for meter sizes DN150/6" and Les transducteurs des compteurs de
smaller are sealed by using two conventional seals; taille DN150/6 po et moins sont scellés au moyen
one on each side of the meter. Each seal passes de deux sceaux classiques : un de chaque côté du
through four capstan screws as depicted in Figure compteur. Chaque sceau passe dans quatre vis à
6. tête percée, comme il est illustré à la Figure 6.
The transducers for meter sizes DN200/8" and Les transducteurs des compteurs de
larger are sealed by using four conventional seals; taille DN200/8 po et plus sont scellés à l’aide de
two on each side of the meter. Each seal passes quatre sceaux classiques : deux de chaque côté du
through four capstan screws as depicted in Figure compteur. Chaque sceau passe dans quatre vis à
5. tête percée, comme il est illustré à la Figure 5.
Installation Requirements Exigences en matière d’installation
Low Flow Cut-off Fonction d’arrêt bas débit

The required low flow cut-off flow rate is entered Le débit établi pour la fonction d’arrêt bas débit est
at coordinate D-09 (Qm lower limit). entré à la coordonnée D-09 (limite inférieure
de Qm).
Meter Installation – Single Meter Installation de compteur – un seul compteur

The inlet and outlet piping requirements without a Les exigences relatives aux tuyaux d’entrée et de
flow conditioner are described below. sortie sans tranquilliseur d’écoulement sont
décrites ci-après.
Unidirectional Operation
The inlet piping shall have a minimum length of 10 Fonctionnement unidirectionnel
pipe diameters. The outlet piping shall have a Le tuyau d’entrée doit avoir une longueur minimale
minimum length of 3 pipe diameters. The correspondant à 10 diamètres de tuyau. Le tuyau de
temperature probe is located 1.5 to 5 pipe sortie doit avoir une longueur minimale
diameters downstream of the meter. correspondant à 3 diamètres de tuyau. La sonde de
température doit être située entre 1,5 et 5 diamètres
de tuyau en aval du compteur.
Bidirectional Operation Fonctionnement bidirectionnel

Both the inlet and outlet piping shall have a Les tuyaux d’entrée et de sortie doivent avoir une
minimum length of 10 pipe diameters. The longueur minimale correspondant à 10 diamètres
temperature probe shall be located 3 to 5 pipe de tuyau. La sonde de température doit être située
diameters from the meter on one of the pipes. entre 3 et 5 diamètres de tuyau du compteur situé
sur l’un des tuyaux.

AG-0622
Meter Installation – Series Connection of Two Installation de compteurs – Branchement en série

Meters de deux compteurs
The meter can be installed in series with either a Le compteur peut être installé en série avec un
meter of this type or an ultrasonic meter of a compteur du même type ou avec un compteur à
different type. The meters can also be in a direct ultrasons d’un type différent. Les compteurs
series connection (meters are connected flange to peuvent aussi être branchés directement en série
flange). The inside diameter of the two meter (les compteurs sont reliés bride à bride). Le
bodies shall not differ by more than ±1.0% of the diamètre intérieur des deux corps des compteurs ne
smaller of the two. doit pas différer de plus de ± 1,0 % de la plus petite
des deux valeurs.
The installation requirements outlined in the Les exigences relatives à l’installation expliquées à
section “Meter Installation – Single Meter” must be la section « Installation de compteur – un seul
met for each meter used for custody transfer except compteur » doivent être respectées pour chaque
for direct series connections used in a compteur utilisé à des fins de comptage
unidirectional operation. divisionnaire à l’exception des branchements
directs en série utilisés pour un fonctionnement
unidirectionnel.
Unidirectional Operation – Direct Series Connection Fonctionnement unidirectionnel – branchement direct

Where the upstream (first) meter is used for en série
custody transfer, the temperature probe for the Lorsque le compteur en amont (premier compteur)
upstream (first) meter shall be located 1.5 to 5 pipe est utilisé à des fins de comptage divisionnaire, la
diameters downstream of the downstream flange of sonde de température de ce compteur doit être
the downstream (second) meter située à une distance de 1,5 à 5 diamètres de tuyau
après la bride du compteur en aval (deuxième
compteur).
Verification Requirements Exigences en matière de vérification
Series Connection of Two Meters Branchement en série de deux compteurs

If the straight piping between the two meters is less Si le tuyau droit entre les deux compteurs a une
than 10 pipe diameters or a direct series connection longueur correspondant à moins de 10 diamètres de
is used, the meters must be verified together. tuyau ou si un branchement direct en série est
utilisé, les compteurs doivent être vérifiés
ensemble.
If the straight piping between the two meters Si le tuyau droit entre les deux compteurs contient
contains a temperature sensor for the upstream un capteur de température pour le compteur en
(first) meter and has a length of at least 10 pipe amont (premier compteur) et qu’il a une longueur
diameters the meters may be verified separately. correspondant à au moins 10 diamètres de tuyau,
les compteurs peuvent être vérifiés séparément.

AG-0622
Mandatory Configuration Parameters Setting

The following configuration parameters must be
set:
Coordinate \ Label \ Étiquette Setting \ Description \ Description

Coordonnée Réglage
D-08 vw lower limit 0.1 Flow velocity cut-off of the weighted corrected flow
velocity. \ Seuil de coupure pour le calcul de la vitesse
d’écoulement corrigée et pondérée.
E-01 USE09 working USE09C Operating mode of the electronics. \ Mode de
mode fonctionnement des composants électroniques.
E-02 path select 11111100 Selection which of the 8 paths are used. \ Sélection du
trajet utilisé parmi les 8 disponibles.
E-03 max. path RV 2 Maximum number of failing paths without error
message (only warning). \ Nombre maximal de
défaillances de trajets sans l’affichage d’un message
d’erreur (avertissement seulement).
E-04 fault time 1 Time after that the error message is shown. \ Temps
écoulé avant l’affichage du message d’erreur.
E-05 error per cent 20 Minimum percentage of valid values before an error
message is shown. \ Pourcentage minimal de valeurs
valides avant l’apparition d’un message d’erreur.
F-01 Basic correction OFF Velocity linearization. / Linéarisation de la vitesse.
H-03 fo corr. factor 1 Correction factor. / Facteur de correction.
H-10 fo mode ON Mode for the frequency outputs (only if the frequency
output is used). \ Mode pour les sorties de fréquence
(seulement si la sortie de fréquence est utilisée).
AK-29 const w1 0.125 Weighing factor for path 1. \ Facteur de pondération
pour le trajet 1.
AL-29 const w2 0.125 Weighing factor for path 2. \ Facteur de pondération
pour le trajet 2.
AM-29 const w3 0.250 Weighing factor for path 3. \ Facteur de pondération
pour le trajet 3.
AN-29 const w4 0.250 Weighing factor for path 4. \ Facteur de pondération
pour le trajet 4.
AO-29 const w5 0.125 Weighing factor for path 5. \ Facteur de pondération
pour le trajet 5.
AP-29 const w6 0.125 Weighing factor for path 6. \ Facteur de pondération
pour le trajet 6.

AG-0622
Firmware Micrologiciel
The firmware version numbers are stored in the Voici les coordonnées des numéros de versions
following coordinates: des micrologiciels :
Firmware Coordinate Label Micrologiciel Coordonnée Étiquette

M32 AF-78 version M32 AF-78 version
Matrix AF-80 Matrix version Matrix AF-80 version Matrix
DSP AF-81 DSP version DSP AF-81 version DSP
FPGA AF-83 FPGA version FPGA AF-83 version FPGA
Evaluated By Évalué Par
Ed DeSousa Ed DeSousa
Senior Legal Metrologist Métrologiste légal principal

AG-0622
Photographs and Diagrams / Photographies et diagrammes
Figure 2 Meter sizes DN200/8" and larger | Tailles de

compteurs DN200/8 po et plus
Figure 1 Meter sizes DN150/6" and smaller | Tailles de
compteurs DN150/6 po et moins
Figure 3. The Calibration Switch (A) in the open (unsealed) position and the Service Switch (B) in the closed (sealed) |
Interrupteur d’étalonnage (A) en position ouverte (non scellé) et interrupteur de service (B) en position fermée (scellé)

AG-0622
Figure 5. Sealing the transducers on one face of the meter for

meter sizes DN200/8" and larger | Scellage des transducteurs
sur un côté du compteur pour les compteurs de tailles
DN200/8 po et plus
Figure 4 Sealing the electronics head | Scellage des

composants électroniques (tête)
Figure 6. Sealing the transducers on one face of the meter, for meter sizes DN150/6"and smaller, using a single sealing wire (red
line) and using two sealing wires (green line) | Scellage des transducteurs sur un côté du compteur pour les compteurs de tailles
DN150/6 po et moins, à l’aide d’un fil de scellage (ligne rouge) et de deux fils de scellage (ligne verte).

AG-0622
APPROVAL: APPROBATION :
The design, composition, construction and La conception, la composition, la construction et le

performance of the meter type(s) identified herein rendement du(des) type(s) de compteur(s)
have been evaluated in accordance with regulations identifié(s) ci-dessus ont été évalués conformément
and specifications established under the Electricity au Règlement et aux normes établis en vertu de la
and Gas Inspection Act. Approval is hereby Loi sur l’inspection de l’électricité et du gaz. La
granted accordingly pursuant to subsection 9(4) of présente approbation est accordée en application du
the said Act. paragraphe 9(4) de la dite Loi.
The sealing, marking, installation, use and manner Le scellage, l’installation, le marquage et
of use of meters are subject to inspection in l’utilisation des compteurs sont soumis à
accordance with regulations and specifications l’inspection conformément au Règlement et aux
established under the Electricity and Gas normes établis en vertu de la Loi sur l’inspection
Inspection Act. The sealing and marking de l’électricité et du gaz. Les exigences de scellage
requirements are set forth in specifications et de marquage sont définies dans les normes
established pursuant to section 18 of the Electricity établies en vertu de l’article 18 du Règlement sur
and Gas Inspection Regulations. Installation and l’inspection de l’électricité et du gaz. Les
use requirements are set forth in specifications exigences d’installation et d’utilisation sont
established pursuant to section 12 of the définies dans les normes établies en vertu de
Regulations. Verification of conformity is required l’article 12 dudit règlement. En plus de cette
in addition to this approval for all metering devices approbation et sauf dans les cas des
excepting instrument transformers. Inquiries transformateurs de mesure, une vérification de
regarding inspection and verification should be conformité est requise. Toute question sur
addressed to the local office of Measurement l’inspection et la vérification de conformité doit
Canada. être adressée au bureau local de Mesures Canada.
Original copy signed by: Copie authentique signée par :
Christian Lachance, P.Eng. Christian Lachance, P.Eng.

Senior Engineer – Gas Measurement Ingénieur principal – Mesure des gaz
Engineering and Laboratory Services Directorate Direction de l’ingénierie et des services de
laboratoire
Date: 2016-07-27
Web Site Address / Adresse du site Internet:

http://mc.ic.gc.ca

Tel: 55 53658200, 63645537
1.4 Carta garantía

Tel: 55 53658200, 63645537
1.5 Catálogo
ULTRASONIC FLOWMETER
USM GT400
The ultrasonic meter USM GT400 from RMG delivers highest accuracy
and reliability based on field proven six path technology.
WHY GT400 BY RMG ?
The ultrasonic meter USM GT400 from RMG delivers

highest accuracy and reliability based on field proven six
path technology. Designed for use in a wide range of gas
custody transfer and secondary metering applications, the
GT400 measures directly bulk flow rate, swirls, cross-flow
and asymmetry. Its patented live precision adjustment/
echo measurement reduces metering uncertainty.
Proven Technology. Superior Performance.

To remain competitive, today’s natural gas industry is
under pressure to reduce capital and operating costs,
improve uptime and reduce risk. Reduction of workforce,
more automation and aging workforce, with nearly half of
employees skilled in control and regulatory technologies
are expected to retire over the next years. Often, end
users must cope with challenges such as high gas pressure
or temperature, valve noise, and attenuation of signal
due to contamination or the presence of liquids. This
requires intelligent solutions to maintain accuracy while
transferring gas between the distributor and the recipient.
Rely on RMG
• Over 150 years of combined experience in the natural gas industry
• Global domain expertise with local support
• Broad suite of products, from single instruments to turnkey solutions
• Seamless integration with plant-wide automation and security
• Guaranteed compliance and accuracy in custody transfer
2
ACCURACY ENSURED
The USM GT400 ultrasonic flowmeter from RMG provides

high accuracy, reliability and long-term stability in the most
demanding environments.
Proven Technology
Today, intelligent solutions are needed to measure and
analyze the quality and volume of natural gas at every
stage of its movement, storage and utilization. Gas
industry organizations can meet this requirement with
RMG’s Regulating and Metering product lines, which
are available individually or as complete systems for
gas metering stations. RMG has more than 150 years of RMG’s advanced 6 Cross (“X”) path
experience, supplying solutions to the major gas trans- technology
mission companies in Europe and Asia.
Application Know-how A Better Solution

We partner closely with industrial, commercial and gas RMG’s USM GT400 is an intelligent ultrasonic flow-
distribution customers to provide the right flow measure- meter which meets today’s strict requirements
ment solution to optimize operations at gas-fired power for accurate and stable measurements in gas
plants, liquefied natural gas (LNG) storage and export industry operations. It’s a multipath meter with
terminals, city gate facilities, petroleum refineries, metals multiple advantages: a field-proven electronics,
and mineral processing plants, combined heat and power sophisticated diagnostics, user-friendly software
generation facilities, and all sites utilizing natural gas as a to monitor the health of the flow metering system
feedstock. and a superior six-path measuring technique.
RMG’s six-path technology has been proven in
Expert Support demanding applications across the industry for
Our gas industry experts assist with developing standard more than a decade.
operating procedures (SOPs) for gas metering station
installations, validation routines, calibration procedures,
and more. Integrated ultrasonic gas meters with control
or SCADA platforms and data collection systems help you
interpret meter diagnostics and troubleshoot operating
problems. Typical applications include:
• Fiscal metering
Local Service • Low-pressure custody/non-custody (atmospheric)
You can depend on RMG for long-term product reliability transfer
and performance, lowest total cost of ownership and • Allocation metering
installation. Global experience, locally applied. • Check metering
• Gas transportation and distribution
• Underground gas storage (bi-directional)
• Gas-fired power plants
• Gas processing plants
• Refining and petrochemicals
• Industrial
120 kHz transducer
3
FEATURES AND FUNCTIONS
For natural gas processes with dry, wet, or corrosive and abrasive gases, or requiring bi-directional
measurement with minimal or no pressure drop, ultrasonic devices generally offer better performance,
greater reliability, and lower capital and ownership costs than mechanical metering technologies.
Proven Six-path Technology Proprietary Detection Algorithm

The GT400 is designed with high stability against The GT400 utilizes numerous criteria to validate pulses
turbulence thanks to its direct path technology with six without compromising high firing rates (pulses per second).
measuring paths on three levels. The paths are arrayed One of the criteria common to many instrumentation
in an “X” pattern in horizontal planes: a central plane, suppliers, including RMG, is peak identification and
and two geometrically similar planes. This orientation quantization of position and amplitude in the pulse
permits measurement of swirl, cross-flow and asymmetry, envelope. However, most companies avoid the use of
as well as transparent path velocity weighting per the comparative analysis of pulses, or “stacking,” since it
Gauss-Chebyshev profile model for compressible fluids. It is a burden on signal processing in noisy and turbulent
is particularly beneficial in city gate applications, where environments–resulting in either data refresh rates
limited space for piping and installation can affect meter exceeding one second, or a reduction of evaluated samples
operation. falling below statistical acceptability.
Field-proven Electronics To improve its signal process capabilities, RMG

implemented additional qualitative analysis to evaluate
The GT400 incorporates electronics that have improved
the pulse envelope and identify ultrasonic pulses, while
metering system uptime in installations worldwide. The
still maintaining high firing rates. Our proprietary, MID-
electronics are used to optimize the meter’s internal
approved detection algorithm is key to insensitivity to
diagnostics; speed of sound (SoS and flow velocity
regulator noise in many installations.
calculations; signal processing; data storage; interface to
flow computers, gas chromatographs and SCADA systems;
and field service diagnostics tools.
Over the past 20 years, ultrasonic flowmeters

Plug & Play Transducer Design have been recognized as the device-of-choice to
At the heart of the GT400 are its transducers, which measure natural gas volume for fiscal accounting.
transmit and receive sound waves or acoustic pulses. Acceptance by gas pipeline companies has occurred
The transit time difference between pairs of transducers due to the meter’s superior precision, repeatability,
is the most significant aspect of meter operation.With capacity and rangeability, as well as its lower main-
the GT400, all path-specific measurements are handled tenance costs. Ultrasonic flowmeters employ
internally by the electronics. RMG’s Exd transducer consists robust transducers generating repeatable pulses
of piezoelectric crystals fully encapsulated in Titanium (amplitude and frequency). They also include high-
housing for resistance to contamination. speed electronics complete with an accurate clock to
detect, resolve and time transmission/reception of
This unique design is plug & play and field-replaceable sonic pulses with sufficient time domain resolution.
under pressure. The transducer operates at standard The meters’ transducer and electronics configuration
frequencies of 120 or 200 kHz for use in most gas metering permits high pulse transmission rates, and transit
applications. Temperature range is -40°C to +80°C (-40°F time measurement allows rapid integration of fluid
to +176°F) and pressure range is 1 bar to 300 bar (14,5 psi flow velocity so accurately measured values can be
to 4351 psi). Wide measuring ranges (120:1 and above) with reported once per second.
correspondingly high flow velocities of more than 40 m/s
(131 ft/s) are also possible. High precision measurement is based on the applica-
tion multipath meters, which are designed to average
axial velocity components over the cross-section of
a closed pipe. Design and performance of ultrasonic
flowmeters are defined in international standards
e.g. ISO 17089 and AGA 9. USMs are the technology
of choice for custody transfer metering and approved
acc. to MID, Measurement Canada and further national
approval bodies.
4
Advanced Noise Immunity
In a gas pipeline system, noise generated by piping
configurations, valves, pressure regulators and nozzle
jetting can impede the performance of some ultrasonic
flowmeters. RMG addressed this problem with its
proprietary MID-approved signal processing algorithm and
unique Exd-rated transducer design, which work together
to extend signal amplitude for a high signal-to-noise
ratio (SNR) in comparison to traditional intrinsically safe
transducers. Noise created at ultrasonic frequencies has
marginal impact on the USM’s measurements.
Precision Delay Time Adjustment

For users of ultrasonic flowmeters, the test for system
delay time and adjustment described in AGA 9 (6.3) is a
critical requirement. Besides the time-of-flight of the
RMGViewUSM facilitates real-time performance monitoring
ultrasonic pulses, delay times caused by signal-processing
electronics, properties of the transducers and calculation Monitoring the health of the GT400: The parameterization and
algorithms can occur within the system. These delay times diagnostics software RMGViewUSM. It is easy to use thanks to
must be determined by laborious measurement techniques intuitive user interface.
at the factory, since they cannot be identified directly.
RMG’s patented “live” Precision Adjustment/Echo Measure- Intuitive User Interface

ment capability enables the most precise adjustment of
Supplied with the GT400, RMGViewUSM allows direct access
delay time and avoids the disadvantages of related testing
to the electronic measuring system via a PC to read out all
procedures.It also preserves measurement uncertainty
parameters; change parameters (if the calibration switch is
resulting from in-situ auto calibration of system delay (Tw)
enabled); represent measured values graphically; and create
after field replacement of transducers.
test certificates and data sheets, and output them as PDF
files. The software facilitates real-time performance moni-
Intelligent Diagnostic Technique toring of all diagnostic parameters e.g.:
One of the key advantages of ultrasonic flowmeters over
all other flow measurement technologies is the availability • Monitoring of AGC levels
of diagnostic information beyond just delivering pulses or • Indication of flow profile
signals proportional to the gas volume.
• Monitoring of turbulence
(profile factor)
RMG offers the Windows™-based RMGViewUSM parameter-
• Comparison of the SoS of each path
ization and diagnostics software as an interface to robust
condition monitoring capabilities. This application is easy • Identification of signal quality
to use and all data is displayed systematically in clearly • Comparison of SoS (per AGA 10) to estimated velocity of
arranged tables. It is also possible to combine selected sound from the composition of natural gas and measured
measured values and parameters in user-defined tables. velocity of sound from the ultrasonic meter
• Monitoring the swirl angle
First, RMGViewUSM monitors the health of the GT400 and
warns if there are any pending problems.
Secondly, it monitors the gas process and alerts when

there are any upset conditions e.g. pipeline contamination,
blockages or liquids in the gas stream. Thirdly, the software
monitors calculated metering uncertainties and provides
alarm notification.
5
BENEFITS TO YOUR BUSINESS
Thanks to the GT400, your business can realize significant benefits affecting your bottom line.
These improvements are key to increased productivity–and profitability–in an increasingly
competitive marketplace.
Lower CAPEX Reduced Risk

With the GT400, users can reduce the cost of implementing RMG’s knowledgeable subject matter experts work with
an advanced gas metering system. This is partly due customers on all aspects of product and application plan-
to the ability to employ smaller size meters with higher ning for ultrasonic flowmeter installations. We recognize
flow velocity, greater rangeability and extended turndown. the critical importance of service and support delivery
The USM’s crossed path arrangement also enables high- throughout the entire plant lifecycle. Our authorized field
accuracy measurement without the need for long inlet pip- technicians can assist with start-up, commissioning and
ing. A single ultrasonic meter can often replace dual turbine field service.
meter runs in low- and high-flow applications. In addition,
the USM’s improved signal conditioning capabilities help do
away with expensive noise reduction infrastructure. The GT400 provides improved overall
performance thanks to:
Reduced OPEX
• Rugged, non-intrusive design
The GT400 is our recommended answer to driving down • Bi-directional measuremet
maintenance and repair costs at gas metering sites. It is a • Real-time system measurement
non-mechanical device with no moving parts. The meter’s • Direct path design
operation is not directly impacted by contamination • Six-cross acoustic paths
on the pipe wall, and the inclusion of high-reliability trans- • Direct “cross flow” measurement
ducers–proven in service since 1999–minimize the need to • Dynamic 3-D flow profile
send technicians to the field. modeling
• Extended diagnostic functions
Improved Uptime • Precise flow profile identification
• Enhanced swirl and asymmetry
Natural gas facilities can avoid
measurement
unplanned shutdowns and loss of production with ultra-
• Best-in-class Exd transducer
sonic technology. The flowmeter’s rugged transducer
• Superior noise suppression
features two-path redundancy (MID- approved) for greater
• No moving parts or pressure drop
reliability in extreme situations. Its Titanium sensor sur-
• Wide turndown ratio (>120:1)
face is also contaminant-repellant, so personnel no longer
• Low-to-high-pressure operation
have to shut down processes to allow for cleaning. Plus,
(0-300 barg, 0-4351 psig)
the unit’s plug & play design shortens the time required to
• Extended flow range
exchange sensors.
(0.15-40 m/s , 0.5-131 ft/s)
• Excellent repeatability and measurement certainty
A Trusted Partner
RMG is one of the few manufacturers that provide complete metering
solutions for the worldwide natural gas market. With personnel
working in key industry locations, including unmatched local technical
support, RMG is your single-source partner for the gas value chain. From
detailed engineering, to project execution and training for operators
and field technicians, you can trust RMG to help make your project more
successful–and your operation more profitable.
6
TECHNICAL SPECIFICATION
Technical Data
Gases Pipeline Quality Natural Gas, Air

Measurements Volume Flow, Totalized Volume, Velocity of Gas, Speed of Sound, Swirl
Sizes DN 80-600 / 3”, 4”, 6”, 8”, 10”, 12”, 16”, 20”, 24” (ANSI 600); Consult RMG for sizes > 24”.
Path Configuration 6 Direct Cross (“X’) Path; 3 Planes
Measurement uncertainty Dry calibration with Nitrogen acc. AGA 9 +/-0,5 %
(from Qt to Qmax) HP-flow calibration. Full measuring range (Qt to Qmax) +/-0,1 %
Repeatability +/- 0,1%
Operating Pressure Range 1 bar (14.5 psi)….. 300 bar (4351psi)
Flanges up to ANSI600; Consult RMG for higher design pressure
Ambient Temperature -40°C (-40°F) to +55°C (131°F)
Gas Temperature Range -40°C (-40°F) to +80°C (176°F)
Operating Relative Humidity up to 95% condensing
Measuring Interval ca. 60 path measurements per sec; Display Update 2 times per sec
Power supply 24 V/DC +/-10 %
Power requirement Typically 7 W
ATEX: Ex II 2G Ex de IIB + H2 T6; IECEx: Ex de IIB + H2 T6 Gb
Hazardous Area Approvals
CSA: Class I, Div 1, Groups B, C, D T6
Metrological Approvals MID, Measurement Canada, GOST and others
Conformities AGA 9, ISO 17089, OIML 137-2012
Analog output 0/4-20 mA (galvanically isolated, programmable, load resistor: max. 400 Ohm, Umax =16 V)
Frequency outputs 2 HF-outputs with fmax = 5 kHz, Namur or Open Collector
Digital I/O 2 X Programmable
Analog input for p & T Galvanically isolated two-wire 4-20 mA p-transmitter or a 4-wire PT100
Interfaces
RS 485-0 Service port with MODBUS-Protocol; RMGViewUSM (max. cable length: 500m / 1640ft);
Ethernet via external module
RS 485-1 Serial connection to RMG’s ERZ 2000-NG Flow Computer
RS 485-2 MODBUS-protocol for interfacing with Third-Party Flow Computers, SCADA;
Ethernet via external module
120 kHz kHz for Sizes ≥ 8” (DN 200)
Transducer Frequency
200 kHz for Sizes ≤ 6” (DN 150)
RMGViewUSM Diagnostics Visualization, flow data, diagnostics, configuration, parameter changes,
Software export/import of parameters and data
Protection IP66
Meter Body Material Casted Steel; CS ASME A352 gr LCC
Material Electronics Housing Aluminum cast
Installation outside With weather protection cover and sun roof
Remarks Consult RMG for special requirements
7
TECHNICAL SPECIFICATION
High pressure > 4 bar/58 psi
Measuring Qmin Qmin extended Qmax Qmin Qmin extended Qmax
Range 3 3
ft/s ACFH ft/s ACFH ft/s ACFH m/s m /h m/s m /h m/s m3/h
1) 1) 1) 1)
DN 80/3” 1.07 177 0.54 89 138.93 23000 0.33 5 0.17 2.5 42.4 650
DN 100/4” 0.98 283 0.491) 142 1) 122.82 35300 0.30 8 0.15 1) 41) 37.4 1000
DN 150/6” 1.08 706 0.541) 353 1) 129.93 84800 0.33 20 0.17 1) 101) 39.6 2400
DN 200/8” 0.99 1130 0.50 565 129.89 148300 0.30 32 0.15 16 39.6 4200
DN 250/10” 0.98 1766 0.49 883 129.91 233100 0.30 50 0.15 25 39.6 6600
DN 300/12” 0.97 2472 0.49 1236 130.78 332000 0.30 70 0.15 35 39.9 9400
DN 400/16” 1.05 4238 0.53 2119 131.73 529700 0.32 120 0.16 60 40.2 15000
DN 500/20” 1.01 6357 0.51 3179 131.37 829900 0.31 180 0.16 90 40.0 23500
DN 600/24” 1.01 9182 0.51 4591 131.52 1200700 0.31 260 0.16 130 40.1 34000
1)
In preparation
Pressure Lenght (L) Height (H/M) Width (B) Weight (approx.)

Dimensions 2) Diameter
Rating (mm) (in) (mm/in) (mm/in) (mm) (in) (kg) (lbs)
DN 80/3” ANSI 600 240 9 328/12.9 435/17.1 418 16 75 165
DN 100/4” ANSI 600 300 12 330/13.0 470/18.4 430 17 100 220
DN 150/6” ANSI 600 450 18 340/13.4 520/20.4 470 19 160 353
DN 200/8” ANSI 600 600 24 360/14.2 570/22.4 530 21 300 662
DN 250/10” ANSI 600 750 30 380/15.0 635/25.0 650 26 450 992
DN 300/12” ANSI 600 900 35 395/15.6 675/26.6 700 28 550 1213
DN 400/16” ANSI 600 1200 47 500/19.7 845/33.2 750 30 950 2094
DN 500/20” ANSI 600 1500 59 550/21.7 960/37.7 900 35 1500 3307
DN 600/24” ANSI 600 1200 47 550/21.7 1020/41.0 1000 39 1550 3417
2)
Consult RMG for sizes >DN600/24”
Top view Front view Side view
min.400|15.7 4)
S0 / S1
H
B
M
T Di
S0 / S1
Technical data is subject to change without notice.

RMG-USMGT400-EN | April 2021 © RMG Messtechnik GmbH

Otto-Hahn-Straße 5
35510 Butzbach
Germany
Tel. +49 (0) 6033 897-0

Fax: +49 (0)6033 897-130 For More Information
Mail [email protected]
To learn more about products and solutions from RMG, visit
www.rmg.com www.rmg.com or contact your account manager.
Tel: 55 53658200, 63645537
1.6 Manuales del USM GT400
1.6.1 Manual Modbus

RMG GT400 Modbus Details
MODBUS List of parameters and measured values

This Document summarizes Modbus details for the RMG GT400 gas ultrasonic meter. The GT400
utilizes the standard Modicon / Gould Modbus.
Codes Supported
The GT400 electronics supports the following function codes:
Code Description
03 Hex Read Holding Registers
06 Hex Preset Single Register
10 Hex Preset Multiple Registers
08 Hex Diagnostic
Code Description
00 Hex Return Query Data
Exception Codes
Code Description
03 Illegal Function
03 Illegal Data Address (Register

not available)
03 Illegal Data Value (Register can-

not be described or incorrect
value)
Data Types
Data type Register Value Byte Byte Byte Byte Byte Byte Byte Byte
1 2 3 4 5 6 7 8
float 2 273.15 0x93 0x33 0x43 0x88
Text 10 USM-GT- 0x53 0x55 0x30 0x5A 0x2D 0x38 0x50 0x36
400
0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00
0x00 0x00 0x00 0x00
intd 1 44067 0xAC 0x23
double 4 14,2740 0x13 0x58 0x8A 0xCF 0x8C 0x4C 0x40 0x2C
long 2 100000 0x86 0xA0 0x00 0x01
Page 1 of 12 Date: 3/12/2021 Revision 1.0a

Example (Question / Answer)

Question Modbus - ASCII Modbus - RTU
Start Char :
Slave Address 01 01
Function 03 03
Starting Address Hi 0F 0F
Starting Address Lo A2 A2 Register = 4002 (0FA2)
No. of Points Hi 00 00
No. of Points Lo 01 01 Amount = 0001 (0001)
LRC / CRC 42 26
carriage return CR FC
line feed LF

The following tables list the read-only parameters that can be read by a flow computer which include the primary meter
diagnostics. It does not contain any configurable parameters (i.e., these are all read-only).
USE09 Primary Measurement Values

Coor- Value (RMG # of
Register Type Unit Description
dinate Description) Reg.
C-02 vwc 6222 2 Float Velocity corrected weighted gas velocity (used in Dashboard)
C-06 Performance 6268 1 Integer % Performance (overall meter used in Dashboard)
D-02 vol. flow rate Qm 6230 2 Float Flow Unit Uncorrected flow rate (used in Dashboard)
AB-01 SOS Average 6228 2 Float Vel. Unit Average Speed of Sound over all paths
AC-15 Swirl Angle 6584 2 Float Swirl angle of plane 1
Plane-1
Plane-2
Plane-3
AC-30 Profile Factor 6820 2 Float Diagnosis: Profile Factor (used in Dashboard)
AC-33 Symmetry 6826 2 Float Symmetry (Used in Dashboard)
The following tables list the read-only parameters for Paths 1 thru 6 that can be read by a flow computer.
Path 1 – Primary Measuring Values

L-06 Valid samples G1 7000 1 Integer % Path 1 valid measuring values in %
L-08 velocity vc1 6200 2 Float velocity Path 1 corrected path velocity
L-09 SoS1 6020 2 Float velocity Path 1 Speed of Sound
L-16 p1.1 AGC-level 6040 2 Float dB Path 1.1 Automated Gain Control
L-18 p1.1 snr 6640 2 Float dB Path 1.1 signal-to-noise ratio
L-26 path-1 turbulence 6776 2 Float dB Path 1 turbulence


M-06 Valid samples G2 7001 1 Integer % Path 2 valid measuring values in %
M-08 velocity vc2 6202 2 Float velocity Path 2 corrected path velocity
M-09 SoS2 6022 2 Float velocity Path 2 Speed of Sound
M-16 P2.1 AGC-level 6042 2 Float dB Path 2.1 Automated Gain Control
M-18 P2.1 snr 6642 2 Float dB Path 2.1 signal-to-noise ratio
M-19 P2.2 snr 6662 2 Float dB Path 2.2 signal-to-noise ratio
M-26 path-2 turbulence 6776 2 Float Path 2 turbulence

N-06 Valid samples G3 7002 1 Integer % Path 3 valid measuring values in %
N-08 velocity vc3 6204 2 Float velocity Path 3 corrected path velocity
N-09 SoS3 6024 2 Float velocity Path 3 Speed of Sound
L-16 P3.1 AGC-level 6044 2 Float dB Path 3.1 Automated Gain Control
N-18 P3.1 snr 6644 2 Float dB Path 3.1 signal-to-noise ratio
N-19 P3.2 snr 6664 2 Float dB Path 3.2 signal-to-noise ratio
N-26 path-3 turbulence 6780 2 Float Path 3 turbulence

O-06 Valid samples G4 7003 1 Integer % Path 4 valid measuring values in %
O-08 velocity vc4 6206 2 Float velocity Path 4 corrected path velocity
O-09 SoS4 6026 2 Float velocity Path 4 Speed of Sound
O-16 P4.1 AGC-level 6046 2 Float dB Path 4.1 Automated Gain Control
O-17 P4.2 AGC-level 6066 2 Float dB Path 4.2 Automated Gain Control
O-18 P4.1 snr 6646 2 Float dB Path 4.1 signal-to-noise ratio
O-19 P4.2 snr 6666 2 Float dB Path 4.2 signal-to-noise ratio
O-26 path-4 turbulence 6782 2 Float dB Path 4 turbulence


P-06 Valid samples G5 7004 1 Integer % Path 5 valid measuring values in %
P-08 velocity vc5 6208 2 Float velocity Path 5 corrected path velocity
P-09 SoS5 6028 2 Float velocity Path 5 Speed of Sound
P-16 P5.1 AGC-level 6048 2 Float dB Path 5.1 Automated Gain Control
P-17 P5.2 AGC-level 6068 2 Float dB Path 5.2 Automated Gain Control
P-18 P5.1 snr 6648 2 Float dB Path 5.1 signal-to-noise ratio
P-19 P5.2 snr 6668 2 Float dB Path 5.2 signal-to-noise ratio
P-26 path-5 turbulence 6784 2 Float dB Path 5 turbulence

Q-06 Valid samples G6 7005 1 Integer % Path 6 valid measuring values in %
Q-08 velocity vc6 6210 2 Float velocity Path 6 corrected path velocity
Q-09 SoS6 6030 2 Float velocity Path 6 Speed of Sound
Q-16 P6.1 AGC-level 6050 2 Float dB Path 6.1 Automated Gain Control
Q-17 P6.2 AGC-level 6070 2 Float dB Path 6.2 Automated Gain Control
Q-18 P6.1 snr 6650 2 Float dB Path 6.1 signal-to-noise ratio
Q-19 P6.2 snr 6670 2 Float dB Path 6.2 signal-to-noise ratio
Q-26 path-6 turbulence 6786 2 Float dB Path 6 turbulence

APPENDIX
This Appendix provides a detailed list of registers that may be of interest in polling. This includes
additional meter diagnostic and operational information, and more detailed per-path information.
USE09 Meter Diagnostic Values

Coor- Value Modbus # of Type Unit Description
dinate Register Reg.
AC-01 Vz plane-1 6560 2 Float velocity Velocity Vz of plane 1


AC-05 Vx plane-1 6568 2 Float velocity Velocity Vx of plane 1


AC-09 Ve plane-1 6576 2 Float velocity Velocity V of plane 1


AC-15 Swirl Angle Plane-1 6584 2 Float ° Swirl angle of plane 1


AC-20 Profile PFY1 6800 2 Float Profile factor PFY1

AC-22 Profile PFY 6804 2 Float Profile factor PFY


AC-27 Profile PFX 6814 2 Float Profile factor PFX
AC-28 Profile PFX12 6816 2 Float Profile factor PFX12
AC-29 Profile PFX56 6818 2 Float Profile factor PFX56
AC-30 Profile Factor 6820 2 Float Diagnosis: Profile Factor
AC-31 Symmetry X 6822 2 Float Symmetry X
AC-32 Symmetry Y 6824 2 Float Symmetry Y
AC-33 Symmetry 6826 2 Float Symmetry

Path 1 – Measuring Values

L-01 p1.1 time of flight 6100 2 Float us Path 1.1 time of flight
L-02 p1.2 time of flight 6120 2 Float us Path 1.2 time of flight
L-03 path-1 delta-t 6140 2 Float us Path 1 time difference
L-04 p1 delta-t corr. 6540 2 Float us Path 1 corrected time difference
L-06 Valid samples G1 7000 1 Integer % Path 1 valid measuring values in %
L-07 path-1 velocity 6000 2 Float velocity Path 1 path velocity
L-08 velocity vc1 6200 2 Float velocity Path 1 corrected path velocity vc
L-09 SoS1 6020 2 Float velocity Path 1 Speed of Sound
L-10 path-1 delta SOS 6080 2 Float % Path 1 Path-SOS / Mean-SOS
L-12 path-1 fault 4030 1 Integer hex Path 1 path error
L-13 path-1 status 4040 1 Integer hex Path 1 path status
L-14 p1.1 Amplitude 7010 1 Integer % Path 1.1 amplitude in per cent
L-15 p1.2 Amplitude 7020 1 Integer % Path 1.2 amplitude in per cent
L-20 path-1 fault (X) 2270 1 Integer hex Path 1 path error (3X-measurement)
L-21 p1.1 AGC-level (X) 6680 2 Float dB Path 1.1 Automated Gain Control (3X-measurement)
L-22 p1.2 AGC-level (X) 6700 2 Float dB Path 1.2 Automated Gain Control (3X-measurement)
L-23 p1.1 snr (X) 6720 2 Float dB Path 1.1 signal-to-noise ratio (3X-measurement)
L-24 p1.2 snr (X) 6740 2 Float dB Path 1.2 signal-to-noise ratio (3X-measurement)
L-26 path-1 turbulence 6776 2 Float dB Path 1 turbulence


M-01 p2.1 time of flight 6102 2 Float us Path 2.1 time of flight
M-02 p2.2 time of flight 6122 2 Float us Path 2.2 time of flight
M-03 path-2 delta-t 6142 2 Float us Path 2 time difference
M-04 p2 delta-t corr. 6542 2 Float us Path 2 corrected time difference
M-06 Valid samples G2 7001 1 Integer % Path 2 valid measuring values in %
M-07 path-2 velocity 6002 2 Float velocity Path 2 path velocity
M-08 velocity vc2 6202 2 Float velocity Path 2 corrected path velocity vc
M-09 SoS2 6022 2 Float velocity Path 2 Speed of Sound
M-10 path-2 delta SOS 6082 2 Float % Path 2 Path-SOS / Mean-SOS
M-12 path-2 fault 4031 1 Integer hex Path 2 path error
M-13 path-2 status 4041 1 Integer hex Path 2 path status
M-14 p2.1 Amplitude 7011 1 Integer % Path 2.1 amplitude in per cent
M-15 p2.2 Amplitude 7021 1 Integer % Path 2.2 amplitude in per cent
M-16 p2.1 AGC-level 6042 2 Float dB Path 2.1 Automated Gain Control
M-17 p2.2 AGC-level 6062 2 Float dB Path 2.2 Automated Gain Control
M-18 p2.1 snr 6642 2 Float dB Path 2.1 signal-to-noise ratio
M-19 p2.2 snr 6662 2 Float dB Path 2.2 signal-to-noise ratio
M-20 path-2 fault (X) 2271 1 Integer hex Path 2 path error (3X-measurement)
M-21 p2.1 AGC-level (X) 6682 2 Float dB Path 2.1 Automated Gain Control (3X-measurement)
M-22 p2.2 AGC-level (X) 6702 2 Float dB Path 2.2 Automated Gain Control (3X-measurement)
M-23 p2.1 snr (X) 6722 2 Float dB Path 2.1 signal-to-noise ratio (3X-measurement)
M-24 p2.2 snr (X) 6742 2 Float dB Path 2.2 signal-to-noise ratio (3X-measurement)
M-26 path-2 turbulence 6778 2 Float % Path 2 turbulence


N-01 p3.1 time of flight 6104 2 Float us Path 3.1 time of flight
N-02 p3.2 time of flight 6124 2 Float us Path 3.2 time of flight
N-03 path-3 delta-t 6144 2 Float us Path 3 time difference
N-04 p3 delta-t corr. 6544 2 Float us Path 3 corrected time difference
N-06 Valid samples G3 7002 1 Integer % Path 3 valid measuring values in %
N-07 path-3 velocity 6004 2 Float velocity Path 3 path velocity
N-08 velocity vc3 6204 2 Float velocity Path 3 corrected path velocity vc
N-09 SoS3 6024 2 Float velocity Path 3 Speed of Sound
N-10 path-3 delta SOS 6084 2 Float % Path 3 Path-SOS / Mean-SOS
N-12 path-3 fault 4032 1 Integer hex Path 3 path error
N-13 path-3 status 4042 1 Integer hex Path 3 path status
N-14 p3.1 Amplitude 7012 1 Integer % Path 3.1 amplitude in per cent
N-15 p3.2 Amplitude 7022 1 Integer % Path 3.2 amplitude in per cent
N-16 p3.1 AGC-level 6044 2 Float dB Path 3.1 Automated Gain Control
N-17 p3.2 AGC-level 6064 2 Float dB Path 3.2 Automated Gain Control
N-18 p3.1 snr 6644 2 Float dB Path 3.1 signal-to-noise ratio
N-19 p3.2 snr 6664 2 Float dB Path 3.2 signal-to-noise ratio
N-20 path-3 fault (X) 2272 1 Integer hex Path 3 path error (3X-measurement)
N-21 p3.1 AGC-level (X) 6684 2 Float dB Path 3.1 Automated Gain Control (3X-measurement)
N-22 p3.2 AGC-level (X) 6704 2 Float dB Path 3.2 Automated Gain Control (3X-measurement)
N-23 p3.1 snr (X) 6724 2 Float dB Path 3.1 signal-to-noise ratio (3X-measurement)
N-24 p3.2 snr (X) 6744 2 Float dB Path 3.2 signal-to-noise ratio (3X-measurement)
N-26 path-3 turbulence 6780 2 Float % Path 3 turbulence

m


O-01 p4.1 time of flight 6106 2 Float us Path 4.1 time of flight
O-02 p4.2 time of flight 6126 2 Float us Path 4.2 time of flight
O-03 path-4 delta-t 6146 2 Float us Path 4 time difference
O-04 p4 delta-t corr. 6546 2 Float us Path 4 corrected time difference
O-06 Valid samples G4 7003 1 Integer % Path 4 valid measuring values in %
O-07 path-4 velocity 6006 2 Float velocity Path 4 path velocity
O-08 velocity vc4 6206 2 Float velocity Path 4 corrected path velocity vc
O-09 SoS4 6026 2 Float velocity Path 4 Speed of Sound
O-10 path-4 delta SOS 6086 2 Float % Path 4 Path-SOS / Mean-SOS
O-12 path-4 fault 4033 1 Integer hex Path 4 path error
O-13 path-4 status 4043 1 Integer hex Path 4 path status
O-14 p4.1 Amplitude 7013 1 Integer % Path 4.1 amplitude in per cent
O-15 p4.2 Amplitude 7023 1 Integer % Path 4.2 amplitude in per cent
O-16 p4.1 AGC-level 6046 2 Float dB Path 4.1 Automated Gain Control
O-17 p4.2 AGC-level 6066 2 Float dB Path 4.2 Automated Gain Control
O-18 p4.1 snr 6646 2 Float dB Path 4.1 signal-to-noise ratio
O-19 p4.2 snr 6666 2 Float dB Path 4.2 signal-to-noise ratio
O-20 path-4 fault (X) 2273 1 Integer hex Path 4 path error (3X-measurement)
O-21 p4.1 AGC-level (X) 6686 2 Float dB Path 4.1 Automated Gain Control (3X-measurement)
O-22 p4.2 AGC-level (X) 6706 2 Float dB Path 4.2 Automated Gain Control (3X-measurement)
O-23 p4.1 snr (X) 6726 2 Float dB Path 4.1 signal-to-noise ratio (3X-measurement)
O-24 p4.2 snr (X) 6746 2 Float dB Path 4.2 signal-to-noise ratio (3X-measurement)
O-26 path-4 turbulence 6782 2 Float % Path 4 turbulence


P-01 p5.1 time of flight 6108 2 Float us Path 5.1 time of flight
P-02 p5.2 time of flight 6128 2 Float us Path 5.2 time of flight
P-03 path-5 delta-t 6148 2 Float us Path 5 time difference
P-04 p5 delta-t corr. 6548 2 Float us Path 5 corrected time difference
P-06 Valid samples G5 7004 1 Integer % Path 5 valid measuring values in %
P-07 path-5 velocity 6008 2 Float velocity Path 5 path velocity
P-08 velocity vc5 6208 2 Float velocity Path 5 corrected path velocity vc
P-09 SoS5 6028 2 Float velocity Path 5 Speed of Sound
P-10 path-5 delta SOS 6088 2 Float % Path 5 Path-SOS / Mean-SOS
P-12 path-5 fault 4034 1 Integer hex Path 5 path error
P-13 path-5 status 4044 1 Integer hex Path 5 path status
P-14 p5.1 Amplitude 7014 1 Integer % Path 5.1 amplitude in per cent
P-15 p5.2 Amplitude 7024 1 Integer % Path 5.2 amplitude in per cent
P-16 p5.1 AGC-level 6048 2 Float dB Path 5.1 Automated Gain Control
P-17 p5.2 AGC-level 6068 2 Float dB Path 5.2 Automated Gain Control
P-18 p5.1 snr 6648 2 Float dB Path 5.1 signal-to-noise ratio
P-19 p5.2 snr 6668 2 Float dB Path 5.2 signal-to-noise ratio
P-20 path-5 fault (X) 2274 1 Integer hex Path 5 path error (3X-measurement)
P-21 p5.1 AGC-level (X) 6688 2 Float dB Path 5.1 Automated Gain Control (3X-measurement)
P-22 p5.2 AGC-level (X) 6708 2 Float dB Path 5.2 Automated Gain Control (3X-measurement)
P-23 p5.1 snr (X) 6728 2 Float dB Path 5.1 signal-to-noise ratio (3X-measurement)
P-24 p5.2 snr (X) 6748 2 Float dB Path 5.2 signal-to-noise ratio (3X-measurement)
P-26 path-5 turbulence 6784 2 Float dB Path 5 turbulence


Q-01 p6.1 time of flight 6110 2 Float us Path 6.1 time of flight
Q-02 p6.2 time of flight 6130 2 Float us Path 6.2 time of flight
Q-03 path-6 delta-t 6150 2 Float us Path 6 time difference
Q-04 p6 delta-t corr. 6550 2 Float us Path 6 corrected time difference
Q-06 Valid samples G6 7005 1 Integer % Path 6 valid measuring values in %
Q-07 path-6 velocity 6010 2 Float velocity Path 6 path velocity
Q-08 velocity vc6 6210 2 Float velocity Path 6 corrected path velocity vc
Q-09 SoS6 6030 2 Float velocity Path 6 Speed of Sound
Q-10 path-6 delta SOS 6090 2 Float % Path 6 Path-SOS / Mean-SOS
Q-12 path-6 fault 4035 1 Integer hex Path 6 path error
Q-13 path-6 status 4045 1 Integer hex Path 6 path status
Q-14 p6.1 Amplitude 7015 1 Integer % Path 6.1 amplitude in per cent
Q-15 p6.2 Amplitude 7025 1 Integer % Path 6.2 amplitude in per cent
Q-16 p6.1 AGC-level 6050 2 Float dB Path 6.1 Automated Gain Control
Q-17 p6.2 AGC-level 6070 2 Float dB Path 6.2 Automated Gain Control
Q-18 p6.1 snr 6650 2 Float dB Path 6.1 signal-to-noise ratio
Q-19 p6.2 snr 6670 2 Float dB Path 6.2 signal-to-noise ratio
Q-20 path-6 fault (X) 2275 1 Integer hex Path 6 path error (3X-measurement)
Q-21 p6.1 AGC-level (X) 6690 2 Float dB Path 6.1 Automated Gain Control (3X-measurement)
Q-22 p6.2 AGC-level (X) 6710 2 Float dB Path 6.2 Automated Gain Control (3X-measurement)
Q-23 p6.1 snr (X) 6730 2 Float dB Path 6.1 signal-to-noise ratio (3X-measurement)
Q-24 p6.2 snr (X) 6750 2 Float dB Path 6.2 signal-to-noise ratio (3X-measurement)
Q-26 Path-6 turbulence 6786 2 Float % Path 6 turbulence

Tel: 55 53658200, 63645537
1.6.2 Manual de Operaciones

Operating Manual
Ultrasonic Flowmeter USM GT400
Issued: 07.05.2021
Version: 10
Firmware: 1.5
Contact
Manufacturer Our customer service is available for technical queries:
Address RMG Messtechnik GmbH

Otto-Hahn-Straße 5
D-35510 Butzbach
Telephone Switchboard +49 6033 897 – 0
Telephone Service +49 6033 897 – 0
Telephone Spare Parts +49 6033 897 – 173
Fax +49 6033 897 – 130
E-Mail [email protected]
Original Document The Ultrasonic Flowmeter USM GT400 OPERATING

INSTRUCTION 07.05.2021 is the original document.
This document may serve as a reference for translations into

other languages. Please use in case of any uncertainties the
German version as main reference.
Note Unfortunately, paper is not updated automatically, whereas
technical development continuously advances. Therefore, we
reserve the right to make technical changes regarding the rep-
resentations and specifications of these operating instructions.
The latest version of this manual (and other devices) can be
downloaded at your convenience from our Internet homepage:
www.rmg.com
Date created 1/31/2014

…
4th revision date 02/12/2018
Document version Document version Ultrasonic Flowmeter USM GT400

and language manual de May 7th 2021
Language EN

Contents
Content
1 ABOUT THIS MANUAL ......................................................................... 1
1.1 Objective of the manual ....................................................................................... 1
I
1.2 Specialized knowledge required ....................................................................... 2
1.2.1 Specialized knowledge required .......................................................................... 2
1.2.2 Abbreviations....................................................................................................... 3
1.2.3 Layout of instructions .......................................................................................... 4
1.2.4 Working with the device ...................................................................................... 5
1.2.5 Risk assessment and minimization ................................................................... 11
1.2.6 Validity of the manual ........................................................................................ 13
1.2.7 Transport ........................................................................................................... 14
1.2.8 Scope of delivery ............................................................................................... 16
1.2.9 Disposal of packaging material ......................................................................... 16
1.2.10 Storage .............................................................................................................. 16
1.3 Explosion-proof design .....................................................................................17
1.3.1 General information ........................................................................................... 17
1.4 Inspection and maintenance work ..................................................................18
1.4.1 General information ........................................................................................... 18
2 QUICK GUIDE ....................................................................................... 20

2.1 Mechanical connection ......................................................................................21
2.1.1 Connection flanges ............................................................................................ 21
2.1.2 Inlet / outlet piping ............................................................................................. 21
2.1.3 Joining pressure connections ............................................................................ 21
2.2 Electrical connection .........................................................................................22
2.3 Start up ..................................................................................................................22
2.4 Earthing .................................................................................................................23
2.5 Parameter setting ................................................................................................24
3 DEVICE OVERVIEW ............................................................................ 25

3.1 Main components................................................................................................25
3.2 Ultrasonic electronics ........................................................................................27
3.3 Arrangement of the ultrasonic transducers .................................................31
4 FUNCTIONAL PRINCIPLE – ULTRASONIC-FLOW

MEASUREMENT .................................................................................. 32

Contents
4.1 General description ............................................................................................ 33

4.2 Correction of the base line ............................................................................... 37
4.2.1 Base line correction via polynomial ................................................................... 38
4.2.2 Correction via a piecewise linearization ............................................................ 39
4.3 Diagnostic function Speed of Sound ............................................................. 40
II 4.3.1 Standard method of SoS calculation ................................................................. 40
4.3.2 SoS calculation via gas components ................................................................ 40
4.3.3 Extended SoS calculation ................................................................................. 41
4.4 Import of gas composition data ...................................................................... 42
4.4.1 Option 4: Data input on fixed defaults ............................................................... 43
4.4.2 Data input on fixed defaults for air .................................................................... 43
4.4.3 Data input via RMGBus .................................................................................... 45
4.4.4 Data via Modbus (USM GT400 is SLAVE) ....................................................... 46
4.4.5 Import of data via Modbus (USM GT400 is Master).......................................... 47
4.5 Batch mode .......................................................................................................... 52
4.6 Signal damping ................................................................................................... 52
5 SAFETY.................................................................................................. 53
5.1 Intended use ........................................................................................................ 54
5.2 Layout of instructions ....................................................................................... 55
5.3 Qualification of the personnel ......................................................................... 56
5.4 Safety instructions ............................................................................................. 57
5.4.1 Hazards during transporting .............................................................................. 58
5.4.2 Hazards during installation ................................................................................ 58
5.4.3 Hazards during start up ..................................................................................... 60
5.4.4 Hazards during cleaning ................................................................................... 61
5.4.5 Hazards during maintenance and repairs ......................................................... 61
5.4.6 Hazards during operation .................................................................................. 62
5.4.7 Hazards for operation in potentially explosive environments ............................ 63
5.5 Responsibilities of the operator ...................................................................... 64
6 TRANSPORT AND STORAGE .......................................................... 65

6.1 Transport .............................................................................................................. 66
6.1.1 Scope of supply ................................................................................................ 66
6.1.2 Transporting the device .................................................................................... 67
6.1.3 Unpacking the device ........................................................................................ 67
6.1.4 Disposal of packaging material ......................................................................... 70
6.1.5 Prior to installation ............................................................................................ 70
6.1.6 Removing the transporting locks ....................................................................... 71

Contents
6.2 Packing the device for transportation............................................................73

6.3 Storage ..................................................................................................................79
6.3.1 Packing the device for storage .......................................................................... 79
6.3.2 Checking the device after storage ..................................................................... 80
7 CONSTRUCTION AND PLANNING .................................................. 81 III

7.1 Connection flanges.............................................................................................81
7.2 Seals .......................................................................................................................82
7.2.1 Flat seal ............................................................................................................. 83
7.2.2 Grooved gaskets ............................................................................................... 84
7.2.3 Spiral seals ........................................................................................................ 85
7.3 Screws ...................................................................................................................87
7.4 Installation possibilities ....................................................................................88
7.4.1 Dependency on the gas flow direction .............................................................. 88
7.4.2 Two devices series connected (Face to Face) .................................................. 91
7.5 Flow computer .....................................................................................................93
8 INSTALLATION .................................................................................... 95
8.1 Assembly work preparations ...........................................................................96
8.2 Installation of the device ...................................................................................99
8.2.1 Mounting the inlet and outlet piping ................................................................... 99
8.2.2 Installation of the connection box .................................................................... 101
8.3 Connecting the device electrically ............................................................... 103
8.3.1 Connecting the power supply .......................................................................... 108
8.3.2 Digital interfaces of USM-GT400 ..................................................................... 108
8.3.3 Connecting the computer for RMGViewUSM ..................................................... 110
8.3.4 Connecting the flow computer ......................................................................... 110
8.3.5 Connection of external DSfG-Device-F via Modbus ........................................ 113
8.3.6 Interface converter .......................................................................................... 124
8.3.7 Connecting the device to earth ........................................................................ 126
8.4 Installing the pressure connection .............................................................. 128
8.5 Outdoor installation ......................................................................................... 130
9 START UP ........................................................................................... 132

9.1 Comparing meter parameters ....................................................................... 132
9.2 Checking functions of the USM .................................................................... 132
9.3 Reading out speed of sound ......................................................................... 133

Contents
10 OPERATION........................................................................................ 134
10.1 Measuring values and parameters ............................................................ 135
10.1.1 Input protection for parameters ....................................................................... 135
10.1.2 Parameter and measuring values with variable units ..................................... 135
10.1.3 Calibration and Service Switch ....................................................................... 136
IV 10.1.4 Interfaces to converters and controllers .......................................................... 136
10.1.5 Interface for service and parameterization ...................................................... 137
10.1.6 Adaptation of the DZU protocol to ERZ 2400 ................................................. 138
10.2 Calling up and changing the parameters via the ultrasonic electronics
139
10.2.1 Calling up the value of a parameter ................................................................ 140
10.2.2 Entering data ................................................................................................... 141
10.2.3 Changing the parameters of protection E and S ............................................. 144
10.3 Parameterize the USM interface ................................................................. 149
10.3.1 Interface 0 ....................................................................................................... 149
10.3.2 Interface 1 ....................................................................................................... 150
10.3.3 Interface 2 ....................................................................................................... 150
10.4 Modbus communication in detail .............................................................. 161
10.4.1 Codes supported ............................................................................................. 161
10.4.2 Data types ....................................................................................................... 161
10.5 Configuration of the current output .......................................................... 163
10.6 List of the measurement values and parameters ................................. 163
11 MAINTENANCE .................................................................................. 164

11.1 Maintenance schedule ................................................................................. 165
11.2 Checking the device for leaks .................................................................... 165
11.3 Checking the device for any signs of damage ....................................... 166
11.4 Changing the battery .................................................................................... 166
11.5 Changing the transducer ............................................................................. 166
11.6 Changing the ultrasonic electronics......................................................... 167
11.7 Cleaning the device ...................................................................................... 167
11.8 Check the official seal .................................................................................. 168
11.9 Decommissioning and disposal ................................................................ 168
12 ALARM AND WARNING MESSAGES ........................................... 170

12.1 Alarm messages ............................................................................................ 171
12.2 Warning messages........................................................................................ 172

Contents
12.3 Notes ................................................................................................................ 175

12.4 Troubleshooting ............................................................................................ 175
13 TECHNICAL SPECIFICATIONS ...................................................... 177

13.1 Performance data.......................................................................................... 178
V
13.2 Approved gas types ..................................................................................... 180
13.2.1 Suitability and safety for natural gas containing H2 ........................................ 180
13.3 Approved measuring range according to MID ....................................... 181
13.4 Type plate ....................................................................................................... 182
13.4.1 Type plate ATEX / IECEx ................................................................................ 183
13.4.2 Type plate NEC (CSA) .................................................................................... 184
13.5 Weights and dimensions ............................................................................ 184
13.5.1 NEC (CSA) ...................................................................................................... 185
13.5.2 ATEX / IECEx .................................................................................................. 186
13.6 Inner diameter of connecting spool pieces ............................................ 189
13.7 Official seal diagram .................................................................................... 192
13.7.1 Type plate........................................................................................................ 192
13.7.2 Ultrasonic electronics ...................................................................................... 193
13.7.3 Ultrasonic gas meter ....................................................................................... 195
13.8 Transducer types .......................................................................................... 197
14 SPARE PARTS AND ACCESSORIES ........................................... 199
15 LISTS OF PARAMETERS AND MEASURED VALUES .............. 201
16 USM GT400 APPROVAL .................................................................. 246

16.1 Metrological approvals ................................................................................ 246
16.2 Pressure devices approval ......................................................................... 246
16.3 Electromagnetic compatibility ................................................................... 246
16.4 Explosion protection approval .................................................................. 246
16.5 Standards, directives and guidelines ...................................................... 247
17 USM GT400 GLOSSARY .................................................................. 249
18 USM GT400 ATTACHMENT............................................................. 250

Contents
VI

1 About this manual
1 About this manual

Content
1
1.1 Objective of the manual 1

1.2 Specialized knowledge required 2
1.2.1 Specialized knowledge required 2
1.2.2 Abbreviations 3
1.2.3 Layout of instructions 4
1.2.4 Working with the device 5
1.2.5 Risk assessment and minimization 11
1.2.6 Validity of the manual 13
1.2.7 Transport 14
1.2.8 Scope of delivery 16
1.2.9 Disposal of packaging material 16
1.2.10 Storage 16
1.3 Explosion-proof design 17
1.3.1 General information 17
1.4 Inspection and maintenance work 18
1.4.1 General information 18
1.1 Objective of the manual

In this chapter you will be given information on this manual.
The manual provides you with the information that is designed for trouble-free and
safe operation.
The ultrasonic gas meter is state of the art and conceived and manufactured ac-
cording to the recognized safety standards and guidelines.
However, risks may arise during use that can be easily avoided by observing this
manual.
For this reason, you may only use the device as intended and in technically sound
condition.
If the ultrasonic gas meter is not used for its intended purpose, warranty claims will
be void.

1 About this manual
1.2 Specialized knowledge required

This manual provides information that is necessary for fault-free and safe opera-
tion.
2
The Ultrasonic Flowmeter USM GT400 was designed and produced according to
the state of the art and generally recognized safety standards and directives. How-
ever, its use can entail dangers that are avoidable by complying with this manual.
The device must only be used as intended and in technically sound condition.
Vorsicht
Unintended use voids all warranty claims and the Ultrasonic Flowmeter
USM GT400 can also lose its approvals.
1.2.1 Specialized knowledge required

Persons working with or on the device must have the following knowledge:
• training / education for working in potentially explosive environments.
• the ability to correctly assess dangers and risks when using the device. Possi-
ble dangers are, e.g., components under pressure or the result of incorrect in-
stallation.
• recognize dangers that could be caused by the used flow medium.
• training / education by RMG for working with gas measuring instruments.
• education / instruction in all country-specific standards and directives to be ob-
served for work that is to be carried out on the device.
Further information can be found under:

Chapter 5.3, „Qualification of the personnel“ on page 56

1 About this manual
1.2.2 Abbreviations
The following abbreviations are used:
AGC Automatic Gain Control 3

ca. circa, approximately
as app. as applicable
max. maximum
MC Measurement Canada
MID Measurement Instruments Directive
min. minimum
SNR Signal to Noise Ratio
SoS Speed of Sound
TD Transducer (ultrasonic transmitter and receiver)
TNG Transducer of a certain production type.
USE Ultrasonic electronics
USM Ultrasonic gas meter
e.g. For example

1 About this manual
1.2.3 Layout of instructions

The following notices are used:
4
Danger
This warning notice informs you of imminently threatening dangers that
can arise due to misuse/operator error. If these situations are not avoided,
death or severe injuries can occur.
Warning
This warning notice informs you of potentially dangerous situations that
can arise due to misuse/operator error. If these situations are not avoided,
minor injuries can occur.
Caution
This notice informs you of potentially dangerous situations that can arise
due to misuse/operator error. If these situations are not avoided, damage
to the device or nearby property can occur.
Note
This notice provides you with helpful tips to make your work easier. This
notice also provides you with further information about the device or the
work process in order to prevent operator error.

1 About this manual
1.2.4 Working with the device

1.2.4.1 Safety instructions Danger, Warning, Caution and Note
5
Danger
All of the following safety notices must be observed!
Disregard of the safety notices can result in danger to the life and limb or
environmental and property damage.
Bear in mind that the safety warnings in this manual and on the device cannot
cover all potentially dangerous situations, because the interaction of various condi-
tions can be impossible to foresee. Merely following the instructions may not suf-
fice for correct operation. Always remain attentive and consider potential conse-
quences.
• Read this operating manual and especially the following safety notices care-
fully before working with the device for the first time.
• Warnings are provided in the operating manual for unavoidable residual
risks for users, third parties, equipment, or other property. The safety in-
structions used in this manual do not refer to unavoidable residual risks.
• Only operate the device in fault-free condition and in observance of the op-
erating manual.
• Compliance with local statutory accident prevention, installation and assem-
bly regulations is also mandatory.
Caution
All notices in the manual must be observed.
Use of the gas chromatograph PGC 9300 is only permitted in accordance
with the specifications in the operating manual.
RMG assumes no liability for damages arising due to disregard of the op-
erating manual.

1 About this manual
Danger
Service and maintenance tasks or repairs that are not described in the op-
erating manual must not be carried out without prior consultation with the
6
manufacturer.
Changes to the device are not permitted.
The technical specifications must be observed and followed for safe oper-
ation (see chapter 13: Technical specifications).
Performance limits must not be exceeded.
Please only use screws, bolts, nuts and seals or parts with comparable
characteristic values for installing the meter in the pipeline. (see chapter 7
Construction and Planning)
For safe operation, the device must only be used in the scope of the in-
tended use. (see chapter 5.1 Intended use).
1.2.4.2 Dangers during commissioning
Initial commissioning The initial commissioning must only be carried out

by specially trained personnel (training by RMG) or
RMG service personnel.
Note
An acceptance test certificate and corresponding test report must be cre-

ated for the commissioning.
These, the operating manual and the CE Declaration of Conformity must
be stored so that they are always readily available. In the process, the en-
tire documentation, including the conformity declarations and certificates
must be checked for completeness.
As far as possible, all sharp edges on the device have been removed. Nev-
ertheless, personal protective equipment must be used for all work, which
must be provided by the operator.

1 About this manual
Danger
This symbol is used in the manual as a warning of the dan-

ger of explosion; observe the instructions following the 7
symbol.
With the danger of explosion, the following must be observed, in particular:

• Install the device as specified in the operating manual. If the device is not
installed as specified in the operating manual, there may be a risk that other
connected devices do not have adequate explosion protection.
The explosion protection is lost!
• Inadequately qualified persons working on the equipment are unable to cor-
rectly estimate dangers. Explosions can be triggered. Only work on the
equipment if you have the appropriate qualifications.
• Components can be damaged if you do not use suitable tools and materi-
als. Use tools that are recommended for the respective work in the operat-
ing manual.
Mechanical installation Mechanical installation must only be performed by ap-

propriately qualified technicians.
Electrical installation Installation on electrical components must only be car-
ried out by qualified electricians.
Mechanical and/or elec- These qualified personnel require training specifically for
trical installation work in explosion-prone areas. Qualified personnel are
persons who have training / education in accordance
with DIN VDE 0105, IEC 364 or comparable stand-
ards.
Danger
Connection of pressurized pipelines must only be carried out by trained
qualified personnel.

1 About this manual
Danger
The installation and removal of the USM GT400 may only take place in a
depressurized state and in an explosion-free atmosphere. During the in-
8
stallation process, the descriptions in the operating instructions must be
observed.
In general, it is recommended to carry out an exchange only in consulta-
tion with RMG Service.
After working on pressure-bearing components, the tightness must be
checked.
All of the above points also apply to repair and maintenance work and gen-
erally when the meter has to be opened.
Flange fastening elements, screw plugs, screw connections and check
valves as well as pressure extraction screw connections, valves and pro-
tective tubes must not be loosened during operation.

1 About this manual
1.2.4.3 Dangers during maintenance and repair
Operating personnel The operating personnel use and operate the device in
the scope of the intended use. 9
Maintenance personnel Work on the device must only be carried out by qualified
personnel who can carry out the respective tasks on the
basis of their technical training, experience and familiar-
ity with the applicable standards and requirements.
These qualified personnel are familiar with the applica-
ble statutory regulations for accident prevention and can
independently recognize and avoid potential dangers.
Maintenance and clean- Maintenance and cleaning must only be performed by
ing appropriately qualified technicians.
Danger
Inadequately qualified persons working on the equipment are unable to

correctly estimate dangers. Explosions can be triggered. If work on live
equipment must be conducted in explosion-prone areas, sparks that are
created can trigger an explosion.
Only work on the equipment if you have the appropriate training and quali-
fications.
Danger
The device can be damaged if it is not cleaned as specified in the operat-
ing manual. Only clean the device as specified in the operating manual.
If you do not use the appropriate tool, components may be damaged. The
explosion protection becomes invalid.
• Only clean the device with a slightly damp cloth!

1 About this manual
Danger
The USM GT400 must only be used as intended! (Chapter 5.1).
10
Danger
Prevent use of the USM GT400 as a potential climbing aid or use of attach-
ments of the USM GT400 as potential handles.
1.2.4.4 Qualifikation of the user

Notice
In general, the following is recommended for all persons working with or on

the USM GT400:
• Training / education for work in explosion-prone areas.
• The capacity to be able to correctly estimate dangers and risks when work-
ing with the gas USM GT400 and all connected devices. Possible dangers
include components that are under pressure and consequences of incor-
rect installation.
• Recognition of dangers that can arise from the flow medium that is used.
• Training / education by RMG for work with gas measuring devices.
• Education / instruction in all national standards and directives to be com-
plied with for the work to be carried out on the USM GT^^400 analytical
computer.

1 About this manual
1.2.5 Risk assessment and minimization

According to assessment by qualified employees of RMG, the USM GT 400 is
subject to risks during its use. Risks can also arise due to high pressures and oc-
casionally due to pressures that are too low. Work outside of the permissible tem- 11
perature range can also lead to dangers. Impermissible current and voltage values
can trigger explosions in explosion-prone areas. The risk assessment requires an
emptying and ventilation of the pipeline for connection of a USM GT 400. Then
and only then it is assured that there is not an explosion-prone gas mixture in the
pipeline. Naturally, work must only be carried out by trained personnel (see chap-
ter 5.3 Qualification of the personnel) who are also trained to recognize suitable
tools and use them exclusively. These risks were summarized alongside develop-
ment and measures were taken to minimize these risks.
Measures for risk minimization:

- All pressurized parts are designed in accordance with AD 2000 rules and regu-
lations, Pressure Equipment Directive, Annex 1
- The complete pressure design has been inspected by TÜV Hessen
- All pressurized parts have been manufactured with a material certificate; there
is an uninterrupted change of batch tracing of pressurized components
- The mechanical properties of all relevant pressurized components have been
subjected to tension tests, notch impact bending tests and hardness tests
- Non-destructive testing was also carried out: X-ray and ultrasonic inspection of
the meter housing for defective points in material, surface crack testing with
magnetic powder and a color penetration process
- Strength tests for components were conducted at 1.5 times the nominal pres-
sure for the pressure testing; the leak testing for the assembly was conducted
at 1.1. times the nominal pressure. Certificates were issued for successfully
passed tests.
- The maximum operating pressure and the permissible temperature range are
specified on the type plate of the device. Operation of the device is only permit-
ted within these specified ranges.

1 About this manual
Danger
The following applies for work in explosion-prone areas (all zones):
12 - Only tools that are approved for Ex Zone 1 are permitted for mainte-
nance and repair tasks. Components can be damaged if you do not
use suitable tools.
The explosion protection is lost.
- Otherwise, work must only be carried out when there is not an ex-
plosive atmosphere.
- The risk of ignition due to impact or friction must be avoided.
- The wiring from and installation of the gas chromatograph PGC 9300
in explosion-prone areas must only be carried out by trained person-
nel in accordance with EN60079-14 and in observance of national
regulations.
- Qualified persons must satisfy the definitions in accordance with
DIN EN 0105 or IEC 364 or directly comparable standards.
- Only trained and instructed personnel are permitted. Work on the
measuring system must only be carried out by qualified persons and
inspected by responsible qualified supervisors.
- Qualified persons have been authorized by the person responsible
for safety of personnel to carrying out such work on the basis of
their training, experience or instruction and familiarity with applica-
ble standards, provisions, accident prevention regulations and sys-
tem conditions. It is essential that these persons are able to recog-
nize and avoid potential dangers in good time.

1 About this manual
1.2.6 Validity of the manual

This manual describes the Ultrasonic Flowmeter USM GT400. The Ultrasonic
Flowmeter USM GT400 is only part of a complete system. The manuals of the
other components of the system must be observed, too. If you find contradictory 13
instructions, contact RMG and/or the manufacturers of the other components.
Caution
Ensure that the power data of the current connection matches the specifi-
cations on the type plate. Observe any applicable national regulations in
the country of use. Use cable that is appropriate for the cable fittings (see
chapter 8.3 Connecting the device electrically).
Danger
Only work on the equipment if you have the appropriate training and quali-
fications.
1.2.6.1 Danger during operation

Observe the specifications of the system manufacturer and/or system operator.
1.2.6.2 Dangers of operation in EX areas

Danger
Only use the ultrasonic flowmeter USM GT 400 in its original condition.
• Only operate the USM GT 400 in fault-free and complete condition. If you make
technical changes to the device, safe operation can no longer be guaranteed.
• When connecting additional measuring components or additional equipment in
explosion-prone areas, ensure that the appropriate explosion protection is pro-
vided for these components.
• They are intrinsically safe devices for which galvanic isolation must be provided
with connection of these devices.

1 About this manual
The USM GT 400 is permitted for operation in Ex Protection Zone 1, but only
within the permissible temperature range (Chapter 13: Technical specifications).
14
1.2.6.3 Responsibility of the operator
As the operator, you must ensure that only adequately qualified personnel work on
the device. Ensure that all employees who work with the device have read and un-
derstood this manual. You are also obligated to train personnel regularly and in-
form them of the dangers. Ensure that all work on the device is carried out exclu-
sively by qualified persons and inspected by responsible qualified supervisors. The
responsibilities for installation, operation, fault rectification, maintenance and
cleaning must be clearly regulated. Instruct your personnel with regard to the risks
involved with working with the device.
Suitable personal protective equipment must be used for all work on the USM
GT400, which you as the operator must provide. This also applies even though all
sharp edges on the device have been removed as far as possible.
1.2.7 Transport
The device is packaged specific to the transport requirements for each customer.
Ensure safe packaging that absorbs light impact and vibrations is used for any fur-
ther transport. Nevertheless, inform the transport company that all types of impact
and vibrations should be avoided during transport.
The following applies in particular to transport:

• Shocks and vibrations are to be avoided
• Protect the USM GT400 from moisture
• If you suspect improper transport or damage during transport, please contact
RMG's service department immediately

1 About this manual
Warning
Risk of injury during transport
Any foot screws must be mounted if they are provided as a transport safe- 15
guard to prevent rolling and tipping. Additional measures must be taken to
ensure that impermissible rolling and tipping are prevented.
Only use the provided lifting eyes / ring screws to lift the meter. Please ob-
serve the relevant permissible loads for the lifting equipment. Prior to lift-
ing, ensure that the load is securely fastened. Do not stand under sus-
pended loads.
The device can slip, topple over or fall down when being lifted and set
down. The device can fall over if the bearing capacity of the lifting equip-
ment is disregarded. There is a risk of severe injury for nearby persons.
If the device is delivered on a Euro pallet, the device can be transported
on the pallet using a pallet truck or forklift.
The gas meters and accessories must be protected from jarring and vibra-
tions during transport.
The gas meters or any inlet/outlet pieces have a flange as an end piece.
The flanges are sealed with a protective sticker or fitted with a plastic
dummy plug. The protective stickers and/or dummy plugs must be re-
moved without leaving any residue prior to installation in the pipeline.
Residue from this film changes the flow and causes measuring errors!
This protection must be re-applied to the flanges for transport or storage
of the device.

1 About this manual
1.2.8 Scope of delivery

The scope of delivery can differ depending on the optional orders. The following is
"normally” included in the scope of delivery:
16
Part Quantity
Ultrasonic Flowmeter USM GT400 1
Manual 1
Test log 1
Calibration certificate 1
Material test certificate 1
Strength test certificate 3.1 optional
1.2.9 Disposal of packaging material

Dispose of the material in an environmentally friendly manner in accordance with
national standards and directives.
1.2.10 Storage
Avoid extended periods of storage. After storage, inspect the device for damage
and test for correct function. Contact the RMG service department to arrange for
inspection of the device after a storage period of longer than one year. For this
purpose, return the device to RMG.
If storage is nevertheless necessary, the following must be observed:
• Storage must take place in a dry and protected room.

• It must be ensured that all open pipes are sealed.

1 About this manual
1.3 Explosion-proof design

1.3.1 General information
17
Danger
The USM GT400 is permitted for installation in explosion-prone areas in Zone 1 that
are endangered by gas and vapor assigned to explosion group IIB+H2 and tempera-
ture class T6.
ATEX – Zulassungsnummer: BVS 14 ATEX E 034 X
Code: II 2G Ex de IIB+H2 T6 Gb
The device conforms to the requirements of Directive 94/9/EC.
The applicable regulations must always be observed during installation and opera-
tion. The device is approved for operation in hazardous areas. The permitted elec-
trical data can be found in chapter 8.3 Connecting the device electrically.
Danger
Risk of destruction by body electricity, e.g. due to friction of clothing - ap-
propriate protective clothing must be worn.
Notice
During installation, it must be ensured that the enclosure protection class
is observed. Direct sunlight must be avoided.
The USM GT400 complies with protection class IP66 due to EN 60529.

1 About this manual
Temperature range
MID:
-20°C bis +55°C (Umgebungstemperatur, für eichamtliche Messung)
18
Nach ATEX:
-40°C bis +80°C
Notice
In case of doubt, the limited range of the MID applies: -25°C to +55°C
(optional -40° bis +55°C)
1.4 Inspection and maintenance work

1.4.1 General information
Explosion-proof electrical control units must be regularly maintenanced. The time
intervals of this maintenance depend on the operating and environmental condi-
tions.
Notice
We recommend at least one check per year (e.g. in connection with the an-
nual calibration).
This chapter provides information on how you can extend the service life of the de-
vice through maintenance. You can only protect the device from premature wear if
you adhere to the maintenance interval described here.
Danger
Work on live electrical equipment is generally prohibited in hazardous ar-
eas (except for intrinsically safe circuits).
In special cases, work can also be carried out on live electrical equipment in haz-
ardous areas if it is ensured that no potentially explosive atmosphere is present.
This may only be done with explosion-proof, approved measuring instruments.

1 About this manual
Danger
If access to electrical modules is necessary, the following precautions
must be taken: 19
• The entire device must be disconnected from the power supply.
• When working with electronic assemblies, a connection must be
established between an earthed object and the body.
Notice
Pay attention to accumulation of water in the housing, because the explo-
sion-proof housing is only conditionally protected from water by the gap
protecting against ignition sparks (IP54).
Rusted or corroded gaps must not be cleaned with grinding materials or
wire brushes; chemical means must be used, such as reducing oils. Then
acid-free anti-corrosive agents, such as ESSO RUST BAN 397, Mobil Oil
Tecrex 39 or equivalent products must be applied to the gaps for protec-
tion.
Danger
The seal for the Ex-e housing must be inspected for damage and replaced
as necessary.
Check cable connections and sealing plugs for tight seating.
Damage to the housing can negate the Ex protection!
If the device is repaired regarding a part which depends on explosion protection, it

may only be put back into operation after it has been checked by a certified expert
(section 1.2.4.4 Qualifikation ).
If repairs are carried out by RMG service, no acceptance by an expert is required.

2 Quick guide
2 Quick guide
This chapter does not replace the rest of the operating instructions. It shows only a
20 brief section of the steps necessary in order to make the device ready for
operation.
The chapter is only directed at experienced users.

• Observe the chapter safety.
Section 5, “Safety” on page 53
Detailed information for this content can be found under:

Section 7, “Construction and Planning” on page 81
Section 8, “Installation” on page 95
Section 9, “Start Up” on page 132
Section 12.4, “Troubleshooting” 175
Danger
This chapter is only intended for experienced users!

It does not replace all safety instructions that are primarily listed in the
first part of the manual but can also be found in the remaining chapters.
Moreover, use of this chapter “Quick guide” requires that the experienced
user is familiar with all of these safety instructions and implements them
when working with the device.
RMG rejects liability for any damage to the device or other connected de-
vices if a user disregards even one of the safety notices in the overall
manual because of this chapter “Quick guide”. This also applies to safety
instructions to which reference was only made in this manual but were not
explicitly listed.

2 Quick guide
2.1 Mechanical connection

2.1.1 Connection flanges
1 Make sure that the device and the connection flange have the same pressure 21
rating / flange standards.
2 Make sure that the device is sealed with the appropriate seals.
2.1.2 Inlet / outlet piping

Operating mode Inlet piping Outlet piping Temperature sensor
position
Unidirectional operation 10 D (no flow condi- 3D 1,5 D to 5 D
tioner)
Unidirectional operation 3 / 5 D (with RMG or 3D 1,5 D to 5 D
standardized flow condi-
tioner)1
Bidirectional operation 10 D (no flow condi- 10 D (no flow condi- 3 D to 5 D
tioner) tioner)
Bidirectional operation 3 / 5 D (with RMG or 3 / 5 D (with RMG or 2 D zo 5 D1
standardized flow condi- standardized flow condi-
tioner)1 tioner)1
1 Depending on the nominal width.
See also “Inner diameter of connecting spool pieces” on page 189
2.1.3 Joining pressure connections
◼ Establish connection with the clamping screw connection.

3 Unscrew the union nut of the clamping screw connection.
4 Remove the blind plug.
5 Push the union nut and clamping rings onto the pipe.
6 Push the pipe into the clamping screw connection until the stop.
7 Tighten the union nut in order to fix and seal the pipe.
◼ Establish connection with the female thread.

8 Unscrew the blind plug.
9 Seal the connection in the thread.

2 Quick guide
2.2 Electrical connection
22
1 Terminal Connections
Fig. 2.1: Connection assignment on the terminal strip
10 Connect the computer to the terminals RS 485-0.

11 Allocate the terminal strips according to the applications.
Option: connect ERZ 2000 (-NG) to RS 485-1.
You find recommended cable types in the chapter 8.3 Connecting the device electri-
cally.
2.3 Start up
12 Supply the device with power supply (24 V DC) via the system.
If the power LED illuminates green permanently, the device is ready for
operation.
If the alarm and warning LED do not flash, the device operates trouble-free.
Section 3.2, "Light emitting diodes" on page 30
The USM-GT-400 is supplied without connection box to the North American

region, the connection is made to cables that are led through a flame arrester.
The marking of the cable (numbers) is (always) identical to the terminal as-
signment.

2 Quick guide
2.4 Earthing
23
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 2.2: Earthing – Ultrasonic gas meters DN100 (4”) and DN150 (6”)
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 2.3: Earthing – Ultrasonic gas meters ≥ DN200 (8”)
13 Connect the earthing cable according to the ultrasonic gas meter version
DN100 (4") to DN150 (6") or from DN200 (8").

2 Quick guide
2.5 Parameter setting

The device shall be supplied pre-assembled according to customer agreement.
Changes to the pre-assembly are more extensive and are therefore not described
24
in this brief instruction. If this should be necessary, you will then find the descrip-
tion:
Section 10.1.3, “Calibration and Service Switch” on page 136

3 Device overview
3 Device overview
In this chapter you will receive information on the main components
of the ultrasonic gas meter and the arrangement of the 25
ultrasonic transducers in the housing of the ultrasonic gas meter.
Content
3.1 Main components 25

3.2 Ultrasonic electronics 27
3.3 Arrangement of the ultrasonic transducers 31
3.1 Main components
1 Covers of the transducer and transducer lines

2 Covers of the transducer
3 Ultrasonic electronics
4 Lifting eyes
5 Joining flanges
6 Transducer
7 Retaining bolts
Fig. 3.1: Main components of the ultrasonic gas meter

3 Device overview
The ultrasonic gas meter consists of the following main components:
Covers of the transducers (1 and 2)

26 The covers protect the connections and the lines of the transducer (TD) against
contamination and mechanical damage.
Ultrasonic electronics (3)
The ultrasonic electronics is in a pressure tight, encapsulated housing mounted on
the ultrasonic gas meter. The ultrasonic electronics evaluates the data recorded by
the transducers. In addition to the display, the parameters can be shown and eval-
uated on a computer using the RMGViewUSM software.
Lifting eyes (4)
The lifting eyes can be used to safely transport the device using a suitable lifting
gear.
Connection flange (5)
The device is bolted onto the gas line using the connection flanges.
Transducer (6)
The transducers are installed in the housing of the ultrasonic gas meter and are
not visible once installed.
Retaining bolts (7)
The retaining bolts are mounted when delivering the device. The retaining bolts
secure the product from tipping over or rolling away. The bolts must be mounted to
ensure for a safe installation or de-installation.

3 Device overview
3.2 Ultrasonic electronics
27
1 Service- and calibration switch

2 Control panel
3 Display
4 Magnet for operation
5 Cover with viewing window
6 Pressure tight housing
Fig. 3.2: Ultrasonic electronics and display
Device data (readings and parameters) can be set and evaluated via the display
and the operating elements.
Moreover, the device data (readings and parameters) can also be shown, evalu-
ated and set using the RMGViewUSM software.
Service and calibration switch (1)

The service switch (right switch) is only for RMG service. The service switch is,
e.g., used to install new firmware.
The calibration switch (left switch) protects the parameters against unauthorized
changes. The device can be configured by opening the calibration switch.
Control panel (2)
The control field comprises buttons that are triggered by pressing a button or mag-
netically. Parameters, readings, warning, alarm and status messages are called up
using the button.
Display (3)
The display shows the readings, warning, alarm and status messages as well as
the parameters.
Magnet for operation (4)
The magnet is used to operate the control panel of the ultrasonic electronics when
the housing is closed. If the magnet is placed above the symbol on the viewing
window, this function is activated.

3 Device overview
Cover with viewing window and pressure tight housing (5 and 6)

The cover and the pressure tight housing encapsulate the ultrasonic electronics
against the potentially explosive atmosphere.
28 During operation, information can be read through the viewing window from the
display and status indicators of the LEDs.
Electrical connection (Terminal strip)
More information on the electrical connection can be found here:
Chapter 8.3, „Connecting the device electrically“ on page 103
Display screen
Fig. 3.3: Ultrasonic electronics display
First line
Shows the name of the parameter (coordinates) called-up, e.g., p-maximum value
(maximum pressure value).
Second line
Shows the value of the parameter (coordinates) called-up, e.g., 52.00 bar a.
Third line
Shows the coordinate designation, e.g., A-06, thus column A, line 06.
The calibration switch is open. The value of the parameter can be

changed.
The calibration switch is closed. The value of the parameter cannot

be changed.
Forth line
Shows the warning, alarm and status messages, e.g., -01 power failure.

3 Device overview
Buttons
When the cover is closed, the buttons can be operated through the glass using the
magnet supplied. The cover must not be opened.
29
Change to the columns. Jump, e.g., from A to B and back again.
When holding for a longer time, you can change the columns by quickly
scrolling back.
When holding for a longer time, you can change the columns by quickly
scrolling back.
When holding for a longer time, you can change the lines quickly scrolling
forward.
Change or scroll back in the lines step by step, e.g., from A-01 to A-02.
When holding for a longer time, you can change the lines with quick return.
Enter values.
Reset button
1 The reset button (1) is for RMG service only. If the reset
button is pressed, the ultrasonic electronics is restarted.
Switches
1 Calibration switch: Activate to change parameters.

2 Service switch: For RMG service only. For installing a new firm-
ware.

3 Device overview
Light emitting diodes
30
1 Flow 6 Calibration
2 Power (calibration switch state)
3 Alarm 7 Service
4 Warning (service switch state)
5 Reset 8 Button states
Fig. 3.4: LEDs of the electronic ultrasonic electronics
LED Illuminates flashing

continuously
Voltage supply is ---
Power
switched on
Flow Gas flow present. ---
Alarm message is Alarm is active.

Alarm
stored.
Warning message is Warning is active.
Warning
stored.
Reset is running. ---
Reset
Calibration switch is ---

Calibration
open.
Service switch is open. ---
Service
---
Control panel Panel is being pressed.

3 Device overview
3.3 Arrangement of the ultrasonic transducers
31
1 Level 1
2 Level 2
3 Level 3
4 Path 1 and 2
5 Path 3 and 4
6 Path 5 and 6
Fig. 3.5: Transducer paths and levels of the ultrasconic gas meter
The figure shows the arrangement of the transducers that are located in the
ultrasonic gas meter. The arrangement of the transducers in the three levels is
shown in three section representations.
Four transducers are installed per level. The transducers form two paths per level
for the measurement.

4 Functional principle – Ultrasonic-flow measurement
4 Functional principle – Ultrasonic-

32
flow measurement
Content
4.1 General description 33

4.2 Correction of the base line 37
4.2.1 Base line correction via polynomial 38
4.2.2 Correction via a piecewise linearization 39
4.3 Diagnostic function Speed of Sound 40
4.3.1 Standard method of SoS calculation 40
4.3.2 SoS calculation via gas components 40
4.3.3 Extended SoS calculation 41
4.4 Import of gas composition data 42
4.4.1 Option 4: Data input on fixed defaults 43
4.4.2 Data input on fixed defaults for air 43
4.4.3 Data input via RMGBus 45
4.4.4 Data via Modbus (USM GT400 is SLAVE) 46
4.4.5 Import of data via Modbus (USM GT400 is Master) 47
4.54.5 Batch modeBatch mode 52

4.1 General description

In this chapter, you are provided with information as to how the ultrasonic gas
meter records the data. The necessary formulas are listed for this purpose.
33
Figure 4.1 shows the general working principle. Transducer TD1 and TD2 are
positioned opposite to each other for the measurement and form a measurement
path with distance L. An ultrasonic pulse travels along the measuring path from
sensor TD1 to transducer TD2 more quickly than the other way around. This is
caused physically by vector addition of the flow velocity to the speed of sound, the
arrow above the ṽ shows the direction of flow.
Fig. 4.1: Two sensors form one path for the measurement
The transit time from TD1 to TD2 (:= tTD12 ) and from TD2 to TD1 (:= tTD21 )
re calculated according to the following formula:
Formulas
𝐿 𝐿
𝑡𝑇𝐷12 = 𝑡𝑇𝐷21 =
𝑐0 + 𝑣̅ · 𝑐𝑜𝑠𝛽 𝑐0 + 𝑣̅ · 𝑐𝑜𝑠𝛽
These transit times of the ultrasonic pulses are determined by the electronic
ultrasonic system. These are used to determine the average velocity ṽ along the
measuring path:
Formula, average path velocity

𝐿 1 1
𝑣̅ = ∙( − )
2 ∙ 𝑐𝑜𝑠𝛽 𝑡𝑇𝐷12 𝑡𝑇𝐷21
𝐿2 𝑡𝑇𝐷21 − 𝑡𝑇𝐷12 𝐿2 𝛥𝑡
𝑣̅ = ∙ = ∙
2 ∙ 𝑑 𝑡𝑇𝐷12 ∙ 𝑡𝑇𝐷21 2 ∙ 𝑑 𝑡𝑇𝐷12 ∙ 𝑡𝑇𝐷21

Legend
v̄ Average flow velocity
34 c0 Speed of sound
β. Path angle to the pipe
L: Path length
d: Diameter D
(For a center path. Outer paths have a corresponding value.)
For this calculation, it is important that only the transit times and the device param-
eters such as the transducer distance and the angle of the measuring path to the
flow direction are required. All parameters that include a gas dependency are
omitted.
In order to consider the average flow profile, in particular an asymmetrical or swirl-

affected flow, a total of 6 paths is measured in 3 levels with the USM-GT-400 ultra-
sonic gas meter. The 3 levels can be derived mathematically via an integration
procedure, the so-called Gauss integration.
„Arrangement of the ultrasonic transducers" on page 33
The respective average path velocities (designated with vi = v̄i for the respective
measuring path i) along these measuring paths results analogically to the formula
above.
Under certain conditions such as, e.g., smaller deviations from the tolerances
during the production, it may be necessary to correct the path velocities with a
common factor:
vki = k vi
Legend
vki = Corrected path velocity (m/s)
k = Correction factor for the path velocities

(This factor is named vw factor d1 for the forward
direction and vw factor d2 for back-flow; see pa-
rameter list)

Thus, one obtains for the average flow velocity:

v
vw = ∑ wi ∙vki
35
i=1
Flow velocity
Legend
vw = Average flow velocity (m/s)
wi = Weighting factor with regard to the flow profile
The summation and the weighting specified result from the mathematic Gaussian
integration procedure.
Quality of installation
The USM-GT-400 provides parameters that allow a rating of the installation. If the
values are within given ranges, then good measurement conditions can be as-
sumed. If the values are outside the accuracy of the reading may be affected by
disturbed flow conditions. Please contact in this case the RMG service.
"Manufacturer" on page I
Turbulence
Due to the actual flow, in particular the turbulence, there will be

characteristic variations (variance σi ) of the individual path velocities
(i = 1..6; number of ultrasonic measuring paths), which
allow an assessment of the installation. The ultrasonic path averaged
turbulence (Tui ) is calculated as follows:
𝑁
1
𝜎𝑖 = √ ∑(𝑣𝑗,𝑖 − 𝑣̅𝑖 )2 ˄ 𝑖 = 1. .6; 𝑁 = 20
𝑁−1
𝑗=1
Variance
𝜎𝑖
𝑇𝑢𝑖 =
𝑣̅𝑖
Turbulence

Legend
v̅i = Time averaged flow velocity along the ultrasonic path
36 v̅j,i = Flow velocity along the ultrasonic path
N = N = number of measured values according to parameter

E-9 “moving average cnt”. For a significant determination
of turbulence, the number should be at least 10.
Typical values at very good flow conditions for middle paths are at 2-3%, for the
outer paths, the turbulence increases to 4%. If these values are above 10%, then
disturbed conditions can be assumed affecting the measurement accuracy. At
lowest velocities the turbulence calculation is switched off.
Profile and symmetry factor
For a fully developed flow the middle path (3 + 4) have the highest velocity, the
two outer paths (1 + 2; 5 + 6) are more or less equal. The profile factor ( PF ) is
typically between 1.05 to 1.20; at values below 1.00 or above 1.50, the flow condi-
tions should be checked.
2(𝑣̅3 + 𝑣̅4 )
𝑃𝐹 =
(𝑣1 + 𝑣̅2 ) + (𝑣̅5 + 𝑣̅6 )
Profile factor
The symmetry factor ( SY ) usually is between 0.9-1.10; at values below 0.75 or

above 1.25 the flow conditions should be checked.
(𝑣̅5 + 𝑣̅6 )
𝑆𝑌 =
(𝑣1 + 𝑣̅2 )
Symmetry factor
Meter performance
This value ( MP ) indicates whether the velocity of all ultrasonic paths could be
measured and involved in the flow calculation. It is calculated on base of the last
20 measurements (same as turbulence).
∑1..100 ∑𝑖=1..6 1(˄𝑣𝑗,𝑖 = 𝑜𝑘)˅0(˄𝑣𝑗,𝑖 ≠ 𝑜𝑘)

𝑀𝑃 =
600

The highest value is 100%; under normal conditions it is above 95%. Since 2
measurement paths can fail before the USM-GT-400 loses its calibrated accuracy,
the value may drop down to 66%; if the path failure is caused by a defect trans-
ducer
an immediate repair of the failed transducers should be initiated. 37
All of these values are given at the display of the USM-GT-400; they are identical
to the values in the RMGViewUSM.
4.2 Correction of the base line

Correction of the baseline for the velocity
There are several influences (e.g. Reynolds number) resulting in a not exactly pro-
portional relation between the measured and according to the formula 4.5 calcu-
lated mean velocity to the exact mean velocity. Here the following correction helps
to compensate these variations:
Formula, corrected average flow velocity

𝐹
𝑣𝑤𝑘 = 𝑣𝑤 ∙ 𝐾𝑣 ∙ (1 + )
100
Legend
vwk = Corrected average flow velocity (m/s)
Kv = Meter factor
F = Error from the characteristic curve correction
These values can be used to calculate the process volume flow rate respectively
the corrected process volume flow:
Formula, process volume flow

𝐷𝑖2 𝑠
𝑄𝑚 = 𝑣𝑤 ∙ 𝜋 ∙ ∙ 3600 ∙
4 ℎ
Formula, corrected process volume flow
𝐷𝑖2 𝑠
𝑄𝑚𝑘 = 𝑘𝑘 ∙ 𝑣𝑤𝑘 ∙ 𝜋 ∙ ∙ 3600 ∙
4 ℎ

Legend
Qmk = Corrected process volume flow
38 vwk = Corrected weighted flow velocity
Di = Inside pipe diameter
Kk = Characteristic curve correction
A 4th degree polynomial permits the so-called basic correction of the device:
4.2.1 Base line correction via polynomial

Formula - Basic correction of the device
𝐾𝑜𝑛𝑠𝑡 − 𝐺𝑚2 𝐾𝑜𝑛𝑠𝑡 − 𝐺𝑚1
𝐹1 = + + 𝐾𝑜𝑛𝑠𝑡 − 𝐺0 + (𝐾𝑜𝑛𝑠𝑡 − 𝐺1 ) ∙ 𝑣𝑤 + (𝐾𝑜𝑛𝑠𝑡 − 𝐺2 ) ∙ 𝑣𝑤2
𝑣𝑤2 𝑣𝑤2
Legend
F1 = Deviation of the error curve (%)
vw = Average flow velocity (m/s)
const-Gx = Constants of the basic correction

(x=m2, m1, 0, 1, 2)
The constants const-Gx (x = m2, m1, 0, 1, 2) are calculated from the measured
value pairs of the deviation with the respective flow velocity. The calculated correc-
tion F1 is used for the corrected average flow velocity for F in the formula above.
Formula, corrected meter factor

𝐹 𝐹1
𝑣𝑤𝑘 = 𝑣𝑤 ∙ 𝐾𝑣 ∙ (1 + ) → 𝑣𝑤 = 𝑣𝑤 ∙ 𝐾𝑣 ∙ (1 + )
100 100
The process volume flow and the corrected process volume flow result, as listed
above, from the multiplication of the corresponding velocities with the pipe cross-
section. The correction formulas above are therefore accordingly easy to transfer
to the volume flows.
Polynomial
The characteristic curve correction is also carried out via a 4th degree polynomial
that represents the error curve of the device.

Formula error equation

𝑐𝑜𝑛𝑠𝑡 − 𝑚2 𝑐𝑜𝑛𝑠𝑡 − 𝑚1
𝐹2 = 2 + + 𝑐𝑜𝑛𝑠𝑡 − 0 + (𝑐𝑜𝑛𝑠𝑡 − 1) ∙ 𝑄𝑏 + (𝑐𝑜𝑛𝑠𝑡 − 2) ∙ 𝑄𝑏2
𝑄𝑏 𝑄𝑏
39
Legend
F2 = Deviation from the error curve (%)
Qb = Flow (m/s)
const-n = Constants
The constants Konst-n (n = m2 bis n = 2) are calculated from the measured value
pairs error F2i and flow Qbi. The characteristic curve correction Kk is used for fur-
ther calculation of the corrected process volume flow.
Formula characteristic curve correction

1 + 𝐹2
𝐾𝑘 = (1 + )
100
4.2.2 Correction via a piecewise linearization

The correction of the base line with a polynomial described in section 4.2.1 takes
into account the typical, characteristic curve of the USM-GT-400 in an ideal way.
This correction is recommended for custody transfer metering in all countries
where the MID is valid. Nevertheless, a comparable accuracy can be achieved
with a piecewise linearization, if a sufficient number of interpolation points are
used. Between the interpolation points, a simple linear interpolation is used. The
correction of the base line with the piecewise linearization may also be used in all
countries where the MID is valid if the error curve of the raw data meets the re-
quirements of the ISO 17089.
In order to achieve a sufficient accuracy most of the measuring points should be

placed in the relevant flow rate range. To take into account the higher gradient of
the curve at lower flow rates the intervals should not be equidistant; recommended
are more
points in this lower flow rate range.

4.3 Diagnostic function Speed of Sound

The USM-GT-400 can calculate the SoS in 3 different ways.
40
4.3.1 Standard method of SoS calculation
The first calculation is realized with help of the transit time tTD12 and tTD12 of the ul-
trasonic pulses (see above) along the measuring path with the length L . It is
straight forward to result in the speed of sound SoS or c0 to:
Calculation of SoS
𝑆𝑜𝑆 = 𝑐0
𝐿 𝑡𝑇𝐷12 +𝑡𝑇𝐷21
= ∙
2 𝑡𝑇𝐷12 ∙𝑡𝑇𝐷21
This first option is pretty fast and is almost permanently "online" available.
4.3.2 SoS calculation via gas components

The second version of SoS calculation uses pressure, temperature and composi-
tion of the gas to determine the SoS according to the specifications of the AGA 10
standard (AGA Report No. 10, Speed of Sound in Natural Gas and Other Related
Hydrocarbon Gases; January 2003; AGA - American Gas Association). The calcu-
lation is based on statistical considerations of thermodynamics; since it is very
complex, it will not be presented here. Knowing the gas composition precisely val-
ues such as density, sound velocity and other gas properties can be calculated
with very high accuracy.
Depending on the type of gas analyzer it may take 5-10 minutes to determine the
volume fractions of the individual gas components accurately. Accordingly, the
precise allocation of flow to the gas composition can be done in this time frame
only.
Diagnostic function SoS

The USM-GT-400 determines with highest accuracy the flow rate of the gas flow-
ing through it. For the payoff the gas quality, respectively the calorific value of the
gas resulting from the gas composition is of course of big interest, too. The USM-
GT-400 allows a second billing of the volume flow rate with the "right" gas compo-
sition, ie the "right" calorific value.
This temporal resolution can be achieved receiving permanently the gas composi-
tion data from a gas analyzer. A comparison of the two differently calculated SoS‘s
in the USM-GT-400 allows the immediate detection of any deviation; in particular,
another gas composition results in a different SoS. A confirmation of another gas
composition then provides the next comparison with the data of the gas analysis
instrument.

The temporal correlation of the actual gas composition (using the SoS calculated
via the gas composition) to the SoS using method 1 results in the higher temporal
resolution for the gas composition, respectively the calorific value.
41
4.3.3 Extended SoS calculation

The third possibility SoS calculation is presented under the name "Extended SoS
measurement". This new method is introduced as an additional determination.
Fig. 4.2: Extended SoS calculation
Transducer TD2 receives at first the ultrasonic pulse (light blue) coming from TD1
at the time (tTD12). This pulse is partially reflected and moves back to TD1 (dark
blue). There this pulse is reflected, too and reaches TD2 (red) again after the time
(tTD12 21 12). The differences of tTD12 21 12 and tTD12 results in a new possibility to cal-
culate SoS:
Calculation of extended SoS
𝑆𝑜𝑆 = 𝑐0
𝐿 𝑡𝑇𝐷12 +𝑡𝑇𝐷21
= ∙
2 𝑡𝑇𝐷12 ∙𝑡𝑇𝐷21
𝐿 (𝑡𝑇𝐷12 21 12 −𝑡𝑇𝐷12 )
= ∙
2 𝑡𝑇𝐷12 ∙(𝑡𝑇𝐷12 21 12 −2∙𝑡𝑇𝐷12 )
Due to a 10-times smaller variance of the SoS calculation this method offers signif-
icantly more accurate result compared to the standard method (version 1). There
are 2 reasons for this result; first, the transmitter / receiver error is eliminated (es-
pecially TW; the transit time of the pulse in electronic and transducer is different in
the individual transducers) and secondly, any flow turbulence in medium has low-
est influence to the transit time (the time interval between tTD12 and tTD21 is as short

as possible). Having typical measuring conditions, this method can easily be ap-
plied, but there are conditions at which this method may fail.
The SoS calculation according to method 1 and 3 run simultaneously and con-
42 trolled using the same criteria. If correct, the result of the extended measurement
is preferred due to its higher accuracy. Otherwise, the standard method 1 is used;
after any change the measurement conditions, both methods are revalued again. If
correct the extended SoS calculation will be chosen again.
TW-setting
Measurement tolerances and/or errors of the standard method are permanently
controlled using the comparison with the expanded method. Having both values a
correction for TW can be determined. When the calibration switch is open, the TW-
value of the standard measurement can be corrected to the value of the extended
measurement. This is an important adjustment help in case of a transducer re-
placed, but also serves as an accurate path lengths determination between the
transducers during the dry calibration.
4.4 Import of gas composition data

To use the diagnostic function SoS, respectively to calculate it from the gas com-
position the USM-GT-400 requires the volume fractions of the individual gas com-
ponents in the gas (up to 21 components), the pressure and the temperature.
From these data SoS is calculated using the guidelines of the AGA 10 standard.
For the data transfer of the gas components four options are available:
Fig. 4.3: Import of gas composition data

4.4.1 Option 4: Data input on fixed defaults

If there are no live data available for the gas analysis, then the gas data can be
stored as fixed values in the USM-GT-400. For the AGA-10 calculation these de-
fault values are used as fixed gas shares (AX-20 - AX-44; in chapter 10 the matrix 43
notation of parameters, measured values and variables will be explained). To
change these values, they have to be confirmed by selecting “Accept new Comp.”
in parameters AX-11 and to be confirmed in “takeover gas components”. Only
then they will be taken over as new values for the AGA-10 calculation.
1. Parameter AX-01 “AGA-10 Source”

Default data
2. Setting of the default values of the individual gas components
Parameter AX-20 to AX-44
Methane default value ....
....
Propene default value
3. Takeover with parameter AX-11 “AGA-10 Source”
“Taking over new components”
4.4.2 Data input on fixed defaults for air

In mode “default air” fixed values of air composition for the gas analysis can be
used. With the additional parameter "rel. humidity" in AX-06 the water content and
component is calculated in mol-% and the remaining components of the air are
normalized to 100%. The unnormalized default values for air are:
Nitrogen: 78,105 mol-%
Oxygen: 20,946 mol-%
Argon: 0,916 mol-%
Carbon dioxide: 0,033 mol-%
Water: 0,0 .. mol-% (calculated)
The water content is calculated via the relative humidity.
1. Parameter AX-01 “SoS source”:
“Default air”
2. Setting of the default values relative humidity
Parameter AX-06 “relative humidity”

All other possibilities to transmit the volume fractions of the individual gas compo-
nents on the USM-GT-400, will use interface 2 of the USM-GT-400.
Terminal connections
44
The following figure shows the terminal connections.
1 Terminal connections
2 COM
3 Gas-Chromatograph
Fig. 4.4: Terminal connections
The SoS calculation depends in addition to the gas components also on the gas
pressure and temperature. How to measure the pressure is described in chapter
8.4; temperature measurement is given in chapter 7.4. Setting of the parameters
AX-02 "SoS Source Temp." and AX-03 "SoS Source Pressure" allows to select
whether these measured values of temperature and pressure are used for AGA-10
calculation or default values AX-04 and AX-05.

45
Fig. 4.5: Pressure and Temperature input
The electric connection of pressure (p) and temperature (T) has to be done a
terminals 26 to 31; AUX1 = p; AUX2 = T.
4.4.3 Data input via RMGBus

The data of a gas chromatograph (eg. RMG GC9000 or GC9300) can be delivered
as RMGBus telegram via the RMGBus protocol. Therefore, the coordinate AX-01
“SoS AGA-10 source data“ is set to "Serial port 2" and the serial interface in the
mode "RMG- Bus". Additionally the parameters of the interfaces USM-GT-400 and
the RMGBus master device have to be aligned to each other.
Because the content of the telegram may have data from different streams, the
„right“ stream has to be set with the parameter AX-09 "Stream selection". Parame-
ter AX-08 "RMGBus mode" fixes how many components are part of the telegram.
When using a GC9000 this parameter has to be set to "RMGBus" to offer a correct
evaluation for older versions of the software GC9000.
1. Parameter J-25 "Opt. Ser2 mode":
"RMGBus"
2. Schnittstellenparameter von Seriell 2 anpassen:
J-26 „baud“
J-27 „bits“
J-28 „parity“
Match RMGBus master:
„Serial port 2“
3. Parameter AX-01 "AGA-10 source“:
"Serial port 2"

4. Parameter AX-07 "maximum timeout":

Time in minutes, within which a new telegram has to come via RMGBus
5. Parameter AX-08 "RMGBus mode":
46
GC9000: "RMGBus"
GC9300: "RMGBus 24 Komp."
6. Parameter AX-09 "Stream selection":
Allows the setting of the desired streams.
4.4.4 Data via Modbus (USM GT400 is SLAVE)

The gas data can be written to Modbus USM-GT-400 (USM-GT- 400 is Slave).
Data source can be any field devices that operate as a Modbus master on the bus.
The individual gas components will be written into the Modbus register of parame-
ters AY-20 to AY-44. To accept these values for the AGA-10 calculation parame-
ters AX-11 has to be set to "Set new comp.". The parameters will be set as:
"Modbus"
2. The parameters of serial port 2 have to be adapted to the setting of the
Modbus master:
J-26 "baud"
J-27 "bits"
J-28 "parity"
3. The Modbus has to be set to "RTU" or "ASCII" according to the setting of
the master. Due to the configuration of the hardware it has to be set to
RS232 or RS485, too:
J-29 "Modbus-2 protocol"
J-30 Modbus-2 HW-mode
4. Parameter AX-01 "AGA-10 source":
"Serial port 2"
"Modbus-Master"

47
Fig. 4.6: Import of data via Modbus
4.4.5 Import of data via Modbus (USM GT400 is Master)

USM-GT-400 gets the gas data via Modbus. It is Modbus master and asks contin-
uously if new data are available. In this case, all the components are re-read and
fed to the AGA-10 calculation. Parameter AX-10 "Modbus Master Target" sets
which device the USM-GT-400 is addressing. If the GC9300 is chosen no Modbus
register needs to be set at AZ-01 to AZ-54 for status and part of the gas compo-
nent.
Time [minutes] in which a new telegram must have come via RMGBus.
2. Adjustment of the parameter of serial port 2
J-26 "baud"
J-27 "bits"
J-28 "parity"
3. Modbus configuration:
J-29 "Modbus-protocol 2"
Master has to be set to "RTU" or "ASCII"
J-30 Modbus-2 HW-mode
Hardware configuration can be selected as RS232 or RS485
J-31 "Modbus-address 2"
Slave-address of the device with the gas data
4. Parameter AX-01 "AGA-10 source":
"Serial Port 2"


Time [minutes] in which a new telegram must have come
48
Time [minutes] in which a new telegram must have come
Timeout: During the transfer of data, an adjustable time-out is
available, generating a status signal if no new data arrived within
the adjusted time.
6. Parameter AX-10
"Modbus-Master Target": "GC9300"?
If yes, continue after 8, otherwise at 7.
7. Parameter AZ-01 - AZ-54
Enter Modbus registers of the gas components and status of the
slave device
Treatment of the gas data

The gas data are validated after transmission and optionally normalized. The
AGA-10 gas equation accepts up to 21 gas components; it might even accept up
to 24 components adding some (surplus) gas components to other components.
Neo-pentane: added to n-pentane (see ISO 12213-2)
Propene: added to propane
Ethen: added to CO2 (see ISO 12213-2).
Hexane+: sum of n-hexane, n-heptane, n-octane, n-nonane and n-decane. If there

is only hexane+ in the samples and none of the above-mentioned components,
then hexane+ is added to hexane. In case one of these components is > 0, then
hexane is + ignored.
.
Normalization to 100 mol-%: If the sum of gas components isn‘t 100 mol-%, then
the components are normalized to a total of ˃ 100 mol-% (can only be applied if
the sum is > 0 mol-% and < 110 mol-%). Otherwise, Bit 0 in AW-01 "SOS calcula-
tion status" will be set and the calculation takes place with 100 mol-% methane in-
stead.

49
Fig. 4.7: Sequence of gas components treatments
Fig. 4.8: Classification of gas components
The following examples demonstrate the classification of the gas components into
the 21 AGA-10 components.

Example 1:
Component Input AGA-10 AGA-10
mol-% unnormalized normalized
50 mol-% mol-%
Methane 35.0 35.0 70.0
Ethane 5.0 5.0 10.0
Propane 1.0 2.0 4.0
Propene 1.0 - -
iso-Pentane 1.0 - -
n-Pentane 1.0 2.0 4.0
CO 2 0.2 1.0 2.0
Ethen 0.8 - -
Hexane+ (5.0) - -
Hexane 3.0 3.0 6.0
Nonane 2.0 2.0 4.0
Sum 50.0 50.0 50.0
Example 2:
Component Input AGA-10 AGA-10
mol-% unnormalized normalized
mol-% mol-%
Methane 80.0 80.0 80.0
Ethane 5.0 5.0 5.0
Propane 2.0 2.0 2.0
n-Butane 1.0 1.0 1.0
neo-Pentane 1.0 - -
n-Pentan 0.0 1.0 1.0
CO 2 0.0 2.0 2.0
Ethen 2.0 - -
Hexane+ 5.0 - -
Hexane - 5.0 5.0
Nitrogen 4.0 4.0 4.0
Sum 100.0 100.0 100.0

Status code der AGA-10 calculation

Coordinate AW-01 gives the status code of the AGA-10 calculation. This is a bit-
coded value represented as a hexadecimal code. A value of "0000h" indicates a
AGA-10 calculation with errors. The meaning of the individual bits are: 51
Bit Meaning
0 Components invalid
Sum of the un-normalized gas components
is <= 0 or > 110 mol-%
1 Timeout of new gas data exceeded
Within the defined time period in AX-07, no new data arrived. Possible
reason:
• Time too short
• Communication interrupted
• transfer register has not been filled (for Modbus slave)
• Wrong RMGBus telegram or wrong stream selection
If there are new gas components latest within three times of the given
timeout time, the error status will be reset.
2 Temperature Error
The temperature measurement is disturbed. Calculation will be done
with the default value.
3 Pressure errors
The pressure measurement is disturbed. Calculation will
be done with the default value.
4 Simulation active
Parameter E-01 „USE09 mode“ is set to simulation no data (results) of
the DSP will be accepted
5 no value
6 no value
7 no value
8 Error AGA-10 calculation
There is an error within the AGA-10 calculation. The calculation is on
hold. Reason may be wrong pressure or temperature values, ...
9-15 no value
The message "188: AGA-10" appears, if the status code is not 0. The Modbus
master function is flexible in order to support PGC's other manufacturers, too; for
example a Siemens PGC. Activating the RS 485 interface as Modbus master is
described in  chapter 10.3.3, “Interface 2” on page 150.

4.5 Batch mode

In general, the USM-GT-400 is set for an optimal operation without disturbance.
The setting / changing of the batch mode allows adaptation to disturbed condi-
52
tions. The setting allows operation at "high-turbulent" flow conditions as well as at
"strong background noise" conditions. High turbulent means highly distorted veloc-
ity profiles and rapidly changing asymmetries. A "smallest" batch mode should be
chosen. At strong background noise, the signal detection can be disturbed, too. A
"longer" batch mode increases the signal stability significantly. The number of
batches permits a change of the signal duration.
• P1 Number of F-batches per measuring path 1

• ...
• P8 Number of F-batches per measuring path 8
The default values are 2. 0 and 1 are identical; there is no batch activated. All
larger values are squared; F-Batch 2 means there are 4 signals superimposed. If
the F-Batch is active the ring down time should be chosen as short as possible,
preferably to 0 ms. The slow batch mode can be activated in coordinate AI-09; it is
to be squared for all paths, too.
4.6 Signal damping

The output signal of the USM can be smoothed using the parameters E-9 (number
of GDs) and AK-34 to AP-24 (F-Batch). The choice of the settings for these
parameters is an optimization between interference immunity (high damping) and
short response time to changes in flow rate (low damping). As standard, the USMs
are delivered with GD=10 and F-Batch=2. This means:
a) The output signal is the moving average over the last 10 measurements. The
number of measured values included in the moving average is entered directly
in E-9.
b) The mean value of 4 raw signals is included in the measurements. The number
of these measurements (F-batch) is path-specific and equal to the square of
the input value in AK-34 to AP-34.
The shortest possible response time is therefore obtained with E-9 = 1 and AK-34
to AP-34 = 1. However, these settings should only be used with stable flow profiles
and low noise levels. If necessary, these parameters must be optimized during
commissioning.

5 Safety
5 Safety
In this chapter you will receive information on using the device in a safe manner.
53
Content
5.1 Intended use 54

5.2 Layout of instructions 55
5.3 Qualification of the personnel 56
5.4 Safety instructions 57
5.4.1 Hazards during transporting 58
5.4.2 Hazards during installation 58
5.4.3 Hazards during start up 60
5.4.4 Hazards during cleaning 61
5.4.5 Hazards during maintenance and repairs 61
5.4.6 Hazards during operation 62
5.4.7 Hazards for operation in potentially explosive environments 63
5.5 Responsibilities of the operator 64

5 Safety
5.1 Intended use

The Ultrasonic Flowmeter USM GT400 device is used to measure the flow velocity
of the gases in a pipeline and calculate the operating flow during running opera-
54
tion.
The Ultrasonic Flowmeter USM GT400 is hereafter designated as ultrasonic gas

meter or device in the following.
When used for its intended purpose, the ultrasonic gas meter is suitable for use in
potentially explosive areas classified as zone 1.
The device complies with ignition protection class

II 2 G Ex de IIB+H2 T6 Gb, ambient temperature between
40°C and +55°C
or
Class 1, Division 1 Group B, C and D, ambient temperature for
code T5/T6 is -40°C to +40/+55°C.
The ultrasonic gas meter complies with the standards, directives and guidelines.
Chapter 16.5, “Standards, directives and guidelines” on page 247
These technical limits must be maintained for a safe use of the ultrasonic gas me-
ter:
Chapter 13, “Technical specifications” on page 177

5 Safety
5.2 Layout of instructions

The following instructions are used:
55
Danger
This warning instruction informs you of potentially hazardous situations that can
occur as a result of incorrect operation or human error. If these situations are
not avoided, they can lead to fatal or severest injuries.
Warning
This warning instruction informs you of possible hazardous situations that can
not avoided, they can lead to fatal or severe injuries.
Caution
This warning instruction informs you of possible hazardous situations that can
not avoided, they can lead to slight or minor injuries.
Notice
This warning instruction informs you of potentially hazardous situations
that can occur as a result of incorrect operation or human error. If
these situations are not avoided, they can result in material damage to
the device or the vicinity.
Dieser Hinweis gibt Ihnen Tipps, wie Sie Ihre Arbeit erleichtern können.
Zusätzlich erhalten Sie mit diesem Hinweis weitere Informationen zum
Gerät oder zum Arbeitsprozess.

5 Safety
5.3 Qualification of the personnel

Operating personnel The operating personnel are to use and operate the
device within the scope of the intended purpose.
56
Maintenance personnel Work on the device must only be carried out by special-
ist personnel that can carry out the respective work as-
signed to them as a result of their training, knowledge
and experience as well as the applicable regulations.
These specialist personnel are familiar with the legal
guidelines for accident prevention and can evaluate and
avoid possible risks by themselves.
• Mechanical installation must only be carried out by

the respectively qualified specialist personnel.
• Installation on electrical components must only be

carried out by qualified electricians.
The specialist personnel require a training especially for

working in potentially explosive environment.
Specialist personnel are persons that can verify a train-
ing / further education according to DIN VDE 0105, IEC
364 or a similar national standards.
• Initial start up must only be carried out by especially

trained personal (training by RMG) or by service per-
sonal from RMG.
• Maintenance and cleaning must only be carried out

by the respectively qualified specialist personnel.
Danger
Observe the following safety instructions
Non-observance of these safety instructions can lead to a risk of life and limb
and health of the person as well as damage to the environment or property
damage.

5 Safety
5.4 Safety instructions

Note that the safety instructions in this operating instruction and on the device
cannot cover all possible hazardous situations as the combination of different
57
circumstances is impossible to predict. To simply follow the instructions specified
may not normally be sufficient enough to ensure for correct operation. Always be
observant and also consider the following:
• Before working with the device for the first time, read through this operating in-
struction and, in particular, follow the safety instructions carefully.
• Always keep the operating instructions within reach for use at the place of in-
stallation.
• The operating instruction warns against the residual risks for users, third par-
ties, devices or other material assets. The safety instructions used refer to
residual risks that cannot be avoided due to the design.
• For safe operation, the safety instructions must be observed and followed.
• Operate the device only in a sound state and when observing the operating
instruction.
• Also observe the local legal accident prevention, installation and assembly
• guidelines.
• The manufacturer is not responsible for any damage that result as a conse-
quence of not observing the operating, instruction.
• Service and maintenance work or repairs that are not described in the operat-
ing instruction must not be carried out without previous consultation with the
manufacturer.
• Changes to the device are forbidden.
• For safe operation, the technical specifications must be observed and followed.
Performance limits must not be exceeded.
• For a safe operation, the device must only be used in the scope of its intended
use.
The device is exposed to different life phases, such as, e.g., installation,
start upstart up, operation, maintenance and cleaning.
The following sections must be sorted thematically according to the life phases.

5 Safety
5.4.1 Hazards during transporting

The device may be damaged when lifting and putting down, tipping over or falling
down. By disregarding the load bearing capacity of the lifting gear, the device may
58 fall. There is a risk of severe injuries for persons in the vicinity.
• Lift the device only on the intended lifting eyes.
• Before lifting, make sure that the load is safely secured.
• Never stand under suspended loads.
Observe the weight specifications for the ultrasonic gas meter at hand.
5.4.2 Hazards during installation

When you carry out work on electric systems in potentially explosive environ-
ments, incorrect work may lead to explosions.
• Make sure that no potentially explosive atmosphere is at hand before starting

work.
If personnel that have insufficient qualifications carry out work, they can incorrectly
assess hazards. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a
trained specialist person.
• Carry out the installation according to the following standards:
• CAN/CSA-C22.2 No. 0-1191
• CSA C22.2 No. 30
• CSA C22.2 No. 142
• UL 916
• UL 1203
or similar national standards.
In potentially explosive atmospheres, dangerous voltages can still remain as igni-

tion sources for up to one minute after being switched off.
• Disconnect the device from the power supply before starting the maintenance
work.
• Securing against reconnection.
• Cordon-off the work area of the device, e.g., using a barrier and signs.
• After switching off the device, wait at least one minute before starting work. En-
sure that the device is voltage-free. Then connect to earth and short-circuit.

5 Safety
• Make sure that the insulation of the cables are intact.

• Make sure that no stripped cable is located outside the housing of the ultra-
sonic electronics and the connection box.
59
If the device is not installed according to the operating instruction, then there is
not enough explosion protection.
• Install the device according to the operating instruction.
If you do not use the appropriate tool and material, component may be dam-
aged. The explosion protection is void.
• Use tools that have been recommended for the respective work in the operat-
ing instruction.
• Make sure that the performance data of the power connection comply with the
specifications of the type plate.
• Use only an Atex or IECEx certified EMC cable screw connection in the protec-
tion category increased safety with a metric thread (M20x1.5).
• Creepage distances and clearances must be maintained.
• Openings for line feeds not used must be sealed by impact resistant, anti-self-
loosening and twisting safe blind plugs.
• The line insulation must reach to the terminals. When stripping, the conductor
itself must not be damaged.
• When closing the housing, take care that the seals remain effective in order to
ensure for the protection category IP 66 / NEMA 4X.
• Housing cover or housing with damaged thread must be replaced immediately.
• Observe the applicable national guidelines in the individual countries.
• Use cables that match the cable glands.
Gas may represent a risk to life and limb in different ways. Depending on the gas
type, different hazards may have an effect on you with respective consequences.
You may experience intoxication and injuries. There is also a risk of explosion.
• Before working, inform yourself about the media in the system.
• Install the device only when the system is switched off, depressurized and se-
cured.
• Make sure that there is no potentially explosive gas mixture at the installation
location.
The device is exposed to high pressures. If components under pressure are re-
moved / assembled, the high pressure may escape suddenly causing the compo-
nent to fly around. Mortal danger!

5 Safety
• Install the device only when the system is depressurized.

• With systems subjected to pressure:
Have the assembly work (Hot-Tapping) only carried out by specially trained
60 personnel.
If gas escapes at high temperature, there is a risk of life-threatening burns. You
may suffer burn injuries in the event of contact with hot surfaces.
• Allow the components to cool down before working in the system.
• Wear personal protective equipment.
If connections not required during operation remain open, gas will escape. Risk of
explosion and intoxication!
• Before start up, seal all open connections with certified blind plugs according to
94/9/EC.
• Replace the blind plugs that have been installed for transportation with certified
blind plugs according to 94/9/EC or NEC500.
5.4.3 Hazards during start up

assess the hazards. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a spe-
cialist person.
If the device is not sealed correctly during installation, then gas may escape. Ex-
plosions can occur. Danger of poisoning!
• Check the connections for leaks.
• Take the system immediately out of operation if you detect a leak.

5 Safety
5.4.4 Hazards during cleaning

If the device is not cleaned according to the operating instruction, then the device
may be damaged.
61
• Clean the device only according to the operating instruction.
If you do not use the appropriate tool, components may be damaged. The explo-
sion protection is void.
• Use tools that have been recommended for the respective work in the operat-
ing instruction.
Cleaning agents / corrosion protection used may be harmful to health.
• Always wear protective gloves and eye protection.
• Ensure for good ventilation and do not inhale vapours!
• Observe the safety data sheet!
5.4.5 Hazards during maintenance and repairs

assess hazards when working. Explosions can occur.
• Carry out the work only if you have the respective qualification and are a
trained specialist person.
Flange joining elements, pressure tapping screw connections and valves must not
be removed if the system is subject to pressure. Components may dangerously
spray. Escaping gas may cause intoxication and burns. Risk of explosion!
• For the flange connection, use only the matching combination of screw bolts,
nuts and seals. Select the appropriate tightening torque of the flange connec-
tion for this combination.
• In doing so, observe the specifications of the system manufacturer or system
operator.
• Use only genuine spare parts from RMG.
It is forbidden to install spare parts from third-party manufacturers. It voids all
guarantees and claims for guarantee. The explosion protection is no longer en-
sured.
When working on live devices in potentially explosive atmospheres, resulting
sparks may lead to an explosion.

5 Safety
• Only work on de-energized devices when in potentially explosive atmospheres

(except for intrinsically safe circuits).
• Make sure that there is no potentially explosive atmosphere before starting
62 work.
• After working provide on pressurized components, leaks may occur. Escaping
gas may lead to intoxication, Risk of explosion!
• Check all components for leaks!
Special requirements for a safe operation in potentially explosive areas classi-
fied as zone 1:
Under normal operating conditions, the transducer cannot be accessed from
the outside, thus no sparks can result from impacts or friction of the transducer
against hard materials.
• The transducers are made from titanium. If objects knock or rub against the
transducers, this can generate a spark thus leading to an explosion!
• prevent hard objects from knocking or rubbing against the transducers.
Also observe these warning instructions:

“Hazards during installation” on page 58
5.4.6 Hazards during operation

If the device is loaded with a pressure that is too high, components may leak and
burst.
• Never exceed the maximum operating pressure (see specifications on the type
plate).
Flange joining elements, pressure tapping screw connections and valves must not
be removed if the system is subject to pressure. Components may dangerously
spray. Escaping gas may cause intoxication and burns. Risk of explosion!
• Observe the specifications of the system manufacturer or system operator.

5 Safety
The device can be heated or cooled by the temperature of the gas. You may be
subject to burns when making skin contact with the device.
• Wear protective gloves that protect against heat and cold for this work.
63
Breakages or cracks may be caused to the device if the gas temperature or ambi-
ent temperature is outside the specified temperature ranges. Gas escaping may
cause intoxication and burns. Risk of explosion!
• Never exceed the maximum gas temperature and / or ambient temperature of
80°C.
5.4.7 Hazards for operation in potentially explosive environ-

ments
If the device is operated with damaged or missing components, then gas may es-
cape. In event of damaged threads, the ignition penetration safe gap is no longer
guaranteed. Escaping gas may cause intoxication and burns. Risk of explosion!
• Operate the device only in a sound and complete state.
If you carry out technical changes to the device, safe operation can no longer be
guaranteed.
• Use the device only in its original state.

5 Safety
5.5 Responsibilities of the operator

• You being the operator must ensure that only sufficiently qualified personnel
64 work on the device.
“Qualification of the personnel” on page 56
• Make sure that all employees that are using the device have read and under-
stood this operating instruction. Moreover, you are also obliged to train the per-
sonnel at regular intervals and inform them of the hazards.
• Make sure that all work on the device is only carried out by qualified persons
and checked by responsible specialist personnel.
• The responsibilities for installation, operation troubleshooting, maintenance and
cleaning must be clearly specified.
• Provide the personnel with the necessary protective equipment.
“Qualification of the personnel” on page 56

Using suitable measures, ensure that that constructive risks are ruled out when
using the device. Inform your personnel about the risks when using the device.

6 Transport and storage

In this chapter you will receive information on the scope of supply, transport and 65
storage of the device.
Content
6.1 Transport 66
6.1.1 Scope of supply 66
6.1.2 Transporting the device 67
6.1.3 Unpacking the device 67
6.1.4 Disposal of packaging material 70
6.1.5 Prior to installation 70
6.1.6 Removing the transporting locks 71
6.2 Packing the device for transportation 73
6.3 Storage 79
6.3.1 Packing the device for storage 79
6.3.2 Checking the device after storage 80

6.1 Transport
The device will be packed to customer-specifics according to the transport require-
ments. In this chapter you will receive information on the standard packaging of
66
the device.
6.1.1 Scope of supply
The scope of supply may deviate depending on the options of the orders.
The following are included in the scope of supply:
Component Quantity
Ultrasonic gas meter 1
USM GT400 (including US-Electronic)
Extension box 1
(In countries where ATEX / IECEx
standards apply, connected at the
ultrasonic electronic)
Special tools to open the US electronic 2
Inlet and outlet spool piece 1 (optional)
Certificate of flow calibration 1
Certificate of material used 1
Certificate of stability 1
Certificate of density 1
Software RMGViewUSM 1
Operating instruction of the device 1

Screws and set of blank plugs 1

6.1.2 Transporting the device
67
1 Euro pallet
2 Retaining bolts x 2
3 Ultrasonic gas meter
4 Retaining strap x 2
5 Timber wedge x 2
Fig. 6.1: Device secured on a Euro pallet
The device is as standard supplied on a Euro pallet (1). The device can be pro-
tected by a customer-specific outer packaging. To secure the device against tip-
ping-over and rolling away, the device (3) is supplied with retaining straps (4) and
bolted to timber wedges (5). The retaining bolts (2) of the device provide
additional support.
The device can be transported on the pallet using a lifting cart or a fork lift.
6.1.3 Unpacking the device

Remove the outer packaging
The outer packaging of the device is suited to customer specifics in order to pro-
tect the device against damage or influences from the environment during
transport.
Options for the outer packaging can be, for example:

• sea-proof wooden crate
• cardboard packagings

1 Remove the outer packing.

2 Recommendation: store the outer packaging for the future or for returning to
RMG for service work.
68
1 Retaining bolts
Fig. 6.2: Retaining bolts of the device
3 Make sure that the retaining bolts (1) are screwed in, if necessary.
▪ Removing the device from the pallet
1 Lifting eyes
2 Lifting gear chains
Fig. 6.3: Attaching the lifting gear

Warning
The device may be damaged when lifting and putting down, tipping over or
69
falling down. By disregarding the load bearing capacity of the lifting gear, the
device may fall. There is a risk of severe injuries for persons in the vicinity.
• Observe the weight specifications for the ultrasonic gas meter at hand.
1 Attach a suitable lifting gear (2) to the lifting eyes (1) of the device.
2 Tension the chain of the lifting gear slightly to secure the device.
1 Timber wedge
2 Tension straps
Fig. 6.4: Remove the timber wedges and retaining straps
3 Undo and remove the tension straps (2).

Warnung
70
4 Carefully lift the device with a lifting gear until the Euro pallet can be pulled
from underneath the device.
5 Pull the Euro pallet from under the device.
6 Recommendation: store the Euro pallet for the future or for returning to
RMG for service work.
6.1.4 Disposal of packaging material

If the packaging material and the Euro pallet are no longer required, dispose of the
material in an environmentally responsible manner according to the country-spe-
cific standards and guidelines.
6.1.5 Prior to installation

The transport locks must only be removed once the device has been installed in
the system and the device has been transported to the installation location.
Hinweis
Damage to the device from contamination and humidity
If transport locks are removed too early, contamination and humidity
may enter the device. The device could be damaged.
• Disassemble the transport locks immediately before installing the device.

The following belong to the transport locks:
▪ Blind plug
▪ Protective sticker 71
▪ Retaining bolts
▪ Recommendation: remove the retaining bolts only if it is absolutely
necessary. This is the only way to ensure that the device does not tip over or
roll away after being installed.
▪ Corrosion protection mat
6.1.6 Removing the transporting locks

The removal of the transport locks is described here on the example of a connec-
tion or flange. The transport locks also have to be removed from all connections
where the transport locks are located.
▪ Removing the protective sticker / blind plugs from the flanges
The flanges are supplied sealed with a protective sticker or blind plug made
of plastic.
1 Protective sticker
2 Flange
Fig. 6.5: Removing the protective sticker

Removing the protective sticker 1 Release the protective sticker from

the sealing surface of the flange.
2 Remove any residual adhesives or
other impurities from the sealing
72 surfaces of the flange using a gentle
cleaning agent.
Remove the blind plugs 1 Pull the blind plugs out of the
openings.
▪ Remove the corrosion protection mat

The inside of the device is protected using a corrosion protection mat. The corro-
sion protection mat must be removed before installation.
1 Corrosion protection mat

Fig. 6.6: Position of the corrosion protection mat
1 Remove the corrosion protection mat (1) from the device.

6.2 Packing the device for transportation

The device must be packed to customer-specifics according to the transport re-
quirements. In this chapter you will receive information as to how the device is as
73
standard packed.
For packaging, use the original packaging material and sealing set that was
supplied with the device.
If you no longer have the original packaging material and sealing set, you can or-
der the packaging material and sealing set required from RMG.
RMG service would be pleased to consult you as to how the device should be
packed.
You need the following for standard packaging:
• Euro pallet with timber wedges (with the original packaging, the timber
wedges are already pre-mounted on the Euro pallet).
• Two tensioning straps
• Transport locks
• Sealing set (blind plugs)
• Acid-free corrosion protection agent, e.g., ESSO RUST BAN 397,
Mobil Oil Tecrex 39
▪ Ensure for a safe position of the device
Caution
Risk of injury from missing retaining bolts
If the device is put down without the retaining bolts, it can tip over or roll away.
Severe injuries may occur.
• Before starting work, make sure that the retaining bolts are screwed in.

74
1 Retaining bolts with counter-nuts

Fig. 6.7: Check the retaining bolts
The retaining bolts are screwed into the device ex-factory. These ensure for a safe
position.
1 Make sure that the retaining bolts are screwed in and that the counter-nuts
are secured.
Recommendation: remove the retaining bolts only if it is absolutely necessary.

This is the only way to ensure that the device does not tip over or roll away
after being installed
▪ Lifting the device onto the Euro pallet
1 Lifting eyes
2 Lifting gear chains
Fig. 6.8: Attaching the lifting gear

Warning
75
1 Attach a suitable lifting gear (2) to the lifting eyes (1) of the device.
2 Tension the chain of the lifting gear slightly.
3 Undo the bolted connections from the system so that the device can be lifted
out.
1 Retaining bolts
2 Tension straps
3 Timber wedge
Fig. 6.9: Secure the device on the Euro pallet
4 Place the Euro pallet under the device.

Without the retaining bolts (1) the flange must be guided between the timber
wedges (3).

Warning
76 The device may be damaged when lifting and putting down, tipping over or
5 Carefully place the device on the Euro pallet with the lifting gear.
6 Secure the device using the tensioning straps (2).
The tensioning straps must have a tight fit and must secure the device.
▪ Place the corrosion protection mat inside the device
Notice
Damage to the device from corrosion
If the device is not protected against corrosion, the function of the
device may be affected.
• Place the corrosion protection mat inside the device.
1 Position of the corrosion protection mat

Fig. 6.10: Corrosion protection mat in the device

1 Clean the device and protect all blank parts against corrosion with an acid-
free corrosion protection agent, e.g., ESSO RUST BAN 397, Mobil Oil Tecrex
39.
Chapter 11.7, “Cleaning the device” on page 167 77
2 Place the corrosion protection mat (1) inside the device.

▪ Provide the connection box (ATEX / IECEx) with blind plugs
1 Wrench
2 Screwed cable gland
3 Blind plug
Fig. 6.11: Mount the blind plugs
1 Insert the blind plugs (3) into the connection.

2 Tighten the screw connection (2) with a suitable wrench (1).
The following sealing bolts supplied must be used in countries where CSA
guidelines apply. If only transport is taking place, you can use 1/2" or 1"
screws with appropriate length as an alternative.
▪ Applying the protective sticker / blind plugs to the flanges

The flanges must be sealed with a protective sticker or blind plug made of
plastic.

Sealing the flange with protective stickers
78
1 Protective sticker
2 Flange
Fig. 6.12: Applying the protective sticker
1 Clean the sealing area with grease remover.

The sealing surface must be free of grease and contamination.
2 Stick the protective sticker (A) onto the sealing surface of the flange (B).
Sealing the flange with blind plugs

1 Insert the blind plugs into the opening of the flange so that the blind plugs
have a tight fit.
▪ Applying the outer packaging to the device
Notice
Damage caused to the device from incorrect storage / transport
If the device is not protected correctly by the packaging material, dirt or humidity
may enter the device and damage it.
• Pack the device according to the instruction.
• Consider the special transport requirements on the packaging material, e.g., for
transport overseas.
• Please contact RMG service in case of doubt.

Use the original packaging that was supplied along with the device. Please contact
RMG service if you have any questions.
Options for the outer packaging can be, for example:

79
• sea-proof wooden crate
• cardboard packaging
1 Protect the device in the outer packaging against environmental influences.
6.3 Storage
In this chapter you will receive information on the correct storage of the device.
You are also provided with information that must be observed when storing for
long periods.
Danger
Mortal danger from damage in the warehouse
If the device is stored for longer than one year, the device may be damaged
from incorrect outer packaging or securing of the device. In potentially explosive
environment, a defective device may lead to an explosion. Danger of poisoning!
• Avoid long storage times.
• Have the device checked by RMG service if the storage time is longer than
one year. For this purpose, send the device to RMG.
6.3.1 Packing the device for storage
Notice
Damage caused to the device from incorrect storage / transport
If the device is not protected correctly by the packaging material, dirt or humidity
may enter the device and damage it.
• Pack the device according to the instruction.
• Consider the special transport requirements on the packaging material,
e.g., for transport overseas.
• Please contact RMG service in case of doubt.

1 Packing the device.

“Packing the device for transportation” on page 73
80 2 Observe the approved ambient temperature for storage.

Chapter 13.1, “Performance data” on page 178
6.3.2 Checking the device after storage

Gefahr
Mortal danger from damage in the warehouse
If the device is stored for longer than one year, the device may be damaged
from incorrect outer packaging or securing of the device. In potentially explosive
environment, a defective device may lead to an explosion. Danger of poisoning!
• Avoid longer storage times.
• Have the device checked by RMG service if the storage time is longer than
one year. For this purpose, send the device to RMG.
▪ Checking the device for any signs of damage

There is a high risk to life and limb if a damaged device is used.
The following damage can compromise safety and the function of the device:
• notches on the flange sealing surfaces
• corrosion in the device or on the sealing surfaces
• cracked glass of the viewing window
• clouded glass of the viewing window
• cracks, flaking on the housing or the covers
• flaking paint
1 Check that the device is intact by a visual inspection.
If you discover that there is, e.g., any damage or other damage to the device,
the device may only be re-used after consulting RMG.
2 If damaged: please contact RMG services.

7 Construction and Planning

In this chapter you will receive information on how you can integrate the device
into the system and what you have to observe during this process. 81
Content
7.1 Connection flanges 81

7.2 Seals 82
7.2.1 Flat seal 83
7.2.2 Grooved gaskets 84
7.2.3 Spiral seals 85
7.3 Screws 87
7.4 Installation possibilities 88
7.4.1 Dependency on the gas flow direction 88
7.4.2 Two devices series connected (Face to Face) 91
7.5 Flow computer 93
7.1 Connection flanges

The devices from RMG are equipped with connection flanges.
The joining dimensions of the flanges for the pipelines to be connected must corre-
spond to the connection dimensions of the device flanges.
• ANSI pressure stages: The flange joining dimensions comply with the standard
ASME B 16.5.
• DIN pressure stages: The flange joining dimensions comply with the standard
DIN EN 1092.

Notice
The USM GT400 with a nominal width of DN 80 (3“) uses different connec-
tion flanges. Instead of the screw lead-throughs - as in the flanges of all
82
other nominal sizes - there are blind holes with internal threads. Corre-
sponding screws are included in the scope of delivery, but can also be re-
ordered if necessary.
7.2 Seals
Danger
Escaping gas from incorrect seals
If incorrect flange seals are used for several ultrasonic gas meters, potentially
explosive gas mixtures can escape due to leaks. Risk of intoxication and explo-
sion! Moreover, the pressure of the flange increases with the improper tighten-
ing of the screw bolt.
• Make sure that the flat seal does not protrude over the sealing surface into
the pipeline.
Notice
Malfunctions from incorrect seals
If flange seals are used for ultrasonic gas meters that protrude into the pipeline,
the measuring accuracy may be influenced.
the pipeline.
The durability of the flange connections has been verified for seals with the follow-
ing maximum material values according to the AD2000 regulations.
Flat seals: k0 x KD = 20 x bD | k1 = 1.3 x bD (N/mm)

Grooved gaskets: k0 x KD = 15 x bD | k1 = 1.1 x bD (N/mm)
Spiral seals: k0 x KD = 50 x bD | k1 = 1.4 x bD (N/mm)
Octagonal ring joint seal: KD = 480 N/mm2

7.2.1 Flat seal

Flat seal according to DIN 2690 / EN 12560-1 Form IBC
83
Dimensions of the seal:

d1 = Inside diameter
d2 = Outside diameter
X = Seal thickness 1.5 to 5 mm
Fig. 7.1: Flat seal
PN10 PN16 ANSI150 PN25 PN40
DN d1 d2
in mm (inch) in mm (inch) in mm (inch)
80 (3) 90 (3.54) 142 (5.59) 142 (5.59) 136.5 (5.37) 142 (5.59) 142 (5.59)
89 (3.5)/ANSI150
100 (4) 115 (4.53) 162 (6.38) 162 (6.38) 175 (6.89) 168 (6.61) 168 (6.61)
150 (6) 169 (6.65) 218 (8.58) 218 (8.58) 222 (8.74) 225 (8.86) 225 (8.86)
200 (8) 220 (8.66) 273 (10.75) 273 (10.75) 279 (10.98) 285 (11.22) 292 (11.52)
250 (10) 274 (10.79) 328 (12.91) 330 (12.99) 340 (13.39) 342 (13.46) 353 (13.90)
300 (12) 325 (12.80) 378 (14.88) 385 (15.16) 410 (16.14) 402 (15.83) 418 (16.46)
400 (16) 420 (16.54) 490 (19.29) 497 (19.57) 514 (20.24) 515 (20.28) 547 (21.54)
500 (20) 520 (20.47) 595 (23.43) 618 (24.33) 607 (23.90) 625 (24.61) 628 (24.72)
600 (24) 620 (24.41) 695 (27.36) 735 (28.94) 718 (28.27) 730 (28.74) 745 (29.33)

7.2.2 Grooved gaskets

Grooved gaskets according to EN 12560-6 with centering ring
84

d1 = Inside diameter
Fig. 7.2: Grooved gaskets
ANSI 300 / ANSI 600 PN64
DN d1 d2 d1 d2
in mm (inch) in mm in mm in mm in mm
80 (3) 98.4 123.8 95 121
100 (4) 123.8 154.0 118 144
150 (6) 177.8 221.7 170 204
200 (8) 228.6 266.7 220 258
250 (10) 282.6 320.7 270 315
300 (12) 339.7 377.8 320 365
400 (16) 422.3 466.7 426 474
500 (20) 530.2 581.0 530 578
600 (24) 631.8 682.6 630 680

7.2.3 Spiral seals

Spiral seals according to EN 12560-2 with centering ring
85

d1 = Inside diameter of the centering ring
d2 = Inside diameter of the seal
Fig. 7.3: Spiral seals
ANSI 300 PN 64 ANSI 600
DN d1 d2 d3 d1 d2 d3 d1 d2 d3
in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm
(inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch)
80 81 101.6 120.7 86 95 119 81 101.6 120.7

(3) (3.19) (3.98) (4.75) (3.39) (3.74) (4.69) (3.19) (3.98) (4.75)
100 106.4 127.0 149.4 108 120 144 106.4 120.7 149.4
(4) (4.19) (5.00) (5.88) (4.25) (4.72) (5.67) (4.19) (4.75) (5.88)
150 157.2 182.6 209.6 162 174 200 157.2 174.8 209.6
(6) (6.19) (7.19) (8.25) (6.38) (6.85) (7.87) (6.19) (6.88) (8.25)
200 215.9 233.4 263.7 213 225 257 215.9 225.6 263.7
(8) (8.5) (9.19) (10.38) (8.39) (8.86) (10.12) (8.5) (8.88) (10.38)
250 268.3 287.3 317.5 267 279 315 268.3 274.6 317.5
(10) (10.6) (11.31) (12.50) (10.5) (10.98) (12.40) (10.6) (10.81) (12.50)
300 317.5 339.9 374.7 318 330 366 317.5 327.2 374.7
(12) (12.5) (13.38) (14.75) (12.5) (12.99) (14.41) (12.5) (12.88) (14.75)

400 400 422.4 463.6 414 426 466 400 412.8 463.6
(16) (15.7) (16.63) (18.25) (16.3) (16.77) (18.35) (15.7) (16.25) (18.25)
500 500 525.5 577.9 518 530 574 500 520.7 577.9
86 (20) (19.7) (20.69) (22.75) (20.4) (20.87) (22.60) (19.7) (20.50) (22.75)
600 603.3 628.7 685.8 618 630 674 603.3 628.7 685.8
(24) (23.8) (24.75) (27.00) (24.3) (24.80) (26.54) (23.8) (24.75) (27.00)

7.3 Screws
Temperature range for bolts and nuts
87
-40°C to +80°C
Pressure Version 1 Version 2 Version 3

stages
PN10, PN16, Boldt according to – –

PN25, PN40, DIN EN ISO 4014 of
PN64 material 25CrMo4, nuts
according to
DIN EN ISO 4032 of
material 25CrMo4
ANSI150, Bolts according to Bolts according to Bolts with reduced shank

ANSI300, ANSI B1.1 of material ANSI B1.1 of material according to DIN 2510 of
ANSI600 ASTM A 320 Grade L7, 42CrMo4, nuts according material 25CrMo4, nuts
nuts according to to ANSI B1.1 of material according to DIN 2510 of
ANSI B1.1 of material 42CrMo4 material 25CrMo4
ASTM A 320 Grade L7
The stability of the flange connection was verified using the screws listed above in
conjunction with the seals listed in Chapter 7.2. Other screw / flange versions have
not been inspected.
Notice
Variant 3 bolts with reduced shank may only be used for devices within the area
of PED (Pressure Equipment Directive) application.
Notice
DN 80
Screws are provided by RMG for the USM-GT400 for diameter DN80.
Depending on the flange type the following hexagonal bolts are used for DN80:

PN10/16 PN25/40 PN64 ANSI150 ANSI300 ANSI600
DIN EN 24014 DIN EN 24014 DIN EN 24014 5/8“ - 11 UNC 3/4“ - 10 UNC 3/4“ - 10 UNC
(DIN931 (DIN931 (DIN931 2A x 2 1/8“ 2A x 2 1/4“ 2A x 2 5/8“
88 ISO4014) ISO4014) ISO4014) L=54mm (2 1/8“) L=57,2mm (2 L=66,7mm (2
M16 x 48 M16 x 52 M16 x 56 UNC A320 1/4“) 5/8“)
L=48 mm or ma- L=52 mm or ma- L=56 mm or ma- Grad7 UNC A320 UNC A320
terial: terial: terial: or material: Grad7 Grad7
25CrMo4 25CrMo4 25CrMo4 42CrMo4 or material: or material:
galvanized galvanized galvanized galvanized 42CrMo4 42CrMo4
galvanized galvanized
These screws can be used down to -40°C.
7.4 Installation possibilities

You have different possibilities when installing the device into your system. Please
verify a proper inner diameter of any pipe that is connected to the meter.
See chapter 13.6 “Inner diameter of connecting spool pieces” on page 189
7.4.1 Dependency on the gas flow direction

In order for the installation to correspond to the requirements of the Measurement
Instrument Directive 2004/22/EC (MID) or Measurement Canada (MC), the device
must be installed with an inlet and outlet piping.
With this installation, the device can be used for calibrated measurements
and for secondary measurements.

89
1 Temperature sensor
Fig. 7.4: Unidirectional operation
1 Flow conditioner
Fig. 7.5: Unidirectional operation compact installation

Bidirectional operation
90
Fig. 7.6: Bidirectional operation
1 Flow conditioner
Fig. 7.7: Bidirectional operation compact installation < DN 300 (12")

91
1 Flow conditioner
Fig. 7.8: Bidirectional operation compact installation ≥ DN 300 (12")
7.4.2 Two devices series connected (Face to Face)

You can install one or several devices in series.
Notice
Malfunctions from pairing the devices incorrectly
If the devices do not match one-another for these installation possibilities,
incorrect measurements may occur.
• Please consult RMG if a Face-to-Face installation is possible with the de-
sired devices and number of devices.

92
1 Tapered bore
2 Inner diameter
Fig. 7.9: Face-to-Face Installation
With this installation option, two or several devices are connected with one-
another via the flanges. Third-party manufacturer devices can also be connected
to RMG devices.
For this purpose, a tapered bore can be applied to the flanges on the inlet and out-
let piping.
The flanges that are used to connect the devices with one-another do not require a
tapering. For third-party manufacturer devices, you have to check if a tapering is
required.
Notice
For the device with the smaller inner diameter it is mandatory to use a tapering.
If two RMG devices are connected with one-another, the inner diameter must be
continuously the same.
Different sized devices cannot be connected to one-another.

7.5 Flow computer

If required, you can connect one or two flow computers to the device.
Follow the installation guidelines of the flow computer:
93
Observe the installation instructions for the flow computer
The 2 interfaces RS485-1 and RS485-2 have the same features and you may
change in the following1 to 2 (and 2 to 1) freely.
However, the RS 485-1 (in contrary to the RS 485-2) does not permit a parameter-
izable byte sequence for the data types Long and Float. We therefore recommend
that you use the RS 485-1 for the DZU protocol and the RS 485-2 for instance F
communication. You may find more information in chapter 8.3.
Flow computer from RMG

The device is compatible with the following flow computer series from RMG:
• ERZ 2000NG
• ERZ 2400
If you want to use the flow computer from RMG specified above, you do not have
to carry out any configurations. The flow computers from RMG can directly pro-
cess the protocol of the ultrasonic gas meter from RMG directly. For this purpose,
the flow computer has to be connected to the digital interface RS485-1 in order to
allow all diagnosis functions to be used. If you want to install an additional flow
computer for reasons of security, this must be connected via the interface
RS485-2.
Flow computer from third party manufacturer

Flow computers from third-party manufacturers can be connected to the device.
These can only be connected to the digital interface RS485-2. This interface com-
municates via a Modbus protocol. In order to be able to use all diagnosis func-
tions, the Modbus must be configured. You can also use the high-frequency out-
puts pulse 1 and 2. When parameterizing, take care that the maximum possible
gas flow rate correlates to a maximum frequency of 2 kHz. All diagnosis functions
cannot be used via this interface. If you are using a third-party manufacturer de-
vice, you have to configure the flow computer.

Connecting a flow computer for example an

ERZ 2000 / ERZ 2400
94
1 Explosive atmospheres Device group II zone I or Class 1, Division 1

2 Maximum distance 500m
3 Safe area
4 Temperature
5 Pressure
6 Pulse
7 Alarm
8 RS 486-2 (Modbus ASCII oder RTU)
9 Service-Interface RS 485-0 for RMG View
Fig. 7.10: Connection diagram for connection of a flow computer
for example ERZ 2000 / ERZ 2400
The cable length must not exceed a length of 500 meters / 1640 feet.
More information on the installation of a flow computer can be found here:
Operating instructions of the flow computer

8 Installation
8 Installation
In this chapter you are provided with information on how you can correctly install
the device and what you have to observe during the process. 95
The tasks of the chapter described must only be carried out by trained and
certified personal.
Content
8.1 Assembly work preparations 96

8.2 Installation of the device 99
8.2.1 Mounting the inlet and outlet piping 99
8.2.2 Installation of the connection box 101
8.3 Connecting the device electrically 103
8.3.1 Connecting the power supply 108
8.3.2 Digital interfaces of USM-GT400 108
8.3.3 Connecting the computer for RMGViewUSM 110
8.3.4 Connecting the flow computer 110
8.3.5 Connection of external DSfG-Device-F via Modbus 113
8.3.6 Interface converter 124
8.3.7 Connecting the device to earth 126
8.4 Installing the pressure connection 128
8.5 Outdoor installation 130

8 Installation
8.1 Assembly work preparations

Danger
96
Mortal danger from electric current
In potentially explosive environments, dangerous voltages can still remain as ig-
nition sources for up to one minute after being switched off.
• Disconnect the device from the power supply before starting the mainte-
nance work.
• Secure the device against being switched back on.
• Cordon-off the work area of the device, e.g., using a barrier and signs.
• After switching off the device, wait at least one minute before starting work.
Ensure that the device is voltage-free. Then connect to earth and
short-circuit.
Mortal danger from components under pressure
Flange joining elements, pressure tapping screw connections and valves must
not be removed if pressure is applied to the device. Components may be flung
around. Gas escaping may cause intoxication and burns. Risk of explosion!
• Carry out work on the device only when it is in a voltage-free state, is vented
and without pressure.
Mortal danger from incorrect work
Hazards can only be recognized and avoided by specially trained personnel.
If work is carried out by persons who have not been trained for these special ac-
tivities in potentially explosive areas, they may cause an explosion.
• Have installations only carried out by especially trained personnel, (expert
according to DIN VDE 0105, IEC 364 or similar national, standards).
Mortal danger from damaged sealing surfaces
If sealing surfaces are damaged, e.g., from notches or scratches, leaks may
occur. Risk of intoxication and explosion!
• Install only an undamaged device

8 Installation
Warning
97
falling down. By disregarding the load bearing capacity of the lifting gear, the de-
vice may fall. There is a risk of severe injuries for persons in the vicinity.
Caution
Risk of injury from missing retaining bolts
If the device is put down without the retaining bolts, it can tip over or roll away.
Serious injuries may occur.
• Before starting work, make sure that the retaining bolts are screwed in.
Notice
Damage to the device when used as a climbing aid
If the device is used as a climbing aid, components may be damaged.
• Do not use the device as a climbing aid.
• Use a suitable non-slip step that allows you to reach the components easily
and safely.
▪ Carry out preparatory work

1 Unpack the device.
Chapter 6.1.3, “Unpacking the device” on page 67
2 Remove the transporting locks.
Chapter 6.1.6, “Removing the transporting locks” on page 71

8 Installation
For ATEX / IECEx
98
1 Wrench
2 Screwed cable gland
3 Blind plug
Fig. 8.1: Remove the blind plugs
3 Unscrew connection (2) with a suitable wrench (1).

4 Pull the blind plugs (3) out of the connection.
5 Screw glandes not required must be replaced by explosionproof screw
connections.
Recommendation: store the blind plugs for the future or for returning to RMG
for service work.
For NEC 500

In countries where CSA guidelines apply, the connections not required must be
provided with gasket screws ex-factory. Please leave these in the screw connec-
tion and only connect the cable that leaves the conduit seal. When joining the con-
duits to the flame block, ensure for a slight gradient away from the flame block in
order to avoid the accumulation of water on the conduit seal. Moreover, also en-
sure that you do not twist the conduit seal when securing the conduit as the cable
in the electrics housing may tear-off as a result. If necessary, use a respective
bolted connection (union).

8 Installation
For all devices

6 Secure the device with retaining bolts for the installation.
Chapter 6.2, “Ensure for a safe position of the device” on page 73
99
7 Check the device for any signs of damage.
Chapter 6.3.2, “Checking the device after storage” on page 80
8 Clean the sealing surface of the flange from contamination with a gentle
cleaning agent.
8.2 Installation of the device

8.2.1 Mounting the inlet and outlet piping
Danger
Escaping gas from incorrect seals
If flange seals are used for ultrasonic gas meters that protrude into the pipeline,
potentially explosive gas mixtures may escape due to leaks. Risk of intoxication
and explosion!
the pipeline.
Observe the instructions for the dimensions!

Chapter 13.5, “Weights and dimensions” on page 184

8 Installation
100
1 Inlet piping
2 Ultrasonic gas meter
3 Outlet piping
Fig. 8.2: Installation of the Inlet and outlet piping
The bolted connection of Inlet (1) and outlet piping (3) must be tightened according
to the tightening torque of the plant manufacturer. The tightening torque must com-
ply with the bolts and seals used.
1 Clean the sealing surface of the flange from contamination with a gentle
cleaning agent.
2 Tighten the bolts crosswise in order to avoid tensioning.
Notice
In general, only the horizontal installation of the USM GT400 is strongly
recommended. Turning the meter by more than 2 flange holes should not be
used to avoid the collection of condensates in the sensor pockets. Only in dry
and clean gas, other installation positions might be possible also, but it is not
recommendable.

8 Installation
8.2.2 Installation of the connection box

The device can be ordered in different versions. Depending on the version or-
dered, another procedure must be carried out for the installation.
101
These are the order versions:
• connection box according to ATEX / IECEx
“Installation of the connection box (ATEX / IECEx)” on page 101
• connection according to NEC 50

no box must be installed here, only connect the cable according to their des-
ignation.
Cable connection “Connecting the device electrically” on page 103
Installation of the connection box (ATEX/IECEx)
1 Connection box Ex-de

Fig. 8.3: Connecting the connection box
This version of the connection box is supplied in countries where the

ATEX / IECEx standards apply.
The external connecting housing is pre-assembled and connected electrically to

the ultrasonic electronics ex-factory.

8 Installation
Open the connection box (Ex-de)
102
1 Cover
2 Screws
3 Screwdriver
Fig. 8.4: Opening the connection box cover
1 Unscrew the screws (2) using a suitable screwdriver (3).

2 Remove cover (1).
▪ Closing the connection box (Ex-de)

1 Place cover (1) onto the connection box.
2 Screw in the screws (2) using a suitable screwdriver (3).
Joining the device to the customers flameproof connection box
With this order version, no connection box is mounted on the device.
The device offers the connection by cable that are routed through the flame block.
The wiring in the ultrasonic electronics is carried out ex-factory. The cables are
marked accordingly for connecting and can be connected in a customer’s connec-
tion box.
Observe the following when installing:
• The cables must be connected according to the lettering.

• Select a maximum cable length of three meters. If you need to use longer ca-
bles, please contact RMG services.

8 Installation
8.3 Connecting the device electrically

In this chapter you will receive information on connecting the electrical connec-
tions.
103
The terminal strip for the electrical connection is located in the external connection
box. The terminal assignment and the markings of the cable are always identical.
Maximum assignment
The maximum assignment is always completely available for the connections of
the Ex-de connection box.
• Current / voltage supply (24 VDC)
• Warning message (Warn)
• Alarm message (Alarm)
• Pulse output for "Forwards mode" (Pulse 1) and "Backwards mode" (Pulse 2)
• 2 x direction detectors for bi-directional operation (I/O1/2)
• Interface for RMGViewUSM (RS 485 0)
• Interface for an RMG flow computer (RS 485 1)
• Interface for any flow computer (RS 485 2)
• Analog output (4-20 mA)
• Connection for a pressure sensor as a 2-wire 4-20mA
(AUX1; Terminal 26: [P +] Terminal 27: [P -])
• Connection for a temperature sensor (PT100; AUX2; Terminal28: [PT100 ++],
Terminal 29: [PT100 +] Terminal 30: [PT100 -] Terminal 31: [PT100 -])
Cable specification
The following cable specifications are according to a complete assignment of the
USM-GT-400 ATEX / IECEx version. The cable types listed are recommendations
that can be replaced by technically comparable cable types.

8 Installation
Power supply ÖLFLEX® CLASSIC Cable Ø

3 x 1.5 mm² oder 12.3 mm
24 VDC 3 x 2.5 mm² 13.5 mm
104 Interface: LIYCY (TP)
RS 485-0,
RS 485-1, RS 485-2 3 x 2 x 0.75 mm² 9.4 mm
(can be laid in one cable)
AUX1 LIYCY
2 x 0.75 mm² 6.0mm
AUX2 LIYCY
2 x 2 x 0.75 mm² 8.5 mm
Analog out LIYCY 6.0 mm
4-20 mA 2 x 0.75 mm²
Warning + alarm LIYCY
2 x 2 x 0.75 mm² 8.5 mm
Pulse 1 + pulse 2 + LIYCY (TP)
I/O 1 + I/O 2 4 x 2 x 0.75 mm² 10.7 mm
Twisted pair cable (TP) are only required in case of multiple circuits in one cable.
Otherwise, LIYCY 2 x 0.75 mm² is sufficient for all signal outputs.
Connection box according to ATEX / IECEx
1 Ex-de connection box for Europe

Fig. 8.6: Close the connection box
In those countries where the standards ATEX and IECEx are valid,
the device is supplied with the connection box Ex-de (1).

8 Installation
The external connection box is connected electrically to the ultrasonic electronics

ex-factory and pre-assembled on the ultrasonic electronics. The external connec-
tion box does not have to be mounted.
105
Connection according to NEC 500
The number of lines that are permitted to be routed through the cable gland (½”
and ¾”) on the electrics housing and flame block is limited. Accordingly, this re-
sults in 4 different constellations that reflect the possibilities for connection.
The numbers given below at each figure only counts the limited number of cables;
all cables are labeled due to the number of the basic upper terminal block
Version 1: Minimum assignment-½” sealing fitting
Fig. 8.7: ½” cable gland with 11 wires, size AWG 18
1 1½” sealing fitting, connected with 11 wires, size AWG 18 (permitted, max.
11; Killark Type ENY-1TM).
For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected via the DZU
protocol (RS 485-1).

8 Installation
Version 2: Minimum assignment for bi-directional operation - ¾” sealing

fitting
106
Fig. 8.8: ¾” cable gland with 20 wires, size AWG 18
2 ¾” sealing fitting, connected with 20 wires, size AWG 18 (permitted, max. 20;
Killark Type ENY-2TM).
For bi-directional operation.

For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected
via the DZU protocol (RS 485-1).
Version 3: Minimum assignment for operation with pressure and tempera-

ture measurement - ¾” sealing fitting
Fig. 8.9: Measuring with pressure and temperature

8 Installation
For measuring with pressure and temperature:

For this version, the ERZ 2000 or ERZ 2000 NG cannot be connected
via the DZU protocol (RS 485-1).
107
Version 4: Maximum assignment

½” and ¾” sealing fitting
Fig. 8.10: ½“ and ¾“ sealing fittings with up to 31 wires of size AWG 18
3 Connect ¾” sealing fitting with 20 wires of size AWG 18 (permitted, max. 20;
Killark type ENY-2TM) and ½” cable gland with 11 wires of size AWG 18 (per-
mitted, max. 11; Killark type ENY-1TM).
All connections are routed to the outside and can be connected and used.
Not used cables need to be isolated or connected to any unused

free terminals.

8 Installation
8.3.1 Connecting the power supply
108
2 Stromversorgung an den Klemmen 24 VDC
1 Connect the power supply to the terminals 24 VDC (2).

Figure 8-16 on page 94.
8.3.2 Digital interfaces of USM-GT400
2 Digital interface RS485-0
3 Digital interface RS 485-1
4 Digital interface RS 485-2
Fig. 8.12: Digital interfaces RS 485-0,1 und 2

8 Installation
The interfaces RS 485-0, RS 485-1 and RS 485-2 are basically equal and can be
set for all possible connections. However, there are minor differences. These are
taken into account in the recommended connections and make it easier to connect
the recommended devices or the PC if they are followed.
109
Notice
Please use the connections as recommended below. If connections are
used differently additional, extensive settings may become necessary.
Recommended connections at the digital outputs.
RS 485-0 RS 485-1 RS 485-2

Proto- RMGViewUSM IGM-protocol Instanz-F
col, DZU-protocol
(service) 2nd ERZ ,
device
ERZ2000, Flow computer
ERZ2400, other suppliers
ERZ2000-NG,
ERZ2000-DI
fea- no parameterizable no parameterizable Modbus-Master, can
tures byte byte handle IGM- and
sequence for sequence for DZU-protocol, too,
data types Long data types Long parameterizable
and Float
and Float byte sequence for
data types Long and
Float

8 Installation
8.3.3 Connecting the computer for RMGViewUSM
110
2 Service connection
1 Connect the computer to the terminals RS 485-0 (1).
In order to connect, you need an interface converter from USB to RS 485.

(please see recommendations in chapter 8.3.4).
8.3.4 Connecting the flow computer
1 Ex-de according to ATEX and IECEx

Fig. 8.14: Connection box types

8 Installation
The flow computer is connected to the terminal strip of the external connection
box (1).
1. Open the cover of the connection box.

111
“Open the connection box (Ex-de) ” on page 102
▪ Connecting the flow computer from RMG
Connection via data cable for ERZ 2000

Use the following cable:
• twisted pair and shielded cable
• maximum length 500 m / 1640 ft
• line cross-section min. 2 × 2 × 0.75 mm2
2 Connection flow computer 1
3 Connection flow computer 2
The 2 interfaces RS 485-1 and RS485-2 are equivalent and you may change in
the following 1 to 2 (and 2 to 1) freely.
The difference is that the RS 485-1 interface does not have a parameterizable byte sequence for
the long and float data types. This interface is particularly suitable for communication using the
DZU protocol. The RS 485-2 is intended for communication via the manufacturer-independent In-
stance-F protocol, as this interface offers a parameterizable byte sequence.
1 Connect the first flow computer to the terminals RS 485-1 (2).
2 Connect the second flow computer to the terminals RS 485-1 (3).

8 Installation
Connecting a flow computer from third-party manufacturers
112
2 Connection Warning messages
3 Connection Warning messages
4 Connection Pulse 1
5 Connection Pulse 2
6 Connection RS 485-1
7 Connection RS 485-2
Flow computers from third-party manufacturers can be connected to RS 485-1 or

RS 485-2 terminals. This interface communicates via a Modbus protocol.
All diagnosis functions can be made available via a configuration of the Modbus.
Flow computers from third-party manufacturers can also be connected to the
terminals Pulse 1 and Pulse 2. When parameterizing, take care that the maximum
possible gas flow rate is assigned to a maximum frequency of 2 kHz. All diagnosis
functions are not available.
1 Connect the flow computer to terminals RS 485-1 (6) or RS 485-2 (7) or

Pulse 1 (4) and 2 (5).
Warning and alarm messages are also available. You also have to connect a
direction contact for bi-directional operation.
2 Connect the terminal Warn (2) for warning messages.
3 Connect the terminal Alarm (3) for alarm messages.

8 Installation
8.3.5 Connection of external DSfG-Device-F via Modbus

The intension to connect Ultrasonic gas meters comparable to an electronic evalu-
ations unit via the same protocol arises due to the wish to transfer "all" data deter-
mined by an ultrasonic gas meter, i. e. measured values as well as status infor- 113
mation or diagnostic data. Therefore, the connection via DSfG-device-F has be-
come the standard in Germany.
Since the USM GT400 does not have its own DSfG bus access, its DSfG-in-
stance-F protocol is implemented externally via a flow computer, the ERZ 2000-
NG, which has this access. To realize the access the necessary data are trans-
ferred between the ERZ 2000-NG and USM GT400 via Modbus, which is often
referred to as Instance-F, although it only provides the data required for DSfG
Instance-F.
1 ERZ 2000NG with external DSfG device F

2 USM-GT-400 Ultrasonic flow rate meter for gas
Fig. 8.17: Data exchange between ERZ 2000 NG and USM-GT-400
The corresponding settings can be found in the VK Modbus Master USM menu in
the ERZ2000-NG. The corresponding register expressions can be found in the VJ
register expressions menu. In the USM GT400, the Modbus registers of instance F
are listed in column BA.

8 Installation
Electrical connection
The following figure shows the rear panel of the ERZ2000-NG.

The USM GT400 is connected to the serial interface COM6.
114
Fig. 8.18: Connection of the USM‘s Modbus interface to COM 6
USM GT400 terminal compartment
Three serial interfaces for Modbus communication are available on the USM
GT400. For instance F Modbus communication, the RS 485-2 is provided with
terminal 21 (GND), terminal 22 (Data +) and terminal 23 (Data -).
Fig. 8.19: Connection of the RS 485-2 (22 +, 23 -) at the USM GT400

8 Installation
Configuration for COM6 and COM7
For communication with ultrasonic gas meters via instance F the optional interface
COM 6 for the ERZ2000-NG is necessary. The DIL switches are located on the
115
option card required for this purpose. The jumpers for the RS 485 require a setting
that is shown in the following Figure. After that, the option card is to be placed into
the COM6 and 7 slots, which is the first one from the right looking from the display
1 Square solder joint is to be aligned bottom left

2 Square solder joint is to be aligned bottom left
3 On top 485, below 232
4 On top 485, below 232
Fig. 8.20: Configuration of the option card to be used as COM 6 and 7 of the
ERZ 2000-NG

8 Installation
116
Fig. 8.21: Slot for the option card with COM 6 and 7 of the ERZ 2000-NG
Operating mode of the ERZ 2000-NG
If the button "DSfG: F-instance COM6/7" in the menu GB Flow rate parameter is
activated, the further necessary settings are suggested in this menu (light yellow-
green background):
• GB16 Volume transducer mode -> „DZU“ mode

• GB51 Device type -> „USM GT400“
• GB53 Meter type -> „USZ“ (or “USM”)

8 Installation
117
Fig. 8.22: Selection of DZU in Vol.transd. mode GB16
The proposal must then be "entered", i. e. accepted.
Protocol type in menu VJ Register Expressions
After the selection of "DZU" in Volume transducer mode the protocol type "DSfG:
F-instance" must be defined in the menu VJ register expressions by button se-
lection. The corresponding registers for the Modbus communication are thus sug-
gested.

8 Installation
118
Fig. 8.23: Selection of DSfG: F-Instanz in VJ98
The proposal must then be "entered", i. e. adopted. In the complete menu you can
see that many other parameters are transferred in addition to the flow rate.
The connection and selection of all other ultrasonic gas meters listed below are
also possible due to legal metrology purposes.
Coordinate VJ98 selected button is used to enter which suggestion was entered.
Notice
Attention:
Even if in the same field with the same register, e. g. the information "swirl" is
transmitted, the value is "swirl" is dependent form the device and path
configuration used. It might be (significantly) different for the various devices.
The same applies to all device-specific parameters.

8 Installation
Interface configuration COM6
For communication via Instance-F, the serial interface COM6 must be operated
with parameters 38400 baud, 8 bits, parity None and 1 stop bit as well as the oper-
119
ating mode Universal Modbus master. These can be found in IB serial interfaces in
coordinates IB31 to IB33.
Fig. 8.24: Interface configuration COM6
Notice
COM6 is then no longer available for communication with a gas chromato-
graph. Therefore, the Modbus Master communication for GC1 and GC2 in
the coordinates IL50 and IL51 must be realized via the serial interface
COM7.
It has to be deactivated if no Modbus IP is used.
Fig. 8.25: Operating mode: Modbus serial C7
Fig. 8.26: Operating mode: OFF

8 Installation
Configuration VK Modbus according to instance F
For communication via DSfG Instance-F, VK Modbus Master USM must be

parameterized according to the DSfG Instance-F specification as shown in the
120
following figure.
Fig. 8.27: Configuration of Modbus Master USM due to Instanz-F
The Modbus address in VK52 must be assigned with the address of the USM
GT400 are the same. They can be found in J-31. Selection values in VK58 and
VK59 are irrelevant because these data types are not included in the instance
protocol.
Configuration USM GT400 for Instance F
Serial interface RS 485-2 (opt. Ser2)
If the ERZ2000-NG is configured according to the DSfG Instance-F specification

as described in the previous chapter, the USM GT400 must be connected to the
RS 485-2 serial interface. This is defined in the coordinates J-25 to J-37 under the
indication "Opt. Ser2 ". Here these are to parameterize, too. The Modbus address
in J-31 can be freely selected and must be set identically in VK52 in the
ERZ2000-NG.

8 Installation
121
Fig. 8.28: Parameterization of RS 485-2 for Modbus according to instance F
Serial interface RS 485-1 (Serial-1)
The serial interface RS 485-1 may be used as well but requires a different setting
due to fixed deviating Byte order. It will not be treated here, in case it is required
you may have a look into the German manual of the USM GT400.
Modbus Registers for Device-F
The Modbus registers for device-F can be found in chapter 18 the Appendix with
the List of parameters. In the last part of this appendix, you may find the relevant
Modbus registers 32768 to 33022 including the name, a short description a the
type of the registers.
Additional Registers
The following Modbus registers contain additional USM-GT-400 data which are not
included in the tables above. A connected ERZ 2000-NG needs this information so
that its DSfG Device-F can be used.
9086 DSfG-Status
Register 9086 is linked to USM coordinate BA-1.

8 Installation
122 Fig. 8.29: Additional register
This register contains 16 USM status bits.
• Bit-0 = 1: The unit “Volume” is set unequal „m3“.

• Bit-1 = 1: The unit “Flow” is set unequal „m3/h“.
• Bit-2 = 1: The unit “Speed” is set unequal „m/s“.
If one of these three bits equals 0 the requesting ERZ 2000-NG gets the message
that the data of the registers 8000 to 80CE are invalid and may not be used for the
external DSfG instance F. In this case the USM is mis-configured and the device-F
will not work. Bits 3 to 15 are currently not in use.
9084 Qt
Register 9084 is linked to USM coordinate D-24.
Fig. 8.30: Additional register
This register contains a characteristic value of the USM which is dependent from
Qbmax and Qbmin.
• Qt = 0,20 x Qbmax If 00 <= (Qbmax / Qbmin) < 30

• Qt = 0,15 x Qbmax If 30 <= (Qbmax / Qbmin) < 50
• Qt = 0,10 x Qbmax If 50 <= (Qbmax / Qbmin)
• Qt = 0,10 x Qbmax If Qbmin = 0
32792 signal acceptance
Register 32792 is linked with USM coordinate C-6 Performance.
Calculating the signal acceptance
The signal acceptance in BA-13 is equal to meter performance, which is given

from coordinate C-6. This term is defined in chapter 4, Section 4.1 General
description.

8 Installation
The value specifies how many values - of a maximum possible determinable quan-
tity - could be taken into account. If one of ten measurements within a measure-
ment cycle for a path is wrong (i.e. 9 valid measurements) the DSP provides 90%
valid measurements, and the path performance is 90%.
123
The overall performance is the average of the performance of all individual paths
(L-6 to Q-6, valid measurement G1 - G6) for the last n measurements (n = moving
average in E-09; the default is 10 measurements).
Notice
The USM-GT-400 keeps its calibrated accuracy even if up to 2 measurement
paths fails! The value “signal acceptance“ falls down to 66% then.
Exceptions:
• If | Vw | <VwUg (the speed is below the minimum speed), then the path perfor-
mance and the overall performance goes to 100%.
Additional documentation/literature Modbus
• Modicon Modbus Protocol Reference Guide, PI-MBUS-300 Rev. J, June 1996
DSfG
• Gas Information Nr. 7 – 4. Überarbeitung 10 / 2009
Technische Spezifikation für DSfG-Realisierungen
Teil 1 Grundlegende Spezifikation
• Gas Information Nr. 7 – 4. Überarbeitung 10 / 2009

Technische Spezifikation für DSfG-Realisierungen
Teil 2 Abbildung der DSfG auf die IEC 60870-5-101
und -104
• DSfG-Datenelementeliste
DSfG Dellist 23-10-09 Teil3
ERZ 2000-NG
• Bedienungsanleitung Flow Computer Serie ERZ 2000-NG

• Operating Instructions Flow Computer Series ERZ 2000-NG

8 Installation
Instance-F: measured values and register addresses in ERZ2000-NG
In the ERZ2000-NG, with the calibration switch locked, the measured values and
status information are displayed; if the calibration switch is open, the Modbus ad-
124 dresses can be seen (see below).
Detailed information including hourly averages and deviations of the individual val-
ues from the mean value can be found in the higher-level Instance-F menu V,
whose subdirectories VA to VI are structured according to measured value catego-
ries.
Fig. 8.31: Modbus register list in ERZ2000-NG with locked (left) and open (right)
calibration switch
8.3.6 Interface converter

In this chapter you get some information about interface converters that have been
tested and approved for operation with USM-GT-400.
Interface converter from Ethernet (PC) to RS 485 (USM GT400)
Here Phoenix module FL COMSERVER UNI 485-2313452 may be used. Link:
https://www.phoenixcontact.com/online/portal/de?uri=pxc-oc-
itemdetail:pid=2313452&library=dede&pcck=P&tab=1
Fig. 8.32: Interface converter from USB to RS485 (USM-GT-400)

8 Installation
There are 3 recommendations:
1 I-7561 U-G CR unter: http://www.icpdas-europe.com

125
Fig. 8.33: Type ICP Con I-7561U-G CR
2 USB-RS485-WE-1800-BT (1,8 m cable length) and USB-RS485-WE-5000-BT

(5,0 m cable length) at: http://rs-online.com
Fig. 8.34: Type USB-RS485-WE-1800-BT 687-7834 (1,8 m) or Type USB-RS485-

WE-5000-BT 730-0164 (5,0 m)
3 USB-RS485-Converter / part number: 0202047 at: http://www.ipcas.com
Fig. 8.35: Type 0202047
You may find more details of the interface converters and their product information
at the given links.

8 Installation
8.3.7 Connecting the device to earth

In this chapter you will receive information on connecting the device to earth and
the protection of the device.
126
The PA connection must be at least 4.0 mm2
Danger
Mortal danger from incorrect earthing
When the device is not correctly connected to earth so that electrostatic
discharge can lead to spark formation, there is a risk of an explosion.
• Connect the device to earth as described in the instructions.
For ultrasonic gas meters DN150 (6") and DN100 (4")
1 Earthing srew M6
2 Earthing srew M6
3 Earthing cable
Fig. 8.36: Connect to earth – Ultrasonic meters DN150 (6") and DN100 (4")
1 Fasten the customers earthing to the earthing screw (1).

8 Installation
For Ultrasonic meters DN200 (8")
127
1 Earthing screw M6
2 Earthing screw M6
3 Earthing cable
Fig. 8.37: Connect to earth – Ultrasonic meters DN200 (8")
1 Fasten the customers earthing to the earthing screw (1).
Cable specifications
From a cable length of 1 m, you must use a screened cable for the data and net-
work cable. The screen must be applied on both sides or only on one side (meter
or control room).
Transducer
The transducers are metallic connected to the meter housing. You do not have to
earth the transducer separately. You must ensure that the conductive connection
with the pipeline of the measuring system is established.

8 Installation
8.4 Installing the pressure connection
Malfunctions from too small pressure connections

128
The cylindrical diameter of the pressure connection must be selected as
≥3 mm according to ISO 17089.
1 USM up to DN150 with shut-off valve

2 USM from DN200 with shut-off valve
3 USM up to DN150 without shut-off valve
4 USM from DN200 without shut-off valve
Fig. 8.38: Device with and without a shut-off valve
The pressure connection can be equipped with a shut-off valve (1 and 2) or with-
out a shut-off valve (3 and 4). If the device is ordered without a shut-off valve, the
connection is provided with a union nut (clamping screw connection) or a female
thread.

8 Installation
▪ Establish connection with the clamping screw connection
129
1 Union nut with clamping screw connection Ø 6 mm

2 Blind plug (plugged)
Fig. 8.39: Connection options of the pressure connection with clamping screw
connection
1 Unscrew the union nut of the clamping screw connection (1).

2 Remove the blind plug (2).
3 Push the union nut and clamping rings onto the pipe.
4 Push the pipe into the clamping screw connection until the stop.
5 Tighten the union nut in order to fix and seal the pipe.
Usually, Swagelok screw connections (or similar) are used here.
6 Tighten the Swagelok screw connection hand tight.
7 Tighten the Swagelok screw connection using a spanner (wide across flats
14) by a further ¼ turn.

8 Installation
▪ Establish connection at the female thread
130
1 Female thread ¼"

2 Blind plug (screwed)
Fig. 8.40: Connection options of the pressure connection with female thread
1 Unscrew the blind plug (2).

2 Seal the connection in the female thread (1).
8.5 Outdoor installation

The USM-GT-400 may be installed outdoor, too. Doing this requires some
important considerations and advices:
1. Please pay attention to the ambient temperature, it must not exceed the range
from -40°C to 55°C.
2. Please prevent any contact of the USM-GT-400 with chemically aggressive
gases and vapors. These gases and vapors may not damage the protective
coating nor the materials used. The materials used can be found below in the
section "Technical data".
3. The USM-GT-400 may not be completely buried or submerged in water.
4. The display must not be exposed to direct sunlight for a longer period of time
(> 5 minutes). In this case please use the recommended sun
protection (see next picture), that can be supplied from RMG service.

8 Installation
131
Fig. 8.41: Sun protection for the US electronic
5. If you expect higher temperatures than 55°C, then the USM-GT-400 has to be
protected under a large sunshield (weather protection roof or similar).

9 Start Up
9 Start Up
In this chapter you will receive information on start up after installation.
132
Content
9.1 Comparing meter parameters 132

9.2 Checking functions of the USM 132
9.3 Reading out speed of sound 133
9.1 Comparing meter parameters

After installing the meter and completing the electrical connections, the meter
parameters must be compared with the values of the calibration certificate or test
certificate. Example:
• Path lengths
• Axial distances
• Limit values
They are listed in an alphabetical order of their corresponding matrix coordinates

and can be found using the operating display. As an alternative, they can be read
out of the USE09 directly using the operating software RMGViewUSM.
9.2 Checking functions of the USM

The functions can be checked as soon as the meter is exposed to pressure.
For this purpose, the content of the valid measurements (in %) are checked in the
coordinates L-6 to Q-6. They should be 100% at zero flow and should also not fall
below 70% under difficult flow conditions, for example, with high flow rates.
If the operating pressure is not reached, a functional check is only possible to a

limited extent.
In this case, contact RMG services.

9 Start Up
9.3 Reading out speed of sound

The slightly different speeds of sound are also readable (coordinate L-9 to Q-9).
133
The values of the individual paths should differ only by a little (< 0.5 m/s). An accu-
rate comparison with the nominal speed of sound of the media is limited within the
operating conditions.
Temperature stratification within a pipeline

If no flow is possible when start up, temperature stratification may occur
within the pipeline so that speed of sound of paths with different measuring
levels may deviate significantly from one another.
Convenient function checks with ERZ 2000 (-NG)
If an ERZ 2000 (-NG) is available, the content of valid measuring values (in
%) and the measured speed of sound can also be checked in the column
FH (ultrasonic diagnosis) for each path.
In case the speed of sound is not plausible, troubleshooting with RMGViewUSM is

possible. If one individual path has failed, then there is probably an error in the
wiring or with the transducers of this path.
Further information can be found at:
Chapter 12, „Alarm and warning messages“ on page 176

10 Operation
10 Operation
This chapter provides you with information for working with parameters, lists and
134 measurement values.
Content
10.1 Measuring values and parameters 135

10.1.1 Input protection for parameters 135
10.1.2 Parameter and measuring values with variable units 135
10.1.3 Calibration and Service Switch 136
10.1.4 Interfaces to converters and controllers 136
10.1.5 Interface for service and parameterization 137
10.1.6 Adaptation of the DZU protocol to ERZ 2400 138
10.2 Calling up and changing the parameters via the ultrasonic electronics
139
10.2.1 Calling up the value of a parameter 140
10.2.2 Entering data 141
10.2.3 Changing the parameters of protection E and S 144
10.3 Parameterize the USM interface 149
10.3.1 Interface 0 149
10.4 Modbus communication in detail 161
10.4.1 Codes supported 161
10.4.2 Data types 161
10.5 Configuration of the current output 163
10.6 List of the measurement values and
parameters 163

10 Operation
10.1 Measuring values and parameters

The measuring values and parameters are arranged in a matrix structure where
the columns are designated with letters and the lines with figures.
135
Operation of the entire system is carried out via the display of the USE09 with
magnetic pin operation or via the service and parameterization software
"RMGViewUSM".
10.1.1 Input protection for parameters

The following table describes the column designation.
Terms Input protection

A: Display values that cannot be changed.
C: User data that can be changed using the user password.
E: Data subject to calibration that can only be changed with
opened calibration switch.
F: Free parameters without protection.
S: Especially protected parameters that can only be changed
via the user password and calibration switch.
10.1.2 Parameter and measuring values with variable units

The units are variable with several parameters and measuring values. The units of
the variable parameters and measuring values can be changed via a central entry
under a coordinate. This change has an effect on all parameters and measuring
values for which the variable units have been defined.
The variable units are marked with an &.
Example:
Several parameters and measuring values have the entry &v: for a variable unit.
The unit m/s is currently set for this variable. All parameters and measuring values
with this variable unit should be converted to ft/s.

10 Operation
Under coordinate AG-32 the value for the unit m/s is converted to ft/s. All parame-
ters and measuring values with this variable unit &v: are converted to ft/s.
136 Possible variable units
Column Coordinates Data type
&v: AG-32 m/s or ft/s (flow velocity)
&Q: AG-33 m³/h or acfh (flow)
&Z: AG-34 m³ or acf (meter)
&P: AG-35 P/m³ or P/cf (puls factor)
10.1.3 Calibration and Service Switch

There are several values / parameters which are protected against any change as
long as the calibration switch is locked. The protection applies to the input from the
keypad as well as to inputs via the Modbus - interface. The service switch extends
the possibility of settings of the coordinate matrix for the service. The service
switch prevents or allows to initialize the device parameters in case of failure with
default values (CRC - error of Ferro - RAM see below).
Notice
• Calibration and service switch must always be closed in custody
transfer operation!
10.1.4 Interfaces to converters and controllers

USM-GT-400 can be connected directly to a USZ 9000 or at an ERZ 2000 USC,
the communication protocol used is IGM compatible. USZ 9000 or ERZ 2000 USC
cannot transmit any data to USM-GT-400 via this interface.

10 Operation
The USM-GT-400 - IGM - interface is non-reactive!
For direct connection to a volume corrector either digital signals

or serial protocols may be used.
137
Digital signals are:
• Two frequency outputs for the actual flow
• Two outputs for two flow directions
• Alarm and warning contacts
Serial protocols are:

• DZU
• DZU-DIAG
• DZU-X
• IGM und USE09
• VO
• DZU-SLAVE
10.1.5 Interface for service and parameterization

For parameterization of the USM-GT-400 different protections are available:
• sealable calibration switch
• individual user codeword
• sealable calibration switch and input of the individual user codeword
• freely programmable
For parameterization of the USM-GT-400 the interfaces "RS485-0", "RS485-1",

"RS485-2" or keypad input and display are used. Protocol is Modbus - RTU or
Modbus - ASCII. These protocols follow the protections noted above, means, if the
calibration switch is closed, the corresponding parameters can not be changed.
Also when using keyboard and display parameter can only be changed after the
protections are unblocked. Display and keyboard do not effect the device further,
i.e. it does not matter whether the display is available or not. Therefore it can be
plugged or removed during operation. The Parameter setting can be changed to
other protocols; but the parameters themselves can‘t be changed using them. In-
terface "RS485-0" can be used to update (to flash) the firmware. To flash a new
firmware the software „HEXLoad“ is necessary at the PC. To initiate the update -
function the calibration switch needs to be activated and the power needs to
switched off / and on, too. An eventually newly flashed firmware can be clearly

10 Operation
identified via its firmware version and its checksum (CRC-16). Therefore, for
matching checksum and version number is deposited at the PTB (registration au-
thority). The checksum itself can be verified via the display or via Modbus.
138
10.1.6 Adaptation of the DZU protocol to ERZ 2400

DZU protocol (DZU slave) becomes bus-capable adjusting the coordinates of the
bus address:
1. J-01 mode serial 0 (extended menu: DZU-Slave)

2. J-12 DZU-0 address
3. J-14 mode serial 1 (extended menu: DZU slave)
4. J-23 DZU-1 Address
5. J-25 opt. ser2 mode (extended menu: DZU-Slave)
6. J-37 DZU-2 address
Notice
This mode can be used only in areas where the MID is applied!

10 Operation
10.2 Calling up and changing the parameters via

the ultrasonic electronics
This chapter provides you with information for operating the ultrasonic electronics 139
via the display with a control panel.
The parameters can be called up and changed via the display with control
panel or RMGViewUSM.
Software instructions RMGViewUSM (separate document)
1 Switch point
2 Magnet
Fig. 10.1: Magnet for operating the buttons
When the cover of the ultrasonic electronics is closed, the buttons can be operated
using the magnets supplied. In order to operate the buttons with the magnets (2),
the magnet must be placed on the glass in the position with the switching point (1)
of the button.

10 Operation
10.2.1 Calling up the value of a parameter
▪ Select the column in the coordinate system

140
Select the column of the coordinate on the control panel of the
ultrasonic electronics using the button.
The button has been allocated with the following functions for
navigating:
• Press the button briefly: one column to the right, e.g., from
A to B.
• Press the button longer: depending on the duration of
pressing the button:
- one column to the left, e.g., from B to A.
- continuously column by column to the left, e.g., from
U to F.
1 Press the button to select the desired column.
▪ Select the line in the coordinate system
Select the line of the coordinate on the control panel of the ul-
trasonic electronics using the button.
The buttons have been allocated with the following functions

for navigating:
• Press the button briefly: one column down, e.g., from

E-01 to E-02.
• Press the button longer: continuously line by line down-
wards.
• Press the button briefly: one column up, e.g., from

E-02 to E-01.
• Press the button longer: continuously line by line upwards.
1 Press the buttons to select the desired line.
The coordinates (column and line) of the parameter are selected. The value of the
parameter is shown on the display.

10 Operation
10.2.2 Entering data
Observe the designations of the columns and the rights assigned. 141
“Input protection for parameters” on page 135
A parameter that is entered in the protection E or S can only be changed
when the calibration switch is open. For a value / parameter / measure-
ment value S, the code word also has to be entered for the ultrasonic elec-
tronics.
If this parameter is changed then the device is no longer considered as cal-
ibrated.
• Only carry out these tasks if you are authorized.
“Changing the parameters of protection E and S” on page 144
Depending on the type of data, you are offered different selection options when
making entries.
In order to change data, the coordinate of the parameter must be selected.
“Calling up the value of a parameter” on page 140
▪ Example for data type Float (F)

Data type Example
Float (F) A-06 p-Max value
1. Press the button until the next value is marked in the display.
2. Press the button to select a value from the list.

Possible value of the list.: 0 /…/ 9 / - / + / . / E / _
3. Press the button to confirm the value.
The value is stored.

10 Operation
▪ Example for data type Integer (I) and Long integer (L)
Data type Example
Integer (I) D-10 Qb-min time
142
Long integer (L) AF-02 electronic no.

Possible value of the list: 0 /…/ 9 / - / _.

▪ Example for data type Text (T)
Data type Example

Text (T) AU-01 User Test-1

Possible value of the list: 0 /…/ 9 / - / + / . / _ / A /…/ Z

Notice
The data type text is not a text in the actual sense, but a bit combination.

10 Operation
▪ Example for data type Menu (M)

Data type Example
Menu (M) A-17 p-mode
143

▪ Example for data type Time (U)

Data type Example
Time (U) D-23 Qb-S time 2
1. Press the button until the next value is marked in the display


10 Operation
10.2.3 Changing the parameters of protection E and S
This chapter provides you with information for changing parameters that are pro-
144 tected by the calibration switch and also by the code word of the ultrasonic elec-
tronics. This affects all parameters that are stored in the coordinates for columns E
and S. For a parameter in column S, the code word also has to be entered for the
ultrasonic electronics.
Danger
Danger to life from opening the device
If the cover or the housing of the device is opened in an area with a potentially
explosive environment, then the device is no longer suitable to be used in the
area with a potentially explosive environment. Risk of explosion!
• Open the device only when the device is voltage free.
Mortal danger from damaged components
If threaded holes, bolts or the sealing surfaces of the housing are damaged, the
spark protection gap can no longer be guaranteed. Sparks resulting may lead to
an explosion.
• Proceed with care when working with the bolt connections.
• Replace damaged components with new ones.
• Make sure that no parts of the housing are damaged.
Please note that for this task the official seal must be broken. The device
must not be used for calibrated operation if the official seal is broken.
If the task is carried out by RMG service, the device does not have to be
calibrated by a testing institute. The device is provided with a new official
seal by RMG service.
• Führen Sie diese Arbeiten nur aus, wenn Sie dazu befugt sind.

10 Operation
▪ Opening the cover of the ultrasonic electronics

1 Switch off the system power supply.
145
1 Threaded pin
2 Boreholes for inserting the special tools
3 Special tool (2 pieces)
Fig. 10.2: Opening the cover
2 Unscrew threaded pin (1) out of the housing.

3 Insert the special tools into the boreholes.
4 Release the cover with the special key.
1 Cover
Fig. 10.3: Opening the cover
5 Screw the cover off with both hands.

10 Operation
▪ Setting the ultrasonic electronics for configuration
146
1 Calibration switch
Fig. 10.4: Opening the calibration switch
1 Press calibration switch (1) upwards to open it.
▪ Screw down the cover of the ultrasonic electronics
1 Cover
2 Position O-ring
Fig. 10.5: Screw down the cover
1 Each time you open the ultrasonic electronic you have to expect that the O-
ring is damaged. Therefore, this damaged O-ring has to be replaced with a
new one in general. (RMG provides a replacement kit with O-ring, grease, ...
sales number: 38.03.001.00)
2 Screw the cover on with both hands.
3 Insert the special tools into the boreholes.
4 Tighten the cover with the special tools.
5 Screw in threaded pin hand tight.
6 Switch on the system.

10 Operation
▪ Entering the code word of the ultrasonic electronics
If you do not have the password for the ultrasonic electronics, request the 147
code word from RMG Service.
1 Enter the code word for the ultrasonic electronics under coordinate AG-4.
▪ Changing the value of the protected parameters
1 Calibration LED
Fig. 10.6: Check LED
AG-4 user code:

Standard setting: 9999 9999
• This value can be changed when the calibration switch is opened.
Note:
• During start up, this value can be set to customer requirements under
the supervision of a calibration inspector.
1 Check LED.
The Calibration lights up. The calibration switch has been
opened correctly.
2 Change the parameter values.
“Changing the parameters of protection E and S” on page 144
An open lock must be shown in the third line of the display to

allow the value of the protected parameters to be changed.

10 Operation
If the lock is not shown as open, check the switch position of

the calibration switch.
3 Activate the button with the magnet.

148 The value of the parameter can be changed.
Figure 10-1 on page 139
4 Activate the button with the magnet in order to position the cur-
sor on the value of the parameters to be changed.
5 Activate the button with the magnet in order to set the desired
value.
6 Activate the button with the magnet in order to confirm the

desired value.
When the parameter is changed, you have to move the

calibration switch back to the closed position.
▪ Conclude work
1 Switch off the system power supply.
2 Open the cover of the ultrasonic electronics.
“Opening the cover of the ultrasonic electronics” on page 145
3 Press calibration switch (A) downwards to close it.
4 Close the cover of the ultrasonic electronics.
“Screw down the cover of the ultrasonic electronics” on page 146
1 Calibration switch
Fig. 10.7: Close the calibration switch

10 Operation
10.3 Parameterize the USM interface

The ultrasonic gas meter has three serial interfaces that can be used for Modbus
communication. The parameterization is carried out in column "J Serial Ports" of
149
the coordinate matrix.
10.3.1 Interface 0
• Is reserved for service purposes or RMGViewUSM.

• The parameterization is carried out using the coordinates J-1 to J-13.
Coordinates Name Value Unit Modbus Address
J-01 Serial 0 modus Modbus 2099
J-02 Serial 0 baud rate 38400 baud 2100
J-03 Seriell 0 bits 8 2101
J-04 Serial 0 parity NONE 2102
J-05 Modbus 0 protocol RTU 2103
J-06 Modbus 0 HW mode RS485 2104
J-07 Modbus 0 adresse 1 2105
J-08 Modbus 0 reg.offset 0 2106
J-09 Modbus 0 gap time 45 2118
J-10 Pressure application OFF 2116
J-11 Lpt interval 10 2117
J-12 DZU-0 adress 1 2283
J-13 Serial 0 status 10 760

10 Operation
10.3.2 Interface 1
• Is intended for exchanging data with volume conversions.

150
J-14 Serial 1 mode DZU X-FRAME 2107
J-15 Serial 1 baud rate 9600 baud 2108
J-16 Serial 1 bits 8 2109
J-17 Serial 1 parity NONE 2110
J-18 Modbus-1 protocol
J-19 Not available
J-20 Modbus-1 address
J-21 Modbus-1 reg.offset
J-22 Modbus-1 gap time
J-23 DZU-1 address 2 2284
J-24 Serial 1 Status 10 770
10.3.3 Interface 2
• Is intended for communication with a Modbus Master.


10 Operation
J-25 Opt. Ser2 modus Modbus 2112

151
J-26 Opt. Ser2 baud rate 38400 baud 2113
J-27 Opt. Ser2 bits 8 2114
J-28 Opt. Ser2 parity NONE 2115
J-29 Modbus-2 protocol RTU 2178
J-30 Modbus-2 HW-mode RS485 2179
J-31 Modbus 2 address 1 2180
J-32 Modbus 2 reg. offset 0 2181
J-33 Modbus 2 gap time 45 2182
J-34 Long Byte order NORMAL 2251
J-35 Float Byte order NORMAL 2252
J-36 Double Byte order NORMAL 2253
J-37 DZU-2 Address 3 2285
J-38 seriel 2 Status
J-39 DZU Interval 100 tics 2111
J-40 DZU Checksum Preset 0x00 2255
• Interface 2 can be configured as RS232 or RS485.

• Factory setting or default is RS485.

10 Operation
152
1 DIP switch RS232 configuration

2 DIP switch RS485 configuration
Fig. 10.8: Configuring interface with DIP switch
• The configuration is carried out via software (coordinate J-30) and hardware
(switch).
• The DIP switch is located on the optional card in the ultrasonic electronics
housing.
Communication as Modbus master
J-25 Mode Opt. Serial 2
To activate the Modbus Master, the mode must be set to Modbus master.
Fig. 10.9: Activation as Modbus master
Coordinates AW-08 and AW-09 indicate the time since of the last AGA10 calcula-
tion respectively the time of last update of the gas components.

10 Operation
153
Fig. 10.10: Status information of the AGA-10 calculation
Using the coordinates AZ-01 Formula Methane to AZ-50 Formula Status the USM-
input variables are linked to the PGC gas data.
USM-GT-400 Coordinates Name Value Unit

USM_Ob AZ-01 Formula Methane F8252
USM_Ob AZ-02 Formula Methane
USM_Ob AZ-03 Formula Ethane F8256
USM_Ob AZ-04 Formula Ethane
USM_Ob AZ-05 Formula Propane F8258
USM_Ob AZ-06 Formula Propane
USM_Ob AZ-07 Formula I-Butane F8260
USM_Ob AZ-08 Formula I-Butane
USM_Ob AZ-09 Formula N-Butane F8262
USM_Ob AZ-10 Formula N-Butane
USM_Ob AZ-11 Formula Neo-Pentane 0
USM_Ob AZ-12 Formula Neo-Pentane
USM_Ob AZ-13 Formula I-Pentane F8266
USM_Ob AZ-14 Formula I-Pentane
USM_Ob AZ-15 Formula l N-Pentane F8268
USM_Ob AZ-16 Formula N-Pentane
USM_Ob AZ-17 Formula Hexane+ 0
USM_Ob AZ-18 Formula Hexane+
USM_Ob AZ-19 Formula Oxygen F8280
USM_Ob AZ-20 Formula Oxygen
USM_Ob AZ-21 Formula Helium F8282
USM_Ob AZ-22 Formula Helium
USM_Ob AZ-23 Formula Hydrogene F8284
USM_Ob AZ-24 Formula Hydrogene
USM_Ob AZ-25 Formula Argon 0
USM_Ob AZ-26 Formula Argon
USM_Ob AZ-27 Formula Nitrogen F8250
USM_Ob AZ-28 Formula Nitrogen
USM_Ob AZ-29 Formula CO2 F8254
USM_Ob AZ-30 Formula CO2
USM_Ob AZ-31 Formula Hexane 0
USM_Ob AZ-32 Formula Hexane
USM_Ob AZ-33 Formula Heptane 0

10 Operation
USM_Ob AZ-34 Formula Heptane

USM_Ob AZ-35 Formula Octane 0
USM_Ob AZ-36 Formula Octane
USM_Ob AZ-37 Formula Nonane 0
154
USM_Ob AZ-38 Formula Nonane
USM_Ob AZ-39 Formula Decane 0
USM_Ob AZ-40 Formula Decane
USM_Ob AZ-41 Formula H2S 0
USM_Ob AZ-42 Formula H2S
USM_Ob AZ-43 Formula H2O 0
USM_Ob AZ-44 Formula H2O
USM_Ob AZ-45 Formula CO 0
USM_Ob AZ-46 Formula CO
USM_Ob AZ-47 Formula Ethene 0
USM_Ob AZ-48 Formula Ethene
USM_Ob AZ-49 Formula Propene 0
USM_Ob AZ-50 Formula Propene
USM_Ob AZ-51 Formula Status u1038==0
USM_Ob AZ-52 Formula Status
USM_Ob AZ-55 MB Pause 20 s
USM_Ob AZ-56 MB Timeout 1000 ms
USM_Ob AZ-57 MB Int16Order 21
USM_Ob AZ-58 MB Int32Order 4321
USM_Ob AZ-59 MB FloatOrder 4321
USM_Ob AZ-60 MB DoubleOrder 43218765
The USM-GT-400 combines the information of the PGC-register 8252 (= Register

address component methane) with the coordinate AZ-01. Data type F8252 means
that methane is delivered as a single-precision floating-point number (Float).
There are different data types: double-precision floating point = D (Double float),
simple-precision floating point = F (Float), 32-bit unsigned integer = U (Long) and
16-bit unsigned integer = u (short).

10 Operation
155
Fig. 10.11: Gas component
Unit Conversion
An implemented formulary offers additional options for a conversion. Values from

the PGC can be converted according to the requirements. For example to multiply
the methane concentration (0.94) with 100 (94%) in coordinate AX-46 has to be
selected F8252 * 100.
Fig. 10.12: Applying the unit conversion
Rules for distributing the gas components
Not all possible gas components can be filled. Then these gas components are to
be distributed according to the distribution rules.
“Treatment of the gas data” on page 32

It might be possible that there is no input field in the USM-GT-400 for a measured
gas component from the PGC, for example, Neo-pentane (register 8264). Neo -
pentane will then be added to N-pentane (register 8268). Coordinate AZ-15 then
has to be formulated as F8264 + F8268.
Fig. 10.13: Applied distribution rule

10 Operation
Rule for splitting gas components
If components as hexane, heptane, octane, nonane and decane are not given indi-
vidually, but as a sum of hexane plus higher alkanes, eg Register in F8272, this
156
sum can be split according to the rule of thirds to the components. Hexane, hep-
tane, octane, nonane and decane are then distributed to 81: 27: 9: 3: 1. Normal-
ized this results in 81/121: 27/121: 9/121: 3/121: 1/121. The coordinates AZ-31 to
AZ-40 become to:
Fig. 10.14: Applied splitting rule
Beside addition and multiplication other mathematical rules such

as division and bracket rules can be applied, too.
Constants
It might be possible that components required from the USM-GT-400 are not given
from the PGC, for example water and hydrogen sulfide. These can be set to 0:
Fig. 10.15: Adjusting gas components

10 Operation
Remarks to the coordinates AZ-01 to AZ-50
The input of a coordinate, for example, AZ-01 can have a maximum

of 20 characters. To specify more complex expressions two
157
coordinate per gas component may be used, for example
methane
• AZ-01 Formula_Methane0 (less significant)

• AZ-02 Formula_Methane1 (highly significant)
An expression with more than 20 characters begins with the less significant coordi-
nate AZ-01 and then continues with one with higher significant AZ-02. Unused
high-order coordinates are filled with spaces.
The formulas combining the USM-GT-400 input variables with the PGC data may
not exceed a maximum of 60 Modbus registers.
AZ-51 Formula Status to AZ-54 Formula Status
For the PGC status could be required for example:
• Value = 1 The PGC measures without error

• Value = 0 The PGC is in alarm
• Value = 0 The PGC is in revision
It is possible that a PGC is not providing its status in this form. Instead, there may
be:
Register 10: It shows the number of pending alarms. When showing 0 the PGC
is free of alarms. It is a 16-bit integer register.
Register 2: It is a bit coded information. In the measuring mode of the PGC the
bit is set to 4. It is a 32-bit integer register.
The following considerations help to formulate the state-formation in coordinate
AZ51:
• The first part of a 16-bit integer registers will be imported. The number of pend-
ing alarms shows the data type of an unsigned integer (unsigned short int). The
prefix is a small u. The register address is 10, therefore, the value u10 should
be requested.

10 Operation
• The value is checked to be 0. The first term is found to be u10 == 0. The result
is true if u10 contains a 0.
• For the second part, a 32-bit integer registers is imported. This value has to be
158 read bitwise. It is a 32-bit unsigned integer (unsigned long int). The prefix is a
large U. Register address is 2; the value U2 must be
requested.
• Now it is checked whether any bit is set to 4. As operator the bitwise "and" has
to be used (&). The second part of the expression results to U2 & 4. The result
is 0 when the bit with the value 4 is not set and a value other than 0 is set. Bits
with other values then 4 do not affect the result.
• The two partial expressions are joined via a logical "and" (&&). Following the
bracket rules both subexpressions have to be put in brackets. The complete ex-
pression for AZ-51 is found to be (u10== 0)&&(U2&4).
Arithmetic Operators Comparison Opera- Logical Operators Bitwise Operators

tors
Addition + greater > Logical And && Bitwise And &
Subtraction - smaller < baud Bitwise Or |
Multiplication * greater or equal >= Logical Or || exclusive or ^
Division / less or equal <= Not! Bitwise negation
Modulo % equal ==
Sign - not equal to =!
Terms may be
• a?b:c means: if a then b else c
• brackets: ()
• constants:
Integers, for example, 42
Floating point, for example, 1.234
Exponential, for example, 1.2345E-3
unsigned, the sign is realized by the operator sign
Information to the status of the PGC

The input field of coordinate AZ-51 accommodates a maximum of 20 characters.
If this is insufficient for the formulation of a more complex expression, there are a
total of four coordinates for the status.

10 Operation
AX-51 Formula Status (lowest significance)

AX-52 Formula Status (low significance)
AX-53 Formula Status (high significance)
159
AX-54 Formula Status (highest significance)
Entering a formula with more than 20 characters starts with the lowest order coor-
dinate AZ-51 and then continues in the higher- AZ-52, AZ-53 and AZ-54. If the
higher order coordinates are not needed, they are to be filled with spaces.
AX-92 MB_Pause: The requests of the USM-GT-400 to the PGC are summarized
in a block. Between two blocks will be an interval. AX92 coordinate indicates the
interval time.
AX-93 MB_Timeout: Maximum time between a PGC request and the associated
response.
AX-94 MB_Int16Order: Adjustment of the byte order of 16-bit integers. A 16-bit

value consists of two bytes, the least significant byte and the most significant byte.
There are two settings: 12 and 21.
AX-95 MB_Int32Order: Adjustment of the byte order of 32-bit integers. A 32-bit

value consists of four bytes. Common sequences are: 1234/2143/3412 / 4321.
However, all other options can be set, too. For example, 4123.
AX-96 MB_FloatOrder: Adjustment of the byte order of single precision floating

point numbers. A single-precision floating-point number consists of four bytes.
Common sequences are: 1234/ 2143/3412 / 4321. However, all other options can
be set, too. For example, 3124.
AX-97 MB_DoubleOrder: Adjustment of the byte order of double- precision float-

ing point numbers. A double-precision floatingpoint number consists of eight bytes.
Consistent Sequences are:
12345678/21436587/34127856/43218765/56781234/65872143/78563412 /
87654321. However, all other options can be set, too.For example, 81,726,354.
Note to the coordinates AX94 to AX97: The numbers represent the significance.
It increases with the value of the byte. The sequence is read from left to right.

10 Operation
160
Fig. 10.16: Significance of the coordinates
AY-46 telegram counter: Here all correct PGC answers are counted.
AY-49 MB timeouts: Here the timeouts detected on the Modbus are counted. The
counter is incremented when no PGC-answer arrives within the time set in AX-93.
AY-50 MB error-counter: Here all incorrect PGC answers are counted.
AY-51 MB error register: If an unexpected answer from the PGC arrives, this co-
ordinate indicates the related Modbus register.
AY-52 MB error answer: Here the PGC answers are counted with exception
code.
AY-55 MB_ErrorBits: This coordinate informs about problems occurring during
the link of the USM-input variables with the PGC data. However displayed is a
three-digit hexadecimal number instead of any bit combination.
Bit 0 - 7: If a link was formulated incorrectly, a coded number here indicates the
first failed formula. Examples:
0 = formula methane is faulty
1 = formula nitrogen is faulty
6 = formula H2S is faulty
Bit 8: Reserved
Bit 9: 0 = no error.
1 = Error for the formulation.
Bit 10: Reserved
Bit 11: Reserved
Bit 12: In the formulas for linking the USM input variables with the PGC data more
than 60 Modbus registers were used in total.
AY-56 MB_InStatus: Here the evaluation result of the status formula (AZ-51 to
AZ-54) is given.

10 Operation
10.4 Modbus communication in detail

10.4.1 Codes supported
161
The ultrasonic electronics supports the following codes:
Function Code Code Description

03 Hex Read Holding Registers
06 Hex Preset Single Register
10 Hex Preset Multiple Registers
08 Hex Diagnostic
00 Hex Return Query Data
Exception Code Code Description

03 Illegal Function
03 Illegal Data Address (Register nicht vorhan-

den)
03 Illegal Data Value (Register nicht beschreibbar
oder Wert falsch)
10.4.2 Data types
Data type Register Value Byte Byte Byte Byte Byte Byte Byte Byte
1 2 3 4 5 6 7 8
float 2 273,15 0x93 0x33 0x43 0x88
text 10 USM 0x53 0x55 0x30 0x5A 0x2D 0x38 0x50 0x36
GT400
0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00
0x00 0x00 0x00 0x00
intd 1 44067 0xAC 0x23
double 4 14,2740 0x13 0x58 0x8A 0xCF 0x8C 0x4C 0x40 0x2C
long 2 100000 0x86 0xA0 0x00 0x01

10 Operation
Example (question / answer)
Question Modbus - ASCII Modbus - RTU

Start Char :
162
Slave Address 01 01
Function 03 03
Starting Address Hi 0F 0F
Starting Address Lo A2 A2 Register = 4002 (0FA2)
No. of Points Hi 00 00
No. of Points Lo 01 01 Amount = 0001 (0001)
LRC / CRC 42 26
carriage return CR FC
line feed LF
Reply:
Start Char :
Slave Address 01 01
Function 03 03
Byte Count 02 02
Data Hi (Reg 2000) A8 A8
Data Lo (Reg 2000) 01 01 Wert = A801
LRC 51 06
carriage return CR 44
line feed LF

10 Operation
10.5 Configuration of the current output

The connection of external devices to the current output of the meter is to be car-
ried out as described in chapter 8.3 Connecting the device electrically.
163
The parameters are then set in column 'I Current Output' of the coordinate matrix
as follows:
1. Enter the code number.

2. Look up the Modbus address of the physical quantity (measured or calculated
value) to be output in the parameter list or with the RMGViewUSM operating soft-
ware under "Values". Then enter this Modbus address in coordinate I-06 (c-
out select).
3. In coordinate I-07 (c-out mode), select the operating mode of the current out-
put (0-20mA or 4-20mA). With "SET VALUE" a constant current can be output,
the value of which is set in coordinate I-05 (c-out set value).
4. In coordinate I-03 (c-out min.), enter the minimum value for the physical quan-
tity at which 0 or 4 mA should be output.
5. In coordinate I-04 (c-out max.), enter the maximum value for the physical
quantity at which 20 mA should be output.
6. In I-08 (c-out err mode) it can then be determined whether the minimum value,
the maximum value or 0 should be output in the event of an error.
The damping value in I-09 can be used to specify how quickly the output current
reacts to a change in the physical quantity. The fastest possible reaction occurs
with the value of 0.
10.6 List of the measurement values and

parameters
The lists for parameter and measured values are in appendix 18.

11 Maintenance
11 Maintenance
164 In this chapter, you are provided with information as to how you can extend the
service life of the device through maintenance. You can only protect the device
against premature wear when observing the maintenance schedules described
here.
Content
11.1 Maintenance schedule 165

11.2 Checking the device for leaks 165
11.3 Checking the device for any signs of damage 166
11.4 Changing the battery 166
11.5 Changing the transducer 166
11.6 Changing the ultrasonic electronics 167
11.7 Cleaning the device 167
11.8 Check the official seal 168
11.9 Decommissioning and disposal 168

11 Maintenance
11.1 Maintenance schedule

The maintenance schedule specifies the intervals in which the maintenance work
has to be carried out in order to maintain the function of the device.
165
Interval Activity
Weekly • Check that the official seal has not been tampered with (this
time interval can be extended to a meaningful length).
As required • Clean the device.
• Check the plug connections and screw connections for
leaks and tight fit, where necessary, replace the seals.
Every 5 to 10 • Check the device for leaks. Please perform a leakage check
Years each time the device has been physical touched.
On consulta- • Check the device for leaks. The leak tightness of the device
tion with RMG. may be limited if non-approved gas types are used. In these
cases, please contact RMG.
11.2 Checking the device for leaks

For safe operation, the device must be sent back to RMG every 5 to 10 years to
check for leaks.
In the course of a recalibration from RMG, the device will also be checked
for leaks at the same time.
If the device is used with the permitted gases, the service life of the seals is
unlimited.
Chapter 13.2, “Approved gas types” on page 180
If other gases are used, please contact RMG.

RMG service will provide you with an interval for the leak test for the inter-
action with the ultrasonic gas meter and the gas type used.
1 Pack the device for transport and shipping to RMG correctly.

Chapter 6.2, „Packing the device for transportation“ on page 73

11 Maintenance
11.3 Checking the device for any signs of damage

The device must only be used in a technically sound state.
166
▪ Checking the device
1 Perform a visual check of the ultrasonic electronics viewing window.
The viewing window must be free of cracks and complete.
2 Perform a visual check of the transducer covers.
The covers must be free of cracks and breaking points.
3 Perform a visual check of the ultrasonic gas meter housing.
The housing must be free of damage resulting from mechanical influences.
11.4 Changing the battery

The ultrasonic electronics contains a battery which keeps date and time when no
power is available. If the battery is empty, the setting for the time and date are lost.
1 Have the empty battery changed by the RMG service.
Notice
Recommendation: The battery should be changed on the regular base of
recalibration but latest each 10 years.
11.5 Changing the transducer

Danger
If transducers of a system under pressure are not changed correctly, this may
cause an explosion. Escaping gas may lead to intoxication.
this activity.
• Observe the separate service instructions for changing the transducer.

11 Maintenance
The special tool from RMG must be used for changing the transducers.
You can find out more about changing the transducers with the tool here:
Service manual for changing the transducers and ultrasonic electronics (sepa- 167
rate document)
11.6 Changing the ultrasonic electronics

Danger
If transducers of a system under pressure are not changed correctly, this may
cause an explosion. Escaping gas may lead to intoxication.
this activity.
• Observe the separate service instructions for changing the transducer.
You can find out more about changing the ultrasonic electronics here:
Service manual for changing the transducers and ultrasonic electronics (sepa-
rate document)
11.7 Cleaning the device

Notice
Malfunction from soiling
If the device is soiled on the inside, it cannot function correctly. This may lead to
incorrect measuring values or a failure.
• Have a device that is contaminated on the inside only cleaned by RMG ser-
vice or by personnel that have been especially trained by RMG.
Damage to the device from incorrect cleaning agent
If the device is cleaned with cleaning agent containing solvents or other unsuita-
ble agents, the paint or plastic parts become brittle, for example.
• Use gentle cleaning agents that are suitable for glass surfaces, metal and
plastic.

11 Maintenance
▪ Performing cleaning
1 Free the device from rough and lose dirt with a soft brush.
2 Clean the viewing window of the ultrasonic electronics with a moist cloth.
168
11.8 Check the official seal

The official seals must be available and must not be damaged for calibrated
operation.
▪ Perform a visual check of the official seals

1 Check that the official seals are intact and complete in a visual inspection.
The positions of the official seals can be found here:
Chapter 13.7, “Official seal diagram” on page 192
11.9 Decommissioning and disposal

Danger
Mortal danger from disassembly in potentially explosive environment.
If the device is disassembled in a potentially explosive environment for
disposal, resulting sparks may lead to an explosion.
• Disassemble the device only in an explosion-proof area.
Warning
Risk of injury from work carried out incorrectly
During decommissioning and removal work, there is a risk of severe injuries
from components under pressure and highly explosive atmospheres if the sys-
tem has not been correctly disconnected from the gas supply network and the
power supply in advance.
• Before starting work, switch off the device and secure it against being
switched back on.
• Depressurize the device.
• Only specialist personnel are allowed to undertake the decommissioning.

11 Maintenance
Observe the applicable national and local guidelines for disposal. Ask your
local authorities about the legal guidelines at your company location as well
169
as about the regional disposal companies or collecting points.
The device mainly comprises materials that can be disposed of as old metal. In the
following we shall specify the components that may not be disposed of as old
metal.
Ultrasonic electronics
Electric components are contained in the housing of the ultrasonic electronics that
must be disposed of as electric waste. In order to remove the ultrasonic electron-
ics, you have to remove the cover of the ultrasonic electronics.
Chapter 10.2.3, “Opening the cover of the ultrasonic electronics” on page 145
Battery
The battery is attached to the PCB of the ultrasonic electronics. In order to remove
the battery, you have to remove the cover of the ultrasonic electronics.
Chapter 10.2.3, “Opening the cover of the ultrasonic electronics” on page 145
Transducer
The transducer comprises titanium, plastic and heavy metals (e.g., lead in piezo
crystal). The transducers must be disposed of according to the applicable national
and local guidelines.
In order to remove the transducers, RMG service shall inform you of the proce-
dure.
„Manufacturer“ on the inside cover

12 Alarm and warning messages

In this chapter, you will find out which information, alarm and warning messages
170 can be displayed. In this chapter, you will also find out how to eliminate problems
with the RMG components.
Content
12.1 Alarm messages 171
12.2 Warning messages 172
0

Notes 175
12.4 Troubleshooting 175
Active warning messages are displayed with a + in front of the message number. 171
Warning messages that can be acknowledged are displayed with a - in front of the
message number.
12.1 Alarm messages

No. Message Explanation
0 No errors Trouble-free operation
1 Power failure Temporary power failure
2 FPGA FPGA communication: FPGA does not answer
Timeout
3 FPGA CRC FPGA-communication: faulty checksum
4 DSP-SPI DSP-communication: Serial Peripheral Interface (Databus) of the digital
Timeout Signal processor does not respond.
5 DSP-SPI CRC DSP-communication: faulty checksum at SPI
6 DSP no data No DSP measuring data arrives
7 DSP R-length DSP-communication: Telegram length invalid
8 DSP Critical DSP fault. Faulty bits can be read-off separately with DSP faults
9 FPGA Critical FPGA fault. Faulty bits can be read-off separately with FPGA
faults
10 COM-0 Fault with data transmission via interface COM-0
14 AD converter Fault at analog digital converter of the option card 2
15 Option card Fault at the option card 1
16 Meter invalid Meter invalid
17 Replacement Replacement value of the path reconstruction invalid
value invalid
18 F-RAM invalid Checksum of the F-RAM telegram invalid
19 F-RAM length Length of the F-RAM telegram invalid
20 opt. Data crc Checksum of the data from the option card invalid
21 ADCData crc Checksum of the data from the AD converter invalid
22 Iout min/max Min/Max limits of the power output violated
23 Send level min Send level too low
24 DSP version DSP SW version not compatible with M32 SW version
25 FPGA version FPGA version not compatible with M32 SW version
26 LOGP invalid Parameter in log memory invalid
30 Path 1 failure Measuring path 1 failed


172
36 Path 7 failure Measuring path 7 failed (spare)
37 Path 8 failure Measuring path 8 failed (spare)
38 max. path Maximum permissible number of path failures exceeded
40 Replacement Replacement value for failed path could not be calculated
value not cal.
41 USE09 Timeout No valid measurement, all measuring paths have failed.
42 ADC ADCfault temperature input
temperature
43 ADC pressure ADC fault pressure input
45 I1 Out min/max Power outlet outside the min. / max. limits
47 Temp. min/max Temperature outside the min. / max. limits
48 Pressure Pressure outside the min. / max. limits
min/max
50 DSP path 1 Critical path error. Error bits can be read-off separately in Path 1 error
54 DSP path 5 Critical path error. Error bits can be read-off separately in Path 5error
(spare)
(spare)
60 P1 AGC limit Amplification factor for path 1 outside the permissible limits
66 P7 AGC limit Amplification factor for path 7 outside the permissible limits (spare)
67 P8 AGC limit Amplification factor for path 8 outside the permissible limits (spare)
77 QVb min. Operating volume flow below Qmin
Grenze
78 QVb max. limit Operating volume flow above Qmax
99 Wrong Parm. Parameter entered is invalid
12.2 Warning messages

No. Messages Explanation
100 Path1 Warn. Proportion invalid measurements for path 1 too high


173
106 Path7 Warn. Proportion invalid measurements for path 7 too high (spare)
107 Path8 Warn. Proportion invalid measurements for path 8 too high (spare)
108 RTC Hardware Hardware fault to the real time clock
109 Ext. Warning External warning
110 P1 V min/max Flow velocity from path 1 outside the min./max. limits
116 P7 V min/max Flow velocity from path 7 outside the min./max. limits (spare)
117 P8 V min/max Flow velocity from path 8 outside the min./max. limits (spare)
118 work.mode test Counter runs in test mode
120 P1 C min/max Speed of sound from path 1 outside the min./max. limits
126 P7 C min/max Speed of sound from path 7 outside the min./max. limits (spare)
127 P8 C min/max Speed of sound from path 8 outside the min./max. limits (spare)
130 P1.1 amplitude Amplitude of the signal from sensor 1.1 too small
136 P7.1 amplitude Amplitude of the signal from sensor 7.1 too small (spare)
150 Pfad1 delta c Deviation from the speed of sound in path 1 from the average speed of
sound too large


sound too large
174 sound too large
sound too large
sound too large
sound too large
sound too large (spare)
sound too large (spare)
170 P1 AGC delta Deviation from the amplification factor in path 1 from the average
amplification factor too large
amplification factor too large (spare)
amplification factor too large (spare)

12.3 Notes
181 Sys. Temp Min System temperature to low
175
182 Sys. Temp Max System temperature to high
183 Rawdata len Length of the raw data telegram wrong
184 Rawdata crc Checksum of the raw data telegram wrong
185 P-LOG full Parameter log memory full
186 DSP-info len Length of the DSP info telegram wrong
187 DSP-info crc Checksum of the DSP info telegram wrong
188 SoS calc. status Status of the SoS calculation
12.4 Troubleshooting
If you cannot find a solution to your problem with the RMG component in
the table below, then please contact the RMG service.
„Manufacturer“ on the inside cover
If problems cannot be eliminated, please contact RMG service.
• Note the active message (number and text) in order to be able to dis-
cuss the problem with RMG service.
No. Description
45 The current output is freely configurable (is only code word protected). Violating the
limit value may occur in an otherwise trouble-free operation if the limits are selected
too close together. In this case, the limits can simply be adjusted. The limits are set
ex-factory in such a manner that they correspond with the limit values of the assigned
measured values, e.g., flow. A limit value violation occurs at the current outlet only if
the meter, for example, is run-over and thus also reports a QVb max error (No.78).
60-65 AGC limits can be violated if an actual fault is at hand on the sensors or it is simply
caused by the operating conditions. In order to limit the cause, one should compare
the values of all paths in L-16/17 to Q-16/17. If only the AGC value of a single path
deviates then one has to expect a defect. If all paths are affected then the cause may
be contamination or condensation deposits on the transducer heads or, also an oper-
ating pressure that is simply too low if, for example, the system has not been applied
yet. If the actual operating pressure deviates significantly from that previously speci-
fied, the parameters must be adjusted by the service. For extremely fluctuating oper-
ating conditions, there is an option for switching the attenuator on and off automati-
cally here, which does not always lead to an optimum setting of the gain as this is
only a 2-point regulation

No. Description
78 QVb max limit appears when the meter is actually run. Then all measuring paths in L-
7 to Q-7 should supply respectively high flow velocities. If only one values stands sig-
nificantly out here then it is probably a malfunction of the path affected.
176 100-105 Path errors occur if one or more of the criterion monitored are violated permanently
so that the content of valid measurement falls below the permitted limit value. If all
measuring paths are affected at the same time, the cause for this is usually due to
unsuitable operating conditions. If, for example, high-pressure gas is not applied to
the system, but it is filled with nitrogen at atmospheric pressure, path error messages
are activated as the limit value for the gain (AGC limit) is exceeded as well as the
speed of sound may fall short or the signal leaves the permissible range of the evalu-
ation window. Change the operating conditions or have the parameters adapted to
the desired mode of operation (service deployment)! Contamination or the accumula-
tion of condensation may also be a possibility. Errors on an individual path typically
indicate a malfunction or a defect of the affected transducer or the corresponding wir-
ing. Check the wiring and plug connectors! Only qualified personnel must change the
transducer!
110-115 The flow velocity of the single paths measured are monitored at the limit values ± 50
m/s. If this is a tangible exceeding of the limit value by the actual flow velocity or it is
a malfunction of an individual path, can be determined by comparing the single meas-
urements in L-7 to Q-7. A subsequent error is no. 78.
120-125 The speed of sound of the single paths measured are monitored at the limit values ±
500 m/s. When using a gas (e.g., hydrogen) that deviates strongly with regard to the
speed of sound, a parameterization must be carried out (service). If strongly deviating
speed of sound are to be expected, the function "Signal Tracking" can also be acti-
vated in AI-27 that then adjusts the respective speed of sound range of the evaluation
window. In case of a path error 100-105, the speed of sound is set to 0 so that the
path can also be clearly identified as faulty on the basis of the measuring value, even
if the reconstructed path velocity with the aid of the replacement-value function ap-
pears plausible.
130-135 These additional messages are helpful in faulty path cases (100-105) in order to de-
und termine the defective transducer of the path affected. Naturally, these error messages
are also triggered if the evaluation electronics were defective, but then, all at the
140-145 same time.
150-155 The monitoring of individual paths with regard to their deviation from the average val-
und ues with respect to measuring variable such as speed of sound and gain (AGC = au-
tomatic gain control) serves the premature recognition of possible irregularities. Thus,
170-175 one has the option to already identify conspicuous paths when the limit values rele-
vant for the calibration have not been violated for the validity of the measurement yet.
Possible causes are identical with those described in 100 -125.

In this chapter you will receive information on the performance data of the device.
177
Content
13.1 Performance data 178

13.2 Approved gas types 180
13.2.1 Suitability and safety for natural gas containing H2 180
0

Approved measuring range according to MID 181

13.4 Type plate 182
13.4.1 Type plate ATEX / IECEx 183
178
13.4.2 Type plate NEC (CSA) 184
13.5 Weights and dimensions 184
13.5.1 NEC (CSA) 185
13.5.2 ATEX / IECEx 186
Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle
konnte nicht gefunden werden. Fehler! Textmarke nicht definiert.
13.6 Inner diameter of connecting spool pieces 189
13.7 Official seal diagram 192
13.7.1 Type plate 192
13.7.2 Ultrasonic electronics 193
13.7.3 Ultrasonic gas meter 195
13.8 Transducer types 197
13.1 Performance data

Power supply Measuring element: 24 VDC
Power consumption Measuring element: typical 7-9 W;

with heated display, typically 12 W;
max. 15 W
Protection class IP 66
Interfaces RS 485 0 (for RMGViewUSM): 9600 / 19200 / 38400 / 57600 Baud
RS 485 1 9600 / 19200 / 38400 / 57600 Baud

Computer)
RS 485 2 9600 / 19200 / 38400 / 57600 Baud

Computer)

Current output Umax= 16 V Load resistance: max. 400 Ω
Pulse output Umax= 30 V fmax= 5 kHz

179
Sensor frequency 200 kHz (DN100 / 4“ and DN150 /
6“) or 120 kHz (DN200 / 8“ and
larger)
Flow velocity -40 to + 40 m/s
Gas temperature range -40 C to +80 C

(-40 F to 176 F)
Maximum operating observe the details on the type

pressure plate.
Ambient conditions -40 C to +55 C

(-40 F to 131 F)

13.2 Approved gas types

The device must only be operated with the following gas types.
180 Safe operation is only guaranteed with the gas types specified:
The components of the gases must be within the concentration limits for test
gases according to EN 437:2009 or similar national standards.
The national standards of other countries demand similar gas type specifications.
Notice
In general, the gas to be measured must not build any condensates in the
operating range of the USM (flow, pressure and temperature range) and
must be free of corrosive and aggressive components, liquids and solids.
In case of deviating conditions a suitable operation has to be agreed with
the RMG service.
13.2.1 Suitability and safety for natural gas containing H2

The USM GT400 can be used in hydrogen-containing natural gas. There are no
safety-related concerns for this use.
Notice
In accordance with the German TR-G19 – the USM GT400 is suitable and
approved for use in custody transfer applications –
in natural gases with a maximum hydrogen content of 10 mol-% without a
loss of the accuracy.
Since there are currently no certified test rigs in Germany to calibrate meters with
higher hydrogen-containing gases, an accuracy above 10 mol-% cannot be tested
or certified.
Not custody transfer measurements are of course possible in natural gases with a
hydrogen content above 10 mol%. However, a reduced measuring range must be
taken into account if applicable. Please contact RMG for further information.

13.3 Approved measuring range according to MID

Nominal diameter Measuring range (m³/h) / (acfh) Extended measuring range (m³/h) /
(acfh) *1 181
mm inches Qmax Qmin Qmin
l780 3 77650 / 23000 5 / 175 (2,5 / 88) abi in preparation
100 4 1000 / 35320 8 / 208 (4 / 140) abcd in preparation
150 6 2400 / 84760 20 / 700 (10 / 350) bci in preparation
200 8 4200 / 148350 32 / 1130 16 / 560
250 10 6600 / 233100 50 / 1750 25 / 880
300 12 9400 / 332000 70 / 2450 35 / 1240
350 12 11400 / 403000 I90 / 3180 45 / 1590
400 16 15000 / 530000 120 / 4230 60 / 2120
450 12 19000 / 670700 150 / 1750 75 / 2650
500 20 23500 / 830000 180 / 6350 90 / 3180
600 24 34000 / 1201000 260 / 9175 130 / 4590
650 26 45000 / 1588000 340 / 12010 170 / 6000
700 28 52000 / 1834800 420 / 14335 210 / 7400
750 30 60000 / 2115000 460 / 16230 320 / 8100
800 32 68000 / 2399000 550 / 19250 550 / 19250
900 36 86000 / 3030000 700 / 24500 700 / 24500
1000 40 108000 / 3800000 850 / 29750 850 / 29750
*1 The extended measuring range only effects Qmin. It can be

used at pressures above p ≥ 4 bar / p ≥ 60 psi.
For meters with a full bore inner diameter according to Di-2 in the table at the end of chapter 13.5,
the table values for Qmin and Qmax are to be increased by a factor of 1.1.
The number of acoustic paths is 6 for all variants.

13.4 Type plate
182
1 Type plate
Fig. 13.1: Position of the type plate
The following details can be found on the type plate:

13.4.1 Type plate ATEX / IECEx
183
Fig. 13.2: Type plate ATEX / IECEx

13.4.2 Type plate NEC (CSA)
184
Fig. 13.3: Type plate NEC (CSA / FM)
13.5 Weights and dimensions
In this chapter you will receive information on the dimensions for the versions NEC
and ATEX /IECEx.
ANSI pressure stages: The flange connecting dimensions comply with the
standard ASME B 16.5.
DIN pressure stages: The flange connecting dimensions comply with the
standard DIN EN 1092.

13.5.1 NEC (CSA)
185
1 Front view
2 Side view
3 Top view
The version NEC and version ATEX / IECEx have identical dimensions. The table
of the versions can be found on the following location:
Fehler! Verweisquelle konnte nicht gefunden werden.188

13.5.2 ATEX / IECEx
186
1 Front view
2 Side view
3 Top view

187
1 Threaded blind hole

Fig. 13.6: Weights and dimensions DN80
Due to the different sizes of the individual components, the device in DN80 is
shown separately.

Dimensions - Version NEC and ATEX / IECEx

DN L L Di-1 Di-2 T1 H2 B2 B2 SO2 S12 Weight3 Weight3
ANSI900 ANSI 900 ANSI 900
188 80 240 - 73.7 77.9 82.5 450 450 - 225 - 75 -

(3) (9.5) (2.9) (3.07) (3.25) (17.72) (17.72) (8.86) (165)
100 300 400 97.2 102.3 107.1 330 595 415 250 - 100 125
(4) (11.81) (15.75) (3.83) (4.03) (4.22) (12.99) (23.43) (16.34) (9.84) (220) (276)
150 450 450 146.4 154.1 159.3 340 470 470 300 - 160 180
(6) (17.72) (17.72) (5.76) (6.07) (6.27) (13.39) (18.5) (18.5) (11.81) (353) (397)
200 600 800 193.7 202.7 207.3 360 530 565 375 1520 300 380
(8) (23.62) (31.5) (7.63) (7.98) (8.16) (14.17) (20.87) (22.24) (14.76) (59.84) (661) (838)
250 750 1000 242.8 254.5 260.4 380 650 615 400 1550 450 560
(10) (29.53) (39.37) (9.56) (10.02) (10.25) (14.96) (25.59) (24.21) (15.75) (61.02) (992) (1235)
300 900 900 288.8 303.2 309.7 395 700 660 425 1575 550 670
(12) (35.43) (35.42) (11.37) (11.94) (12.19) (15.55) (27.56) (25.98) (16.73) (62.01) (1213) (1477)
350 1050 - 284-348 333.5 - 420 730 - 450 1600 700 -

(11.2-13.7)
(14) (41.34) (14.31) (16.54) (28.74) (17.72) (62.99) (1543)
400 1200 1200 363.5 381.0 292.2 500 750 750 475 1620 950 1050
(16) (47.24) (47.24) (14.31) (15.0) (11.50) (19.69) (29.53) (29.53) (18.70) (63.78) (2094) (2315)
450 1350 - 367-449 428.7 - 530 820 - 500 1650 1000 -

(16) (53.15) (14.4-17.7) (16.88) (20.87) (32.28) (19.69) (64.96) (2205)
500 1500 1500 455.6 477.8 493.8 550 900 860 525 1670 1500 1650
(20) (59.06) (59.06) (17.94) (18.81) (19.44) (21.65) (35.43) (31.5) (20.67) (65.75) (3307) (3638)
600 1200 1500 547.7 574.7 595.8 550 1000 1045 600 1725 1550 2500
(24) (47.24) (59.06) (21.56) (22.63) (23.46) (21.65) (39.37) (41.14) (23.62) (67.91) (3417) (5512)
650 1200 - 632-648 - 680 1040 - 610 1740 1650 -

(24.9-25-5)
(26) (47.24) (26.77) (40.94) (24.02) (68.5) (3638)
700 1200 - 679-699 - 700 1050 - 615 1750 1800 -

(26.8-27.5)
(28) (47.24) (27.56) (41.34) (24.21) (68.9) (3968)
750 1500 - 730-749 - 800 1100 - 650 1780 1900 -

(28.8-29.5)
(30) (59.06) (31.5) (43.31) (25.59) (70.08) (4189)
800 1500 - 778-800 - 850 1150 - 675 1800 2200 -

(30.6-31.5)
(32) (59.06) (33.46) (45.28) (26.57) (70.87) (4850)
900 1500 - 876-902 - 1000 1300 - 750 1875 2600 -

(34.5-35.5)
(36) (59.06) (39.37) (51.18) (29.53) (73.82) (5732)
1000 1500 - 978-1000 - 1200 1400 - 800 1930 3000 -

(38.5-39.4)
(40) (59.06) (47.24) (55.12) (31.5) (75.98) (6614)
Dimensions are in mm (inch); weight in kg (lbs)

The given values are for pressure level ANSI 600, respectively ANSI900 (speci-
fied).

Di-1 = inner diameter (tapered, schedule 80)

Di-2 = inner diameter full bore (schedule 40)
1 189
Maximum diameter at the flange, depending on tapering.
2
Approximate dimension.
3
Approximate values. Weights can vary due to casting tolerances.
An angle of 7° is used for tapering.
13.6 Inner diameter of connecting spool pieces

Connection diameter at tapering of the USM GT400
(= inner diameter for inlet and outlet spool pieces)
Maximum deviation from meter to piping:
+/- 1% acc. MID
For calibrated spool pieces belonging to the measuring instrument, the deviation
may be up to +/- 3%. For the full-bore version, generally +5% / -2% are allowed re-
gardless of the use during calibration.
The blue marked inner diameters for every ANSI pressure rating are to be under-
stood as a recommendation if no inner diameter is specified by the customer.

in DN
/ Inch
80 ANSI150 73,7 73 74,4 80
80 ANSI150 77,9 77,2 78,7 40
80 ANSI300 73,7 73 74,4 80
80 ANSI300 77,9 77,2 78,7 40
80 ANSI600 73,7 73 74,4 80
80 ANSI600 77,9 77,2 78,7 40
100 ANSI150RF 97.2 96.2 98.2 80
100 ANSI150RF 102.3 101.3 103.3 40
100 ANSI300RF 97.2 96.2 98.2 80
100 ANSI300RF 102.3 101.3 103.3 40
100 ANSI600RF 97.2 96.2 98.2 80
100 ANSI600RF 102.3 101.3 103.3 40
100 ANSI600RTJ 97.2 96.2 98.2 80
100 ANSI600RTJ 102.3 101.3 103.3 40
150 ANSI150RF 146.4 144.9 147.9 80
150 ANSI150RF 154.1 152.6 155.6 40


in DN
/ Inch
190 150 ANSI300RF 146.4 144.9 147.9 80
150 ANSI300RF 154.1 152.6 155.6 40
150 ANSI600RF 146.4 144.9 147.9 80
150 ANSI600RF 154.1 152.6 155.6 40
150 ANSI600RTJ 146.4 144.9 147.9 80
150 ANSI600RTJ 154.1 152.6 155.6 40
200 ANSI150RF 193.7 191.8 195.6 80
200 ANSI150RF 198.5 196.5 200.5 60
200 ANSI150RF 202.7 200.7 204.7 40
200 ANSI300RF 193.7 191.8 195.6 80
200 ANSI300RF 198.5 196.5 200.5 60
200 ANSI300RF 202.7 200.7 204.7 40
200 ANSI600RF 193.7 191.8 195.6 80
200 ANSI600RF 198.5 196.5 200.5 60
200 ANSI600RF 202.7 200.7 204.7 40
200 ANSI600RTJ 193.7 191.8 195.6 80
200 ANSI600RTJ 198.5 196.5 200.5 60
200 ANSI600RTJ 202.7 200.7 204.7 40
250 ANSI150RF 242.8 240.4 245.2 80
250 ANSI150RF 247.6 245.1 250.1 60
250 ANSI150RF 254.4 251.9 256.9 40
250 ANSI300RF 242.8 240.4 245.2 80
250 ANSI300RF 247.6 245.1 250.1 60
250 ANSI300RF 254.4 251.9 256.9 40
250 ANSI600RF 242.8 240.4 245.2 80
250 ANSI600RF 247.6 245.1 250.1 60
250 ANSI600RF 254.4 251.9 256.9 40
250 ANSI600RTJ 242.8 240.4 245.2 80
250 ANSI600RTJ 247.6 245.1 250.1 60
250 ANSI600RTJ 254.4 251.9 256.9 40
300 ANSI150RF 288.8 285.9 291.7 80
300 ANSI150RF 295.3 292.3 298.3 60
300 ANSI150RF 303.2 300.2 306.2 40
300 ANSI300RF 288.8 285.9 291.7 80
300 ANSI300RF 295.3 292.3 298.3 60
300 ANSI300RF 303.2 300.2 306.2 40
300 ANSI600RF 288.8 285.9 291.7 80
300 ANSI600RF 295.3 292.3 298.3 60
300 ANSI600RF 303.2 300.2 306.2 40
300 ANSI600RTJ 288.8 285.9 291.7 80


in DN
/ Inch
300 ANSI600RTJ 295.3 292.3 298.3 60 191
300 ANSI600RTJ 303.2 300.2 306.2 40
400 ANSI150RF 363.5 359.9 367.1 80
400 ANSI150RF 373.1 369.4 376.8 60
400 ANSI150RF 381 377.2 384.8 40
400 ANSI300RF 363.5 359.9 367.1 80
400 ANSI300RF 373.1 369.4 376.8 60
400 ANSI300RF 381 377.2 384.8 40
400 ANSI600RF 363.5 359.9 367.1 80
400 ANSI600RF 373.1 369.4 376.8 60
400 ANSI600RF 381 377.2 384.8 40
400 ANSI600RTJ 363.5 359.9 367.1 80
400 ANSI600RTJ 373.1 369.4 376.8 60
400 ANSI600RTJ 381 377.2 384.8 40
500 ANSI150RF 455.6 451.0 460.2 80
500 ANSI150RF 466.8 462.1 471.5 60
500 ANSI150RF 477.8 473.0 482.6 40
500 ANSI300RF 455.6 451.0 460.2 80
500 ANSI300RF 466.8 462.1 471.5 60
500 ANSI300RF 477.8 473.0 482.6 40
500 ANSI600RF 455.6 451.0 460.2 80
500 ANSI600RF 466.8 462.1 471.5 60
500 ANSI600RF 477.8 473.0 482.6 40
500 ANSI600RTJ 455.6 451.0 460.2 80
500 ANSI600RTJ 466.8 462.1 471.5 60
500 ANSI600RTJ 477.8 473.0 482.6 40
600 ANSI300RF 547.7 542.2 553.2 80
600 ANSI300RF 560.4 554.8 566.0 60
600 ANSI300RF 574.6 568.9 580.3 40
600 ANSI600RF 547.7 542.2 553.2 80
600 ANSI600RF 560.4 554.8 566.0 60
600 ANSI600RF 574.6 568.9 580.3 40

13.7 Official seal diagram

In this chapter you will receive information at which location the official seals are
attached to the device.
192
The device must not be used for a calibrated operation if the official seal is
broken.
13.7.1 Type plate
1 Seal
Fig. 13.7: Position of the official seal on the type plate

13.7.2 Ultrasonic electronics
193

1 Side view
2 Top view
3 Seal
Fig. 13.8: Official seal diagram according to AEX / IECEx

194

1 Side view
2 Top view
3 Seal
Fig. 13.9: Official seal diagram according to NEC

13.7.3 Ultrasonic gas meter
195
Fig. 13.10: Devices DN 80 (3”), DN 100 (4“) and DN 150 (6“)

196
1 Front view 2 Side view

3 Top view 4 View without cover
5 Seal 6 Type plate
Fig. 13.11: Devices DN 200 (8 ") and larger
Seals of the measuring element of type USM-GT-400
Valid for sizes DN 200 upwards
Representation: DN 200

13.8 Transducer types

Danger
197
If transducers of a device under pressure are not changed correctly, this may
cause an explosion. Escaping gas mixtures may lead to intoxication.
this activity.
• Observe the separate service instruction for changing the transducer.
1 TNG 10-CP / -CHP

Fig. 13.12: Trancducer type TNG 10-CP / -CHP
1 TNG 20-SP / -SHP

Fig. 13.13: Trancducer type TNG 20-SP / -SHP

Transducer Operating fre- Operating pressure Ambient temperature Gas temper-

type quency (kHz) range bar (psi) °C (°F) ature °C (°F)
198
TNG 10-CP 120 1–150 -40 to +55 °C to +80 °C
(14,5 to 2175.57) (55 to 131 °F) (176 °F)
TNG 10-CHP 120 1–300 -40 to +55 °C to +80 °C

(14,5 to 4351.13) (55 to 131 °F) (176 °F)
TNG 20-SP 200 1–150 -40 to +55 °C to +80 °C

(14,5 to 2175.57) (55 to 131 °F) (176 °F)
TNG 20-SHP 200 1–300 -40 to +55 °C to +80 °C

(14,5 to 4351.13) (55 to 131 °F) (176 °F)

14 Spare parts and accessories

Order number Description
199
Electronics
98800-14400 USE 09, complete electronics
98800-13352 USE 09, display circuit board
98800-13512 USE 09, Options card 1 (RS485 and pulse outputs)
98800-13762 USE 09, Options card 2 (P&T inputs)
98800-13020 USE 09, Multiplexer (4 channels)
00.66.197.00 Magnetic pin, complete with holder
External elements
00.65.142.00 Weather protection cover for electronics housing
00.64.923.00 Complete grill element DN 100 (4”)
00.64.855.00 Complete grill element DN 150 (6”)
00.64.811.00 Transducer cover for DN 80 (3”) to DN 150 (6”)
00.64.798.00 Grill element DN 200 (8”)
00.64.860.00 Grill element DN 250 (10”)
00.64.862.00 Grill element DN 300 (12”)
00.64.864.00 Grill element DN 400 (16”)
00.64.866.00 Grill element DN 500 (20”)
00.64.868.00 Grill element (middle level) DN 600 (24”)
00.64.926.00 Grill element (outer levels) DN 600 (24”)
87.06.050.00 Cable bushing M20x1.5 (Ø 3‐9)
87.06.051.00 Cable bushing M20x1.5 (Ø 6‐12)
84.08.023.00 Shut-off valve NV2F-4N-R-K 2x1/4NPT inn.H.

Pipe bundles
00.64.767.01 Pipe bundle for DN 100 (4”)
200
Transducers
00.64.758.00 USM-transducer type TNG 20-SP (3”-6”), 200 kHz, up to 150 bar(a)
00.65.000.00 USM-transducer type TNG20-SHP (3”-6”), 200 kHz, up to 300 bar(a)
00.64.757.00 USM-transducer type TNG 10-CP (8”-40”), 120 kHz, up to 150 bar(a)
00.64.839.00 USM-transducer type TNG10-CHP (8”-40”), 120 kHz, up to 300 bar(a)
Tools for transducer replacement

00.64.669.00 Special tool for transducer replacement DN200 (8”)
38.00.014.00 Special tool pair d=7x10 for USE-09
00.61.128.00 Special tool for transducer replacement under pressure (from DN 200)
Interface converter
30.00.212.00 RS 485 to USB converter for top hat rail (I‐7561U‐G CR)
35.00.023.00 RS 485 to Ethernet converter (FL Comserver)

15 Lists of parameters and measured values
15 Lists of parameters and measured

values 201
The following tables show the parameters that can be shown and edited using the
RMGViewUSM software or via the display with control panel.
With different versions of the device software, individual parameters may

have different coordinates.
The abbreviations in the Type and Protection (Prot.) columns have the following
meanings:
Type Protection
F Float R Reading Value
M Menu S Official Key
I Integer F free programmable
U Unixtime C Codeword
L Long Int. CS Code and Official Key
T Text
D Double
C Code
(d) to the right of a menu option means “default value”.

Pressure
Coord. Value Reg. No. Type Prot. Unit Description
202 A-01 Pressure 6252 2 F R → Units: Pressure a Shows the measured pressure
A-03 Current Input 6254 2 F R mA Shows the input value in mA
A-05 p min value 1392 2 F S → Units: Pressure a Measuring pressure min. value
A-06 p max value 1394 2 F S → Units: Pressure a Measuring pressure max. value
A-09 p set value 1396 2 F S → Units: Pressure a Measuring pressure default value
A-11 p at base cond. 1398 2 F S → Units: Pressure a base pressure
A-12 curr. inp. gradient 1400 2 F S Gradient (correction of the mA value)
A-13 curr. inp. offset 1402 2 F S Offset (correction of the mA value)
A-14 p err. min 1404 2 F S → Units: Pressure a Lower error limit of measuring pressure
A-15 p err. max 1406 2 F S → Units: Pressure a Upper error limit of measuring pressure
A-17 p mode 4078 1 M S Operating mode of measuring pressure
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 4-20mA
0x0003 4-20mA_ERR
Temperature

B-01 temperature 6256 2 F R → Units: Temp. PT100-input
B-03 PT100 resistance 6258 2 F R Ohm PT100-input
B-09 T set value 1408 2 F S → Units: Temp. PT100-input
B-11 T at base cond. 1410 2 F S → Units: Temp. base temperature
B-12 T gradient 1412 2 F S Gradient (correction of the Ohm value)
B-13 T offset 1414 2 F S Offset (correction of the Ohm value)
B-14 T err. min 1416 2 F S → Units: Temp. Lower error limit of measuring tempera-
ture
B-15 T err. max 1418 2 F S → Units: Temp. Upper error limit of measuring tempera-
ture
B-17 T mode 4079 1 M S Operating mode of measuring tempera-
ture
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 PT100
0x0003 PT100_ERR

USE09-C Meas. Val.

C-01 vw 6220 2 F R → velocity unit weighted gas velocity
C-02 vwc 6222 2 F R → velocity unit corrected weighted gas velocity 203
C-03 Qm 6224 2 F R → flow unit Intermediate result for Qm (with pre-
ceding sign)
C-04 Qmb 6238 2 F R → flow unit Intermediate result for Qmb (with pre-
ceding sign)
C-05 Qmc 6226 2 F R → flow unit Intermediate result for Qmc (with pre-
ceding sign)
C-06 performance 6268 1 I R % Performance
USE09-C Qm

D-01 vol. Flow rate Qm 730 10 T R → flow unit Volumetric flow rate Qm after all cor-
rections (as amount) with up-
stream/downstream identification
D-02 vol. flow rate Qm 6230 2 F R → flow unit Volumetric flow rate Qm after all cor-
rections (Qm lower limit will be ob-
served)
D-03 Qm damped 6264 2 F R → flow unit Volumetric flow rate Qm damped (Qm
lower limit will be observed)
D-04 Qm min. 1320 2 F S → flow unit Qm min. limit
D-05 Qm max. 1322 2 F S → flow unit Qm max. limit
D-06 vw factor d1 1324 2 F S [1] Constant Kv direction 1
D-07 vw factor d2 1436 2 F S [1] Constant Kv direction 2
D-08 vw lower limit 1326 2 F S → Calib. units: v vw lower limit (creeping quantity before
apply. polynomial)
D-09 Qm lower limit 1328 2 F S → flow unit Qm lower limit (creeping quantity)
D-10 Qm-min time 2120 1 I S s Time below Qm min
D-15 Qm damping 1446 2 F C Damping for Qmc-D (0.0=off, 1.0=max)
D-16 pipe diameter 1334 2 F S → Calib. units: Pipe diameter
Length
D-17 geometry correct- 2258 1 M S Correction of the effects of press. and
ing temp.
0x0000 OFF (d)
0x0001 ON
D-18 temp. coefficient 1450 2 F S Temperature coefficient
D-19 pressure coeff. 1452 2 F S Pressure coefficient
D-20 Qm-max value 1 1330 2 F C → flow unit Qm max. value of direction 1
D-21 Qm-max time 1 2580 2 U C Time of Qm max. value 1
D-22 Qm-max value 2 1332 2 F C → flow unit Qm max. value of direction 2
D-23 Qm-max time 2 2582 2 U C Time of Qm max. value 2
D-24 Qt 9084 2 F R Transition flow Qt

Parameters

E-01 USE09 working 2090 1 M S USE09 operating mode
204 mode
0x0000 IGM (d)
0x0001 USE09C
0x0002 SIMU
0x0003 SIMU_K
0x0004 SIMU_N
0x0005 SIMU_EW
E-02 path select 690 10 T S Select activated paths (path 1.1, path
1.2 … path 4.2)
E-03 max. path RV 2121 1 I S Maximum number of used replacement
values
E-04 fault time 2122 1 I S s Time limit for IGM timeout
E-05 error per cent 2123 1 I S % A measurement quality below this level
will cause a path error
E-09 moving average 2125 1 I C Number of measured values for the
cnt moving average, V, SoS
E-15 SoS mode 2240 1 M C Speed of Sound mode
0x0000 STANDARD (d)
0x0001 EXTENDED
0x0002 CALIBRATION
0x0003 STATISTIC OFF
E-16 delta SoS mode 2091 1 M C Delta SoS observing ON / OFF
0x0000 OFF
0x0001 ON (d)
E-17 delta SoS limit 1344 2 F C % Limit for Delta SoS
E-18 std. SoS corr-fac- 1370 2 F S [1] Standard SoS correction-factor
tor
E-19 adv. SoS corr-fac- 9068 2 F S [1] Advanced SoS correction-factor
tor
E-20 std. SoS v factor 1372 2 F S [1] Standard SoS v correction-factor
E-21 adv. SoS v factor 9070 2 F S [1] Advanced SoS v correction-factor
E-22 delta AGC limits 1438 2 F C dB Max. deviation between path-AGC and
AGC-mean
E-23 Tw correct 2281 1 M S Correct TWs
0x0000 OFF (d)
0x0001 SET
E-24 Tw damping 1518 2 F C Damping for TW adjustment
USE09-C polynom-B

Flow correction

G-01 error curve lin. 2093 1 M S Error curve linearization mode
0x0000 OFF (d) 205
0x0001 POLYNOMIAL
0x0002 piecewise lin.
G-02 const m2 d.1 1276 2 F S [1] Error polynomial for direction 1
G-04 const 0 d.1 1280 2 F S [1] Error polynomial for direction 1
G-20 dir. 1: flowrate 1 1600 2 F S → Calib. units: Q Linear interpolation direction 1: flow
rate 1
G-21 dir. 1: error 1 1602 2 F S % Linear interpolation direction 1: error 1
rate 2
rate 3
rate 4
rate 5
rate 6
rate 7
rate 8
rate 9
rate 10

rate 11
206 rate 12
rate 1
rate 2
rate 3
rate 4
rate 5
rate 6
rate 7
rate 8
rate 9
rate 10
rate 11
rate 12

Freq.,Pulse Outputs

H-01 fo base value 6248 2 F R → flow unit Measured value of the frequency out-
put 207
H-02 frequency value 6250 2 F R Hz Frequency value of the frequency out-
put (in Hz)
H-03 fo corr. factor 1386 2 F S Correction factor of the frequency out-
put
H-04 corr. frequency 6266 2 F R Hz Correction of the frequency value of the
frequency output (in Hz)
H-05 fo base max. 1388 2 F S → Calib. units: Q Upper range value of the frequency out-
put (physical value)
H-06 fo freq. max. 1444 2 F S Hz Maximum value of the frequency out-
put (in Hz)
H-07 pulse value 6262 2 F R → pulse unit Indication of the calculated pulse value
of the frequency output
H-08 fo set value 1390 2 F S Hz Calibration frequency
H-09 fo select 2161 1 M C Selection of the measured value for the
frequency output
0x0000 QMC (d)
0x0001 QMC-D
H-10 fo mode 2162 1 M S Operating mode of the frequency out-
put
0x0000 OFF
0x0001 SET VALUE
0x0002 ON (d)
0x0003 TEST
H-11 fo2 error mode 2163 1 M S Frequency-2 mode if a fault occurs
0x0000 F2 STOP (d)
0x0001 F2 ACTIVE
0x0002 CRYSTAL TEST
H-12 ferr waveform 6260 2 F R Hz Frequency delta
gen.
H-15 IO-1 mode 2165 1 M C Mode for IO-1
0x0000 OFF
0x0001 DIRECTION (d)
0x0002 DIRECTION
INV.
0x0003 INPUT
0x0004 TEST
0x0005 WARN-INPUT
HIGH
0x0006 WARN-INPUT
LOW
H-16 IO-2 mode 2166 1 M C Mode for IO-2
0x0000 OFF
0x0001 DIRECTION (d)

0x0002 DIRECTION
INV.
0x0003 INPUT
0x0004 TEST
208 0x0005 CPU
H-17 mode ext. warn- 2186 1 M C Mode in the case of external warning
ing
0x0000 OFF (d)
0x0001 LOW_POWER
H-20 Test Alarm a. 1 M C Tests the warning and alarm contacts
Warn 4081
0x0000 OFF (d)
0x0001 TEST
Current Output

I-01 c-out physical val. 6244 2 F R Current output, physical value
I-02 c-out value 6246 2 F R mA Current output in mA
I-03 c-out min. 1374 2 F C Current output, physical minimum value
I-04 c-out max. 1376 2 F C Current output, physical maximum
value
I-05 c-out set value 1378 2 F C mA Current output, set value
I-06 c-out select 2158 1 I C Current output, selection of the meas-
ured value (Modbus reg.)
I-07 c-out mode 2159 1 M C Current output, operating mode
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 0-20mA
0x0003 4-20mA
I-08 c-out err mode 2160 1 M C Current output, operating mode if a
fault occurs
0x0000 OFF (d)
0x0001 MIN
0x0002 MAX
I-09 c-out damping 1380 2 F C Current output, damping (0.0=OFF,
1.0=max)
I-10 c-out gradient 1382 2 F S Current output, gradient
I-11 c-out offset 1384 2 F S Current output, offset
Serial Ports

J-12 DZU-0 address 2283 1 I F Serial interface -1 DZU slave ID (ASCII:
00-99)
J-13 serial-0 status 760 10 T R Serial interface -1 status

J-14 serial-1 mode 2107 1 M F Serial interface -1 mode

0x0000 OFF (d)
0x0001 IGM
0x0002 USE09
209
0x0003 DZU
0x0004 DZU-DIAG
0x0005 DZU X-FRAME
0x0006 VO
0x0007 DZU-SLAVE
0x0008 Modbus
J-15 serial-1 baud rate 2108 1 M F baud Serial interface -1 baud rate
0x0000 2400
0x0001 4800
0x0002 9600
0x0003 19200 (d)
0x0004 38400
0x0005 57600
J-16 serial-1 bits 2109 1 M F Serial interface -1 number of bits
0x0000 7
0x0001 8 (d)
J-17 serial-1 parity 2110 1 M F Serial interface -1 parity
0x0000 NONE (d)
0x0001 EVEN
0x0002 ODD
00-99)
J-24 serial-1 status 770 10 T R Serial interface -1 status
J-25 opt. ser2 mode 2112 1 M F Optional serial interface -2 mode
0x0000 OFF
0x0001 Modbus (d)
0x0002 IGM
0x0003 USE09
0x0004 DZU-SLAVE
0x0005 RMGBus
0x0006 Modbus mas-
ter
J-26 opt. ser2 baud 2113 1 M F baud Optional serial interface -2 baud rate
rate
0x0000 2400
0x0001 4800
0x0002 9600
0x0003 19200
0x0004 38400 (d)

0x0005 57600
J-27 opt. ser2 bits 2114 1 M F Optional serial interface -2 number of
bits
0x0000 7
210 0x0001 8 (d)
J-28 opt. ser2 parity 2115 1 M F Optional serial interface -2 parity
0x0000 NONE (d)
0x0001 EVEN
0x0002 ODD
J-29 Modbus-2 proto- 2178 1 M F Optional serial interface -2 Modbus op-
col erating mode (Off, Ascii or RTU)
0x0000 OFF
0x0001 RTU (d)
0x0002 ASCII
J-30 Modbus-2 hw- 2179 1 M F Optional serial interface -2 Modbus
mode hardware (RS232 or RS485)
0x0000 RS232
0x0001 RS485 (d)
J-31 Modbus-2 ad- 2180 1 I F Optional serial interface -2 Modbus ad-
dress dress (ID)
J-32 Modbus-2 reg.off- 2181 1 I F Optional serial interface -2 Modbus reg-
set ister offset
J-33 Modbus-2 gap 2182 1 I F Optional serial interface -2 Modbus
time turn-off time
J-34 Long Byte Order 2251 1 M F Ser-2 Modbus byte order with long:
(1,0)(3,2) or (3,2)(1,0)
0x0000 NORMAL
0x0001 SWAPPED (d)
J-35 Float Byte Order 2252 1 M F Ser-2 Modbus byte order with float:
(1,0)(3,2) or (3,2)(1,0)
0x0000 NORMAL
0x0001 SWAPPED (d)
J-36 Double Byte Or- 2253 1 M F Ser-2 Modbus byte order with double:
der (1,0)(3,2)(5,4)(7,6) or (7,6)(5,4)(3,2)(1,0)
0x0000 NORMAL (d)
0x0001 SWAPPED
00-99)
J-38 serial-2 status 780 10 T R Optional serial interface -2 status
J-39 DZU Interval 2111 1 I S tics Optional serial interface -2 DZU-interval
J-40 DZU Checksum 2255 1 M F Serial interface -1, initial DZU checksum
Preset value
0x0000 0x00 (d)
0x0001 0x7F

DSP,FPGA values

K-20 DSP status 4004 1 I R hex DSP status (bit encoded)
K-21 DSP error 4003 1 I R hex DSP error (bit encoded) 211
K-22 DSP bytes re- 7034 1 I R Counts the receive telegrams from DSP
ceived
K-23 FPGA status 4006 1 I R hex FPGA status (bit encoded)
K-24 FPGA error 4005 1 I R hex FPGA error (bit encoded)
Path1 Meas. Values

L-01 p1.1 time of flight 6100 2 F R us Path 1.1 time of flight
L-02 p1.2 time of flight 6120 2 F R us Path 1.2 time of flight
L-03 path-1 delta-t 6140 2 F R us Path 1 time difference
L-04 p1 delta-t corr. 6540 2 F R us Path 1 corrected time difference
L-06 Valid samples G1 7000 1 I R % Path 1 valid measuring values in %
L-07 path-1 velocity 6000 2 F R → velocity unit Path 1 path velocity
L-08 velocity vc1 6200 2 F R → velocity unit Path 1 corrected path velocity vc
L-09 SoS1 6020 2 F R → velocity unit Path 1 Speed of Sound
L-10 path-1 delta SoS 6080 2 F R % Path 1 Path-SoS / Mean-SoS
L-12 path-1 fault 4030 1 I R hex Path 1 path error
L-13 path-1 status 4040 1 I R hex Path 1 path status
L-14 p1.1 Amplitude 7010 1 I R % Path 1.1 amplitude in per cent
L-15 p1.2 Amplitude 7020 1 I R % Path 1.2 amplitude in per cent
L-16 p1.1 AGC-level 6040 2 F R dB Path 1.1 Automated Gain Control
L-17 p1.2 AGC-level 6060 2 F R dB Path 1.2 Automated Gain Control
L-18 p1.1 snr 6640 2 F R dB Path 1.1 signal-to-noise ratio
L-19 p1.2 snr 6660 2 F R dB Path 1.2 signal-to-noise ratio
L-20 path-1 fault (X) 2270 1 I R hex Path 1 path error (3X-measurement)
L-21 p1.1 AGC-level (X) 6680 2 F R dB Path 1.1 Automated Gain Control (3X-
measurement)
L-22 p1.2 AGC-level (X) 6700 2 F R dB Path 1.2 Automated Gain Control (3X-
measurement)
L-23 p1.1 snr (X) 6720 2 F R dB Path 1.1 signal-to-noise ratio (3X-meas-
urement)
L-24 p1.2 snr (X) 6740 2 F R dB Path 1.2 signal-to-noise ratio (3X-meas-
urement)
L-26 path-1 turbulence 6776 2 F R % Path 1 turbulence

Path2 Meas. Values

M-01 p2.1 time of flight 6102 2 F R us Path 2.1 time of flight
212 M-02 p2.2 time of flight 6122 2 F R us Path 2.2 time of flight
M-03 path-2 delta-t 6142 2 F R us Path 2 time difference
M-04 p2 delta-t corr. 6542 2 F R us Path 2 corrected time difference
M-06 Valid samples G2 7001 1 I R % Path 2 valid measuring values in %
M-07 path-2 velocity 6002 2 F R → velocity unit Path 2 path velocity
M-08 velocity vc2 6202 2 F R → velocity unit Path 2 corrected path velocity vc
M-09 SoS2 6022 2 F R → velocity unit Path 2 Speed of Sound
M-10 path-2 delta SoS 6082 2 F R % Path 2 Path-SoS / Mean-SoS
M-12 path-2 fault 4031 1 I R hex Path 2 path error
M-13 path-2 status 4041 1 I R hex Path 2 path status
M-14 p2.1 Amplitude 7011 1 I R % Path 2.1 amplitude in per cent
M-15 p2.2 Amplitude 7021 1 I R % Path 2.2 amplitude in per cent
M-16 p2.1 AGC-level 6042 2 F R dB Path 2.1 Automated Gain Control
M-17 p2.2 AGC-level 6062 2 F R dB Path 2.2 Automated Gain Control
M-18 p2.1 snr 6642 2 F R dB Path 2.1 signal-to-noise ratio
M-19 p2.2 snr 6662 2 F R dB Path 2.2 signal-to-noise ratio
M-20 path-2 fault (X) 2271 1 I R hex Path 2 path error (3X-measurement)
M-21 p2.1 AGC-level (X) 6682 2 F R dB Path 2.1 Automated Gain Control (3X-
measurement)
M-22 p2.2 AGC-level (X) 6702 2 F R dB Path 2.2 Automated Gain Control (3X-
measurement)
M-23 p2.1 snr (X) 6722 2 F R dB Path 2.1 signal-to-noise ratio (3X-meas-
urement)
M-24 p2.2 snr (X) 6742 2 F R dB Path 2.2 signal-to-noise ratio (3X-meas-
urement)
M-26 path-2 turbulence 6778 2 F R % Path 2 turbulence
Path3 Meas. Values

N-01 p3.1 time of flight 6104 2 F R us Path 3.1 time of flight
N-02 p3.2 time of flight 6124 2 F R us Path 3.2 time of flight
N-03 path-3 delta-t 6144 2 F R us Path 3 time difference
N-04 p3 delta-t corr. 6544 2 F R us Path 3 corrected time difference
N-06 Valid samples G3 7002 1 I R % Path 3 valid measuring values in %
N-07 path-3 velocity 6004 2 F R → velocity unit Path 3 path velocity
N-08 velocity vc3 6204 2 F R → velocity unit Path 3 corrected path velocity vc
N-09 SoS3 6024 2 F R → velocity unit Path 3 Speed of Sound
N-10 path-3 delta SoS 6084 2 F R % Path 3 Path-SoS / Mean-SoS
N-12 path-3 fault 4032 1 I R hex Path 3 path error

N-13 path-3 status 4042 1 I R hex Path 3 path status

N-14 p3.1 Amplitude 7012 1 I R % Path 3.1 amplitude in per cent
N-15 p3.2 Amplitude 7022 1 I R % Path 3.2 amplitude in per cent
N-16 p3.1 AGC-level 6044 2 F R dB Path 3.1 Automated Gain Control
213
N-17 p3.2 AGC-level 6064 2 F R dB Path 3.2 Automated Gain Control
N-18 p3.1 snr 6644 2 F R dB Path 3.1 signal-to-noise ratio
N-19 p3.2 snr 6664 2 F R dB Path 3.2 signal-to-noise ratio
N-20 path-3 fault (X) 2272 1 I R hex Path 3 path error (3X-measurement)
N-21 p3.1 AGC-level (X) 6684 2 F R dB Path 3.1 Automated Gain Control (3X-
measurement)
N-22 p3.2 AGC-level (X) 6704 2 F R dB Path 3.2 Automated Gain Control (3X-
measurement)
N-23 p3.1 snr (X) 6724 2 F R dB Path 3.1 signal-to-noise ratio (3X-meas-
urement)
N-24 p3.2 snr (X) 6744 2 F R dB Path 3.2 signal-to-noise ratio (3X-meas-
urement)
N-26 path-3 turbulence 6780 2 F R % Path 3 turbulence
Path4 Meas. Values

O-01 p4.1 time of flight 6106 2 F R us Path 4.1 time of flight
O-02 p4.2 time of flight 6126 2 F R us Path 4.2 time of flight
O-03 path-4 delta-t 6146 2 F R us Path 4 time difference
O-04 p4 delta-t corr. 6546 2 F R us Path 4 corrected time difference
O-06 Valid samples G4 7003 1 I R % Path 4 valid measuring values in %
O-07 path-4 velocity 6006 2 F R → velocity unit Path 4 path velocity
O-08 velocity vc4 6206 2 F R → velocity unit Path 4 corrected path velocity vc
O-09 SoS4 6026 2 F R → velocity unit Path 4 Speed of Sound
O-10 path-4 delta SoS 6086 2 F R % Path 4 Path-SoS / Mean-SoS
O-12 path-4 fault 4033 1 I R hex Path 4 path error
O-13 path-4 status 4043 1 I R hex Path 4 path status
O-14 p4.1 Amplitude 7013 1 I R % Path 4.1 amplitude in per cent
O-15 p4.2 Amplitude 7023 1 I R % Path 4.2 amplitude in per cent
O-16 p4.1 AGC-level 6046 2 F R dB Path 4.1 Automated Gain Control
O-17 p4.2 AGC-level 6066 2 F R dB Path 4.2 Automated Gain Control
O-18 p4.1 snr 6646 2 F R dB Path 4.1 signal-to-noise ratio
O-19 p4.2 snr 6666 2 F R dB Path 4.2 signal-to-noise ratio
O-20 path-4 fault (X) 2273 1 I R hex Path 4 path error (3X-measurement)
O-21 p4.1 AGC-level (X) 6686 2 F R dB Path 4.1 Automated Gain Control (3X-
measurement)
O-22 p4.2 AGC-level (X) 6706 2 F R dB Path 4.2 Automated Gain Control (3X-
measurement)
O-23 p4.1 snr (X) 6726 2 F R dB Path 4.1 signal-to-noise ratio (3X-meas-
urement)

O-24 p4.2 snr (X) 6746 2 F R dB Path 4.2 signal-to-noise ratio (3X-meas-
urement)
O-26 path-4 turbulence 6782 2 F R % Path 4 turbulence
214
Path5 Meas. Values

P-01 p5.1 time of flight 6108 2 F R us Path 5.1 time of flight
P-02 p5.2 time of flight 6128 2 F R us Path 5.2 time of flight
P-03 path-5 delta-t 6148 2 F R us Path 5 time difference
P-04 p5 delta-t corr. 6548 2 F R us Path 5 corrected time difference
P-06 Valid samples G5 7004 1 I R % Path 5 valid measuring values in %
P-07 path-5 velocity 6008 2 F R → velocity unit Path 5 path velocity
P-08 velocity vc5 6208 2 F R → velocity unit Path 5 corrected path velocity vc
P-09 SoS5 6028 2 F R → velocity unit Path 5 Speed of Sound
P-10 path-5 delta SoS 6088 2 F R % Path 5 Path-SoS / Mean-SoS
P-12 path-5 fault 4034 1 I R hex Path 5 path error
P-13 path-5 status 4044 1 I R hex Path 5 path status
P-14 p5.1 Amplitude 7014 1 I R % Path 5.1 amplitude in per cent
P-15 p5.2 Amplitude 7024 1 I R % Path 5.2 amplitude in per cent
P-16 p5.1 AGC-level 6048 2 F R dB Path 5.1 Automated Gain Control
P-17 p5.2 AGC-level 6068 2 F R dB Path 5.2 Automated Gain Control
P-18 p5.1 snr 6648 2 F R dB Path 5.1 signal-to-noise ratio
P-19 p5.2 snr 6668 2 F R dB Path 5.2 signal-to-noise ratio
P-20 path-5 fault (X) 2274 1 I R hex Path 5 path error (3X-measurement)
P-21 p5.1 AGC-level (X) 6688 2 F R dB Path 5.1 Automated Gain Control (3X-
measurement)
P-22 p5.2 AGC-level (X) 6708 2 F R dB Path 5.2 Automated Gain Control (3X-
measurement)
P-23 p5.1 snr (X) 6728 2 F R dB Path 5.1 signal-to-noise ratio (3X-meas-
urement)
P-24 p5.2 snr (X) 6748 2 F R dB Path 5.2 signal-to-noise ratio (3X-meas-
urement)
P-26 path-5 turbulence 6784 2 F R % Path 5 turbulence
Path6 Meas. Values

Q-01 p6.1 time of flight 6110 2 F R us Path 6.1 time of flight
Q-02 p6.2 time of flight 6130 2 F R us Path 6.2 time of flight
Q-03 path-6 delta-t 6150 2 F R us Path 6 time difference
Q-04 p6 delta-t corr. 6550 2 F R us Path 6 corrected time difference
Q-06 Valid samples G6 7005 1 I R % Path 6 valid measuring values in %
Q-07 path-6 velocity 6010 2 F R → velocity unit Path 6 path velocity

Q-08 velocity vc6 6210 2 F R → velocity unit Path 6 corrected path velocity vc
Q-09 SoS6 6030 2 F R → velocity unit Path 6 Speed of Sound
Q-10 path-6 delta SoS 6090 2 F R % Path 6 Path-SoS / Mean-SoS
Q-12 path-6 fault 4035 1 I R hex Path 6 path error
215
Q-13 path-6 status 4045 1 I R hex Path 6 path status
Q-14 p6.1 Amplitude 7015 1 I R % Path 6.1 amplitude in per cent
Q-15 p6.2 Amplitude 7025 1 I R % Path 6.2 amplitude in per cent
Q-16 p6.1 AGC-level 6050 2 F R dB Path 6.1 Automated Gain Control
Q-17 p6.2 AGC-level 6070 2 F R dB Path 6.2 Automated Gain Control
Q-18 p6.1 snr 6650 2 F R dB Path 6.1 signal-to-noise ratio
Q-19 p6.2 snr 6670 2 F R dB Path 6.2 signal-to-noise ratio
Q-20 path-6 fault (X) 2275 1 I R hex Path 6 path error (3X-measurement)
Q-21 p6.1 AGC-level (X) 6690 2 F R dB Path 6.1 Automated Gain Control (3X-
measurement)
Q-22 p6.2 AGC-level (X) 6710 2 F R dB Path 6.2 Automated Gain Control (3X-
measurement)
Q-23 p6.1 snr (X) 6730 2 F R dB Path 6.1 signal-to-noise ratio (3X-meas-
urement)
Q-24 p6.2 snr (X) 6750 2 F R dB Path 6.2 signal-to-noise ratio (3X-meas-
urement)
Q-26 path-6 turbulence 6786 2 F R % Path 6 turbulence
Path7 Meas. Values

R-01 p7.1 time of flight 6112 2 F R us Path 7.1 time of flight
R-02 p7.2 time of flight 6132 2 F R us Path 7.2 time of flight
R-03 path-7 delta-t 6152 2 F R us Path 7 time difference
R-04 p7 delta-t corr. 6552 2 F R us Path 7 corrected time difference
R-06 Valid samples G7 7006 1 I R % Path 7 valid measuring values in %
R-07 path-7 velocity 6012 2 F R → velocity unit Path 7 path velocity
R-08 velocity vc7 6212 2 F R → velocity unit Path 7 corrected path velocity vc
R-09 SoS7 6032 2 F R → velocity unit Path 7 Speed of Sound
R-10 path-7 delta SoS 6092 2 F R % Path 7 Path-SoS / Mean-SoS
R-12 path-7 fault 4036 1 I R hex Path 7 path error
R-13 path-7 status 4046 1 I R hex Path 7 path status
R-14 p7.1 Amplitude 7016 1 I R % Path 7.1 amplitude in per cent
R-15 p7.2 Amplitude 7026 1 I R % Path 7.2 amplitude in per cent
R-16 p7.1 AGC-level 6052 2 F R dB Path 7.1 Automated Gain Control
R-17 p7.2 AGC-level 6072 2 F R dB Path 7.2 Automated Gain Control
R-18 p7.1 snr 6652 2 F R dB Path 7.1 signal-to-noise ratio
R-19 p7.2 snr 6672 2 F R dB Path 7.2 signal-to-noise ratio
R-20 path-7 fault (X) 2276 1 I R hex Path 7 path error (3X-measurement)

R-21 p7.1 AGC-level (X) 6692 2 F R dB Path 7.1 Automated Gain Control (3X-
measurement)
R-22 p7.2 AGC-level (X) 6712 2 F R dB Path 7.2 Automated Gain Control (3X-
measurement)
R-23 p7.1 snr (X) 6732 2 F R dB Path 7.1 signal-to-noise ratio (3X-meas-
216 urement)
R-24 p7.2 snr (X) 6752 2 F R dB Path 7.2 signal-to-noise ratio (3X-meas-
urement)
R-26 path-7 turbulence 6788 2 F R % Path 7 turbulence
Path8 Meas. Values

S-01 p8.1 time of flight 6114 2 F R us Path 8.1 time of flight
S-02 p8.2 time of flight 6134 2 F R us Path 8.2 time of flight
S-03 path-8 delta-t 6154 2 F R us Path 8 time difference
S-04 p8 delta-t corr. 6554 2 F R us Path 8 corrected time difference
S-06 Valid samples G8 7007 1 I R % Path 8 valid measuring values in %
S-07 path-8 velocity 6014 2 F R → velocity unit Path 8 path velocity
S-08 velocity vc8 6214 2 F R → velocity unit Path 8 corrected path velocity vc
S-09 SoS8 6034 2 F R → velocity unit Path 8 Speed of Sound
S-10 path-8 delta SoS 6094 2 F R % Path 8 Path-SoS / Mean-SoS
S-12 path-8 fault 4037 1 I R hex Path 8 path error
S-13 path-8 status 4047 1 I R hex Path 8 path status
S-14 p8.1 Amplitude 7017 1 I R % Path 8.1 amplitude in per cent
S-15 p8.2 Amplitude 7027 1 I R % Path 8.2 amplitude in per cent
S-16 p8.1 AGC-level 6054 2 F R dB Path 8.1 Automated Gain Control
S-17 p8.2 AGC-level 6074 2 F R dB Path 8.2 Automated Gain Control
S-18 p8.1 snr 6654 2 F R dB Path 8.1 signal-to-noise ratio
S-19 p8.2 snr 6674 2 F R dB Path 8.2 signal-to-noise ratio
S-20 path-8 fault (X) 2277 1 I R hex Path 8 path error (3X-measurement)
S-21 p8.1 AGC-level (X) 6694 2 F R dB Path 8.1 Automated Gain Control (3X-
measurement)
S-22 p8.2 AGC-level (X) 6714 2 F R dB Path 8.2 Automated Gain Control (3X-
measurement)
S-23 p8.1 snr (X) 6734 2 F R dB Path 8.1 signal-to-noise ratio (3X-meas-
urement)
S-24 p8.2 snr (X) 6754 2 F R dB Path 8.2 signal-to-noise ratio (3X-meas-
urement)
S-26 path-8 turbulence 6790 2 F R % Path 8 turbulence

Path1 Sig. Analysis

T-01 p1.1 tw offset 6600 2 F R us Path 1.1 corrected delay time
T-02 p1.2 tw offset 6620 2 F R us Path 1.2 corrected delay time 217
T-03 p1 Tw damped 6830 2 F R us Path 1 delay time TwD
Path2 Sig. Analysis

U-01 p2.1 tw offset 6602 2 F R us Path 2.1 corrected delay time
U-02 p2.2 tw offset 6622 2 F R us Path 2.2 corrected delay time
U-03 p2 Tw damped 6832 2 F R us Path 2 delay time TwD
Path3 Sig. Analysis

V-01 p3.1 tw offset 6604 2 F R us Path 3.1 corrected delay time
V-02 p3.2 tw offset 6624 2 F R us Path 3.2 corrected delay time
V-03 p3 Tw damped 6834 2 F R us Path 3 delay time TwD
Path4 Sig. Analysis

W-01 p4.1 tw offset 6606 2 F R us Path 4.1 corrected delay time
W-02 p4.2 tw offset 6626 2 F R us Path 4.2 corrected delay time
W-03 p4 Tw damped 6836 2 F R us Path 4 delay time TwD
Path5 Sig. Analysis

X-01 p5.1 tw offset 6608 2 F R us Path 5.1 corrected delay time
X-02 p5.2 tw offset 6628 2 F R us Path 5.2 corrected delay time
X-03 p5 Tw damped 6838 2 F R us Path 5 delay time TwD
Path6 Sig. Analysis

Y-01 p6.1 tw offset 6610 2 F R us Path 6.1 corrected delay time
Y-02 p6.2 tw offset 6630 2 F R us Path 6.2 corrected delay time
Y-03 p6 Tw damped 6840 2 F R us Path 6 delay time TwD

Path7 Sig. Analysis

Z-01 p7.1 tw offset 6612 2 F R us Path 7.1 corrected delay time
218 Z-02 p7.2 tw offset 6632 2 F R us Path 7.2 corrected delay time
Z-03 p7 Tw damped 6842 2 F R us Path 7 delay time TwD
Path8 Sig. Analysis

AA-01 p8.1 tw offset 6614 2 F R us Path 8.1 corrected delay time
AA-02 p8.2 tw offset 6634 2 F R us Path 8.2 corrected delay time
AA-03 p8 Tw damped 6844 2 F R us Path 8 delay time TwD
USE09 meas. val.

AB-01 SoS average 6228 2 F R → velocity unit Average Speed of Sound over all paths
AB-02 p.1 AGC average 6056 2 F R dB Path x.1 average AGC over all paths
AB-03 p.2 AGC average 6076 2 F R dB Path x.2 average AGC over all paths
USE09 Diagnosis

AC-01 Vz plane-1 6560 2 F R → velocity unit Velocity Vz of plane 1
AC-05 Vx plane-1 6568 2 F R → velocity unit Velocity Vx of plane 1
AC-09 Ve plane-1 6576 2 F R → velocity unit Velocity V of plane 1
AC-15 Swirl Angle Plane- 6584 2 F R ° Swirl angle of plane 1
1
2
3
4

AC-20 Profile PFY1 6800 2 F R Profile factor PFY1

AC-22 Profile PFY 6804 2 F R Profile factor PFY
219
AC-27 Profile PFX 6814 2 F R Profile factor PFX
AC-28 Profile PFX12 6816 2 F R Profile factor PFX12
AC-29 Profile PFX56 6818 2 F R Profile factor PFX56
AC-30 Profile Factor 6820 2 F R Diagnosis: Profile factor
AC-31 Symmetry X 6822 2 F R Symmetry X
AC-32 Symmetry Y 6824 2 F R Symmetry Y
AC-33 Symmetry 6826 2 F R Symmetry
Time and Date

AD-01 time 2560 2 U F date and time
USE09-C Totalizers

AE-01 Tot. Volume d.1 3000 4 D CS → volume unit Actual volume counter for direction 1
AE-02 Tot. Volume d.2 3004 4 D CS → volume unit Actual volume counter for direction 2
AE-04 Tot. VolumeErr 3008 4 D CS → volume unit Actual disturbed volume counter for di-
d.1 rection 1
AE-05 Tot. VolumeErr 3012 4 D CS → volume unit Actual disturbed volume counter for di-
d.2 rection 2
AE-07 Tot. VolumeSum 3016 4 D CS → volume unit Actual summarized volume counter for
d.1 direction 1
AE-08 Tot. VolumeSum 3020 4 D CS → volume unit Actual summarized volume counter for
d.2 direction 2
AE-09 Total Volume 3024 4 D CS → volume unit Total volume totalizer for volume at
measurement conditions, both direc-
tions
AE-10 tot. Error-mode 2096 1 M S Error mode of Vm and test totalizers
0x0000 STOP (d)
0x0001 RUN
AE-11 Total Volume 2098 1 M S Mode of the total volume totalizer (VO)
mode
0x0000 D1 - D2 (d)
0x0001 DIRECTION_1
0x0002 DIRECTION_2
AE-20 test-tot. mode 2097 1 M F Start/stop of the Vm test totalizers

0x0000 STOP (d)

0x0001 RUN
AE-21 Vm-dir.1 test sum 3040 4 D R → volume unit Actual volume test-counter for direction
1
220 AE-22 Vm-dir.2 test sum 3044 4 D R → volume unit Actual volume test-counter for direction
2
AE-23 time for test sum 6242 2 F R s Duration of on-the-fly calibration
AE-30 Unit LF-Volumes 2217 1 M F Unit (factor) for totalizers of type LONG
0x0000 x1 (d)
0x0001 x 0.1
0x0002 x 0.01
AE-31 L: Tot. Volume d.1 2600 2 L R → Unit LF-Volumes Copy of Vm totalizer, direction 1 (with
factor in Long format)
AE-32 L: Tot. Volume d.2 2602 2 L R → Unit LF-Volumes Copy of Vm totalizer, direction 2 (with
AE-34 L: Tot. Vol.Err d.1 2604 2 L R → Unit LF-Volumes Copy of disturbing Vm totalizer, direc-
tion 1 (with factor in Long format)
AE-35 L: Tot. Vol.Err d.2 2606 2 L R → Unit LF-Volumes Copy of disturbing Vm totalizer, direc-
tion 2 (with factor in Long format)
AE-37 L: Tot. Vol.Sum 2608 2 L R → Unit LF-Volumes Copy of total volume totalizer
d.1 (Vm+VmD), direction 1 (with factor in
Long format)
AE-38 L: Tot. Vol.Sum 2610 2 L R → Unit LF-Volumes Copy of total volume totalizer
d.2 (Vm+VmD), direction 2 (with factor in
Long format)
AE-39 L: Total Volume 2612 2 L R → Unit LF-Volumes Copy of Vm total volume totalizer (with
ID

AF-01 electronic type 500 10 T S ID: Device type
AF-02 electronic no 2564 2 L S ID: Device No.
AF-03 unit type 510 10 T S ID: Type of measuring element
AF-04 unit no 2562 2 L S ID: Measuring element No.
AF-05 manufacturer 2151 1 M S ID: Manufacturer of the USE09
0x0000 RMG (d)
AF-06 model (year) 2152 1 I S ID: Year of construction of the USE09
(DZU interface)
AF-07 meter size 520 10 T S ID: Meter size
AF-08 nominal diameter 2210 1 I S → Calib. units: ID: Nominal diameter DN
DN Length
AF-09 pressure rating 740 10 T S ID: Pressure rating
AF-10 pipe flange type 2211 1 M S ID: Flange standard
0x0000 PN (d)
0x0001 ANSI
AF-11 pipe flange value 2212 1 I S ID: Flange value
AF-12 Qmin 1346 2 F S → flow unit ID: q-min

AF-13 Qmax 1348 2 F S → flow unit ID: q-max

AF-14 pmin 1350 2 F S → Units: Pressure g ID: Calibration pressure min
AF-15 pmax 1352 2 F S → Units: Pressure g ID: Calibration pressure max
AF-16 meas.press. min 1520 2 F S → Units: Pressure a ID: Measuring pressure min
221
AF-17 meas.press. max 1522 2 F S → Units: Pressure a ID: Measuring pressure max
AF-18 Tmin 1354 2 F S → Units: Temp. ID: T-min
AF-21 Tmax 1356 2 F S → Units: Temp. ID: T-max
AF-23 gas type 2154 1 M S ID: Gas type
0x0000 NATURAL GAS (d)
AF-24 p type 2155 1 M S ID: P-type
0x0000 3051CA (d)
0x0001 G1151Ap
0x0002 G1151
0x0003 2088A
AF-25 p no. 2566 2 L S ID: P-No.
AF-26 T type 2156 1 M S ID: T-type
0x0000 AGG-EX (d)
0x0001 Q-4407
0x0002 PT100
0x0003 F-56
0x0004 F-57
AF-27 T no 2568 2 L S ID: T-No.
AF-28 Transducer type 9072 10 T S ID: Transducer type
AF-29 Transducer 1.1 no. 530 10 T S ID: transducer 1/1 No.
AF-30 Transducer 1.1 1524 2 F S → Calib. units: ID: transducer 1/1 length
len. Length
AF-31 Transducer 1.1 2291 1 I S ID: transducer 1/1 year of manufacture
built
len. Length
built
len. Length
built
len. Length
built
len. Length


built
222 len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built
len. Length
built

len. Length
built
AF-77 serial number 790 10 T S ID: serial number USE09
USE09 223
AF-78 version 100 2 F R ID: M32C software version
AF-79 CPU CRC 201 1 I R hex ID: M32C CRC-16
AF-80 Matrix version 200 1 I R ID: M32C Matrix version
AF-81 DSP version 102 2 F R ID: DSP software version
AF-82 DSP CRC 202 1 I R hex ID: DSP CRC-16
AF-83 FPGA version 104 2 F R ID: FPGA software version
AF-84 FPGA CRC 203 1 I R hex ID: FPGA CRC-16
AF-85 fiscal par. CRC 204 1 I R hex ID: fiscally parameters crc-16
AF-86 piecewise lin. CRC 205 1 I R hex ID: piecewise linearization parameters
crc-16
Mode

AG-04 codeword 750 10 C F Entry of codeword
AG-26 test working 2185 1 M S Test mode for debugging the DSP
mode
0x0000 OFF (d)
0x0001 DEBUG
0x0002 WD
AG-27 Display, LED test 65535 10 T R Display test, bottom
AG-28 Test LEDs 4080 1 M C Tests the LEDs on the front panel
0x0000 OFF (d)
0x0001 TEST
AG-30 language 2094 1 M C Selection of language
0x0000 GERMAN (d)
0x0001 ENGLISH
AG-31 units 2095 1 M CS Selection of units
0x0000 METRICAL- (d)
UNITS
0x0001 IMPERIAL-
UNITS
AG-32 velocity unit 7030 1 M R Unit: Velocities
0x0000 m/s
0x0001 ft/s
AG-33 flow unit 7031 1 M R Unit: Flow rate
0x0000 m3/h
0x0001 acfh
AG-34 volume unit 7032 1 M R Unit: Totalizers

0x0000 m3
0x0001 acf
AG-35 pulse unit 7033 1 M R Unit: Pulse value
0x0000 Imp/m3
224
0x0001 Imp/cf
AG-36 Units: Temp. 7035 1 M S Unit: temperature
0x0000 °C (d)
0x0001 °F
0x0002 K
0x0003 °Ra
AG-37 Units: Pressure 7036 1 M S Unit: pressure
0x0000 bar (d)
0x0001 psi
AG-38 Units: Pressure a 7037 1 M R Unit: absolute pressure
0x0000 bar_a
0x0001 psi_a
AG-39 Units: Pressure g 7038 1 M R Unit: relative pressure
0x0000 bar_g
0x0001 psi_g
AG-40 Calib. units: 7039 1 M S Calibration unit: length
Length
0x0000 mm (d)
0x0001 in
AG-41 Calib. units: v 7040 1 M S Calibration unit: speed
0x0000 m/s (d)
0x0001 ft/s
AG-42 Calib. units: Q 7041 1 M S Calibration unit: flow
0x0000 m3/h (d)
0x0001 acfh
Faults

AH-01 fault message 710 10 T R Fault message as rolling text
AH-02 fault time 7500 2 U R Date and time of the fault
AH-03 clear fault 2126 1 M F Clear fault
0x0000 NO (d)
0x0001 YES
AH-04 fault mode 2127 1 M S Fault mode below Qm-min
0x0000 NORMAL (d)
0x0001 ALL

AH-05 fault display 2128 1 M S Fault display mode active: Shows all cur-
mode rently active faults
0x0000 NORMAL (d)
0x0001 ACTIVE
AH-06 path error mode 2129 1 M S Error mode in the case of a path failure 225
0x0000 WARNING (d)
0x0001 ALARM
AH-07 fault,warn contact 2254 1 M F Mode for alarm and warning contact
0x0000 NORMAL (d)
0x0001 5_SECONDS
0x0002 HOLD
AH-09 path ok 700 10 T R Indication of the path status (path moni-
toring is considered)
AH-10 hint status 4008 1 M R Current hint status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-11 warning status 4001 1 M R Current warning status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-12 warn contact 4120 1 M R Current warning contact
0x0000 OFF
0x0001 ON
AH-13 fault status 4000 1 M R Current alarm status
0x0000 OFF
0x0001 ON
0x0002 QUIT
AH-14 fault contact 4121 1 M R Current alarm contact
0x0000 OFF
0x0001 ON
AH-15 USE09 device sta- 4002 1 I R hex USE09 device status
tus
AH-16 Fault bit 0-15 4010 1 I R hex Active faults (bit-coded) 0-15

226
DSP Parameters

AI-09 number of 2136 1 I C Number of batches
batches
AI-10 Relay delay time 2137 1 I S ms Relay delay time (RDT)
AI-11 sample frequency 2138 1 M S MHz Sample frequency in MHz
0x0000 1
0x0001 1,25
0x0002 1,67
0x0003 2
0x0004 2,5
0x0005 3,33
0x0006 4
0x0007 5 (d)
0x0008 6,67
0x0009 10
AI-12 fifo size 2139 1 M S Size of the receiving memory
0x0000 512
0x0001 1024
0x0002 2048 (d)
AI-13 FPGA testpin ctrl. 2214 1 I F hex Hexadecimal control word for the FPGA
test pins
AI-14 transmission level 2140 1 I S % Transmission level control in %
AI-15 send mux time 1364 2 F S ms Response time of transmit multiplexer
in ms
AI-16 receive mux time 1366 2 F S ms Response time of receive multiplexer in
ms
AI-17 Attenuator mode 2141 1 M S Operating mode of the attenuator
0x0000 OFF (d)
0x0001 ON
0x0002 TEST
0x0003 AUTO_SEPA-
RATE
AI-18 Attenuator on 2142 1 I S dB Limit for the attenuator ON
AI-19 Attenuator off 2143 1 I S dB Limit for the attenuator OFF
AI-20 Attenuator HV 2144 1 I S dB Limit for the attenuator HV mode
AI-21 amp. regulator 2145 1 M C Operating mode of amplitude control
mode
0x0000 SET VALUE
0x0001 ON (d)

0x0002 HOLD
AI-22 amp. regulator 2146 1 I C % Min. range for amplitude control
min
AI-23 amp. regulator 2147 1 I C % Max. range for amplitude control
max 227
AI-24 amp. damping 1448 2 F C Damping for amplitude control
AI-25 theoretical SoS 1368 2 F S → velocity unit Theoretical speed of sound of the fluid
AI-26 ADC gain 2164 1 M S FPGA AD gain 0 dB, +6 dB, -6 dB
0x0000 1 (d)
0x0001 2
0x0002 0.5
AI-27 signal tracking 2169 1 M C Switches signal tracking on or off
0x0000 ON
0x0001 OFF (d)
AI-28 max. track. Offset 2187 1 I C Tics Max. size of the tracking window
AI-37 corr. mode 2256 1 M S Correlation mode
0x0000 OFF (d)
0x0001 FADE_IN
AI-38 corr. length 2189 1 I S Length of the correlation window
AI-39 Batch: amp. min. 2279 1 I S % Batch: Minimum amplitude
AI-47 AmplitudeMin 2000 1 I S % Limit for the input signal (Low)
AI-48 AmplitudeMax 2010 1 I S % Limit for the input signal (High)
AI-49 Vmin 1000 2 F S → Calib. units: v Lower limit for the flow velocity
AI-50 Vmax 1020 2 F S → Calib. units: v Upper limit for the flow velocity
AI-51 Cmin 1040 2 F S → Calib. units: v Lower limit for the speed of sound
AI-52 Cmax 1060 2 F S → Calib. units: v Upper limit for the speed of sound
DSP Parameters 3X

AJ-07 corr. mode (X) 2257 1 M S Correlation mode (3X measurement)
0x0000 OFF (d)
0x0001 FADE_IN
AJ-09 Batch: amp. min. 2280 1 I S % Batch: Minimum amplitude (3X meas-
urement)

Path1 Parameters

AK-09 p1 f-trans set val 2500 2 L S Hz Path 1 transmit frequency intended
228 value in Hz
AK-10 path-1 trans. freq. 2520 2 L R Hz Path 1 transmit frequency actual value
in Hz
AK-11 path-1 band limits 2190 1 I S % Path 1 limits to observe
AK-12 path-1 2040 1 I S Path 1 number of transmit pulses
trans.pulses
AK-13 p1 filter selection 2170 1 M S kHz Path 1 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AK-14 path-1 tw 1080 2 F S us Path 1 delay time
AK-16 path-1 DAC-G1 2050 1 I S Path 1 DAC-G1 command register
cmd
AK-17 path-1 DAC-G1 val 2060 1 I S Path 1 DAC-G1 data register
AK-18 path-1 DAC-G2 2070 1 I S Path 1 DAC-G2 command register
cmd
AK-19 path-1 DAC-G2 val 2080 1 I S Path 1 DAC-G2 data register
AK-20 p1 blanking delay 1100 2 F R us Path 1 blanking delay
AK-21 p1 blanking count 2540 2 L R tic Path 1 blanking count
AK-22 path-1 decay time 1120 2 F S ms Path 1 pulse decay time
AK-23 path-1 path 1140 2 F S → Calib. units: Length Path 1 path length
length
AK-24 path-1 axial dist. 1160 2 F S → Calib. units: Length Path 1 smallest path distance
AK-25 p1 assembly an- 1500 2 F S ° Path 1 assembly angle
gle
AK-26 p1 delta-t offset 1420 2 F S us Path 1 time difference offset
AK-29 const w1 1240 2 F S [1] Path 1 weigthing factor w1
AK-30 p1 tic offset 2200 1 I S tic Path 1 tic offset
AK-31 p1 tic offset (X) 2260 1 I S tic Path 1 tic offset (3X-measurement)
AK-32 p1 AGC-limit 2220 1 I S dB Path 1 AGC limit
AK-34 p1 no. of f- 2312 1 I C Path 1 no. of measurement (FBatches)
batches

Path2 Parameters

AL-09 p2 f-trans set val 2502 2 L S Hz Path 2 transmit frequency intended
value in Hz 229
AL-10 path-2 trans. freq. 2522 2 L R Hz Path 2 transmit frequency actual value
in Hz
AL-11 path-2 band limits 2191 1 I S % Path 2 limits to observe
AL-12 path-2 2041 1 I S Path 2 number of transmit pulses
trans.pulses
AL-13 p2 filter selection 2171 1 M S kHz Path 2 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AL-14 path-2 tw 1082 2 F S us Path 2 delay time
AL-16 path-2 DAC-G1 2051 1 I S Path 2 DAC-G1 command register
cmd
AL-17 path-2 DAC-G1 val 2061 1 I S Path 2 DAC-G1 data register
AL-18 path-2 DAC-G2 2071 1 I S Path 2 DAC-G2 command register
cmd
AL-19 path-2 DAC-G2 val 2081 1 I S Path 2 DAC-G2 data register
AL-20 p2 blanking delay 1102 2 F R us Path 2 blanking delay
AL-21 p2 blanking count 2542 2 L R tic Path 2 blanking count
AL-22 path-2 decay time 1122 2 F S ms Path 2 pulse decay time
AL-23 path-2 path 1142 2 F S → Calib. units: Length Path 2 path length
length
AL-24 path-2 axial dist. 1162 2 F S → Calib. units: Length Path 2 smallest path distance
AL-25 p2 assembly an- 1502 2 F S ° Path 2 assembly angle
gle
AL-26 p2 delta-t offset 1422 2 F S us Path 2 time difference offset
AL-29 const w2 1242 2 F S [1] Path 2 weigthing factor w2
AL-30 p2 tic offset 2201 1 I S tic Path 2 tic offset
AL-31 p2 tic offset (X) 2261 1 I S tic Path 2 tic offset (3X-measurement)
AL-32 p2 AGC-limit 2221 1 I S dB Path 2 AGC limit
AL-34 p2 no. of f- 2313 1 I C Path 2 no. of measurement (FBatches)
batches

Path3 Parameters

AM-09 p3 f-trans set val 2504 2 L S Hz Path 3 transmit frequency intended
230 value in Hz
AM-10 path-3 trans. freq. 2524 2 L R Hz Path 3 transmit frequency actual value
in Hz
AM-11 path-3 band limits 2192 1 I S % Path 3 limits to observe
AM-12 path-3 2042 1 I S Path 3 number of transmit pulses
trans.pulses
AM-13 p3 filter selection 2172 1 M S kHz Path 3 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AM-14 path-3 tw 1084 2 F S us Path 3 delay time
AM-16 path-3 DAC-G1 2052 1 I S Path 3 DAC-G1 command register
cmd
AM-17 path-3 DAC-G1 val 2062 1 I S Path 3 DAC-G1 data register
AM-18 path-3 DAC-G2 2072 1 I S Path 3 DAC-G2 command register
cmd
AM-19 path-3 DAC-G2 val 2082 1 I S Path 3 DAC-G2 data register
AM-20 p3 blanking delay 1104 2 F R us Path 3 blanking delay
AM-21 p3 blanking count 2544 2 L R tic Path 3 blanking count
AM-22 path-3 decay time 1124 2 F S ms Path 3 pulse decay time
AM-23 path-3 path 1144 2 F S → Calib. units: Length Path 3 path length
length
AM-24 path-3 axial dist. 1164 2 F S → Calib. units: Length Path 3 smallest path distance
AM-25 p3 assembly an- 1504 2 F S ° Path 3 assembly angle
gle
AM-26 p3 delta-t offset 1424 2 F S us Path 3 time difference offset
AM-29 const w3 1244 2 F S [1] Path 3 weigthing factor w3
AM-30 p3 tic offset 2202 1 I S tic Path 3 tic offset
AM-31 p3 tic offset (X) 2262 1 I S tic Path 3 tic offset (3X-measurement)
AM-32 p3 AGC-limit 2222 1 I S dB Path 3 AGC limit
AM-34 p3 no. of f- 2314 1 I C Path 3 no. of measurement (FBatches)
batches

Path4 Parameters

AN-09 p4 f-trans set val 2506 2 L S Hz Path 4 transmit frequency intended
value in Hz 231
AN-10 path-4 trans. freq. 2526 2 L R Hz Path 4 transmit frequency actual value
in Hz
AN-11 path-4 band limits 2193 1 I S % Path 4 limits to observe
AN-12 path-4 2043 1 I S Path 4 number of transmit pulses
trans.pulses
AN-13 p4 filter selection 2173 1 M S kHz Path 4 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AN-14 path-4 tw 1086 2 F S us Path 4 delay time
AN-16 path-4 DAC-G1 2053 1 I S Path 4 DAC-G1 command register
cmd
AN-17 path-4 DAC-G1 val 2063 1 I S Path 4 DAC-G1 data register
AN-18 path-4 DAC-G2 2073 1 I S Path 4 DAC-G2 command register
cmd
AN-19 path-4 DAC-G2 val 2083 1 I S Path 4 DAC-G2 data register
AN-20 p4 blanking delay 1106 2 F R us Path 4 blanking delay
AN-21 p4 blanking count 2546 2 L R tic Path 4 blanking count
AN-22 path-4 decay time 1126 2 F S ms Path 4 pulse decay time
AN-23 path-4 path 1146 2 F S → Calib. units: Length Path 4 path length
length
AN-24 path-4 axial dist. 1166 2 F S → Calib. units: Length Path 4 smallest path distance
AN-25 p4 assembly an- 1506 2 F S ° Path 4 assembly angle
gle
AN-26 p4 delta-t offset 1426 2 F S us Path 4 time difference offset
AN-29 const w4 1246 2 F S [1] Path 4 weigthing factor w4
AN-30 p4 tic offset 2203 1 I S tic Path 4 tic offset
AN-31 p4 tic offset (X) 2263 1 I S tic Path 4 tic offset (3X-measurement)
AN-32 p4 AGC-limit 2223 1 I S dB Path 4 AGC limit
AN-34 p4 no. of f- 2315 1 I C Path 4 no. of measurement (FBatches)
batches

Path5 Parameters

AO-09 p5 f-trans set val 2508 2 L S Hz Path 5 transmit frequency intended
232 value in Hz
AO-10 path-5 trans. freq. 2528 2 L R Hz Path 5 transmit frequency actual value
in Hz
AO-11 path-5 band limits 2194 1 I S % Path 5 limits to observe
AO-12 path-5 2044 1 I S Path 5 number of transmit pulses
trans.pulses
AO-13 p5 filter selection 2174 1 M S kHz Path 5 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AO-14 path-5 tw 1088 2 F S us Path 5 delay time
AO-16 path-5 DAC-G1 2054 1 I S Path 5 DAC-G1 command register
cmd
AO-17 path-5 DAC-G1 val 2064 1 I S Path 5 DAC-G1 data register
AO-18 path-5 DAC-G2 2074 1 I S Path 5 DAC-G2 command register
cmd
AO-19 path-5 DAC-G2 val 2084 1 I S Path 5 DAC-G2 data register
AO-20 p5 blanking delay 1108 2 F R us Path 5 blanking delay
AO-21 p5 blanking count 2548 2 L R tic Path 5 blanking count
AO-22 path-5 decay time 1128 2 F S ms Path 5 pulse decay time
AO-23 path-5 path 1148 2 F S → Calib. units: Length Path 5 path length
length
AO-24 path-5 axial dist. 1168 2 F S → Calib. units: Length Path 5 smallest path distance
AO-25 p5 assembly an- 1508 2 F S ° Path 5 assembly angle
gle
AO-26 p5 delta-t offset 1428 2 F S us Path 5 time difference offset
AO-29 const w5 1248 2 F S [1] Path 5 weigthing factor w5
AO-30 p5 tic offset 2204 1 I S tic Path 5 tic offset
AO-31 p5 tic offset (X) 2264 1 I S tic Path 5 tic offset (3X-measurement)
AO-32 p5 AGC-limit 2224 1 I S dB Path 5 AGC limit
AO-34 p5 no. of f- 2316 1 I C Path 5 no. of measurement (FBatches)
batches

Path6 Parameters

AP-09 p6 f-trans set val 2510 2 L S Hz Path 6 transmit frequency intended
value in Hz 233
AP-10 path-6 trans. freq. 2530 2 L R Hz Path 6 transmit frequency actual value
in Hz
AP-11 path-6 band limits 2195 1 I S % Path 6 limits to observe
AP-12 path-6 2045 1 I S Path 6 number of transmit pulses
trans.pulses
AP-13 p6 filter selection 2175 1 M S kHz Path 6 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AP-14 path-6 tw 1090 2 F S us Path 6 delay time
AP-16 path-6 DAC-G1 2055 1 I S Path 6 DAC-G1 command register
cmd
AP-17 path-6 DAC-G1 val 2065 1 I S Path 6 DAC-G1 data register
AP-18 path-6 DAC-G2 2075 1 I S Path 6 DAC-G2 command register
cmd
AP-19 path-6 DAC-G2 val 2085 1 I S Path 6 DAC-G2 data register
AP-20 p6 blanking delay 1110 2 F R us Path 6 blanking delay
AP-21 p6 blanking count 2550 2 L R tic Path 6 blanking count
AP-22 path-6 decay time 1130 2 F S ms Path 6 pulse decay time
AP-23 path-6 path 1150 2 F S → Calib. units: Length Path 6 path length
length
AP-24 path-6 axial dist. 1170 2 F S → Calib. units: Length Path 6 smallest path distance
AP-25 p6 assembly an- 1510 2 F S ° Path 6 assembly angle
gle
AP-26 p6 delta-t offset 1430 2 F S us Path 6 time difference offset
AP-29 const w6 1250 2 F S [1] Path 6 weigthing factor w6
AP-30 p6 tic offset 2205 1 I S tic Path 6 tic offset
AP-31 p6 tic offset (X) 2265 1 I S tic Path 6 tic offset (3X-measurement)
AP-32 p6 AGC-limit 2225 1 I S dB Path 6 AGC limit
AP-34 p6 no. of f- 2317 1 I C Path 6 no. of measurement (FBatches)
batches

Path7 Parameters

AQ-09 p7 f-trans set val 2512 2 L S Hz Path 7 transmit frequency intended
234 value in Hz
AQ-10 path-7 trans. freq. 2532 2 L R Hz Path 7 transmit frequency actual value
in Hz
AQ-11 path-7 band limits 2196 1 I S % Path 7 limits to observe
AQ-12 path-7 2046 1 I S Path 7 number of transmit pulses
trans.pulses
AQ-13 p7 filter selection 2176 1 M S kHz Path 7 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AQ-14 path-7 tw 1092 2 F S us Path 7 delay time
AQ-16 path-7 DAC-G1 2056 1 I S Path 7 DAC-G1 command register
cmd
AQ-17 path-7 DAC-G1 val 2066 1 I S Path 7 DAC-G1 data register
AQ-18 path-7 DAC-G2 2076 1 I S Path 7 DAC-G2 command register
cmd
AQ-19 path-7 DAC-G2 val 2086 1 I S Path 7 DAC-G2 data register
AQ-20 p7 blanking delay 1112 2 F R us Path 7 blanking delay
AQ-21 p7 blanking count 2552 2 L R tic Path 7 blanking count
AQ-22 path-7 decay time 1132 2 F S ms Path 7 pulse decay time
AQ-23 path-7 path 1152 2 F S → Calib. units: Length Path 7 path length
length
AQ-24 path-7 axial dist. 1172 2 F S → Calib. units: Length Path 7 smallest path distance
AQ-25 p7 assembly an- 1512 2 F S ° Path 7 assembly angle
gle
AQ-26 p7 delta-t offset 1432 2 F S us Path 7 time difference offset
AQ-29 const w7 1252 2 F S [1] Path 7 weigthing factor w7
AQ-30 p7 tic offset 2206 1 I S tic Path 7 tic offset
AQ-31 p7 tic offset (X) 2266 1 I S tic Path 7 tic offset (3X-measurement)
AQ-32 p7 AGC-limit 2226 1 I S dB Path 7 AGC limit
AQ-34 p7 no. of f- 2318 1 I C Path 7 no. of measurement (FBatches)
batches

Path8 Parameters

AR-09 p8 f-trans set val 2514 2 L S Hz Path 8 transmit frequency intended
value in Hz 235
AR-10 path-8 trans. freq. 2534 2 L R Hz Path 8 transmit frequency actual value
in Hz
AR-11 path-8 band limits 2197 1 I S % Path 8 limits to observe
AR-12 path-8 2047 1 I S Path 8 number of transmit pulses
trans.pulses
AR-13 p8 filter selection 2177 1 M S kHz Path 8 DSP filter selection
0x0000 50
0x0001 75
0x0002 100 (d)
0x0003 125
0x0004 150
0x0005 175
0x0006 200
0x0007 225
0x0008 250
0x0009 275
0x000a 300
0x000b 325
AR-14 path-8 tw 1094 2 F S us Path 8 delay time
AR-16 path-8 DAC-G1 2057 1 I S Path 8 DAC-G1 command register
cmd
AR-17 path-8 DAC-G1 val 2067 1 I S Path 8 DAC-G1 data register
AR-18 path-8 DAC-G2 2077 1 I S Path 8 DAC-G2 command register
cmd
AR-19 path-8 DAC-G2 val 2087 1 I S Path 8 DAC-G2 data register
AR-20 p8 blanking delay 1114 2 F R us Path 8 blanking delay
AR-21 p8 blanking count 2554 2 L R tic Path 8 blanking count
AR-22 path-8 decay time 1134 2 F S ms Path 8 pulse decay time
AR-23 path-8 path 1154 2 F S → Calib. units: Length Path 8 path length
length
AR-24 path-8 axial dist. 1174 2 F S → Calib. units: Length Path 8 smallest path distance
AR-25 p8 assembly an- 1514 2 F S ° Path 8 assembly angle
gle
AR-26 p8 delta-t offset 1434 2 F S us Path 8 time difference offset
AR-29 const w8 1254 2 F S [1] Path 8 weigthing factor w8
AR-30 p8 tic offset 2207 1 I S tic Path 8 tic offset
AR-31 p8 tic offset (X) 2267 1 I S tic Path 8 tic offset (3X-measurement)
AR-32 p8 AGC-limit 2227 1 I S dB Path 8 AGC limit
AR-34 p8 no. of f- 2319 1 I C Path 8 no. of measurement (FBatches)
batches

Service

AS-01 CPU speed 2574 2 L CS Hz Actual M32 clock speed
236 AS-02 DSP speed 2576 2 L S Hz Actual DSP clock speed
AS-04 FPGA speed 2578 2 L S Hz Actual FPGA clock speed
AS-05 ext. card s.no. 2584 2 L S IO card s. No.
AS-06 ext. ADC s.no. 2586 2 L S IO-ADC card s. No.
AS-07 write opt.EEProm 2167 1 M S (Service key!) Writes paramet. in the
OPT-EEP
0x0000 NO (d)
0x0001 YES
AS-08 write ADC 2168 1 M S (Service key!) Writes paramet. in the
EEProm OPT-ADC-EEP
0x0000 NO (d)
0x0001 YES
AS-09 LCD lighting 2183 1 M F Display lighting if key is pressed or
steady light
0x0000 KEY (d)
0x0001 always
AS-10 parameter reset 2148 1 M CS Load new parameters
0x0000 NO (d)
0x0001 YES
AS-12 RV reset 2149 1 M C Clear replacement values
0x0000 NO (d)
0x0001 YES
AS-13 RV: number 2150 1 I C Number of average values for the calcu-
lation of replacement values
AS-14 RV status 720 10 T R Status for the replacement value
AS-15 RV mode 2213 1 M S Mode of replacement values
0x0000 OFF
0x0001 ON (d)
AS-16 Raw data path no. 2124 1 I F Raw data: Path selection (0=OFF)
AS-17 Raw data type 2184 1 M F Raw data: Type selection
0x0000 TEST
0x0001 RAW (d)
0x0002 FILTER
0x0003 RAW ERR
0x0004 FILTER ERR
0x0005 FFG
0x0006 RAW FFT
0x0007 FILTER FFT
AS-18 Raw data function 2215 1 I F Raw data: Trigger function (subselection)
AS-20 M32 Temperature 5000 2 F R → Units: Temp. Temperature of the M32 board

AS-21 Transmit Level 5002 2 F R % Transmission level HV analog board

AS-22 +-5V symmetry 5004 2 F R V Symmetry +-5V, analog board
AS-23 System Tempera- 5006 2 F R → Units: Temp. Temperature, baseboard
ture
AS-24 +-12V symmetry 5008 2 F R V Symmetry +-12V, analog board 237
AS-25 1V2 voltage 5010 2 F R V Voltage 1V2 DSP board
AS-26 1V5 voltage 5012 2 F R V Voltage 1V5 DSP board
AS-27 3V3 voltage 5014 2 F R V Voltage 3V3 M32 board
AS-28 adc-p binary val. 7502 2 L R Pressure input, transmitter value
AS-29 adc-t binary val. 7504 2 L R PT100 input, transmitter value
AS-30 max. sys. temp. 1440 2 F C → Units: Temp. System temperature, max. value
AS-31 time max. sys. 2588 2 U C Time of max. system temperature
temp
AS-32 min. sys. temp. 1442 2 F C → Units: Temp. System temperature, min. value
AS-33 time min. sys. 2590 2 U C Time of min. system temperature
temp
Log Data

AT-01 Log-data date 800 10 T R Data logger, date of last change
AT-02 Log-data coordi- 810 10 T R Data logger, coordinate of last change
nate
AT-03 Log-data old value 820 10 T R Data logger (old value)
AT-04 Log-data new 830 10 T R Data logger (new value)
value
AT-10 Log-data fill level 4007 1 I R % Data logger, fill level
AT-11 clear par-log 2157 1 M S Clear parameter logging list
0x0000 NO (d)
0x0001 YES
AT-12 clear event-log 2216 1 M F Clear event logging list
0x0000 NO (d)
0x0001 YES
Site Information

AU-01 User Text-1 840 10 T F User-programmable text line 1

Remote Control

AV-01 remote access 10000 1 M C Remote access
238 0x0000 NO (d)
0x0001 YES
AV-02 remote keycode 10001 1 I C Keyboard code
AV-03 lcd row 1 10010 10 T R Actual line 1 LCD
AGA-10 Values

AW-01 SoS calc. status 8000 1 I R hex Status AGA-10 calculation
AW-02 SoS 8001 2 F R → velocity unit Measured average speed of sound
AW-03 SoS calculated 8003 2 F R → velocity unit Result speed of sound AGA-10
AW-04 rel. error SoS 8005 2 F R % Relative error measured SoS to SoS cal-
culated
AW-05 abs. error SoS 8007 2 F R → velocity unit SoS measured - SoS AGA-10
AW-06 temperature 8009 2 F R → Units: Temp. Temperature: AGA-10 equation
AW-07 pressure 8011 2 F R → Units: Pressure a Pressure: AGA-10 equation
AW-08 last calculation 8013 2 U R Time of last AGA-10 calculation
AW-09 last gas comp. 8015 2 U R Time of last gas components input
AW-20 norm. methane 8040 2 F R mol-% Methane: fraction in AGA-10 equation
AW-21 norm. ethane 8046 2 F R mol-% Ethane: fraction in AGA-10 equation
AW-22 norm. propane 8048 2 F R mol-% Propane: fraction in AGA-10 equation
AW-23 norm. iso-butane 8060 2 F R mol-% I-Butane: fraction in AGA-10 equation
AW-24 norm. n-butane 8062 2 F R mol-% N-Butane: fraction in AGA-10 equation
AW-26 norm. iso-pen- 8064 2 F R mol-% I-Pentane: fraction in AGA-10 equation
tane
AW-27 norm. n-pentane 8066 2 F R mol-% N-Pentane: fraction in AGA-10 equation
AW-29 norm. oxygen 8058 2 F R mol-% Oxygen: fraction in AGA-10 equation
AW-30 norm. helium 8078 2 F R mol-% Helium: fraction in AGA-10 equation
AW-31 norm. hydrogen 8054 2 F R mol-% Hydrogen: fraction in AGA-10 equation
AW-32 norm. argon 8080 2 F R mol-% Argon: fraction in AGA-10 equation
AW-33 norm. nitrogen 8042 2 F R mol-% Nitrogen: fraction in AGA-10 equation
AW-34 norm. CO2 8044 2 F R mol-% Carbon dioxide: fraction in AGA-10
equation
AW-35 norm. n-hexane 8068 2 F R mol-% N-Hexane: fraction in AGA-10 equation
AW-36 norm. n-heptane 8070 2 F R mol-% N-Heptane: fraction in AGA-10 equation
AW-37 norm. n-octane 8072 2 F R mol-% N-Octane: fraction in AGA-10 equation

AW-38 norm. n-nonane 8074 2 F R mol-% N-Nonane: fraction in AGA-10 equation

AW-39 norm. n-decane 8076 2 F R mol-% N-Decane: fraction in AGA-10 equation
AW-40 norm. H2S 8052 2 F R mol-% Hydrogen sulfide: fraction in AGA-10
equation
AW-41 norm. water 8050 2 F R mol-% Water: fraction in AGA-10 equation 239
AW-42 norm. CO 8056 2 F R mol-% Carbon monoxide: fraction in AGA-10
equation
AGA-10 Config

AX-01 SoS calc source 8100 1 M F Source gas analysis for AGA-10
0x0000 OFF (d)
0x0001 SET VALUE
0x0002 default air
0x0003 serial port 2
AX-02 SoS source temp. 8101 1 M F Source temperature for AGA-10
0x0000 SoS default (d)
0x0001 USE09
AX-03 SoS source press. 8102 1 M F Source pressure for AGA-10
0x0000 SoS default (d)
0x0001 USE09
AX-04 SoS temp. default 8104 2 F F → Units: Temp. Default value temperature for AGA-10
AX-05 SoS press. default 8106 2 F F → Units: Pressure a Default value pressure for AGA-10
AX-06 relative humidity 8108 2 F F % Relative humidity
AX-07 timeout max. 8110 1 I F min Timeout time for new analysis (except
default)
AX-08 RMGBus mode 8111 1 M F Selection 24 or 9 gas components via
RMGBus
0x0000 RMGBus 24 (d)
comp.
0x0001 RMGBus
AX-09 stream number 8112 1 M F Selection of the stream with RMGBus
0x0000 without indi- (d)
cation
0x0001 stream 1
0x0002 stream 2
0x0003 stream 3
0x0004 stream 4
AX-10 Modbus master 8113 1 M F Target for Modbus master
target
0x0000 RMG GC9300 (d)
0x0001 custom 1
AX-11 set gas comp. 8350 1 M F Set new components
0x0000 gas comp. are (d)
set

0x0001 set new

comp.
AX-20 default methane 8140 2 F F mol-% Methane: default value
AX-21 default ethane 8142 2 F F mol-% Ethane: default value
240 AX-22 default propane 8144 2 F F mol-% Propane: default value
AX-23 default iso-bu- 8146 2 F F mol-% iso-Butane: default value
tane
AX-24 default n-butane 8148 2 F F mol-% n-Butane: default value
AX-25 default neo-pen- 8150 2 F F mol-% neo-Pentane: default value
tane
AX-26 default iso-pen- 8152 2 F F mol-% iso-Pentane: default value
tane
AX-27 default n-pentane 8154 2 F F mol-% n-Pentane: default value
AX-28 default hexane+ 8156 2 F F mol-% Hexane+: default value
AX-29 default oxygen 8158 2 F F mol-% Oxygen: default value
AX-30 default helium 8160 2 F F mol-% Helium: default value
AX-31 default hydrogen 8162 2 F F mol-% Hydrogen: default value
AX-32 default argon 8164 2 F F mol-% Argon: default value
AX-33 default nitrogen 8166 2 F F mol-% Nitrogen: default value
AX-34 default CO2 8168 2 F F mol-% Carbon dioxide: default value
AX-35 default n-hexane 8170 2 F F mol-% n-Hexane: default value
AX-36 default n-heptane 8172 2 F F mol-% n-Heptane: default value
AX-37 default n-octane 8174 2 F F mol-% n-Octane: default value
AX-38 default n-nonane 8176 2 F F mol-% n-Nonane: default value
AX-39 default n-decane 8178 2 F F mol-% n-Decane: default value
AX-40 default H2S 8180 2 F F mol-% Hydrogen sulfide: default value
AX-41 default water 8182 2 F F mol-% Water vapour: default value
AX-42 default CO 8184 2 F F mol-% Carbon monoxide: default value
AX-43 default ethene 8186 2 F F mol-% Ethene: default value
AX-44 default propene 8188 2 F F mol-% Propene: default value
AX-45 sum of def. comp. 8190 2 F R mol-% Sum of default values
AX-92 MB_Pause 8980 1 I F s Modbus-master pause
AX-93 MB_Timeout 8981 1 I F ms Modbus-master time outs
AX-94 MB_Int16Order 8982 10 T F Int16 order
AX-95 MB_Int32Order 8992 10 T F Int32 order
AX-96 MB_FloatOrder 9002 10 T F Float32 order
AX-97 MB_DoubleOrder 9012 10 T F Float64 order

Gas Comp. RMGBus

AY-20 methane 8300 2 F F mol-% RMGBus/Modbus value methane
AY-21 ethane 8302 2 F F mol-% RMGBus/Modbus value ethane 241
AY-22 propane 8304 2 F F mol-% RMGBus/Modbus value propane
AY-23 iso-butane 8306 2 F F mol-% RMGBus/Modbus value iso-butane
AY-24 n-butane 8308 2 F F mol-% RMGBus/Modbus value n-butane
AY-25 neo-pentane 8310 2 F F mol-% RMGBus/Modbus value neo-pentane
AY-26 iso-pentane 8312 2 F F mol-% RMGBus/Modbus value iso-pentane
AY-27 n-pentane 8314 2 F F mol-% RMGBus/Modbus value n-pentane
AY-28 hexane+ 8316 2 F F mol-% RMGBus/Modbus value hexane+
AY-29 oxygen 8318 2 F F mol-% RMGBus/Modbus value oxygen
AY-30 helium 8320 2 F F mol-% RMGBus/Modbus value helium
AY-31 hydrogen 8322 2 F F mol-% RMGBus/Modbus value hydrogen
AY-32 argon 8324 2 F F mol-% RMGBus/Modbus value argon
AY-33 nitrogen 8326 2 F F mol-% RMGBus/Modbus value nitrogen
AY-34 CO2 8328 2 F F mol-% RMGBus/Modbus value carbon dioxide
AY-35 n-hexane 8330 2 F F mol-% RMGBus/Modbus value n-hexane
AY-36 n-heptane 8332 2 F F mol-% RMGBus/Modbus value n-heptane
AY-37 n-octane 8334 2 F F mol-% RMGBus/Modbus value n-octane
AY-38 n-nonane 8336 2 F F mol-% RMGBus/Modbus value n-nonane
AY-39 n-decane 8338 2 F F mol-% RMGBus/Modbus value n-decane
AY-40 H2S 8340 2 F F mol-% RMGBus/Modbus value hydrogen sulfide
AY-41 Water 8342 2 F F mol-% RMGBus/Modbus value water vapour
AY-42 CO 8344 2 F F mol-% RMGBus/Modbus value carbon monox-
ide
AY-43 ethene 8346 2 F F mol-% RMGBus/Modbus value ethene
AY-44 propene 8348 2 F F mol-% RMGBus/Modbus value propene
AY-45 sum of gas comp. 8351 2 F R mol-% Sum of components via Modbus/RMG-
Bus
AY-46 telegram counter 8126 1 I R Counter for new gas component trans-
fers
AY-47 RMGBus status 8127 1 M R Last valid status
0x0000 revision
0x0001 calibration
0x0002 analysis
0x0003 revision error
0x0004 calibration er-
ror
0x0005 analysis error
0x0006 invalid
AY-48 RMGBus stream 8128 1 I R Stream number of the last telegram
AY-49 MB timeouts 8129 1 I R Number of modbus-master time outs

AY-50 Modbus errors 8130 1 I R Number of Modbus master telegram er-

rors
AY-51 Modbus error reg. 8131 1 I R MB register of the last error
AY-52 Modbus error 8132 1 I R MB register of the last error
242 resp.
AY-53 MB_NAN_Coun- 9022 1 I R MB register of the last error
ter
AY-54 MB_SyntaxError 9023 10 T R Modbus master syntax error coordinate
AY-55 MB_ErrorBits 9033 2 L R hex Int. Modbus master error bits
AY-56 MB_InStatus 9035 1 I F Modbus master status input
Gas Comp. Modbus

AZ-01 Formula methane 8440 10 T S Formula methane
AZ-02 Formula methane 8450 10 T S Formula methane
AZ-03 Formula ethane 8460 10 T S Formula ethane
AZ-04 Formula ethane 8470 10 T S Formula ethane
AZ-05 Formula propane 8480 10 T S Formula propane
AZ-06 Formula propane 8490 10 T S Formula propane
AZ-07 Formula i-butane 8500 10 T S Formula i-butane
AZ-08 Formula i-butane 8510 10 T S Formula i-butane
AZ-09 Formula n-butane 8520 10 T S Formula n-butane
AZ-10 Formula n-butane 8530 10 T S Formula n-butane
AZ-11 Formula neo-pen- 8540 10 T S Formula neo-pentane
tane
AZ-12 Formula neo-pen- 8550 10 T S Formula neo-pentane
tane
AZ-13 Formula i-pentane 8560 10 T S Formula i-pentane
AZ-14 Formula i-pentane 8570 10 T S Formula i-pentane
AZ-15 Formula n-pen- 8580 10 T S Formula n-pentane
tane
AZ-16 Formula n-pen- 8590 10 T S Formula n-pentane
tane
AZ-17 Formula hexane+ 8600 10 T S Formula hexane
AZ-18 Formula hexane+ 8610 10 T S Formula hexane
AZ-19 Formula oxygen 8620 10 T S Formula oxygen
AZ-20 Formula oxygen 8630 10 T S Formula oxygen
AZ-21 Formula helium 8640 10 T S Formula helium
AZ-22 Formula helium 8650 10 T S Formula helium
AZ-23 Formula hydrogen 8660 10 T S Formula hydrogen
AZ-24 Formula hydrogen 8670 10 T S Formula hydrogen
AZ-25 Formula argon 8680 10 T S Formula argon
AZ-26 Formula argon 8690 10 T S Formula argon
AZ-27 Formula nitrogen 8700 10 T S Formula nitrogen

AZ-28 Formula nitrogen 8710 10 T S Formula nitrogen

AZ-29 Formula CO2 8720 10 T S Formula CO2
AZ-30 Formula CO2 8730 10 T S Formula CO2
AZ-31 Formula hexane 8740 10 T S Formula hexane
243
AZ-32 Formula hexane 8750 10 T S Formula hexane
AZ-33 Formula heptane 8760 10 T S Formula heptane
AZ-34 Formula heptane 8770 10 T S Formula heptane
AZ-35 Formula octane 8780 10 T S Formula octane
AZ-36 Formula octane 8790 10 T S Formula octane
AZ-37 Formula nonane 8800 10 T S Formula nonane
AZ-38 Formula nonane 8810 10 T S Formula nonane
AZ-39 Formula decane 8820 10 T S Formula decane
AZ-40 Formula decane 8830 10 T S Formula decane
AZ-41 Formula H2S 8840 10 T S Formula H2S
AZ-42 Formula H2S 8850 10 T S Formula H2S
AZ-43 Formula water 8860 10 T S Formula water
AZ-44 Formula water 8870 10 T S Formula water
AZ-45 Formula CO 8880 10 T S Formula CO
AZ-46 Formula CO 8890 10 T S Formula CO
AZ-47 Formula ethene 8900 10 T S Formula ethane
AZ-48 Formula ethene 8910 10 T S Formula ethane
AZ-49 Formula propene 8920 10 T S Formula propene
AZ-50 Formula propene 8930 10 T S Formula propene
AZ-51 Formula status 8940 10 T S Formula status
DSfG Instance-F

BA-01 DSfG error 9086 1 I R DSfG Error (0000 if no error)
BA-02 vol. flow rate Qm 32768 2 F R m3/h Volume flow (pos. FD1, neg. FD2)
BA-03 Gas velocity 32770 2 F R m/s Velocity of Gas (pos. FD1, neg. FD2)
BA-04 SoS 32772 2 F R m/s Speed of Sound
BA-05 Gas volume sum 32774 2 L R → Unit LF-Volumes Volume of Gas total Flow direction 1
d.1 (V_tot_d1=Vm_d1+Vm_err_d1)
BA-06 Gas volume sum 32776 2 L R → Unit LF-Volumes Volume of Gas total Flow direction 2
d.2 (V_tot_d2=Vm_d2+Vm_err_d2)
BA-07 Gas vol no err d.1 32778 2 L R → Unit LF-Volumes Volume of Gas undisturbed Flow direc-
tion 1 (Vm_d1)
BA-08 Gas vol no err d.2 32780 2 L R → Unit LF-Volumes Volume of Gas undisturbed Flow direc-
tion 2 (Vm_d2)

BA-09 Gas vol error d.1 32782 2 L R → Unit LF-Volumes Volume of Gas disturbed Flow direction
1 (Vm_err_d1)
BA-10 Gas vol error d.2 32784 2 L R → Unit LF-Volumes Volume of Gas disturbed Flow direction
2 (Vm_err_d2)
BA-11 Valence 32786 2 L R Valency
244
BA-12 Flow > Qt 32788 2 L R Flow bigger Qt (0 = no, unequal 0 = yes)
BA-13 Signal acceptance 32790 2 L R % Signal acceptance
BA-14 Meter error 32792 2 L R Meter disturbed (0 = no, unequal 0 =
yes)
BA-15 Number of Paths 32794 2 L R Number of Paths
BA-16 SoS deviation P1 32796 2 F R % Speed of Sound deviation Path 1
(SoS_1_dev = (SoS_1-SoS)/SoS*100)
BA-24 Path velocity vc1 32896 2 F R m/s Velocity of Gas Path 1
BA-25 SoS P1 32898 2 F R m/s Speed of Sound Path 1
BA-26 Signal acceptance 32900 2 F R % Signal acceptance Path 1
P1
BA-27 SNR P1 AB 32902 2 F R dB Signal-Noise-Ratio AB Path 1
BA-28 SNR P1 BA 32904 2 F R dB Signal-Noise-Ratio BA Path 1
BA-29 AGC-level P1 AB 32906 2 F R dB Automatic gain AB Path 1
BA-30 AGC-level P1 BA 32908 2 F R dB Automatic gain BA Path 1
BA-31 Path velocity vc2 32912 2 F R m/s Velocity of Gas path 2
P2
P3


P4
245
P5
P6
P7
BA-69 SNR P7 AB 32998 2 F R Signal-Noise-Ratio AB Path 7
P8

16 USM GT400 Approval

In this section, you will receive information in which fields of application the device
246 is approved. The standards, guidelines and regulations are also listed which are
applied for the development and manufacturing.
16.1 Metrological approvals

The device has the following approvals:
• MID approval (DE-14-MI002-PTB002)
• MC type approval (metrological approval of Measurement
Canada, AG-0622)
16.2 Pressure devices approval
• PED 2014/68/EU /
EU-type examination certificate (Module B)
ISG-22-14-1630
• ASME B31.3 Ed.2012
• CRN
16.3 Electromagnetic compatibility
• FS-1312-249580-001
• FS-1312-249585
16.4 Explosion protection approval
• ATEX (BVS 14 ATEX E 034X)

• IECEx (BVS 14.0029X)
• CSA (NA) C22.2 No 0.-M91, 30-M1986, 142-M1987

16.5 Standards, directives and guidelines

We, RMG Messtechnik GmbH, herewith declare that due to its design and
construction in the version brought onto the market the devices described in this
247
operating instruction conforms to the relevant fundamental health and safety re-
quirements of the applicable EC Directive.
In the event of a modification of the device is not authorized by us, this declaration
shall be rendered void.
EC guidelines
2014/68/EU EC Pressure Equipment Directive
2014/30/EU Electromagnetic Compatibility
2014/34/EU ATEX Operational Directive.
2014/32/EU MID - Measuring Instrument Directive.
2011/65/EU RoHS
Applied harmonized standards
DIN ISO 8434-1 Metallic tube connections.

(DIN 2353)
DIN ISO 17089 Measurement of fluid flow in closed conduits.
DIN EN 334:2009-07 Gas pressure regulators for inlet pressures up to 100 bar
DIN EN 14382 Safety devices for gas pressure regulating stations and installa-
tions - Gas safety shut-off devices for inlet pressures up to 100
bar
DIN IEC 60529:A1 IP protection categories.
OIML R137-1&2 1. Metrological and technical requirements.

2. Metrological controls and performance tests.
OIML R137-3 OIML Report format for type evaluation.
DIN EN and Explosive atmospheres

IEC/EN 60079-0

DIN EN and Explosive atmospheres - Part 1: Equipment protection by flame-

IEC/EN 60079-1 proof enclosures "d"
248 DIN EN and Explosive atmospheres - Part 7: Equipment protection by flame-

IEC/EN 60079-7 proof enclosures "e"
CAN C22.2 No. 30 Explosion-Proof Enclosures for Use in Class I Hazardous Loca-
tions
UL 1203 Explosion-Proof and Dust- Ignition-Proof Electrical Equipment for

Use in Hazardous Locations
USA Directives
ASME B31.3 Pressure safety

Ed. 2012
AGA report No. 9 Measurement of Gas by Multipath Ultrasonic Meters.
AGA report No. 10 Speed of Sound in Natural Gas and Other Related Hydrocarbon
Gases.
Canada Directives
PS-G-06 Provisional Specifications for the Approval, Verification, Reverifi-

cation, Installation and Use of Ultrasonic Meters.
G-16 Recognition of Test Data From Gas Meter Test Facilities.
S-EG-05 Specifications for the Approval of Software Controlled Electricity

and Gas Metering Devices.
S-G-03 Specifications for Approval of Type of Gas Meters and Auxiliary

Devices - Amendments to Measurement Canada Specification
LMB-EG-08.
S-EG-06 Specifications Relating to Event Loggers for Electricity and Gas

Metering Devices.
GEN-40 Application and Implementation of Measurement Canada's Spec-

ifications for the Approval of both Software Controlled Electricity
and Gas Meters and Event Loggers.
CRN Canadian Registration Number

17 USM GT400 Glossary
17 USM GT400 Glossary

In this chapter you will be given information on terminology.
249
Ultrasonic gas meter (USM)
The flow of the gas is measured at different levels with ultrasonic transducers.
Ultrasonic electronics (USE)

The ultrasonic electronics are mounted on the ultrasonic gas meter. The ultrasonic
electronics evaluate the data recorded by the sensors. The parameters can be dis-
played and evaluated on a computer with the USM software.
Plot
Graphic display of one or more measured values.
Meter
In der Software wird der Ultraschallzähler zum Teil als Messwerk bezeichnet.
Device
In the software the ultrasonic gas meter is sometimes called a meter.
Transducer
The transducer or sensor is built into the device. The transducer sends the oppos-
ing transducer an ultrasonic signal. Using the time measured for the ultrasonic
signal to travel the distance between the two transducers, the ultrasonic electron-
ics calculates the gas flow. 12 transducers are built into the device. They are dis-
tributed across three levels with four transducers on every level. Per level two
paths measure the gas flow. A path comprises two opposing transducers.
In the manual the transducer is called a sensor.
Sensor
Transducer
Meter
Ultrasonic gas meter (USM)


You will find the declaration of conformity and approvals of the device in this sec-
250 tion.

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

Contact
Technische Änderungen vorbehalten
Weitere Informationen
Wenn Sie mehr über die Produkte und
Lösungen von RMG erfahren möchten,
besuchen Sie unsere Internetseite:
www.rmg.com
oder setzen Sie sich mit Ihrer lokalen
Vertriebsbetreuung in Verbindung

Otto-Hahn-Straße 5
35510 Butzbach, Deutschland
Tel: +49 (0) 6033 897 – 0
Fax: +49 (0) 6033 897 – 130
Email: [email protected]

Tel: 55 53658200, 63645537
1.6.3 Manual de Software

Operating Instruction
RMGViewUSM
Firmware: 5.0
State: 2021, February 11th
Version: 05 EN
Contact
Manufactorer Contact our customer service department for technical

information:

Otto-Hahn-Straße 5
D-35510 Butzbach
Main office +49 6033 897 – 0
Service +49 6033 897 – 0
Spare parts +49 6033 897 – 173
Fax +49 6033 897 – 130
E-mail [email protected]
Original document The RMGViewUSM_manual_en_05 for the

USM-GT400 from 2020, April 27th is a translation of the
original German manual. Anyhow, this document may
serve as reference for translations into other languages.
Please use in case of any uncertainties the German ver-
Remark sion as main reference.
Note Unfortunately, paper is not updated automatically,

whereas technical development continuously advances.
Therefore, we reserve the right to make technical
changes in regard to the representations and specifica-
tions of these operating instructions. The latest version
of this manual (and the one of other devices) can be
downloaded at your convenience from our Internet page:
www.rmg.com
Creation date January 2014

…
2nd revision September 2017
3rd revision Juni 2017
4th revision 2020, April 27th
Document version Document version RMGViewUSM_manual_en_05

and language 2020, April 27th
Language EN
Operating Instruction RMGViewUSM · EN05 · 2021 February 11th

Contents
Contents
1 GENERAL ..................................................................................... 1
1.1 Motivation for the software .......................................................................1
1.2 About this manual ......................................................................................2
I
1.2.1 Trade mark ..................................................................................................2
1.2.2 Objective of the manual .............................................................................3
1.2.3 Prerequisite knowledge required .............................................................3
1.2.4 Structure of notes ......................................................................................3
1.2.5 Abbreviations used ....................................................................................4
1.2.6 Symbols used .............................................................................................4
1.2.7 Validity ........................................................................................................4
2 INSTALLATION ............................................................................ 5
2.1 System requirements .................................................................................5
2.2 Files delivered ............................................................................................5
2.3 Preparing devices for connection ............................................................6
2.4 Installing software ......................................................................................7
2.5 Configuring the site and devices ..............................................................9
2.5.1 Setting the language and start window .................................................13
2.5.2 Entering user data ....................................................................................16
2.6 Ensuring connection ...............................................................................18
2.7 Adding further devices to the site ..........................................................20
3 SOFTWARE OVERVIEW............................................................ 22
3.1 Operating and display elements .............................................................22
3.2 Standard buttons .....................................................................................26
3.3 Status icons ..............................................................................................27
3.4 User levels ................................................................................................29
3.5 Structure of the Software ........................................................................30
3.6 Data/readings/parameters .......................................................................34
3.7 Help function ............................................................................................35
3.8 File types ...................................................................................................36
Operating Instruction RMGViewUSM · EN 05 · 2021 February 11th

Contents
3.9 Password ..................................................................................................37

3.10 License ......................................................................................................37
4 SOFTWARE DESCRIPTION ...................................................... 38

4.1 Site overview ............................................................................................39
4.2 Dashboard ................................................................................................41
II
4.3 Values ........................................................................................................45
4.4 Lists ...........................................................................................................47
4.5 Plots ..........................................................................................................49
4.6 Raw data ...................................................................................................50
4.7 Logs ...........................................................................................................52
4.7.1 USM history ..............................................................................................53
4.7.2 USM parameter log ..................................................................................54
4.7.3 USM event log ..........................................................................................55
4.7.4 Modbus messages ...................................................................................56
4.8 Errors ........................................................................................................57
4.9 Password input ........................................................................................58
4.10 Record data ..............................................................................................59
4.11 Edit list (Creating a new list) ...................................................................60
4.12 New user defined list: Select type ..........................................................61
4.13 Site specific, user defined list (Plot) ......................................................62
4.14 Color, line thickness ................................................................................64
4.15 Save plot as JPG image ...........................................................................65
4.16 Information on installation ......................................................................66
4.17 USM settings ............................................................................................67
4.17.1 Modbus tab ...............................................................................................68
4.17.2 Limits tab ..................................................................................................69
4.17.3 Register Card Advanced .........................................................................70
4.18 Log-Player .................................................................................................71
4.19 Inspection test ..........................................................................................72
4.20 Password list ............................................................................................81
4.21 User settings ............................................................................................82
4.22 Base line correction .................................................................................84

Contents
4.23 License info ..............................................................................................86

4.24 Process license ........................................................................................86
4.25 Report editor .............................................................................................86
5 OPERATION ............................................................................... 87
5.1 User settings ............................................................................................87 III
5.1.1 Login users ...............................................................................................87
5.1.2 User log out ..............................................................................................88
5.2 Adjusting the size of graphic contents ..................................................89
5.3 Working with windows ............................................................................90
5.3.1 User defined window configurations .....................................................90
5.3.2 Cloning windows ......................................................................................93
5.3.3 Closing RMGViewUSM ...............................................................................94
5.3.4 Close windows for a device ....................................................................95
5.4 Parametrize USM ......................................................................................95
5.5 Open folder user data ............................................................................100
5.6 Open folder APPDATA ...........................................................................101
5.7 Screen dump in jpg format ....................................................................102
5.8 Error- and warning messages ...............................................................103
5.9 Creating a log of a user action ..............................................................104
5.10 Creating a log on parameter change ....................................................106
6 TROUBLESHOOTING .............................................................. 107

6.1 cfg-file missing .......................................................................................107
6.1.1 cfg-file creation ......................................................................................107
6.2 Discontinuity in connection to the meter ............................................109
6.3 Display „RMGViewUSM is already running… “ .....................................109
6.4 Display „The file USE_112c.rmx … “ ....................................................110

1 General
1 General
In this chapter you will receive general information on the manual and on the de-
vice.
1
1.1 Motivation for the software
1 PC with RMGViewUSM 5 Devices for Site 1

2 Site 1 6 Devices for Site 2
3 Site 2 7 Devices for Site 3
4 Site 3
Figure 1: Application example
You can manage several sites with the RMGViewUSM software. For every site you
can include as many devices with their connection data as you wish. Using these
Modbus addresses, data can be read from the device and data can be transmitted
from the PC (1) to the device.

1 General
The example shows how three sites (2, 3, 4) can be managed with the
RMGViewUSM software. For every site, Modbus addresses are set up using
RMGViewUSM to enable a connection to the devices.
• For site 1 (2), two Modbus addresses (5) were set up to establish the con-
nection.
2 • For site 2 (3), one Modbus address (6) was set up.
• For site 3 (4), two Modbus addresses (7) were set up.
With RMGViewUSM you can:

• Set up and manage several sites.
• Assign several devices (USM) to a site and manage them.
• Read out the actual measured values (actual values) in real time.
• Display values in table form, as diagrams, as graphics or in individual fields.
• Request predefined lists that read out and show certain parameters from
the device.
• Request predefined plots that display the parameters in a diagram.
• Create user defined lists and output them as reports.
• Create user defined plots that display the parameters in a diagram.
• RMGViewUSM automatically recognizes the firmware of the attached device.
Only those parameters that are functional with the attached device are dis-
played
• Parameterize the attached device.
• Create test reports
1.2 About this manual

In this chapter you will receive information regarding the organization and objec-
tive of the manual and the knowledge prerequisites needed by the reader.
1.2.1 Trade mark

All the hardware and software names used in the manual may also be registered
trademarks of third parties or under other brand protection. In this respect, the
trade mark rights of third parties are to be respected.

1 General
1.2.2 Objective of the manual

The manual provides you with the information that is needed for trouble-free and
safe operation. The software is state of the art and conceived and programmed
according to the recognized safety standards and guidelines. However, hazardous
situations may arise as a result of their use. Possible hazards for:
• functions of the connected devices
3
For this reason, you may only operate the software as intended and in technically
defect-free condition.
1.2.3 Prerequisite knowledge required

The manual assumes that the users are familiar with Microsoft Windows operating
system and the operating elements, e.g. drop-down menus, buttons etc. MS Win-
dows typical screens e.g. Save As... and their operating elements are not de-
scribed in this manual.
1.2.4 Structure of notes

The following information screens are used in the manual:
Note
This warning screen informs you of potentially hazardous situations that

can occur as a result of incorrect operation or human error. If these situa-
tions are not avoided, they can result in material damage to the machine
or in the vicinity.
This information gives you tips on how to simplify your work. With this
screen, you additionally receive further information on the product or the
work process.

1 General
1.2.5 Abbreviations used

In this chapter of the manual, the abbreviations used are explained.
AGC Automatic Gain Control

ca. circa, approximately
4 as app. as applicable
max. maximum
MC Measurement Canada
MID Measurement Instruments Directive
min. minimum
SNR Signal Noise Ratio
SoS Speed of Sound (ultrasonic velocity)
TD Transducer
TNG Transducer of a certain type
USE Ultrasonic electronic
USM (USZ) Ultrasonic gas meter
e.g. For example
1.2.6 Symbols used

1, 2, … Steps within a work operation.
..
1.2.7 Validity
This manual describes the software RMGViewUSM.
The software RMGViewUSM is only a part of a complete site system. Please also
observe the manuals of the other components of the site in order to guarantee
safe operation.

2 Installation
2 Installation
In this chapter you will be given information on the system requirements for the
PC, on the software installation and on making a connection to the device.
5
2.1 System requirements
The PC must fulfill following specification:
• Operating system Microsoft Windows 7 (32 Bit and 64 Bit) and Windows 10
(64 Bit)
• Min. screen resolution of 1024 × 768 pixel
• A converter that converts the signal for RS 232 / RS 485 is required for USB
or COM interfaces.
• For the conversion “Modbus over IP“ a converter is required, too.
2.2 Files delivered
Figure 2: Files delivered

2 Installation
You will receive various files on delivery of the RMGViewUSM software. As an ex-
ample, the installation files and the associated rmx files in RMGViewUSM 5.0 ver-
sion are shown.
6
2.3 Preparing devices for connection
During installation, information on the COM port or the IP address will be required
in order to make a connection between the software and the ultrasonic electronics.
1 PC with RMGViewUSM 4 USM-GT400

2 IP Address 5 USE (Electronic on the USM-GT400)
3 COM Interface (RS485 / RS232)
Figure 3: Connection scheme
The following connection options to the USE are available to you:

• Connection via a serial COM port (RS 485/RS 232) on the PC.
PC (1) and USE (5) are connected with a cable.
• Connection via IP address.
For this the PC is connected to the Internet.
Determine the connection data
1.) Determine the IP address of the USE respectively the name of the COM
port on the PC.

2 Installation
2.4 Installing software

Note
In order to install the new version of RMGViewUSM it is not necessary to
uninstall the older version.
7
Starting Installation
1. Double click here on the installation file e.g.

RMGViewUSM installer xxx.exe.
The window RMGViewUSM X.X Setup opens.
Figure 4: Agree to license contract
You must read the license contract and agree to it in order to continue with the in-
stallation.
2. Check the box I agree to the terms and conditions of the license con-
tract.
3. Click the Install button.
The status of the installation is shown by an animated time bar.

The successful installation is displayed in the RMGViewUSM xxx Setup window.

2 Installation
Figure 5: Finish installation
4. Click „Finish“.
The installation is then completed.
Connect PC
1. Connect the PC with the IP address of the device via the network.
or
Connect the USE cable to the COM port on the PC.
COM port: see the operating instructions USM-GT400
Connection via cable
Use the following cable:

• Twisted pair and shielded cable
• maximum length 500 m
• Type LiYCX 2 × 2 × 0,75 mm2

2 Installation
2.5 Configuring the site and devices

Start RMGViewUSM
1. Press the Windows key on the keyboard.
2. Click menu entry RMGViewUSM
9
A start screen will be displayed.
Note
It is possible that the version and revision number may differ from that of
the figure shown.
Figure 6: Start screen
After the starting sequence the Select Site screen will be displayed.
With RMGViewUSM you may manage several sites.
You may install and monitor several devices at each site.

2 Installation
10
Figure 7: Select Site screen
Assigning site names
After starting RMGViewUSM a site is shown in the window Select Site with the title
New Site 1. You may give this site any name.
1. Click on New Site 1 with the right mouse.
The context menu is opened.

2. Click on the menu entry Rename and assign a name.
3. Confirm the name with Enter.
The window Select Site closes. The window USM Settings Modbus opens.

2 Installation
Using the context menu, you can start following actions:

• Menu entry New Folder: File sites in folders.
• Menu entry New Site: Create further sites.
• Menu entry Delete Site: Delete sites. The devices in the site are also de-
leted.
11
In this window you can create a first device and set up the connection. You have
two alternatives for creating a connection to the device. Connection via:
• IP address
• COM port on the PC
Setting up devices (Ultrasonic gas meter)
Figure 8: USM settings window: Modbus

2 Installation
1. Select the device to which you want to create a connection. Rename the
device - if you require.
2. Enter the Modbus address with which the device should operate.
3. Define type of connection:
ⱱ⃞ IP address
12 ⇒ continue at step 4
⃞ COM interface
⇒ continue at step 5
For connections via IP Address

4. Enter the IP address of the USE
⇒ continue at step 8
Via COM port

5. Select value 38400 for the baud rate.
6. Select value 8N1 for Bits, Parity, Stop Bits.
7. Select COM port on the PC to which the USE is connected.
Finish set up
8. Click button Apply.
Note
If you want to create further connection data for a device, you will find in-
formation in chapter 2.7 Adding further devices to the site, p. 20
The window USM settings closes. The window Site Overview - RMGViewUSM
opens. Location and meter for the device are defined in this window.

2 Installation
2.5.1 Setting the language and start window

Activate the window for user options
1. Activate window Dashboard - All USMs.

(see chapter 4.1 Site overview, p. 39).
13
Figure 9: Menu entry select user settings
2. Click on menu Settings in the menu ribbon.

3. Click on menu entry User Settings.
The User Settings: User Interface menu bar opens.

2 Installation
Set language
14
Figure 10: Set language
1. Open drop-down menu Language and select the appropriate entry.

2. Click OK.
The settings are saved.
Set-up start screen
Note
You can define a window as start screen that is displayed after the soft-
ware is started. The windows that can be cued via the multifunction bar
can be selected. (see chapter 3.1 Operating and display elements, p. 22).

2 Installation
15
Figure 11: Set-up start screen
1. Open drop down menu Start with.. and select appropriate entry.
2. Click OK.

2 Installation
2.5.2 Entering user data

Open window for site information

16
Figure 12: Select menu entry Site Information
2. Click on menu Settings in the menu bar.

3. Click menu entry Site Information.
The Site information window opens.

2 Installation
Enter values
17
1. Complete fields Name, Client and Location.

(see chapter 4.16 Information on installation, p. 66).
2. Open drop-down menu Location and select appropriate entry.
3. You may choose an image that will be displayed at the protocol as a logo.
Press the button "..." and choose the appropriate image in the directories.
4. Click OK.

2 Installation
2.6 Ensuring connection

In the Site Overview you can view the connection status for the installed Modbus
addresses. Usually the connection can be realized without any problems.
18
Figure 14: Overview installation window
For a successful connection:

The connection status to the device is shown as (1).
The device is operating correctly. There are no errors..
A warning exists.
An alarm is pending.
There is an interruption between the PC and the device.
Open details on connection problem
You can find more information on the problem occurring in the window Errors.
(see chapter 4.8 Errors, p. 57).
1. Click Errors.
The window Errors opens. The list informs you about the actions for setting up
connections.

2 Installation
Open details on connection problem
You can find more information on the problem occurring in the window Errors.
(see chapter 4.8 Errors, p. 57).
Click the window Errors.
The window Errors opens. The list informs you about the actions for setting up 19
connections.
Fix connection problems

1. Check physical connections.
2. Check the Modbus address settings, if necessary, recreate Modbus ad-
dress.
3. If the connection problems still exist, contact RMG service.
(Contact see p. II)

2 Installation
2.7 Adding further devices to the site

You can add further devices to particular installation retroactively.
Open the window USM Settings

20 (see chapter 4.1 Site overview, p. 39).
2. Click on menu Settings in the menu bar.

3. Click menu entry USM Settings.
The window USM Settings opens.

2 Installation
Setting up additional devices (USM)
21
Figure 16: USM Settings window: Modbus
1. Click button aAdd.
An additional device will be shown in the list.

2. Enter the device data.
(see chapter 2.5 Configuring the site and devices, p. 9)

3 Software overview
3 Software overview
In this chapter you will be given detailed information regarding user interface ele-
ments as well as functions and operating capabilities of the software.
22
3.1 Operating and display elements
In this chapter you get an overview of the user interface for RMGViewUSM. You will
find the description of the individual windows and functions in chapter 4 Software
description, p. 38.
Figure 17: Dashboard window
Header
Figure 18: Header
The header shows the name of the window opened. The description of the window
can be found under this name in chapter "Description of the software". The content
of the header for some windows changes depending on the lists, plots or parame-
ters selected.

3 Software overview
Menu bar
Figure 19: Menu bar
The menu bar contains various menus with which the functions and windows can
be called up. Using the menus you can open following windows/functions: 23
• File
Clone opened window. Close window for a device. Open and save window ar-
rangement on the desktop. Open folder for APP data and user data. Close
RMGViewUSM.
• Reports
Conduct device check. Output test reports as log file. Open the parameter list and
the list of parameter changes. Depending on the license settings, there is the op-
tional function of creating user-defined logs or changing existing logs.
• Setting
Enter user information for the device. Show or hide the window Select Site for
software start. Set communication settings for the device, change or add a new
device for the selected site. Switch software to another language. Set start screen
for the software to start. Show or hide tool tips display. Show or hide macro names
for filtering certain data. Open the password list for the selected device, change,
create and delete. Change current license settings.
• Tools
Open the log player. The log player plays the recorded log files in real time. Pa-
rameterize the ultrasonic gas meter with opened calibration switch. Calculate a
characteristic curve correction for the values determined
• Help
Open the operating instructions as a PDF file. Open the RMG website. Request in-
formation on the software

3 Software overview
Multifunction bar
Figure 20: Multifunction bar
24
The multifunction bar comprises single buttons. Using these buttons you can ac-
cess following data:
• Site Overview
List of devices that are set up for the selected site.
• Dashboard
Request values and status of the selected device. The values are displayed in
graphic form (see chapter 4.2 Dashboard, p. 41).
• Values
Display parameter, readings or display values (see chapter 4.3 Values, p. 45).
• Lists
Request lists for one selected ultrasonic gas meter, for all ultrasonic gas meters or
for several particular ultrasonic gas meters (see chapter 4.4 Lists, p. 47).
• Plots
Request lists for one selected ultrasonic gas meter, for all ultrasonic gas meters or
for several particular ultrasonic gas meters. Open predefined or user defined plots.
Create and change user defined plots (see chapter 4.5 Plots, p. 49).
• Raw data
Request data from selected sensors. The data is displayed with the help of a plot
(graphic illustration of the values). Create an image file of the plots
(see chapter 4.6 Raw data, p. 50).
• Logs
Request list of actions, ParameterLog and EventLog, that are carried out via the
software (see chapter 4.7 Logs, p. 52).
• Errors
Request list of errors and warning messages that have occurred
(see chapter 4.3 Values, p. 45).

3 Software overview
• Password Input
Log into password-protected user level. (see chapter 4.9 Password input, p. 58).
25
Figure 21: Dashboard window
Ultrasonic gas meter preselection (1)

The information on the selected device such as live values, functions or parame-
ters are shown in the display area.
Display area (3)

The display area shows the contents of the windows that have been opened using
the multifunction bar.

3 Software overview
Status bar (2)

The status bar gives information on the current status of the selected device. Con-
nection to selected device, current readings and position of the service switch and
of the calibration switch. A percent display gives information on the actual utiliza-
tion of the device. The status for the code word of the device is displayed.
You may find possible symbols for the actual status here chapter 3.3 Status icons,
26 p. 27.
3.2 Standard buttons

The following buttons are a feature of many windows. Their functions are the same
in all windows.
Confirm the entered value. The values will be saved.
Cancel the current entry. The entered values will not be saved.
The current screen will be saved as a jpg file
Create a new, user-defined list or plot.
Delete user-defined list or plot.
Process user-defined list or plot.
Export data.
Import data.
Move an entry down a list.
Move an entry up a list.
Record values or list and stop recording.

3 Software overview
Refresh screen.
Clone window. The selected window will be opened a second time.
Enlarge view of plot.

27
Display plots in original size.
3.3 Status icons

The following icons are a feature of many windows. Their functions are the same
in all windows.
Calibration switch for ultrasonic electronics is closed. The parame-

ters of the ultrasonic electronics cannot be programmed.
Calibration switch for ultrasonic electronics is open. The parame-
ters of the ultrasonic electronics can be programmed.
The ultrasonic gas meter does not match the basic configuration of
the CFG file. The device cannot be used.
The ultrasonic gas meter matches the basic configuration of the
CFG file. The device can be used.
Connection between PC and the device is OK.
There is a discontinuity between PC and device.
The device is operating correctly. There is no warning.
A warning exists.
There is a defect.
The element (list or plot) is protected and cannot be changed.
The symbol is an attribute for lists or plots that are used by more
than one device.

3 Software overview
No password has been entered. Device is password-protected. Pa-

rameters that are protected by the password cannot be changed.
The password has been entered. Password-protected parameters
can be changed.
Service switch is locked. Only for RMG service.
28
Service switch is open. Only for RMG service.
The user level Monitor is active

See chapter 3.4 User levels, p. 29
The user level Operator is active.
The user level Configurator is active.
The user level Expert Mode is active
Performance display for correct measurements.

The performance display can be customized. You can define
the thresholds in percent below which a warning message or
a defect message will be displayed.

3 Software overview
3.4 User levels

To avoid incorrect operation the RMGViewUSM software is divided into different
user levels. These user levels are assigned to certain user groups.
Note
29
Not all the contents and functions of the RMGViewUSM are displayed for
every user group.
Only after you have entered a password for the user level the information
and functions for this user group are displayed and can be operated.
The description of the windows and menus indicates which user level is
enabled in the respective windows or menus
(see chapter 4 Software, p. 38).
The following user groups are assigned to the user level:
Monitor All user groups

No password required. This user level serves to display the contents of the win-
dows. The data cannot be processed.
Operator Operating personnel

Password for operator required. The operating personnel can create user-defined
lists, change parameters and delete user-defined lists.
Configurator Maintenance/setup personnel

Password required for Configurator. Set up all access rights and password for op-
erating personnel.
Expert mode Service personnel (from RMG)

Password for Expert Mode required. All access rights for operating personnel,
maintenance and setup personnel. In addition, the licenses can be managed.

3 Software overview
3.5 Structure of the Software

The following chart shows the structure of the RMGViewUSM software. Every field
represents a window.
30 Start screen
RMGViewUSM – Select Sites
USM Settings: Modbus
Start screen
e.g. Site Overview
Multifunction bar Menu bar

⇒ Figure 23: , p. 31
Figure 22: Structure of the software
Note
The start screen can be specified. The following windows can be selected
as start screen:
• Site Overview
• Dashboard
• Lists
• Plots
• Raw data
• Logs
• Errors
• Input Password
See chapter 2.5.1 Setting the language and start window, p. 13

3 Software overview
Multifunction bar
Site Overview
Dashboard 31
Values Record data
Lists ⇒ Figure 24: , p. 31
Plots ⇒ Figure 25: , p. 32
Raw data ⇒ Figure 26: , p. 32
Logs
Errors
Input Password
Figure 23: Structure of multifunction bar
Lists
Record data
Process list – Measuring
New user-defined list:

Process list
Select type
Figure 24: Structure of lists

3 Software overview
Plots
PlotsDefine a new plot
32 Export plot as file; resp. save as
Save plot as jpg image
User-defined list
Figure 25: Structure of plots
Raw data
Header data
Select raw data file
Save raw data as an image
Color, line width
Figure 26: Structure of raw data
Reports menu
Conduct check
Report editor
Figure 27: Structure of reports menu

3 Software overview
Menu settings
Site information
USM Settings: Modbus 33
Password list
User settings: User interface
Manage license
Figure 28: Structure of menu settings
Tools menu
Log - Player
Characteristic curve correction)
Figure 29: Structure of tools menu
Help menu
Software manual as PDF
RMG website
Info
Figure 30: Structure of help menu

3 Software overview
3.6 Data/readings/parameters
The data/readings/parameters are stored in a coordinate system. Via the coordi-
nates (letter for column and number for a row) data / readings / parameters can be
addressed. The data / readings / parameters can be opened using the ultrasonic
electronics display or with the software RMGViewUSM and can be selected for
tasks such as user-defined lists
34 (see chapter 4.13 Site specific, user defined list (Plot), p. 62).
Example Parameter structure
Figure 31: Structure of a parameter
As a rule, parameters are structured as follows:

• Associated USM (1), e.g. 910302.
• Coordinates of the parameter (2), e.g. H-1.
• Name of the parameter (3), e.g. for base value.
• Value that the parameter should read out or specify (4), e.g. 122.527.
• Assignment of the unit (5), e.g. m3/h.
• Assignment to the Modbus address (6), e.g. 6248.

3 Software overview
3.7 Help function
35
Figure 32: Help menu
1. Using the Help menu, you receive following information:

• Details of the software version and the license number
(see chapter 4.23 License info, p.86)
• Software manual as PDF-file
• Website www.rmg.com

3 Software overview
3.8 File types

The following table describes the file types (file suffixes) that are needed to work
with the RMGViewUSM software.
CSV List with recorded values of parameters, events or plots: The list can
36 be imported for processing in a spreadsheet program.
RPR File contains a template for generating PDF files.
RMW Stored screen configurations. After this file has been opened the
screens will be arranged according to the settings of this file.
CFG The file stores the configuration of an ultrasonic gas meter. Based on
CFG files, differences to start configuration can be identified.
RMX Software system file. RMGViewUSM.
EXE Executable files
HTML Output format for a RPR file, can be opened in any browser.
PDF Output format for a RPR file, reports, graphic representation of read-
ings (plots) or test certificate. This file can be opened by every PDF
viewer.
JPG Image file for graphics of readings (plots).
BIN Output file for the raw data of the sensors. Recording of the signals,
without any changes, from the ultrasonic electronics.
XML File stores the RMGViewUSM settings, e.g. language settings, screen
configuration.

3 Software overview
3.9 Password
With a password you will be given access to protected user levels in the software
RMGViewUSM. On delivery of the software RMGViewUSM, you will have received a
password from RMG for every protected user level.
Note 37
Should the passwords no longer be available, then request these from the
RMG service (contact see p. II).
The user with the password to the user level Configurator can generate pass-
words with user level assignment (see chapter 4.20 Password list, p. 81).
3.10 License
Mit Hilfe der Lizenz können Sie die Funktionen des Protokoll-Editors, Kennlinien-
korrektur und Header-Daten der Rohdaten freischalten. Mit dem Protokoll-Editor
können Sie Protokolle nach eigenen Bedürfnissen zusammenstellen.
With the help of the license you can enable the functions of the report editor, char-
acteristic curve correction and header data for the raw data. With the report editor
you can compile reports according to your requirements.
Note
Training by RMG is required for working with the report editor

(contact see p. II).
As an alternative RMG offers the service of creating client-specific reports.

4 Software description
This chapter contains information on fields, sectors and other contents of the win-
dows. Operating system windows, e.g. Save as are not described.
You will find following information with respect to the windows

38
• Name of the window.
• Details on the window path.
• Illustration of the window.
• General description of the window's functions.
• Field elements in the window.
Depending on the user level certain contents and functions of RMGViewUSM are
displayed or hidden (see chapter 3.4 User levels, p. 29).
Note
The RMGViewUSM software offers the possibility to create, organize and
present data and parameters (and additionally calculated parameters) of
the USM-GT400 and USZ08 ultrasonic gas meters.
• Note that certain parameter settings may change the measuring be-
havior of ultrasonic gas meters.
• Since usually Ultrasonic gas meter and RMGViewUSM are used to-
gether it will not be distinguished between individual parameters of
this units

4.1 Site overview

RMGViewUSM > Select Site > Site Overview
39
Figure 33: Site Overview
In the window Site Overview you can manage the ultrasonic gas meter.
USM
Name of the ultrasonic gas meter. By clicking on an entry, you can switch to the
dashboard of the selected ultrasonic gas meter.
(see chapter 4.2 Dashboard, p. 41).
Status
Connection status between ultrasonic gas meter and RMGViewUSM
(see chapter 3.3 Status icons, p. 27).

Performance
Display of valid measurements in percent. Performance values <100 means inva-
lid measurements have occurred and have been discarded.
Flow
Volume flow rate per hour, e.g. cubic meters
40 • Positive value = Gas is flowing in the flow direction.

• Negative value = Gas is flowing against the flow direction.
Gas velocity
Velocity of the gas, e.g. meters per second.
SoS
Speed of Sound. Speed of the ultrasonic waves that are used to measure the gas
velocity.
Switches
Configuration options for following switches:
• Calibration switch
• Service switch
• Password for the PC (see chapter 3.3 Status icons, p. 27)

4.2 Dashboard
RMGViewUSM > Select Site > Dashboard
41
Figure 34: Dashboard
In the window Dashboard you can display the current measurement values of the
ultrasonic gas meter.
Status display
Symbols for the user-defined warning and alarm signals.
• SoS
• AGC
• SNR
• Profile = Profile indication
• Swirl = Angle of flow of the gas in a plane

• Configuration = Comparison of the parameters in the ultrasonic gas meter

with the parameters saved in the configuration file in the RMGViewUSM
(see chapter 3.3 Status icons, p. 27)
USM Electronics
Display for measuring errors or hitches in the ultrasonic gas meter:
42 • Electronics = Status display for the ultrasonic electronics.
o Grey = Ready for operation.
o Yellow = Ready for operation, measurement error recognized.
o Red = Not ready for operation.
• Path 1-6 =
Transducer's measurement paths for the gas flow. If errors occur on a path,
then these are displayed as status symbols in front of the path. If an error
occurs at a transducer, the transducer is highlighted in color:
o Blue = High enough portion of valid measurements.
o Yellow = Warning, portion of invalid measurements is too high.
o Red = Problem, component is not ready for function.
(see chapter 3.3 Status icons,p. 27)
Profile Indication
Profile for the flow distribution in the pipe. The optimum value (reference value) for
the symmetry is 1.0 and for the profile factor 1.1. and is displayed as a green dot.
Deviations from the optimum value are shown in the graphics with a connecting
line to a black dot. The red dashed borderline shows the limits for triggering of
alarm signals. The ultrasonic gas meters are delivered with the limit values preset.
The site-specific limits for warnings are set by RMG service.
Path & Transducer Statistics

Overview of the transducer's individual configurations and measurement values.
• Path = Number of the transducer path.
• Column with no name = Number of the transducers.
The transducers are numbered in the ultrasonic gas meter accordingly.
• AGC dB = Automatic Gain Control (Transducer's amplifier unit)
This is the value of the transducer's signal amplification in decibels.
• SNR dB = Signal Noise Ratio
This is the power ratio between signal and background noise in decibels.

• SoS m/s = Speed of Sound

SoS for the transducer signals in meters per second.
• Perf. % = Performance
Performance of the path is the portion of valid measurements in percent.
Performance values < 100 means invalid measurements have occurred and
have been discarded. The difference between 100 % and the percent value
displayed gives the error rate. 43
Path Velocity
Graphic display of the gas speed measured on the transducer paths. Two match-
ing paths, each give the gas speed for one of the three meter levels in the ultra-
sonic gas meter.
SoS
Graphic display of the speed of sound measured on the transducer paths.
Axial Velocity
Graphic display of the gas speed measured in the meter levels.
Tangential Velocity
Graphic display of the horizontal deviations measured to the gas's direction of flow
in meters per second.
Turbulence
Graphic display of the speed and the change of direction for the gas flow. A yellow
dashed line is the user-defined limit for warning signals. A red dashed line is the
user-defined limit for alarm signals.
Swirl angle
Graphic display of the horizontal deviations measured in degrees of an angle in re-
lation to the direction of gas flow. A yellow dashed line is the user-defined limit for
warning signals. A red dashed line is the user-defined limit for alarm signals.

Trend overview 1
44
Figure 35: Trend overview 1
Trend overview 2
Figure 36: Trend overview 2
The trend overview 1 in Figure 35: shows the temporal behavior of the speed of
the gas along the measuring path. This can be compared with trend overview 2 in
Figure 36: , that shows the SoS along the measuring paths.

Using the drop-down menu you may select predefined calculations and have these
values displayed in a (new) trend overview.
4.3 Values
RMGViewUSM > Select Site > Values 45
Figure 37: Values
In the Values window you can have the actual data, measured values and param-
eter displayed. The data measured values and parameter are read out via the
RMGViewUSM from the ultrasonic electronics.

Values
List with predefined data, measured values or parameter lists. The parameters as-
sociated can be displayed in the right-hand window area.
Filter
Filter panel for searching for data, measured values or parameters, e.g. frequency.
For the search you can enter keywords or parts of keywords but not use wildcards.
46
USM
Name of the ultrasonic gas meter.
Coordinate
Memory cell for the parameter in the device. The parameter is stored in a coordi-
nate system. A parameter can be addressed using the coordinates (letter for the
column, number for the row).
The parameter can be called up using the window Lists and selected for tasks
e.g. creating user-defined lists. (see chapter 4.4 Lists, p. 47).
Name
Description of the parameter to be measured.
Value, unit
Numerical value and unit of the parameter to be measured.
Modbus address
Address of the communication protocol between PC and ultrasonic gas meter.

4.4 Lists
RMGViewUSM > Select Site > Lists
47
Figure 38: Lists
In the window Lists you can, in the left-hand window sector, administer the prede-
fined and the user-defined lists with the system parameters contained. In the right-
hand window area, you can view the parameter in the selected list. With lists you
configure the parameter that are to be read out of the device.
Lists
Universal or site-specific list. A list can contain predefined or user-defined system
parameter:

• Universal = Universal lists are configured with parameters for all types of ul-
trasonic gas meters in a site.
• Site-specific = Site-specific lists are configured with parameters for a selec-
tion of certain types of ultrasonic gas meters in a site.
48
• Predefined lists are marked with the symbol of a locked padlock and cannot
be changed or deleted.
• User-defined lists are shown without a symbol and can be changed or de-
leted.
• Several meters in a list are marked with the multi-USM symbol.

o For universal parameters the symbol contains a list with values for all
ultrasonic gas meters of a site.
o For site-specific parameters the symbol contains a list with values for
all ultrasonic gas meters of a site.
Filter
Filter panel for searching for data, measured values or parameters, e.g. frequency.
For the search you enter keywords or parts of a keyword. You cannot use wild-
cards.
The columns are described in chapter 4.3 Values, p. 45

4.5 Plots
RMGViewUSM > Select Site > Plots
49
Figure 39: Plots
In the window Plots you can show the trend as a graphic of the readings listed.
Using the drop-down menu, you must first select the device for the measurements.
In the left window you can select a parameter, e.g. speed of sound. In the right-
hand window sector the values measured for the parameter can be listed and dis-
played in a trend graphic.
The button at the left bottom (1) allows you to set the plot as default when starting.
Using the diskette symbol (2) you can export a screenshot of the graphic dis-
played, as a jpg file (see chapter 4.15 Save plot as JPG image, p. 65).

4.6 Raw data

RMGViewUSM > Select Site> Raw Data
50
Figure 40: Raw data
In the window Raw Data, you can display the readings for the individual transduc-
ers or their paths. Two connected transducers form a measurement path.
Note
Please regard that here you have access to parameters of the USE and
may change them.
Transducer
In this window sector you can administer the parameters for the measurements.

Raw data type

Filtered display type of raw data. Raw data can be displayed graphically with and
without filtered values.
Only for RMG service personnel. If you have any questions or queries please con-
tact the RMG service personnel (contact see p. II).
Raw data function 51

Type of function in order to calculate raw data.
Only for RMG service personnel. If you have any questions or queries please con-
tact the RMG service personnel (contact see p. II).
Path 1, 2, 3, 4, 5, 6
Measuring path for ultrasonic transducers. Two paths represent a level of the total
of three levels for the measurements in the ultrasonic gas meter:
• Path 1+2 = Level 1.
⃞1
Transducer for measurements in the direction of flow.
Transducer 1+2 give the flow velocity of a path.
• ⱱ⃞ = Read values measured and display.
• ⃞ = No measured values read.
⃞2
Transducer for measuring against the direction of flow.
Transducer 1+2 give the flow velocity of a path.
• ⱱ⃞ = Read values measured and display.
• ⃞ = No measured values read.
Raw Data
In this window sector the values of the measurements and the corresponding
graphic illustrations can be displayed. Using the diskette symbol you can export a
screen shot of the graphic displayed, as a jpg file
(see chapter 4.15 Save plot as JPG image, p. 65).

4.7 Logs
RMGViewUSM > Select Site > Logs
In the window Logs you can manage all RMGViewUSM reports.
In the left window sector, you can select a protocol type:

52
• USM History = Overview of all reports created.
• USM Parameter Log = Reports of all changes to parameters.
• USM Event Log = Reports of all events that have occurred.
• Modbus Messages = Reports of the connection status.
In the right-hand window sector, the reports in the report types can be displayed.

4.7.1 USM history

The window USM History all reports created can be displayed.
53
Figure 41: USM History
Time
Time stamp of the device for which a protocol entry was created.
USM
Label of the device for which a protocol entry was created.
Operator
Name of the user who caused an event.
Event
Message for which a protocol entry was created.

4.7.2 USM parameter log

In the window USM Parameter Log you can display the reports for all parameters
of the selected device. You select the device using the drop-down menu in the up-
per left-hand corner.
54
Figure 42: Protocols of the parameters of the selected device
Time
Time stamp when a parameter change was logged.
Coordinates
Memory cell for the parameters in the device.
Name
Identifier of the parameter.
Old value
Value no longer currently valid.
New value
Currently valid value.

4.7.3 USM event log

In the window USM Event Log you can display the reports for all occurring events
of the selected device You select the device using the drop-down menu in the up-
per left-hand corner.
55
Figure 43: Protocols of the parameters of the selected device
Time
Time stamp when an event was logged.
Type
Type of event, e.g. error.
Info
Additional information on the event.

4.7.4 Modbus messages

In the window Modbus Messages you can display the messages of the status of
the communication protocol.
56
Figure 44: Messages to the status of the communication protocol
Time
Time stamp of the device for which a protocol was created.
USM
Time stamp of the ultrasonic gas meter for which a protocol was created.
Message
Messages on the status of the communication protocol.

4.8 Errors
RMGViewUSM > Select Site > Errors
57
Figure 45: Errors
In the window Errors you can display the warnings and error messages for the ul-
trasonic gas meter selected or for all ultrasonic gas meters.
USM
Message
Status display with messages about warnings and errors
(see chapter 3.3 Status icons, p. 27).

4.9 Password input

RMGViewUSM > Select Site > Multi-function Ribbon > User Symbol
58
Figure 46: Password Input
In the window Password Input you can log-in for a user level. Depending on the
user level you have extended access to RMGViewUSM. Depending on the user
level certain contents and functions of RMGViewUSM are displayed or hidden.
Radio button user groups

Radio button for selecting the user groups.
• Monitor
• Operator
• Configuration
• Expert mode
Further information on the possibilities of the user groups can be found in chapter
3.4 User levels, p. 29.
Password
Entry field for the password. As a default setting you may use the following pass-
words:
• configurator: RMGUSE-P
• expert: RMGUSE-E

4.10 Record data

RMGViewUSM > Select Site > Lists > Filled Circle
RMGViewUSM > Select Site > Values > Filled Circles
In the figures, which you may see if you activate one of two links above, a small
black circle on a light-grey square can be seen in the upper right corner. If you
click on it with the mouse, the following window is opening. 59
Figure 47: Record data
In the window Record Data, you can record the trend data and save it in a file.
File
Storage location and name of the file.
Time Base
Recording intervals of the trend values.
As soon as the entries in this field are confirmed with "OK", the recording starts.
This is indicated by changing the circle to a square. At the same time, a clock is
running, which indicates the duration of the recording.
By clicking on the square, the recording ends.

4.11 Edit list (Creating a new list)

RMGViewUSM > Select Site > Lists > Select List > Pencil Symbol
RMGViewUSM > Select Site > Lists > Plus Symbol > Select Type > OK Button
60
Figure 48: Edit list
In the window Edit List you can process the parameter lists for the ultrasonic gas
meters or create new ones. Using the parameter readings reports and mainte-
nance reports can be created. You can reuse the parameter lists for devices of the
same type.
The elements of the window are shown in chapter 4.13 Site specific, user defined
list (Plot), p. 62. In addition, following fields are displayed:

List name
Identifier for self-defined list.
Select Value
Select parameters for the self-defined list.
61
4.12 New user defined list: Select type

RMGViewUSM > Select Site > Lists > Symbol Plus
Figure 49: New User-Defined List: Select Type

In the window New User-Defined List: Select Type you can create a new param-
eter list. Using parameter lists the values measured in the device can be read out.
• Display values for the selected ultrasonic gas meter.
Type is universal:
List for the selected ultrasonic gas meter.
List of ultrasonic gas meters is selectable for all sites.
62 • Display values for all ultrasonic gas meters.
Type is universal:
List of all ultrasonic gas meters in a site.
List of ultrasonic gas meters is selectable for all sites.
• Display values for different, selectable ultrasonic gas meters.
Type is site-specific:
List for selected types of ultrasonic gas meters of a single site.
• Framed field:
Is only available for user level service personnel.
4.13 Site specific, user defined list (Plot)

RMGViewUSM > Select Site > Lists / Plots > Plus Symbol > Select Type > OK
Figure 50: User-defined list

In the window Edit List you can compile self-defined lists of parameters or meas-
urements or self-defined lists of parameter plots Trend overviews are created us-
ing the values read out for the parameters or the values measured. You can reuse
the parameter lists and parameter plots for devices of the same type.
Name of the plot

Label for plot.
63
Select USM
List of ultrasonic gas meters in the site.
Select value
Select parameters for the plot graphic.
Filter panel (search for values)

Text panel to filter the list of parameters.
Values in the plot
USM
Name
Parameter label for the plot.
Minimum
Minimum value for the parameter in the plot.
Maximum
Maximum value for the parameter in the plot.
Color
Name of the color for the graphic in the plot.
Line Thickness
Line thickness in pixels.
Values in the list
USM
Text
Parameter in the self-defined list.

4.14 Color, line thickness

RMGViewUSM > Select Site > Raw Data > Pencil Symbol
64
Figure 51 Color and line size selection
In the Color, Line Thickness window you can configure the graphic display of the
trend curves for individual ultrasonic paths.
Name
Name of the ultrasonic path.
Color
Specification of color.
Line Thickness
Line thickness in pixel.

4.15 Save plot as JPG image

RMGViewUSM > Select Site > Raw data > Diskette Symbol
RMGViewUSM > Select Site > Plots > Diskette Symbol
65
Figure 52: Save Plot as a jpg Image
In the window Save Plot as jpg Image you can export the current display as a jpg
image.
???? x ???? Pixels

Width x height of the image in pixels.

4.16 Information on installation

RMGViewUSM > Select Site > Settings > Site Information
66
Figure 53: Site information
In the window Site Information you can manage the information on the client and
the location of his site.
Name
Station name of the site.
Customer
Name of the customer.
Location
Location of the site.
Always use this site, Skip Site Selection

If you want to manage a single site, then – at the start of RMGViewUSM – you can
skip the window for Site Selection.
• ⱱ⃞ Skip the window RMGViewUSM – Select Site.
• ⃞ Open window RMGViewUSM – Select Site.

4.17 USM settings

RMGViewUSM > Select Site > Settings > USM Settings
67
Figure 54: USM Settings
In the window USM Settings: Modbus you can conduct the configuration of the
ultrasonic gas meters in the site using the tabs. In the left window sector you can
maintain the list of the ultrasonic gas meters (USM):
• Select USM
• Rename USM
• Delete USM
• Add USM
The tabs for the configuration settings for the ultrasonic gas meters (see chapter
4.17.1 Modbus, p. 68) and an overview of the limit values for warning and alarm
signals (see chapter 4.17.2 Limits tab, p. 68) are in the right window sector.
1. Import
This button can be used to import the configurations from a file.
2. Export
This button can be used to export the configurations to a file.

4.17.1 Modbus tab

RMGViewUSM > Select Site > Settings > USM Settings
68
Figure 55: USM Settings – Modbus
In this tab you configure the communications connection between RMGViewUSM

and ultrasonic gas meter.
Modbus Address
Address of the ultrasonic gas meter at the bus.
IP
Use connection via Internet protocol address of a network or a serial interface.
• ⱱ⃞ Use IP address for the connection (network cable).
• ⃞ Use serial port (e.g. RS485) for the connection (serial cable).
IP-Address
IP address, for the connection between ultrasonic gas meter and RMGViewUSM,
e.g. 192.168.100.125
IP-Port (mostly 502)

Port number of the RMGViewUSM service for the connection via the IP Address.

Baudrate
Transfer rate for serial communication.
Bits, Parity, Stop Bits

Parameter interface.
COM-Port
Name of the serial port for the connection between the ultrasonic gas meter and 69
RMGViewUSM.
Timeout
Time span until a communication attempt is dropped as an error.
Recommendation for connections:
• IP-Address = timeout of 500 ms (milliseconds).
• Serial Port = timeout of 50 ms (milliseconds).
4.17.2 Limits tab

RMGViewUSM > Select Site > Settings > USM Settings > Limits
Figure 56: USM Settings – Limits

Note
Note that you have access to USE parameters here and that you can vary
them. This means that the measuring behavior may clearly change.
70
4.17.3 Register Card Advanced

RMGViewUSM > Select Site > Settings > USM Settings > Register Card Advanced
Figure 57: USM Settings – Register Card Advanced
With the help of the check box you may selected here to create a reference data-
base for the selected device or not.
With “reset reference database“ an existing reference database can be deleted.
The reference database is used for the function "conduct test". It stores flow rate
dependent reference values.

4.18 Log-Player
RMGViewUSM > Select Site > Tools > Log Player
71
Figure 58: Log Player
In chapter 4.10 Record data, p. 59 was explained, how data logs can be recorded.
Using the Log Player you can display a data protocol. The Log Player has the
standard functions e.g. play, fast-forward and pause.

4.19 Inspection test

RMGViewUSM > Select Site > Protocols > Inspection Test
In "test protocol from log file" you can create a maintenance report from a log
file.
72
Figure 59: Inspection Test
Here you may set parameters for an USM inspection test.

Logfile
During the test, USM data are stored in a log file. There are two possibilities:
• Create a new log file.
RMGViewUSM suggests a directory path as well as a file name consisting of
the USM name and the current date. Also, to be set is:
o Duration of the logging process in seconds.
o Whether Cache or Live data of the USM should be used 73
• Use an existing file.
A former log file is used.
(There are not append of new data.)
Inspection report
A test of an USM is documented with an inspection report. To store the inspection
report name and directory path has to be defined. RMGViewUSM suggests a file-
name consisting of the USM name and the current date.
Reference
A USM test can be done against a reference. An internal database (flow rate de-
pendent) or an existing log file can be used for the reference data.
Source AGA10 SoS

There are the following possibilities to determine SoS, which is required for the in-
spection:
• Manual entry
The value of SoS is entered manually.
(You don‘t need to enter any gas data.)
• AGA10
RMGViewUSM calculates SoS based on gas data according to AGA10 rules.
Gas data may be entered in the window „AGA10 measurement values“.
• Calculated by USM
The gas data are taken from the USM, which calculates SoS according to
AGA10.
Extended settings
Further test settings are possible clicking the following buttons:
• Limits
• Transmitter calibration
• AGA10 readings
(The start of the test is carried out in this window!)

RMGViewUSM > Select Site > Protocols > Perform testing > limits
74
Figure 60: Inspection test: Limits
During USM testing all characteristic parameters are monitored. In this window
you can define possible deviations for each measured or calculated value, sepa-
rately as warning and alarm. The percentages given are the maximum deviations
from the current mean value. The turbulence is given in percent, too. The limits for
warning and alarm are absolute values here.

For "max. deviation Profile Factor" and "max. deviation Symmetry" the set point
has to be entered additionally.
RMGViewUSM > Select Site > Protocols > Perform testing > Transmitter calibra-
tion
75
Figure 61: Inspection test: Calibration

In this window you may enter the calibration data of the PGC pressure and tem-
perature transmitters. These will be displayed in the final test protocol, too.
RMGViewUSM > Select Site > Protocols > Perform testing > AGA10 readings
76
Figure 62: Inspection test: AGA10 readings

This window summarizes the default values for the SoS calculation according to
the AGA10. This relates to pressure, temperature and the gas components. The
default values for pressure and temperature can be entered directly, too. There
are also presets as defaults for the gas components.
77
For some known gases records already exist. These are marked with a lock sym-
bol (see left) that means they are protected and can‘t be changed.
The required data can be selected from a list. New components of a gas can be
entered if is chosen from empty.
Save the selected record under a new name. He is not generally protected and re-
quires amending the only active when you create access right.
Save the selected record under its previous name.
Delete the selected record, and remove from the list of existing records.
Rename the selected record.
• With the above-mentioned default values SoS can be calculated due to

AGA10. It is displayed in the window under "SOS AGA10".
• Directly under it appears the actual measured value from the USM “meas-
urement value USM“.
• Below the percental deviation of both values is displayed.
Using “AGA10-setting“ you‘ll have access to the related parameters..

RMGViewUSM > Select Site > Protocols > Perform testing > AGA10 readings >
AGA settings
78
Figure 63: Performing test: AGA10 setting
This window summarizes the settings for the SoS calculation due to AGA10.

Select the source for pressure and temperature.

• Read values from USM.
• Use the input values of RMGViewUSM.
Check and fix the units of these values.
Use the gas components 79

• Select the normalization method.
A requirement for the SoS calculation due to AGA10 is that the sum of all
gas components is exactly 100%. To ensure this the gas components are
automatically normalized. There are two possibilities:
o Pro-Rata method
o Normalize on C1
• Select the gas components ratio..
The ratio between hexane C6, heptane C7 and octane C8 have to be fixed.
There are 2 methods:
o The Components be read as independent readings from USM.
o The Components are in fixed relationship.
Three predefined combinations can be selected.
In the fourth combination of two components can be freely entered.
Standard selection for SOS

There are two possibilities to calculate SoS:
• AGA10
• ISO20765

RMGViewUSM > Select Site > Protocols > Perform testing > AGA10 readings >
Perform Testing
80
Figure 64: Inspection report
In the next figure you may see a part of a test protocol that is automatically gener-
ated after the test of the USM.

4.20 Password list

RMGViewUSM > Select Site > Settings > Manage Passwords
81
Figure 65: Password List
In the window Password List you can manage the user and passwords.
Name
User's name.
Password
Password character sequence.
Unnamed column
User level selection.

4.21 User settings

RMGViewUSM > Select Site > Settings > User Settings
82
Figure 66: User Settings: User Interface
In the window User Settings: User Interface you can maintain the user – defined
settings in RMGViewUSM for the graphic interface.
User data directory

Source path for user interface configuration file.
Use last folder if possible, folder as standard

Use last default setting:
• ⱱ⃞ Use the lastly selected directory path.
• ⃞ Do not use default setting.

CSV Delimiter
Selection of the delimiter used in CSV files.
• ; = use semicolon separator.
• TAB = Use tabulator separator.
..decimal point 83
Select the indicator for the decimal place for values.
• . = Use point, e.g. 15.0 bar.
• , = Use comma, e.g. 15,0 bar.
Start with..
Select the window with which RMGViewUSM is started:
• Site Overview
• Dashboard
• Values
• Lists
• Plots
• Raw data
• Reports
• Errors
Language
Language to be used for the user interface.
Display tool tips (list)

Display information on list elements in tool tips.
• ⱱ⃞ Display tool tips for list elements.
• ⃞ Do not display tool tips for list elements.
Filter: Use Macro

Filter macro and display.
• ⱱ⃞ Filter for macros and list..
• ⃞ Do not filter for macros.

4.22 Base line correction

RMGViewUSM > Select Site > Tools > Base line correction
The base line correction of the ultrasonic meter (USM-GT400) can be done either
with two different methods.
84 Base line correction of the flow rate using a polynomial fit
Figure 67: Base line correction using a polynomial fit
The correction is realized using a polynomial of degree 4. This reproduces the er-
ror curve of the USM depending on the flow.
𝐴!" 𝐴!% "

𝐹= " + + 𝐴& + 𝐴% ∙ 𝑄#$ + 𝐴" ∙ 𝑄#$
𝑄#$ 𝑄#$
Legend
𝐹 = Deviation form baseline [%]
𝑄#$ = Volume flow rate at operating conditions [m3/h]
𝐴' = Constants (n =-2, -1, 0, 1, 2)
The coefficients of the polynomial 𝐴' (n = -2 bis n = 2) are determined using the
values of the deviation Fi at the individual process flow rates QVb_i . Instead of the
constant meter factor KV the corrected factor KVk will be used for further calcula-
tions.

𝐹
𝐾#( = 𝐾# ∙ /1 + 2
100
Legend
𝐾# = Constant factor
85
The coefficients of the polynomial An are determined and given from the manufac-
turer of the USM-GT400.
Base line correction of the flow rate using a piecewise linear interpolation
Figure 68: Base line correction
This method takes into account up to 12 free chose-able set points in each direc-
tion of the flow, means in total up to 24 points. The input values from the reference
are given for the x- axis. At each point of the reference the deviation of the USM
has to be entered. Between the set points a linear interpolation is assumed.
Instead of the constant meter factor KV, the corrected meter factor KVC for further
calculation is used:
𝐹
𝐾#) = 𝐾# ∙ /1 + 2
100
The set points and the deviations from the base line are given from the error curve
of the USM.

The corrected process volume flow rate is then calculated using the following
equation:
𝑓#
𝑄*#+ = ∙ 3600
𝐾#)
Legend
86
𝑄*#+ = corrected volume flow rate at operating conditions [m3/h]
𝐾#) = corrected gas meter factor [Imp/m3]

𝑓# = Frequency of the meter [Hz]
𝐾# = uncorrected meter factor of the USM [Imp/m3]
4.23 License info

RMGViewUSM > Select Site > Help > About RMGViewUSM
In the window License Info, information on the software license is displayed: If

you have any questions or queries please contact the RMG service personnel
4.24 Process license

RMGViewUSM > Select Site > Settings > RMGViewUSM Process License
4.25 Report editor

RMGViewUSM > Select Site > Reports > User-Defined Reports > Report Editor
In the window Report Editor you can compile protocols according to your require-
ments. A training by RMG is required before working with the Protocol Editor. As
an alternative RMG offers the service of creating client specific reports.
If you have any questions or queries, please contact the RMG service personnel.

5 Operation
5 Operation
In this chapter you will receive information on carrying out operations with the soft-
ware.
87
5.1 User settings
In this chapter you will receive information on logging in and out of a user level.
5.1.1 Login users

The users are assigned the access rights for the user level by logging in with their
password.
Logging users in at a protected user level
Figure 69: Opening Password Input window

5 Operation
The following steps are conducted from the RMGViewUSM window Dashboard –
All USMs (see chapter 4.1, „Übersicht Anlage“ auf Seite 46)
1 Click the buton Password Input

The window Password Input opens.
88
Figure 70: Login user
2 Click the radio button for the user level e.g. Configurator.
3 Enter the password in the Password field.
4 Click the OK button.
If the password was entered correctly, the button on the Password Input field
changes to the name of the user e.g. Operator.
If the password was not entered correctly the user level switches to Monitor and in
in red letters appears: „Wrong Password“.
Note
The number of login attempts is not limited.
5.1.2 User log out

For security reasons you must make sure that you log out of the protected user
level before you leave the PC.

5 Operation
Logging out users from a protected user level
1 Open the window Password Input.
For this you carry out following steps:
Step 1: Logging users in at a protected user level

e.g. as „Monitor“ 89
Figure 71: Login users
2 Click the Monitor radio button.

3 2 Click the OK button.
Access to the previously opened user level is disabled.
5.2 Adjusting the size of graphic contents

In order to enhance your view, you can enlarge or shrink areas of diagrams (plot).
Enlarging areas

5 Operation
90
Figure 72: Enlarging areas
1 With left mouse button pressed mark the desired area (2) of the plot (1).
2 After releasing the left mouse button, the view of the marked frame is en-
larged.
Reset areas
1 Press the Z key on the keyboard.
The previously enlarged view is set back to the original size.
5.3 Working with windows

In this chapter you will receive information on organizing the windows.
5.3.1 User defined window configurations

You can arrange the windows on your desktop and save the configuration under a
desired name. This configuration can be opened again any time.

5 Operation
Save Window Configuration
1. Open the window Dashboard - All USMs

2. Arrange the windows on the desktop to your requirements.
91
Figure 73: Save window configurations
3. Click menu item File in the menu bar.

4. Click menu item Workspace.
5. Click menu item Save Window Configuration.
The arrangement of the opened windows is saved as a RMW file.
Note
Give the RMW file a name that you can easily recognize as being your con-
figuration.

5 Operation
Opening window configurations

(see chapter see chapter 4.1 Site overview, p. 39).
92
Figure 74: Save Window Configuration

3. Click menu item Workspace.
4. Click menu item Restore Window Configuration.
Windows are opened automatically and arranged according to the configu-
ration on the desktop.

5 Operation
5.3.2 Cloning windows
93
Figure 75: Cloning buttons
1. Open window that is to be opened again.

2. Click the Clone window button.
The current window is opened once again.

5 Operation
5.3.3 Closing RMGViewUSM

You can close all RMGViewUSM windows with just a few mouse clicks.
Exiting the software

Figure 76: Menu item RMGViewUSM

3. Click menu item Exit RMGViewUSM.
All windows of the software are closed.

5 Operation
5.3.4 Close windows for a device
95
Figure 77: RMGViewUSM close windows

2. Click menu item Close Window.
The current window is closed.
5.4 Parametrize USM

Note
To use this function you have to login as a configurator user (at mini-
mum).
You must open the ultrasonic electronics' calibration switch so that values can be
transferred to the ultrasonic electronics. Please note that for this task the lead seal

5 Operation
must be broken. The ultrasonic gas meter may not be run with a broken seal. The
device no longer has the status "calibrated".
• Only carry out these tasks if you are authorized.

Please observe the "Operating instructions ultrasonic gas meters".
96 Create a CSV file for parameterizing

1. Create a CSV file.
2. Remove the lead seal from the calibration switch.
3. Set the calibration switch to the switch position Parameterize, by sliding the
switch upwards. Please observe the "Operating instructions ultrasonic gas
meters".
If the calibration switch is not correctly set to the switch position Parameter-
ize, then following message is displayed:
Figure 78: Status message
If this message is displayed, check the setting of the calibration switch.
Transfer CSV file to USE
1. Login user in at user level Configurator

(see chapter 5.1.1 Login users, p. 87).
(see chapter 4.2 Dashboard, p. 41).

5 Operation
97
Figure 79: Menu item parameterize USM
3. Click menu item Tools in the menu bar.

4. Click menu item Parameterize USM.
A windows screen for selecting a CSV file will be displayed.
5. Select CSV file and confirm selection.
The window Parameterize USE: Parameter_OB.csv opens.

5 Operation
98
Figure 80: Select Blacklist and start process
Collect all the parameters that are not to be transferred to the ultrasonic electron-
ics in a list. Ready-made lists (blacklists) are available.
6. Select blacklist.
7. Click the Start button.
The status of parameterization is illustrated by an animated time bar.
The CSV file is transferred to the ultrasonic electronics and the ultrasonic electron-
ics are parameterized with the values from the CSV file.
Successful parameterization is displayed in the window Parameterize USE: Pa-
rameter_OB.csv.

5 Operation
99
Figure 81: Parameterization successfully completed
8. Click the Ready button.

Parameterization is completed.
Complete work on the USE
9. Set the calibration switch to the switch position Protected, by sliding the
switch downwards (see operating instructions ultrasonic gas meters).
10. Have the lead seal on the calibration switch replaced by an authorized cali-
bration center.

5 Operation
5.5 Open folder user data

You can open the folder User Data using the RMGViewUSM software.
Open Folder User Data

Figure 82: Menu item Open Folder User Data

3. Click menu item Open Directory.
4. Click menu item Open Folder User Data.
Windows Explorer opens. The filing location is displayed.

5 Operation
5.6 Open folder APPDATA

You can open the Appdata Folder using the RMGViewUSM software.
Opening the APPDATA Folder
1. Open the window Dashboard - All USMs.

(see chapter 4.1 Site overview, p. 39). 101
Figure 83: Menu item APPDATA Folder

3. Click menu item Open Directory.
4. Click menu item Open RMGView Appdata Folder.
The Windows explorer opens. The filing location of the APP data is dis-
played.

5 Operation
5.7 Screen dump in jpg format

You can create a jpg file of the Plots and Raw Data. The JPG file is created in the
same manner for both windows.
Creating the jpg file

102 1. Open the Raw Data window
(see chapter 4.6 Raw data p. 50)
Figure 84: Button save as jpg image
2. Click the button Save as jpg image.
Windows explorer opens. The jpg file is created

5 Operation
5.8 Error- and warning messages

The RMGViewUSM software stores error and warning messages from the ultrasonic
electronics. For analysis purposes, the error and warning messages can be called
up.
Retrieving error and warning messages

103
Figure 85: Errors window
1. Open Errors window

(see chapter 4.8 Errors, p. 57)

5 Operation
5.9 Creating a log of a user action

Every user action executed by the user is recorded by the RMGViewUSM software.
You can open this list as a window. It is also possible to export this list as a PDF
file.
Display log
104
Figure 86: USM history
1. Click the USM History entry.
The window USM History opens. All the actions taken are listed.

5 Operation
Note
The contents of the list can be filtered for a certain meter, user or for a
message. (chapter 4.7 Logs p. 52).
105
Creating a log file as a PDF
Figure 87: Exporting a list as a PDF file
1. Click the Export button..
The Save as... dialog box opens. The filing location must be selected. The
PDF file is created.

5 Operation
5.10 Creating a log on parameter change

Every parameter change that can have an impact on the accuracy of measure-
ment is recorded by the ultrasonic gas meter. You can open this list as a window.
In addition, it is possible to export this list as a PDF.
Display log
106
Figure 88: List of changed parameters
1. Click the USM Parameter Log button.
The list opens. All the actions taken are listed.
Note
The contents of the list can be filtered for a certain meter, user or for a
message (chapter 4.7 Logs p. 52).

6 Troubleshooting
6 Troubleshooting
In this chapter you will receive information on possible problems and how you
solve the problems.
Note 107
If you cannot find a solution to your problem with the RMG component,
then please contact the RMG service. (contact see p. II).
6.1 cfg-file missing

The cfg file should have been filed in the specified directory during installation and
should be able to be called up from there.
6.1.1 cfg-file creation

You can create a cfg-file in the RMGViewUSM via the dashboard. If you move the
mouse pointer over the symbol from
Status Display -> Configuration
you get - in a yellow frame - the hint that you can select further features with a
"right click" of the mouse.

6 Troubleshooting
108
Figure 89: Features „under“ the mouse pointer
With a right-mouse-click you may now generate a new cfg-file.
Figure 90: Generation of a cfg-file
The cfg-file is required to get all necessary parameters. RMGViewUSM cyclically

checks whether the parameters of the ultrasonic gas meter still match the parame-
ters from the cfg-file.

6 Troubleshooting
6.2 Discontinuity in connection to the meter

The following message will be displayed: „You have just removed COM 5.“
1. Please check the USB cable connection from the device to the computer.
A loose USB connection could also be responsible for the timeout. The
cause could also be an excessively long or poorly shielded cable. 109
Please only use twisted pair shielded cables up to a maximum length of

500 m. Recommended type LiYCX 2 x 2 x 0.75 mm². The green status LED
at the bottom left shows if communication is operating correctly.
6.3 Display „RMGViewUSM is already running… “

The following message will be displayed: „ RMGViewUSM is already running on
COM 5“
This means that one instance of RMGViewUSM is already running. It cannot be

started a second time at the same interface.
Fix
1. Close RMGViewUSM or, if this doesn't work, use the Windows Task Man-
ager, (right mouse key on the Windows task bar -> Start Task Manager) to
end the RMGViewUSM.exe process in the processes tab.
If a connection from the same computer to several ultrasonic gas meters is de-
sired, then initially, in the already opened instance of RMGViewUSM you must
switch to the second, connected COM port before RMGViewUSM can be restarted
on the standard COM port.

6 Troubleshooting
6.4 Display „The file USE_112c.rmx … “

…could not be found. Get in touch with RMG in order to receive a USE_xxx.rmx
file that is suitable for your USM09.
1. Procure an .rmx file suitable for the firmware of your ultrasonic gas meter.
110 a. Disconnect your ultrasonic gas meter.
b. Start RMGViewUSM.
c. Select the menu item
Tools->RMGViewUSM Open RMG APPDATA folder
d. Copy the .rmx file into the folder displayed.
2. Close RMGViewUSM.
3. Reconnect the ultrasonic gas meter. Start RMGViewUSM.

Kontakt
111
Subject to technical modification.
For further information

If you would like to learn more about the
products and solutions from RMG,
please visit our website:
www.rmg.com
or your local support office

or contact your local sales representative.

Otto-Hahn-Straße 5
D-35510 Butzbach, Deutschland
Phone:: +49 (0) 6033 897 – 0
Fax: +49 (0) 6033 897 – 130

Tel: 55 53658200, 63645537
1.6.4 Manual de Servicio

Ultrasonic Gas Flowmeter USM GT400
SERVICE MANUAL
Reliable Measurement of Gas
STATUS EN02 OCTOBER 2017

...............................................................................................................................................................................................................
Manufacturer Our customer service is available for technical queries

Otto-Hahn-Straße 5
D-35510 Butzbach
Telefon switchboard +49 6033 897 – 0
Telefon service +49 6033 897 – 127
Telefon spare parts +49 6033 897 – 173
Fax +49 6033 897 – 130
E-mail [email protected]
Original Document The Service-Manual USM_GT400_SM_en_02 from

October, 12th for ultrasonic gas meter USM-GT400 is the
original document. This document may serve as reference for
translations into other languages. Please use in case of any
uncertainties the German version as main reference.
Note Unfortunately, paper is not updated automatically, whereas

technical development continuously advances. Therefore, we
reserve the right to make technical changes in regard to the
representations and specifications of these operating
instructions. The latest version of this manual (and other
devices) can be downloaded at your convenience from our
Internet home-page
www.rmg.com.
Date created 12/18/2015

1st revision date OCTOBER 2017
2nd revision date
Document version and language Document version Service-Manual Oct. 12th 2017
Language EN
...............................................................................................................................................................................................................
Service manual USM GT400 · EN02 OCTOBER 2017
CONTENTS
...............................................................................................................................................................................................................
1 REQUIRED QUALIFICATION ..................................................1

1.1 Skills .............................................................................................................. 1
1.2 Authorization ............................................................................................... 1
2 SAFETY INSTRUCTIONS...........................................................2
2.1 Pressurized components .............................................................................. 2
2.2 Explosion protection .................................................................................... 2
2.3 Protective equipment ................................................................................... 2
3 LEGAL CALIBRATION REGULATIONS ...............................3

3.1 Type approvals ............................................................................................. 3
3.2 National calibration regulations ................................................................. 3
4 COMMISSIONING .......................................................................4
4.1 Description of connections .......................................................................... 4
4.1.1 Electrical connection in compliance with ATEX / IECEx ................................ 5
4.1.2 Electrical connection in compliance to NEC 500 ............................................. 5
4.2 Pressure connection ..................................................................................... 6
USM
4.3 RMGView operating program ............................................................. 7
4.3.1 System requirements ......................................................................................... 7
4.3.2 PC connection ................................................................................................... 7
USM
4.3.3 Installing, starting and using RMGView ..................................................... 7
5 REPAIRS AND TESTING ............................................................8

5.1 Mechanical.................................................................................................... 8
5.1.1 Grill and grill elements ..................................................................................... 8
5.1.2 Pipe bundle........................................................................................................ 9
5.1.3 Transducer replacement .................................................................................. 11
5.2 Electronics .................................................................................................. 36
5.2.1 Opening the housing ....................................................................................... 36
5.2.2 Display circuit board ....................................................................................... 36
5.2.3 Complete electronics ....................................................................................... 37
5.2.4 Mux card ......................................................................................................... 38
5.2.5 Options card 1 ................................................................................................. 38
5.2.6 AD transmitters for p and T sensors (Options card 2) .................................... 39
5.3 Re-calibration ............................................................................................. 40
5.3.1 USM dry calibration in accordance with AGA 9 with nitrogen ..................... 40
6 DOCUMENTATION OF THE DEVICE STATUS..................50

6.1 Logs / documentation ................................................................................ 50
...............................................................................................................................................................................................................
Service manual USM GT400 · EN02 · OCTOBER 2017
CONTENTS
...............................................................................................................................................................................................................
6.1.1 Test logs .......................................................................................................... 50

6.1.2 Calibration logs ............................................................................................... 52
6.2 Communication with RMG Butzbach ..................................................... 53
6.2.1 Archiving ........................................................................................................ 53
6.2.2 Support from RMG Service ............................................................................ 54
7 SPARE PARTS .............................................................................55

7.1 Software and firmware update ................................................................. 55
7.1.1 Saving the parameterization ............................................................................ 55
7.1.2 Firmware check ............................................................................................... 55
7.1.3 Firmware flash ................................................................................................ 56
7.1.4 Loading the standard data set and original parameterization .......................... 57
7.1.5 Functional test of the ultrasonic electronics .................................................... 57
7.1.6 Documentation of parameter changes ............................................................. 58
7.2 Mechanical parts / electronics .................................................................. 60
8 TOOLS / SPECIAL TOOLS .......................................................61
APPENDIX .........................................................................................62
USE 09 flash programming ................................................................................ 62
...............................................................................................................................................................................................................
1 REQUIRED QUALIFICATION
...............................................................................................................................................................................................................
1 Required qualification
The present service manual describes work processes that are normally performed by employees of
RMG Customer Service. This work goes beyond an operator's normal installation, commissioning
and operating tasks as described in the operating manual. Only persons having sufficient skills and
who have been authorized by RMG are permitted to carry out such tasks!
1.1 Skills
The following is required of personnel for the tasks described in the service manual:
- Knowledge of the content of the operating manual for the USM GT400
- Knowledge of the operating manual for the software RMGViewUSM
- Knowledge of safety regulations for explosion protection and for working with pressure
equipment. Appropriate certifications are mandatory for this purpose.
- The general standards and guidelines for work on gas equipment
- National regulations for measurements subject to official calibration
1.2 Authorization
Work that is not described in the operating manual may only be carried out by persons who have
been authorized to do so by RMG. Non-compliance with this requirement voids all warranty claims.
The supplied devices must be provided with seals. These seals may only be removed in
coordination with local calibration authorities. Whoever removes a seal assumes responsibility for
changes to the meter that can be made after the removal of this seal.
...............................................................................................................................................................................................................
2 SAFETY INSTRUCTIONS
...............................................................................................................................................................................................................
2 Safety instructions
Dangers can arise due to improper work on the meter. Therefore, the safety instructions in the
operating manual must be observed! It must be observed, in particular, that the meter housing is
pressurized and that there may be an explosion-prove atmosphere near to the meter.
2
2.1 Pressurized components
The ultrasonic meter is under pressure. Therefore, the line pressure must be lowered to atmospheric
pressure before removing the meter or individual transducers.
With use of the RMG replacement tool, replacement of a transducer under a pressure of up to 100
bar is possible. For this purpose, read the instructions for use of the replacement tool.
2.2 Explosion protection

All electrical components that can create a spark are enclosed in a pressure-proof Ex-d housing. The
housing may not be opened before there is no explosive gas around and the meter has been
USM
disconnected electronically. If a PC is used to operate the diagnostic software RMGView , it
must be ensured that the PC is outside of the explosion-prove zone.
2.3 Protective equipment

The following protective equipment is required for service work on the ultrasonic meter in order to
prevent accidents:
− Gas warning device
− Protective goggles
− Protective gloves
− Fire extinguisher
...............................................................................................................................................................................................................
3 LEGAL CALIBRATION REGULATIONS
...............................................................................................................................................................................................................
3 Legal calibration regulations

3.1 Type approvals
The ultrasonic gas flowmeter USM GT400 complies with the current directives for measurements
subject to calibrations at the time of its market introduction. The following approvals and/or
certificates are available:
3
• MID approval (DE-14-MI002-PTB002)
• Additional local approvals are available and can be requested from RMG.
The provisions of the respective valid approval must be observed for repairs and parameterization.
Only original spare parts may be used; otherwise the approval becomes void.
3.2 National calibration regulations

Essential components and the calibration switch for protection of parameters relevant for calibration
laws are protected with seals. Seals may only be removed by authorized persons. New seals must be
applied by the authorized persons after a repair. In the process, the seal diagrams in the operating
manual must be observed!
Compliance with national regulations and laws is mandatory!
...............................................................................................................................................................................................................
4 COMMISSIONING
...............................................................................................................................................................................................................
4 Commissioning
4.1 Description of connections
Refer to the operating manual for the mechanical connection of the meter. The necessary feed and
outlet lines and the screws and seals to be used are indicated there.
4 The electrical connection takes place depending on the explosion protection regulation to be applied
at the measuring point. In the area of validity of ATEX or IECEx, meters with an electrical
connection box are used; in the area of validity of NEC 500, meters are equipped with a connection
cable instead of a connection box.
Maximum configuration
The following connections are always in the Ex-de connection box; with the version with
connection cable, they are only completely available in the maximum configuration:
• Current / voltage supply (24 VDC)
• Warning indicator (Warn)
• Alarm indicator (Alarm)
• 2 x pulse output for two-channel transmission
• 2 x direction recognition for bidirectional operation (I/O1 and I/O2)
• Service interface for the software RMGViewUSM (RS 485-0)
• 2 x Modbus interface for connection of a flow computer or other superordinate systems
(RS 485-1 and RS 485-2)
• Analog output (4-20 mA)
• Connection for a pressure sensor (AUX1)
• Connection for a temperature sensors (PT100; AUX2)
• Pressure and temperature sensors are necessary if an AGA 10 calculation of the speed of sound
should be performed due to the available gas components.
A proper ground connection must also be ensured for both versions. Refer to the operating manual
for more information.
...............................................................................................................................................................................................................
4 COMMISSIONING
...............................................................................................................................................................................................................
4.1.1 Electrical connection in compliance with ATEX / IECEx

The device is delivered with an Ex-de connection box in countries where the standards ATEX and
IECEx are applicable. The electrical connections can be found there. The terminal configurations
and cable identifications are always identical. The external connection box is electrically pre-
assembled and connected to the ultrasonic electronics at the factory. The external connection box
does not have to be installed.
5
4.1.2 Electrical connection in compliance to NEC 500

The number of lines that can be routed through the openings (½" and ¾") on the electronics housing
and/or flame arrester is limited. There are 4 different resulting constellations that then reflect the
connection possibilities.
Variant 1: Minimum configuration - ½" opening

Connect ½" opening with 11 size AWG 18 wires (maximum permissible = 11; Killark type
ENY-1TM).
Variant 2: Minimum configuration for bidirectional operation - ¾" opening

Connect ¾" opening with 20 size AWG 18 wires (maximum permissible = 20; Killark type
ENY-2TM).
Variant 3: Minimum configuration for operation with pressure and temperature measurement
- ¾" opening
Minimum configuration for bidirectional operation - ¾" opening
ENY-2TM).
Variant 4: Maximum configuration ½" and ¾" openings

ENY-2TM) and ½" opening with 11 size AWG 18 wires (maximum permissible = 11; Killark type
ENY-1TM).
All connections are routed outward and can be connected and used.
...............................................................................................................................................................................................................
4 COMMISSIONING
...............................................................................................................................................................................................................
Wire numbers for the connection cable:

Variant 1 2 3 4
+ 1 1 1 1
24 VDC
- 2 2 2 2
PE 3 3 3 3
+ 12 12 12
Warn
- 13 13 13
+ 4 4 4 4
6 Alarm
- 5 5 5 5
+ 6 6 6 6
Pulse 1
- 7 7 7 7
+ 14 14
Pulse 2
- 15 15
+ 16 16
I/O 1
- 17 17
+ 18 18
I/O 2
- 19 19
a 8 8 8 8
RS 485-0
b 9 9 9 9
a 21
RS 485-1
b 22
GD 20 20 20
RS 485-2 a 10 10 10 10
b 11 11 11 11
+ 29
4-20mA
- 30
1 14 23
AUX1*
2 15 24
1 16 25
2 17 26
AUX2*
3 18 27
4 19 28
*only with option card plus analog input module
4.2 Pressure connection

Refer to the description in the operating manual for connection of a pressure transducer to the pr tap
of the ultrasonic meter. Ensure that an end-to-end slope is present between the pressure transducer
and meter so that no condensate water can collect in the pressure measuring line.
...............................................................................................................................................................................................................
4 COMMISSIONING
...............................................................................................................................................................................................................
4.3 RMGViewUSM operating program

Parameters can be read and changed directly on the display using a magnetic pen or with the
operating program RMGViewUSM. The following functions are also available with RMGViewUSM:
• Creation and management of multiple stations.
• Assignment and management of multiple devices (USM) in a station.
• Readout of current measurements (actual values) in real-time.
• Display of values in tabular form, as a diagram, as a graph or in individual fields.
7
• Querying of predefined lists, readout and display of specific parameters from the device.
• Querying of predefined plots that display the parameters in a diagram.
• Creation of user-defined list and output as logs.
• Creation of user-defined plots that display the parameters in a diagram.
• RMGViewUSM automatically recognizes the firmware of the connected device. Only parameters
that are functional with the connected device are displayed.
• Parameterization of the connected device.
• Creation of test reports.
4.3.1 System requirements

The PC must meet the following specifications:
• Operating system Microsoft Windows 2000, XP, 7, 8
• Minimum screen resolution of 1024 x 768 pixels
4.3.2 PC connection
Connection of the PC takes place at the RS485-0 interface of the ultrasonic meter. Use of an
interface converter from RS 485 to USB (or TCP/IP) between meter and PC for conversion of the
signals is recommended.
4.3.3 Installing, starting and using RMGViewUSM

RMGViewUSM can be installed automatically with the file RMGViewUSMInstallerx.x.x.x.exe (for
the respective version x.x.x.x) on the supplied installation CD. Older versions do not have to be
deleted beforehand.
To establish the connection, the COM belonging to the interface converter must be selected or the
IP address of the converter must be entered under "Settings/ USM settings".
For further details about the installation and an extensive description of the operation, refer to the
operating manual for the software RMGViewUSM.
...............................................................................................................................................................................................................
5 REPAIRS AND TESTING
...............................................................................................................................................................................................................
5 Repairs and testing

5.1 Mechanical
5.1.1 Grill and grill elements
The grill elements cover the transducers and the pipe bundle. They must be removed before any
8 transducer change or replacement of the pipe bundle.
Pipe bundle cover
Pipe bundle fastening

screw
Grill
The pipe bundle cover can be removed by unscrewing the two side screws.
To remove the grill elements, first remove the two screws on a grill side section and pull the grill
section off the meter at an angle (approx. 45°). Then unscrew the screws of the other side section.
The middle section can then be pulled out to the side. Then unscrew the other side section.
The side sections can be mounted first for the reassembly. The middle section can slide into the
guide until it engages.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.1.2 Pipe bundle

In order to remove the pipe bundle, first remove the pipe bundle cover and grill elements on both
sides of the meter (see above).
Pipe bundle holder
Cover panel Individual pipe holder
Remove the cover panels held in place by 4 fastening screws and open the two pipe bundle holders
(black) and all individual pipe holders (green).
Then remove the ultrasonic electronics as described in the chapter "Complete replacement of
electronics" (page 37).
All plug connectors must then be disconnected from the transducers as described in the chapter
"Mechanical transducer replacement" (page 11).
If the pipe bundle is already pre-bent, the electronics housing must be removed as described in the
text below. If the pipe bundle is not pre-bent, the housing can remain on the meter. We recommend
using pre-bent pipe bundles, because there are no standard tools for the bending of the pipes and
templates with the appropriate bend radius must be created for this purpose. The pipes may be
kinked without using such templates.
With a pre-bent pipe bundle, unscrew the

electronics housing fastened with four (4) screws
and place it on a suitable surface so that the two
pipe bundles can hang down freely.
Now unscrew the lock nut on the opening of the

pipe bundle to be replaced with a hook wrench.
Then unscrew the pipe bundle from the electronics
housing with an open-end wrench.
Remove the lock nut and washer from the old pipe bundle and use both parts for the new pipe
bundle.
Now screw in the new pipe bundle in the electronics housing so that its thread ends with the inner
wall of the electronics housing and the pipe bundle hangs down.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
If applicable, re-assemble the electronics housing on the meter housing.
Now plug the plug-in connectors into the transducers and tighten the screw connection as described
in the chapter "Mechanical transducer replacement" (page 11). Fasten the two pipe bundles with the
pipe bundle holder and individual pipe holders.
Tighten the lock not on the replaced pipe bundle with the hook wrench.
10 Now re-install the ultrasonic electronics as described in the chapter "Complete replacement of
electronics" (page 37).
Re-assemble the pipe bundle covers and grill elements.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.1.3 Transducer replacement

Transducer replacement always consists of the mechanical part – i.e. the actual replacement of the
ultrasonic transducer on the meter body – and the subsequent parameter adjustment in the ultrasonic
electronics.
All path lengths of the ultrasonic meter are measured exactly after installation of the transducers.
The transducer lengths, measured from the clamping flange to the transducer face end, are also
known, but vary slightly from transducer to transducer. Therefore, manual adjustment of the path
length stored in the ultrasonic electronics is necessary after transducer replacement. For more 11
information, refer to the section "Adjustment of the parameterization" (page 32).
5.1.3.1 Mechanical transducer replacement

There are two variants of ultrasonic transducers available, which differ in their length dimensions.
This determines whether the transducer replacement can take place under pressure. Types TNG 20-
SP and TNG 20-SHP (for pipe sizes DN 100 and DN 150) have a short length of only 36 mm.
Transducer replacement for these types is only possible in a depressurized pipe.
Required protective equipment

You require the following protective equipment to avoid accidents:
− Fire extinguisher
Required tools
You require the following tools to replace an ultrasonic transducer:
− AF 1.5, AF 2, AF 6, AF 10 and AF 10 Allen keys
− Grooved nut key
− AF 12, 22 and AF 32 open end wrenches
− Slot socket key (RMG special tool)
− Screwdriver (slot)
− Pipe wrench, suitable for AF 65
− Torque wrench with AF 22 open-end wrench (for tightening of the transducer)
Working in the measuring space

Before you begin, switch off the supply voltage to the meter. Ensure that the meter is depressurized
and free from flammable gas. It should be flushed with nitrogen. Before starting with the work, it
must be verified that the atmosphere is absolutely free from gas.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.1.3.2 Replacement in the depressurized state

First remove the grill elements, cover plate and pipe bundle cover on the side on which the
transducer to be replaced is located, as described above.
No special removal tool is required for transducer replacement under atmospheric pressure. Proceed
as follows:
1. Open the pipe bundle holder.
12 2. Remove the seal and open the individual pipe holder.
3. Remove the transducer protective seal.
4. Tighten the transducer that you want to replace to a torque of at least 20 Nm.
Torque wrench
5. Unscrew the pipe/cable plug connector with an AF 12 open end wrench and/or slot socket key
(counterclockwise).
Attention: The ø 1/8" pipe moves with the plug connector.
- The slot socket key must be used for the upper and lower transducers (Attention: there is a
different key for each pipe size).
- An AF 12 open end wrench can be used for the middle transducers.
Where necessary, insert the slot socket key in the sleeve of the transducer screw connection
and unscrew the plug screw connection. Then pull the plug connector out of the transducer
sleeve.
6. Unscrew the grooved nut with the grooved nut key.
Grooved nut
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
7. Then unscrew the transducer screw connection until the transducer can be pulled out.
8. Then unscrew the 3 setting screws (M3) in the transducer screw connection and pull the
transducer out of the screw connection. For this purpose, use AF 1.5 Allen key (cannot be used
for TNG 20-SP and TNG 20-SHP).
13
9. Push the new transducer as far as possible into the screw connection and tighten the 3 setting
screws (not with TNG 20-SP and TNG 20-SHP).
10. Insert the new transducer with the screw connection into the meter housing and screw it in.
Tighten it to a torque of at least 20 Nm.
11. Fit the transducer protective seal in the appropriate position.
12. Then re-insert the plug-in connector on the transducer and tighten it to a torque of 5 Nm.
13. Pull off the transducer protective seal again.
14. Unscrew the transducer screw connection and tighten it again to a torque of 10 Nm for
transducer types TNG 10-CP / TNG 10-CHP or TNG 20-LP / TNG 20-LHP and to 5 Nm for
types TNG 20-SP / TNG 20-SHP.
15. Then tighten the grooved nut with which the transducer connection is screwed. It must be
secured that no higher torque is exerted to the grooved nut.
Grooved nut
16. Slide the transducer protective seal back to the appropriate position.
17. Then fasten the individual pipe holder and then the pipe bundle holder.
18. Re-assemble the cover panel, grill elements and pipe bundle cover. Now the mechanical
component of the transducer replacement is finished.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.1.3.3 Replacement under pressure

A. Preparations
A special tool is required in order to replace an ultrasonic transducer that is under pressure. The gas
pressure exerts enormous force on the transducer that can be held when moving out and must be
overcome when moving in. For this reason, a special tool must be screwed onto the meter body to
control the transducer and move it in and out of the housing without posing a danger to persons.
The tool grips the transducer, which is first unscrewed from the meter housing with a
14 counterclockwise rotation on both handles of the tool. The transducer is then in a gas-tight chamber
of the tool, so no gas escapes. With further rotation, the transducer is rotated through the ball valve.
After closing the ball valve, the tool can be taken apart by unscrewing so that the transducer can be
replaced.
Then the new transducer is moved in with clockwise rotation of the handles. Once the new
transducer is screwed in, the gas-tight chamber of the tool is vented again and the tool is removed.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
B. Safety instructions
Attention: The tool is under pressure during transducer replacement! Therefore, it is necessary to
proceed according to the exact steps described in this manual and to observe the safety instructions,
in particular.
The replacement tool can be used for replacement of transducers of the ultrasonic gas flowmeter
USM GT400 with pipe sizes of DN 200 or greater under operating pressures of up to 120 bar.
The replacement tool is only suitable for ultrasonic gas flowmeters with the new design (face to
face dimension 3 DN) with transducer type TNG 10-CP or TNG 20-LP. 15
The replacement tool complies with current standards and regulations. However, danger arises with
misuse.
Transducer replacement may only be carried out by trained personnel who are familiar with the
current regulations for pressure equipment and natural gas systems, particularly the subject of
explosion protection.
Observe the following:
Personal injury
This symbol is used in the manual as a warning of danger to the life and health of
persons; observe the instructions following the symbol. The following must be
observed, in particular:
• When an ultrasonic transducer is replaced, parts of the replacement tool are
pressurized or subject to heavy mechanical tension. When used incorrectly, parts can
come loose and be ejected at high speed.
• In this case, use your personal protective equipment. This includes gas warning
device, protective goggles and work gloves.
Explosion protection
There are special regulations for explosion protection in gas metering systems. Observe
the following, in particular:
• Since metal objects are moved during transducer replacement and sparks can be
created, the room atmosphere must be checked before commencing with the work!
• Gas can escape and ignite during transducer replacement. Therefore, keep suitable
fire extinguishing equipment readily available.
Property damage
This symbol is used in the manual to warn of potential property damage. The
information after the symbol informs you how to avoid damage to the ultrasonic gas
flowmeter or the replacement tool.
The warning notices in this manual and the generally applicable rules of safety must be observed.
The warranty is voided when the replacement tool is used incorrectly!
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
C. Replacement tool
16
13
Thread unit with
turning handles
19
14
10
12 11
Pressure
15 chamber with
18 ball valve
9
17
2 Mounting
16 6 flange with
7 glass window
3 1
4
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
Individual parts
The replacement tool for ultrasonic transducers comprises the following individual parts:
Position Description Units

1 Plastic guide ring 1
2 Mounting flange with glass window (16) 1
3 45.2 x 3 O-ring for mounting flange 1
17
4 M12 x 35 Allen screws (DIN 912 8.8 GalZn8) for fastening of the 4
mounting flange
5 Coupling rod 1
6 26 x 2 O-ring on coupling rod 1
7 M4 x 5 threaded pin (DIN 914 4SH GalZn8) for fastening of the 3
coupling rod
8 Pressure chamber with ball valve (17), pressure gauge and vent plug 1
(18)
9 45.2 x 3 O-ring for ball valve connection 1
10 Slide bushing 1
11 15.3 x 2.4 O-ring for inner slide bushing 2
12 41.0 x 2.4 O-ring for outer slide bushing 1
13 Thread unit with turning handles and traveling nut with pressure 1
equalizing spring (19)
14 Shoulder screw for traveling nut in thread unit 1
15 M8 x 16 cylinder screw (DIN 912 GalZn) as a fixing screw for the 1
coupling nut of the thread unit
10
Guide ring Slide bushing
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
D. Preparations
Transducer inspection
The replacement tool is only suitable for transducers of the type TNG 10-CP or TNG 20-LP (see
figure to the right). The type designation can be found on the type plate on the transducer.
Working in the measuring space

Before commencing with work, it must be ensured that the atmosphere is free from gas and
18 the supply voltage of the meter must be switched off!
Working on the meter

The following work must be performed on the meter before the replacement tool can be mounted:
1. First remove the grill elements, cover plate and pipe bundle cover on the side on which the
transducer to be replaced is located, as described above.
2. Open the pipe bundle holder.
3. Remove the seal and open the individual pipe holder.
4. Unscrew the pipe/cable plug connector with an AF 12 open end wrench and/or slot socket key
(counterclockwise).
Attention: The ø 1/8" pipe moves with the plug connector.

- The slot socket key must be used for the upper and lower transducers.
- An AF 12 open end wrench can be used for the middle transducers.
Where necessary, insert the slot socket key in the sleeve of the transducer screw connection and
unscrew the plug screw connection. Then pull the plug connector out of the transducer sleeve.
5. Remove the transducer protective seal.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
E. Mounting the replacement tool

The replacement tool is mounted on the meter housing as described in the following steps:
1. Unscrew the grooved nut on the transducer with the grooved nut key.
2. Then unscrew the locking screw no more than ½ rotation with the AF 22 open end wrench.
Attention: Never unscrew the locking screw more than ½ rotation. If it is

unscrewed too far, gas can escape or the locking screw can be forced off due to the 19
gas pressure!
Grooved nut
Transducer screw
3. Fit the guide ring (made of plastic) on the transducer. The larger inside diameter must face the
front.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
4. Move the coupling rod towards the transducer.
Attention: The surface of the rod is a seal surface along which an O-ring glides
when the transducer is pulled out. It must not be scratched!
20
5. Plug the coupling rod onto the transducer. Then Allen socket on the coupling rod must be fit on
the hexagon head of the transducer such that the coupling rod can no longer rotate. Then fix the
rod with the 3 threaded pins (M4) using an AF 2 Allen key. The threaded pin must be firmly
tightened.
Threaded pin for fastening of

the rod
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
6. Carefully slide the mounting flange over the coupling rod and guide ring. Then fasten the
mounting flange with the 4 Allen screws (M12 x 35/8.8). For this purpose, use the AF 10 long
Allen key. Make sure that the viewing glass is visible.
Only use the supplied screws or M12 x 35 screws in accordance with DIN 912 with
strength class 8.8! Otherwise the screws can be pulled out as soon as the
transducer is unscrewed and the replacement tool is pressurized.
21
Glass window
Mounting flange
7. Now slide the pressure chamber with ball valve over the coupling rod and firmly hand-tighten.
Pressure chamber
with ball valve
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
8. Now slide the slide bushing onto the coupling rod. Then screw in the slide bushing in the
pressure chamber unit (AF 32). Make sure that no surfaces (seal surfaces) are damaged.
Coupling rod
22
AF 32
Slide bushing
9. Manually screw the coupling nut of the thread unit on the pressure chamber without tightening
it. The threaded sleeve (with brass part inside) must still turn.
Coupling nut
Threaded sleeve
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
10. Now connect the coupling rod with the traveling nut in the threaded sleeve. Screw in the
threaded sleeve and the traveling nut with the turning handles such that the oblong hole of the
coupling rode, one of the two oblong slots on the threaded sleeve and the threaded hole in the
traveling nut face the same direction, in other words so that the oblong hole and threaded hole
are both visible. Then screw the shoulder screw into the threaded hole and tighten with a
screwdriver (slot). The screw must be firmly seated and may not protrude into the oblong slot of
the threaded sleeve, which means the traveling nut must still rotate against the threaded sleeve.
The shoulder of the shoulder screw must protrude into the oblong hole of the coupling rod as an
actuator. 23
Threaded
hole
Oblong hole of the coupling rod Traveling nut Threaded sleeve

Side view
Seitenansicht
Top view
Draufsicht
SideSeitenansicht
view after
mounting
nach Montage
11. Now firmly tighten the coupling nut of the threaded unit and secure it with the fixing screw (AF 6
Allen screw). Now the replacement tool is mounted.
Fixing screw
Coupling nut
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
F. Unscrewing the transducer

When the replacement tool has been completely mounted, the transducer can be unscrewed from the
meter housing. For this purpose, proceed as follows:
1. Unscrew the transducer by slowly turning the handles counterclockwise.
Do not exert any lateral force and do not support yourself on the replacement
24 tool!
2. After about eight rotations the pressure chamber begins to fill with gas. Wait until the
manometer displays the operating pressure in the meter!
Do not unscrew any screw connections as long as the replacement tool is

pressurized. Only perform the steps described below from this point forward!
3. Carefully continue turning; the turning becomes more difficult because the line pressure is not
applied. When turning further, the transducer - which has been held thus far by the screw-in
thread - is released and pushes the coupling rod outward somewhat. The spring of the traveling
nut is tensioned in the process.
4. Unscrew the transducer until the traveling nut is at the end (stop) of the threaded sleeve.
5. Close the ball valve.
Ball valve open Ball valve closed
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
6. Slowly release the pressure from the pressure chamber by slowly opening the knurled cap on the
vent plug.
Wait until the pressure gauge displays the atmospheric pressure. The steps
described below may only be performed from this point forward!
25
Pressure chamber
Fixing screw
Vent plug
Knurled cap
7. Then unscrew the shoulder screw in the traveling nut (see page 23).
8. Now unscrew the fixing screw and loosen the coupling nut.
9. Completely unscrew the coupling nut and remove the threaded unit.
10. Unscrew the sliding sleeve with the coupling rod from the pressure chamber.
11. Now you can pull out the coupling rod together with the transducer. Make sure once more not to
scratch the surface of the coupling rod.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
G. Transducer replacement
1. Unscrew the 3 threaded pins (cf. "Mounting the replacement tool", step 4) on the coupling rod.
26
2. Now pull the transducer out of the sleeve of the coupling rod.
3. Unscrew the 3 threaded pins (M3) in the locking screw of the transducer and then pull the
transducer out of the locking screw (AF 1.5 Allen screw).
4. Slide the new transducer into the locking screw until the stop and tighten the 3 threaded pins.
5. Now slide the new transducer with locking screw in until the stop in the sleeve of the coupling
rod.
Document which transducer is installed in which position. For this purpose, use the notation
from the drawings in the USM manual so that there are no mix-ups in the subsequent
programming of the transducer parameters.
6. Then re-tighten the 3 threaded pins (M4) with the Allen key (AF 2).
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
H. Moving the transducer in

Now the transducer must be moved into the meter housing against the operating pressure. Proceed
according to the described work steps. It is not exactly the reverse order as for moving the
transducer out.
1. Carefully guide the coupling rod with the transducer into the pressure chamber and tighten the
sliding sleeve.
27
Attention: In the process, the transducer must not strike against the ball in the
ball valve!
2. Now hand-tighten the threaded unit with the coupling nut on the pressure chamber. Make sure
that the threaded sleeve can still rotate (cf. "Mounting the replacement tool", step 8).
3. Now connect the coupling rod to the traveling nut in the threaded unit as described in "Mounting
the replacement tool", step 9.
4. Tighten the coupling nut and secure it with the fixing screw.
5. Slowly open the ball valve until the line pressure is displayed on the pressure gauge.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
6. Now you can screw in the new transducer. A certain amount of force must be applied, because
the transducer is being screwed in against the line pressure. Slight resistance may be perceptible
when at first screwing into the thread of the meter housing, then the resistance decreases.
7. The transducer has been moved in correctly when the red mark on the coupling rod is in the
middle of the viewing glass.
28
8. When the transducer is screwed in, release the pressure chamber with the vent plug.
9. Then close the vent plug and observe the pressure gauge. There must not be any pressure
build-up. Otherwise, remove the transducer again – as described above – and inspect all seal
rings and surfaces for damage. If there is no pressure build-up, the replacement tool can be
removed.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
I. Removing the replacement tool
1. Before removal, check whether the pressure gauge displays atmospheric pressure.
Never remove the replacement tool when the pressure chamber is pressurized!
2. Unscrew the shoulder screw from the traveling nut. If necessary, the transducer can be
unscrewed up to ½ rotation. 29
3. Now unscrew the traveling nut until the coupling rod is released.
Step 2 Step 5
4. Then completely unscrew the coupling nut and remove the threaded unit.
5. Unscrew the sliding sleeve from the pressure chamber.
6. Unscrew the ball valve unit from the mounting flange. If the ball valve unit cannot be unscrewed
by hand, use an AF 65 open-end wrench or a pipe wrench.
Attention: The ball valve unit is heavy. It must not strike the coupling rod!
Pull the ball valve unit back over the coupling rod.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
Use an AF 65 open-end wrench or pipe

wrench if necessary.
30
7. Unscrew and remove the screws on the mounting flange.
8. Then unscrew the 3 threaded pins on the coupling rod and pull the coupling rod off of the
transducer.
9. Remove the guide ring.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
10. Tighten the transducer to the correct torque as specified in the table below.
Operating pressure in the meter (bar) Torque for the transducer (Nm)
0 10
10 13
20 13
30 14 31
40 14
50 14
60 16
70 16
80 16
90 18
100 20
110 22
120 24
Grooved nut
Torque wrench
11. Tighten the grooved nut with which the transducer screw connection must be secured such that a
higher torque is not exerted with the tightening of the grooved nut.
12. Slide the transducer protective seal back to the appropriate position.
13. Then fasten the individual pipe holder and then the pipe bundle holder.
14. Re-assemble the cover panel, grill elements and pipe bundle cover. Now the mechanical
component of the transducer replacement is finished.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.1.3.4 Adjustment of the parameterization

After transducer replacement, some path parameters of columns AK to AP (screen 5.1) must be
adjusted using the service and operating software RMGViewUSM. For this purpose, the technical
data of the old and new transducers must be known. This information can be found on the test
certificate of the USM GT400. The calibration switch of the ultrasonic electronics must be opened
to enter the data and the software must be switched to configurator mode with the configurator
password (screen 5.2).
32
Screen 5.1: Path parameters AK to AP based on the example of Path1
Screen 5.2: Password
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
A. Path length and path distance

Normally, nothing changes in the adjustment of the "Path distance" in AK-24 to AP-24 as long as
the transducer ends flush with the pipe wall. Only when this is no longer the case it changes in its
axial distance by the amount that the center of its face ends protrude axially into the pipe.
The change of path length in AK-23 to AP-23 depends on the transducer length, which is listed on
the test certificate. The following equation applies:
P2 = P1 + (L1 - L2)
The following applies: 33
P1 = Path length before the transducer replacement (e.g. 202.3 mm)
P2 = Path length after the transducer replacement
L1 = Length of the removed transducer (e.g. 57.46 mm) from the type plate (column AF)
L2 = Length of the installed transducer (e.g. 57.50 mm)
Example calculation:
P2 = 202.30 mm + (57.46 mm – 57.50 mm) = 202.26 mm
B. Dead time Tw
After adjustment of the path length, the speed of sound measurement of the relevant path must be
compared with the set point speed of sound / reference speed of sound, depending of the gas
composition, temperature and pressure. For this purpose, the dead time Tw in AK-14 to AP-14 must
be determined according to the following formula:
Tw = Fm – P / Cs
The following applies:
Tw = Dead time (coordinates for the 6 measuring paths: AK-14 to AP-14)
Fm = Average travel time from outward and return measurement (coordinates for the
6 measured paths: L-1 to Q-1 and L-2 to Q-2; identical at standstill)
P = Path length (coordinates for the 6 measuring paths: AK-23 to AP-23)
Cs = Speed of sound set point (coordinates for the 6 measuring paths: L-9 to Q-9)
If the speed of sound set point calculated according to AGA 10 is not available using the gas
composition, the average speed of sound (L-9 to Q-9, screen 5.3) of the remaining measured paths
can be used instead.
Note: However, carrying this out at a standstill (zero pressure flow) is not recommended, because
measurement errors can occur due to temperature gradient in the pipework. At a standstill, the
compensation should take place in comparison with the other path in that plane, because it operates
under identical temperature conditions.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
34
Screen 5.3: Path measurements L to Q based on the example of Path1
C. Serial number
The serial number of the newly installed transducer, along with length and year of manufacture,
must be entered in the electronic type plate in the appropriate location (AF-28 to AF-63,
screen 5.4).
Screen 5.4: Serial numbers of the transducers
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
D. Creating a test certificate

A new test certificate must be created after the parameter adjustment is completed. For this purpose,
select the function "Reports" -> "USM GT400 Test Certificate" (screen 5.5) and then enter
transducer type, test mark, test location and test date, as well as place and date of issue (screen 7.9).
The test certificate must then be saved as a PDF document.
35
Screen 5.5: Creating a test certificate
Screen 5.6: USM GT400 test certificate input field
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.2 Electronics
5.2.1 Opening the housing
Attention: The meter supply voltage must be switched off before you open the electronics housing
in order to eliminate the risk of explosion!
36 Holes
Threaded pin
First remove the threaded pin with which the housing cover is fixed.
There are two holes in the housing cover to accommodate the opening handle. Insert the opening
handle in the holes and turn the housing cover counterclockwise. Set the cover aside and make sure
that the cover and thread are not damaged. Otherwise the explosion protection is no longer assured.
5.2.2 Display circuit board
Mounting bridge
The display circuit board is fastened with four screws. Unscrew these screws, carefully remove the
display circuit board and place it on the connection box. Now remove the mounting bridge fastened
with spacer bolts and then unscrew the flat tape plug connector.
Make sure that no screws or washers fall into the housing, because they can cause short-circuits.
The display circuit board can be rotated 90° or 180° for assembly.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.2.3 Complete electronics

5.2.3.1 Firmware version and parameterization for a replacement of the electronics
Each of the ultrasonic electronics units of the USM GT400 has an individual parameterization with
device-specific alignment values of the analog inputs and outputs and the meter-specific settings,
geometric data and correction values. With the replacement of one of the ultrasonic electronics,
it is important to transfer the meter-specific values to the new electronics without having to
overwrite the device-specific alignment values! In order to ensure this, the necessary steps must
be performed as described in section 7.1. 37
5.2.3.2 Electronic unit removal and installation

1. Remove the display circuit board (see above).
2. Unscrew the two screws on the terminal cover and raise the terminal cover. Then unscrew the
PE line and remove the terminal cover.
3. Pull off the two terminal plug connectors upwards.

4. Pull the 12 plug connectors of the transducer cables.
5. Pull all cables upwards and fix them (e.g. with adhesive tape) so that there are as few cables as
possible in the interior of the housing.
6. Using a magnetic screwdriver, unscrew the four Allen screws with which the electronics unit is
fastened in the housing.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
7. Pull the electronics unit upwards out of the housing. To do so, it is necessary to tilt the unit
slightly towards the connection box in order to navigate around the connection cables.
8. Insert the new electronics unit in the housing and fasten with the four Allen screws.
9. Re-connect the plug connectors of the transducer cables. In the process, pay attention to the
labeling of the lines.
10. Plug in the terminal plug connector.
38 11. Re-connect the PE line to the terminal cover and screw on the terminal cover.
12. Mount the display circuit board (see above).
5.2.4 Mux card

2. Pull the 12 plug connectors of the transducer cables.
3. Unscrew the cover plate. There are three mux cards arranged below it.
4. Pull the defective card out vertically and insert the new card into the now unoccupied slot.
5. Mount the cover plate and plug in the signal cable. In the process, pay attention to the labeling
of the lines.
5.2.5 Options card 1

2. Unscrew the circuit board cover – multiple circuit boards are then revealed. Options card 1 is
recognizable by the block with 8 DIL switches.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
39
3. Options card 1 has two tabs at the top that protrude slightly over the side walls. Grasp the
options card by the tabs and carefully pull the card out upwards.
Jack for
AD card
4. Then insert the new card in the indicated direction (DIL switches face away from the transducer
cables). The card must be flush at the top with the side walls.
5. Re-mount the circuit board cover.
5.2.6 AD transmitters for p and T sensors (Options card 2)

The AD converters are located on Options card 2, which is plugged into Options card 1.
1. Remove Options card 1 (see above).
2. Plug Options card 2 into Options card 1.
3. Re-insert Options card 1.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.3 Re-calibration
In Germany and many other countries, calibration is performed by an authorized organization and
the service is only relevant in the case of a removal or installation and a connection of the meter.
However, a dry calibration can substitute a re-calibration in some countries. Therefore, it is
described below.
40
5.3.1 USM dry calibration in accordance with AGA 9 with nitrogen
We recommend a nitrogen pureness of 3.0 or higher (N2 > 99.9 %).
Basically, the dry calibration is in accordance to AGA 9 for the speed of sound test (max. deviation
= 0.2 % from the set point) and the zero-flow test (max. 0.006 m/s). Proceed as follows.
5.3.1.1 Setup and connection

The meter must be closed with the blind flanges. They must be fitted with porous foam (e.g. BASF
Basotect) in order to prevent superimposing of signals from echoes reflected off the wall. Since a
PT100 temperature sensor is required, at least one thermocouple screw connection must be provided
in the center of the flange. A pressure transducer with a suitable measuring range must also be
connected to the Pr connection and two additional connections must be provided for evacuation
and/or flushing. After a leakage test, the meter is evacuated with a vacuum pump and then filled to
the desired calibration pressure with nitrogen. Then a stabilization time of at least 2 hours, possibly
more, is required so that a temperature-related equalization movement inside the meter can be
eliminated. The calibration should be performed in an air-conditioned room in order to ensure
temperature stability. Radiation from energy-intensive light sources (e.g. halogen lamps) on the
meter must be avoided.
On the USE side, a voltage supply with 24 VDC to Terminal 1(+), 2(-) and the PE terminal as well
as the service interface to Terminal 15 (Ground), 16(a and/or Tx) and 17 (b and/or Rx) are required
for the calibration. The latter must be connected to the PC via interface converter RS-485/USB. The
pressure transducer must also be connected to Terminal 26 (+) and 27 (-) and the temperature
transducer must be connected to Terminal 28 (red/blue), 29 (red), 30 (white) and 31 (white/blue).
On the hardware side, the two options cards are required for measurement processing of the
pressure and temperature transducers and it may be necessary to retrofit Options card 2. Sufficient
grounding and shielding of the meter must be provided according to the wiring instructions in the
operating manual.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
5.3.1.2 Dry calibration process description

The signals must be optimized before the actual dry calibration can begin. For this purpose, the
signal tracking in AI-27 must be deactivated (select OFF) and the amplification must be adjusted
appropriately.
A. Amplification adjustment
41
Screen 5.7: DSP parameter column AI
Depending on the later testing and/or operating pressure and the gas composition to be expected, the
amplification of the ultrasonic signals must be adjusted (ADC gain: factor 0.5/1/2) and a speed of
sound set point must be specified. For very low operating pressures below 10 bar, the attenuator
must be deactivated (screen 5.7).
The standard setting (nitrogen) for the delta T offset – calibration at 110 bar (ANSI 600) is
attenuator "ON", SoS "375 m/s" and ADC-Gain "0.5" (for TNG 20-LP) and/or "1" (for TNG 10-
CP).
The settings attenuator "ON", SoS "355 m/s" and ADC-Gain "2" must be selected for pressures
below 50 bar.
The parameters must be set as follows for testing with atmospheric air:
Attenuator "OFF", SoS "345 m/s" and ADC-Gain "2".
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
B. Path length correction

The speed of sound set point is required for the path length correction. This can be determined in
coordinate A-17 / B-17 after activation of the pressure and temperature inputs. For this purpose,
select p-mode "4-20mA" in A-17, enter the measurement range limits of the pressure transducer in
A-5 / A-6 and select T-mode "PT100" in B-17.
The mechanical path lengths that were detected after transducer installation by means of an inner
micrometer and entered in the measurement log do not correspond exactly to the acoustic path
lengths. Therefore, there may be deviations from the set point in the individual path speeds.
42 Therefore, the path lengths must be corrected. Normally, this correction is within a range of a few
tenths of a millimeter (max. +0.35 mm). For this purpose, first open a new plot and select the speed
of sound window. Then open a new values table and switch the SoS mode from "STANDARD" to
"EXTENDED" in coordinate E-15 (screen 5.8).
Screen 5.8: Speed of sound mode "SoS mode (standard / extended)"
The speed of sound measurements of the individual paths should now run together (screen 5.9).
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
43
Screen 5.9: Path length calibration to speed of sound
Now open a new list and select "Dry Calibration". The pressure and temperature values are
displayed at the top (screen 5.10); they can be used to calculate the speed of sound at
http://www.peacesoftware.de/einigewerte/stickstoff_e.html. In Version 1.403 or higher, the set
point according to AGA 10 is also calculated directly in the USE09. For this purpose, enter the gas
analysis (100% nitrogen in this case) in the AX column and activate the calculation by selecting
"SPECIFICATION" in AX-1 as well as "USE09" in AX-2 and AX-3. The calculated set point is
available in AW-3 and can be compared with the average measured speed of sound in AW-2. The
percentage and absolute deviation between the two values is also shown in AW-4 and AW-5.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
44
Screen 5.10: "Dry Calibration" log file
Then open a new values table and select columns AK to AP "Path 1 to 6 parameters" and adjust the
path length in line 23 until the measured individual path velocities are as close to the calculated set
point as possible. Basically, a 0.1 m/s speed of sound correction corresponds approximately to a
path length change of 0.1 mm.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
45
Screen 5.11: Path parameters in columns AK to AP
If a gradient of the speed of sound measurements indicate that paths 1 and 2 have the largest value
and paths 5 and 6 have the lowest value, a real temperature gradient inside the meter must be
assumed. In this case, either the stabilization time must be extended or the path length must be
adjusted while maintaining the level distances and the average level (paths 3 and 4). If all path
lengths are corrected, the SoS mode in E-15 must be reset to "STANDARD" and the Tw damping in
E-24 must be set to 0.9 (screen 5.8).
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
C. Calibration of the delta T offset

If the Delta T calibration has not taken place during the leak and strength testing, it must be carried
out after the path length correction. For this purpose, open six new plots and then assign the
selection dT P1 to dT P6 to the individual graphs (screen 5.12). The uncorrected runtime difference
dT is shown in green. The path-based delta T offset must be selected such that the average is zero.
The corrected blue curve should then oscillate around zero. The correctness of the selected
correction values can be checked in the USE09-C measurements column. All measurements here
should be approximately zero. For this purpose, the Vmin shutoff should be set to 0 m/s in coordinate
46 D-8. Normal calibration values lie within +/- 0.02 µs. If there are significantly different values here,
e.g. on the middle paths 3 and 4, an actual flow in the meter interior must be assumed. The
stabilization time must be extended and possible causes must be eliminated: leaks, convection due
to temperature differences, possibly also electrical interference or acoustic echoes (ground the
meter, check/replace the foam coating of the blind flange). Read and check the raw signals. By
varying the face times in AK-22 to AP-22, it can be determined whether it involves echoes/
interference or real signals. Reals signals remain, whereas interferences wanders over the duration
of the fade time.
Screen 5.12: New plot (dT P1 in this case)
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
D. Tw calibration (RMG Precision Adjustment)

The Tw calibration is the actual dry calibration. The individual speeds of sound are calibrated to the
setpoint and the electronics are set to the condition as supplied with respect to the speed of sound
measurement.
Then the actual status must be determined for the calibration certificate. For this purpose, open a
new window and select "Dry Calibration" (screen 5.13) and then click on the button. Assign the
file name DC1_meternumber.csv (Screen 5.14) and allow the recording to run for several minutes.
Then stop the recording with the button.
47
Screen 5.13: Data recording in the "Dry Calibration" window
Screen 5.14: Log file before Tw calibration Screen 5.15: Log file after Tw calibration
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
48
Screen 5.16: TW calibration with RMG Precision Adjustment in coordinate E-21 “TW SET”
Transfer the Tw values calculated in the background by means of echo measurement (=RMG
Precision Adjustment) to the respective path coordinates AK-14 to AP-14 in coordinate E-23 with
the "SET" command (Screen 5.16). Then check in the speed of sound plot whether the paths were
corrected appropriately (screen 5.17) and make any necessary changes manually! With larger pipe
sizes (DN400 or higher) – i.e. long measurement paths – there may be limitations in the use of echo
measurement depending on the test pressure and transducer quality. In this case, the suitable Tw
must be entered manually in line 14 of the path parameters (columns AK to AP). With these pipe
sizes, Tw is calculated from the measured average flight time Fm, the saved path length P and the
speed of sound set point Cs based on the formula.
Tw = Fm – P / Cs
However, Tw can be determined empirically more quickly and easily. 0.1 µs corresponds to
approximately 0.1 m/s, depending on the path length. Realistic Tw values lie between 6.5 µs and
18 µs, depending on transducer frequency and cable length. 200 kHz transducers are at 7 µs and
120 kHz transducers at 15 µs. This value also increases with the cable length.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
49
Screen 5.17: Speed of sound measurement after Tw calibration
If all paths are calibrated to the set point, the delta T offsets must be checked again and corrected as
necessary. Proceed iteratively, because delta T and Tw corrections influence each other. Check in
the DryCal list that all paths do not exceed the 0.006 m/s required by AGA-9 and the speed of
sound values do not differ from the set point by more than 0.1 m/s (AGA 9 requires 0.2%). Then the
DryCal Log file must be restarted and saved as DC2_meternumber.csv (screen 5.15). Record the
measuring data for several minutes and then save the speed of sound plot as C.jpg. Finally, save the
parameters log as Parameters_DC_meternumber.csv. Do not forget to set the Vmin shut-off in
coordinate D-8 to 0.1 m/s and deactivate the pressure and temperature inputs in coordinates A-17 /
B-17 ("OFF" selection). The signal tracking in coordinate AI-27 must also be switched on again.
...............................................................................................................................................................................................................
6 DOCUMENTATION OF THE DEVICE STATUS
...............................................................................................................................................................................................................
6 Documentation of the device status

6.1 Logs / documentation
6.1.1 Test logs
50
Screen 6.1: Testing
The service program RMGViewUSM makes it possible to carry out a meter test. For this purpose, a
duration of time is specified during which the meter is monitored and the measurement results and
most important graphics of the instrument board are saved in a log. The test is started in the menu
under "Reports/Run inspection". The following dialog window opens:
Screen 6.2: Log files
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
The names of the output files (as csv tables and pdf) can be entered here and the duration of the
recording can be entered under "Log duration". There are three options under "Source AGA10 Sos"
for determining the theoretical speed of sound:
− Manual input: Enter the value in the field and start the test with "Run inspection!".
− USM calculated SoS: The value is calculated by the meter based on the analysis values in
column AX, start with "Run inspection!".
− AGA 10: Continue with the button "AGA10 settings". An input window appears for the gas
composition, pressure and temperature:
51
Screen 6.3: Gas composition for AGA 10
After input of the values, start the test with the "Run inspection!" button.
After the test is completed, a window with the test log appears.
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
6.1.2 Calibration logs
52
Screen 6.4: Test certificate selection
Calibration logs are created with "Reports/Test certificates". There are various test certificates
available for the USM GT400.
With the licensed version of RMGViewUSM, it is also possible to create user-defined test
certifications with free selection of text and parameters. A company logo can also be placed on the
test certificate. For this purpose, it is necessary to switch to expert mode with the expert password .
The log editor can be reached through the path "Reports/User-defined reports/Report editor". A test
certificate screen can be saved as a .rpr file and can be loaded as a standard test certificate at a later
time.
After the start of the protocol editor, the input can take place as follows:
Graphic: A logo can be loaded at the top left as a .jpg file. The position and height of the
graphic can be adjusted at the bottom left. Then transfer it to the list to the right with
"+".
Text: Text can be entered below the input field for the graphic file name. The position and
height of the test can be adjusted. After entry of the text, parameters and input
variables transfer them to the list with "+".
Parameters: Select parameters to be displayed from the list and then transfer the coordinate,
name, value and unit to the text input field as necessary with " ".
Input: A dialog field can be created with the ASK field. The dialog field can be used to
query the station name, for instance, with the creation of a test certificate. This value
is entered as a variable in the text input field.
The layout of the test certificate can be viewed with "Test"; the created test certificate can be saved
as a .rpr file with "Save".
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
53
Screen 6.5: Report editor
6.2 Communication with RMG Butzbach

6.2.1 Archiving
In order to provide support from Butzbach, the current status of the meter must be known in the
factory. For this purpose, it is necessary to report every change to RMG so that it can be recorded in
our database.
We require:
− After a transducer replacement, the serial numbers of the installed and removed transducers
with specification of the serial number of the meter.
− After commissioning or a firmware update, the parameter report of the meter as a csv file with
the serial number as file name, e.g. "Parameterization_12345678.csv" as well as the test report.
Send the data to: [email protected]
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
6.2.2 Support from RMG Service

When contacting RMG Service for support, the following additional information is helpful:
− The parameter report in order to ensure that RMG Service receives the current data. Creation
of the report is described on page 55.
− Test report (pdf file) of a meter test (see page 50) with a duration of at least 2 minutes.
− Log file for this test (csv file). The file name and path are entered in the first dialog window,
which appears after selection of the menu "Reports/Run inspection".
54 − The recording of raw signals if there are transducer problems. For this purpose, have the
corresponding signal curve displayed in the "Raw data" window. The raw data can be saved
with the button.
Select path
Screen 6.6: Raw signal
...............................................................................................................................................................................................................
7 SPARE PARTS
...............................................................................................................................................................................................................
7 Spare parts
7.1 Software and firmware update
7.1.1 Saving the parameterization
Before a firmware flash, save the parameterization with RMGViewUSM. For this purpose, select
"Reports" in the menu bar, then the submenu "Parameter report" (screen 7.1) and the data record 55
under the serial number of the ultrasonic gas flow meter as a csv file (e.g. 12345678.csv, screen 7.3).
Screen 7.1: Reports -> Parameter report -> "12345678.csv"
7.1.2 Firmware check

Then the installed firmware version of the electronics to be replaced must be checked. It can be read
with RMGViewUSM or the operating panel in the type plate column AF (screen 7.2). If this is not
possible due to an electronics defect, the firmware version can be found in the "USM GT400" test
certificate. The test certificate can be requested from RMG.
If the version of the replacement electronics does not match that of the defective electronics, a
firmware flash must be performed. Please contact RMG Service before any firmware update.
...............................................................................................................................................................................................................
7 SPARE PARTS
...............................................................................................................................................................................................................
56
Screen 7.2: Type plate with firmware version
7.1.3 Firmware flash

The firmware comprises three components: USBios.mot, Fpga.mot and dsp.mot. These three
components are loaded with the program HexLoad. The procedure is explained in detail in the
document "Flashprogramming.pdf". In short, the USBios.mot file is transferred via the menu item
"Target" -> "Auto" and the files Fpga.mot and dsp.mot are transferred individually in success via
the menu item "Target" -> "Program". Then the close calibration and service switch and open it
again. The parameterization can take place after the restart of the electronics. For this purpose, first
deactivate the log memory by selecting YES in coordinate AT-13 "New! Parametrize".
Screen 7.3: Saving a parameter file Screen 7.4: Password input
...............................................................................................................................................................................................................
7 SPARE PARTS
...............................................................................................................................................................................................................
7.1.4 Loading the standard data set and original parameterization

Then the standard data set for the respective firmware version must be loaded with Blacklist2
(standard data set, screen 7.6). For this purpose, first enter the password for expert mode (screen
7.4) in the menu bar under "Monitor" (screen 7.1). Then select the "Tool" button and the submenu
"Parametrize USM" (screen 7.5) and transfer the corresponding csv file (screen 7.6). Then load the
saved original parameterization with Blacklist3 (software update, screen 7.7) and deactivate the
function "New! Parametrize" in coordinate AT-13 (NO). Otherwise, the USE9 returns the error
message "Test mode". 57
Screen 7.5: Parametrize USM
Screen 7.6: Load standard data set Screen 7.7: Select Blacklist
7.1.5 Functional test of the ultrasonic electronics

After a firmware update, the electronics must be tested for fault-free function. For this purpose, the
measurements of the C and AB column are checked for plausibility and the status information in the
menu bar is checked (screen 7.8). The meter symbol should be outlined in green and the
performance display should indicate 100%. Any error texts are explained in the operating manual
and can be corrected with appropriate measures. With updates from older firmware versions,
manual parameter adjustments may be necessary in the type plate column and the path and DSP
parameters. Refer to the document "Information for the firmware update for ultrasonic gas
flowmeters".
...............................................................................................................................................................................................................
7 SPARE PARTS
...............................................................................................................................................................................................................
58
Screen 7.8: Status information and measurements
7.1.6 Documentation of parameter changes

The test certificate for the electronics and new parameterization must be created with the function
"Reports" -> "Test certificates" in the menu bar (screens 7.9 and 7.9), the input field must be filled
out (test certificate, location, date, etc.) and the test certificate must be saved as a PDF document.
The parameterization must also be saved as a csv file in the form "Parameterization_12345678.csv"
with the function "Reports" "Parameter report" and then sent together with the inspection report to
the inspection authority for archiving purposes.
...............................................................................................................................................................................................................
7 SPARE PARTS
...............................................................................................................................................................................................................
59
Screen 7.9: Creating a test certificate
Screen 7.10: Test certificate input field

...............................................................................................................................................................................................................
7 SPARE PARTS
...............................................................................................................................................................................................................
7.2 Mechanical parts / electronics

Description Order number
Electronics
USE 09, complete electronics 98800-14400
USE 09, display circuit board 98800-13352
USE 09, Options card 1 (RS485 and pulse outputs) 98800-13512
USE 09, Options card 2 (P&T inputs) 98800-13762
60
Magnetic pen for operation of the USE 09 00.60.553.00
External elements
Weather protection cover for electronics housing 00.65.142.00
Complete grill element DN 100 (4”) 00.64.923.00
Complete grill element DN 150 (6”) 00.64.855.00
Transducer cover for DN 100 (4”) & DN 150 (6”) 00.64.811.00
Grill element DN 200 (8”) 00.64.798.00
Grill element DN 250 (10”) 00.64.860.00
Grill element DN 300 (12”) 00.64.862.00
Grill element DN 400 (16”) 00.64.864.00
Grill element DN 500 (20”) 00.64.866.00
Grill element (middle level) DN 600 (24”) 00.64.868.00
Grill element (outer levels) DN 600 (24”) 00.64.926.00
Cable bushing M20x1.5 (Ø 3-9) 87.06.050.00
Cable bushing M20x1.5 (Ø 6-12) 87.06.051.00
Pipe bundles
Pipe bundle for DN 100 (4”) 00.64.767.01
Transducers
USM transducer TNG 10-CP (DN 200-600) 38.00.010.00
USM transducer TNG 20-CP (DN 100-150) 38.00.011.00
Tools for transducer replacement
Special tool for transducer replacement DN200 (8”) 00.64.669.00
Special tool for transducer replacement under pressure (TNG 10) 00.61.128.00
Interface converter
RS 485 to USB converter for top hat rail (I-7561U-G CR) 30.00.212.00
RS 485 to Ethernet converter (FL Comserver) 35.00.023.00
...............................................................................................................................................................................................................
8 TOOLS / SPECIAL TOOLS
...............................................................................................................................................................................................................
8 Tools / special tools

When working on the ultrasonic meter, be sure to pay attention to your special equipment.
You require:
− Fire extinguisher 61
The following tools are required for service work:
Tool Transducer replacement Pipe bundle / Electronics

grill elements
under pressure depressurized
Allen key AF 1.5, AF 2, AF 1.5, AF 4, AF 4, AF 5, AF 2.5
AF 4, AF 5, AF AF 5, AF 6 AF 6
6, AF 10 and
AF 10 long
Grooved nut key - -
Open end wrench AF 12, AF 22 AF 12, AF 22 - AF 5
and AF 32
Slot socket key* DN 200 or DN 200 or DN 200 or -
larger larger larger
individual size for each

pipe size!
Screwdriver Slot - - Slot, Phillips
Pipe wrench suitable for AF - - -
65
Torque wrench with AF 22 AF 22 - -
open-end wrench
Opening handle* - - 2x 2x
*RMG special tool (can be ordered as a spare part)
...............................................................................................................................................................................................................
APPENDIX
...............................................................................................................................................................................................................
Appendix
USE 09 flash programming
The program "HexLoad" is required for flash programming of the USE09.
62
Screen 8.1: Starting HexLoad
The correct COM port must be selected if that has not already been done. The menu "Options-
>Project..."
opens the "Options" dialog (screen 8.2) where the baud rate (115200) and port can be set.
Screen 8.2: Options dialog
...............................................................................................................................................................................................................
APPENDIX
...............................................................................................................................................................................................................
After all settings have been made, a connection to the device must be established. Therefore, the
device must be switched on and/or reset. Now the connection data is displayed in the Target
window (screen 8.3).
63
Screen 8.3: Connection to M32 with closed front key
As shown in the Target window, the calibration switch / front key may still be closed. In this case, it
must be opened and the connection window appears as shown in screen 8.4.
Screen 8.4: Connection to M32 with open front key
...............................................................................................................................................................................................................
APPENDIX
...............................................................................................................................................................................................................
If the connection has been established, the flashing can begin. The flashing comprises 3 processes:
1. Flashing of M32-Bios
2. Flashing of DSP-Bios
3. Flashing of FPGA-Bios
64
Screen 8.5: Starting the flash process for the M32
The M32-Bios "USBios.mot" is opened from the menu "File->Open...". The currently loaded flash
file is displayed in the "Project" windows. The flash process is started with the F9 key or the menu
"Target->Auto" (screen 8.5).
Now the "Clear target", "Programming target", "Make valid" and "Get CRC" windows are opened
in succession. Then the "Auto" dialog appears with the message "Job succeed" (screen 8.6).
...............................................................................................................................................................................................................
APPENDIX
...............................................................................................................................................................................................................
65
Screen 8.6: Flash routine for M32-Bios
Now the flashing of FPGA and/or DSP-Bios can begin, wherein the sequence does not matter. The
bios for the DSP "DSP.mot" is loaded via the menu "File->Open...". The flash process is started
with the F7 key or the menu "Target->Program".
The FPGA-Bios is programmed by repeating the process with the file "FPGA.mot".
When successful, the respective dialog window "Programming target" appears with the message
"Target programmed" for both processes (screen 8.7).
Screen 8.7: "Programming target" dialog window
...............................................................................................................................................................................................................
Subject to technical modification
For further information

please visit our website:
www.rmg.com
or contact your local sales support
office to learn more about
products and solutions from RMG.

Otto-Hahn-Straße 5
35510 Butzbach, Deutschland
Tel: +49 (0) 6033 897 – 0
Fax: +49 (0) 6033 897 – 130
Internet: www.rmg.com
Tel: 55 53658200, 63645537
1.7 Certificado de calibración
Ultrasónico RMG 8” 600# N/S: 827610 y

Acondicionador de flujo CPA
50E N/S: 6305-012
CERTIFICATE OF CALIBRATION
Traceable to the
NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY
Serial Number: 827610
Job Number: CE36795 CEESI Data File(s): 23SIGMA-0062 23SIGMA-0063
Item Calibrated: Ultrasonic Flowmeter Customer: ARES CONTROL S.A. DE C.V.

Report Number: Address: NYC OFFICE
Model Number: USM-GT-400 111 WEST 19Th STREET, 8Th FLOOR
Order: 1109 NY 10011
Date: April 06, 2023
The calibration identified by the above CEESI DATA FILE(s) was performed in accordance with the
American Gas Association TMC Report Number 9 using calibration standards that
are traceable to the National Institute of Standards and Technology. All natural gas properties were
calculated in compliance with American Gas Association TMC Report Number 8 and TMC Report
Number 10.
Calibration Performed at: CEESI Iowa High Flow Natural Gas Facility
2365 240th St.
Garner, Iowa 50438
Calibration Performed by: Evan Pischel
Jason Johansen Bryan Trostel

Measurement Assurance On Behalf of Colorado Engineering Experiment
Station Inc.
NOTE:
This Certificate and accompanying documentation shall not be reproduced, except in full, without the written
consent of Colorado Engineering Experiment Station Inc.
54043 County Road 37 | Nunn, Colorado 80648 | +1 (970) 897-2711 | +1 (970) 897-2710 (fax) | CEESI.com
Calibration Overview
Item Calibrated: Ultrasonic Flowmeter
Job Number: CE36795
Data File Number(s): 23SIGMA-0062

23SIGMA-0063
Order Number: 1109
Model Number: USM-GT-400
Part Number: N/A
Tag Number: N/A
Electronics Serial Number:
Calibration Date: April 06, 2023
Inlet Diameter: 7.620 Inches (193.548 mm)
Meter Diameter: 7.620 Inches (193.548 mm)
Fluid Type: NATURAL GAS
Standard Density: 0.049388 lbm/cubic foot (0.791123 kg/m³)
Standard Pressure: 14.73 PSIA (101.55977 KPa)
Standard Temperature: 60 °F (15.56 °C)
SPU Revision Number: 1.523
Meter Output: Modbus
23SIGMA-0062 23SIGMA-0063 Page 2 of 22

Witness List
Job Number: CE36795 Data File Number: 23SIGMA-0062 23SIGMA-0063
David Schwartzenburg - RMG

Uni-directional Calibration Configuration Details
Figure 1: Piping Configuration
Meter Tube Identification:
Identifier Length Serial Number

B - Upstream Tube 80 Inches (2032.0 mm) Not Present
D - Inlet Tube 80 Inches (2032.0 mm) Not Present
E - Exit Tube 40 Inches (1016.0 mm) Not Present
Meter Flow Conditioner Identification:
Identifier Installed Manufacturer Serial Number Flow Arrow Top Dead Center
C - Upstream Flow Conditioner Yes CPA 50E 6305-012 Verified Verified
Meter Thermowell Identification:
Identifier Distance to Closest Meter Flange Face Quantity

F - Exit Thermowell 24 Inches (609.60 mm) 2
Fitting Identification:
Identifier Type
A - Entrance Fitting Straight Pipe
G - Exit Fitting Straight Pipe
Meter package assembled manually using CEESI provided parts, and was disassembled for shipment to the customer

Velocity of Sound Verification
Component Value
Press Temp Calc VOS Meter VOS VOS Error
Methane 82.4985 [psia] [°F] [ft/sec] [ft/sec] [%]
Nitrogen 2.7596 993.40 64.73 1262.9 1262.2 -0.050
Carbon Dioxide 0.9837
Ethane 12.9888
Press Temp Calc VOS Meter VOS VOS Error
Propane 0.6241 [bara] [°C] [m/sec] [m/sec] [%]
Hydrogen 0.0776 68.492 18.18 384.9 384.7 -0.050
Iso-Butane 0.0142
Normal-Butane 0.0248
Iso-Pentane 0.0020
Normal-Pentane 0.0020
C6+ 0.0004
Helium 0.0244
Heating Value 1085.804
(BTU/ft³)
Total UnNormalized (%) 100.2945
Table 1: Used For Speed of Sound Verification

Calibration Data - 23SIGMA-0062
The calibration results are summarized in the table below. The column labeled 'Calibration Factor' is the value by
which the volume flowrate is multiplied to achieve the corrected value.
CEESI Flowrate Meter Flowrate Velocity Calibration Factor Percent Error

[ACFH] [ACFH] [ft/sec] [%]
114769.5 114874.1 100.8 0.99909 0.091

86256.07 86240.23 75.6 1.00018 -0.018
57620.81 57587.54 50.5 1.00058 -0.058
29138.73 29132.07 25.6 1.00023 -0.023
11588.43 11593.63 10.2 0.99955 0.045
5822.423 5821.701 5.11 1.00012 -0.012
2908.018 2908.163 2.55 0.99995 0.005
Table 2: Calibration Results

Coefficient Data
Upon completion of the calibration the coefficients listed below were entered into the meter.
1 2908 1 0.0000
2 5822 2 -0.0100
3 11594 3 0.0400
4 29132 4 -0.0200
5 57588 5 -0.0600
6 86240 6 -0.0200
7 114874 7 0.0900
8 0 8 0.0000
9 0 9 0.0000
10 0 10 0.0000
11 0 11 0.0000
12 0 12 0.0000
Table 3: Coefficient Inputs

Calibration Results - 23SIGMA-0062
Figure 2: Calibration Results

Calibration Data Table - 23SIGMA-0062
Press Temp Density Lab Flowrate Lab Flowrate Meter Flowrate Percent Error
[psia] [°F] [lbm/ft³] [ACFH] Uncertainty [ACFH] [%]
[%]
993.40 64.73 3.9421 114802 0.18 114890 0.077
993.12 64.75 3.9404 114709 0.18 114881 0.150
992.68 64.77 3.9382 114779 0.18 114791 0.011
992.51 64.78 3.9381 114788 0.18 114933 0.127
994.67 65.06 3.9431 86639.7 0.18 86593.1 -0.054
994.42 65.05 3.9420 86384.3 0.18 86396.6 0.014
994.08 65.05 3.9417 86006.7 0.18 86009.8 0.004
993.95 65.04 3.9412 85993.7 0.18 85961.5 -0.037
1003.3 65.40 3.9790 57531.2 0.23 57501.8 -0.051
1003.2 65.38 3.9788 57656.8 0.23 57629.7 -0.047
1003.1 65.36 3.9783 57781.9 0.23 57760.3 -0.037
1002.3 65.30 3.9752 57513.4 0.23 57458.4 -0.096
1004.2 65.32 3.9814 29107.9 0.23 29110.3 0.008
1002.3 65.04 3.9748 29128.7 0.23 29139.0 0.036
1001.9 65.00 3.9738 29106.4 0.23 29082.8 -0.081
1001.6 64.96 3.9727 29211.9 0.23 29196.2 -0.054
1000.6 64.74 3.9728 11601.3 0.23 11603.5 0.019

Calibration Data Table - 23SIGMA-0062
[%]
999.56 64.58 3.9726 11569.5 0.23 11580.9 0.098
999.15 64.53 3.9713 11581.7 0.23 11580.1 -0.014
998.22 64.42 3.9685 11601.2 0.23 11610.0 0.076
996.37 64.18 3.9643 5836.26 0.23 5840.92 0.080
995.88 64.10 3.9630 5819.42 0.23 5817.72 -0.029
995.61 64.01 3.9644 5821.43 0.23 5820.50 -0.016
995.70 63.97 3.9655 5812.59 0.23 5807.66 -0.085
995.99 63.97 3.9683 2933.30 0.23 2932.85 -0.015
996.14 63.94 3.9694 2920.50 0.23 2923.96 0.119
996.37 63.94 3.9705 2900.97 0.23 2899.09 -0.065
996.85 63.92 3.9751 2877.29 0.23 2876.75 -0.019

Verification Data - 23SIGMA-0063
The verification results are summarized in the table below.
CEESI Flowrate Meter Flowrate Velocity Percent Error

[ACFH] [ACFH] [ft/sec] [%]
57822.44 57812.44 50.7 -0.017

11564.86 11567.78 10.1 0.025
Table 5: Verification Results

Verification Results - 23SIGMA-0063
Figure 3: Verification Results

Verification Data Table - 23SIGMA-0063
[%]
993.28 64.28 3.9545 57822.4 0.23 57812.4 -0.017
998.81 64.50 3.9871 11564.9 0.23 11567.8 0.025

Metric Calibration Data - 23SIGMA-0062
The calibration results are summarized in the table below. The column labeled 'Calibration Factor' is the value by
which the volume flowrate is multiplied to achieve the corrected value.
CEESI Flowrate Meter Flowrate Velocity Calibration Factor Percent Error

[ACMH] [ACMH] [m/sec] [%]
3249.910 3252.872 30.7 0.99909 0.091

2442.500 2442.051 23.1 1.00018 -0.018
1631.640 1630.697 15.4 1.00058 -0.058
825.1170 824.9284 7.79 1.00023 -0.023
328.1478 328.2951 3.10 0.99955 0.045
164.8727 164.8522 1.56 1.00012 -0.012
82.34590 82.35001 0.777 0.99995 0.005

Coefficient Data
Upon completion of the calibration the coefficients listed below were entered into the meter.
1 2908 1 0.0000
2 5822 2 -0.0100
3 11594 3 0.0400
4 29132 4 -0.0200
5 57588 5 -0.0600
6 86240 6 -0.0200
7 114874 7 0.0900
8 0 8 0.0000
9 0 9 0.0000
10 0 10 0.0000
11 0 11 0.0000
12 0 12 0.0000
Table 8: Coefficient Inputs

Metric Calibration Results - 23SIGMA-0062
Figure 4: Calibration Results

Metric Calibration Data Table - 23SIGMA-0062
[bara] [°C] [kg/m³] [ACMH] Uncertainty [ACMH] [%]
[%]
68.492 18.18 63.147 3250.82 0.18 3253.33 0.077
68.473 18.20 63.120 3248.21 0.18 3253.08 0.150
68.443 18.21 63.084 3250.19 0.18 3250.53 0.010
68.431 18.21 63.082 3250.42 0.18 3254.54 0.127
68.580 18.37 63.162 2453.36 0.18 2452.04 -0.054
68.562 18.36 63.145 2446.13 0.18 2446.48 0.014
68.539 18.36 63.140 2435.44 0.18 2435.53 0.004
68.530 18.36 63.132 2435.07 0.18 2434.16 -0.037
69.175 18.56 63.737 1629.10 0.23 1628.27 -0.051
69.168 18.55 63.733 1632.66 0.23 1631.89 -0.047
69.158 18.54 63.727 1636.20 0.23 1635.59 -0.037
69.109 18.50 63.677 1628.60 0.23 1627.04 -0.096
69.236 18.51 63.776 824.245 0.23 824.311 0.008
69.103 18.35 63.671 824.832 0.23 825.125 0.036
69.080 18.33 63.653 824.202 0.23 823.533 -0.081
69.055 18.31 63.637 827.189 0.23 826.744 -0.054
68.992 18.19 63.638 328.511 0.23 328.574 0.019

Metric Calibration Data Table - 23SIGMA-0062
[%]
68.917 18.10 63.635 327.613 0.23 327.934 0.098
68.889 18.07 63.614 327.957 0.23 327.913 -0.014
68.824 18.01 63.569 328.509 0.23 328.759 0.076
68.697 17.88 63.502 165.264 0.23 165.397 0.080
68.663 17.84 63.481 164.788 0.23 164.740 -0.029
68.644 17.79 63.504 164.844 0.23 164.818 -0.016
68.651 17.76 63.521 164.594 0.23 164.455 -0.085
68.671 17.76 63.565 83.0619 0.23 83.0491 -0.015
68.681 17.74 63.584 82.6994 0.23 82.7974 0.118
68.697 17.74 63.601 82.1464 0.23 82.0930 -0.065
68.730 17.73 63.675 81.4759 0.23 81.4605 -0.019

Metric Verification Data - 23SIGMA-0063
The verification results are summarized in the table below.
CEESI Flowrate Meter Flowrate Velocity Percent Error

[ACMH] [ACMH] [m/sec] [%]
1637.349 1637.066 15.5 -0.017

327.4803 327.5631 3.09 0.025

Metric Verification Results - 23SIGMA-0063
Figure 5: Verification Results

Metric Verification Data Table - 23SIGMA-0063
[%]
68.484 17.94 63.345 1637.35 0.23 1637.07 -0.017
68.865 18.06 63.867 327.480 0.23 327.563 0.025

Uncertainty Analysis and Traceability
Uncertainty Analysis:
The uncertainty analysis for the Iowa facility is performed using methods documented in the ISO GUM and NIST
Tech. Note 1297. Each component of uncertainty is classified as Type A or Type B and assigned a statistical
distribution (normal or rectangular). Numerical values for standard uncertainty, degrees of freedom, and
correlation coefficients are estimated. Standard uncertainty values are propagated by addition in quadrature as
described in the ISO GUM. The effective degrees of freedom are estimated using the Welch-Satterthwaite
approximation.
The uncertainty values in the current report are stated with a coverage factor of k=2 which represents a
confidence interval of approximately 95%.
Traceability:
Traceability of pressure, temperature, and gas composition measurements is maintained based on traditional
instrument calibration. Traceability of flowrate measurement is based on periodic engineering analysis of data
from three sources:
1) Control Charts
2) Turbine Substitution Test
3) Direct Turbine Meter Calibrations

Job Number: CE36795 Data File Number: 23SIGMA-0062, 23SIGMA-0063
Addendum
Attached File(s) in Order
DACG Addendum 23SIGMA-0062.pdf
Disabled Path 23SIGMA-0064
As Found Config 827610 23SIGMA-0062.pdf
As Left Config 827610 23SIGMA-0063.pdf
REPEATABILITY
Repeatability is defined as the closeness of agreement between successive measurements of the same measure and
carried out under repeatability conditions. Repeatability conditions include the same measurement procedure, same
operators, same measuring system, same operating conditions and same location, over a short period of time.
Repeatability is calculated as the standard deviation of the data points obtained under repeatability conditions.
REPRODUCIBILITY
Reproducibility is defined as the closeness of agreement between successive measurements of the same measure and
carried out under reproducibility conditions. Reproducibility conditions will increase uncertainty after the meter has
been operating in the field. With the present calibration, reproducibility cannot be predicted because it depends on
the installation and operating conditions. CEESI has neither knowledge nor control of these conditions.
Reproducibility is not included in the estimate of combined meter uncertainty.
CEESI Flowrate Repeatibility Combined Meter

[ACFH] [%] Uncert* [%]
114769 0.053 0.209
86256 0.028 0.189
57621 0.022 0.234
29139 0.047 0.248
11588 0.044 0.247
5822 0.059 0.259
2908 0.068 0.268
*RSS combination of facility and repeatability uncertainties. Expressed at a 95% level of confidence (k=2).
LINEARITY
Linearity is defined as the maximum deviation from ideal meter performance. Linearity is defined as half of the
maximum peak-to-peak error in AGA 9.
Linearity is calculated as one half the maximum average error minus the minimum average error:
Maximum average error = 0.091%
Minimum average error = -0.058%
Linearity = +/-0.074%
MAXIMUM OBSERVED ERROR

A value of qt = 9500 ACFH is assumed.
The maximum observed error is the largest of the absolute values of maximum positive and maximum negative
errors
Low flow, below qt High flow, above qt

Maximum positive error 0.119 0.150
Maximum negative error -0.085 -0.096
23SIGMA-0062 23SIGMA-0063 Addendum 1, Page 1 of 1

CERTIFICATE OF CALIBRATION
Traceable to the SI
through THE NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY
Customer: ARES CONTROL S.A. DE C.V. Item Calibrated: Ultrasonic Flowmeter

Address: NYC OFFICE Model Number: USM-GT-400
111 WEST 19Th STREET, 8Th FLOOR Serial Number: 827610
NY 10011
Calibration Date: April 06, 2023 Order Number: 1109
CEESI Data File(s): 23SIGMA-0064 Job Number: CE36795
The uncertainty in the flowrate indicated by CEESI standards is contained in this report under
Statement of Uncertainties.
The calibration(s) identified by the above CEESI DATA FILE(S) were performed using standards
that are traceable to the SI through The National Institute of Standards and Technology. The
calibration(s) were performed in accordance with any or all of the following: The current revision
of CEESI PROCEDURE NO. 010; ISO/IEC 17025:2017; ANSI/NCSL Z540-1-1994; and
accrediting body requirements for quality system and technical competence.
Calibration Method: [ ] Primary [X] Secondary

This calibration is: [ ] As Found [X] As Left
04-11-2023
Bryan Trostel - Measurement Assurance Report Date
NOTES:
1. Re-calibration intervals should be determined by the user and based on meter type, conditions of use, and the degree of risk
associated with the measurement. Please contact CEESI for guidance in establishing adequate re-calibration intervals.
2. This Certificate and accompanying documentation shall not be reproduced, except in full, without the written consent of Colorado
Engineering Experiment Station Inc. The signing of the document does not claim or imply product certification, approval, or
endorsement by accrediting body, NIST, CEESI, or any agency of the federal government.
3. The attached calibration results, identified by the CEESI Data File Number(s), relate only to the meter(s) calibrated under this
CEESI Certificate of Calibration.
Form 140 1-15-2020

54043 County Road 37 | Nunn, Colorado 80648 | +1 (970) 897-2711 | +1 (970) 897-2710 (fax) | CEESI.com
Item Calibrated: Ultrasonic Flowmeter
Job Number: CE36795
Data File Number(s): 23SIGMA-0064
Order Number: 1109
Model Number: USM-GT-400
Part Number: N/A
Tag Number: N/A
Electronics Serial Number: N/A
Calibration Date: April 06, 2023
Inlet Diameter: 7.620 Inches (193.548 mm)
Exit Diameter: 7.620 Inches (193.548 mm)
Fluid Type: NATURAL GAS
Standard Density: 0.049529 lbm/cubic foot (0.793382 kg/m³)
Standard Pressure: 14.73 PSIA (101.55977 KPa)
Standard Temperature: 60 °F (15.56 °C)
Comments: Disabled Path
23SIGMA-0064
23SIGMA-0062 (Template
23SIGMA-0063
#:017-8F8) Addendum 2, Page 2 of 6
Job Number CE36795
Data File Number(s) 23SIGMA-0064
Average Pressure: 999.06 PSIA (68.883 Bar)
Average Temperature: 64.4 °F (18.0 °C)
Average Density: 3.9907 lbm/ft^3 (63.925 kg/m^3)
Average Viscosity: 7.1974E-07 lbm/(in*sec) (0.012853 cP)
Average Compressibility: 0.83259
Room Temperature: 70.961 °F (21.6 °C)
Barometer: 14.248 PSIA (0.982 Bar)
Relative Humidity: 24.112 %
23SIGMA-0064
23SIGMA-0063
Calibration of Ultrasonic Flowmeter
Job Number: CE36795 Data File Number: 23SIGMA-0064
Pt. Data point number
Mtr Read Customer meter reading, digital
Ind. VolF Indicated Volumetric flowrate at meter body, actual cubic feet per minute
VolFlow Volumetric flowrate at meter body, actual cubic feet per minute
%Error Percent error of indicated to true flowrate
MtrFactor Actual Volumeric flowrate/Indicated Volumeric flowrate
Vel Meter velocity, feet per second
ReyNo Pipe Reynolds Number, dimensionless
Density Flowing density at meter body, pounds mass per cubic foot
Press Meter body static pressure, pounds per square inch absolute
Temp Exit temperature, degrees Fahrenheit
Pt. Mtr Read Ind. VolF VolFlow %Error MtrFactor Vel ReyNo Density Press Temp
[-] [acfm] [acfm] [%] [-] [ft/sec] [-] [lbm/ft³] [psia] [°F]
1 11562.3 192.70 192.66 0.022 0.99978 10.139 2974929 3.9907 999.065 64.38
23SIGMA-0064
23SIGMA-0063
Metric Calibration of Ultrasonic Flowmeter
Mtr Read Customer meter reading, digital
Ind. VolF Indicated Volumetric flowrate at meter body, actual cubic meters per minute
VolFlow Volumetric flowrate at meter body, actual cubic meters per minute
%Error Percent error of indicated to true flowrate
MtrFactor Actual Volumeric flowrate/Indicated Volumeric flowrate
Vel Meter velocity, meters per second
ReyNo Pipe Reynolds Number, dimensionless
Density Flowing density at meter body, kilogram per cubic meter
Press Meter body static pressure, bar absolute
Temp Exit temperature, degrees Celsius
Pt. Mtr Read Ind. VolF VolFlow %Error MtrFactor Vel ReyNo Density Press Temp
[-] [acmm] [acmm] [%] [-] [m/sec] [-] [kg/m³] [bara] [°C]
1 11562.3 5.4568 5.4556 0.022 0.99978 3.0905 2974929 63.925 68.883 17.99
23SIGMA-0064
23SIGMA-0063
Statement of Uncertainties
Mtr Read Uncertainty in frequency
VolFlow Uncertainty in volumetric flowrate
Vel Uncertainty in velocity
ReyNo Uncertainty in Reynolds Number
Density Uncertainty of density
Press Uncertainty in pressure
Temp Uncertainty in temperature
All uncertainties are listed as a % of read at a 95% confidence level (k=2).
Pt. Mtr Read VolFlow Vel ReyNo Density Press Temp

[%] [%] [%] [%] [%] [%] [%]
1 0.33 0.23 0.23 2.3 - 0.0070 0.025
23SIGMA-0064
23SIGMA-0063
Parameter Report
4/6/2023 8:15:04 AM Page 1
Column A: Pressure
A-5 p min value 14.50 psi_a
A-6 p max value 290.08 psi_a
A-9 p set value 950.000 psi_a
A-11 p at base cond. 14.7300 psi_a
A-12 curr. inp. gradient 1.00000e+00
A-13 curr. inp. offset 0.00000e+00
A-14 p err. min 0.000 psi_a
A-15 p err. max 1450.377 psi_a
A-17 p mode SET VALUE
Column B: Temperature
B-9 T set value 60.00 °F
B-11 T at base cond. 60.00 °F
B-12 T gradient 1.00000e+00
B-13 T offset 0.00000e+00
B-14 T err. min 32.00 °F
B-15 T err. max 212.00 °F
B-17 T mode SET VALUE
Column D: USE09-C Qm
D-4 Qm min. 375.00 acfh
D-5 Qm max. 144000.00 acfh
D-6 vw factor d1 0.9970 [1]
D-7 vw factor d2 0.9970 [1]
D-8 vw lower limit 0.30 ft/s
D-9 Qm lower limit 375.00 acfh
D-10 Qm-min time 10000 s
D-15 Qm damping 0.000
D-16 pipe diameter 7.62 in
D-17 geometry correcting ON
D-18 temp. coefficient 4.12000e-05
D-19 pressure coeff. 6.00000e-06
D-20 Qm-max value 1 169260.69 acfh
D-21 Qm-max time 1 4/6/2023 3:13:25 PM
D-23 Qm-max time 2 4/6/2023 2:44:00 PM
Column E: Parameters
E-1 USE09 working mode USE09C
E-2 path select 11111100
E-3 max. path RV 2
E-4 fault time 1 s
E-5 error per cent 30 %
E-9 moving average cnt 10
E-15 SoS mode STANDARD
E-16 delta SoS mode ON
E-17 delta SoS limit 0.30 %
E-18 std. SoS corr-factor 0.65 [1]
E-19 adv. SoS corr-factor 0.00 [1]
E-20 std. SoS v factor 0.75 [1]
E-21 adv. SoS v factor 0.00 [1]
E-22 delta AGC limits 10.00 dB
E-23 Tw correct OFF

Parameter Report
4/6/2023 8:15:04 AM Page 2
E-24 Tw damping 0.00
Column F: USE09-C polynom-B

F-1 basic correction OFF
F-2 const Gm2 d.1 0.00000e+00 [1]
F-3 const Gm1 d.1 0.00000e+00 [1]
F-4 const G0 d.1 0.00000e+00 [1]
F-5 const G1 d.1 0.00000e+00 [1]
F-6 const G2 d.1 0.00000e+00 [1]
F-10 const Gm2 d.2 0.00000e+00 [1]
F-11 const Gm1 d.2 0.00000e+00 [1]
F-12 const G0 d.2 0.00000e+00 [1]
F-13 const G1 d.2 0.00000e+00 [1]
F-14 const G2 d.2 0.00000e+00 [1]

Parameter Report
4/6/2023 8:15:04 AM Page 3
Column G: Flow correction

G-1 error curve lin. OFF
G-2 const m2 d.1 0.00000e+00 [1]
G-3 const m1 d.1 0.00000e+00 [1]
G-4 const 0 d.1 0.00000e+00 [1]
G-5 const 1 d.1 0.00000e+00 [1]
G-6 const 2 d.1 0.00000e+00 [1]
G-10 const m2 d.2 0.00000e+00 [1]
G-11 const m1 d.2 0.00000e+00 [1]
G-12 const 0 d.2 0.00000e+00 [1]
G-13 const 1 d.2 0.00000e+00 [1]
G-14 const 2 d.2 0.00000e+00 [1]
G-20 dir. 1: flowrate 1 0.00 acfh
G-21 dir. 1: error 1 0.000 %
G-23 dir. 1: error 2 0.000 %
G-25 dir. 1: error 3 0.000 %
G-27 dir. 1: error 4 0.000 %
G-29 dir. 1: error 5 0.000 %
G-31 dir. 1: error 6 0.000 %
G-33 dir. 1: error 7 0.000 %
G-35 dir. 1: error 8 0.000 %
G-37 dir. 1: error 9 0.000 %
G-39 dir. 1: error 10 0.000 %
G-41 dir. 1: error 11 0.000 %
G-43 dir. 1: error 12 0.000 %
G-45 dir. 2: error 1 0.000 %
G-47 dir. 2: error 2 0.000 %
G-49 dir. 2: error 3 0.000 %
G-51 dir. 2: error 4 0.000 %
G-53 dir. 2: error 5 0.000 %
G-55 dir. 2: error 6 0.000 %
G-57 dir. 2: error 7 0.000 %
G-59 dir. 2: error 8 0.000 %
G-61 dir. 2: error 9 0.000 %
G-63 dir. 2: error 10 0.000 %

Parameter Report
4/6/2023 8:15:04 AM Page 4

G-65 dir. 2: error 11 0.000 %
G-67 dir. 2: error 12 0.000 %
Column H: Freq.,Pulse Outputs

H-3 fo corr. factor 1.000000
H-5 fo base max. 144000.000 acfh
H-6 fo freq. max. 5000.000 Hz
H-8 fo set value 0.000 Hz
H-9 fo select QMC
H-10 fo mode ON
H-11 fo2 error mode F2 ACTIVE
H-15 IO-1 mode DIRECTION
H-17 mode ext. warning OFF
H-20 Test Alarm a. Warn OFF
Column I: Current Output

I-3 c-out min. 0.000
I-4 c-out max. 144000.000
I-5 c-out set value 12.000 mA
I-6 c-out select 6226
I-7 c-out mode 4-20mA
I-8 c-out err mode MAX
I-9 c-out damping 0.000
I-10 c-out gradient 7.13946e-01
I-11 c-out offset -5.33333e-03

Parameter Report
4/6/2023 8:15:04 AM Page 5
Column J: Serial Ports

J-1 serial-0 mode Modbus
J-2 serial-0 baud rate 38400 baud
J-3 serial-0 bits 8
J-4 serial-0 parity NONE
J-5 Modbus-0 protocol RTU
J-6 Modbus-0 hw-mode RS485
J-7 Modbus-0 address 1
J-8 Modbus-0 reg.offset 0
J-9 Modbus-0 gap time 45
J-10 print job OFF
J-11 print interval 10
J-12 DZU-0 address 1
J-16 serial-1 bits 8
J-19 not available RS485
J-25 opt. ser2 mode Modbus
J-26 opt. ser2 baud rate 38400 baud
J-27 opt. ser2 bits 8
J-28 opt. ser2 parity NONE
J-34 Long Byte Order NORMAL
J-35 Float Byte Order NORMAL
J-36 Double Byte Order NORMAL
J-39 DZU Interval 100 tics
J-40 DZU Checksum Preset 0x00
Column AD: Time and Date

AD-1 time 4/6/2023 3:15:43 PM
Column AE: USE09-C Totalizers

AE-1 Tot. Volume d.1 000033750.32 acf
AE-4 Tot. VolumeErr d.1 000011931.65 acf
AE-7 Tot. VolumeSum d.1 000045681.97 acf
AE-9 Total Volume 000045681.97 acf
AE-10 tot. Error-mode STOP
AE-11 Total Volume mode DIRECTION_1
AE-20 test-tot. mode STOP
AE-30 Unit LF-Volumes x 0.01

Parameter Report
4/6/2023 8:15:04 AM Page 6
Column AF: ID
AF-1 electronic type USE09
AF-2 electronic no 827610
AF-3 unit type USM-GT-400
AF-4 unit no 827610
AF-5 manufacturer RMG
AF-6 model (year) 2022
AF-7 meter size -
AF-8 nominal diameter DN 8 in
AF-9 pressure rating ANSI600
AF-10 pipe flange type ANSI
AF-11 pipe flange value 600
AF-12 Qmin 1130.0 acfh
AF-13 Qmax 148300.0 acfh
AF-14 pmin 1.00 psi_g
AF-15 pmax 1523.00 psi_g
AF-16 meas.press. min 0.00 psi_a
AF-17 meas.press. max 0.00 psi_a
AF-18 Tmin -40 °F
AF-21 Tmax 176 °F
AF-23 gas type NATURAL GAS
AF-24 p type 3051CA
AF-25 p no. 0
AF-26 T type AGG-EX
AF-27 T no 0
AF-28 Transducer type TNG 10-CP
AF-29 Transducer 1.1 no. 44966
AF-30 Transducer 1.1 len. 2.260 in
AF-31 Transducer 1.1 built 2022

Parameter Report
4/6/2023 8:15:04 AM Page 7
Column AF: ID
AF-77 serial number USE09 3013131
Column AG: Mode

AG-4 codeword ********
AG-26 test working mode OFF
AG-28 Test LEDs OFF
AG-30 language ENGLISH
AG-31 units IMPERIAL-UNITS
AG-36 Units: Temp. °F
AG-37 Units: Pressure psi
AG-40 Calib. units: Length in
AG-41 Calib. units: v ft/s
AG-42 Calib. units: Q acfh
AG-43 Units: aut. calc. OFF
Column AH: Faults

AH-3 clear fault NO
AH-4 fault mode NORMAL
AH-5 fault display mode NORMAL
AH-6 path error mode WARNING
AH-7 fault,warn contact NORMAL

Parameter Report
4/6/2023 8:15:04 AM Page 8
Column AI: DSP Parameters

AI-1 D+F operating mode ON
AI-2 DSP boot mode M32
AI-3 DSP flash-addr. 10000 hex
AI-4 DSP send interval 10 tics
AI-5 DSP reset NO
AI-6 FPGA boot mode M32
AI-7 FPGA flash-adr. D0000 hex
AI-8 FPGA reset NO
AI-9 number of batches 1
AI-10 Relay delay time 10 ms
AI-11 sample frequency 5.0 MHz
AI-12 fifo size 2048
AI-13 FPGA testpin ctrl. 0000 hex
AI-14 transmission level 100 %
AI-15 send mux time 1.00 ms
AI-16 receive mux time 1.00 ms
AI-17 Attenuator mode ON
AI-18 Attenuator on 15 dB
AI-19 Attenuator off 37 dB
AI-20 Attenuator HV 6 dB
AI-21 amp. regulator mode ON
AI-22 amp. regulator min 33 %
AI-23 amp. regulator max 38 %
AI-24 amp. damping 0.900
AI-25 theoretical SoS 1320.000 ft/s
AI-26 ADC gain 1
AI-27 signal tracking OFF
AI-28 max. track. offset 512 Tics
AI-29 Signal Noise Ratio 50 %
AI-30 rise time deviation 20 %
AI-31 RSQ error 2 v.T.
AI-32 max. amp. (Av) 8
AI-33 AV up/down 8
AI-34 As:Av ratio 5
AI-35 median pt. mode MOD-G
AI-36 abs. threshold 15 %
AI-37 corr. mode OFF
AI-38 corr. length 128
AI-39 Batch: amp. min. 20 %
AI-40 Calculation mode 0000 hex
AI-41 stride 1
AI-42 orientation flow
AI-43 median ON
AI-44 corr. verified OFF
AI-45 fast sample ON
AI-46 max peak count 15
AI-47 AmplitudeMin 3 %
AI-48 AmplitudeMax 99 %
AI-49 Vmin -164.04 ft/s
AI-50 Vmax 164.04 ft/s
AI-51 Cmin 984.25 ft/s
AI-52 Cmax 1640.42 ft/s

Parameter Report
4/6/2023 8:15:04 AM Page 9
Column AJ: DSP Parameters 3X

AJ-1 RSQ error (X) 5 v.T.
AJ-2 max. amp. (Av) (X) 20
AJ-3 AV up/down (X) 18
AJ-4 As:Av ratio (X) 2
AJ-5 median pt. mode (X) OFF
AJ-6 abs. threshold (X) 30 %
AJ-7 corr. mode (X) FADE_IN
AJ-8 corr. length (X) 300
AJ-9 Batch: amp. min. 20 %
AJ-10 stat: RAM length 20
AJ-11 stat: min level 20 %
AJ-12 stat: delta-t limit 2.0 us
AJ-13 stat: dt-hysteresis 0 %
Column AK: Path1 Parameters

AK-9 p1 f-trans set val 120000 Hz
AK-11 path-1 band limits 30 %
AK-12 path-1 trans.pulses 4
AK-13 p1 filter selection 125 kHz
AK-14 path-1 tw 15.686 us
AK-16 path-1 DAC-G1 cmd 3
AK-17 path-1 DAC-G1 val 1000
AK-22 path-1 decay time 4.00 ms
AK-23 path-1 path length 7.642 in
AK-24 path-1 axial dist. 3.776 in
AK-25 p1 assembly angle 35.00 °
AK-26 p1 delta-t offset 0.0064 us
AK-29 const w1 0.1250 [1]
AK-30 p1 tic offset 0 tic
AK-31 p1 tic offset (X) 0 tic
AK-32 p1 AGC-limit 40 dB
AK-33 p1 G-filter faktor 0.45
AK-34 p1 no. of f-batches 1

Parameter Report
4/6/2023 8:15:04 AM Page 10
Column AL: Path2 Parameters

AL-9 p2 f-trans set val 120000 Hz
AL-11 path-2 band limits 30 %
AL-12 path-2 trans.pulses 4
AL-13 p2 filter selection 125 kHz
AL-14 path-2 tw 16.338 us
AL-16 path-2 DAC-G1 cmd 3
AL-17 path-2 DAC-G1 val 1000
AL-22 path-2 decay time 4.00 ms
AL-23 path-2 path length 7.644 in
AL-24 path-2 axial dist. 3.802 in
AL-25 p2 assembly angle 35.09 °
AL-26 p2 delta-t offset 0.0139 us
AL-29 const w2 0.1250 [1]
AL-30 p2 tic offset 0 tic
AL-31 p2 tic offset (X) 0 tic
AL-32 p2 AGC-limit 40 dB
AL-33 p2 G-filter faktor 0.45
AL-34 p2 no. of f-batches 1
Column AM: Path3 Parameters

AM-9 p3 f-trans set val 120000 Hz
AM-11 path-3 band limits 30 %
AM-12 path-3 trans.pulses 4
AM-13 p3 filter selection 125 kHz
AM-14 path-3 tw 16.222 us
AM-16 path-3 DAC-G1 cmd 3
AM-17 path-3 DAC-G1 val 1000
AM-22 path-3 decay time 4.00 ms
AM-23 path-3 path length 9.898 in
AM-24 path-3 axial dist. 5.346 in
AM-25 p3 assembly angle 35.04 °
AM-26 p3 delta-t offset -0.0010 us
AM-29 const w3 0.2500 [1]
AM-30 p3 tic offset 0 tic
AM-31 p3 tic offset (X) 0 tic
AM-32 p3 AGC-limit 40 dB
AM-33 p3 G-filter faktor 0.45
AM-34 p3 no. of f-batches 1

Parameter Report
4/6/2023 8:15:04 AM Page 11
Column AN: Path4 Parameters

AN-9 p4 f-trans set val 120000 Hz
AN-11 path-4 band limits 30 %
AN-12 path-4 trans.pulses 4
AN-13 p4 filter selection 125 kHz
AN-14 path-4 tw 16.321 us
AN-16 path-4 DAC-G1 cmd 3
AN-17 path-4 DAC-G1 val 1000
AN-22 path-4 decay time 4.00 ms
AN-23 path-4 path length 9.897 in
AN-24 path-4 axial dist. 5.341 in
AN-25 p4 assembly angle 35.01 °
AN-26 p4 delta-t offset -0.0041 us
AN-29 const w4 0.2500 [1]
AN-30 p4 tic offset 0 tic
AN-31 p4 tic offset (X) 0 tic
AN-32 p4 AGC-limit 40 dB
AN-33 p4 G-filter faktor 0.45
AN-34 p4 no. of f-batches 1
Column AO: Path5 Parameters

AO-9 p5 f-trans set val 120000 Hz
AO-11 path-5 band limits 30 %
AO-12 path-5 trans.pulses 4
AO-13 p5 filter selection 125 kHz
AO-14 path-5 tw 16.480 us
AO-16 path-5 DAC-G1 cmd 3
AO-17 path-5 DAC-G1 val 1000
AO-22 path-5 decay time 4.00 ms
AO-23 path-5 path length 7.644 in
AO-24 path-5 axial dist. 3.774 in
AO-25 p5 assembly angle 34.99 °
AO-26 p5 delta-t offset 0.0074 us
AO-29 const w5 0.1250 [1]
AO-30 p5 tic offset 0 tic
AO-31 p5 tic offset (X) 0 tic
AO-32 p5 AGC-limit 40 dB
AO-33 p5 G-filter faktor 0.45
AO-34 p5 no. of f-batches 1

Parameter Report
4/6/2023 8:15:04 AM Page 12
Column AP: Path6 Parameters

AP-9 p6 f-trans set val 120000 Hz
AP-11 path-6 band limits 30 %
AP-12 path-6 trans.pulses 4
AP-13 p6 filter selection 125 kHz
AP-14 path-6 tw 16.003 us
AP-16 path-6 DAC-G1 cmd 3
AP-17 path-6 DAC-G1 val 1000
AP-22 path-6 decay time 4.00 ms
AP-23 path-6 path length 7.644 in
AP-24 path-6 axial dist. 3.768 in
AP-25 p6 assembly angle 35.17 °
AP-26 p6 delta-t offset 0.0121 us
AP-29 const w6 0.1250 [1]
AP-30 p6 tic offset 0 tic
AP-31 p6 tic offset (X) 0 tic
AP-32 p6 AGC-limit 40 dB
AP-33 p6 G-filter faktor 0.45
AP-34 p6 no. of f-batches 1
Column AQ: Path7 Parameters

AQ-9 p7 f-trans set val 100000 Hz
AQ-11 path-7 band limits 30 %
AQ-12 path-7 trans.pulses 4
AQ-13 p7 filter selection 100 kHz
AQ-14 path-7 tw 12.000 us
AQ-16 path-7 DAC-G1 cmd 3
AQ-17 path-7 DAC-G1 val 1000
AQ-22 path-7 decay time 20.00 ms
AQ-23 path-7 path length 10.472 in
AQ-24 path-7 axial dist. 2.624 in
AQ-25 p7 assembly angle 35.00 °
AQ-26 p7 delta-t offset 0.0000 us
AQ-29 const w7 0.1250 [1]
AQ-30 p7 tic offset -15 tic
AQ-31 p7 tic offset (X) -15 tic
AQ-32 p7 AGC-limit 60 dB
AQ-33 p7 G-filter faktor 0.35
AQ-34 p7 no. of f-batches 1

Parameter Report
4/6/2023 8:15:04 AM Page 13
Column AR: Path8 Parameters

AR-9 p8 f-trans set val 100000 Hz
AR-11 path-8 band limits 30 %
AR-12 path-8 trans.pulses 4
AR-13 p8 filter selection 100 kHz
AR-14 path-8 tw 12.000 us
AR-16 path-8 DAC-G1 cmd 3
AR-17 path-8 DAC-G1 val 1000
AR-22 path-8 decay time 20.00 ms
AR-23 path-8 path length 10.354 in
AR-24 path-8 axial dist. 2.598 in
AR-25 p8 assembly angle 35.00 °
AR-26 p8 delta-t offset 0.0000 us
AR-29 const w8 0.1250 [1]
AR-30 p8 tic offset -15 tic
AR-31 p8 tic offset (X) -15 tic
AR-32 p8 AGC-limit 60 dB
AR-33 p8 G-filter faktor 0.35
AR-34 p8 no. of f-batches 1
Column AS: Service

AS-1 CPU speed 18432000 Hz
AS-2 DSP speed 20000000 Hz
AS-4 FPGA speed 40000000 Hz
AS-5 ext. card s.no. 3166
AS-6 ext. ADC s.no. 0
AS-7 write opt.EEProm NO
AS-8 write ADC EEProm NO
AS-9 LCD lighting KEY
AS-10 parameter reset NO
AS-11 USE09 restart NO
AS-12 RV reset NO
AS-13 RV: number 140
AS-15 RV mode ON
AS-16 Raw data path no. 0
AS-17 Raw data type FILTER
AS-18 Raw data function 0000
AS-30 max. sys. temp. 86.18 °F
AS-31 time max. sys. temp 5/30/2022 7:15:49 AM
AS-32 min. sys. temp. 62.29 °F
AS-33 time min. sys. temp 4/6/2023 2:19:55 PM
Column AT: Log Data

AT-11 clear par-log NO
AT-12 clear event-log NO
AT-13 new! parameterize NO
AT-14 Log-data type stack (Europe)

Parameter Report
4/6/2023 8:15:04 AM Page 14
Column AU: Site Information

AU-1 User Text-1 SN: 827610
AU-2 User Text-2 8 inch
AU-3 User Text-3 ANSI600
AU-4 User Text-4 Sch 80
AU-5 User Text-5 DS 03-27-2023
Column AV: Remote Control

AV-1 remote access NO
AV-2 remote keycode 0
Column AX: AGA-10 Config

AX-1 SoS calc source OFF
AX-2 SoS source temp. SoS default
AX-3 SoS source press. SoS default
AX-4 SoS temp. default 68.00 °F
AX-5 SoS press. default 145.038 psi_a
AX-6 relative humidity 20.00 %
AX-7 timeout max. 10 min
AX-8 RMGBus mode RMGBus 24 comp.
AX-9 stream number without indication
AX-10 Modbus master target RMG GC9300
AX-11 set gas comp. gas comp. are set
AX-20 default methane 0.000 mol-%
AX-21 default ethane 0.000 mol-%
AX-22 default propane 0.000 mol-%
AX-23 default iso-butane 0.000 mol-%
AX-24 default n-butane 0.000 mol-%
AX-25 default neo-pentane 0.000 mol-%
AX-26 default iso-pentane 0.000 mol-%
AX-27 default n-pentane 0.000 mol-%
AX-28 default hexane+ 0.000 mol-%
AX-29 default oxygen 0.000 mol-%
AX-30 default helium 0.000 mol-%
AX-31 default hydrogen 0.000 mol-%
AX-32 default argon 0.000 mol-%
AX-33 default nitrogen 100.000 mol-%
AX-34 default CO2 0.000 mol-%
AX-35 default n-hexane 0.000 mol-%
AX-36 default n-heptane 0.000 mol-%
AX-37 default n-octane 0.000 mol-%
AX-38 default n-nonane 0.000 mol-%
AX-39 default n-decane 0.000 mol-%
AX-40 default H2S 0.000 mol-%
AX-41 default water 0.000 mol-%
AX-42 default CO 0.000 mol-%
AX-43 default ethene 0.000 mol-%
AX-44 default propene 0.000 mol-%
AX-92 MB_Pause 10 s
AX-93 MB_Timeout 1000 ms
AX-94 MB_Int16Order 21
AX-96 MB_FloatOrder 2143
AX-97 MB_DoubleOrder 21436587

Parameter Report
4/6/2023 8:15:04 AM Page 15
Column AY: Gas Comp. RMGBus

AY-20 methane 0.000 mol-%
AY-21 ethane 0.000 mol-%
AY-22 propane 0.000 mol-%
AY-23 iso-butane 0.000 mol-%
AY-24 n-butane 0.000 mol-%
AY-25 neo-pentane 0.000 mol-%
AY-26 iso-pentane 0.000 mol-%
AY-27 n-pentane 0.000 mol-%
AY-28 hexane+ 0.000 mol-%
AY-29 oxygen 0.000 mol-%
AY-30 helium 0.000 mol-%
AY-31 hydrogen 0.000 mol-%
AY-32 argon 0.000 mol-%
AY-33 nitrogen 0.000 mol-%
AY-34 CO2 0.000 mol-%
AY-35 n-hexane 0.000 mol-%
AY-36 n-heptane 0.000 mol-%
AY-37 n-octane 0.000 mol-%
AY-38 n-nonane 0.000 mol-%
AY-39 n-decane 0.000 mol-%
AY-40 H2S 0.000 mol-%
AY-41 water 0.000 mol-%
AY-42 CO 0.000 mol-%
AY-43 ethene 0.000 mol-%
AY-44 propene 0.000 mol-%
AY-56 MB_InStatus 0

Parameter Report
4/6/2023 8:15:04 AM Page 16
Column AZ: Gas Comp. Modbus

AZ-1 Formula Methane F8252
AZ-2 Formula Methane
AZ-3 Formula Ethane F8256
AZ-4 Formula Ethane
AZ-5 Formula Propane F8258
AZ-6 Formula Propane
AZ-7 Formula I_Butane F8260
AZ-8 Formula I_Butane
AZ-9 Formula N_Butane F8262
AZ-10 Formula N_Butane
AZ-11 Formula Neo_Pentane F8264
AZ-12 Formula Neo_Pentane
AZ-13 Formula I_Pentane F8266
AZ-14 Formula I_Pentane
AZ-15 Formula N_Pentane F8268
AZ-16 Formula N_Pentane
AZ-17 Formula Hexane+ F8270
AZ-18 Formula Hexane+
AZ-19 Formula Oxygen F8280
AZ-20 Formula Oxygen
AZ-21 Formula Helium F8282
AZ-22 Formula Helium
AZ-23 Formula Hydrogene F8284
AZ-24 Formula Hydrogene
AZ-25 Formula Argon 0
AZ-26 Formula Argon
AZ-27 Formula Nitrogen F8250
AZ-28 Formula Nitrogen
AZ-29 Formula CO2 F8254
AZ-30 Formula CO2
AZ-31 Formula Hexane 0
AZ-32 Formula Hexane
AZ-33 Formula Heptane 0
AZ-34 Formula Heptane
AZ-35 Formula Octane 0
AZ-36 Formula Octane
AZ-37 Formula Nonane 0
AZ-38 Formula Nonane
AZ-39 Formula Decane 0
AZ-40 Formula Decane
AZ-41 Formula H2S 0
AZ-42 Formula H2S
AZ-43 Formula Water 0
AZ-44 Formula Water
AZ-45 Formula CO 0
AZ-46 Formula CO
AZ-47 Formula Ethene 0
AZ-48 Formula Ethene
AZ-49 Formula Propene 0
AZ-50 Formula Propene
AZ-51 Formula Status u1038==0
AZ-52 Formula Status

Parameter Report
4/6/2023 9:25:57 AM Page 1
Column A: Pressure
A-5 p min value 14.50 psi_a
A-6 p max value 290.08 psi_a
A-9 p set value 950.000 psi_a
A-11 p at base cond. 14.7300 psi_a
A-12 curr. inp. gradient 1.00000e+00
A-13 curr. inp. offset 0.00000e+00
A-14 p err. min 0.000 psi_a
A-15 p err. max 1450.377 psi_a
A-17 p mode SET VALUE
Column B: Temperature
B-9 T set value 60.00 °F
B-11 T at base cond. 60.00 °F
B-12 T gradient 1.00000e+00
B-13 T offset 0.00000e+00
B-14 T err. min 32.00 °F
B-15 T err. max 212.00 °F
B-17 T mode SET VALUE
Column D: USE09-C Qm
D-4 Qm min. 375.00 acfh
D-5 Qm max. 144000.00 acfh
D-6 vw factor d1 0.9970 [1]
D-7 vw factor d2 0.9970 [1]
D-8 vw lower limit 0.30 ft/s
D-9 Qm lower limit 375.00 acfh
D-10 Qm-min time 10000 s
D-15 Qm damping 0.000
D-16 pipe diameter 7.62 in
D-17 geometry correcting ON
D-18 temp. coefficient 4.12000e-05
D-19 pressure coeff. 6.00000e-06
D-21 Qm-max time 1 4/6/2023 3:13:25 PM
D-23 Qm-max time 2 4/6/2023 2:44:00 PM
E-1 USE09 working mode USE09C
E-2 path select 11111100
E-3 max. path RV 2
E-4 fault time 1 s
E-5 error per cent 30 %
E-9 moving average cnt 10
E-15 SoS mode STANDARD
E-16 delta SoS mode ON
E-17 delta SoS limit 0.30 %
E-18 std. SoS corr-factor 0.65 [1]
E-19 adv. SoS corr-factor 0.00 [1]
E-20 std. SoS v factor 0.75 [1]
E-21 adv. SoS v factor 0.00 [1]
E-22 delta AGC limits 10.00 dB
E-23 Tw correct OFF

Parameter Report
4/6/2023 9:25:57 AM Page 2
E-24 Tw damping 0.00
Column F: USE09-C polynom-B

F-1 basic correction OFF
F-2 const Gm2 d.1 0.00000e+00 [1]
F-3 const Gm1 d.1 0.00000e+00 [1]
F-4 const G0 d.1 0.00000e+00 [1]
F-5 const G1 d.1 0.00000e+00 [1]
F-6 const G2 d.1 0.00000e+00 [1]
F-10 const Gm2 d.2 0.00000e+00 [1]
F-11 const Gm1 d.2 0.00000e+00 [1]
F-12 const G0 d.2 0.00000e+00 [1]
F-13 const G1 d.2 0.00000e+00 [1]
F-14 const G2 d.2 0.00000e+00 [1]

Parameter Report
4/6/2023 9:25:57 AM Page 3

G-1 error curve lin. piecewise lin.
G-2 const m2 d.1 0.00000e+00 [1]
G-3 const m1 d.1 0.00000e+00 [1]
G-4 const 0 d.1 0.00000e+00 [1]
G-5 const 1 d.1 0.00000e+00 [1]
G-6 const 2 d.1 0.00000e+00 [1]
G-10 const m2 d.2 0.00000e+00 [1]
G-11 const m1 d.2 0.00000e+00 [1]
G-12 const 0 d.2 0.00000e+00 [1]
G-13 const 1 d.2 0.00000e+00 [1]
G-14 const 2 d.2 0.00000e+00 [1]
G-21 dir. 1: error 1 0.000 %
G-23 dir. 1: error 2 -0.010 %
G-25 dir. 1: error 3 0.040 %
G-27 dir. 1: error 4 -0.020 %
G-29 dir. 1: error 5 -0.060 %
G-31 dir. 1: error 6 -0.020 %
G-33 dir. 1: error 7 0.090 %
G-35 dir. 1: error 8 0.000 %
G-37 dir. 1: error 9 0.000 %
G-39 dir. 1: error 10 0.000 %
G-41 dir. 1: error 11 0.000 %
G-43 dir. 1: error 12 0.000 %
G-45 dir. 2: error 1 0.000 %
G-47 dir. 2: error 2 0.000 %
G-49 dir. 2: error 3 0.000 %
G-51 dir. 2: error 4 0.000 %
G-53 dir. 2: error 5 0.000 %
G-55 dir. 2: error 6 0.000 %
G-57 dir. 2: error 7 0.000 %
G-59 dir. 2: error 8 0.000 %
G-61 dir. 2: error 9 0.000 %
G-63 dir. 2: error 10 0.000 %

Parameter Report
4/6/2023 9:25:57 AM Page 4

G-65 dir. 2: error 11 0.000 %
G-67 dir. 2: error 12 0.000 %
Column H: Freq.,Pulse Outputs

H-3 fo corr. factor 1.000000
H-5 fo base max. 144000.000 acfh
H-6 fo freq. max. 5000.000 Hz
H-8 fo set value 0.000 Hz
H-9 fo select QMC
H-10 fo mode ON
H-11 fo2 error mode F2 ACTIVE
H-17 mode ext. warning OFF
H-20 Test Alarm a. Warn OFF
Column I: Current Output

I-3 c-out min. 0.000
I-4 c-out max. 144000.000
I-5 c-out set value 12.000 mA
I-6 c-out select 6226
I-7 c-out mode 4-20mA
I-8 c-out err mode MAX
I-9 c-out damping 0.000
I-10 c-out gradient 7.13946e-01
I-11 c-out offset -5.33333e-03

Parameter Report
4/6/2023 9:25:57 AM Page 5
Column J: Serial Ports

J-3 serial-0 bits 8
J-10 print job OFF
J-11 print interval 10
J-16 serial-1 bits 8
J-19 not available RS485
J-25 opt. ser2 mode Modbus
J-26 opt. ser2 baud rate 38400 baud
J-27 opt. ser2 bits 8
J-28 opt. ser2 parity NONE
J-34 Long Byte Order NORMAL
J-35 Float Byte Order NORMAL
J-36 Double Byte Order NORMAL
J-39 DZU Interval 100 tics
J-40 DZU Checksum Preset 0x00
Column AD: Time and Date

AD-1 time 4/6/2023 4:26:39 PM
Column AE: USE09-C Totalizers

AE-9 Total Volume 000097361.58 acf
AE-10 tot. Error-mode STOP
AE-11 Total Volume mode DIRECTION_1
AE-20 test-tot. mode STOP
AE-30 Unit LF-Volumes x 0.01

Parameter Report
4/6/2023 9:25:57 AM Page 6
Column AF: ID
AF-1 electronic type USE09
AF-2 electronic no 827610
AF-3 unit type USM-GT-400
AF-4 unit no 827610
AF-5 manufacturer RMG
AF-6 model (year) 2022
AF-7 meter size -
AF-8 nominal diameter DN 8 in
AF-9 pressure rating ANSI600
AF-10 pipe flange type ANSI
AF-11 pipe flange value 600
AF-12 Qmin 1130.0 acfh
AF-13 Qmax 148300.0 acfh
AF-14 pmin 1.00 psi_g
AF-15 pmax 1523.00 psi_g
AF-16 meas.press. min 0.00 psi_a
AF-17 meas.press. max 0.00 psi_a
AF-18 Tmin -40 °F
AF-21 Tmax 176 °F
AF-23 gas type NATURAL GAS
AF-24 p type 3051CA
AF-25 p no. 0
AF-26 T type AGG-EX
AF-27 T no 0
AF-28 Transducer type TNG 10-CP

Parameter Report
4/6/2023 9:25:57 AM Page 7
Column AF: ID
AF-77 serial number USE09 3013131
Column AG: Mode

AG-4 codeword ********
AG-26 test working mode OFF
AG-28 Test LEDs OFF
AG-30 language ENGLISH
AG-31 units IMPERIAL-UNITS
AG-36 Units: Temp. °F
AG-37 Units: Pressure psi
AG-40 Calib. units: Length in
AG-41 Calib. units: v ft/s
AG-42 Calib. units: Q acfh
AG-43 Units: aut. calc. OFF
Column AH: Faults

AH-3 clear fault NO
AH-4 fault mode NORMAL
AH-5 fault display mode NORMAL
AH-6 path error mode WARNING
AH-7 fault,warn contact NORMAL

Parameter Report
4/6/2023 9:25:57 AM Page 8
Column AI: DSP Parameters

AI-1 D+F operating mode ON
AI-2 DSP boot mode M32
AI-3 DSP flash-addr. 10000 hex
AI-4 DSP send interval 10 tics
AI-5 DSP reset NO
AI-6 FPGA boot mode M32
AI-7 FPGA flash-adr. D0000 hex
AI-8 FPGA reset NO
AI-9 number of batches 1
AI-10 Relay delay time 10 ms
AI-11 sample frequency 5.0 MHz
AI-12 fifo size 2048
AI-13 FPGA testpin ctrl. 0000 hex
AI-14 transmission level 100 %
AI-15 send mux time 1.00 ms
AI-16 receive mux time 1.00 ms
AI-17 Attenuator mode ON
AI-18 Attenuator on 15 dB
AI-19 Attenuator off 37 dB
AI-20 Attenuator HV 6 dB
AI-21 amp. regulator mode ON
AI-22 amp. regulator min 33 %
AI-23 amp. regulator max 38 %
AI-24 amp. damping 0.900
AI-25 theoretical SoS 1320.000 ft/s
AI-26 ADC gain 1
AI-27 signal tracking OFF
AI-28 max. track. offset 512 Tics
AI-29 Signal Noise Ratio 50 %
AI-30 rise time deviation 20 %
AI-31 RSQ error 2 v.T.
AI-32 max. amp. (Av) 8
AI-33 AV up/down 8
AI-34 As:Av ratio 5
AI-35 median pt. mode MOD-G
AI-36 abs. threshold 15 %
AI-37 corr. mode OFF
AI-38 corr. length 128
AI-39 Batch: amp. min. 20 %
AI-40 Calculation mode 0000 hex
AI-41 stride 1
AI-42 orientation flow
AI-43 median ON
AI-44 corr. verified OFF
AI-45 fast sample ON
AI-46 max peak count 15
AI-47 AmplitudeMin 3 %
AI-48 AmplitudeMax 99 %
AI-49 Vmin -164.04 ft/s
AI-50 Vmax 164.04 ft/s
AI-51 Cmin 984.25 ft/s
AI-52 Cmax 1640.42 ft/s

Parameter Report
4/6/2023 9:25:57 AM Page 9
Column AJ: DSP Parameters 3X

AJ-1 RSQ error (X) 5 v.T.
AJ-2 max. amp. (Av) (X) 20
AJ-3 AV up/down (X) 18
AJ-4 As:Av ratio (X) 2
AJ-5 median pt. mode (X) OFF
AJ-6 abs. threshold (X) 30 %
AJ-7 corr. mode (X) FADE_IN
AJ-8 corr. length (X) 300
AJ-9 Batch: amp. min. 20 %
AJ-10 stat: RAM length 20
AJ-11 stat: min level 20 %
AJ-12 stat: delta-t limit 2.0 us
AJ-13 stat: dt-hysteresis 0 %
Column AK: Path1 Parameters

AK-9 p1 f-trans set val 120000 Hz
AK-11 path-1 band limits 30 %
AK-12 path-1 trans.pulses 4
AK-13 p1 filter selection 125 kHz
AK-14 path-1 tw 15.686 us
AK-22 path-1 decay time 4.00 ms
AK-23 path-1 path length 7.642 in
AK-24 path-1 axial dist. 3.776 in
AK-25 p1 assembly angle 35.00 °
AK-26 p1 delta-t offset 0.0064 us
AK-29 const w1 0.1250 [1]
AK-30 p1 tic offset 0 tic
AK-31 p1 tic offset (X) 0 tic
AK-32 p1 AGC-limit 40 dB
AK-33 p1 G-filter faktor 0.45
AK-34 p1 no. of f-batches 1

Parameter Report
4/6/2023 9:25:57 AM Page 10
Column AL: Path2 Parameters

AL-9 p2 f-trans set val 120000 Hz
AL-11 path-2 band limits 30 %
AL-12 path-2 trans.pulses 4
AL-13 p2 filter selection 125 kHz
AL-14 path-2 tw 16.338 us
AL-22 path-2 decay time 4.00 ms
AL-23 path-2 path length 7.644 in
AL-24 path-2 axial dist. 3.802 in
AL-25 p2 assembly angle 35.09 °
AL-26 p2 delta-t offset 0.0139 us
AL-29 const w2 0.1250 [1]
AL-30 p2 tic offset 0 tic
AL-31 p2 tic offset (X) 0 tic
AL-32 p2 AGC-limit 40 dB
AL-33 p2 G-filter faktor 0.45
AL-34 p2 no. of f-batches 1
Column AM: Path3 Parameters

AM-9 p3 f-trans set val 120000 Hz
AM-11 path-3 band limits 30 %
AM-12 path-3 trans.pulses 4
AM-13 p3 filter selection 125 kHz
AM-14 path-3 tw 16.222 us
AM-22 path-3 decay time 4.00 ms
AM-23 path-3 path length 9.898 in
AM-24 path-3 axial dist. 5.346 in
AM-25 p3 assembly angle 35.04 °
AM-26 p3 delta-t offset -0.0010 us
AM-29 const w3 0.2500 [1]
AM-30 p3 tic offset 0 tic
AM-31 p3 tic offset (X) 0 tic
AM-32 p3 AGC-limit 40 dB
AM-33 p3 G-filter faktor 0.45
AM-34 p3 no. of f-batches 1

Parameter Report
4/6/2023 9:25:57 AM Page 11
Column AN: Path4 Parameters

AN-9 p4 f-trans set val 120000 Hz
AN-11 path-4 band limits 30 %
AN-12 path-4 trans.pulses 4
AN-13 p4 filter selection 125 kHz
AN-14 path-4 tw 16.321 us
AN-22 path-4 decay time 4.00 ms
AN-23 path-4 path length 9.897 in
AN-24 path-4 axial dist. 5.341 in
AN-25 p4 assembly angle 35.01 °
AN-26 p4 delta-t offset -0.0041 us
AN-29 const w4 0.2500 [1]
AN-30 p4 tic offset 0 tic
AN-31 p4 tic offset (X) 0 tic
AN-32 p4 AGC-limit 40 dB
AN-33 p4 G-filter faktor 0.45
AN-34 p4 no. of f-batches 1
Column AO: Path5 Parameters

AO-9 p5 f-trans set val 120000 Hz
AO-11 path-5 band limits 30 %
AO-12 path-5 trans.pulses 4
AO-13 p5 filter selection 125 kHz
AO-14 path-5 tw 16.480 us
AO-22 path-5 decay time 4.00 ms
AO-23 path-5 path length 7.644 in
AO-24 path-5 axial dist. 3.774 in
AO-25 p5 assembly angle 34.99 °
AO-26 p5 delta-t offset 0.0074 us
AO-29 const w5 0.1250 [1]
AO-30 p5 tic offset 0 tic
AO-31 p5 tic offset (X) 0 tic
AO-32 p5 AGC-limit 40 dB
AO-33 p5 G-filter faktor 0.45
AO-34 p5 no. of f-batches 1

Parameter Report
4/6/2023 9:25:57 AM Page 12
Column AP: Path6 Parameters

AP-9 p6 f-trans set val 120000 Hz
AP-11 path-6 band limits 30 %
AP-12 path-6 trans.pulses 4
AP-13 p6 filter selection 125 kHz
AP-14 path-6 tw 16.003 us
AP-22 path-6 decay time 4.00 ms
AP-23 path-6 path length 7.644 in
AP-24 path-6 axial dist. 3.768 in
AP-25 p6 assembly angle 35.17 °
AP-26 p6 delta-t offset 0.0121 us
AP-29 const w6 0.1250 [1]
AP-30 p6 tic offset 0 tic
AP-31 p6 tic offset (X) 0 tic
AP-32 p6 AGC-limit 40 dB
AP-33 p6 G-filter faktor 0.45
AP-34 p6 no. of f-batches 1
Column AQ: Path7 Parameters

AQ-9 p7 f-trans set val 100000 Hz
AQ-11 path-7 band limits 30 %
AQ-12 path-7 trans.pulses 4
AQ-13 p7 filter selection 100 kHz
AQ-14 path-7 tw 12.000 us
AQ-22 path-7 decay time 20.00 ms
AQ-23 path-7 path length 10.472 in
AQ-24 path-7 axial dist. 2.624 in
AQ-25 p7 assembly angle 35.00 °
AQ-26 p7 delta-t offset 0.0000 us
AQ-29 const w7 0.1250 [1]
AQ-30 p7 tic offset -15 tic
AQ-31 p7 tic offset (X) -15 tic
AQ-32 p7 AGC-limit 60 dB
AQ-33 p7 G-filter faktor 0.35
AQ-34 p7 no. of f-batches 1

Parameter Report
4/6/2023 9:25:57 AM Page 13
Column AR: Path8 Parameters

AR-9 p8 f-trans set val 100000 Hz
AR-11 path-8 band limits 30 %
AR-12 path-8 trans.pulses 4
AR-13 p8 filter selection 100 kHz
AR-14 path-8 tw 12.000 us
AR-22 path-8 decay time 20.00 ms
AR-23 path-8 path length 10.354 in
AR-24 path-8 axial dist. 2.598 in
AR-25 p8 assembly angle 35.00 °
AR-26 p8 delta-t offset 0.0000 us
AR-29 const w8 0.1250 [1]
AR-30 p8 tic offset -15 tic
AR-31 p8 tic offset (X) -15 tic
AR-32 p8 AGC-limit 60 dB
AR-33 p8 G-filter faktor 0.35
AR-34 p8 no. of f-batches 1
Column AS: Service

AS-1 CPU speed 18432000 Hz
AS-2 DSP speed 20000000 Hz
AS-4 FPGA speed 40000000 Hz
AS-5 ext. card s.no. 3166
AS-6 ext. ADC s.no. 0
AS-7 write opt.EEProm NO
AS-8 write ADC EEProm NO
AS-9 LCD lighting KEY
AS-10 parameter reset NO
AS-11 USE09 restart NO
AS-12 RV reset NO
AS-13 RV: number 140
AS-15 RV mode ON
AS-16 Raw data path no. 0
AS-17 Raw data type FILTER
AS-18 Raw data function 0000
AS-30 max. sys. temp. 87.03 °F
AS-31 time max. sys. temp 4/6/2023 4:11:26 PM
AS-32 min. sys. temp. 62.29 °F
AS-33 time min. sys. temp 4/6/2023 2:19:55 PM
Column AT: Log Data

AT-11 clear par-log NO
AT-12 clear event-log NO
AT-13 new! parameterize NO
AT-14 Log-data type stack (Europe)

Parameter Report
4/6/2023 9:25:57 AM Page 14
Column AU: Site Information

AU-1 User Text-1 SN: 827610
AU-2 User Text-2 8 inch
AU-3 User Text-3 ANSI600
AU-4 User Text-4 Sch 80
AU-5 User Text-5 DS 03-27-2023
Column AV: Remote Control

AV-1 remote access NO
AV-2 remote keycode 0
Column AX: AGA-10 Config

AX-1 SoS calc source OFF
AX-2 SoS source temp. SoS default
AX-3 SoS source press. SoS default
AX-4 SoS temp. default 68.00 °F
AX-5 SoS press. default 145.038 psi_a
AX-6 relative humidity 20.00 %
AX-7 timeout max. 10 min
AX-8 RMGBus mode RMGBus 24 comp.
AX-9 stream number without indication
AX-10 Modbus master target RMG GC9300
AX-11 set gas comp. gas comp. are set
AX-20 default methane 0.000 mol-%
AX-21 default ethane 0.000 mol-%
AX-22 default propane 0.000 mol-%
AX-23 default iso-butane 0.000 mol-%
AX-24 default n-butane 0.000 mol-%
AX-25 default neo-pentane 0.000 mol-%
AX-26 default iso-pentane 0.000 mol-%
AX-27 default n-pentane 0.000 mol-%
AX-28 default hexane+ 0.000 mol-%
AX-29 default oxygen 0.000 mol-%
AX-30 default helium 0.000 mol-%
AX-31 default hydrogen 0.000 mol-%
AX-32 default argon 0.000 mol-%
AX-33 default nitrogen 100.000 mol-%
AX-34 default CO2 0.000 mol-%
AX-35 default n-hexane 0.000 mol-%
AX-36 default n-heptane 0.000 mol-%
AX-37 default n-octane 0.000 mol-%
AX-38 default n-nonane 0.000 mol-%
AX-39 default n-decane 0.000 mol-%
AX-40 default H2S 0.000 mol-%
AX-41 default water 0.000 mol-%
AX-42 default CO 0.000 mol-%
AX-43 default ethene 0.000 mol-%
AX-44 default propene 0.000 mol-%
AX-92 MB_Pause 10 s
AX-93 MB_Timeout 1000 ms
AX-96 MB_FloatOrder 2143
AX-97 MB_DoubleOrder 21436587

Parameter Report
4/6/2023 9:25:57 AM Page 15
Column AY: Gas Comp. RMGBus

AY-20 methane 0.000 mol-%
AY-21 ethane 0.000 mol-%
AY-22 propane 0.000 mol-%
AY-23 iso-butane 0.000 mol-%
AY-24 n-butane 0.000 mol-%
AY-25 neo-pentane 0.000 mol-%
AY-26 iso-pentane 0.000 mol-%
AY-27 n-pentane 0.000 mol-%
AY-28 hexane+ 0.000 mol-%
AY-29 oxygen 0.000 mol-%
AY-30 helium 0.000 mol-%
AY-31 hydrogen 0.000 mol-%
AY-32 argon 0.000 mol-%
AY-33 nitrogen 0.000 mol-%
AY-34 CO2 0.000 mol-%
AY-35 n-hexane 0.000 mol-%
AY-36 n-heptane 0.000 mol-%
AY-37 n-octane 0.000 mol-%
AY-38 n-nonane 0.000 mol-%
AY-39 n-decane 0.000 mol-%
AY-40 H2S 0.000 mol-%
AY-41 water 0.000 mol-%
AY-42 CO 0.000 mol-%
AY-43 ethene 0.000 mol-%
AY-44 propene 0.000 mol-%
AY-56 MB_InStatus 0

Parameter Report
4/6/2023 9:25:57 AM Page 16
Column AZ: Gas Comp. Modbus

AZ-1 Formula Methane F8252
AZ-2 Formula Methane
AZ-3 Formula Ethane F8256
AZ-4 Formula Ethane
AZ-5 Formula Propane F8258
AZ-6 Formula Propane
AZ-7 Formula I_Butane F8260
AZ-8 Formula I_Butane
AZ-9 Formula N_Butane F8262
AZ-10 Formula N_Butane
AZ-11 Formula Neo_Pentane F8264
AZ-12 Formula Neo_Pentane
AZ-13 Formula I_Pentane F8266
AZ-14 Formula I_Pentane
AZ-15 Formula N_Pentane F8268
AZ-16 Formula N_Pentane
AZ-17 Formula Hexane+ F8270
AZ-18 Formula Hexane+
AZ-19 Formula Oxygen F8280
AZ-20 Formula Oxygen
AZ-21 Formula Helium F8282
AZ-22 Formula Helium
AZ-23 Formula Hydrogene F8284
AZ-24 Formula Hydrogene
AZ-25 Formula Argon 0
AZ-26 Formula Argon
AZ-27 Formula Nitrogen F8250
AZ-28 Formula Nitrogen
AZ-29 Formula CO2 F8254
AZ-30 Formula CO2
AZ-31 Formula Hexane 0
AZ-32 Formula Hexane
AZ-33 Formula Heptane 0
AZ-34 Formula Heptane
AZ-35 Formula Octane 0
AZ-36 Formula Octane
AZ-37 Formula Nonane 0
AZ-38 Formula Nonane
AZ-39 Formula Decane 0
AZ-40 Formula Decane
AZ-41 Formula H2S 0
AZ-42 Formula H2S
AZ-43 Formula Water 0
AZ-44 Formula Water
AZ-45 Formula CO 0
AZ-46 Formula CO
AZ-47 Formula Ethene 0
AZ-48 Formula Ethene
AZ-49 Formula Propene 0
AZ-50 Formula Propene
AZ-51 Formula Status u1038==0

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2. ACONDICIONADOR DE FLUJO
2.1 Hoja de datos y certificado de

material
Tel: 55 53658200, 63645537
2.2 Dibujo dimensional

CPA Flow Conditioner Dimensional Information, Typical Configurations
CPA Flow Conditioner

Dimensional Information,
Typical Configurations
1.888.349.3569 | www.flowconditioner.com | [email protected] | May 2019

55
CPA 50E Type A – Raised Face – FOEL/FOE
FOEL Offset Style Flange

Pipe Inside Flange Thickness Flange CPA 50E
NPS Schedule
Diameter (ID) Diameter (OD) (T) Thickness (FT) Weight (lbs)
40 2.067 3.625 0.500 0.125 0.40
2"
80 1.939 3.625 0.500 0.125 0.39
40 3.068 5.000 0.640 0.250 1.35
3"
80 2.900 5.000 0.640 0.250 1.33
FOE Style Flange

Pipe Inside Flange Thickness Flange CPA 50E
NPS Schedule
Diameter (ID) Diameter (OD) (T) Thickness (FT) Weight (lbs)
40 2.067 3.625 0.310 0.125 0.40
2"
80 1.939 3.625 0.291 0.125 0.39
40 3.068 5.000 0.460 0.250 1.39
3"
80 2.900 5.000 0.435 0.250 1.37
40 4.026 6.190 0.604 0.250 2.40
4"
80 3.826 6.190 0.574 0.250 2.32
40 6.065 8.500 0.910 0.250 5.93
6"
80 5.761 8.500 0.864 0.250 5.57
40 7.981 10.620 1.197 0.375 13.06
8"
80 7.625 10.620 1.144 0.375 11.94
40 10.020 12.750 1.503 0.375 22.90
10"
80 9.562 12.750 1.435 0.375 21.36
40 11.938 15.000 1.791 0.375 36.85
12"
80 11.374 15.000 1.706 0.375 33.94
40 13.124 16.250 1.969 0.500 50.20
14"
80 12.500 16.250 1.875 0.500 46.60
40 15.000 18.500 2.250 0.500 72.13
16"
80 14.312 18.500 2.147 0.500 66.68
40 16.876 21.000 2.531 0.500 101.80
18"
80 16.124 21.000 2.419 0.500 93.90
40 18.814 23.000 2.822 0.750 146.33
20"
80 17.938 23.000 2.691 0.750 136.24
24" 40 22.626 27.250 3.394 0.750 242.25
30" 40 28.500 33.750 4.275 1.000 480.81
36" 40 34.500 40.250 5.175 1.500 869.05
All dimensions are in inches. Weights calculated using 316SS. Custom sizes are available, please contact CPA for more information.
CPA Flow Conditioners are sized based on the target pipe ID for each line size and schedule. For any concerns about fitment or pipe
tolerances, please contact CPA for more information. A custom size may be required!

56
CPA 55E/65E Type A – Raised Face – FOE
CPA 55E/65E, FOE Style Flange

Pipe Inside Flange Thickness Flange CPA 55E Weight CPA 65E Weight
NPS Schedule
Diameter (ID) Diameter (OD) (T) Thickness (FT) (lbs) (lbs)
40 2.067 3.620 0.673 0.125 0.52 0.47
2"
80 1.939 3.620 0.632 0.125 0.49 0.44
40 3.068 5.000 0.999 0.250 1.79 1.60
3"
80 2.900 5.000 0.945 0.250 1.71 1.55
40 4.026 6.190 1.311 0.250 3.32 2.89
4"
80 3.826 6.190 1.246 0.250 3.11 2.75
40 6.065 8.500 1.975 0.250 9.10 7.64
6"
80 5.761 8.500 1.876 0.250 8.29 7.04
40 7.981 10.620 2.599 0.375 20.24 16.90
8"
80 7.625 10.620 2.483 0.375 18.64 15.74
40 10.020 12.750 3.264 0.375 37.18 30.59
10"
80 9.562 12.750 3.115 0.375 33.76 28.03
40 11.938 15.000 3.888 0.375 61.08 49.93
12"
80 11.374 15.000 3.705 0.375 54.89 45.23
40 15.000 18.500 4.886 0.500 119.68 97.55
16"
80 14.312 18.500 4.662 0.500 107.94 88.70
40 18.814 23.000 6.128 0.750 240.73 197.05
20"
80 17.938 23.000 5.842 0.750 217.96 180.11
40 22.626 27.250 7.369 0.750 407.09 331.12
24"
80 21.564 27.250 7.023 0.750 365.47 299.71
All dimensions are in inches. Weights calculated using 316SS. Custom sizes are available, please contact CPA for more information.
CPA Flow Conditioners are sized based on the target pipe ID for each line size and schedule. For any concerns about fitment or pipe tolerances, please
contact CPA for more information. A custom size may be required!

57
CPA Type C – Pin Style – TBR/TBRL
Pipe Size TBR TBRL
Pipe Inside Diameter Thickness Diameter Thickness

NPS Schedule
Diameter (ID) (D) (T) (D) (T)
2" 40 2.067 2.040 0.490 2.040 1.470

2" 80 1.939 1.912 0.490 1.912 1.470
3" 40 3.068 3.038 0.460 3.038 1.380
3" 80 2.900 2.870 0.435 2.870 1.305
4" 40 4.026 3.986 0.604 3.986 1.812
4" 80 3.826 3.786 0.574 3.786 1.722
All dimensions are in inches. Custom sizes are available, please contact CPA for more information!
Further patents pending.
WARNING: Inherent to the design of pinned style flow conditioners; proper pipe ID tolerances and carefully installation must
be followed. Pin style flow conditioners can still be dislodged due to impact from foreign objects or debris.

58
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2.3 Certificado de conformidad

Compliance
CPA Flow Conditioners comply with the following standards:
ASME B16.48, ASME B16.5 and ASME B31.3 – THE CPA 50E/55E/65E flange design follows flange
requirements in these standards to meet the required pressure and strength compliance.
AGA 3-2000/API 14.3 – Overviews the performance requirements for a flow conditioner when used in a
AGA3 compliant orifice meter run.
ISO 5167 - Overviews the performance requirements of a flow conditioner when to be used in a ISO
5167 compliant orifice meter run. This compliance is achieved using the AGA 3-2000/API 14.3 test data.
Meeting the requirements in AGA 3-2000/API 14.3 and ISO 5167 demonstrates that CPA Flow
Conditioners can generate a fully developed, swirl free flow. CPA flow conditioners will give significantly
improved measurement accuracy when used with flow meters that require a symmetric, fully developed
flow profile to provide maximum performance.
NACE MR0175/ISO 15156 – Overviews the requirements for a material to be compatible for sour
service. All 316/316L SS CPA Flow Conditioners are automatically NACE MR0175 compliant. This
compliance can also be included on 304/304L SS and select Carbon Steel flow conditioners per request.
Each CPA Type A Raised Face flow conditioner is compatible with all ANSI 150# - 2500# raised face
flanges. When specifying a CPA flow conditioner for ANSI raised face flange applications, only the NPS
and Schedule need to be provided, the ANSI rating is not needed and will not change the flow conditioner
provided for these applications. CPA’s default inventory 316SS material is rated for pressures of up to
5160 psig at 200F, while being compatible with temperatures down to -50F.
Canada Pipeline Accessories guarantees that all CPA flow conditioners are Made in Canada using
North American labour.
Danny Sawchuk, P.Eng.

CEO
[email protected]
1.888.349.3569 | www.flowconditioner.com | [email protected] | October 2022

1
Measurement Performance
Canada Pipeline Accessories has over 25 years of test data, independent research and compliance data
demonstrating the performance of our flow conditioners in many measurement applications, for both
liquids and gases. This data has demonstrated that when CPA’s absolute minimum recommendations of
3D upstream of the flow conditioner and 3D downstream of the flow conditioner are followed, a significant
improvement of the state of the fluid is consistently made. Upstream swirl can be reduced by 85 – 90
percent, while a fully developed flow profile will be restored.
This improvement isn’t specific to any single meter type. As the flow conditioner is a device that was
designed to improve the quality of volumetric fluid flows, any flow meter that requires repeatable, fully
developed, swirl free flow will benefit from the use of the flow conditioner. In the case of turbine meters,
this can reduce the uncertainty to +/-0.3%, +/- 0.1% for ultrasonic meters, and +/- 0.25% for orifice
meters. CPA Flow Conditioners will give significantly improved measurement accuracy in all cases
when used with flow meters that require a symmetric, fully developed flow profile to provide maximum
performance.
Use of the CPA flow conditioners can easily help meters meet accuracy and uncertainty requirements in
AGA3-2016, AGA7, AGA9, AGA11, ISO5167, OIMLR137, ASME-MFC-3M, API Chapters 5 & 6 and
many other custody transfer measurement standards.
AGA Report No 9
Use of CPA Flow Conditioners can help ultrasonic flow meter installations meet uncertainty requirements
specified within AGA Report No. 9 for custody transfer flow metering. CPA recommends meter run
length minimums of 5D/5D for the 50E and 3D/3D for the 55E & 65E.
AGA Report No 3
Use of CPA Flow Conditioners can help orifice flow meters installations meet uncertainty requirements
specified within AGA Report No. 3 for custody transfer flow metering. CPA has completed testing as
outlined in AGA Report No 3, Appendix 2-D. This testing involves a baseline calibration, good flow
conditions, two 90 degree elbows out of plane, 50% pipe blockage, high swirl, pipe size scaling and
Reynolds number sensitivity. CPA recommends meter run length minimums of 13D, 15D, 17D, 29D or
45D.
Liquid Applications
CPA flow conditioners meet the various standard requirements for use in a API 5.3 & 5.8 liquid meter
runs. The CPA 65E has been tested in liquid ultrasonic and turbine meter runs with lengths down to
5D/5D.

CEO
[email protected]

2
CPA Warranty
Canada Pipeline Accessories warrants products as follows:
• Product is free from manufacturing defects and defects in material and workmanship.
• Product is manufactured to CPA drawing dimensions and product specifications.
• Material specification is as agreed between buyer and CPA and in accordance with
purchase order.
• Product dimensioning of CPA 50E/55E/65E/TBR/TBRL is geometrically exactly as tested
for compliance data.
• Nozzle dimensioning is per chosen flow measurement standard with customer approval
prior to manufacturing.
Canada Pipeline Accessories will replace product not meeting above for a period of 3 years from
purchase date.
Canada Pipeline Accessories product warranty is only valid for official CPA manufactured
components such as:
• CPA 50E Flow Conditioners

• CPA TBR Flow Conditioners
• CPA TBRL Flow Conditioners
• CPA Sonic Nozzles
• CPA Venturi Nozzles & Venturi Tubes
• CPA Spacer Plates & Lifting Tabs
• CPA Static Mixers
Verification of CPA product authenticity will be required before warranty coverage can be provided.

CEO
[email protected]

3
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2.4 Certificado de inspección / Reporte

dimensional
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2.5 Carta garantía

Tel: 55 53658200, 63645537
2.6 Catálogo
CPA Flow Conditioners
 CPA isolating perforated plate flow conditioners are applicable for all volumetric metering applications: Orifice, Ultrasonic,
Venturi, Vortex, Turbine, Cone, Coriolis, Magnetic etc.
 Available in multiple geometries: CPA 50E, CPA 55E, CPA 65E, CPA TBR, CPA TBRL.
 Compatible with all liquid and gas scenarios: methane, natural gas, air, hydrogen, carbon dioxide, nitrogen, water, biogas,
petroleum products, crude oil and many others!
 Eliminates swirl and provides a fully developed velocity flow profile.
 All verification tests were done in independent high-pressure gas testing facilities and low Reynolds Number (Re) liquids
testing facilities.
 Stocked in many sizes in 316SS NACE MR0175.
 Can custom manufacture for 3/8” to 48” pipe sizes.
 Available in Carbon Steel, 316SS, 304SS, Aluminum, Hastelloy, Duplex, Monel, Inconel, Titanium, etc.
 Stocked for Raised Face (RF) and pinned (TBR) installations, but can be custom manufactured for Ring Type Joint (RTJ)
flanges, weld in and various other insertion installations.
 Can be ordered with paddle tabs or lifting tabs with ANSI specific bolt patterns, allowing the flow conditioner to easily be
installed, centered and removed from a flange.
 EN 10204 3.1b material quality reports are included with every order and are available in our online database.
 Detailed custom pressure drop calculations are available for all fluid applications using the process conditions for the
specific scenario.
 AGA3, AGA9, OIMLR137, and much more data is available!
 Comprehensive product and technical support from CPA’s engineers, including CFD recommendations, compliance
letters, etc.
FloAlign Notch
All 3” and larger Raised Face CPA flow conditioners automatically include the FloAlign Notch. This is a 1/8” mark machined into
the flange at the top dead center location of the flow conditioner. It is used as a visual reference to indicate the orientation of the
flow conditioner while installed in the flange. The FloAlign notch is a valuable reference for Ultrasonic flow measurement.
Maintaining the calibrated position of the flow conditioner is important for minimizing deviation from the calibrated lab performance
of the flow meter and reducing measurement uncertainty. The FloAlign notch has no relevance for orifice or turbine flow
measurement.
Pressure & Temperature
CPA flow conditioners are designed for use with ANSI Raised Face (RF) flanges and are compatible with ANSI 150# to 2500#
applications. Due to the specification of ANSI RF flanges, the raised face diameter is standard across the ANSI pressure range
when dealing with a particular pipe NPS. CPA’s default inventory 316SS material is rated for pressures of up to 5160 psig at 200F,
while being compatible with temperatures down to -50F.
1.888.349.3569 | www.flowconditioner.com | [email protected] | June 2020

11
Flow Conditioner Models
Canada Pipeline Accessories offers multiple flow conditioner models so that applications can be customized to use a specific
style based on the line size, installation method, flow meter type and process conditions.
CPA 50E
 The CPA 50E is CPA’s main flow conditioner model.

 Most tested and accepted flow conditioner in the industry.
 Over 20 years of orifice, ultrasonic and turbine data.
 Usable for all gas and liquid applications.
 Stocked in 316SS, NACE MR0175 in sizes 2” – 20”, schedules 40/80, Type A for ANSI RF flanges.
 Minimum meter run recommendations are 13D for orifice applications (5D Upstream, 8D Downstream), 10D for
Ultrasonic and Turbine applications (5D Upstream, 5D Downstream).
 Can be custom made in Type B (FWO RF), Type D (RTJF/RTJF) and many other installation options for custom
applications.
CPA TBR/TBRL
 Designed to be pinned in the pipe using a set screw, does not require a flange for installation.
 The CPA TBRL is a newer ‘TBR Long’ design. It is designed with a longer sleeve to ensure higher stability in the pipe,
eliminating the ability to rock and resulting in easier installation and lower chance of the flow conditioner being dislodged
by debris.
 Recommended for orifice meter applications.
 Stocked in 316SS, NACE MR0175 in sizes 2” – 4”, schedules 40/80, Type C for pinned applications.
 CPA does not offer the TBR/TBRL in sizes larger than 4”. The increased surface area results in higher risk of the set
screw shearing and the flow conditioner being dislodged.
 CPA does not recommend the TBR/TBRL for liquid applications, where the higher drag forces and pressure drop result
in a higher risk of the flow conditioner being dislodged.
 Minimum meter run recommendations are 13D for orifice applications (5D Upstream, 8D Downstream).

12
CPA 55E/65E
The CPA 55E and 65E are CPA’s newest flow conditioner models. They use a unique, cutting edge stepped profile
geometry to result in higher performance, lower turbulence and lower noise.
CPA 55E
 Optimized for aggressive measurement and gas applications but is effective for all fluid applications.
 Similar pressure drop to the CPA 50E to maintain flow profile aggressiveness.
 Designed for Gas Ultrasonic, Turbine and Orifice applications.
 Increased swirl and cross flow elimination.
 Innovative stepped design was optimized using fluid dynamic fundamentals; noise levels are up to 30 dB lower than the CPA
50E and lower amounts of turbulence are generated, allowing the flow conditioner to be installed much closer to ultrasonic
meters.
 Minimum 13D (5D Upstream, 8D Downstream) for orifice applications (AGA3).
 Minimum 6D (3D Upstream, 3D Downstream) for gas USM applications (AGA9/OIMLR137), optimal is 10D (5D Upstream, 5D
Downstream).
 Minimum 10D (5D Upstream, 5D Downstream) for gas turbine applications (AGA7) and other meter types.
 Recommended for more severe measurement scenarios where meter performance and meter run length are more
critical than the flow conditioner pressure drop.
 Stocked in 316SS, NACE MR0175 in sizes 2” – 16”, schedules 40/80, Type A for ANSI RF flanges, custom sizes are available!
 Can be custom made in Type B (FWO RF), Type D (RTJF/RTJF) and many other installation options for custom applications.
CPA 65E
 Optimized for liquid applications and scenarios where pressure drop is critical!
 Half the pressure drop of typical plate style flow conditioners and lower pressure drop than many tube bundle straightening
vanes!
 Designed for Gas/Liquid Ultrasonic, Turbine and Coriolis applications (not recommended for critical dP applications).
 Increased swirl and cross flow elimination.
 Innovative stepped design was optimized using fluid dynamic fundamentals; noise levels are up to 30 dB lower than the CPA
50E and lower amounts of turbulence are generated, allowing the flow conditioner to be installed much closer to ultrasonic
meters.
 Minimum 6D (3D Upstream, 3D Downstream) for gas USM applications (AGA9/OIMLR137),, optimal is 10D (5D Upstream, 5D
Downstream).
 Minimum 10D (5D Upstream, 5D Downstream) for liquid turbine & USM (API 5.3/5.8), gas turbine (AGA7), and other meter
types.
 Recommended for less severe measurement or liquid scenarios where pressure drop is a significant concern.
 Stocked in 316SS, NACE MR0175 in sizes 2” – 16”, schedules 40/80, Type A for ANSI RF flanges., custom sizes are
available!
 Can be custom made in Type B (FWO RF), Type D (RTJF/RTJF) and many other installation options for custom applications.

13
Flow Conditioner Model Comparison
CPA Flow Conditioner Type
TBR TBRL 50E 55E 65E
Size Range 2" - 4" 2" - 4" 0.5" and larger 0.5" and larger 0.5" and larger
Pressure Drop 2.0 2.0 2.01 2.01 1.01
Orifice Meter Run

5D/8D 5D/8D 5D/8D 5D/8D N/A
Lengths (UL1/UL2)
Turbine Meter Run

5D/8D 5D/8D 5D/8D 5D/5D2 5D/5D2
Lengths (UL1/UL2)
Ultrasonic Meter
Run Lengths 5D/8D 5D/8D 5D/8D 3D/3D2 3D/3D2
(UL1/UL2)
Other Volumetric
Meter Run Lengths 5D/8D 5D/8D 5D/8D 5D/5D2 5D/5D2
(UL1/UL2)
Gas/Liquid1, but Gas/Liquid1, but
Gas/Liquid Gas Gas Gas/Liquid1
Gas Optimized Liquid Optimized
Swirl Reduction Moderate Moderate Moderate High High
Turbulence Level Moderate Moderate Moderate Low Low
Pinned, RF, Pinned, RF, Pinned, RF,

Installation Style Pinned Pinned
RTJ, Weld In RTJ, Weld In RTJ, Weld In
1 Please consult the K Factor/dP information to help decide which flow conditioner to use based on the measurement
application.
2 Shorter lengths may be available based on application details and CPA test data.
Flow Conditioner Engineering Support
EN10204 3.1b Material Test Reports are included with every order. Default MTR’s for inventory flow conditioners
will be 316/316L with NACE MR0175. Current and historic MTR’s are available in CPA’s online database at
www.flowconditioner.com. If your particular MTR cannot be located, please contact us for more information.
CPA Pressure Drop calculations can be performed for any application! Using an extensive database of experimental
pressure drop behavior from multiple CPA models across a wide range of Reynolds numbers and viscosities, CPA’s
engineers can perform extremely accurate calculation custom to your specific measurement scenario. Calculations
can also be done for generic pipe fittings and even tube bundles for pressure loss comparisons.

14
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2.7 Manual de instalación y operación

CPA 50E Recomendaciones de Instalación
¿Cómo sabemos que nuestros acondicionadores de flujo son la solución más efectiva para
sus necesidades de acondicionamiento de flujo? Porque han sido ampliamente probados y
evaluados por laboratorios independientes y han demostrado ser superiores para estabilizar
el rendimiento aguas abajo, incluso en las situaciones más exigentes.
Eso significa que siempre obtendrá mediciones precisas, sin importar si se trata de una
aplicación de aire, gas natural, agua, petróleo, petróleo líquido o cualquier otro fluido.
Nos enorgullecemos de la entrega rápida. Tenemos modelos de cara elevada ANSI en stock y
listos para su envío inmediato, y tenemos tiempos de respuesta rápidos para diseños y
fabricación personalizados. Ofrecemos una amplia variedad de materiales y podemos
diseñar para cualquier tamaño de ½ "a 60 pulgadas, múltiples opciones de instalación, baja
temperatura, alta temperatura, NORSOK, NACE y más.
EN 10204 3.1b Se incluyen informes de prueba de materiales con cada parte, así como
cálculos de caída de presión, certificados de control de calidad y dibujos con cada pedido.
Acondicionador de flujo CPA 50E

El CPA 50E es el acondicionador de flujo más probado en la industria y está respaldado por
más de 20 años de datos de prueba por laboratorios de flujo independientes. El CPA 50E está
diseñado para producir un perfil de flujo completamente desarrollado sin remolinos,
mejorando la confiabilidad y reduciendo los errores, al tiempo que acorta el funcionamiento
del medidor.
Canada Pipeline Accessories es el único fabricante del acondicionador de flujo CPA 50E y es
la única compañía que ha verificado los datos de prueba y cumplimiento utilizando muchos
fluidos diferentes, incluidos gas natural, aire, agua, petróleo líquido y petróleo pesado. Este
extenso cuerpo de datos de prueba solo es aplicable al CPA 50E fabricado por Canada
Pipeline Accessories, y está inherentemente vinculado a los programas de fabricación,
ingeniería y calidad de CPA.
Características
• Inventario disponible para entrega rápida. Disponible en configuración de tipo A de cara
elevada ANSI, tamaños de 2 a 16 pulgadas, material 40 y 80, material de acero inoxidable
316.
• Se puede fabricar a medida para tubos de 3/8 ″ - 48 ″.
• Disponible en acero al carbono, 316SS, 304SS, aluminio, Hastelloy, dúplex, Monel, Inconel,
titanio, etc.
• Aplicable a tipos de medidores de flujo, incluidos orificios, ultrasonidos, turbinas, Coriolis y
más.
• Adecuado para su uso en todo tipo de fluidos, incluidos gas natural, petróleo, agua, vapor,
petróleo líquido y más.
• Compatible con las pestañas CPA FloAlign y CPA Paddle para ayudar a levantar, inspeccionar,
instalar y alinear.
• Los informes de calidad del material EN 10204 3.1b se incluyen con cada pedido y están
disponibles en nuestra base de datos en línea.
• ¡AGA3, AGA9, OIMLR-137 y muchos más datos están disponibles!
• Producto completo y soporte técnico de los ingenieros de CPA, incluidas las
recomendaciones de CFD, cartas de cumplimiento, etc.
CPA 50E RTJF

El CPA Tipo D está diseñado para aplicaciones que usan juntas de juntas de tipo anillo. El
acondicionador de flujo tipo D se fabrica para que coincida con la presión nominal de las
bridas y juntas.
Hay dos subtipos adicionales del acondicionador de flujo Tipo D: el RTJ hembra (RTJF) y el
RTJ macho (RTJM).
En una configuración RTJF, la instalación del acondicionador de flujo implica colocar el

acondicionador de flujo entre dos bridas de unión de tipo anillo y juntas de anillo
coincidentes.
En una configuración RTJM, las juntas están integradas en el acondicionador de flujo, por lo
que no se requieren juntas adicionales y se reduce el espacio entre bridas.
Dado que las juntas integrales en el RTJM están diseñadas para deformarse durante
la instalación, el acondicionador de flujo no debe reutilizarse si se abren las bridas.
Características
• Diseño personalizado para cada aplicación con una amplia gama de opciones de tamaño y
material.
• Disponible para clasificaciones ANSI 150 # a 2500 #, API 2000 a 20000 y brida compacta
Norsok.
• Puede ser diseñado para acomodar cáncamos forjados ASME 18.15.
• Totalmente compatible con los mínimos de espesor de pieza RTJ especificados en ASME
B16.48‐2005 y ASME B31.3‐2004.
Información de instalación de placa

En un RTJF, recomendamos que la cara de lavado se coloque contra la brida aguas abajo del
tubo del medidor.
Para un RTJM, el acondicionador de flujo debe insertarse en el tubo del medidor aguas
abajo. Este posicionamiento asegura que el acondicionador de flujo esté centrado en relación
con el medidor de flujo y aísla adecuadamente el tubo del medidor aguas arriba.
En un CPA 50E, la geometría no es direccional y el acondicionador de flujo se puede instalar

hacia atrás si es necesario sin ningún cambio en el rendimiento del medidor de flujo.
El CPA 55E y 65E tienen una dirección preferida. Están diseñados para instalarse con el
lado escalonado hacia arriba para un rendimiento adecuado.
Espesor de diseño de junta tipo anillo femenino (RTJF)
Todos los acondicionadores de flujo tipo anillo hembra (RTJF) fabricados por Canada
Pipeline Accessories están diseñados para cumplir con ASME B31.3 y ASME B16.48. Estas
normas proporcionan las dimensiones requeridas para la instalación segura de espacios en
blanco RTJ, espaciadores y persianas de línea.
Las dimensiones requeridas para un acondicionador de flujo RTJF se basan en el esfuerzo al

que se somete la pieza cuando se sujeta y atornilla. Las bridas a cada lado del RTJF deben
apretarse juntas, lo suficiente para que las juntas de anillo se deformen ligeramente y se
asienten en las ranuras. Esta es la condición de diseño dominante para la que debe diseñarse
el RTJF: debe ser lo suficientemente fuerte como para no fallar cuando se aprieta.
El grosor del RTJF es un factor importante para determinar qué tan fuerte es la pieza. A
medida que el RTJF se comprime entre sí mediante el atornillado de la brida, fuerzan a las
superficies de la ranura a separarse y someten fuertemente al material entre las ranuras. En
un RTJF con el grosor adecuado, hay suficiente material para resistir las fuerzas que separan
la brida. Si la brida RTJF es demasiado delgada, no habrá suficiente material y resistencia
para evitar que la pieza falle.
La Figura 1 a continuación muestra el resultado de un análisis de elementos finitos (FEA) en

una brida RTJF que cumple con el espesor mínimo ASME. Las áreas de color púrpura oscuro
indican regiones que están estresadas más allá del límite elástico del material y están cerca
de fallar. Se espera que ceda en el área inmediata alrededor de las ranuras RTJF, ya que las
piezas deben sujetarse lo suficientemente juntas como para deformar las juntas de anillo. Sin
embargo, tenga en cuenta que la mayoría del área de la brida RTJF está muy por debajo del
límite elástico del material y fácilmente tiene la resistencia necesaria para mantenerse unida.
Figura 1: Este gráfico visualiza el esfuerzo en una brida conforme a ASME B16.48. Las áreas
de color púrpura oscuro indican que el material está estresado más allá de los límites
aceptables y está cerca de fallar.
En la figura 2 a continuación, el grosor de la brida RTJF se ha reducido al grosor de un anillo
de purga común. Como antes, las áreas de color púrpura oscuro indican material que está
estresado más allá del rango máximo permitido y que está a punto de fallar. Debido a que la
brida en la figura 2 es más delgada, no hay suficiente material para resistir la fuerza que
mantiene juntas las bridas. El área púrpura oscura se extiende por todo el grosor de la
materia, y en este grosor, la brida RTJF está en riesgo de fallar catastróficamente.
Figura 2: Este gráfico visualiza la tensión en una brida delgada de RTJF. Los colores morados
oscuros indican material que está estresado más allá de los límites aceptables y está a punto
de fallar.
Los acondicionadores de flujo de CPA están diseñados para tener en cuenta la tensión a la
que están sometidas las bridas RTJF cuando se instalan. Para el cumplimiento adecuado de
la ingeniería, es muy importante cumplir con las dimensiones especificadas en ASME B31.3
y ASME B16.48. Los diseños más delgados estarán en riesgo de falla severa.
Orientación de placa
Para facilitar la instalación, el acondicionador de flujo CPA Tipo D tiene un marcador de
punto muerto superior grabado en la circunferencia exterior de la brida. Esta flecha grabada
está alineada con el eje de 90 grados del acondicionador de flujo y se proporciona para
ayudar con la orientación del acondicionador de flujo cuando se utilizan medidores de flujo
ultrasónicos.
La orientación del acondicionador de flujo de CPA no es aplicable al rendimiento de

medición cuando se usan otros tipos de medidores de flujo.
No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
2. RTD AND TERMOWELL

No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
3. VALVES – 3/4"
No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
4. VALVES – 8” 600#
I. GENERAL
ARRAGEMENT
DRAWING
NEWAY VALVE (SUZHOU) CO.,LTD.
II. MATERIAL AND
TEST REPORTS
MATERIAL TEST REPORT TC No.
PAGE:
100970-70(80994038)
1 OF 4
EN 10204-2004 Type 3.1
CUSTOMER: QTY. PART NO. PRODUCT CODE PRODUCT DESCRIPTION
Neway Valve International, Inc 12 12254814 8FP-BS6R-A105N-57666-NC-G 8BS6R-G V1,C40/5K262626 [-A40/600-POS1-TSF,-SF-B7M/2HM]

ASTM A105N, TRIM F316/F316L/DEVLON V
SIDE ENTRY, FORGED, TRUNNION MOUNTED BALL VALVE, 8 INCH,
CLASS 600, RAISED FACE END
PO NO.: PO5500007502NVI_BALL111921 PRESSURE TEST (MPa/PSI) OTHER INSPECTION

ITEM NO.: 7 SHELL SEATS/BACKSEAT SEATS RESULT VISUAL DIMENSION OPERATION MARKING
HYDROSTATIC HYDROSTATIC PNEUM Accepted Accepted Accepted Accepted Accepted
PROJECT: N/A
15.4/2233 11.3/1638 0.6/87
PROJECT NO.: N/A
APPLICABLE STANDARDS AND SPECIFICATION

- P/T RATING: ASME B16.34
- MAIN MATERIAL: RELEVANT ASTM STANDARD
- DESIGN: API6D ASME B16.34
- TEST: API 6D
- TRIM MATERIAL (SEAT/STEM) AND BOLTING ARE ACCORDING TO THE P.O. AND MATERIAL SPECIFICATION
- VALVES CONFORM TO NACENACE MR0175/NACE MR0103 LATEST REVISION
-NOTE:ALL RELATED STANDARDS ARE THE LATEST VERSION UNLESS SPECIFIED BY PURCHASE ORDER.
We hereby certify that the valves listed above are manufactured and tested in
accordance with the requirements of valve standard and purchase order.
WITNESSED BY: NEWAY VALVE
Quality Director
DATE:2022.05.25
Address: NO. 666 TaiShan Road SuZhou New District China Tel : 86-512-666-51365 Fax:86-512-666-51360 http://www.newayvalve.com
PAGE:
100970-70(80994038)
2 OF 4
EN 10204-2004 Type 3.1
PRODUCT TRACEABILITY TABLE
MATERIAL CODE AND HEAT NO. MATERIAL CODE AND HEAT NO.
SERIAL NO. BODY CLOSURE L CLOSURE R BALL TAG NO. SERIAL NO. BODY CLOSURE L CLOSURE R BALL TAG NO.
A105N A105N A105N F316/F316L A105N A105N A105N F316/F316L
100970-070-1 SY7267 XT7081 XT7081 KCM13 / 100970-070-2 SY7267 XT7081 XT7081 KCM13 /
PAGE:
100970-70(80994038)
3 OF 4
EN 10204-2004 Type 3.1
MATERIAL COMPONENTS AND PROPERTIES
Material Heat treatment TempoC(oF) Holding time(h) Cooling media Furnace
A105N NORMALIZED 850~920 (1562~1688℉) 1H/25MM,>=1H AIR ELECTRIC FURNACE
We hereby certify that the material are manufactured, inspected and
tested in accordance with the material specification and purchase
order requirements.
PART NAME MATERIAL HEAT NO. CHEMICAL ANALYSIS MECHANICAL PROPERTIES
C Mn Si S P Cr Ni Mo Cu V C.E. TS YS/Rp E R HARD IMPACT TEST VALUE

% % % % % % % % % % % MPa 0.2MPa % % HB TEMP oC:
MAX. 0.3500 1.0500 0.3500 0.0400 0.0350 0.3000 0.4000 0.1200 0.4000 0.0800 187 Avg. Min:
MIN. 0.6000 0.1000 485 250 22 30 1 2 3
CE:C+Mn/6+(Cr+Mo+V)/5+(Ni+Cu)/15≤0.43
BODY A105N SY7267 0.1700 1.2800 0.2600 0.0020 0.0060 0.0500 0.0300 0.0100 0.0100 0.0050 0.399 508 328 38 72 145
BODY A105N SY7439 0.1700 1.2500 0.2500 0.0060 0.0090 0.0700 0.0300 0.0100 0.0100 0.0100 0.399 498 302 40 68 142
CLOSURE A105N XT7081 0.1900 0.9400 0.2600 0.0030 0.0100 0.1400 0.0300 0.0050 0.0400 0.0020 0.381 499 312 34 52 146
L
CLOSURE A105N XT7081 0.1900 0.9400 0.2600 0.0030 0.0100 0.1400 0.0300 0.0050 0.0400 0.0020 0.381 499 312 34 52 146
R
PAGE:
100970-70(80994038)
4 OF 4
EN 10204-2004 Type 3.1
MATERIAL COMPONENTS AND PROPERTIES
Material Heat treatment TempoC(oF) Holding time(h) Cooling media Furnace
F316/F316L SOLUTION >= 1040 (1904℉) 1H/25MM,>=1H WATER ELECTRIC
We hereby certify that the material are manufactured, inspected and
tested in accordance with the material specification and purchase
order requirements.
PART NAME MATERIAL HEAT NO. CHEMICAL ANALYSIS MECHANICAL PROPERTIES
C Mn Si S P Cr Ni Mo N TS YS/Rp E R HARD IMPACT TEST VALUE

% % % % % % % % % MPa 0.2MPa % % HB TEMP oC:
MAX. 0.0300 2.0000 1.0000 0.0300 0.0450 18.000 14.000 3.0000 0.1000 237 Avg. Min:
MIN. 16.000 10.000 2.0000 515 205 30 50 1 2 3
BALL F316/F316L KCM13 0.0210 0.6500 0.2400 0.0020 0.0360 16.330 10.080 2.0500 0.0500 563 309 65 72 163
III. CERTIFICATE OF
COMPLIANCE
IV.
6D-0848
NEWAY VALVE (SUZHOU) CO., LTD.

#666 Taishan Road
Suzhou New District
Suzhou, Jiangsu
People's Republic of China
API-6D
6D-0848
The scope of this license includes the following: Check Valves, Ball Valves and Gate Valves
QMS Exclusions: No Exclusions Identified as Applicable
Effective Date: JULY 21, 2020

Expiration Date: JULY 21, 2023
Vice President of Global Industry Services

Certificate no.: Initial certification date: Valid:
6880-1998-AQ-RGC-RvA 06 January, 1998 06 January, 2021 – 06 January, 2024
This is to certify that the management system of
Neway Valve (Suzhou) Co., Ltd.
No.666 Tai Shan Road, Suzhou New District, Suzhou, Jiangsu, China, 215129
has been found to conform to the Quality Management System standard:

GB/T 19001-2016/ISO 9001:2015
This certificate is valid for the following scope:
Design, Manufacture and Service of Industrial Valve and Marine Valve
Place and date: For the issuing office:

Shanghai, 09 December, 2020 DNV GL – Business Assurance
Suite A, Building 9, No.1591 Hongqiao
Road, Changning District, Shanghai
200336, P.R. China
TEL: +86 21 32799000
Zhu Hai Ming

Management Representative
Lack of fulfilment of conditions as set out in the Certification Agreement may render this Certificate invalid.
ACCREDITED UNIT: DNV GL Business Assurance B.V., ZWOLSEWEG 1, 2994 LB, BARENDRECHT, NETHERLANDS. TEL:+31102922689. assurance.dnvgl.com
Doc No: NWS4101
Rev No: 2008
Painting Specification
Painting Process Specification for NWS4101- A2
1. Scope
1.1 This procedure covers the method of surface preparation, coating system and material, their
application and inspection applied to coating system on carbon steel valves. This is a special 3
stages painting system of hydroblasting body/bonnet, primer coating and finish paint after
testing.
2. Coating System
2.1 Painting system code: NWS 4101 – A2
2.2 Approved paint manufacturer/ Brand:
SHANGHAI GUANGYAO SPECIAL PRIMER CO., LTD / GUANGYAO (For primer)
SHANGHAI BOFAN COATING CO., LTD / BOFAN (For topcoat)
2.3 Details
Primer Intermediate Topcoat
Name Anti-rust primer N.A. Acrylic polyurethane
Code Guangyao RPY-618 N.A. Bofan BFJ-2
DFT (μ) 20 N.A. 30
TDFT(μ) 50
Finish colour Optional (Default :blue_RAL 5003)
3. Surface Preparation
3.1 Degrease/ clean the surface free from grease, oil, dirt etc by spraying with high pressure hot
water.
3.2 Dry with oil free compressed air.
3.3 Before cleaning, the machined surface should be suitably protected.
4. Primer Coating
Primer: RPY-618
Single component
Thinner RPY-108
Cleaner RPY-108
Colour Blue dark
Gloss Matt
Application By spray using conventional gun
DFT 15 microns
WFT 20 microns
Drying time Touch Dry -15 minutes to 1 hour at 40 deg. C
Page 30 of 110
Doc No: NWS4101
Rev No: 2008
Hard dry 1 hours
Pot Life for mixer 12 hours at 25 deg. C
Storage
Shelf Life 12 months minimum at 25 deg. C
5. Top Coating
Top: BFJ-2
Single component
Thinner BF800
Cleaner BF800
Colour Blue
Gloss High gloss
DFT 35 microns
WFT 50 microns
Drying time Touch Dry -1 minutes to 3 hour at 30 ~40 deg. C
Hard dry 3 hours
Storage
6. Inspection
6.1 Visual examination: Free of any oil, grease and contamination on the surface.
6.2 Wet Film Thickness: Using with Wet film gauge
6.3 Dry Film Thickness: By Electronic/Digital coating thickness Gauge.
Primer coat 20 microns (min.)
Top coat 30 microns (min.)
Total Thickness 50 Microns (min.)
7. Repair
7.1 Before application of repair coating, surfaces shall be washed with fresh water.
7.2 Rust and surface contaminants shall be removed. The area shall be then be cleaned by solvent
washing.
7.3 Coating material shall be applied immediately after completion of surface preparation.
Page 31 of 110
IV. BROCHURE
Introduction
ASME Class
Code
Class (LB)
Item
1
10
11
12
13
14
15
16
17
18
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Note: Side entry includes two piece body and three piece body.
The shape and size of following pictures are for reference Note: Side entry includes two piece body and three piece body. The shape and size of following pictures
only, and actual product shall prevail. are for reference only, and actual product shall prevail.
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
①- Please contact factory for materials supplied.

Item Item
1 19 Item
2 20
3 21
1
4 22
5 23 2
6 24 3
7 25
4
8 26
5
9 27
10 28 6
11 29
7
12 30
8
13 31
14 32 9
15 33 10
16 34
11
17 35
18 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Class 2500
17 15 14 12 12 11
43 38 34 31 31 28
86 76 66 61 61 56
227 211 187 167 167 148
423 384 330 294 294 181
1139 965 860 832 749 434
2416 2093 1759 1710 1564 995
5241 5183 4400 4212 3918 3107
10471 9991 8713 8245 6921 5240
17709 17154 14573 14123 11376 8451
26241 25460 22389 20864 16835 12295
32857 31176 28863 24483 20967
44474 42409 38998 33741 27901
57002 55420 50703 44491 35761
73076 70180 63936 55915 45445
88907 85757 78750
113639 109796 99314
= outlet pressure (psia)

V. WARRANTY LETTER
VAS Válvulas y Actuadores, S.A. de C.V.
RFC: VVA190219FL2 FOLIO: 0218
Avenida Ayuntamiento No.168 Piso 3,
Tlalnepantla Centro, Tlalnepantla de Baz, Estado de México
CP-54000, Tel 55 53840977 con 10 líneas
e-mail: [email protected]
Cliente: ARES CONTROL, S.A. DE C.V.

Orden de Compra: 7711 REV 03
Orden de Venta: PV665
Fecha: 11/05/2023
CARTA GARANTÍA
ITEM MATERIAL DESCRIPCION CANTIDAD
1 VBT08R06FZDGY VALVULA BOLA TRUNNION 8" RF 600# A105N
1.1 8FP-BS6R-A105N-57666-NC-G 2
2 VBT08R06FZDYYB VALVULA BOLA TRUNNION 8" RF 600# ACT. SR
2.1 8FP-BS6R-A105N-57666-NC 1
2.2 G2016-SR2 1
VAS Válvulas y Actuadores, S.A. de C.V. garantiza que los bienes manufacturados están libres de defectos en
materiales y mano de obra.
VAS Válvulas y Actuadores, S.A. de C.V. garantiza el buen funcionamiento de los equipos por un periodo de 18
meses a partir de la fecha de entrega en sitio y/o 12 meses en operación, lo que ocurra primero.
La garantía no será válida si los equipos son manipulados, transportados, almacenados, instalados y operados
en forma diferente a lo indicado en los manuales de los fabricantes de cada elemento. Los trabajos de diagnostico
e instalación deberá ser por personal autorizado por VAS Válvulas y Actuadores, S.A. de C.V. para que esta
garantía sea efectiva.
Para hacer efectiva la garantía, el usuario deberá notificar por escrito a VAS Válvulas y Actuadores, S.A. de
C.V. de la falla, dentro de los 15 días calendario, siguientes a la fecha de ocurrencia de la misma.
VAS Válvulas y Actuadores, S.A. de C.V. reparará o reemplazará los equipos y/o servicios que haya
suministrado en la orden de compra de referencia.
Sólo se atenderán los reclamos que se notifiquen por escrito y que estén avalados por ARESCONTROL, S.A.
DE C.V.
Los bienes reparados y/o reemplazados dentro del período de garantía, permanecerán en garantía por el
tiempo restante del período de garantía original.
ATENTAMENTE
______________________________
Coordinación de Operaciones
No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
5. VALVE WITH ACTUATOR – 8” 600#

I. GENERAL
ARRAGEMENT
DRAWING
NEWAY VALVE (SUZHOU) CO.,LTD.
25.984
660.00
419.00
16.496
2.776
70.50
14.193
360.50
0 CONSTRUIDO 12/05/23
Revisión Descripción Fecha
VAS Valvulas y Actuadores S.A. de C.V
Av. Ayuntamiento No. 168 Piso.3

Col: Tlalnepantla Centro
Tlalnepantla Edo. de Mexico
CP:54000
N.M.G REFERENCIAS DEL CLIENTE

Diseño
B.Z.A Fecha: 14/03/2023 Fecha Lib: 09/05/2023
Reviso
No. de proyecto: PV665
12.000
304.80
***
Aprobó Orden de compra No: 7711 Rev.0
PROYECTO: PV665 ARES NEWFORTRESS VAVULAS 8IN

Cantidad: 1
Titulo: Dim:
DIMENSIONES VALVULA BOLA 8FP-BS6R (in)
8" - 600# mm
Plano N°: VVAP-PV665-002-01 Rev.0 1-1 Revisión: 0
ELABORADO POR VALVE AUTOMATION SOLUTIONS S.A. DE C.V. Y SE SUMINISTRA EN CONSIDERACIÓN DE QUE NO SERÁ REPRODUCIDO, COPIADO, PRESTADO NI UTILIZADO EN FORMA DIRECTA O INDIRECTA NI USADO PARA OTRO PROPÓSITO QUE PARA EL QUE FUE ESPECÍFICAMENTE PRESTADO.
LOS EQUIPOS MOSTRADOS ESTÁN PROTEGIDOS POR PATENTES REGISTRADAS CUALQUIER VIOLACIÓN PUEDE CAUSAR EFECTOS LEGALES
58.775
1492.89
20.678
525.23
206.38
8.125
412.75
16.250

CP:54000

Diseño
Reviso
***
PROYECTO: PV665 ARES NEWFORTRESS VALVULAS 8IN

Cantidad: 1
Titulo: Dim:
DIMENSIONES ACTUADOR NEUMATICO BETTIS (in)
G2014-SR3-CW mm
Plano N°: VVAP-PV665-002-02 Rev.0 1-1 Revisión: 0
1.0 ACTUADOR NEUMÁTICO RETORNO POR RESORTE
2.0 PLATINA DE CONTROL NEUMÁTICO.
2.1 PLATINA INTERRUPTORES DE PRESION
3.0 VÁLVULA DE CORTE 3 VÍAS.

4.0 I INTERRUPTOR DE PRESIÓN POR BAJA
4.1 INTERRUPTOR DE PRESIÓN POR ALTA

5.0 VÁLVULA NEUMÁTICA 5 VÍAS 2 POSICIONES CON LLAVE LOCAL/REMOTO
5.1 VÁLVULA NEUMÁTICA 5 VÍAS 2 POSICIONES LOCAL- ABRIR/CERRAR
6.0 FILTRO REGULADOR DE BAJA PRESIÓN.
7.0 VÁLVULA DE RELEVO DE BAJA PRESIÓN.
8.0 VÁLVULA NEUMÁTICA 3 VÍAS 2 POSICIONES SEÑAL SDV.
9.0 VÁLVULA SOLENOIDE 3 VÍAS 2 POSICIONES 3/2 24VCD ABRIR/CERRAR.
10.0 INTERRUPTOR DE POSICIÓN
11.0 VÁLVULA DE ESCAPE RÁPIDO
12.0 VÁLVULA REGULADORA DE CAUDAL
13.0 VÁLVULA OR
/Part. Cant. Descripción MODELO
23.000 1 1 PLATINA DE CONTROL NEUMATICO VVAP-PV665-001-01
584.20 2 1 FILTRO REGULADOR PUERTOS: 1/2" NPT 350-DD
3 1 VALVULA SOLENOIDE 3/2 VSG-2321-316-ME-XX
4 8 CONECTOR CODO 1/4"NPT-1/4"O.D. CLMA4-4-S316
6 3 4 22 26 27 13 11 5 1 VALVULA BOLA 3 VIAS 1/4"NPT HB2B3F-4N-S316
15 6 1 VALVULA DE RELEVO PARA BAJA PRESION 1/4"NPT RV1MF-4N-S316
7 2 ADAPTADOR MACHO 3/8"O.D-1/2"NPT CAM-6-8N-S316
8 1 TE DE RAMAL HEMBRA 1/4"NPT-3/8"O.D. CBTF6-4N-S316
9 1 CONECTOR RECTO 1/4"NPT-3/8"O.D. CMC-6-4N-S316
1 11 1 VALVULA PILOTEDA NEUMATICAMENTE VPP-3401-316

12 1 T MACHO 1/4"NPT-1/4"O.D. CRTM4-4N-S316
13 1 CONECTOR CODO 3/8"NPT-3/8"O.D. CLMA6-6N-S316
14 1 T HEMBRA 1/4"O.D. 1/4"NPT CRTF6-4N-S316
9 21 15 1 CONECTOR RECTO 3/8"NPT 3/8"O.D CMC6-6N-S316

19 1 VALVULA 5/2 SELECTOR MANUAL CON LLAVE CZA-4302-316-357E
12.750
323.85
20 2 VÁLVULA OR SV-3-316
21 4 CONECTOR RECTO 1/4"NPT-1/4" OD CMC4-4N-S316
26 8 SILENCIADOR MFS-4-S316
27 1 REDUCCION BUSHING 3/8" NPT 1/4" NPT H-SHB6-4N-316
28 1 PLACA IDENTIFICACION ABRIR/CERRAR VVAP-PV665-001-01
20 29 1 PLACA DE IDENTIFICACION LOCAL/REMOTO VVAP-PV394-001-01
30 1 VALVULA 5/2 CON SELECTOR MANUAL VIA-4302-3016-NNN
31 2 BRAKET PARA INTERRUPTOR DE POSICION H-SNR4-2N-S316
2 7 14 12 19 29 30 28

CP:54000

Diseño
Reviso
***
Material: ACERO INOXIDABLE Cantidad: 1

Titulo: Dim:
PLATINA
(in)/mm
Plano N°: VVAE-PV665-001 Rev.0 1-1 Revisión: 0
1 2 MANIFOLD PARA PILOTOS DE PRESION VA69637-312-F
2 1 NIPPLE 1/4"NPT X 4" H-SNA-4N-N-S316
3 2 PILOTO DE PRESION P-40
4 3 CONECTOR CODO 1/4"NPT-1/4"O.D. CLMA4-4-S316
3 8 6 1 T MACHO 1/4"NPT-1/4"O.D. CRTM4-4N-S316
7 1 VALVULA OR SV-5-316
8 2 CONECTOR RECTO 1/2"NPT-1/4O.D. CMC4-8N-316
9 1 CONECTOR CODO 1/2"NPT-1/4O.D. CLMA4-8N-316
6
4
0 COMENTARIOS 12/05/23

CP:54000

Diseño
Reviso
***
1 2 Material: ACERO AL CARBON

Titulo:
Cantidad: 1
Dim:
ENSAMBLE PILOTOS DE ALTA Y BAJA
PRESION (in)/mm
Plano N°: VVAE-PV665-003 Rev.0 1-1 Revisión: 0
SENTIDO DE FLUJO
58.775
1492.89
20.678 15.549 10.976

525.23 394.95 278.80
LAS DIMENSIONES PUEDEN VARIAR

HASTA UN 5%
33.384
847.94

1152.74
45.384

CP:54000

Diseño
Reviso
***
Material: ACERO AL CARBON Cantidad: 1

Titulo: Dim:
ENSAMBLE VÁLVULA - ACTUADOR
8FP-BS6R - G2016-SR2-CW (in)/mm
Plano N°: VVAE-PV665-002-01 Rev.0 1-1 Revisión: 0
1 1 VALVULA BOLA 8"-600# 8FP-BS6R
10 37 7 2 1
ACTUADOR NEUMATICO TIPO YUGO ESCOCES
RETORNO POR RESORTE
G2016-SR2-CW
2 3 1 INTERRUPTOR DE POSICION DXP-M21GNEB
4 1 BRAKET PARA ACTUADOR-INTERRUPTOR DE POSICION VVAP-PV665-002-05
5 4 TACON PARA PLATINA VVAP-PV665-001-04
6 1 COPLE PARA ENSAMBLE VÁLVULA ACTUADOR VVAP-PV665-002-06
7 1 VALVULA DE ESCAPE RAPISDO 1/2" NPT QE-5-316
8 1 CONECTOR RECTO 1/2"NPT-3/8"O.D. CMC-6-8N-316
9 1 BRAKET PARA VALVULA-ACTUADOR VVAP-PV665-002-03
10 1 REDUCCION NIPLE 3/4"NPT-1/2"NPT H-SNR12-8N-S316
37 1 SILENCIADOR AN500-06
38 1 PLATINA DE CONTROL NEUMATICO VVAE-PV665-001
39 1 ENSAMBLE PILOTOS DE ALTA Y BAJA PRESION VVAE-PV665-003
3
5 4
39
9 Revisión Descripción Fecha
6 Col: Tlalnepantla Centro

1 CP:54000
38 N.M.G REFERENCIAS DEL CLIENTE

Diseño
Reviso
***
Material: ACERO AL CARBON Cantidad: 1

Titulo: Dim:
LISTADO DE PARTES ENSAMBLE VÁLVULA -
ACTUADOR (in)/mm
8FP-BS6R - G2016-SR2-CW
Plano N°: VVAE-PV665-002-02 Rev.0 1-1 Revisión: 0
II. MATERIAL AND
TEST REPORTS
MATERIAL TEST REPORT TC No. 100970-70(80994038)
EN 10204-2004 Type 3.1 PAGE: 1 OF 6
CUSTOMER QUANTITY PART No. PRODUCT CODE PRODUCT DESCRIPITION

BALL VALVE,8BS6R-G V1,C40/5K262626 [-A40/600-POS1-TSF,-SF-
Neway Valve International, Inc 1 12254814 8FP-BS6R-A105N-57666-NC-G B7M/2HM]
SIDE ENTRY, FORGED, TRUNNION MOUNTED BALL VALVE 8 CLASS 600
ASTM A105N F316/F316L/DEVLON V
RAISED FACE END
PRESSURE TEST(MPa/PSI) OTHER INSPECTION

PURCHASE ORDER:
PO5500007577NVI_BALL HYDROSTATIC PNEUM RESULT VISUAL DIMENSION OPERATION MARKING
SHELL SEATS/BACKSEAT SEATS Accepted Accepted Accepted Accepted Accepted

PROJECT: N/A
15.4/2234 11.3/1639 0.6/87
PROJECT No.: N/A
APPLICABLE STANDARDS AND SPECIFICATION:

- P/T RATING: ASME B16.34
- MAIN MATERIAL: RELEVANT ASTM STANDARD
- DESIGN: API6D ASME B16.34
- TEST: API 6D
NOTE:ALL RELATED STANDRADS ARE THE LATEST VERSION UNLESS SPECIFIED BY PURCHASE ORDER.
- VALVES CONFORM TO NACE STANDARD MR.MR0175/MR.MR0103 LATEST REVISION
We hereby certify that the valves listed above are manufactured and tested in
accordance with the requirements of valve standard and purchase order

WITNESSED BY:__________
NEWAY VALVE
Quality Director
Date: 2022-05-25
Address: NO.666 TaiShan SuZhou New District China Tel:86-512-666-51365 Fax:86-512-666-51360 http://www.newayvalve.com
EN 10204-2004 Type 3.1 PAGE: 2 OF 6
PRODUCT TRACEABILITY TABLE
MATERIAL CODE AND HEAT NO. MATERIAL CODE AND HEAT NO.
PRODUCT PRODUCT
SERIAL NO. BODY CLOSURE L CLOSURE R BALL SERIAL NO. BODY CLOSURE L CLOSURE R BALL
NO. NO.
A105N A105N A105N F316/F316L A105N A105N A105N F316/F316L
100970-070-5 SY7267 XT7081 XT7081 KCM13 /
EN 10204-2004 Type 3.1 PAGE: 3 OF 6
MATERIAL COMPONENT AND PROPETRIES
Material Heat treatment Temp°C(°F) Holding time(h) Cooling media Furnace

2HM QUENCHED ≥ 850(≥1562)°F 1H/25MM,≥1H OIL ELECTRIC We hereby certify that the material are manufactured, inspected and
tested in
2HM TEMPERED ≥ 620(≥1148)°F 1H/25MM,≥1H AIR ELECTRIC accordance with the material specification and purchase order
requirements.
PART HEAT
MATERIAL CHEMICAL ANALYSIS MECHANICAL PROPERTIES
NAME NO.
IMPACT TEST
C Si Mn P S TS YS E R HARD VALUE
% % % % % MPa MPa % % HB TEMP °C:-29
MAX. 0.400 1.000 0.040 0.050 235 Avg: 40 Min:28
MIN.
0.400 0.000 0.000 0.000 0.000 159 1 2 3
NUT 2HM YIA165 0.460 0.220 0.560 0.020 0.006 222 42 51 48
EN 10204-2004 Type 3.1 PAGE: 4 OF 6

F316/F316L SOLUTION ≥1040(≥1904)°F 1H/25MM,≥1H WATER ELECTRIC We hereby certify that the material are manufactured, inspected and
tested in
accordance with the material specification and purchase order
requirements.
PART HEAT
NAME NO.
IMPACT TEST
C Si Mn P S Cr Ni Mo N TS YS E R HARD VALUE
% % % % % % % % % MPa MPa % % HB TEMP °C:-29
MAX. 0.030 1.000 2.000 0.045 0.030 18.000 14.000 3.000 0.100 237 Avg: 27 Min:22
MIN.
0.000 0.000 0.000 0.000 0.000 16.000 10.000 2.000 0.000 515 205 30 50 1 2 3
STEM F316/F316L B1M34 0.016 0.480 1.010 0.033 0.002 16.820 10.030 2.050 0.042 537 279 68 79 152 124 159 106
SEAT F316/F316L KZL1 0.022 0.430 0.980 0.022 0.002 16.320 10.110 2.090 0.059 565 285 61 79 143 296 294 288
RETAINER
BALL F316/F316L KCM13 0.021 0.240 0.650 0.036 0.002 16.330 10.080 2.050 0.050 563 309 65 72 163
EN 10204-2004 Type 3.1 PAGE: 5 OF 6

A105N NORMALIZED 850~920(1562~1688°F) 1H/25MM,≥1H AIR ELECTRIC We hereby certify that the material are manufactured, inspected and
tested in
accordance with the material specification and purchase order
requirements.
PART HEAT
NAME NO.
IMPACT TEST
C Si Mn P S Cr Ni Mo Cu V TS YS E R HARD
C.E. VALUE
% % % % % % % % % % MPa MPa % % HB TEMP °C:-29
MAX. 0.350 0.350 1.050 0.035 0.040 0.300 0.400 0.120 0.400 0.080 187 Avg: 27 Min:22
MIN.
0.000 0.100 0.600 0.000 0.000 0.000 0.000 0.000 0.000 0.000 485 250 22 30 1 2 3
CLOSURE R A105N XT7081 0.190 0.260 0.940 0.010 0.003 0.140 0.030 0.005 0.040 0.002 0.381 499 312 34 52 146 82 69 78
CLOSURE L A105N XT7081 0.190 0.260 0.940 0.010 0.003 0.140 0.030 0.005 0.040 0.002 0.381 499 312 34 52 146 82 69 78
BODY A105N SY7267 0.170 0.260 1.280 0.006 0.002 0.050 0.030 0.010 0.010 0.005 0.399 508 328 38 72 145 104 108 125
EN 10204-2004 Type 3.1 PAGE: 6 OF 6

B7M QUENCHED ≥850(≥1562)°F 1H/25MM,≥1H OIL ELECTRIC We hereby certify that the material are manufactured, inspected and
tested in
B7M TEMPERED ≥620(≥1148)°F 1H/25MM,≥1H AIR ELECTRIC accordance with the material specification and purchase order
requirements.
PART HEAT
NAME NO.
IMPACT TEST
C Si Mn P S Cr Mo TS YS E R HARD VALUE
% % % % % % % MPa MPa % % HB TEMP °C:-29
MAX. 0.480 0.350 1.000 0.035 0.040 1.100 0.250 235 Avg: 40 Min:28
MIN.
0.380 0.150 0.750 0.000 0.000 0.800 0.150 690 550 18 50 200 1 2 3
STUD B7M YKF158 0.400 0.240 0.810 0.011 0.003 0.960 0.190 731 636 23 62 214 43 50 48
Certificate of Approval
This is to certify that the Management System of:
Emerson Process Management Valve Automation

19200 Northwest Freeway, Houston, TX, 77065, United States
has been approved by LRQA to the following standards:

ISO 9001:2015
Cliff Muckleroy - Area Operations Manager Americas

Issued by: Lloyd's Register Quality Assurance, Inc.
Current issue date: 8 July 2019 Original approval(s):

Expiry date: 7 July 2022 ISO 9001 – 8 July 2016
Certificate identity number: 10200628
Approval number(s): ISO 9001 – 0015242
The scope of this approval is applicable to:

The Sales, Design, Manufacture, Modification, Assembly, Testing & Distribution of Actuators, Actuator
Accessories and Valve Assemblies.
Lloyd's Register Group Limited, its affiliates and subsidiaries, including Lloyd's Register Quality Assurance Limited (LRQA), and their respective officers, employees or agents are, individually and collectively, referred to in this clause as
'Lloyd's Register'. Lloyd's Register assumes no responsibility and shall not be liable to any person for any loss, damage or expense caused by reliance on the information or advice in this document or howsoever provided, unless that
person has signed a contract with the relevant Lloyd's Register entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract.
Issued by: Lloyd's Register Quality Assurance, Inc., 1330 Enclave Parkway, Suite 200, Houston, Texas 77077, United States
Page 1 of 1
III. CERTIFICATE OF
COMPLIANCE
IV.
6D-0848
NEWAY VALVE (SUZHOU) CO., LTD.

#666 Taishan Road
Suzhou New District
Suzhou, Jiangsu
People's Republic of China
API-6D
6D-0848
The scope of this license includes the following: Check Valves, Ball Valves and Gate Valves
QMS Exclusions: No Exclusions Identified as Applicable
Effective Date: JULY 21, 2020

Expiration Date: JULY 21, 2023
Vice President of Global Industry Services

Certificate no.: Initial certification date: Valid:
6880-1998-AQ-RGC-RvA 06 January, 1998 06 January, 2021 – 06 January, 2024
This is to certify that the management system of
Neway Valve (Suzhou) Co., Ltd.
No.666 Tai Shan Road, Suzhou New District, Suzhou, Jiangsu, China, 215129
has been found to conform to the Quality Management System standard:

GB/T 19001-2016/ISO 9001:2015
This certificate is valid for the following scope:
Design, Manufacture and Service of Industrial Valve and Marine Valve
Place and date: For the issuing office:

Shanghai, 09 December, 2020 DNV GL – Business Assurance
Suite A, Building 9, No.1591 Hongqiao
Road, Changning District, Shanghai
200336, P.R. China
TEL: +86 21 32799000
Zhu Hai Ming

Management Representative
Lack of fulfilment of conditions as set out in the Certification Agreement may render this Certificate invalid.
ACCREDITED UNIT: DNV GL Business Assurance B.V., ZWOLSEWEG 1, 2994 LB, BARENDRECHT, NETHERLANDS. TEL:+31102922689. assurance.dnvgl.com
Doc No: NWS4101
Rev No: 2008
Painting Process Specification for NWS4101- A2
1. Scope
1.1 This procedure covers the method of surface preparation, coating system and material, their
application and inspection applied to coating system on carbon steel valves. This is a special 3
stages painting system of hydroblasting body/bonnet, primer coating and finish paint after
testing.
2. Coating System
2.1 Painting system code: NWS 4101 – A2
2.2 Approved paint manufacturer/ Brand:
SHANGHAI GUANGYAO SPECIAL PRIMER CO., LTD / GUANGYAO (For primer)
SHANGHAI BOFAN COATING CO., LTD / BOFAN (For topcoat)
2.3 Details
Primer Intermediate Topcoat
Name Anti-rust primer N.A. Acrylic polyurethane
Code Guangyao RPY-618 N.A. Bofan BFJ-2
DFT (μ) 20 N.A. 30
TDFT(μ) 50
Finish colour Optional (Default :blue_RAL 5003)
3. Surface Preparation
3.1 Degrease/ clean the surface free from grease, oil, dirt etc by spraying with high pressure hot
water.
3.2 Dry with oil free compressed air.
3.3 Before cleaning, the machined surface should be suitably protected.
4. Primer Coating
Primer: RPY-618
Single component
Thinner RPY-108
Cleaner RPY-108
Colour Blue dark
Gloss Matt
DFT 15 microns
WFT 20 microns
Drying time Touch Dry -15 minutes to 1 hour at 40 deg. C
Page 30 of 110
Doc No: NWS4101
Rev No: 2008
Hard dry 1 hours
Storage
5. Top Coating
Top: BFJ-2
Single component
Thinner BF800
Cleaner BF800
Colour Blue
Gloss High gloss
DFT 35 microns
WFT 50 microns
Drying time Touch Dry -1 minutes to 3 hour at 30 ~40 deg. C
Hard dry 3 hours
Storage
6. Inspection
6.1 Visual examination: Free of any oil, grease and contamination on the surface.
6.2 Wet Film Thickness: Using with Wet film gauge
6.3 Dry Film Thickness: By Electronic/Digital coating thickness Gauge.
Primer coat 20 microns (min.)
Top coat 30 microns (min.)
Total Thickness 50 Microns (min.)
7. Repair
7.1 Before application of repair coating, surfaces shall be washed with fresh water.
7.2 Rust and surface contaminants shall be removed. The area shall be then be cleaned by solvent
washing.
7.3 Coating material shall be applied immediately after completion of surface preparation.
Page 31 of 110
IEC 61508 Functional Safety Assessment
Project:
G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators
Customer:
Valve Automation
Emerson Automation Solutions
Houston, Texas
USA
Contract Number: Q19/11-035

Report No.: EAS 16/06-010 R003
Version V3, Revision R2 Mar 2, 2021
Loren Stewart
The document was prepared using best effort. The authors make no warranty of any kind and shall not be liable in any
event for incidental or consequential damages in connection with the application of the document.
© All rights reserved.
Management Summary
This report summarizes the results of the functional safety assessment according to IEC 61508
carried out on the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators
The functional safety assessment performed by exida consisted of the following activities:
- exida assessed the development process used by Emerson Automation Solutions through
an audit and review of a detailed safety case against the exida certification scheme which
includes the relevant requirements of IEC 61508. The investigation was executed using
subsets of the IEC 61508 requirements tailored to the work scope of the development team.
exida reviewed and assessed a detailed Failure Modes, Effects, and Diagnostic Analysis
(FMEDA) of the devices to document the hardware architecture and failure behavior.
- exida performed a detailed Failure Modes, Effects, and Diagnostic Analysis (FMEDA) of the
devices to document the hardware architecture and failure behavior.
- exida reviewed field failure data to verify the accuracy of the FMEDA analysis.
- exida reviewed the manufacturing quality system in use at Emerson Automation Solutions.
The functional safety assessment was performed to the requirements of IEC 61508: ed2, 2010, SIL
3 for mechanical components. A full IEC 61508 Safety Case was prepared using the exida Safety
Case tool as the primary audit tool. Hardware process requirements and all associated
documentation were reviewed. Environmental test reports were reviewed. Also, the user
documentation (safety manual) was reviewed.
The results of the Functional Safety Assessment can be summarized as:
The audited development process as tailored and implemented by the Emerson Automation
Solutions G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators development project,
complies with the relevant safety management requirements of IEC 61508 SIL 3, SC 3 (SIL 3
Capable).
The assessment of the FMEDA, done to the requirements of IEC 61508, has shown that the G Series
and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators can be used in a low demand safety
related system in a manor where the PFDavg is within the allowed range for up to SIL 2 (HFT = 0) or
SIL 3 (HFT=1) according to table 2 of IEC 61508-1.
The assessment of the FMEDA also shows that the G Series and CB/CBA/CBA300/CBB Series
Scotch Yoke Actuators meets the requirements for architectural constraints of an element such that
it can be used to implement a SIL 2 safety function (with HFT = 0) or a SIL 3 safety function (with
HFT = 1).
This means that the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators is
capable for use in SIL 3 applications in Low DEMAND mode, when properly designed into a
Safety Instrumented Function per the requirements in the Safety Manual and when using the
versions specified in section 3 of this document.
© exida EAS 16-06-010 R003 V3R2 CB & G Series Assessment Report.docx

T-023 V4R8 exida 80 N. Main St, Sellersville, PA 18960 Page 2 of 21
The manufacturer will be entitled to use the Functional Safety Logo.

Table of Contents
Management Summary ................................................................................................... 2
1 Purpose and Scope ................................................................................................... 6
1.1 Tools and Methods used for the assessment ............................................................... 6
2 Project Management.................................................................................................. 7
2.1 exida............................................................................................................................ 7
2.2 Roles of the parties involved ........................................................................................ 7
2.3 Standards and literature used ...................................................................................... 7
2.4 Reference documents .................................................................................................. 7
2.4.1 Documentation provided by Valve Automation Emerson Automation Solutions . 7
2.4.2 Documentation generated by exida ................................................................... 9
2.5 Assessment Approach ................................................................................................. 9
3 Product Descriptions................................................................................................ 10
3.1 Hardware Version Numbers ....................................................................................... 10
4 IEC 61508 Functional Safety Assessment Scheme................................................. 11
4.1 Methodology............................................................................................................... 11
4.2 Assessment level ....................................................................................................... 11
5 Results of the IEC 61508 Functional Safety Assessment ........................................ 12
5.1 Lifecycle Activities and Fault Avoidance Measures..................................................... 12
5.1.1 Functional Safety Management ....................................................................... 12
5.1.2 Safety Requirements Specification and Architecture Design ............................ 13
5.1.3 Hardware Design ............................................................................................. 13
5.1.4 Validation......................................................................................................... 14
5.1.5 Verification....................................................................................................... 14
5.1.6 Proven In Use .................................................................................................. 14
5.1.7 Modifications.................................................................................................... 14
5.1.8 User documentation......................................................................................... 15
5.2 Hardware Assessment ............................................................................................... 15
6 2020 IEC 61508 Functional Safety Surveillance Audit............................................. 17
6.1 Roles of the parties involved ...................................................................................... 17
6.2 Surveillance Methodology .......................................................................................... 17
6.2.1 Documentation provided by Emerson Automation Solutions ............................ 18
6.2.2 Surveillance Documentation generated by exida............................................. 18
6.3 Surveillance Results ................................................................................................... 19
6.3.1 Procedure Changes ......................................................................................... 19
6.3.2 Engineering Changes ...................................................................................... 19
6.3.3 Impact Analysis ............................................................................................... 19
6.3.4 Field History .................................................................................................... 19
6.3.5 Safety Manual.................................................................................................. 19
6.3.6 FMEDA Update ............................................................................................... 19
6.3.7 Evaluate use of certificate and/or certification mark ......................................... 19
6.3.8 Previous Recommendations ............................................................................ 19
6.4 Surveillance Audit Conclusion .................................................................................... 19
7 Terms and Definitions .............................................................................................. 20
8 Status of the Document ........................................................................................... 21
8.1 Liability ....................................................................................................................... 21
8.2 Version History ........................................................................................................... 21
8.3 Future Enhancements ................................................................................................ 21
8.4 Release Signatures .................................................................................................... 21

1 Purpose and Scope
This document shall describe the results of the IEC 61508 functional safety assessment of the Valve
Automation Emerson Automation Solutions:
➢ G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators
by exida according to accredited exida certification scheme which includes the requirements of
IEC 61508: ed2, 2010.
The assessment has been carried out based on the quality procedures and scope definitions of
exida.
The results of this provides the safety instrumentation engineer with the required failure data as per
IEC 61508 / IEC 61511 and confidence that sufficient attention has been given to systematic failures
during the development process of the device.
1.1 Tools and Methods used for the assessment

This assessment was carried by using the exida Safety Case tool. The Safety Case tool contains
the exida scheme which includes all the relevant requirements of IEC 61508.
For the fulfillment of the objectives, expectations are defined which builds the acceptance level for
the assessment. The expectations are reviewed to verify that each single requirement is covered.
Because of this methodology, comparable assessments in multiple projects with different assessors
are achieved. The arguments for the positive judgment of the assessor are documented within this
tool and summarized within this report.
The assessment was planned by exida agreed with Valve Automation Emerson Automation
Solutions.
All assessment steps were continuously documented by exida (see [R1] to [R3]).

2 Project Management
2.1 exida
exida is one of the world’s leading accredited Certification Bodies and knowledge companies,
specializing in automation system safety and availability with over 500 years of cumulative
experience in functional safety. Founded by several of the world’s top reliability and safety experts
from assessment organizations and manufacturers, exida is a global company with offices around
the world. exida offers training, coaching, project-oriented system consulting services, safety
lifecycle engineering tools, detailed product assurance, cyber-security and functional safety
certification, and a collection of on-line safety and reliability resources. exida maintains a
comprehensive failure rate and failure mode database on process equipment based on 350 billion
hours of field failure data.
2.2 Roles of the parties involved

Valve Automation Emerson Automation Solutions Manufacturer of the G Series and
CB/CBA/CBA300/CBB Series Scotch Yoke
Actuators
exida Performed the hardware assessment
exida Performed the IEC 61508 Functional Safety
Assessment per the accredited exida scheme.
Valve Automation Emerson Automation Solutions originally contracted exida in June 2016 for the
IEC 61508 Functional Safety Assessment of the above mentioned devices.
2.3 Standards and literature used

The services delivered by exida were performed based on the following standards / literature.
[N1] IEC 61508 (Parts 1 - 7): 2010 Functional Safety of Electrical/Electronic/Programmable

Electronic Safety-Related Systems
2.4 Reference documents
2.4.1 Documentation provided by Valve Automation Emerson Automation Solutions

[D1] US006029-1, 7/8/2013 ISO 9001:2008 certificate of approval, Emerson Process
Management, Houston, Texas, USA; Superseded See
Section 6
[D2] QMS, ISS. 2, Rev 3, Global Quality Management System Manual; Superseded
3/23/2016 See Section 6
[D3] 14-HS1191666-PDA, ABS design assessment certificate, CB Series
7/31/2014
[D4] 14-HS1191665-3-PDA ABS design assessment certificate, G Series

[D5] BASP, 8/13/2003 Bettis Actuators Selection Procedure
Provides definitions for functions and performance capabilities of
actuator. States areas of concern to address during selection
[D6] CPI 1, 3/1/2005 CBA-Series Actuator Torque Ratings
Provides specified torque ratings for actuators at specified operating
pressures
[D7] CPI 2, 6/1/2003 CBA-Series Actuator Performance Data
Provides pressure and volume data for estimating speed response
[D8] DDOP, Rev G, 5/2/2007 Design / Drafting Operating Procedural Guidelines
[D9] EDOP, Rev F, 4/10/2007 Engineering Design Operating Procedural Guidelines
[D10] ELOP, Rev Q, 3/11/2011 Engineering Laboratory Operating Procedures
[D11] ES-42, Rev A, 03/15/2006 ES-42, IEC 61508 SIS/SIL Additional Procedural
Requirements
Additional procedures to ensure compliance with IEC 61508
[D12] GEOP, Rev K, 4/10/2007 General Engineering Operating Procedures
[D13] QA-08, Rev F, 09/22/2005 QA-08, Training and Records
Procedure for training and training records
[D14] QA-21, Rev L, 9/15/2015 Customer Returns and Complaints
[D15] QA-22, Rev G, 9/15/2015 Corrective Action / Preventative Action
Procedure for management of solutions of non-conformities;
Superseded See Section 6
[D16] GPI 1.11, 8/2015 G-Series Actuator Torque Ratings
Torque rating for actuators at specified operating pressures
[D17] GPI 2.01, Rev C, 1/2016 G-Series Actuator Performance Data
Provides pressure and volume data for estimating speed response
[D18] 137464, Rev F, 7/2012 Service Instructions for CB/CBA Actuators
Installation Instructions, operating and maintenance requirements
[D19] 124840E, Rev F; 7/2015 Service Instructions for G/GH/GHC Actuators
Installation Instructions, operating and maintenance requirements;
Superseded See Section 6
[D20] 137462E, Rev D, 8/2015 Service Instructions for CBAX30 Actuators
[D21] 137463E, Rev D, 8/2015 Service Instructions for CBAX30-SR Actuators
[D22] ES 47, Rev B, 12/8/2010 Bettis CBA & G Series IEC 61508 SIS/SIL Safety Manual
[D23] Lloyds 96/60075(E6), Lloyds Type Approval Certificate, G Series
1/29/2016
[D24] Lloyds 93/60111(E4), Lloyds Type Approval Certificate, CB Series
2/6/2013
[D25] DF-92, 09/30/1998 Design Plan / Design File Checklist for CBA3XX
Pneumatic Actuator
[D26] DF-92 review, 07/25/2002 Final Design Review CBAx30 Pneumatic Actuator
[D27] T203019, 06/04/2003 Test Evaluation Report
Multiple verification tests for CBA actuators

[D28] T200123, 11/20/2001 Test Evaluation Report
High cycle test for CBA actuators
[D29] Wyle 47221, 08/08/2002 Wyle Laboratories Test Report, Environmental testing
[D30] Design Review, 5/21/09 CBB Design review
[D31] Gate 5 Review, 7/21/09 CBB SY Actuator Gate 5 Review
[D32] T209018, 4/6/09 CBB Engineering Lab Test Request (IP66)
[D33] T209021, 5/28/09 CBB Engineering Lab Test Request (Seal assembly test)
[D34] T209024, 5/22/09 CBB Engineering Lab Test Request (Torque shaft leak
test)
2.4.2 Documentation generated by exida

[R1] EAS 16-06-010 R001 V2R1 FMEDA report, G Series Actuators
FMEDA G Series Actuator
[R2] EAS 16-06-010 R002 V1R1 FMEDA report CB Series Actuators
FMEDA CB Series Actuator
[R3] Q1106016_EPVAWaller IEC 61508 SafetyCase for G Series and
Mechanical SafetyCase Data CB/CBA/CBA300/CBB Series Scotch Yoke Actuators
r1.esc
2.5 Assessment Approach

The certification audit was closely driven by requirements of the exida scheme which includes
subsets filtered from IEC 61508.
The assessment was planned by exida and agreed upon by Valve Automation Emerson Automation
Solutions.
The following IEC 61508 objectives were subject to detailed auditing:
• FSM planning, including
o Safety Life Cycle definition
o Scope of the FSM activities
o Documentation
o Activities and Responsibilities (Training and competence)
o Configuration management
• Safety Requirement Specification
• Change and modification management
• Hardware design / probabilistic modeling
• Hardware and system related V&V activities including documentation, verification
• Hardware-related operation, installation and maintenance requirements
3 Product Descriptions
The G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators are quarter-turn actuators
designed for on-off or modulating control of any quarter-turn ball, butterfly, rotary plug valve,
automation of louvers and dampers or any quarter-turn mechanism.
G-Series double-acting models produce guaranteed torque outputs from 12,581 lb-in to 6,000,000
lb-in (1420-678,000 Nm). Spring-return units produce spring torques in excess of 3,000,000 lb-in
(339,000 Nm). G-Series actuators are suitable for continuous operation at pneumatic pressures from
40-2000 PSIG (3-14 BAR) and hydraulic pressures to 5000 PSIG (345 BAR).
Double-acting CB/CBA-Series actuators, requiring pressure to rotate in either direction, are available
with guaranteed minimum torque outputs to 12,245 lb-in (1,384 Nm). The CB/CBA-Series spring-
return models require pressure in only one direction of travel and are suitable for fail clockwise or
counterclockwise applications without modification. These models produce guaranteed spring
ending torques to 4,971 lb-in (562 Nm).
3.1 Hardware Version Numbers

gives an overview of the different versions that were considered in the FMEDA of the G Series and
CB/CBA/CBA300/CBB Series Scotch Yoke Actuators.
Table 1 Version overview
G Series, Pneumatic, SR Pneumatic G Series, Spring-Return

G Series, Pneumatic, DA Pneumatic G Series, Double Acting
G Series, Hydraulic, SR Hydraulic G Series, Spring-Return (with and without
Hydraulic override)
G Series, Hydraulic, DA - SP Hydraulic G Series, Double Acting, Single Piston
G Series, Hydraulic, DA - SP, HO Hydraulic G Series, Double Acting, Single Piston with
Hydraulic Override
G Series, Hydraulic, DA - DP Hydraulic G Series, Double Acting, Double Piston
CB/CBA Series, Pneumatic, SR Pneumatic CB/CBA Series, Spring-Return
CB/CBA Series, Pneumatic, DA Pneumatic CB/CBA Series, Double Acting
Damper Hydraulic Damper for G Series Actuators
The G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators are classified as Type A1
devices according to IEC 61508, having a hardware fault tolerance of 0.
The Fail-Safe state of the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators is
defined as the state where hold-open pressure is released and the spring is extended (Spring-
return option), or the state where the hold-position pressure is released and pressure is supplied to
the trip side of the actuator (Double Acting option).
1
Type A component: “Non-Complex” component with well-defined failure modes, for details see 7.4.3.1.2
of IEC 61508-2.
4 IEC 61508 Functional Safety Assessment Scheme
exida assessed the development process used by Valve Automation Emerson Automation
Solutions for this development project against the objectives of the exida certification scheme which
includes subsets of IEC 61508 -1 to 3. The results of the assessment are documented in [R3].
4.1 Methodology
The full functional safety assessment includes an assessment of all fault avoidance and fault control
measures during hardware development and demonstrates full compliance with IEC 61508 to the
end-user. The assessment considers all requirements of IEC 61508. Any requirements that have
been deemed not applicable have been marked as such in the full Safety Case report, e.g. software
development requirements for a product with no software. The assessment also includes a review
of existing manufacturing quality procedures to ensure compliance to the quality requirements of IEC
61508.
As part of the IEC 61508 functional safety assessment the following aspects have been reviewed:
• Development process, including:
o Functional Safety Management, including training and competence recording, FSM
planning, and configuration management
o Specification process, techniques and documentation
o Design process, techniques and documentation, including tools used
o Validation activities, including development test procedures, test plans and reports,
production test procedures and documentation
o Verification activities and documentation
o Modification process and documentation
o Installation, operation, and maintenance requirements, including user documentation
o Manufacturing Quality System
• Product design
o Hardware architecture and failure behavior, documented in a FMEDA
The review of the development procedures is described in section 5. The review of the product
design is described in section 5.2.
4.2 Assessment level

The G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators has been assessed per IEC
61508 to the following levels:
• SIL 3 capability
The development procedures have been assessed as suitable for use in applications with a
maximum Safety Integrity Level of 3 (SIL 3) according to IEC 61508.

5 Results of the IEC 61508 Functional Safety Assessment
exida assessed the development process used by Valve Automation Emerson Automation
Solutions for these products against the objectives of the exida certification scheme which includes
IEC 61508 parts 1, & 2. The development of the G Series and CB/CBA/CBA300/CBB Series Scotch
Yoke Actuators was done per this IEC 61508 SIL 3 compliant development process. The Safety
Case was updated with project specific design documents.
5.1 Lifecycle Activities and Fault Avoidance Measures

Valve Automation Emerson Automation Solutions has a defined product lifecycle process in place.
This is documented in the Quality Management System Manual [D2] and various Quality Procedures
[D8]-[D15]. A documented modification process is documented in the DDOP document [D8].
Emerson Automation Solutions is ISO 9001:2008 certified, see [D1]. In addition, Valve Automation
Emerson Automation Solutions is certified by Lloyds [D23] & [D24] for manufacturing in the following
locations:
Valve Automation Emerson Automation Solutions – Valve Automation
19200 NW Freeway
Houston, Tx – 77065, USA
NOTE: Tianjin factory entity name change 3/2/2021

Emerson Process Management (Tianjin) Valves Co., Ltd
No 15, Xingwang Road
Wuqing Development Area
Tianjin 301700
People’s Republic of China
Emerson Automation Solutions Hungary Kft. – Valve Automation
Berenyi U. 72-100 (Videoton Industrial Park, building number:230)
Szekesfehervar 8000 Hungary
No software is part of the design and therefore any requirements specific from IEC 61508 to software
and software development do not apply.
The assessment investigated the compliance with IEC 61508 of the processes, procedures and
techniques as implemented for product design and development. The investigation was executed
using the exida certification scheme which includes subsets of IEC 61508 requirements tailored to
the SIL 3 work scope of the development team. The result of the assessment can be summarized
by the following observations:
The audited Valve Automation Emerson Automation Solutions design and development
process complies with the relevant managerial requirements of IEC 61508 SIL 3.
5.1.1 Functional Safety Management

The valves manufactured by Valve Automation Emerson Automation Solutions are not built for
inventory. These valves are built-to-order. The basic designs are standardized, but each order can
have trim and materials variations, or specific customer requested proof tests. Due to the specialized
nature of each valve, documentation that defines all of the requirements is generated for every order
as part of the process.

FSM Planning
Valve Automation Emerson Automation Solutions has a defined process in place for product design
and development. Required activities are specified along with review and approval requirements.
This is documented in the EDOP Procedure. Templates and sample documents were reviewed and
found to be sufficient. The modification process is covered by in the section titles Engineering
Change Notice of the DDOP procedure [D8]. This process and the procedures referenced therein
fulfill the requirements of IEC 61508 with respect to functional safety management for a product with
simple complexity and well-defined safety functionality.
Version Control
Procedure DDOP [D8] requires that all documents be under document control. Use of this to control
revisions was evident during the audit.
Training, Competency recording
QA-08 [D13] requires the Human Resource department to maintain training records of education,
experience, training and qualifications for all personnel. Department heads are responsible for
identifying and providing the training needs for their department as well as proficiency evaluations.
The procedures and records were examined and found up-to-date and sufficient. Valve Automation
Emerson Automation Solutions hired exida to be the independent assessor per IEC 61508 and to
provide specific IEC 61508 knowledge.
5.1.2 Safety Requirements Specification and Architecture Design

For the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators, the simple primary
functionality of the actuator is the same as the safety functionality of the product (Valve changes
position, Close / Open). Therefore, no special Safety Requirements Specification was needed. The
normal functional requirements were sufficient. As the G Series and CB/CBA/CBA300/CBB Series
Scotch Yoke Actuators designs are simple and are based upon standard designs with extensive field
history, no semi-formal methods are needed. General Design and testing methodology is
documented and required as part of the design process. This meets SIL 3.
5.1.3 Hardware Design

The design process is documented in the EDOP Procedure [D9]. Valve Automation Emerson
Automation Solutions uses the following CAD tools, 2D, SolidEdge (originally ProE was used).
Design calculations may be performed with MathCad or Excel. Other design tools may be used as
appropriate, e.g. for failure investigation. The output from all design tools has significant cross
checking, e.g. each individual drawing is reviewed. Outputs for tools require checking and sign off.
Items from IEC 61508-2, Table B.2 include observance of guidelines and standards, project
management, documentation (design outputs are documented per quality procedures), structured
design, modularization, use of well-tried components / materials, and computer-aided design tools.
This meets SIL 3.

5.1.4 Validation
Validation Testing is created for each order. The test plan includes testing per all standard and
customer performance requirements. As the G Series and CB/CBA/CBA300/CBB Series Scotch
Yoke Actuators are purely mechanical devices with a simple safety function, there is no separate
integration testing necessary. The G Series and CB/CBA/CBA300/CBB Series Scotch Yoke
Actuators perform only 1 Safety Function, which is extensively tested under various conditions during
validation testing.
Items from IEC 61508-2, Table B.3 include functional testing, project management, documentation,
and black-box testing (for the considered devices this is similar to functional testing). Field
experience and statistical testing via regression testing are not applicable. This meets SIL 3.
Items from IEC 61508-2, Table B.5 included functional testing and functional testing under
environmental conditions, project management, documentation, failure analysis (analysis on
products that failed), expanded functional testing, black-box testing, and fault insertion testing. This
meets SIL 3.
5.1.5 Verification
Verification activities are defined in the EDOP Procedure. Methods of design verification used by
Valve Automation Emerson Automation Solutions include alternate calculation, comparison to similar
proven design, or by testing and demonstration. Additionally, a design file checklist is available to
review all items that need to be included in the Design File for a new development, e.g. see [D25].
All verification activities are documented. This meets SIL 3.
5.1.6 Proven In Use

In addition to the Design Fault avoidance techniques listed above, a Proven in Use evaluation was
carried out on the Valve Automation Emerson Automation Solutions G Series and
CB/CBA/CBA300/CBB Series Scotch Yoke Actuators. Shipment records were used to determine
that the actuators have >200 million hours in use and they have demonstrated a field failure rate less
than the failure rates indicated in the FMEDA reports. This meets the requirements for Proven In
Use for SIL 3.
5.1.7 Modifications
Modifications are initiated per the Engineering Change Request form as described in the DDOP
Procedure. The request is reviewed by the requestor’s manager prior to submission into the ECR /
ECN system. The request is entered into the system as an Engineering Change Notice. All changes
are first reviewed and analyzed for impact before being approved. Measures to verify and validate
the change are developed following the normal design process.
The modification process has been successfully assessed and audited, so Valve Automation
Emerson Automation Solutions may make modifications to this product as needed.
As part of the exida scheme a surveillance audit is conducted every 3 years. The modification
documentation listed below is submitted as part if the surveillance audit. exida will review the
decisions made by the competent person in respect to the modifications made.
o List of all anomalies reported
o List of all modifications completed
o Safety impact analysis which shall indicate with respect to the modification:

▪ The initiating problem (e.g. results of root cause analysis)
▪ The effect on the product / system
▪ The elements/components that are subject to the modification
▪ The extent of any re-testing
o List of modified documentation
o Regression test plans
This meets SIL 3.
5.1.8 User documentation

Valve Automation Emerson Automation Solutions creates the following user documentation: service
instructions [D18] to [D21] and a Safety Manual [D22]. The Safety Manual was found to contain all
of the required information given the simplicity of the products. The Safety Manual references the
FMEDA reports which are available and contain the required failure rates, failure modes, useful life,
and suggested proof test information.
Items from IEC 61508-2, Table B.4 include operation and maintenance instructions, user
friendliness, maintenance friendliness, project management, documentation, limited operation
possibilities (G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators perform well-
defined actions) and operation only by skilled operators (operators familiar with type of valve,
although this is partly the responsibility of the end-user). This meets SIL 3.
5.2 Hardware Assessment

To evaluate the hardware design of the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke
Actuators Failure Modes, Effects, and Diagnostic Analysis’s were performed by exida. These are
documented in [R1] and [R2].
A Failure Modes and Effects Analysis (FMEA) is a systematic way to identify and evaluate the effects
of different component failure modes, to determine what could eliminate or reduce the chance of
failure, and to document the system in consideration. An FMEDA (Failure Mode Effect and
Diagnostic Analysis) is an FMEA extension. It combines standard FMEA techniques with extension
to identify online diagnostics techniques and the failure modes relevant to safety instrumented
system design.
From the FMEDA, failure rates are derived for each important failure category. All failure rate analysis
results and useful life limitations are listed in the FMEDA report [R1] and [R2]. Tables in the FMEDA
report list these failure rates for the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke
Actuators under a variety of configurations. The failure rates listed are valid for the useful life of the
actuators.
According to IEC 61508 the architectural constraints of an element must be determined. This can be
done by following the 1 H approach according to 7.4.4.2 of IEC 61508 or the 2 H approach according
to 7.4.4.3 of IEC 61508.
The 1H approach involves calculating the Safe Failure Fraction for the entire element.
The 2H approach involves assessment of the reliability data for the entire element according to
7.4.4.3.3 of IEC 61508.

The failure rate data used for this analysis meets the exida criteria for Route 2H. Therefore, the G
Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators can be classified as a 2 H device.
When 2H data is used for all of the devices in an element, the element meets the hardware
architectural constraints up to SIL 2 at HFT=0 (or SIL 3 @ HFT=1) per Route 2H.
If Route 2H is not applicable for the entire final element, the architectural constraints will need to be
evaluated per Route 1H.
Note, as the G Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators are only one part
of a (sub)system, the SFF should be calculated for the entire final element combination.
These results must be considered in combination with PFD avg values of other devices of a Safety
Instrumented Function (SIF) in order to determine suitability for a specific Safety Integrity Level (SIL).
The architectural constraints requirements of IEC 61508-2, Table 2 also need to be evaluated for
each final element application. It is the end user’s responsibility to confirm this for each particular
application and to include all components of the final element in the calculations.
The analysis shows that the design of the G Series and CB/CBA/CBA300/CBB Series Scotch
Yoke Actuators can meet the hardware requirements of IEC 61508, SIL 3 and SIL 2 for the
actuators depending on the complete final element design. The Hardware Fault Tolerance and
PFDavg requirements of IEC 61508 must be verified for each specific design.

6 2020 IEC 61508 Functional Safety Surveillance Audit
6.1 Roles of the parties involved
Emerson Automation Solutions Manufacturer of the G Series and CB/CBA/CBA300/CBB Series
Scotch Yoke Actuators
exida Performed the hardware assessment review
exida Performed the IEC 61508 Functional Safety Surveillance Audit per
the accredited exida scheme.
Emerson Automation Solutions contracted exida to perform the surveillance audit for the above G
Series and CB/CBA/CBA300/CBB Series Scotch Yoke Actuators. The surveillance audit was
conducted remotely.
6.2 Surveillance Methodology

As part of the IEC 61508 functional safety surveillance audit the following aspects have been
reviewed:
• Procedure Changes – Changes to relevant procedures since the last audit are reviewed to
determine that the modified procedures meet the requirements of the exida certification
scheme.
• Engineering Changes – The engineering change list is reviewed to determine if any of the
changes could affect the safety function of the G Series and CB/CBA/CBA300/CBB Series
Scotch Yoke Actuators.
• Impact Analysis – If changes were made to the product design, the impact analysis
associated with the change will be reviewed to see that the functional safety requirements for
an impact analysis have been met.
• Field History – Shipping and field returns during the certification period will be reviewed to
determine if any systematic failures have occurred. If systematic failures have occurred
during the certification period, the corrective action that was taken to eliminate the systematic
failure(s) will be reviewed to determine that said action followed the approved processes and
was effective.
• Safety Manual – The latest version of the safety manual will be reviewed to determine that it
meets the IEC 61508 requirements for a safety manual.
• FMEDA Update – If required or requested the FMEDA will be updated. This is typically done
if there are changes to the IEC 61508 standard and/or changes to the exida failure rate
database.
• Evaluate use of the certificate and/or certification mark - Conduct a search of the applicant’s
web site and document any misuse of the certificate and/or certification mark. Report any
misuse of the certificate and/or certification mark to the exida Managing Director.
• Recommendations from Previous Audits – If there are recommendations from the previous
audit, these are reviewed to see if the recommendations have been implemented properly.

6.2.1 Documentation provided by Emerson Automation Solutions
[D35] VA001-196-30 rev 1; Oct 2015 CBB Double-Acting Series Pneumatic Actuators
Service Instructions
[D36] VA137465E rev F; May 2012 CBB-Series Spring Return Pneumatic Actuators
Service Instructions
[D37] VA124840E rev G; Mar 2017 G/GH/GHC Series Pneumatic Actuators Service
Instructions; Supersedes [D19]
[D38] EOP 06 rev 04; Oct 2018 Operating Procedure – Engineering – Design &
Development Product Configuration Engineering
Change Control
[D39] Global QMS; Issue 3; rev 1; Oct Global Quality Management System Manual;
2018 Supersedes [D2]
[D40] QA-20 rev D; Nov 2015 Quality Assurance Procedure Non-Conforming
Product
[D41] QA-22 rev H; Sept 2015 Quality Assurance Procedure Corrective / Preventive
Actions; Supersedes [D15]
[D42] QC-08 rev T; May 2017 Quality Control Procedure Final Test
[D43] ES 6 CB/CBA/CBB rev G Final Quality Testing of Actuators; CB/CBA/CBB
Series Spring Return - Pneumatic
[D44] ES 6 rev AR Engineering Specification; Final Quality Testing of
Bettis Brand Scotch-Yoke Actuators
[D45] ES 8 CBA-CBB rev F Engineering Specification – Pressure Requirements
and Limitations for Bettis Actuators
[D46] ES 8 rev AG Engineering Specification – Pressure Requirements
and Limitations for Bettis Actuators
[D47] ES 31 rev P Engineering Specification – Pressure Equipment
Directive for Actuator Requirements
[D48] QC-02 rev V Quality Control Procedures – Receiving Inspection
[D49] QCM-0313 Approved until 6/20 17025Accredited Certificate of Calibration
[D50] QCM-0523 Approved until 6-20 17025Accredited Certificate of Calibration
[D51] ISO 9001:2015 exp July 2022 Emerson Process Management Valve Automation –
Certificate of Approval – ISO 9001:2015;
Supersedes [D1]
6.2.2 Surveillance Documentation generated by exida

[R4] EAS 19-11-035 PIU V1R0 Proven In Use Analysis for G Series and
CB/CBA/CBA300/CBB Series Scotch Yoke Actuators

6.3 Surveillance Results
6.3.1 Procedure Changes

Changes to the documents in Section 6.2.1 were reviewed and were found to be consistent with the
requirements of IEC 61508.
6.3.2 Engineering Changes

There were no significant design changes to these products during the previous certification period.
6.3.3 Impact Analysis

There were no safety-related design changes during the previous certification period.
6.3.4 Field History

The field histories of these products were analyzed and found to be consistent with the failure rates
predicted by the FMEDA.
6.3.5 Safety Manual

The safety manual did not change since the last assessment and continues to be compliant with IEC
61508:2010.
6.3.6 FMEDA Update

The FMEDA report was not updated during this assessment since no changes were made or needed.
6.3.7 Evaluate use of certificate and/or certification mark

The Emerson Automation Solutions website was searched and no misleading or misuse of the
certification or certification marks was found.
6.3.8 Previous Recommendations

There were no previous recommendations to be assessed at this audit.
6.4 Surveillance Audit Conclusion

The result of the Surveillance Audit Assessment can be summarized by the following observations:
The Emerson Automation Solutions G Series and CB/CBA/CBA300/CBB Series Scotch Yoke
Actuators continues to meet the relevant requirements of IEC 61508:2010 for SIL 3 in low
demand applications based on the initial assessment and considering:
- field failure history
This conclusion is supported by the updated SafetyCase and certification documents.

7 Terms and Definitions
Architectural Constraint The SIL limit imposed by the combination of SFF and HFT for Route 1 H or
by the HFT and Diagnostic Coverage (DC applies to Type B only) for
Route 2H
exida criteria A conservative approach to arriving at failure rates suitable for use in
hardware evaluations utilizing the 2 H Route in IEC 61508-2.
Fault tolerance Ability of a functional unit to continue to perform a required function in the
presence of faults or errors (IEC 61508-4, 3.6.3)
FIT Failure In Time (1x10-9 failures per hour)
FMEDA Failure Mode Effect and Diagnostic Analysis
HFT Hardware Fault Tolerance
Low demand mode Mode, where the demand interval for operation made on a safety-related
system is greater than twice the proof test interval.
PFDavg Average Probability of Failure on Demand
PVST Partial Valve Stroke Test
It is assumed that the Partial Stroke Testing, when performed, is
automatically performed at least an order of magnitude more frequent than
the proof test, therefore the test can be assumed an automatic diagnostic.
Because of the automatic diagnostic assumption, the Partial Valve Stroke
Testing also has an impact on the Safe Failure Fraction.
Random Capability The SIL limit imposed by the PFDavg for each element.
SFF Safe Failure Fraction summarizes the fraction of failures, which lead to a
safe state and the fraction of failures which will be detected by diagnostic
measures and lead to a defined safety action.
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System – Implementation of one or more Safety
Instrumented Functions. A SIS is composed of any combination of
sensor(s), logic solver(s), and final element(s).
Systematic Capability The SIL limit imposed by the capability of the products manufacturer.
Type A element “Non-Complex” element (using discrete components); for details see
7.4.4.1.2 of IEC 61508-2
Type B element “Complex” element (using complex components such as micro controllers
or programmable logic); for details see 7.4.4.1.3 of IEC 61508-2

8 Status of the Document
8.1 Liability
exida prepares reports based on methods advocated in International standards. exida accepts no
liability whatsoever for the use of this report or for the correctness of the standards on which the
general calculation methods are based.
8.2 Version History

Contract Report Number Revision Notes
Number
Q19/11-035 EAS 16-06-010 R001 V3R1 Recertification; LLS 5/28/2020
Q18/07-152 EAS 16/06-010 R001 V2R1 Added Hydraulic Damper
Q16/06-010 EAS 16-06-010 R001 V1R1 Recertification Release
Q03/08-24 BET 03-08-24 R007 V2R1 Previous Assessment Report
Reviewer: Ted Stewart, exida, 5/28/2020
Status: Released, 5/28/2020
8.3 Future Enhancements

At request of client.
8.4 Release Signatures
Loren L. Stewart, CFSE, Senior Safety Engineer
Ted E. Stewart, CFSP, exidaCSP

Program Development & Compliance Manager

Certificate / Certificat
Zertifikat /
EAS 1606010 C002
exida hereby confirms that the:
The manufacturer G Series Scotch Yoke Actuators

may use the mark:
Valve Automation
Emerson Automation Solutions
Has been assessed per the relevant requirements of:
IEC 61508 : 2010 Parts 1-7

and meets requirements providing a level of integrity to:
Systematic Capability: SC 3 (SIL 3 Capable)
Revision 3.0 May 28, 2020

Random Capability: Type A, Route 2H Device
Surveillance Audit Due PFDAVG and Architecture Constraints
January 1, 2023 must be verified for each application
Safety Function:
The actuator will move the actuator/valve combination to the
designed safe position within the specified safety time.
Application Restrictions:
The unit must be properly designed into a Safety Instrumented
Function per the Safety Manual requirements.
Place embossed
seal here for
Evaluating Assessor
originals, lining it
up at the bottom
Certifying Assessor
ISO/IEC 17065
PRODUCT CERTIFICATION BODY
#1004
Page 1 of 2
Certificate / Certificat / Zertifikat /
EAS 1606010 C002
Systematic Capability: SC 3 (SIL 3 Capable)
Random Capability: Type A, Route 2H Device
PFDavg and Architecture Constraints
must be verified for each application
Systematic Capability :
The product has met manufacturer design process requirements of Safety
G Series Scotch Yoke Integrity Level (SIL) 3. These are intended to achieve sufficient integrity
Actuators against systematic errors of design by the manufacturer.
A Safety Instrumented Function (SIF) designed with this product must not
be used at a SIL level higher than stated.
Random Capability:
The SIL limit imposed by the Architectural Constraints must be met for
each element. This device meets exida criteria for Route 2H.
IEC 61508 Failure Rates in FIT*

Application (Pneumatic) λSD λSU λDD λDU
Spring Return 0 218 0 427
Double Acting / Single Piston 0 0 0 550
Double Acting / Double Piston 0 0 0 865
Adder for Damper 0 0 0 85
Application (Hydraulic) λSD λSU λDD λDU
Spring Return 0 121 0 415
Double Acting Single Piston 0 0 0 470
Double Acting – Single Piston, w/HO 0 0 0 580
Double Acting – Double Piston, 0 0 0 640
Adder for Damper 0 0 0 85
* FIT = 1 failure / 109 hours
SIL Verification:
The Safety Integrity Level (SIL) of an entire Safety Instrumented Function (SIF)
must be verified via a calculation of PFDavg considering redundant architectures,
proof test interval, proof test effectiveness, any automatic diagnostics, average
repair time and the specific failure rates of all products included in the SIF. Each
element must be checked to assure compliance with minimum hardware fault
tolerance (HFT) requirements.
The following documents are a mandatory part of certification:
Assessment Report: EAS 16/10-010 R003 V3R1
Safety Manual: ES 47 Rev C
80 N Main St
Sellersville, PA 18960
T-061, V4R1
Page 2 of 2
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1 PRODUCTION/PRODUCT QUALITY ASSURANCE NOTIFICATION
2 Equipment and protective systems intended for use in potentially explosive

atmospheres Directive 2014/34/EU
Conformity to Type based on Quality Assurance of the Production Process/Product Quality

Assurance
3 Notification No. SIRA 07 ATEX M387
4 Equipment, protective system or components as listed:
Valve Position Monitors and Controllers, Intrinsic safety (ia/ib), Flameproof (d), Dust
Switchgear, Contactors, Starters, Circuit Ignition by Enclosure (t), Increased Safety
Breakers (e), Encapsulation (m)
5 Manufacturer or Topworx Inc

Authorised Representative: 3300 Fern Valley Road
Louisville
KY 40213
USA
6 Manufacturing locations: As above
7 CSA Group Netherlands B.V. (CSA), Notified Body No. 2813 in accordance with Article 17 of
the Council Directive 2014/34/EU, notifies that the manufacturer has a quality system which
complies with the requirements of Annexes IV & VII of Directive 2014/34/EU.
8 This notification is based upon Report No. 80015452 issued on 22 August 2019. This
notification can be withdrawn if the manufacturer no longer satisfies the requirements of
Annexes IV/VII. Results of periodical assessment of the quality system form part of this
notification.
9 According to Article 16 [3] of Directive 2014/34/EU the CE marking shall be followed by the
identification number 2813 of CSA Group Netherlands B.V. as the Notified Body involved in the
production control stage.
Date of Initial Certification: 14 August 2007

Date of Issue: 02 September 2019
Date of Expiry: 08 August 2022
James May
On behalf of CSA
Notification No. SIRA 07 ATEX M387

This certificate remains valid subject to the company maintaining its system to the required standards, which will be monitored by CSA.
The use of this Certificate and the CSA Certification Mark are subject to the Regulations Applicable to Holders of CSA Certificates
CSA Group Netherlands B.V., Utrechtseweg 310, 6812 AR, Arnhem, Netherlands
DQD507.24 Issue Date: 2018-04-20
FUNCTIONAL SAFETY CERTIFICATE
This is to certify that the
D-Series Switchbox
Manufactured by
Topworx
3300 Fern Valley Road
Louisville
Kentucky 40213
USA
Has been assessed by Sira Certification Service with reference to the CASS
methodologies and found to meet the requirements of
IEC 61508-2:2010
Systematic Capability (SC3)
As an element suitable for use in safety related systems performing safety functions up
to and including
Use as a Controller – up to and including SIL 2*

Use as an Indicator – up to and including SIL 3*
When used in accordance with the scope and conditions of this certificate
* This certificate does not waive the need for further functional safety verification to
establish the achieved Safety Integrity Level (SIL) of the safety related system
Certification Manager:
Wayne Thomas
Certification Manager
Initial Certification: 19th June 2012

This certificate re-issued: 04th September 2018
Renewal date: 18th June 2022
This certificate may only be reproduced in its entirety without any change.
Sira Certification Service

CSA Group UK
Certificate No.: Sira FSP 11018/09
Unit 6 Hawarden Industrial Park,
Form 7016 issue 3
Hawarden, CH5 3US, United Kingdom.
Page 1 of 11
Tel: +44 (0) 1244 670900
Web: www.csagroupuk.org
Report Summary
D-Series Discrete Valve Controller

Safety Function:
“TO CLOSE OFF (RELIEVE) PNEUMATIC PRESSURE TO THE SPOOL VALVE”
Type A Proof Test Interval =8760Hrs
SIL2
Architectural constraints: HFT=0 MTTR = 8 Hrs
SFF 74%
λDD = 0 λSD = 0
Random hardware failures: λDU = 2.90E-08 λSU = 8.40E-08
PFDAVG=1.27E-04 SIL3
Probability of failure on demand:
(Low Demand Mode)
Average Frequency of Dangerous failure PFH = 2.90E-08 SIL3
on safety function: (High Demand Mode)
Hardware safety integrity compliance Route 1H
Systematic safety integrity compliance Route 1S
Systematic Capability SC 3 (See report R56A24114B)
SIL 2 (Low Demand)

Overall SIL-capability achieved
SIL 2 (High Demand)

CSA Group UK
Form 7016 issue 3
Page 2 of 11
Tel: +44 (0) 1244 670900
D-Series Discrete Valve Controller
Safety Function:
“TO OPEN (ADMIT) PNEUMATIC PRESSURE TO THE SPOOL VALVE”
SIL1
SFF 29%
λDD = 0 λSD = 0
Probability of failure on demand: PFDAVG=8.10E-04 SIL3
(Low Demand Mode)
SIL 1 (Low Demand)

SIL 1 (High Demand)

CSA Group UK
Form 7016 issue 3
Page 3 of 11
Tel: +44 (0) 1244 670900
D-Series Switchboxes used as Indicators
Safety Function:
“TO PROVIDE AN INDICATION OF THE MONITORED VALVE POSITION”
SIL2
SFF=89%
λDD = 6.74E-08 λSD = 0.00E-00
(Low Demand Mode)
SIL 2 (Low Demand)

SIL 2 (High Demand)

CSA Group UK
Form 7016 issue 3
Page 4 of 11
Tel: +44 (0) 1244 670900
D-Series Indicator using GO switches (Z series, L series and 35 series)
Safety Function:
“TO PROVIDE AN INDICATION OF THE MONITORED VALVE POSITION”
SIL3
SFF=91%
λDD = 7.07E-08 λSD = 0.00E-00
(Low Demand Mode)
SIL 3 (Low Demand)

SIL 3 (High Demand)

CSA Group UK
Form 7016 issue 3
Page 5 of 11
Tel: +44 (0) 1244 670900
Product description and scope of certification
On/Off Valve controllers and Indicators (D-Series)
D-Series discrete valve controllers are certified for use in every world
area. They carry IECEx, ATEX, and UL certifications in a single model,
making it easier for global customers to standardize across plants in
multiple world areas.
The D-Series consists of three models. DXP, DXS, and DXR variants are all capable of
incorporating a pilot valve and position sensors with the enclosure differing per model
type depending on the application requirements
Modules in the D-Series Valve Controller

The D-Series Valve Controller consists of the following modules:
 Pilot Valve
 Spool Valve
 Shaft (only plays part in indicator safety function)
 Sensor Module (see Annex A for a full list of sensor module options covered by
this certificate)
 Indicator Beacon (only plays part in indicator safety function)
D-Series Safety Functions

The safety functions of the D-Series Valve Controller are defined as:
D-Series as a controller:
 To relieve pneumatic pressure to the spool valve by de-energising the solenoid
valve allowing the actuator to perform its safety function.
 To admit pneumatic pressure to the spool valve by energising the solenoid
valve allowing the actuator to perform its safety function.
D-Series as an Indicator:
 To provide an accurate indication of the monitored valve position.
Product identification and configuration
The product is defined in the manufacturer’s drawings listed in Table 1 below.
Table 1: Certified product drawings

Document no. Re Date Document description
v
ES-01141-1 7 3/15/2012 D series final assembly drawing
ES-01857-1 13 - D Series master installation, operation and
maintenance manual
ES-02292-1 1 - D series (DXP) configuration document
ES-02293-1 1 - D series (DXS) configuration document
ES-04900-1 6 10/30/2017 HART Module Assembly
The assessment has produced the supporting information given in Table 2 below.

CSA Group UK
Form 7016 issue 3
Page 6 of 11
Tel: +44 (0) 1244 670900
Table 2: Base Information
1 Product identification: D-Series as described in manufacturer’s product
catalogue
2 Functional specification: Refer to paragraph above ‘Use in safety
functions’ and full specification in manufacturer’s
product catalogue.
3-5 Random hardware failure rates: Refer to table in report summary
6 Environment limits: Temperature range:
Solenoid option:-20 to +100oC for the D-Series
GO switch option:-60 to +100oC for the D-Series
7 Lifetime/replacement limits: Refer to IOM manual
8 Proof Test requirements: D-Series – ES-01857-1 R13
9 Maintenance requirements:
10 Diagnostic coverage: NA
11 Diagnostic test interval:
12 Repair constraints: Refer to IOM manual
D-Series – ES-01857-1 R13
13 Safe Failure Fraction: Refer to table in report summary
14 Hardware fault tolerance (HFT):
15 Highest SIL (architecture/type A/B):
16 Systematic failure constraints: The requirements of this clause are contained in
the relevant IOM Manual
D-Series – ES-01857-1 R13
17 Evidence of similar conditions in previous Compliance Route 2H (proven-in-use) not used
use:
18 Evidence supporting the application under
different conditions of use:
19 Evidence of period of operational use:
20 Statement of restrictions on functionality:
21 Systematic capability: This assessment is based on an element which
22 Systematic fault avoidance measures: is to be used in a SRS and is not a full SRS
23 Systematic fault tolerance measures: design related assessment.
24 Validation records:
Additional Manufacturing Facilities
The following locations have been assessed by CSA Group UK and were found to be in
conformance to IEC61508:2010 and follow the same level of rigor and process quality and
control as TopWorx Inc (USA).
Emerson Process Management Emerson Machinery Equipment

8000 Székesfehérvár Bao Heng Industry Park, Liu Xian 1st Road,
Holland fasor 6 District 68 Bao'an District, Shenzhen, P.R.
Hungary China.
Post code: 518101

CSA Group UK
Form 7016 issue 3
Page 7 of 11
Tel: +44 (0) 1244 670900
Conditions of Certification
The validity of the certified data is conditional on the Manufacturer complying with the following
conditions:
1. The manufacturer shall analyse failure data from returned products on an on-going basis.
Sira Certification Service shall be informed in the event of any indication that the actual
failure rates are worse than the certified failure rates. (A process to rate the validity of field
data should be used. To this end, the manufacturer should co-operate with users to operate
a formal field-experience feedback programme).
2. Sira shall be notified in advance (with an impact analysis report) before any modifications to
the certified equipment or the functional safety information in the user documentation is
carried out. Sira may need to perform a re-assessment if modifications are judged to affect
the product’s functional safety certified herein.
3. On-going lifecycle activities associated with this product (e.g., modifications, corrective
actions, field failure analysis) shall be subject to surveillance by Sira in accordance with
‘Regulations Applicable to the Holders of Sira Certificates’.
Conditions of Safe Use

The validity of the certified data is conditional on the user complying with the following
conditions:
1. The user shall comply with the requirements given in the manufacturer’s user
documentation (referred to in Table 2 above) in regard to all relevant functional safety
aspects such as application of use, installation, operation, maintenance, proof tests,
maximum ratings, environmental conditions, repair, etc;
2. Selection of this equipment for use in safety functions and the installation, configuration,
overall validation, maintenance and repair shall only be carried out by competent personnel,
observing all the manufacturer’s conditions and recommendations in the user
documentation.
3. All information associated with any field failures of this product should be collected under a
dependability management process (e.g., IEC 60300-3-2) and reported to the
manufacturer.
4. The unit should be tested at regular intervals to identify any malfunctions; in accordance
with the safety manual.
General Conditions and Notes

1. This certificate is based upon a functional safety assessment of the product described in
Sira Test & Certification Assessment Report R56A24114A.
2. If certified product or system is found not to comply, Sira Certification Service should be
notified immediately at the address shown on this certificate.
3. The use of this Certificate and the Sira Certification Mark that can be applied to the product
or used in publicity material are subject to the ‘Regulations Applicable to the Holders of Sira
Certificates’ and ‘Supplementary Regulations Specific to Functional Safety Certification’.
4. This document remains the property of Sira and shall be returned when requested by the
issuer.

CSA Group UK
Form 7016 issue 3
Page 8 of 11
Tel: +44 (0) 1244 670900
Certificate History
Issue Date Document no. Comment

05 15/06/2015 SIRA FSP 11018 Certificate updated to include additional
manufacturing faculties as a result of successful
audit – report R70005298.
06 23/01/2017 SIRA FSP 11018 Certificate updated to correct incorrect SFF value
in results tables 1 and 2.
07 27/06/2017 R70118946A Certificate reissued as a result of successful
recertification.
08 04/01/2018 70168119 Certificate updated to include documentation for
HART v7 module. Note. HART transmitter in
Annex A refers to the new HART v7 module.
09 04/09/2018 - Minor changes to reflect systematic capability.

CSA Group UK
Form 7016 issue 3
Page 9 of 11
Tel: +44 (0) 1244 670900
Annex A
Below is a list of switch module configurations supported by this certificate:
00 - No switches
0A - No switches w/ 0-1K potentiometer
0B - No switches w/ 0-10K potentiometer
0H - HART transmitter
0X - 4-20mA transmitter
31 - (1) P+F NJ5-30GK-S1N
32 - (2) P+F NJ5-30GK-S1N
42 - (2) P+F NBB2-V3-E2
44 - (2) P+F NBB2-V3-E2
52 - (2) P+F NBB3-V3-Z4
54 - (4) P+F NBB3-V3-Z4
62 - 2-wire N/O 0-253V 200mA
72 - 3-wire PNP 0-60VDC 200mA
82 - (2) ITW mechanical DPDT
B2 - (2) P+F NJ2-12GK-SN
B3 - (3) P+F NJ2-12GK-SN
E1 - (1) P+F NJ2-V3-N inductive NAMUR
EH - HART transmitter w/ P+F NJ2-V3-N inductive NAMUR
ES - ESD/PST module w/ GO™ Switch
EX - 4-20mA transmitter w/ P+F NJ2-V3-N inductive NAMUR
F2 - (2) P+F NJ2-12GK-N
J1 - (1) P+F NJ2-11-SN-G
J2 - (2) P+F NJ2-11-SN-G
K2 - (2) Mechanical SPDT gold contacts
KH - HART transmitter w/ mechanical SPDT gold contacts
KX - 4-20mA transmitter w/ mechanical SPDT gold contacts
L1 - (1) GO™ Switch SPDT hermetic seal
L2 - (2) GO™ Switches SPDT hermetic seal

CSA Group UK
Form 7016 issue 3
Page 10 of 11
Tel: +44 (0) 1244 670900
LH - HART transmitter w/ GO™ Switch SPDT
LX - 4-20mA transmitter w/ GO™ Switch SPDT
M2 - (2) Mechanical SPDT
MA - (2) Mechanical SPDT switches w/ 0-1K potentiometer
MH - HART transmitter w/ mechanical SPDT
MX - 4-20mA transmitter w/ mechanical SPDT
N2 - Namur switches
PN - (2) SPDT module w/o LEDs, 1A max
PS - (2) SPDT module w/ LEDs, 250mA max
T2 - (2) Mechanical DPDT
TX - 4-20mA transmitter w/ mechanical DPDT
V1 - (1) P+F NJ3-18GK-S1N
V2 - (2) P+F NJ3-18GK-S1N
V3 - (3) P+F NJ3-18GK-S1N
Z1 - (1) GO™ Switch DPDT hermetic seal
Z2 - (2) GO™ Switches DPDT hermetic seal
ZH - HART transmitter w/ GO™ Switch DPDT
ZX - 4-20mA transmitter w/ GO™ Switch DPDT

CSA Group UK
Form 7016 issue 3
Page 11 of 11
Tel: +44 (0) 1244 670900
FUNCTIONAL SAFETY CERTIFICATE
This is to certify that the
Versa Type ARDA, ARFA, ARNA & ANFA Regulators

(1/4”, 1/2" and 1”)
manufactured by
Versa Products Co. Inc.

22 Spring Valley Road
Paramus
NJ 07652
have been assessed by Sira Certification Service with reference to the

CASS methodologies and found to meet the requirements of
IEC 61508-2:2010
Routes 1H & 1S
Systematic Capability (SC3)
as an element/subsystem suitable for use in safety related systems performing safety

functions up to and including
SIL 2 capable with HFT=0 (1oo1)*

SIL 3 capable with HFT=1 (1oo2)*
when used in accordance with the scope and conditions of this certificate.
*
This certificate does not waive the need for further functional safety verification to
establish the achieved Safety Integrity Level (SIL) of the safety related system
Certification Manager:
Wayne Thomas
Initial Certification : 16/07/2018

This certificate re-issued : 16/07/2018
Renewal date : 10/07/2023
This certificate may only be reproduced in its entirety, without any change.

Part of CSA Group UK
Certificate No.: Sira FSP 18012/00 Hawarden, CH5 3US, United Kingdom.
Form 7016 issue 5 Tel: +44 (0) 1244 670900
Page 1 of 7 Email: [email protected]
Product description and scope of certification
The Versa Type ARDA, ARFA & ARNA Regulators series of stainless steel regulators and filter
regulators are designed to stand up to the harshest environments while providing highly accurate
pressure regulation. It has proven 316 stainless steel housing and filter assemblies along with
fluorocarbon, low temperature NBR or ethylene propylene diaphragm construction for compatibility
with sour gas and adaptability to off shore environments. It is designed to operate with pressure
inlets between 0 and 290 psig of gas. It can regulate to pressure ranges that include but are not
limited to 0-30 psig, 0-60 psig, 0-100 psig. When the setting screw is turned clockwise, the top
spring applies pressure on the poppet and the regulator opens and supplies a pressure to the setting
desired by the user. When the setting screw is turned counter clockwise, the force of the spring
lessens and reduces pressure. When it is completely disengaged, the regulator goes into a closed
position, isolating the process from its media.
Like the regulators and filter regulators, the ANFA is a standalone filter designed to stand up to the
harshest environments while providing reliable media filtration for pressures up to 290 psi. It comes
standard with a 5 micron mesh (25 micron and 40 micron sizes available). It continuously provides
devices downstream with protection against particles larger than the mesh size that could hamper
operation.
Figure 1: Typical Assembly of the Versa ARDA, ARFA, ARNA, & ANFA (left to right)
Element Safety Function

The element safety function of the Versa Type Regulators (ARFA, ARDA & ARNA) is defined as
follows:
To shut off the pressure (closed position) when the set screw is completely disengaged.
The element safety function of the Versa Type Filters (ARFA, ARDA & ANFA) is defined as follows:

Form 7016 issue 5 Tel: +44 (0) 1244 670900
To pass through media with particulates which are smaller than the size of the mesh
Certified Data in support of use in safety functions

As part of the product assessment and supporting evidence of conformity in with respect to
‘hardware safety integrity’ against the requirements of IEC 61508-2; Versa Product Co. Inc. have
submitted the Versa Type ARDA, ARFA, ARNA & ANFA Regulators (1/4”, 1/2" and 1”) for FMEA
assessment to attain SIL capability. The component failure rates and modes for the Versa Type
ARDA, ARFA, ARNA & ANFA Regulators (1/4”, 1/2" and 1”) have been extracted from or calculated
using Quanterion Automated Databook, Item Toolkit and Faradip 3.0. Table 1 and 2 summarise the
FMEA assessment for the Versa Type ARDA, ARFA, ARNA & ANFA Regulators (1/4”, 1/2" and 1”).
Table 1a: FMEA Summary for the ARDA, ARFA & ARNA - 1/4” & 1/2” Regulator
Safety Function (ARFA, ARDA & ARNA): To shut off the pressure (closed position) when the set
screw is completely disengaged.
Safety Function (ARFA & ARDA): To pass through media with particulates which are smaller
than the size of the mesh
Summary of IEC 61508-2 ARDA, ARFA & ARNA 1/4” & 1/2” Regulators
Clauses 7.4.2 and 7.4.4 1oo1 1oo2
Architectural constraints & HFT = 0 HFT = 1
Type of product A/B Type A Type A
Safe Failure Fraction (SFF) 85% 85%
Random hardware λDD 0.00E+00 0.00E+00
failures: [h-1] λDU 4.73E-08 4.73E-08
Random hardware λSD 0.00E+00 0.00E+00
failures: [h-1] λSU 2.84E-07 2.84E-07
Diagnostic Coverage 0% 0%
Risk Reduction Factor (RRF)
5,524 48,076
PTI = 8760 hrs, MTTR = 8 hrs
PFD 1.81E-04 2.08E-05
Hardware safety integrity compliance Route 1H Route 1H
Systematic safety integrity Route 1S
Route 1S
compliance See report
See report R70176570B
R70176570B
Systematic Capability
(SC1, SC2, SC3, SC4) SC 3 SC 3
Hardware safety integrity achieved SIL 2 SIL 3

Form 7016 issue 5 Tel: +44 (0) 1244 670900
Table 1b: FMEA Summary for the ARDA, ARFA & ARNA - 1” Regulator
Safety Function (ARFA, ARDA & ARNA): To shut off the pressure (closed position) when the set
screw is completely disengaged.
Safety Function (ARFA & ARDA): To pass through media with particulates which are smaller
Summary of IEC 61508-2 ARDA, ARFA & ARNA 1” Regulators
Random hardware failures: [h- λDD 0.00E+00 0.00E+00
1
] λDU 4.73E-08 4.73E-08
Random hardware failures: [h- λSD 0.00E+00 0.00E+00
1
] λSU 2.04E-07 2.04E-07
Risk Reduction Factor
5,524 48,076
PTI = 8760 Hrs, MTTR = 8 Hrs.
PFD 1.81E-04 2.08E-05
Systematic safety integrity Route 1S Route 1S
compliance See report R70176570B See report R70176570B
Table 2: FMEA Summary for the ANFA – 1/4” 1/2” & 1” Filter
Safety Function: To pass through media with particulates which are smaller than the size of the
mesh
Summary of IEC 61508-2 ANFA Filter
λDD 0.00E+00 0.00E+00
Random hardware failures: [h-1]
λDU 1.50E-08 1.50E-08
λSD 0.00E+00 0.00E+00
Random hardware failures: [h-1]
λSU 3.27E-08 3.27E-08
Risk Reduction Factor
17,391 151,975
PTI = 8760 Hrs, MTTR = 8 Hrs.
PFD 5.75E-05 6.58E-06
Systematic safety integrity compliance Route 1S Route 1S
See report R70176570B See report R70176570B

Form 7016 issue 5 Tel: +44 (0) 1244 670900
Note 1: The failure data:
1) The PFDAVG figure shown is for illustration only assuming a proof test interval of 8760 hours and
MTTR of 8 hours. Refer to IEC 61508-6 for guidance on PFDAVG calculations from the failure
data.
2) The verified failure rates used in the safe failure fraction and diagnostic coverage do not include
(λ no parts or no effect) failures in the calculation.
The failure data above is supported by the base information given in Table 3 below.
Table 3: Base information for the FM10A2 flame monitoring system

1 Product identification: Versa Type ARDA, ARFA, ARNA & ANFA Regulators (1/4”, 1/2"
and 1”)
2 Functional specification: Versa Type Regulators (ARFA, ARDA & ARNA):
To shut off the pressure (closed position) when the set screw
is completely disengaged.
Versa Type Filters (ARFA, ARDA & ANFA):

To pass through media with particulates which are smaller
3-5 Random hardware failure rates: Refer to table 1a, 1b and 2 of this certificate.
6 Environment limits: Operating temperature: -15°C to +149°C
7 Lifetime/replacement limits: 20 years
8 Proof Test requirements: Refer to safety manual.
9 Maintenance requirements: Refer to safety manual.
10 Diagnostic coverage: 0% diagnostic coverage.
11 Diagnostic test interval: Refer to safety manual.
12 Repair constraints: Refer to safety manual.
13 Safe Failure Fraction: 85% (ARDA, ARFA & ARNA - 1/4” & 1/2”)
81% (ARDA, ARFA & ARNA - 1”)
68% (ANFA – 1/4”, 1/2” & 1”)
14 Hardware fault tolerance (HFT): See Table 1a, 1b and 2 above
15 Highest SIL (architecture/type A/B): Type A, SIL2 (1oo1)
Type A, SIL3 (1oo2)
16 Systematic failure constraints: The hardware safety integrity assessment was based on a
proof test interval of 1 year. For further information refer to
safety manual.
17 Evidence of similar conditions in previous Not applicable.
use:
18 Evidence supporting the application Not applicable.
under different conditions of use:
19 Evidence of period of operational use: Not applicable.
20 Statement of restrictions on functionality: See systematic report R70176570B.
21 Systematic capability (SC1, SC2, SC3) SC3 - See systematic report R70176570B.
22 Systematic fault avoidance measures: Compliance with techniques and measures from IEC 61508-2
Annex B - See systematic report R70176570B.
23 Systematic fault tolerance measures: Compliance with techniques and measures from IEC 61508-2
Annex A to support the SFF achieved – see hardware safety
integrity report R70176570A.
24 Validation records: All documents that have been used in support of the hardware
have been documented in section 5.26 of report R70176570A;
this includes the FMEA document.

Form 7016 issue 5 Tel: +44 (0) 1244 670900
Management of functional safety
The assessment has demonstrated that the product is supported by an appropriate
functional safety management system that meets the relevant requirements of IEC 61508-
1:2010 clause 6, see report R70176570B.
Identification of certified equipment

The certified equipment and it’s safe use is defined in the manufacturer’s documentation
listed in Table 4 below.
Table 4: Certified documents

Document no. Pages Rev Date Document description
ARDA-3111-316 1 of 1 D 23 Nov 09 ARDA Regulator Assembly Drawing
ARFA-3111-316 1 of 1 A 08 Jun 18 ARFA Regulator Assembly Drawing
ARNA-3011-316 1 of 1 A 08 Jun 18 ARNA Regulator Assembly Drawing
ANFA-3100-316-(TAB)-(TAB) 1 of 1 C 24 Mar 14 ANFA Filter Assembly Drawing
Conditions of Certification
The validity of the certified base data is conditional on the manufacturer complying with the
following conditions:
1. The manufacturer shall analyse failure data from returned products on an on-going basis. Sira
Certification Service shall be informed in the event of any indication that the actual failure rates
are worse than the certified failure rates. (A process to rate the validity of field data should be
used. To this end, the manufacturer should co-operate with users to operate a formal field-
experience feedback programme).
2. Sira shall be notified in advance (with an impact analysis report) before any modifications to the
certified equipment or the functional safety information in the user documentation is carried out.
Sira may need to perform a re-assessment if modifications are judged to affect the product’s
functional safety certified herein.
3. On-going lifecycle activities associated with this product (e.g., modifications, corrective actions,
field failure analysis) shall be subject to surveillance by Sira in accordance with ‘Regulations
Applicable to the Holders of Sira Certificates’.
Conditions of Safe Use
The validity of the certified base data in any specific user application is conditional on the user
complying with the following conditions:
1. The user shall comply with the requirements given in the manufacturer’s user documentation in
regard to all relevant functional safety aspects such as application of use, installation, operation,
maintenance, proof tests, maximum ratings, environmental conditions, and repair.
2. Selection of this product for use in safety function and the installation, configuration, overall
validation, maintenance and repair shall only be carried out by competent personnel, observing
all the manufacturer’s conditions and recommendations in the user documentation.
3. All information associated with any field failures of this product should be collected under a
dependability management process (e.g., IEC 60300-3-2) and reported to the manufacturer.
4. The safety device is to have an independent power supply, it must not share the same power
supply as non-safety devices that may cause a fault to the safety device.
5. A proof test interval of 1 year.

Form 7016 issue 5 Tel: +44 (0) 1244 670900
General Conditions and Notes
1. This certificate is based upon a functional safety assessment of the product described in Sira
Test & Certification Assessment Report R70176570A and any further reports referenced
(R70176570B).
2. If the certified product or system is found not to comply, Sira Certification Service should be
notified immediately at the address shown on this certificate.
3. The use of this Certificate and the Sira Certification Mark that can be applied to the product or
used in publicity material are subject to the ‘Regulations Applicable to the Holders of Sira
Certificates’ and ‘Supplementary Regulations Specific to Functional Safety Certification’.
4. This document remains the property of Sira and shall be returned when requested by the issuer.
5. No part of the Functional safety related aspects stated in the instruction manual shall be
changed without approval of the certification body.
6. This certificate will remain valid subject to completion of two surveillance audits within the five
year certification cycle, and upon receipt of acceptable response to any findings raised during
this period. This certificate can be withdrawn if the manufacturer no longer satisfies scheme
requirements.
Certificate History
Issue Date Report no. Comment

0 16/07/2018 R70176570A The release of prime certificate.
R70176570B

Form 7016 issue 5 Tel: +44 (0) 1244 670900
CERTIFICATE OF COMPLIANCE
Certificate Number 20170207 – E125326
Report Reference E125326 – 20001204
Issue Date 2017-FEBRUARY-07
Issued to: TOPWORX INC

3300 Fern Valley Rd
Louisville, KY 40213-3528 USA
This is to certify that Telemetering Equipment for Use in Hazardous Locations

representative samples of (See following page for additional information.)
Have been investigated by UL in accordance with the

Standard(s) indicated on this Certificate.
Standard(s) for Safety: ANSI/ISA-12.12.01-2011, Nonincendive Electrical

Equipment for Use in Class I and II, Division 2 and Class III,
Divisions 1 and 2 Hazardous (Classified) Locations, 2011
Edition Approved 2011-08-24, UL 1203, Third Edition, and
UL 508, Seventeenth Edition.
CSA C22.2 No. 30-M1986, C22.2 No. 213-M1987 and
C22.2 No. 14-92.
Additional Information: See the UL Online Certifications Directory at
www.ul.com/database for additional information
Only those products bearing the UL Certification Mark should be considered as being covered by UL's
Certification and Follow-Up Service.
Look for the UL Certification Mark on the product.
Bruce Mahrenholz, Director North American Certification Program
UL LLC
Any information and documentation involving UL Mark services are provided on behalf of UL LLC (UL) or any authorized licensee of UL. For questions, please
contact a local UL Customer Service Representative at http://ul.com/aboutul/locations/
Page 1 of 2
CERTIFICATE OF COMPLIANCE
Certificate Number 20170207 – E125326
Report Reference E125326 – 20001204
Issue Date 2017-FEBRUARY-07
This is to certify that representative samples of the product as specified on this certificate were tested
according to the current UL requirements.
Additional Information:
USL, CNL Class I, Division 2, Groups A, B, C and D; Class II, Division 2, Groups F and G Hazardous
Locations.
Model DVC or DVM followed by AS or PB, followed by Z2, followed by B or N, followed by P, followed
by one to four alphanumeric character designators.
Model DVC or DVM, followed by MB or DN, followed by Z2, followed by letter, followed by P, followed
by one to three alphanumeric character designations
Valve Controller/Monitor, Model DXR followed by AS or PB, followed by 2, followed by a letter or

number, followed by S, N, 1 or 2, followed by E, 4, M, 5, 8, 6, 1, 9, or 7, followed by B, V, E, or S,
followed by Blank, 1, 2, or 3, followed by Blank, A, S, 6, B or R, followed by any number or letter,
followed by any number or letter.
USL, CNL Class I, Division 1, Groups C and D; Class I, Division 2, Groups A, B, C and D; and Class II,
Division 2, Groups F and G Hazardous Locations.
Valve Controller/Monitor, Model DXS/DXP/DXR-AS, followed by AS or PB, followed by 1 or 2, followed

by a letter or number, followed by S, N, 1 or 2, followed by E, 4, M, 5, 8, 6, 1, 9, or 7, followed by B, V,
E, or S, followed by Blank, 1, 2, or 3, followed by Blank, A, S, 6, B or R, followed by any number or
letter, followed by any number or letter.
Bruce Mahrenholz, Director North American Certification Program
UL LLC
Any information and documentation involving UL Mark services are provided on behalf of UL LLC (UL) or any authorized licensee of UL. For questions, please
contact a local UL Customer Service Representative at http://ul.com/aboutul/locations/
Page 2 of 2
IECEx Quality
Assessment Report Summary
INTERNATIONAL ELECTROTECHNICAL COMMISSION
IEC Certification System for Explosive Atmospheres
for rules and details of the IECEx Scheme visit www.iecex.com
QAR Ref. No.: NL/DEK/QAR11.0007/06 Page 1 of 1
QAR Free Ref. No.: 382685800 Status: Issued
Details of change: Re-assessment audit Date of issue: 2020-02-21
Site(s) audited: VERSA Products Company, Inc. Valid until: 2023-02-21

Paramus NJ 07652
Audit date: 2020-02-21
United States of America
Issuing ExCB: DEK - DEKRA Certification B.V.
Manufacturer: VERSA Products Company, Inc.

Paramus NJ 07652
Location of United States of America

Manufacturer:
Product information: Electromagnetic Solenoid Valve Operators
Protection concept: Ex d, e, i, m, t
Related QARs:
NL/DEK/QAR11.0007/00 NL/DEK/QAR11.0007/01 NL/DEK/QAR11.0007/02
NL/DEK/QAR11.0007/03 NL/DEK/QAR11.0007/04 NL/DEK/QAR11.0007/05
Related Certificates KEMA 02ATEX1199 X

(manual insertion): KEMA 02ATEX2182 X
KEMA 02ATEX2281 X
KEMA 03ATEX2507
KEMA 08ATEX0142 X
Sira 09ATEX1094 X
Sira 10ATEX1118 X
Sira 16ATEX1157 X
PTB 11ATEX2007
For the following IECEx related certificates, see also NL/KEM/QAR08.0018:
IECEx KEM 09.0044X
IECEx KEM 09.0045
Related Certificates
(automatic linking):
Related Certificates for

previous versions:
IECEx CSA 16.0029X issue: 0 IECEx CSA 16.0029X issue: 1 IECEx CSA 16.0029X issue: 2
IECEx CSA 16.0029X issue: 3 IECEx KEM 09.0043X issue: 1 IECEx KEM 09.0043X issue: 2
IECEx KEM 10.0030X issue: 1 IECEx PTB 11.0015 issue: 1 IECEx SIR 09.0044X issue: 4
IECEx SIR 09.0044X issue: 5 IECEx SIR 10.0058X issue: 2 IECEx SIR 10.0058X issue: 3
Comments: The listed ATEX certificates are related to Notification No. DEKRA11ATEXQ0072
For previous QARs see NL/KEM/QAR08.0018.

(https://www.csagroup.org/contact/)
HOME (HTTPS://WWW.CSAGROUP.ORG/) / TESTING AND CERTIFICATION
(HTTPS://WWW.CSAGROUP.ORG/TESTING-CERTIFICATION/) / CSA GROUP PRODUCT LISTING
(HTTPS://WWW.CSAGROUP.ORG/TESTING-CERTIFICATION/PRODUCT-LISTING/) /
CERTIFICATION RECORD
Contact an Expert
Certification Record
CUSTOMER CLASS FILE NUMBER
Versa Products Company, Inc. 3221-01 (../class/?class=3221-01) 045276_0_000

22 Spring Valley Rd, VALVES-General purpose
Paramus
New Jersey
United States
07652
Pneumatic/hydraulic valves solenoid operated Models of Series A, K, M, V, T, ESM-2, -3, -7 and -8, all 10W or less, 575V or less, 60Hz, 265V dc or less.
Notes:
/
1. A complete product number is formed by the addition of numbers and/or letters to the series designation which indicate valve type, port s, body and
2. Optional features are indicated by su ix designations -243, -G5R, -M, RUGGD-CUL, -JJS, -JJD, M5R, -3, -14, -B and -N and additional su ix letters
and/or numbers indicate minor external mechanical variations.
3. All grommet housing valve and other valves without a proper grounding terminal or lead are certified for use in other equipment where the suitability of
the combination is to be determined by the final application.
4. All valves provided with a junction box and acceptable ground or conduit hub models provided with suitable ground lead are certified for general use.
(https://www.csagroup.org/contact/)
All other valves are certified for component use in other equipment where the suitability is to be determined by the Canadian Standards Association.
Solenoid operators, 480V and less, 50/60Hz, 18W and less, 120V dc and less, 16W and less, Models V021 to V026, V031 to V036, V051 to V056 and V071
to V076.
Contact an Expert
Notes:
1. Solenoid operators are Certified for use in other equipment where the suitability of the combination is to be determined by Canadian Standards
Association.
2. Model numbers have su ixes of numbers and letters to include combinations of electrical and mechanical design.
Contact an
Expert
We’re always here to help. Let’s talk.

We’re here to answer your questions and help you get
started right away. Call or send us a message anytime.
Contact Us (https://www.csagroup.org/contact)
/
1/26/2021 VAPT.E37780 - Solenoids for Use in Hazardous Locations | UL Product iQ
VAPT.E37780 - Solenoids for Use in Hazardous Locations
Solenoids for Use in Hazardous Locations

See General Information for Solenoids for Use in Hazardous Locations
PETER PAUL ELECTRONICS CO INC E37780

480 John Downey Dr
PO BOX 1180
New Britain, CT 06051-2910 USA
Class I, Groups A, B, C and D; Class II, Groups E, F and G.
Model Nos. OELW51, -52, -53, OEW-51, -52, -53, -54, -55, -56, followed by three suffix letters, followed by D, U, V, X or Z, followed by C or CC. Model No. may be preceded by V or VO.
Model Nos. OELW51, -52, -53, OEW-51, -52, -53, -54, -55, -56, followed by Z, followed by any four digit number, followed by a suffix letter, followed by C or CC, followed by A, P or S. Model No.
may be preceded by V or VO.
Class I, Groups C and D; Class I, Div. 2, Groups A, B, C and D; Class II, Groups E, F and G.Model Nos. OE21-26 incl., OEH22 followed by Z, followed by additional suffix letters or letters with a
number, followed by a single letter, followed by BC, BCC, C, CC E or EC, followed by F, H, M or P. Solenoids with suffix P or F may be marked "Rain tight".
Models OE51, 52, 53, 54, 55, or 56, may be preceded by V or V0, followed by Z, followed by any four digit number, followed by any single letter, followed by C, CC, E, or EC, followed by H, M, P, or
F.
Models OEL51, 52, or 53, may be preceded by V or V0, followed by Z, followed by any four digit number, followed by any single letter, followed by S, C, CC, H, M, P, F, E, or EC. Solenoids with suffix
P may be marked "Rain tight" or Type 4X.
Models OELL51, 52, or 53, may be preceded by V or V0, followed by Z, followed by any four digit number, followed by any single letter, followed by S, C, CC, H, M, P, F, E, or EC. Solenoids with
suffix P may be marked "Rain tight" or Type 4X.
Model Nos. OE21-26 incl., OEH22 followed by additional suffix letters or letters with a number, followed by D, U, X, Z, followed by B, C, CC E or EC, followed by A, F, H, M, P or S, followed by
additional numbers. Solenoids with suffix P or F may be marked "Rain tight".
Models OE51, 52, 53, 54, 55, or 56, may be preceded by V or V0, followed by a single suffix, followed by a single suffix, followed by D, followed by D, U, Z, X, or W, followed by B, C, CC, E, or EC,
followed by M, P, A, S, D, H, or F, followed by 6, 9, 12, 24, 28, 48, 60, 72, 76, 100, 110, 115, 120, 125, 127, 139, 141, 143, 200, 208, 215, 220, 230, 240, 245, 253, 380, 415, 440, 460, or 480, followed by
50 or 60.
Models OEL51, 52, or 53, may be preceded by V or V0, followed by a single suffix, followed by a single suffix, followed by D, followed by D, U, Z, X, or V, followed by B, C, CC, E, or EC, followed by
M, P, A, S, H, or F, followed by 5, 6, 12, 24, 48, 110, 120, 230, or 240, followed by 50 or 60. Solenoids with suffix P may be marked "Rain tight" or Type 4X.
https://iq.ulprospector.com/en/profile?e=159158 1/2
1/26/2021 VAPT.E37780 - Solenoids for Use in Hazardous Locations | UL Product iQ
Models OELL52, or 53, may be preceded by V or V0, followed by a single suffix, followed by a single suffix, followed by D, followed by D, U, Z, X, or V, followed by B, C, CC, E, or EC, followed by M,
P, H, or F. Solenoids with suffix P may be marked "Rain tight" or Type 4X.
Models OEL21, OEL22, OEL23, OEL24, OEL25 or OEL26, followed by any single letter A through Z, followed by any single letter A through Z, followed by D, followed by D, U, Z, or X, may be
followed by B, followed by C, CC, E, or EC, followed by P or F, followed by 12 or 24. May be prefixed by V or VO.
Models OEL21, OEL22, OEL23, OEL24, OEL25 or OEL26, followed by Z, followed by any four numbers, followed by any single letter A through Z, may be followed by B, followed by C, CC, E, or EC,
followed by P or F, may be followed by additional letters A through Z. May be prefixed by V or VO.
Class I, Division 2, Groups A, B, C and D; Class II, Division 2, Groups F and G Hazardous Locations.Models ON71 to ON76, inclusive; followed by J, K, N, O, P, R, T; followed by J, K, N, O, P, R;
followed by letter D; followed by D or Z; followed by B, BC, C or CC; followed by, A, F, P or S.
Models ON71 to 76, inclusive; followed by Z0000 to Z9999, inclusive; followed by Letter A, C, D, E, F, G, H, J, K, L, N, O, P, R, S, T, U, V, W, X, Y or Z; followed by B, BC, C or CC; with or without A, F, P
or S.
Last Updated on 2020-04-08
The appearance of a company's name or product in this database does not in itself assure that products so identified have been manufactured under UL's Follow-Up Service. Only those products
bearing the UL Mark should be considered to be Certified and covered under UL's Follow-Up Service. Always look for the Mark on the product.
UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions: 1. The Guide Information, Assemblies, Constructions, Designs,
Systems, and/or Certifications (files) must be presented in their entirety and in a non-misleading manner, without any manipulation of the data (or drawings). 2. The statement "Reprinted from the
Online Certifications Directory with permission from UL" must appear adjacent to the extracted material. In addition, the reprinted material must include a copyright notice in the following format:
"© 2021 UL LLC"
https://iq.ulprospector.com/en/profile?e=159158 2/2
IV. BROCHURE
Introduction
ASME Class
Code
Class (LB)
Item
1
10
11
12
13
14
15
16
17
18
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Note: Side entry includes two piece body and three piece body.
The shape and size of following pictures are for reference Note: Side entry includes two piece body and three piece body. The shape and size of following pictures
only, and actual product shall prevail. are for reference only, and actual product shall prevail.
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
①- Please contact factory for materials supplied.

Item Item
1 19 Item
2 20
3 21
1
4 22
5 23 2
6 24 3
7 25
4
8 26
5
9 27
10 28 6
11 29
7
12 30
8
13 31
14 32 9
15 33 10
16 34
11
17 35
18 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Class 2500
17 15 14 12 12 11
43 38 34 31 31 28
86 76 66 61 61 56
227 211 187 167 167 148
423 384 330 294 294 181
1139 965 860 832 749 434
2416 2093 1759 1710 1564 995
5241 5183 4400 4212 3918 3107
10471 9991 8713 8245 6921 5240
17709 17154 14573 14123 11376 8451
26241 25460 22389 20864 16835 12295
32857 31176 28863 24483 20967
44474 42409 38998 33741 27901
57002 55420 50703 44491 35761
73076 70180 63936 55915 45445
88907 85757 78750
113639 109796 99314
= outlet pressure (psia)

Lightweight, Efficient and
Reliable - All in a Compact,
Modular Package
G-Series Pneumatic and Hydraulic Actuators

Next Generation Actuation Technologies Solutions
Design and Construction
Emerson, a leading pioneer in the valve automation and control industry for more than
55-years, has developed numerous innovations that have become today’s industry
Bettis™ G-Series standards. With continued focus on ingenuity, reliability, quality and product safety,
with Wireless Transmitter our entire product offering is considered to be the global standard for automating
valves in the oil & gas, power generation, pulp and paper, petrochemical, chemical,
wastewater, and numerous other process industries. Performance has been the main
differentiator. Emerson is recognized for effectiveness and reliability in some of the
world’s most difficult operating environments.
Emerson sets the G-Series pneumatic and hydraulic actuators provide the latest in valve actuation
standards for design. A highly unique and reliable means for operating ball, butterfly or plug valves
along with louvers, dampers and other 90 degree rotating mechanisms, the G-Series
innovation and carries an industry leading five-year warranty on materials and workmanship.
quality in pneumatic
and hydraulic valve G-Series Application And Features
automation • PED 97/23/EC compliant to meet the stringent requirements of pressure

mounting vessels
Lightweight, efficient • Meets both IP66 and IP67M specifications for submergence and high pressure
water deluge test. Offers superior water ingress and corrosion protection
and reliable - all in • Suitability for use within the demanding applications of a SIL environment
a compact, modular • Available in both spring-return or double-acting configurations and can operate
with either a symmetric or canted yoke
package
• Offers multiple configurations, with a modular design that enables safe field
maintenance and reduced inventory costs
Available with either • More compact than other actuators of equal torque output – 1/3 lighter and 1/2
symmetric or canted smaller
yokes to suit your • Interchangeable power and spring modules for quick reversal of the fail-safe
mode
operating requirements • Close Loop Instrument System for actuators should always be used for the
following applications: high humidity, salt air, corrosive dust, inks and dyes, wash
downs. The closed loop system routes the operating media being exhausted
from the power side of the cylinder to the vented side of the cylinder. Maximum
pressure on the vented side of the power cylinder is to be 5 to 8 psig
• 5-Year Warranty
Bettis G-Series
with Topworx™ Positioner
Operating Ranges Reduces Wear
G-Series has guaranteed torque outputs for spring-return The Powr-Swivl™ piston rod and guide block connection
models in excess of 3,000,000 lb-in (339,000 Nm) and compensates for side load deflection and reduces wear.
double-acting 12,581 – 6,000,000 lb-in (1420 – 678,000 Nm). Seal-lubricating bearings protect sliding and rotating
Operating pressures are: components.
Pneumatic – 40-220 psig (3-14 Bar)
Hydraulic – to 5,000 psig (345 Bar)
Standard High Temp. Low Temp.

Trim Trim (-10) Trim (-11)
None-PED and PED None-PED PED
-20°F to +200°F 0°F to +350°F -40°F to +150°F Consult
-29°C to +93°C -18°C to +177°C -40°C to +66°C Factory
Powr-Swivl™
Promotes Safety Resists Corrosion

The patented Tension-Lok™ device positively locks the spring Tie-bars on pneumatic power modules are corrosion resistant,
module to allow its safe removal and installation, eliminating and internal and external surfaces are coated to protect in harsh
accidental release of the spring force. environments.
Seals Positively
With dual drive module vent checks, breather seals, total O-ring
sealing and no gaskets, the G-Series prevents water ingress and
seals out the environment.
Bidirectional Travel Stops

Integral bidirectional travel stops,
adjustable from 80° to 100° of total valve
travel, assist G-Series in prolonging valve
Tension-Lok™ seat integrity.
Other G-Series Actuation Solutions
GS-Series Jackscrew is available for the G1, G2, and G3

Emerson actuators have long been a preferred brand Offered in a variety of mechanical and manual overrides,
for use in marine environments. GS-Series actuators are the G-Series with the M11 hydraulic override may also
well suited for splash zone, riser and other offshore fail- be used with either spring-return pneumatic or hydraulic
safe applications. They are available with diver or ROV models. The M3 jackscrew manual override for G1, G2,
intervention systems. and G3 models is available with or without handwheel.
Symmetric or Canted Yokes

G-Series actuators
available with
either symmetric
or canted yokes.
Traditional
NG-Series symmetric yokes
NG-Series actuators have been independently tested to provide efficient
include LOCA (Loss of Cooling Accident), meets IEEE 382 operation at both
standards, seismic, and various aging processes required to the break and end
meet current nuclear qualification criteria. positions. Canted
(or inclined) yokes
have a torque
advantage in
applications where
higher break
torque is needed to unseat the valve, with less critical needs
at the run or full open positions.
Symmetric Yoke Canted Yoke
Other Emerson controls and accessories:

GH-Series Fisher™
The GH-Series actuators provide specialized higher maximum • Digital Valve Controllers
operating pressures (MOP) where required. Available in either
• Positioners
canted (model GHC) or symmetric (GH) yoke configurations
for spring-return, fail-safe projects. An optional SR0 spring is • Regulators
available for higher spring start and end torques.
TopWorx™
Safety Integrity Level (SIL) • Switch Boxes
G-Series actuators are well suited for demanding SIL
applications. These actuators have a Failure Modes and • Wireless Position Monitoring
Effects Diagnostics Analysis (FMEDA) capability with
reporting performed through Exida.com™ for SIL suitability. ASCO Numatics™
When a Fisher, TÜV-certified FIELDVUE® controller is added • Solenoid Valves
to the G-Series, it is capable of partial stroke testing and
providing continuous monitoring of supply pressure,
valve position and pressure values to verify proper
working condition. The G-Series then becomes an integral For more detailed technical information go to our online
component in controlling the final control element in SIL 1, 2 documentation at www.bettis.com/technical-data
or 3 applications.
Options Modular Versatility
Overrides •Enables Online Field Maintenance

•Lowers Inventory
Emerson offers a variety of
Blind End
mechanical and manual overrides for Cap
G-Series models. The M11 hydraulic
override can be used with either
Pneumatic M11 Manual Hydraulic
spring-return pneumatic or hydraulic Power Pump Assembly
Spring
Module
models. The M3 jackscrew manual Module
override for G1, G2 and G3 models is
available with or without handwheel.
The G-Ride (shown) is an economical Spring
Module
external non-declutchable Tandem
with Integral
Pneumatic
mechanical override for G4 and G5 Power
Hydraulic
Override
spring-return models available with Module
Cylinder
standard hex nut or handwheel.
Pneumatic
Power Module Pneumatic
with Extended Power Module
Travel Stop (Dual Cylinder
(shown)or Configuration)
Jackscrew
Drive
Module
M11 Override
Extended Travel Stop
for Hydraulic DA
(shown) or Jackscrew
Actuators
The G-Series adds an extra measure

of versatility with its field serviceable
modular configuration. It can be altered
Automated Valve Packages from a single acting to a double-acting Spring Module with Extended
Travel Stop Module
and add a hydraulic manual override after
Emerson offers complete valve installation. Both the module and spring
G-Ride™
operating systems for final modules are removable without the Manual Gear
valve control. At our World Area need for special tools or disassembly of Override for
G4 & G5
Configuration Centers (WACC), any modules. Modules can be purchased
we combine the G-Series actuator, separately at an Emerson World
controls and a valve in a single Configuration Center and can be serviced Hydraulic Power Module or
M11 Override Cylinder for
system. We can integrate a at your own maintenance facility. DA Pneumatic Actuators
complete controls offering including
world-class PlantWeb® digital Note: The above graphic is for illustration purposes only.
Please consult factory for certified dimensional drawings.
plant architecture. We also supply
BettisSystems™, pre-engineered and Standards and Certifications
documented controls packages,
available at our WACC reducing lead
G-Series actuators are manufactured to meet the following worldwide
times, simplifying purchasing and
quality and safety standards:
installation.
PED/97/23/EC –
Pressure
Equipment
ISO-9001 ABS Directive
Shell DEP 2016 Compliance
World’s very first complete actuator product line that successfully passed
stringent “Shell Endurance Test” per Shell DEP 2016 and EN15714-3
Standard. The test was supervised and monitored by Shell and Lloyd agency
throughout and the final result was certified by Shell Projects & Technology
PACO Principal Technical Expert.
Download Shell DEP Acceptance of Endurance Testing on Bettis G-Series
webpage.
World Area Configuration Centers (WACC) offer sales support, service,
inventory and commissioning to our global customers. Choose the WACC This product is only intended for use in large-scale fixed installations
or sales office nearest you: excluded from the scope of Directive 2011/65/EU on the restriction
of the use of certain hazardous substances in electrical and
NORTH & SOUTH AMERICA MIDDLE EAST & AFRICA electronic equipment (RoHS 2).
19200 Northwest Freeway P. O. Box 17033
Houston TX 77065 Jebel Ali Free Zone
USA Dubai
T +1 281 477 4100 T +971 4 811 8100
Av. Hollingsworth P. O. Box 10305
325 Iporanga Sorocaba Jubail 31961
SP 18087-105 Saudi Arabia
Brazil T +966 3 340 8650
T +55 15 3413 8888
24 Angus Crescent
ASIA PACIFIC Longmeadow Business Estate East
P.O. Box 6908 Greenstone
No. 9 Gul Road
1616 Modderfontein Extension 5
#01-02 Singapore 629361
South Africa
T +65 6777 8211
T +27 11 451 3700
No. 1 Lai Yuan Road
EUROPE
Wuqing Development Area
Tianjin 301700 Holland Fasor 6
P. R. China Székesfehérvár 8000
T +86 22 8212 3300 Hungary
T +36 22 53 09 50
Strada Biffi 165
29017 Fiorenzuola d’Arda (PC)
Italy
T +39 0523 944 411
©2019 Emerson. All rights reserved.

For complete list of sales and manufacturing sites, please visit The Emerson logo is a trademark and service mark of Emerson Electric Co.
www.emerson.com/actuationtechnologieslocations or contact us at Bettis™ is a mark of the Emerson family of companies. All other marks are property of
[email protected] their respective owners.
www.emerson.com/bettis
BRO-02-01-0016-EN-US Rev H 07-19
Type 350/360/370SS Series
Stainless Steel Regulators and Filters
Type 350SS Stainless Steel Filter Regulator | Type 360SS Stainless Steel Regulator
Type 370SS Stainless Steel Filter
The Type 350/360/370SS series of stainless steel

regulators, filter regulators and filters are designed
to stand up to the harshest environments while
providing highly accurate pressure regulation.
Proven 316L stainless steel housing and 316 stain-
less steel filter assemblies along with fluorocarbon
elastomers make the 350/360/370SS compatible
with sour gas and adaptable to oﬀ shore environ-
ments. These quality instruments are economical
to buy as well as operate, and provide extremely
stable and repeatable control of gas pressure.
Oversized valving helps the units achieve high
flow rates with minimal pressure drop.
Features
• All 316 Stainless Steel Construction
Ideal for sour gas and/or corrosive
environments
• NACE Compliant
Meets NACE #MR-0175 material requirement
for sulfide stress cracking
• 1/4" NPT and 1/2" NPT
Ported Versions
• Autodrain Option
• Low Temperature Option
• High Flow Capacity
• Tapped Exhaust Port
Permits remote venting of
hazardous gases
• Minimal Air Consumption
Low cost of ownership
Specifications
Type 350SS Type 360SS Type 370SS

Output Ranges: 0-30 psig (0-2.0 BAR), 0-60 psig (0-4.0 BAR), 0-100psig (0-7.0 BAR), 0-150 psig (0-10.0 BAR) Not applicable
Exhaust Capacity: 1.0 SCFM (30 Nl/min) at downstream pressure of 10 psig (0.7 BAR) above set point Not applicable
Maximum 290 psig (20.0 BAR) 290 psig (20.0 BAR) 150 psig (10.0 BAR)
Supply Pressure: Autodrain: 150 psig (10.0 BAR) Autodrain: 150 psig (10.0 BAR)
Maximum Flow 1/4" = 1.2
Coefficients (Cv): 1/2" = 3.3
Air Consumption: 4 SCFH (2 Nl/min) maximum Not applicable
Operating -20° to +185° F (-29° C to +85° C)
Autodrain Option: (Type 350 and Type 370 only) 32° to 185°F (0° to 85°C)
Temperatures: Low Temperature Option: -61° to +194° F (-52° to + 90° C)
Filter: 25 micron Not applicable 25 micron
optional 5 micron filter optional 5 micron filter
Porting: Inlet/Outlet: 1/4" NPT or 1/2" NPT 1/4" NPT or 1/2" NPT 1/4" NPT or 1/2" NPT
Gauge (2): 1/4" NPT 1/4" NPT 1/4" NPT
Exhaust: 1/8" NPT 1/8" NPT
Materials: 316L stainless steel: housings
316 stainless steel: filter, range spring, trim
Inconel: valve spring
Fluorocarbon: diaphragm, seals
Silicone: diaphragm, seals (low temperature option)
Weight: 1/4" NPT: 2.2 lbs. (1.0 kg) 1/4" NPT: 2.0 lbs. (0.9 kg) 1/4" NPT: 2.1 lbs. (0.95 kg)
1/2" NPT: 2.8 lbs. (1.3 kg) 1/2" NPT: 2.6 lbs. (1.2 kg) 1/2" NPT: 2.5 lbs. (1.14 kg)
Additional for Autodrain: 0.6 lbs. (0.3 kg)
Operating Media: Air, inert gas, sweet (natural) and sour gases
Regulated Pressure vs. Flow (Type 350/360SS, typical) Pressure Drop vs. Flow (Type 370SS, typical)
(0-100 psig range, 105 psig supply)
Regulated Pressure vs Flow: 1/4” Type 350 Regulated Pressure vs Flow: 1/2” Type 350 1/4" NPT Port 1/2" NPT Port
90 90 10 10
(6.2) (6.2)
SUPPLY
80 Supply Pressure: 100psig 80 Supply Pressure: 100psig 9 120 PSI 9 SUPPLY
(5.5) (5.5)
Cv: 1.2 Cv: 3.3 120 PSI
Regulated Pressure, psi (bar)
Regulated Pressure, psi (bar)
70 70 8 8
(4.8) (4.8) SUPPLY
60 60 7 90 PSI 7 SUPPLY
90 PSI
Pressure drop (psi)
Pressure drop (psi)
(4.1) (4.1)
50 50 6 SUPPLY 6
(3.5) (3.5) 60 PSI SUPPLY
5 5 60 PSI
40 40
(2.8) (2.8) 4 4
30 30
(2) (2) 3 SUPPLY 3 SUPPLY
20 20 30 PSI 30 PSI
(1.4) (1.4) 2 2
10 10 1 1
(0.07) (0.07)
0 0 0 0
0 10 20 30 40 50 60 0 20 40 60 80 100 120 140 160 180 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
(283) (566) (849) (1132) (1415) (1698) (566) (1132) (1698) (2264) (2830) (3396) (3964) (4530) (5097) (0) (283) (566) (849) (1132) (1415) (1698) (1981) (2264) (2547) (2830) (0) (283) (566) (849) (1132) (1415) (1698) (1981) (2264) (2547) (2830)
FLOW, scfm (nl/min) FLOW, scfm (nl/min) Flow, scfm (nl/min) Flow, scfm (nl/min)
Clean, stable performance for tough, dirty process control
Type 350SS
• Low air consumption

for greater operating
economy
• Tapped exhaust for
c o n t r ol A ir In c .
remote venting
• 1/4" NPT and 1/2" NPT
TYPE 350S
S
316 STAINLESS STEEL
porting
• Competetively priced
• Low droop at high
flow levels
• 316 stainless steel
housing and
filter assemblies
• High flow
ow manual drain
for easy maintenance
• Compact size
• Large flow
ow paths to
minimize pressure
Type 360SS drop
• Meets all NACE
requirements
• Automatic drain
option (shown)
• Excellent stability and
repeatability, even in
c o n t r ol A ir In c .
harsh environments
TYPE 360SS
316 STAINLESS STEEL
Mounting Bracket Panel Nut
Pressure Gauge
370SS
Co ntro lAir Inc .
Knob
Drawing downloads available

at www.controlair.com
Ordering
Type 350SS Filter Regulator Options Add proper letter at end of model number.
Model Part Number Port Size Output Range A - Automatic Drain (Type 350 and Type 370 only)
(NPT) (psi) (BAR) Float operated drain with 1/8” NPT connection. Maximum 150 psig
supply pressure. Minimum 32°F (0°C) temperature.
350SS 350-BA 1/4" 0 - 30.0 0 - 2.0 F - 5 Micron Filter
350SS 350-BB 1/4" 0 - 60.0 0 - 4.0 Standard 25 micron filter is replaced with 5 micron filter for more com-
plete air filtration
350SS 350-BC 1/4" 0 -100.0 0 - 7.0
K - Knob with stainless steel stem
350SS 350-BD 1/4" 0 -150.0 0 -10.0 L - Low Temperature Operation
350SS 350-DA 1/2" 0 - 30.0 0 - 2.0 For “Arctic” applications. Good for temperatures range of -61°F to
+194°F (-52°C to +90°C). Not suitable for sour natural gas
350SS 350-DB 1/2" 0 - 60.0 0 - 4.0
N - Nonrelieving
350SS 350-DC 1/2" 0 -100.0 0 - 7.0 For constant flow or downstream pressure relief applications
350SS 350-DD 1/2" 0 -150.0 0 -10.0 R - EAC TR-CU

X - ATEX 2014/34/EU
Note: Options A and L cannot be combined.
Type 360SS Regulator
Model Part Number Port Size Output Range Accessories.
(NPT) (psi) (BAR)
Panel Nut -P/N 446-734-052
360SS 360-BA 1/4" 0 - 30.0 0 - 2.0 Mounting Bracket Kit -P/N 448-542-011
360SS 360-BB 1/4" 0 - 60.0 0 - 4.0 Includes mounting bracket and panel nut
Pressure Gauge -2” face: dual scale: 1/4” NPT centerback connection:
360SS 360-BC 1/4" 0 -100.0 0 - 7.0
stainless steel case and internals
360SS 360-BD 1/4" 0 -150.0 0 -10.0 0-30 psig (0-2.0 BAR) P/N 445-725-019
360SS 360-DA 1/2" 0 - 30.0 0 - 2.0 0-60 psig (0-4.0 BAR) P/N 445-725-020
360SS 360-DB 1/2" 0 - 60.0 0 - 4.0 0-160 psig (0-11.0 BAR) P/N 445-725-021
Bug Screen - P/N 445-761-005
360SS 360-DC 1/2" 0 - 100.0 0 - 7.0
1/8" NPT stainless steel exhaust screen fitting
360SS 360-DD 1/2" 0 - 150.0 0 - 10.0
Applications
Type 370SS Filter
The Type 350/360/370SS is used extensively by OEMs and
Model Part Number Port Size end users to supply clean air to pneumatic controllers,
(NPT) transmitters, transducers, valve positioners, air cylinders,
370SS 370-BX 1/4" and a wide range of pneumatic control systems.
370SS 370-DX 1/2" Applications include:
Petrochemical processing, both on and offshore

Warranty ControlAir LLC products are warranted to be free from defects in
materials and workmanship for a period of eighteen months from the date of
sale, provided said products are used according to ControlAir LLC recommended Food, pulp and paper, and pharmaceutical processing
usages. ControlAir LLC’s liability is limited to the repair, purchase price refund, or
replacement in kind, at ControlAir LLC’s sole option, of any products proved
Pollution control
defective. ControlAir LLC reserves the right to discontinue manufacture of any
products or change products materials, designs or specifications without notice.
Note: ControlAir does not assume responsibility for the selection, use, or Waste water treatment
maintenance of any product. Responsibility for the proper selection, use, and
maintenance of any ControlAir product remains solely with the purchaser and
end user. Drawing downloads available at www.controlair.com
Drawing downloads available at www.controlair.com
8 Columbia Drive / Amherst, NH 03031 USA / www.controlair.com / [email protected] / 603-886-9400 / FAX 603-889-1844
An ISO 9001:2015 Registered Company
P/N 441-625-023 8/17/20
Type
350/360/370SS Stainless Steel Regulators
Series Installation, Operation and
Maintenance Instructions
Type 350SS 1/2" NPT Type 360SS 1/4" NPT

Adjustment Screw Adjustment Screw
Assembly Assembly
Bonnet Bonnet
Spring Guide Spring Guide
Range Spring Range Spring
*Diaphragm * Diaphragm
Assembly Assembly
* Pintle Assembly * Pintle Assembly
Body Assembly
* Housing Seal O-Ring Body Assembly * Housing Seal O-Ring
Collar
* Filter O-Ring (2)
Pintle Spring
Drip Well Housing Filter, 25 Micron, SS Base

Assembly
Filter Retainer Pintle Spring
Filter Retaining Screw
Type 370SS 1/2" NPT

Cover
Contents
Sealing Diaphragm Section Description Page
1.0 Specifications 2
Body Assembly
2.0 Installation 2
3.0 Operation 3
Collar
4.0 Maintenance & Repair 3
* Housing Seal O-
Ring 5.0 Warranty 4
Filter, 25 Micron, SS * Filter Seal
O-Ring (2)
Drip Well Housing

Assembly
Filter Retainer 8 Columbia Drive

Filter Retaining Screw Amherst, NH 03031 USA
603-886-9400
Fax: 603-889-1844
www.controlair.com
[email protected]
*Included with repair kit
441-622-075 350/60/70 SS Page 1

DANGER, WARNING, CAUTION and NOTE statements
DANGER Refers to conditions or hazards which could result in serious personal injury or death.
WARNING Refers to conditions or hazards which could result in personal injury.
CAUTION Refers to conditions or hazards which could result in equipment or property damage.
NOTE Alerts you to facts or special instructions.
ALL DANGER, WARNING, AND CAUTION NOTICES MUST BE COMPLIED WITH IN FULL
Personal injury, property damage, equipment damage, or leakage due to escaping gas or bursting of
DANGER pressure containing parts may result if this regulator is over pressurized or installed where service
conditions could exceed the limits given in the specifications. To avoid such injury or damage, provide
pressure-relieving or limiting devices (as required by the appropriate code, regulation or standard) to
prevent service conditions from exceeding those limits.
1. SPECIFICATIONS
TYPE 350SS TYPE 360SS TYPE 370SS
Output Ranges: 0-30 psig (0-2.0 BAR), 0-60 psig (0-4.0 BAR), 0-100 psig (0-7.0 BAR), Not applicable
0-150 psig (0-10.0 BAR)
Exhaust Capacity: 1.0 SCFM (1.7 m3/hr) at downstream pressure of Not applicable
10 psig (0.7 BAR) above set point
Maximum Supply
Pressure: 290 psig (20.0 BAR) 150 psig (10.0 BAR)
Maximum Flow 1/4” = 1.2
Coefficients (Cv): 1/2” = 3.3
Air Consumption: 4 SCFH (0.1 m3/hr) Not applicable

Operating -20° to +185° F (-29° to +85° C)
Temperatures: Autodrain Option: (Type-350 and Type-370 only) 320 to 1850F (00 to 850C)
Low Temperature Option: -58° to +194° F (-50° to +90° C)
Filter: 25 micron Not applicable 25 micron
optional 5 micron filter optional 5 micron filter
Porting: Inlet/Outlet: 1/4" NPT or 1/2" NPT 1/4" NPT 1/4" NPT or 1/2" NPT
Gauge (2): 1/4" NPT 1/4" NPT 1/4" NPT
Exhaust: 1/8" NPT 1/8" NPT
Materials: 316 stainless steel: body, bonnet, filter, range spring, pintle spring
Fluorocarbon: diaphragm, seals
Silicone: diaphragm, seals (low temperature option)
Weight: 1/4" NPT: 2.2 lbs. (1.0 kg) 1/4" NPT: 2.0 lbs. (0.9 kg) 1/4" NPT: 2.1 lbs (0.95 kg)
1/2" NPT: 2.8 lbs. (1.3 kg) Not applicable 1/2" NPT: 2.5 lbs (1.14 kg)
Operating Media: Air, inert gas, sweet (natural) and sour gases
2. INSTALLATION
2.1 Install the regulator/filter as close as possible to the instrument or tool it is to service.
2.2 Clean all pipelines to remove dirt and scale prior to installation.
NOTE Failures attributable to air supply contamination are not covered by the warranty.
WARNING This instrument vents to atmosphere. The use of gas other than air may create a
hazardous environment.
2.3 Install the regulator/filter so that the direction of flow is from the "IN" to "OUT" connection as
marked on the body of the regulator/filter.
441-622-075 350/60/70 SS Page 2

2.4 For best drainage, orient the drain valve so that it is at the lowest point on the drip well
housing. Positioning of the drain valve may be improved by rotating the drip well with respect
to the body.
2.5 The exhaust port should be kept free and unplugged. Position the regulator so that the vent is
at the lowest point possible, or provide additional protection to prevent contaminants from
entering the regulator. Rotating the bonnet relative to the body may change the vent hole
orientation.
WARNING The Type 350/360SS has a low capacity internal relief that provides limited down-stream protection
against over pressurization .
WARNING Non-relieving version does not provide internal relief of excess pressure. To avoid exceeding outlet
pressure limits, a pressure-limiting device should be used.
2.6 Exhaust may be remotely vented by installing tubing to the 1/8" NPT port.
2.7 Apply pipe compound or sealing tape to the male pipe threads prior to installing regulator/filter.
Use caution to prevent the sealant from getting inside the regulator/filter.
3. OPERATION
3.1 Prior to turning on supply air, back off adjusting screw until there is no compression of the
range spring.
3.2 After applying the air supply, output pressure will be increased by rotating the adjustment
screw clockwise. Pressure can be decreased by turning counter clockwise.
3.3 Tighten locknut to maintain desired pressure setting.
4. MAINTENANCE & REPAIR
4.1 To remove condensate from the Type 350 and Type 370, slowly open drain valve by turning
clockwise and bleed accumulated liquid.
To avoid personal injury, property damage, or equipment damage caused by sudden release of pres-
DANGER sure or explosion of accumulated gas, do not attempt any maintenance or disassembly without first
isolating the regulator from system pressure and relieving all internal pressure from the regulator.
4.2 To clean filter element (Type 350 and Type 370)

4.2.1 Shut off supply pressure and relieve all internal pressure.
4.2.2 Drain condensate from drip well.
4.2.3 Remove four corner bolts from bottom of unit and remove drip well housing.
4.2.4 Remove filter retaining screw.
4.2.5 Remove filter retainer, filter o-ring seals and filter.
4.2.6 Clean parts and reassemble in reverse order.
4.3 To clean/replace pintle assembly

4.3.1 Follow steps 4.2.1 through 4.2.4.
4.3.2 Unscrew collar and remove.
4.3.3 Remove pintle spring and pintle. 1/4" NPT version may require needle nose pliers or push pintle stem
from above by removing bonnet and diaphragm assembly.
4.3.4 Clean/replace parts and reassemble in reverse order.
441-622-075 350/60/70 SS Page 3

4.4 To clean/replace diaphragm assembly
4.4.1 Back out the adjusting screw until the spring is no longer compressed.
4.4.2 Remove the four bonnet screws and separate the bonnet from the body of the regulator. Remove the
spring guide and spring.
4.4.3 Remove the diaphragm assembly, clean or replace it as necessary and reassemble in reverse order.
After placing the diaphragm assembly on the body, push down the assembly to make sure that the
pintle is seated properly and strokes smoothly.
4.5 Repair kits/replacement parts
4.5.1 Repair kits include all parts marked with an asterisk (*). See diagrams on page 1.
4.5.2 When ordering repair kits or replacement filters, order as:
REPAIR KITS
Type 350 Includes: Pintle Assembly, Housing Seal O-Ring, Diaphragm Assembly, Filter Seal O-Ring (2)
Model Porting Description Part Number
Type 350 1/4” NPT Relieving 449-871-068
Type 350 1/4” NPT Non-relieving 449-871-069
Type 360 Includes: Pintle Assembly, Housing Seal O-Ring, Diaphragm Assembly
Type 360 1/2" NPT Relieving 449-871-094
Type 360 1/2" NPT Non-relieving 449-871-095
REPLACEMENT FILTERS
Type 350/370 1/4” NPT 25 micron filter 446-777-011
4.5.3 Other replacement parts are available. Please consult the factory for part numbers and availability.
5.WARRANTY & DISCLAIMER

ControlAir LLC products are warranted to be free from defects in materials and workmanship for a period of
eighteen months from the date of sale, provided said products are used according to ControlAir LLC
recommended usages. ControlAir LLC’s liability is limited to the repair, purchase price refund, or replacement in
kind, at ControlAir LLC’s sole option, of any products proved defective. ControlAir LLC reserves the right to
discontinue manufacture of any products or change products materials, designs or specifications without notice.
WARNING These products are intended for use in industrial compressed-air systems only.
Do not use these products where pressures and temperatures can exceed those
listed under Specifications.
Before using these products with fluids other than air, for non-industrial application, life-support systems, or other
applications not within published specifications, consult ControlAir LLC
8 Columbia Drive
Amherst, NH 03031 USA
603-886-9400
Fax: 603-889-1844
www.controlair.com
[email protected]
441-622-075 REV 05/25/2022 350/60/70 SS Page 4

  
X X X
X X X
º
X X X
º
º
º
º


Discrete Valve Controllers
for On/Off Valves.
A complete line of TopWorx™ discrete valve controllers

and monitors for every protocol, application, environment,
and hazardous area.
A Global Leader in Valve Control and
Proximity Sensing.
Emerson is a global leader in valve control and proximity sensing for the process industries.
Our TopWorx solutions enable plants, platforms, and pipelines to manage and control operations
more intelligently and efficiently under the most demanding and extreme conditions.
Global Technology Leadership Global Hazardous Area Global Service & Support
The technology advancements Certifications With company locations in the United
in TopWorx products are at the In addition to high temperature States, United Kingdom, South Africa,
forefront of innovation in the process +204 °C (+399 °F), cold temperature Bahrain, and Singapore, Emerson is
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products use wireless technologies (23,000 ft) applications, TopWorx outstanding support. In addition,
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FOUNDATION Fieldbus, DeviceNet, Flameproof/Explosion Proof, Non- throughout the world are available
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reduce installation costs and enable areas with IECEx, ATEX, GOST, when needed.
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ii
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1
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TopWorx™™D-SERIES
D-Series Discrete Valve Controllers
World-Class Discrete Valve
Built for demanding Controllers with the Highest Technology Available
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TopWorx D-Series discrete valve controllers are certified for use in every world area.
They carry IECEx, ATEX, and UL certifications in a single model, making it easier for
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D-Series discrete valve controllers can survive in virtually any plant condition. Their
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The D-Series is Built Tough.

Designed to provide reliable service for a lifetime, the D-Series has been built to last in the most demanding
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Wet Dirty Explosive

Tested against intense water Tested in dust chamber Tested by UL and Sira for use in
pressure blasts and complete and proven dust tight explosive environments with
submersion underwater for no seal-off fittings required
96 hours at a depth of Abusive (DXP, DXS)
30 meters. Tested against the “300 pound
man step test” and proven Chemical Compatibility
Hot impact and step resistant Tested against hundreds
Tested for long-term of chemicals with varying
functionality in temperatures Corrosive exposure times, temperatures,
up to 176ºF/80ºC Tested against hundreds and concentrations. Please
of corrosive and caustic contact factory for
Cold elements and proven to resist compatibility information.
Tested for endurance in deterioration or chipping
temperatures down
to -76ºF/-60ºC
2
Rugged Enclosures for Every Environment Visual Display
• Aluminum, Composite, Stainless • Impact resistant polycarbonate
• Up to four conduit entries (English or Metric) • Intuitive colors (Green/Red)
• O -ring seals everywhere • Adjustable/customizable
• Buna, Silicone o-ring options • Pre-adjusted to 90° for easy
installation
Bus Networking / Sensor options • Less than 1 3/4" tall
• FOUNDATION Fieldbus, Profibus,
DeviceNet, AS-Interface, HART Stainless Steel Shaft & Fasteners
• GO™ Switch, Proximity, P+F™, • ¼" DD or NAMUR Shaft
Mechanical, 4-20mA Transmitter • Captive cover bolts
• Captive dome screws
Pilot Valves
• Aluminum or 316 Stainless Steel
• Low Power Solenoid or Ultra-Low Environmental Extremes
Power Piezo • Rated for environments from
• Single or Dual Coil –76°F/–60°C to 347°F/175°C
• 1.06 Cv and 3.7 Cv • NEMA Type 4, 4X, IP66/67
• Integrally mounted for extra protection
• Built-in filter protects the pilots against debris
• Fast, easy troubleshooting:
- Pneumatic tubing is color-coded for trouble
shooting while system is pressurized
- Troubleshoot valve without removing
the cover
Multiple D-Series Platforms for Every Environment
DXP Tropicalized Aluminum DXS 316 Stainless Steel

Flameproof/Explosion Proof/Intrinsically Safe Flameproof/Explosion Proof
Class I, Div 1 & 2 /Intrinsically Safe
Class II, Div 1 & 2 Class I, Div 1 & 2
Ex ia IIC T6/T4 Class II, Div 1 & 2
Ex d IIB+H2 or IIC T6/T5/T4/T3 Ex ia IIC T6/T4
Tamb -60°C up to +175°C Ex d IIB+H2 or IIC T6/T5/T4/T3
Ex tb IIIC Tamb -60°C to +175°C
Tamb -50°C up to +92°C Ex tb IIIC T135°C
II2GD,Type 4X, IP66/67 Tamb -50°C to + 92°C
II2GD, IP66/67, Type 4X
D-ESD Partial Stroke Testing for DXR Composite Resin

Emergency Shutdown Valves Non-Incendive/Intrinsically Safe
Suitable for use in SIL-3 applications Class I & II, Div 2
Stainless Steel or Aluminum, Ex ia IIC T6/T4
SIL- 3 Flameproof/Explosion Proof Ex e mb IIC T4
IEC 61508 /Non-Incendive Ex tb IIIC
Class I Div 1 & 2 -40°C to +92°C T4
Class II Div 1 & 2 II2GD, IP65, Type 4X
Ex d IIB+H2 T6
Ex tb IIIC T135°C
Tamb -50°C to + 60°C
II2GD, IP66/67, Type 4X
Note: Product certification markings will vary according to

protection method and internal components specified.
3
TopWorx™ T-Series Switchboxes
High-Value Switchboxes with a Variety of Options
TopWorx T-Series switchboxes deliver outstanding value by providing full functionality

in compact, direct-mount enclosures.
Available with a variety of position sensors, integral solenoid valves, and bus networks, the
T-Series is suitable for use in all hazardous areas and carry IECEx, ATEX, and UL certifications.
The TopWorx T-Series Delivers Outstanding Value.

Designed to provide maximum functionality in a compact form factor, the TopWorx T-Series has a number of unique
features that save space, time, and money.
Optimum Use of Space TwistSet™ Cams

The unique layout supplies ample Unique TwistSet cam design allows easy
working space inside the enclosure access and accurate stepless setting of
for wiring and setting of the switches sensor position with minimum hysteresis.
while taking up very little space
above the actuator. Color-coded strikers enable quick
identification of open/closed switches.
Includes locking feature to ensure no
target migration.
Low Profile Design Direct Mounting

The unique direct- Unique mounting design
mounting feature enables simple attachment
eliminates expensive to any ISO/NAMUR actuator
mounting brackets without the need for expen-
while reducing the sive mounting brackets
height of the switch-
box and the overall
footprint above
the actuator.
The T-Series direct mount feature helps

to reduce cost by omitting the need for
custom brackets.
4
Solid Enclosures for Every Environment Visual Display
• Aluminum, Composite, Stainless • Impact resistant polycarbonate
• Up to four conduit entries • Intuitive colors (Green/Red)
(English or Metric) • Pre-adjusted to 90° for easy
• O -ring seals everywhere installation
• Low profile/High visibility
• Customizable
Bus Networking / Sensor Options
• AS-Interface, Profibus Environmental Extremes
• GO Switch, Proximity, • Operating temperatures from
P+F, Mechanical -76°F/-60°C to +175°F/80°C
• Type 4, 4X, IP66/67
Pilot Valves
• Low Power Solenoid Stainless Steel Shaft and Fasteners
• Single Coil • NAMUR Shaft
• 1.0 Cv • Captive cover bolts and indicator
screws
• Integrally mounted for
extra protection
Multiple T-Series Platforms for Every Environment

TXS Direct-Mount Stainless Steel TXP Direct-Mount Aluminum
Flameproof/Intrinsically Safe/ Flameproof/Intrinsically Safe/
Explosion Proof /Non-Incendive Explosion Proof /Non-Incendive
Class I Div 1 & 2 Class I Div 1 & 2
Class II Div 1 & 2 Class II Div 1 & 2
Ex ia IIC T6/T4/T3 Ex ia IIC T6/T4/T3
Ex d IIB or IIC T6/T4 Ex d IIB or IIC T6/T4
Tamb -65°C to 100°C Tamb -65°C to 100°C
Ex tb IIIC T135C Ex tb IIIC T135C
Tamb -50°C to 100°C Tamb -50°C to 100°C
II2GD, IP66/67, Type 4X II2GD, IP66/67, Type 4X
Note: Product certification markings will vary according to protection

method and internal components specified.
5
TopWorx™ TV-Series Switchboxes
High-Value Switchboxes with a Variety of Options
Compact, rugged, and dependable solution for discrete valve control and valve position
monitoring where weight and real estate are at a premium. Light weight and robust
enclosures specially designed for non-incendive, intrinsically safe and general purpose
application. Each enclosure is suited for heavy wash down and corrosive environments
and IP66/68 tested.
66
Light, Rugged and Compact Enclosure Environmental Extremes
• Aluminum, Stainless or Aluminum base • Operating temperatures from
with clear polycarbonate options -58°F/-50°C to + 185°F/95°C
• (2) M20, M25, 1/2NPT, or 3/4NPT • NEMA Type 4, 4X
conduit options
• Direct ISO/NAMUR mount
• Silicone seals everywhere Visual Display
• Impact resistant polycarbonate
Up to (4) Four Sensors Inside • Pre-adjusted to 90° for easy
installation
• Factory Sealed GO Switches
• Intuitive colors
• Mechanical –SPDT or DPDT
• Customizable
• Inductive
• Proximity
• NAMUR Pilot Valves
• Low or high power solenoid
options
• Single of dual coil—single acting
or double acting actuators
Stainless Steel Shaft and Fasteners • Aluminum or Stainless Steel
• NAMUR Shaft spool valve options
• Captive cover bolts and indicator screws
Multiple Tv-Series Platforms for Every Environment
TVH Stainless Steel TVL Tropicalized Aluminum

Intrinsically Safe/Non-Incendive Intrinsically Safe/Non-Incendive
Class I & II, Div 2 Class I & II, Div 2
Ex ia IIC T6/T4/T3 Ex ia IIC T6/T4/T3
-65°C up to +100°C -65°C up to +100°C
Ex nA nC T4/T3 Ex nA nC T4/T3
Tamb -40°C up to +95°C -40°C up to +95°C
Ex tc IIIC Ex tc IIIC
-50°C up to +85°C -50°C up to +85°C
II2GD, IP66/67, Type 4X, II2GD, IP66/67, Type 4X
TVF Tropicalized Aluminum Base with TVA Direct-Mount Composite Resin

Polycarbonate Lid Intrinsically Safe
Intrinsically Safe/Non-Incendive General Purpose
Class I & II, Div 2 Ex ia IIC T4 II2G
Ex ia IIC T6/T4/T3 Tamb -40°C to 60°C
-65°C up to +100°C
Ex nA nC T4/T3
-40°C up to +95°C
II2G, IP66/67, Type 4X

7
TopWorx™ K-Series Switchboxes
Minimal Maintenance Required
Compact and robust product solution that conforms to the latest European Directives.
The use of quality materials and attention to detailed design and manufacturing has
resulted in an excellent reputation for reliability.
88
Solid Enclosures for Every Environment Environmental Extremes
• Aluminum, Composite, Stainless • Operating temperatures from
• Up to four conduit entries -76°F/-60°C to 248°F/120°C
(English or Metric) • IP66/67 standard rating
• O -ring seals everywhere • IP68 to 30 or 150 meters on request
• Type 4, 4X, 6, 6P
Engineered for Dependability

316 Stainless Steel Shaft
• Available in Aluminum or and Fasteners
316 Stainless Steel
• VDI/VDE 3845 F05 Mounting
• Unique coating for hazardous
• Special lever options available for
locations with Aluminum option
linear applications
• Red coating for Explosion Proof/
Flameproof installations
• Blue coating for Intrinsically Visual Display
Safe installations, including blue • Impact resistance polycarbonate
terminal strip
• Static free indicators
• Aluminum enclosures are
• No need to clean with a damp
fully anodized
cloth in Hazardous Locations
• RoHS 2 Compliant
• Flat-top Options
K1S
K1 AND K2 SERIES
K1P K1P = Aluminum K2P K2P = Aluminum

K1S K1S = 316 Stainless Steel K2S K2S = 316 Stainless Steel
Class I & II, Div 1 & 2 Class I & II, Div 1 & 2
Class I, Zone 1, Ex/AEx d IIC T6/T4 Class I, Zone 1, Ex/AEx d IIC T6/T4
Class II, Zone 21, Ex//AEx tb/tD IIIC Class II, Zone 21, Ex//AEx tb/tD
Ex ia IIC T6/T4 IIIC
Ex d IIC T6/T4 Ex ia IIC T6/T4
Ex tb IIIC Ex d IIC T6/T4
-50°C up to +100°C Ex tb IIIC
Type 4X, IP66/67/68 -50°C up to +100°C
Conduit Entries: (2)1/2 NPT or M20 Type 4X, IP66/67/68
Available with (2) switches or a Conduit Entries: (4)1/2NPT,
4-20mA analog or HART transmitter 3/4NPT, M20 or M25
Unique two point cover reduces Available with (4) switch or (2)
commissioning time switches and analog or HART
transmitter

9
TopWorx™ K-Series
Confidence that your switchbox will work on demand
Robust, Low Profile and Compact Visual Display

• RoHS 2 compliant • Impact resistant polycarbonate
• (2) M20 or 1/2NPT conduits • Static free paint
• Highly accessible internals • Pre-adjusted to 90° for easy installation
• Aluminum enclosure, fully anodized • Flat-top options
and polyester coated inside and out
• Blue coating for Intrinsically Sate
installations, including terminal strip Environmental Extremes
• Black coating for Ordinary Locations • Operating temperatures from
• Special lever options for linear -58°F/-50°C to 158°F/70°C
applications, maximum travel • IP66/67
option of 230mm
316 Stainless Steel Shaft Multiple Switch Options

and Fasteners • Potential Free
• Two point cover fixing • Inductive
• Captive lid bolts • Proximity
• VDI/VDE 3845 F05 Mounting • NAMUR
K5L with Indicator
K5L Available with (2) switches K7L Available with (4) switches
and (2) conduit entries and (2) conduit entries along with
4-20 and HART transmitter options
Ex ia IIC T6/T4 Ex ia IIC T6/T4

Ex tb IIIC Ex tb IIIC
-50°C up to +70°C -50°C up to +70°C
IP66/67 High Temperature Options
available up to 400˚C

10
TopWorx™ K-Series
Durable valve control solutions for elevated and high temperature applications
Ensure your damper is shut down in the event of a fire or power loss. The TopWorx K7L has been specially engineered for
high temperature application reliability. Tested by a third party to operate at multiple high temperatures with a varied
exposure time for Smoke Dampers or On/Off Valves. With a compact design the K7L provides field proven assurance and
accurate process feedback
High temperature wire with pressed-on

terminal spades – no lead solder Ceramic Terminal Strip
High Temperature SPDT switches

– test to 400•C
Stainless Steel Cams
K7L High Temp
Operating Temperature Exposure Time Independently Tested

250•C 3 hours Yes
300 C
•
3 hours Yes
350•C 3 hours Yes
400 C
•
3 hours Yes
11
TopWorx™ Custom Products
Engineered for your special application
Sub-Sea
KSS - DUPLEX and SUPER DUPLEX
KCS - Carbon steel with custom specified coating
Applications
Depths up to 2500 meters.
Enclosures are available in a range of materials including carbon steel,
316L stainless steel, 254SMO stainless steel (20%Cr–18%Ni–6%Mo),
Duplex 2205 and Super Duplex KSS
Available with a wide variety of switches in combination with a
4-20ma transmitters and HART
Custom penetrations can be accommodated to accept a customer
specified sub-sea connector or cable entry
Applications
• Rig positioning
• Sub-sea emergency shut down
• Manifold valves and taker loading or balancing
KCS
1212
High Vibration
• Custom #7338
• Engineered for high vibration applications
• Locked-in target magnets
• Samarium Cobalt target magnets provide
a powerful magnetic field that will ensure
strong contact pressure
• Available with (2) SPDT GO™ Switches
Applications
• Compressor Stations
• Pump Stations
• Pipes with water hammer D-Series
• Flow induced vibration
Example: DXS-L21GNEB000007338
13
TopWorx™ Bus Networks
Connectivity to Every Fieldbus Network
Sensor-Communication Modules Bus Networks

TopWorx Sensor-Communication Modules are microprocessor TopWorx Sensor-Communication
based ‘brains’ that mount inside TopWorx enclosures to deliver Modules make it easy to connect
position sensing and bus networking functionality to on/off automated on/off valves to modern
valves. They combine position sensors, bus communications, bus networking protocols such as
solenoid outputs, and wiring terminals into a compact, sealed FOUNDATION Fieldbus, DeviceNet,
module that drops into various TopWorx enclosures. AS-interface, Profibus, and HART.
SCM Features:
• Short-circuit protection
• Resistant to impact,
moisture, shock, vibration,
contamination
• LEDs indicate valve position
and facilitate sensor set-up
FOUNDATION Fieldbus ASi DeviceNet
HART Profibus
14
FOUNDATION Fieldbus
• Factory programmed with: • Consumes only 17mA to operate, • Position feedback via DO readback
(2) DI, (1) DO, (1) AI, (1) PID, reduces VCRs and DSTs required reduces number of function blocks.
with the ability to add 10 new • Local calibration button for factory
function blocks. setting open and closed position.
• Pre-defined templates, on-board
diagnostics, and EDDL-enhanced
on-board diagnostics.
HART
• Local user interface via graphic LCD • Five-point valve position • Burst Mode and Event Notification
• Selectable endpoint hysteresis calibration • Point to Point and Multi-drop mode
+/- 3% • Polarity and overvoltage
• Internal device temperature protection
monitoring • Full options of alarms and
• Supports NE-107 and NE-43 counters to diagnose
potential device problems
Monitoring features Calibration Switch

• The two built in cycle counters, a life cycle counter Equipped with a local calibration button for
and adjustable counter, with high limit alarm that pre-installation function testing of the valve actuator
gives the user needed information to implement a package. This ensures that all valve automators can
preventative maintenance strategy. function test packages before installation without
• With built in timers that record valve time in open having to purchase expensive test equipment. LEDs
position, open travel time, and close travel time indicate correct position setting of the switches.
allowed for failure prediction by trending opening
and closing times.
Bus Networking
• 3 Discrete Inputs, • ASi 2.1 with up to 4 • Profibus DP V0 • Digital confirmation

2 Discrete Outputs, Discrete Inputs and 3 • 4 Discrete Inputs of analog signal
1 Analog lnput Discrete Outputs 2 Discrete Outputs • Auto-calibration via
• Rockwell, Emerson • Early warning LEDs • Early warning LEDs handheld
DeltaV approved
• On-board diagnostics
and early warning LEDs
15
TopWorx™ Position Sensors
The Industry’s Leading Selection of Position Sensors
Emerson provides the industry’s leading selection of TopWorx Sensors & Switches
valve position sensors, including GO™ Switch leverless limit • GO Switch leverless limit switches
switches, proximity sensors, mechanical limit switches, • 4 -20mA position transmitters with
potentiometers, and 4-20mA position transmitters. HART protocol
• Proximity
• Reed
• Mechanical
All-In-One Proximity Sensor and Limit Switch

GO Switches are hermetically sealed to outperform all other position Unique cam design allows quick and
sensors in hot, cold, wet, dirty, abusive, corrosive, and explosive accurate setting of the GO Switch
conditions. GO Switches deliver best-in-class capabilities: positions reducing deadband and
hysteresis to a minimum. Switches
• Highest amp rating (4amp/120vac, 3amp/24vdc)
can easily be set in the mid-position
• Highest temperature rating: 105°C
for control applications such as
• Up to four GO Switches inside
3-way ball valves or diverter valves.
• Hermetically Sealed contacts
• SPDT, DPDT, and Stainless Steel options
• Proximity operation – nothing to jam, bend,
break, or wear out
• Resistant to electrical noise, radio frequency
interference, dust, dirt, and most chemicals
• No leakage current, not voltage
or polarity sensitive
• Simple device – inherently intrinsically safe
with barrier
• Unlike reed switches, gold flashed contacts
allow for use in both low and high current
applications within a single switch
New GO Switch Option in T-Series

Introducing an exciting new GO Switch offering in the T-Series line.
This new GO Switch offers the same reliability as existing GO Switches
with improved features and benefits. The 36 GO Switch will offer the
option of 2 or 4 switch configurations for the TX and TV Enclosures.
Integrated solenoid valves are optional in the 2-switch configuration
for even more control.
Features:
• Fully encapsulated switch cluster
• Sealed contact
• screw type terminals into the switch cluster
• 1A@24VDC, 3A@24VDC, and 4A@120VAC options
• Tested to 1-million cycles at PLC loads
• Immune to electrical noise
16
Pilot Valves
Solenoid Valves to Pilot Any Actuator
Emerson provides a portfolio of self-contained ASCO™ pilots and spool valves Solenoid Valves
to control pneumatic actuators. ASCO spool valves are specially designed to • 24vdc, 120vac, 220vac
stay open for long periods of time and close when needed. The ASCO unique • Aluminum, 316 Stainless,
design combines hard T-seal and flexible o-rings, provides bubble-tight • Single Coil, Dual Coil,
shutoff, resistance to dirt, and mutimillion cycle life controlling air or inert gas, • High Flow up to 3.7Cv
making them a perfect fit for any application. • Low Power Consumption
(solenoid 0.5 watts; piezo 12mw)
MSN bietet präzise, spielfreie Führung bei schmalen Abmessungen. Vielseitige Befestigungs- und Belüftungsmöglichkeiten er-
Pilot
lauben Valves
den Einsatz in nahezu allen Positionen und Lagen.
Pilots Valve Bodies Manual Overrides

• Internally mounted for protection • Anodized Aluminum • Momentary/Latching
from the environment • 316 Stainless Steel
• Low Power Solenoid or Ultra-Low
Power Piezo pilots Flow Rates
• Single or Dual Pilots • 1.06 Cv and 3.7 Cv
• Fail open, Fail closed, Fail in last position
• 50 million cycle minimum life
• Class F coil insulation
(Class H available on request)
• Response time 10mS
Special ASCO seal design with T-Seals are designed to:

• Reduce leakage by applying more pressure to a smaller area around the spool sealing surface
• Self-cleaning design and less sensitive to particulate contamination in the medium
• Provide a dynamic wiping action making them better suited to spool valves than plain “o-rings”
• Eliminate “stiction” with smaller contact area and higher contact pressure provided by the
cushioning rings located behind the T-seal
FLAME ARRESTORS
These double as in line filters, protecting the pilot against damage caused by dirty air. This design also allows the users to
replace or work on the external valve in situ without affecting the integrity of the explosion proof enclosure.
Integrated metal manifold with color coded tubing for supply and work to allow for easy of trouble shooting. In case of
a solenoid failure easily diagnose the failed component: pilot or spool.
17
TopWorx™ D-ESD Valve Controllers
SIL-3 Partial Stroke Test Solutions
TopWorx SIL-3 ESD Valve Controllers provide a complete Partial Stroke Test Solution with
unique features and functionality that enable partial stroke testing of emergency shutdown
valves without disrupting or shutting down the process.
The TopWorx Partial Stroke Test Solution comes complete with:

• Sensor Control Module to partially close the valve without disrupting the process
• Pass/Fail indication via high/low response on the return signal
• Open and Closed position sensors for feedback to the DCS or PLC
• Onboard Diagnostics to enable predictive maintenance and early-warning alerts
• Aluminum, Composite, and 316 Stainless Steel platforms certified for use in
Flameproof/Explosion Proof, or Non-Incendive hazardous areas
• An optional local, lockable partial stroke Test Button integral to the unit
The TopWorx Partial Stroke Test Solution provides Onboard Diagnostics

to alert the user to the following Dangerous Failures:
• Valve packing/shaft damage
• Actuator spring fatigue/breakage
• Solenoid pilot exhaust blockage
• Solenoid spring failure
Convenient Partial Partial Stroke

Stroke Testing Test Module
Integral
GO Switch
Solenoid
Partial Stroke
Confirmation
Switch
Spool Valve
18
DXP Tropicalized Aluminum DXS 316 Stainless Steel
Flameproof/Explosion Proof Flameproof/Explosion Proof
Capabilities
- Suitable for use in SIL-3 applications
- Certified for use in hazardous areas
- Integrated solution with all controls in a single housing
- Onboard diagnostics for performance validation
19
19
Applications
Valve control solutions for every application
TopWorx SIL-3 ESD Valve Controllers provide a complete Partial Stroke Test Solution with
unique features and functionality that enable partial stroke testing of emergency shutdown
valves without disrupting or shutting down the process.
The stainless steel, 35-Series GO Switch

Hermetically-Sealed, Stainless Steel, DPDT Proximity Switch
For over fifty years, GO Switch, all in one proximity sensor and limit switches, have
set the standard for reliability and durability in the process industries. Their unique
operating principle and best-in-class capabilities have made them the most specified
switch in the world for demanding process applications.
Once again, we have improved on greatness.

The 35-Series GO Switch is available in two versions:
The original Single Pole Double Throw GO Switch or the
stainless steel, Double Pole Double Throw, version.
Features:
• One-piece, stainless steel housing
• Hermetically-sealed, Double Pole Double Throw contacts
• Suitable for both Ex d and Intrinsically Safe applications
• Up to four (4) switches in a single enclosure
• Extremely low hysteresis
• PLC and higher current ratings with AC/DC
- NO/NC wiring flexibility
• 4amp/120vac and 3amp/24vdc
• Available with SOV and HART options
20
Applications
4-20mA POSITION TRANSMITTER

• Fully potted electronic module with LEDs and Auto Calibration feature
• Precise setting of the zero and span can be done in seconds for both CW
and CCW rotation with a simple push button
• Position feedback sensor is mounted directly to the switchbox shaft
eliminating backlash caused by traditional gear train
• Up to 300° rotation for choke valve applications
• The need for re-calibration is eliminated
• Available with GO Switches
DXP AND DXS with IEC/ATEX IIC Certification

The Only IIC Valve Controller with an Integral Solenoid.
Most ATEX Ex d IIC valve controllers have small containers with screw-top lids
and very few options. Often the threads on the screw-top lids bind up, causing
safety issues on multiple levels. TopWorx is changing all of that
with the IIC-certified DXS valve controller.
There is no competition.
The unique modular design of the TopWorx™ discrete valve controller
combines bus networking, pilot valve and position sensors into a
globally certified, explosion proof enclosure that attaches to any
automated valve package.
Features:
• Serrated Flange (No binding of threads)
• Improved ingress protection
• IECEx, ATEX, & Ex d Group IIC
• The only IIC Box with integral solenoid
• Available with all Bus & Sensor options!
Serrated Flange
21
Applications
TopWorx™ Visual Indicators Cold Temp to -60°C/-76°F

A variety of indicators to fit every application, including The TopWorx D-Series will give accurate position
multiple color combinations such as Green/Red and indication down to -60°C with the use of the
Yellow/Black, plus three-way, 90° and 180° flow paths. GO Switch.
Other languages are also available upon request.
TopWorx TVF Now Available with LED’s

The TVF with high intensity LEDs will give you a clear and bright
visual indication of your valve state in the darkest of conditions.
Have the confidence you need to ensure your valve is in the
proper state visually and electrically with TopWorx.
Benefits:
• Intrinsically Safe or Zone 2/Div 2 approved
• Available with GO Switches, reeds, or mechanical
• 10 point terminal strip
• Fully integrated options with internal pneumatics
• Conformal coated PCB board for enhanced reliability
• 24VDC or 120VAC @ 250mA
• Type 4X, IP67 Rated
22
TopWorx™ Mounting Kits
VIP™ Brackets to Fit Any Rotary Valve or Actuator
VIP Mounting Kit

TopWorx valve controllers can be mounted on any rack-n-pinion, scotch- We offers thousands of mounting
yoke, or vane actuator, quarter-turn manual valves, linear knifegate and kits to fit a wide variety of valves and
control valves, and positioners. actuators. Each kit comes complete with
Visit www.topworx.com for a complete list of available kits or to request a parts list and installation instructions.
a custom design.
3Z Valve Larox
Actreg Ledeen
Airtorque MAGNETROL
ANCHOR DARLING Marwin
Apollo Masoneilan
Automax Mogas
AXELSON Neles-Jamesbury
Baumann Neway
Bettis Newcon Valve
Biffi Orbinox
Bray Orbit
BROOKS BRODIE PBM
Cameron PBV
CCI Poyam
ChemValve Protech
Clarkson PVC
Compaq QTRCO
Conbraco Radius
Contromatics RCS
COPES VULCAN Remote Control
Crane RF Technologies
DeZurik Rhino
Linear Actuator with DXP Durco Rotork
El-O-Matic SAMSON
Fabri Valve Severn Glocon
Fisher SPEAKMAN
Flowbus TBV
Flowserve Triac
General Valve Trutorq
Grinnell Unitorq
HAWS Valtek
HONEYWELL Valvtechnologies
Hytork Vanessa
ITT Velan
KENNETH ELLIOT VTI
Keystone-Morin Watts
Kinetrol WKM
Kitz Worcester
KTM Xomox-Matryx
23
Technical Information
Dimensional Drawings, Electrical Ratings
D-Series MODELS
DXP DXR DXS
TX-Series MODELS
TXP TXS
K-Series MODELS
K2P/S K1P/S K7L K5L
TV-Series Models
TVA TVF TVH TVL
*Technical information with dimensional drawings are available at Emerson.com/topworx

Please see Installation and Operation Manual for complete product dimensions or contact us
for additional information at [email protected]
24
Online product configurator
Product datasheets can be generated using the
Online Product Configurator. By walking through
the selection process, you can easily create the part
number and datasheet that meets your application
needs. Product datasheets include dimensional
data, product options, a wiring diagram, a visual
indicator image, and nameplate information.
Example Datasheet for model DXP-L21GNEB:
25
Technical Information
Dimensional Drawings, Electrical Ratings
GO Switches
Contact
Option Contact Type Form Electrical Rating
Gold-Flashed, 4A@120VAC,
L Dry-Contact SPDT 3A@24VDC
Palladium Silver, 4A@120VAC,

Z Dry-Contact DPDT 3A@24VDC
L2
Transmitters
Option
GO Switches Type Signal Electrical Rating
GO_XSwitchesPotentiometer 4-20mA 8.5-34VDC
Contact
4-20mA,
Option
_H Contact Type
Potentiometer Form
Contact
HART Electrical
15-39VDCRating
Option Contact Type
Gold-Flashed, Form Electrical
4A@120VAC,Rating
L Dry-Contact
Gold-Flashed, SPDT 3A@24VDC
4A@120VAC,
L Dry-Contact SPDT 3A@24VDC
Palladium Silver, 4A@120VAC,
Z Dry-Contact
Palladium Silver, DPDT 3A@24VDC
4A@120VAC,
Z Dry-Contact DPDT 3A@24VDC
_X
Solenoid Valves
L2
HART L2
Transmitters
D-Series
Transmitters
Voltage Power Consumption Pressure Rating

Option Type Signal Electrical Rating
Option
24VDC Type.5W Signal 45-150Electrical
PSI Rating
_X Potentiometer 4-20mA 8.5-34VDC
_X
110VAC Potentiometer
3VA 4-20mA,
4-20mA 45-150 PSI 8.5-34VDC
_H Potentiometer 4-20mA,
HART 15-39VDC
220VAC
_H 3VA
Potentiometer HART 45-150 PSI
15-39VDC
Piezo 12mW 45-150 PSI
T-Series _X
_X
Solenoid Valves
Solenoid Valves
Please see Installation and Operation Manual for complete product dimensions or contact us for additional
24VDC at [email protected]
information .5W (I.S.), 1W (non-I.S.) 30-100 PSI
D-Series
110VAC
D-Series 3VA 30-100 PSI
220VAC
Voltage 3VA
Power Consumption 30-100 PSI
Pressure Rating
26
24VDC .5W 45-150 PSI
24VDC .5W 45-150 PSI
Option Type Signal Electrical Rating
_X Potentiometer 4-20mA 8.5-34VDC

4-20mA,
_H Potentiometer HART 15-39VDC
_X
Solenoid Valves
D-Series
24VDC .5W 45-150 PSI
110VAC 3VA 45-150 PSI
220VAC 3VA 45-150 PSI
Piezo 12mW 45-150 PSI
T-Series
24VDC .5W (I.S.), 1W (non-I.S.) 30-100 PSI
110VAC 3VA 30-100 PSI
220VAC 3VA 30-100 PSI
27
Ordering Guide
How to configure the right product for your application.
We recommend you call your local sales representative, inside sales, or use the online configurator tool at
Emerson.com/TopWorx to ensure you choose the right product for your application.
The following is an example of how to configure your product using the TopWorx Ordering Guide. A switchbox part
number can be configured by following a number of sequential steps. The ordering guide is organized in a number of
categories which are setup as columns. By moving from right to left and filling in the boxes at he bottom of each
column you will create a valid switchbox part number.
The following example is for reference and does not reflect all the available options of a TopWorx switchbox.
Refer to the full ordering guide for full product options.
Product part number example:

DXP-L21GNEB1A21
TOPWORX™ D-SERIES, DXP, DXR, DXS ORDERING GUIDE

Choose one option from each category to build a complete model number.
Consult factory for options not shown below.
Enclosure Bus/Sensor Area Classification Visual Display Shaft Conduit Entries

DXP Tropicalized Bus Network 0 Intrinsically safe G Standard 90° S 1
/4" DD DXP/DXS
Aluminum AS AS-Interface (Bus/sensor cannot be Green OPEN, 304 stainless steel (Metal Conduit Entries)
(Area class cannot be 0) AS, DN, ES, or _X; Red CLOSED E (2) 3/4" NPT
DXR Composite Resin *FF Foundation Requires appropriate N NAMUR
Fieldbus w/ 0 -10K Pot I.S. barrier)
(“S” Silicone R Standard 90° 304 stainless steel 4 (2) 3/4" NPT
*FL Foundation Fieldbus w/(2) - North America
O-Rings only; Green CLOSED, (2) 1/2" NPT
SPDT GO Switches Class I Div 1&2
Stainless steel *FP Foundation Fieldbus w/(2) Groups A, B, C, D Red OPEN R 1
/4" DD
conduit entries) SPDT GO Switches Type 4, 4X 316 stainless steel M (2) M20
(Area Classification and 0-10K Pot - ATEX/IECEx B 90O Black OPEN, (Shaft & external
“0” only available with DN DeviceNet Zone 0 Yellow CLOSED hardware) 3 (4) M20
ATEX/IECEx approvals) (Area class cannot be 0) II2GD, T6/T4 No Adder
232 Ex ia IIC M NAMUR 6 (4) 3/4" NPT
Partial Stroke Test Ex tb IIIC, IP66/67 Y 90° Yellow OPEN, 316 stainless steel
ES ESD/PST (Foundation Fieldbus)
DXS 316 Black CLOSED (Shaft & external DXR
Module w/GO Switch Zone 1, Ex ib IIC T4, IP67
Stainless steel hardware) (Stainless Conduit Entries Required
(Area class cannot be 0)
(Only available with “R” for North American approval)
or “M” shaft options) GO Switches 1 Explosion proof / 1 3 way, 90O P (2) 1/2" NPT
L2 (2)GO Switches Flame proof (DXP/S only) L Port
SPDT hermetic seal - North America E (2) 3/4" NPT
L4 (4)GO Switches Class I Div 1
SPDT hermetic seal(not Groups C, D; M (2) M20
available with pilot) Class I Div 2,
Z2 (2)GO Switches Groups A, B, C, D.
3 3 way, 90O DXR
DPDT hermetic seal (Groups A & B must be
T Port (Resin Conduit Entries)
Z4 (4)GO Switches hermetically sealed)
DPDT hermetic seal, Type 4, 4X, A (2) 1/2" NPT
(not available with pilot) - ATEX/IECEx
Zone 1 B (2) 3/4" NPT
Mechanical Switches II2G, II2GD, T6/T4/T3
(Area class cannot be 2, DXR Ex d IIB+H2 5 3 way, 90O C (2) M20
with G approval not available Ex tb IIIC IP66/67 T Port
with pilot) (O-Rings must be S for
M2 (2)Mech SPDT No Adder DUST certification)
M4 (4)Mech SPDT
M6 (6)Mech SPDT
T2 (2)Mech DPDT 2 Non-incendive
K2 (2)Mech SPDT (Bus/sensor must be 7 3 way, 180O
gold contacts L, Z, P, E, AS, FF,_X, _H, _E T Port 3 position
K4 (4)Mech SPDT or DN)
gold contacts - North America
Class I Div 2
Proximity Switches Groups A, B, C, D; 9 3 way, 180O
R2 (2) SPDT Prox switches Class II Div 2
T Port 3 position
R4 (4) SPDT Prox switches Groups F,G
(R2 & R4 only available with - ATEX (DXP/S only)
DXR and Ex me certification) II3G Ex nA nC tb, IP66/67
(O-Rings must be S for
Inductive Sensors DUST certification)
E2 (2) p+f NJ2-V3-N
inductive NAMUR G General Purpose Type 4, 4X

E4 (4) p+f NJ2-V3-N (not available with DXR with
mechanical switches)
inductive NAMUR
Analog Output C Flameproof

(Available with 2-switch (DXS not available with
options only for L,Z,M,K,E,T) valve; Conduit entries must
_X 4-20mA be E or M) ATEX/IECEx
transmitter II2G, II2GD, T6/T4/T3
_H 4-20mA Ex d IIC
transmitter with HART Ex tb IIIC IP66/67
(Not available with switch
option T; LH not available
w/pilot valve) (LH, ZH Not M Flameproof (only available
available with DXR) with R2 and R4 sensor
Example: options) (DXR only) ATEX/
LH =(2) GO Switches IECEx Zone 1, II2GD
with HART™ transmitter Ex e mb IIC T4, Ex tb IIIC
T66 IP67
* *FF, *FL and *FP with Area
Classification “0” has an ib W No approvals; Type 4, 4X
protection IP66/68
For complete information

on certification options,
Ordering Guide go to www.topworx.com
Fill in the boxes to create and download the
your 'ordering number.' applicable product
certificate.
Enclosure Bus/Sensor Area Classification Visual Display Shaft Conduit Entries

1 DXP L 2 1 G N E
28
When configuring a valve monitor, the part number is considered complete once the “o-ring” option is specified
and the rest of the options can be left blank, i.e., DXP-L21GNEB. If a on/off valve controller is configured the
part number is considered complete once the “Valve Cv” option is specified, i.e, DXP-L21GNEB1A2. “Regional
Certs” and “Manual Override” options can be left blank or specified. If a “Regional Certs” options is specified and
“Manual Override” is left blank the part number will look as follows: DXP-L21GNEB1A20N.
Product part number example:

DXP-L21GNEB1A21
Ordering Examples:
DXP-FF0GNEBPA2
ory to build a complete model number. DXP-L21GNEB1A2
wn below.
O-Rings Pilot Spool Valve Valve Cv Manual Override Regional Certs

B Buna-N Blank Blank Blank Blank Blank
No Adder No pilot device(s) No Spool Valve No Spool Valve No override No Regional Cert
S Silicone 1 (1) 24 Vdc pilot, fail A Aluminum 2 .86 Cv (1/4" NPT Ports) 1 Single Pushbutton B InMetro (Area
No Adder open/closed Hard coat anodized Momentary/Latching Class 0,1 and C
0.5 W (non- I.S.) 3 3.7 Cv (1/2" NPT Ports) only)
6 316 Stainless steel (For manual override 2 Dual Pushbutton
0.5W (I.S) consult factory) Momentary/Latching N NEPSI
(Spool Valve A)
2 (2) 24 Vdc pilots, fail (Spool Valve 6) T Partial stroke test button F FISCO
last position with lockable cover (Sensor (Bus/Sensor
NOTE: 0.5W (non-I.S) ES only) (Not avail w/ Area must be FF;
For Temperatures below Class C) (DXP/S - Conduit Area Class
-40°C, Silicone o-rings 0.5W (I.S) Entries 4 or 3 only. must be 0)
are recommended DXR - consult factory)
4 (1) 220 Vac pilot, 2W, K KOSHA
fail open/closed (DXP/S only)
(Area class 1 or C)
5 (2) 220 Vac pilots, 2W,
fail last position R EAC (DXP/S
only)(O-Rings must
7 (1) 110 Vac pilot, 1.1W, be B or S,B=Gas
fail open/closed Approved;S=
Gas/Dust Approved)
8 (2) 110 Vac pilots, 1.1W,
fail last position A ANZEx
Ex d IIC,
P (1) piezo pilot, fail Ex d IIB+H2
open/closed (FF only) (DXP/S only)
R (2) piezo pilots, fail last

position (FF only) P PESO (India)
(Gas approval
only)
O-Rings Pilot Spool Valve Cv Override Regional Certs

B 1 A 2 1 N/A
TOPWORX™ ACCESSORIES
Description Part Number
Pneumatic Accessories
Flow Control, 1/4" NPT (1 per kit) (DXP/TXP/TVA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AL-M21

Flow Control, 1/2" NPT (1 per kit) (DXP w/3.0Cv spool valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AL-M22
Breathers, 1/4" NPT (2 per kit) (DXP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AL-M31
T O P W O R X™ D I S C R E T E VA LV E C O N T R O L L E R S 2
29
Enabling communication with your
automated on/off valves.
TopWorx discrete valve control and GO Switch position sensing technology

provides absolute assurance in the most challenging applications by
increasing reliability, profitability and reducing down time. Engineered
to meet tough applications while offering high reliability and installation
flexibility, these rugged, dependable, and affordable models are designed
to provide dependability in all environments.
Visit us: Emerson.com/TopWorx

Your local contact: Emerson.com/contactus
Emerson.com/TopWorx
Facebook.com/EmersonAutomationSolutions
LinkedIn.com/company/Emerson-Automation-Solutions
Twitter.com/EMR_Automation
The Emerson logo is a trademark and service mark of Emerson Electric Co. Brand logotype are registered trademarks of one of the
Emerson family of companies. All other marks are the property of their respective owners. © 2020 Emerson Electric Co. All rights reserved.
BR000074ENUS-02_08-20 / Printed in the U.S.A.
BULLETIN
ACC-2017
Reviewed 5/2021
ACCESSORIES FOR AIR VALVES & AIR SYSTEMS
SI
BC
QE
SV
FCV
DE
RV
DE DE
ISO 9001
CERTIFIED
BB BV
Versa Products Company, Inc., 22 Spring Valley Road, Paramus, New Jersey, USA 07652 ▪ TEL: 201-843-2400 FAX: 201-843-2931
Versa BV, Prins Willem Alexanderlann 1429, 7312 GB Apeldoorn, The Netherlands ▪ TEL: +31-55-3681900 FAX: +31-55-3681909
1
ACCESSORIES
CONTENTS GUIDE
DUST EXCLUDERS & VENT SCREEN........................... Page 3
FLOW CONTROL, CHECK & NEEDLE VALVES ............. Page 4
CONTROL VALVES .................................................... Page 5
BLEED VALVES ........................................................ Page 5
SHUTTLE VALVES ..................................................... Page 6
STATUS INDICATOR .................................................. Page 7
QUICK EXHAUST VALVES .......................................... Page 8
ELECTRICAL QUICK EXHAUST VALVES ...................... Page 9
HAZARDOUS LOCATION JUNCTION BOX .................. Page 10
PRESSURE RELIEF VALVE ....................................... Page 11
BLOCK & BLEED VALVE .............................................. Page 11
Warranty ............................................................ Back Cover

03-2017
2
ACCESSORIES
DUST EXCLUDERS
VENT SCREENS
(For Pneumatic Application Only)
a range of unique Dust Excluders and Vent Screens made from Aluminum or 316 Stainless Steel
Dust Excluders Vent Screen
B
HEX
VERSA
N . J . U.S.A. &
NETHERLANDS
A
A
General Description General Description

Versa Dust Excluders are available in aluminum and 316 Stainless Steel. Versa Vent Screens are available in 316 Stainless Steel. Threaded
They are screwed into the exhaust port of a directional control valve and into the exhaust port of a directional control valve they offer effective
offer effective protection against dirt, dust, moisture and insects entering protection against dirt, dust and insects entering the valve, with
the valve, through the exhaust port, without obstructing the flow. minimal effect on flow.
Functional Description Functional Description
The function of the Versa Dust Excluder is based on a flexible seal resting The function of the Versa Vent Screen is based on a special
on a large diameter seat. designed stainless steel wire screen.
This principle offers: This principle offers:
- Tightly closed exhaust port - Low profile
- Low ‘break away’ pressure - High mechanical resistance
- Large flow capacity - Sound damping
- Self cleaning action. -Exceptional corrosion resistance
316 Stainless Steel
Materials Aluminum body with NBR (Nitrile) seal Materials
316 Stainless Steel body with CR (Neoprene) seal
Pressures Range: 0 to 200 psi (14 bar) pneumatic Pressures Range: 0 to 300 psi (20 bar) pneumatic
Flow Symbol Flow Symbol

Mounting Mounting
For best protection Dust Excluders are preferably mounted such that the For best protection Vent Screens are preferably mounted such that the
outlet opens to the side or down. outlet opens to the side or down.
†conforms to NACE standard MR-01-75 †conforms to NACE standard MR-01-75
Sizes/Connections/Types/Dimensions/Weights
D DUST EXCLUDER
U
S PRODUCT NUMBER DIMENSIONS IN INCH (MM) Weights in lbs (kg)
THREAD
T STAINLESS ALUMINUM STAINLESS STEEL STAINLESS
SIZE ALUMINUM ALUMINUM
E STEEL† A B A B STEEL
X ⅛” NPT DE-2 1.56” (40) 1.25” (32) 0.07 (0.03)
C ¼” NPT DE-3 DE-3-316 1.56” (40) 1.25” (32) 1.18” (30) 1.25” (32) 0.07 (0.03) 0.15 (0.07)
L ⅜” NPT DE-4 DE-4-316 1.62” (41) 1.25” (32) 1.25” (32) 1.25” (32) 0.07 (0.03) 0.17 (0.08)
U ½” NPT DE-5 DE-5-316 1.62” (41) 1.25” (32) 1.25” (32) 1.25” (32) 0.07 (0.03) 0.19 (0.09)
D ¾” NPT DE-6 DE-6-316 2.0” (51) 1.37” (35) 2.0” (51) 1.37” (35) 0.11 (0.05) 0.30 (0.13)
E 1” NPT DE-7 DE-7-316 2.0” (51) 1.37” (35) 2.0” (51) 2.0” (51) 0.12 (0.06) 0.30 (0.13)
R
V VENT SCREEN
E PRODUCT NUMBER WEIGHTS
N THREAD SIZE A HEX
MATERIAL 316 lbs (kg)
T
⅛” NPT MFS-2-316 0.69 (17.5 ) .5 (12.7 ) 0.02 (0.009)
S
¼” NPT MFS-3-316 0.88 (22.4 ) .625 ( 15.9) 0.038 (0.017)
C
R ⅜” NPT MFS-4-316 1.00 (25.4 ) .75 (19 ) 0.04 (0.018)
E ½” NPT MFS-5-316 1.19 (30.2) 1.0 (25.4 ) 0.048 (0.02)
E ¾” NPT MFS-6-316 1.50 (38.1 ) 1.12 (28.4 ) 0.08 (0.036)
N 1” NPT MFS-7-316 1.63 (41.4 ) 1.5 (38.1 ) 0.08 (0.036)
3
ACCESSORIES
FLOW CONTROL
CHECK
NEEDLE
a Family of Stainless Steel “FULL” Flow Control Valves
Flow Control Valve Check Valve Needle Valve
Mounting Holes 2 Places

Mounting
Holes Mounting A
2 Places
Holes
A 2 Places
A
C = Width C = Width
C = Width
General Description General Description General Description
Versa Products Company’s Flow Control Versa Products Company’s Check Valve (CV) is Versa Products Company’s Needle Valve (NV)
Valve (FCV) is a 316 stainless steel, NACE a 316 stainless steel, NACE compliant* device is a 316 stainless steel, NACE compliant* device
compliant* device combining a check and designed to prevent reverse flow in a pneumatic designed to meter flow in a pneumatic circuit.
needle valve to control the speed of pneumatic circuit.
actuators and cylinders.
The CV allows unrestricted full flow in one
The FCV allows unrestricted full flow in one direction and blocked Bubble Tight flow in the
direction and adjustable flow in the reverse. reverse.
Functional Description Functional Description Functional Description

The key to Versa’s full flow is the internal design The Versa Check Valve uses a pilot spring assist The flow can be gradually adjusted from
and the Versa “shuttle.” This combination “shuttle” to block the reverse flow. As the line pressure zero (closed) to maximum (full open, 10
provides a larger surface area and yields much drops the “shuttle” is moved by the spring and air from turns). Constant flow can be secured at the
higher flows than controls utilizing ball checks. the downstream side, into its seat, blocking reverse required setting by tightening the lock nut.
When the flow is reversed, placing pressure flow. The maintained air pressure and the spring Flow adjustment is controlled by Versa’s proven
on the “shuttle” it rapidly opens to a high flow assure a positive seal. needle design from our “Bleed Control” family
orifice that instantly empties the volume in the of products.
line.
Flow adjustment is controlled by Versa’s proven
needle design from our “Bleed Control” family
of products.
Specifications FCV CV NV
Materials: 316 Stainless Steel: Body, Shuttle, Cap, & valve stem; meets NACE*
Seals: FKM (standard), low temp Buna (option -44)
Mounting: In line with piping or by mounting holes provided. Not orientation sensitive.
Temperature: 5° F to 300°F (-15°C to 149°C)
-40° F to 200°F (-40°C to 93°C) w/ option -44
Pressure: 400 psi (27. 5 bar).
Flow Symbol Flow Symbol Flow Symbol
Part number, Flow rate, Weight & Dimensions

FCV CV NV Dimensions
Cv Weights Weights Weights Dimensions Inch (mm)
THREAD PRODUCT PRODUCT PRODUCT
Cv Cv
SIZE NUMBER Controlled Uncontrolled lbs (kg) NUMBER lbs (kg) NUMBER lbs (kg) A B FCV B CV B NV C Mounting
Direction Direction Hole Ø
0** to 0.70 0.54 0 to 0.50 2.5 3.23 2.3 2.59 1 .22
¼” FCV-3-316 2.0 CV-3-316 2.0 NV-3-316
2.0 (0.32) (0.24) 2.0 (0.22) (63.5) (82.0) (58.4) (65.7) (25.4) (5.6)
1.1 0.86 0 to 0.9 3.35 4.1 2.84 3.1 1.25 .22
½” FCV-5-316 0**to 5.0 5.0 CV-5-316 5.0 NV-5-316
(0.5) (0.4) 5.0 (0.4) (85.2) (104.1) (72.2) (79) (31.8) (5.6)
0** to 3.9 3.1
1” FCV-7-316 13.6 CV-7-316 13.6 — — — — — — — — —
9.5 (1.8) (1.4)
*conforms to NACE standard MR-01-75 ** Not pressure tight at shutoff for safety reasons †For hydraulic service contact factory
4
ACCESSORIES
BLEED CONTROL VALVES

(For Pneumatic application Only)
a range of Bleed Control Valves in different sizes, made of Brass or 316 Stainless Steel
C
A
General Description
Versa Bleed Control Valves provide an economical, effective With a Versa 5/2 or 5/3 four-way valve - having a separate
flow control in pneumatic applications. exhaust port for each side of a double acting cylinder - the
They can be screwed into the exhaust port of any Versa speed in one direction of stroke may be set at a different
directional control valve to offer “built-in” cylinder speed control. speed than the other stroke.
Flow
Functional Description Exhausting flow can be gradually adjusted from zero (closed)
to maximum (full open). Constant flow can be secured at the
The Versa Bleed Control Valve has a precision machined
required setting by tightening the lock nut.
needle. The flow area, through which the air - or any other gas
Materials Flow Symbol
- passes to the atmosphere, can be finely adjusted by turning valve exhaust port
the needle in or out. After the Bleed Control Valve has been All parts: - Brass or 316 Stainless Steel†
adjusted to suit, it can be securely locked at its setting with the Pressure
lock nut provided. Range: 0 to 200 psi (14 bar) air
CONNECTIONS PRODUCT NUMBER DIMENSIONS IN INCH (MM) WEIGHTS
PORT SIZE BRASS STAINLESS STEEL A B C D E lbs (Kg)
⅛” NPT BC-2 1.31” (33.3) 0.75” (19.1) 0.31” (7.9) 0.19” (4.8) 0.56” (14.3) 0.07 (0.03)
¼” NPT BC-3 BC-3-316 1.31” (33.3) 0.75” (19.1) 0.31” (7.9) 0.19” (4.8) 0.56” (14.3) 0.08 (0.04)
⅜” NPT BC-4 BC-4-316 1.56” (39.7) 0.94” (23.8) 0.38” (9.5) 0.25” (6.4) 0.69” (17.5) 0.13 (0.06)
½’ NPT BC-5 BC-5-316 1.63” (41.3) 1.00” (25.4) 0.38” (9.5) 0.25” (6.4) 0.88” (22.2) 0.15 (0.07)
¾” NPT BC-6 BC-6-316 2.44” (61.9) 1.50” (38.1) 0.50” (12.7) 0.25” (6.4) 1.31” (33.3) 0.55 (0.25)
1” NPT BC-7 BC-7-316 2.44” (61.9) 1.50” (38.1) 0.50” (12.7) 0.25” (6.4) 1.31” (33.3) 0.62 (0.28)
†Conforms to NACE standard MR-01-75 Dimensions: Inches (mm)
BLEED VALVES
(For Pneumatic Applications Only)
a low cost, simple way to manually or mechanically control bleed functions
⅜” (9.5) Ø
Functional Description
These versatile valves can be used to operate a bleed pilot control valve. Bleed valves
are used to vent pressure from one end of the control valve to allow pressure from the
opposite end to shift the spool, changing the flow pattern
½” (12.7) HEX Installation can be made directly on the pilot cap or at a remote location by simply
running a single line from the bleed button valve to the pilot cap.
1.03 Materials Product Number Flow Symbol

(26.2) Body: Brass BV-2
⅛” NPT
Plunger & Spring: 440 & 302 Stainless Steel
Seals: NBR (Nitrile)
Pressures
Range: 0 to 200 psi (0 to 14 bar) air
5
ACCESSORIES
SHUTTLE VALVES
a range of Shuttle Valves made of 316 Stainless or Brass in various sizes
®
B
VERSA
A C
General Description Functional Description

Versa Shuttle Valves are constructed of solid Brass or 316 Shuttle Valves have a free moving shuttle that blocks one of
Stainless Steel, with resilient seals providing tight shut off. two inlet ports while the other inlet port is connected to the
Shuttle valves are 3/2 valves, primarily used to charge and (common) outlet port. When a pressure signal enters the port
discharge a pressure line or chamber from two - or more - blocked by the shuttle, it will cause the shuttle to shift over to
sources. close the opposite inlet port. The shuttle will stay there while
A typical schematic is shown below: the line or chamber connected to the outlet port is charged
and/or discharged and will only shift when pressure is applied
to the inlet port it is blocking at that time.
In logic terms a shuttle valve is an ‘OR’ - function.
1 2 3 Pressures
Range: Pneumatic: 5 to 200 psi (0.35 to 14 bar)
Materials Hydraulic: 5 to 500 psi (0.35 to 35 bar)
Type: Brass Stainless Steel
Body: Brass 316 Stainless Steel† Flow Symbol OUT
Shuttle: Nylon (Zytel) 316 Stainless Steel†

IN IN
Seals: NBR (Nitrile) FKM (Fluorocarbon)
Screws: Plated Steel 316 Stainless Steel†
Mounting
Preferably with the center line of the two inlet ports horizontal.
As shown in the drawing above
Product Number Dimensions In Inch (mm) Flow Cv Weights in lbs (kg)
“P” Brasss Stainless Steel “A” “B” “C” Brass Stainless Steel Brass Stainless Steel
¼” NPT SV-3 SV-3-316 2.0” (51) 1.5” (38) 1.0” (25) 1.8 1.9 0.57 (0.26) 0.33 (0.15)
⅜” NPT SV-4 2.5” (64) 1.9” (48) 1.3” (32) 4.5 — 1.10 (0.50) —
½” NPT SV-5 SV-5-316 2.5” (64) 1.9” (48) 1.3” (32) 4.9 5.1 1.10 (0.50) 0.65 (0.29)
¾” NPT SV-6 3.5” (89) 2.8” (70) 1.5” (38) 7.3 — 2.16 (0.98) —
†conforms to NACE standard MR-01-75
6
ACCESSORIES
STATUS INDICATOR
a Pressure Indicator, made from 316 Stainless Steel
Dimensions: Inch
⅛”-27 NPT (mm)
Pressure Supply Port
1.5
(38)
2.48
(63)
General Description
Materials:
Some applications require visual indication when a system is
Body and internal wetted metal parts– 316 Stainless Steel†
pressurized or when a system has lost pressure. The Versa
Working seals– FKM (Fluorocarbon)
Status Indicator provides such a display within a stainless
Lens–poly carbonate (sealed to prevent moisture intrusion),
steel shell that can be mounted as an integral part of a panel.
resistant to ultraviolet rays
Viewing the panel provides the operator with an instantaneous
evaluation of the pressure condition in the system or systems
being monitored. Pressure Range:
0 to 200 psi (14 bar)
Functional Description Mounting:

Versa’s Status Indicator provides visual indication of pres- Panel hole opening 1” (25.4 mm) ø
sure in a system. The standard product displays a green field Can be mounted in any orientation with maximum panel
when a minimum of 8 psi (0.55 bar) to a maximum of 200 psi thickness 0.50” (12.7 mm) with one panel nut; maximum
(14 bar) is present. Complete loss of pressure causes the panel thickness 0.21” (5.3 mm) with two panel nuts (suffix
indicator to display a red field, marked with the recognition -43E)
character “R”. Other field colors are available. See Types/ *For hydraulic service consult factory.
Weights below. †conforms to NACE standard MR-01-75
Types/Weights
Operating Pressure Range
Depressurized Pressurized
Product Number 0 psi (0 bar) 8 psi (0.55 bar) to 200 psi (14 bar) Weights
SI-2-316 Red (R) Green
SI-2-316-403GR Green (G) Red
SI-2-316-403YG Yellow (Y) Green
0.50 lbs. (0.23 kg)
SI-2-316-403GY Green (G) Yellow
SI-2-316-403BG Black (B) Green
SI-2-316-403BR Black (B) Red
7
ACCESSORIES
QUICK EXHAUST VALVES

QE-3-316 QE-5-316 QE-6-316 QE-7-316 1” NPT

¼” NPT x ⅜” NPT ½” NPT x ¾” NPT ¾” NPT x 1” NPT QE-9-316 1½” NPT
General Description Temperature range:

A Quick Exhaust Valve is a 3/2 valve with extra large QE-3
exhaust orifice, designed to be fitted directly at a cylinder QE-3-316 -20°F (-29°C) to +200°F (+93°C)
port connection. The main purpose of a Quick Exhaust Valve
QE-5-316
is to get extra fast movement of the cylinder rod or valve
QE-6-316
actuator.
Standard -30°F (-34°C) to +250°F (+121°C)
Optional -EP* -60°F (-51°F) to +300°F (+149°C)
QE-7-316
Functional Description QE-9-316
A quick Exhaust Valve is a three-ported valve with one inlet
Standard -5°F (-15°C) to +194°F (+90°C)
port, one cylinder port and a larger exhaust port.
Optional -44 -40°F (-40°C) to +194°F (+90°C)
Optional -T40** -62°F (-52°F) to +194°F (+90°C)
When the inlet port is pressurized, the exhaust port is closed
Seal material: *Ethylene Propylene **Fluorosilicone
by the “Flapper” (“Shuttle” on QE-6-316) and the inlet port is
connected to the cylinder port. Flow Symbol
Weights lbs (kg)
When pressure falls at the inlet of the Quick Exhaust Valve QE-3 1.12 (0.53) IN EXH
the cylinder port is automatically opened to the exhaust and QE-3-316 0.81 (0.37
the cylinder is rapidly depressurized. QE-5-316 2.16 (0.98)
CYL
QE-6-316 2.44 (1.11)
QE-7-316 27.0 (12.2)
QE-9-316 26.6 (12.1)
Sizes / Connections / Product Numbers & Pressures / Materials / Flow

Size FLOW Cv MATERIALS
PRODUCT
PRESSURES
Inlet Cyl Exhaust NUMBER Inlet Exhaust Body Seals Fasteners
Electroless Nickel
1/4” NPT 1/4” NPT 3/8” NPT QE-3 5-150 psi (0.35 - 10 bar)
3.0 3.3 Plated Brass FKM (Fluorocarbon) O rings
1/4” NPT 1/4” NPT 3/8” NPT QE-3-316 5-150 psi (0.35 - 10 bar) CR (Neoprene) coated nylon
Investment cast 316L
flapper
1/2” NPT 1/2” NPT 3/4” NPT QE-5-316 5-150 psi (0.35 - 10 bar) 3.8 8.8 Stainless Steel
(conforms to NACE MR- 316
FKM (Fluorocarbon) O rings
3/4” NPT 3/4” NPT 1” NPT QE-6-316 15-175 psi (1 - 12 bar) 4.6 13.6 01-75) Stainless
CR (Neoprene) single lip seal
Steel
5-175 psi (0.3 - 12 bar) Std & -44
1” NPT 1½” NPT 1½” NPT QE-7-316 20 52 316L Stainless Steel
5 to 125 psi (0.3 to 8.5 Bar) for -T40 FKM (Fluorocarbon)
(conforms to NACE MR-
5-175 psi (0.3 - 12 bar) Std & -44 O rings
1½” NPT 1½” NPT 1½” NPT QE-9-316 23 52 01-75)
5 to 125 psi (0.3 to 8.5 Bar) for -T40
8
ACCESSORIES
ELECTRIC QUICK EXHAUST VALVES

Functional Description Construction
The Electric Quick Exhaust Valve is a three-way, NC, 3/2 valve Body: 316 Stainless Steel. (Conforms to NACE standard MR-01-75)
with extra large exhaust orifice in order to provide extra fast Solenoid Operator: 304, 430F & 302 Stainless Steel (wetted parts)
movement of the cylinder rod, or to exhaust systems rapidly. Seals: FKM (Fluorocarbon) O ring seals;
When the solenoid is energized, the outlet port is connected to CR (Neoprene) coated nylon flapper.
the inlet port and the exhaust port is closed. When the sole- Screws: Stainless Steel
noid is de-energized, the inlet port is closed and the outlet port
is connected to the exhaust port, providing rapid evacuation of
the system.
E5QE ¼” E4QE ¼” EQE ½”

with -XX with -XDB with -XMAF
E5QE E4QE EQE

General purpose, NEMA 1 (none) CSA/ATEX, junction box (-XDB*1) ATEX, (m) junction box (-XMA*)
Function Size General purpose, NEMA 4/4X (-PC) ATEX, (i) junction box (-XIF*)
UL/CSA, flying lead ½” condit hub (-XX)
ATEX, flying leads M20 conduit hub (-XN)
FM/CSA, Intrinsic Safe, DIN (-XIS*)
Ports Flow Cv Flow Cv Flow Cv
Basic PSI Part Number PSI Part Number PSI Part Number
Inlet Outlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust
3-Way
3/2 5-150 E5QE-30304-316-*-** 0.06 3.3 5-150 E4QE-30304-316-*-** 0.06 3.3
Normally ¼ ¼ ¼ ⅜
5-100 E5QE-30404-316-*-** 0.106 3.3 5-125 E4QE-30404-316-*-** 0.106 3.3
Closed
5-150 E5QE-50304-316-*-** 0.06 8.8 5-150 E4QE-50304-316-*-** 0.06 8.8 5-150 EQE-50203-316-*-** 0.022 8.8
½ ¼ ½ ¾
5-100 E5QE-50404-316-*-** 0.106 8.8 5-125 E4QE-50404-316-*-** 0.106 8.8 5-150 EQE-50304-316-*-** 0.06 8.8
* Specify Suffix Options from chart below. **Specify Voltage.
SUFFIX CHART (for additional specifications

Suffix
Description contact factory)
General Purpose E5QE E4QE EQE
NEMA 1, 1/2” Conduit, 24” wire leads (standard no suffix required) None
NEMA 4, 4X 1/2” Conduit, 24” wire leads -PC
Hazardous Location
UL/CSA Explosion Proof, 1/2” Conduit, 24” wire leads. Other available options:
-LB Low watt (consult factory for pressure range)
-XX
-PC Potted Coil
-ST Stainless housing
ATEX/IEC Flame Proof (d), M20 Conduit, 24” wire leads. Other available options: NA
-LB Low watt (consult factory for pressure range) NA
-XN
-PC Potted Coil
-ST Stainless housing
FM/CSA Intrinsic Safe, Spade terminals. Other available options:
-HC DIN Connector, Pg9 cord grip
-XISC (FM/CSA)
-HCC DIN Connector, 1/2” conduit
-XISX6 (ATEX)
Note: Part number changes to E5QE-30202-316 and E5QE-50202-316.
Pressure is 5-115 psi (0.3-7.9 bar) and Inlet Flow is 0.02 Cv
ATEX/IECEx/CSA Flame Proof (d), Increased Safety(e), Enclosure/Dust (td) -XDBS1 (M20)
Class I, Div I, Grp B,C,D - Class I, Div II, Grp E,F,G- Class I, Div III, integral junction box -XDBT1 (½”)
ATEX/IECEx Encapsulated (mb), Increased Safety (e) Enclosure/Dust (td) -XMAA (M20)
NA
integral junction box -XMAF (½”)
NA
-XIFA (M20)
Intrinsic Safe (ia), integral junction box -XIFF (½”)
9
ACCESSORIES
HAZARDOUS LOCATION JUNCTION BOX

CSA, ATEX, IEC & INMETRO Approved!
Versa Products Company, Inc. offers a stainless steel junction box with terminals to allow the
installation of equipment such as solenoid valves, switches, indicators and other electronic
devices. These small effective boxes allow easy wiring in hazardous wet locations simplifying
insulation and reduced space. Simple screw off cover design reduces the hassle of lost
parts and screws at installation. These explosion and weather protected electrical boxes are
manufactured to be certified in accordance with agencies around the world. The junction box
is manufactured in stainless steel assuring resistance to environmental issues yielding a long
durable product life.
Specifications:
Description: Junction Box
Area Certification: ATEX/IECEx/INMETRO Ex d e IIC Gb
*CSA Class I, Div. 1 Groups B, C, D
*CSA Class II, Div. 1 Groups E, F and G; Class III
Ingress Protection: IP 66
Materials of Construction P-1102-27V-VJBT
Body: 316 Stainless Steel Shown
Cover: 316 Stainless Steel
Seal: Viton
Connections: ½” NPT or M20 (2 places)
Integral 2 or 4 position terminal strip
*CSA ½” NPT conduit hub only.
Agency Approvals
®
C US
2.50 1.5 1.5

Ø 63.5 38.1 38.1
1/2” 2 4
Part Number M20
NPT* position position 2.34
59.4
P-1102-27V-VJBT X X
P-1102-27V-VJBTC X X
P-1102-27V-VJBS X X .79
20.1
P-1102-27V-VJBSC X X
IN .71 See Tabulation for port size
mm 18.0
10
ACCESSORIES
A
PRESSURE RELIEF VALVE
¼” and ½” NPT, 316 stainless steel, high flow pressure relief (For Pneumatic Application Only)
valve, with factory set and tested pressure settings
B
Pressure Weight Dimension
Size Part Number
Range lbs kg A B
¼” NPT RV-3-316-* 30 to 150 psi 0.16 0.07 0.69” 2.13”
½” NPT RV-5-316-* 15 to 150 psi 0.38 0.17 0.875” 3.06”
* Add relief pressure to part number in 5 psi increments
from 60 to 150 psi for ¼” & 15 to 150 psi for ½”.
Block & Bleed

a Block and Bleed gauge monitoring valve assembly
Materials:
Body and valve stems: 2.27 CLOSED
2.50 OPEN
316 Stainless Steel
BB-3-316
900 WOG
OUTLET
1.13 316 SS
INLET
Pressures:
HEAT NUMBER
.56 1/4 M X 1/4 F
PO#
VENT
.56 3.50
Operating Pressure Range: 2.27 CLOSED
1.13
0 to 600 psig (0 to 54.4 bar) 2.50 OPEN
¼” NPT INLET
Media: Water, Oil & Gas

.50
2.03
¼” NPT VENT
BB-3-316
OUT
The Versa Block and Bleed valve is a traditional

isolation valve. It consists of “block” and “vent”
VENT
needle valves to isolate and vent downstream
pressure during gauge changes.
IN
AR-190-316-1 valve extension
11
Versa
has been
supplying the
oil and gas
industr y with
pneumatic
and hydraulic
components
for over 50
years. We
have built a
reputation
for quality
that is
unsur passed
in the market
for high
perfor mance
solenoids,
pneumatic
relays, resets
and pilot
valves
WARNINGS REGARDING THE DESIGN APPLICATION,

INSTALLATION AND SERVICE OF VERSA PRODUCTS
The warnings below must be read and reviewed before designing a system utilizing,
installing, servicing, or removing a Versa product. Improper use, installation or servicing of LIMITED WARRANTY DISCLAIMER
a Versa product could create a hazard to personnel and property. AND LIMITATION OF REMEDIES
DESIGN APPLICATION WARNINGS Versa’s Series products are warranted
Versa products are intended for use where compressed air or industrial hydraulic fluids are to be free from defective material and
present. For use with media other than specified or for non-industrial applications or other workmanship for a period of ten years
applications not within published specifications, consult Versa. from the date of manufacture, provided
Versa products are not inherently dangerous. They are only a component of a larger said products are used in accordance
system. The system in which a Versa product is used must include adequate safeguards with Versa specifications. Versa’s
to prevent injury or damage in the event of system or product failure, whether this failure liability pursuant to that warranty
be of switches, regulators, cylinders, valves or any other system component. System is limited to the replacement of the
designers must provide adequate warnings for each system in which a Versa product
is utilized. These warnings, including those set forth herein, should be provided by the Versa product proved to be defective
designer to those who will come in contact with the system. provided the allegedly defective
product is returned to Versa or its
Where questions exist regarding the applicability of a Versa product to a given use, inquiries authorized distributor. Versa provides
should be addressed directly to the manufacturer. Confirmation should be obtained directly
from the manufacturer regarding any questioned application prior to proceeding. no other warranties, expressed or
implied, except as stated above.
INSTALLATION, OPERATION AND SERVICE WARNINGS There are no implied warranties
Do not install or service any Versa product on a system or machine without first of merchantability or fitness for a
depressurizing the system and turning off any air, fluid, or electricity to the system or
machine. All applicable electrical, mechanical, and safety codes, as well as applicable particular purpose. Versa’s liability for
governmental regulations and laws must be complied with when installing or servicing a breach of warranty as herein stated is
Versa product. the only and exclusive remedy and in
no event shall Versa be responsible or
Versa products should only be installed or serviced by qualified, knowledgeable personnel
who understand how these specific products are to be installed and operated. The liable for incidental or consequential
individual must be familiar with the particular specifications, including specifications for damages.
temperature, pressure, lubrication, environment and filtration for the Versa product which
is being installed or serviced. Specifications may be obtained upon request directly from
Versa. If damages should occur to a Versa product, do not Operate the system containing
the Versa product. Consult Versa for technical information.
Versa Products Company Inc. Versa BV

22 Spring Valley Road Prins Willem Alexanderlaan
Paramus, New Jersey 07652 1429
USA 7321 GB Apeldoorn
Phone: 201-843-2400 The Netherlands
Fax: 201-843-2931 Phone: 01131-55-368-1900 www.versa-valves.com
Fax: 01131-55-368-1909 email: [email protected]
$''>@,1+(,*+772$//2:
)255(029$/2)/,' >@
DXP-M21GNEB
Switchbox DXP and DXS
>@
6((63(&,),&$7,216)25
&21'8,7(175<6,=(
Enclosure Tropicalized aluminum
237,21$/&21'8,7 Bus/Sensor (2) Mechanical SPDT
(175,(6 Area Classification Explosionproof/flameproof
Visual Display Standard 90◦ Green OPEN, Red CLOSED
Shaft NAMUR 316 stainless steel
Conduit Entries (2) 34 " NPT
>@
O-Rings Buna-N
>@ >@
>@ >@ Pilot No pilot device(s)
>@
Spool Valve No spool valve
Valve Cv No valve Cv
>@ >@
Manual Override No manual override
>@
>@ Regional Certification No regional certification
N Switch No N Switch
81&%
02817,1*+2/(6
Q>@3$77(51
>@
OPEN CLOSED
Current as of September 22, 2021 – Subject to change without notice.
Cl I Div 1, Grps C-D;

Type 4X; T4 -50◦ C≤ Ta ≤ 60◦ C
Ex db IIB + H2 T6/T5/T4/T3 Gb; -50◦ C≤ Ta ≤ 60◦ C/75◦ C/110◦ C/175◦ C
IP66/67
SWITCH: SPDT 15A/125VAC, 250VAC
Model #: Serial #:
Bulletin C-316
2018R
C-316 SERIES
Versa Product Company, Inc., 22 Spring Valley Rd., Paramus, NJ 07652 USA Phone: (201)843-2400 Fax: (201)843-2931
Versa BV, Prins Willem Alexanderlaan 1427, 7312 GB Apeldoorn, The Netherlands Phone: +31-55-368-1900 Fax: +31-55-368-1909
E-mail: [email protected] www.versa-valves.com
THE C-316 SERIES
General Description.................................................................................................................Page 3
Specifications...........................................................................................................................Page 4
Repair kits................................................................................................................................Page 4
Cross Reference Chart............................................................................................................Page 5
Recommended Hazardous Location Solenoid Option Packages.............................................Page 5
THE C-316 Side Por ted
Solenoid Operated
Solenoid Operated............................................Page 8
Solenoid, Palm button.......................................Page 9
Solenoid Latching.............................................Page 10
Electrical..............................................................Page 6-7-7
Pilot Operated
Pilot Operated...................................................Page 11
Pilot, Palm button,.............................................Page 11 - 12
Pilot Latching....................................................Page 12 - 13
Manually Operated
Manual Palm Button.........................................Page 13 - 14
Rotary................................................................Page 14
Key....................................................................Page 15
Lock Out............................................................Page 16
By Pass.............................................................Page 16
Mechanical
CAM.......................................................Page 17
THE C-316 NAMUR

NAMUR – Direct Mount
Solenoid Operated................................................Page 18
Latching................................................................Page 18
CMAP
CMAP – Modular Air Package
Solenoid Operated............................................Page 19
Latching............................................................Page 19
Options
Solenoid Manual Override...................................Page 17
042020
Solenoid Vent Options.........................................Page 17

Stainless Steel Tag..............................................Page 17
2 www.versa-valves.com
THE C-316 SERIES
GENERAL DESCRIPTION
Series “C-316”
The C-316 Series consists of 3-Way 3/2 and 4-Way 5/2 investment cast, 316 stainless steel valves, in three categories:
Side Ported, NAMUR style direct mount and CMAP, an integral stainless steel regulator and valve.
“C-316” Body Ported Valves “C-316” Namur Valves CMAP Modular Air Package
The C-316 Series is available as either a 4-way, for The Versa C-316 Series stainless steel NAMUR mount A CMAP system consists of a filter/regulator, gauge
double acting devices or a 3-way, for spring return actuator control valve is a high flow, bubble-tight, and directional control valve all in one.
devices. The 3-way function can be specified as either 5-port, Pilot valve. It is designed to mount directly
CMAP is based on Versa’s field proven C-316 and
normally closed or opened. to any NAMUR actuator, thus reducing actuator
AR Series. All inter-component connections utilize
response time and space.
All solenoid actuators are solenoid/pilot type, which “O”-ring interface sealing reducing potential leakage
allows the use of the smallest solenoids available Installed costs are also lower as the need for tubing, points. The combination of C-316 & AR reliability, “O”
resulting in low power consumption. This design fittings, brackets and assembly labor are greatly ring sealing and a simple design principal all provide
also assures a positive shifting force which makes reduced. All mounting screws and seals are included a reliable and easily maintained product. CMAP is the
certain the valve shifts when energized and reduces with valve. sensible choice.
the chance of coil burnout. Single solenoid spring The 5-port design allows the C-316 NAMUR to be The basic CMAP system is made of two configurable
return models utilize an air assisted spring return ordered as either a 4-way, for double acting actuators modules. Module one is the air preparation module
feature assuring a positive return. Double solenoid or a 3-way, for spring return actuators. When the consisting of filter/regulators, gauges and drains.
models are equipped with a detent that maintains 3-way function is utilized, the unused exhaust port Module two is the control valve module consisting
the valve in the last shifted position, even in high becomes an actuator vent where a filter/ muffler can of many different variations of 3-way control valves.
vibration environments. be installed to prevent contaminants from entering See page 19.
A complete selection of electrical connections, power either the valve or the actuator.
requirements and area classifications are available. The 5-port design allows the user to independently
See page 6-7 control actuator speed in either the open or close
direction. Speed or bleed controls are optional.
See page 18.
CONSTRUCTION: Epoxy Molded Coil

Epoxy molding offers
Large Diameter Pilot moisture resistance
Large diameter pilot piston and heat dissipation
produces high shifting forces in in the toughest ap-
Wafer Sealing
Versa C-316 pilot and Solenoid plications.
Wafer type elastomer sealing
Balanced Spool actuated applications assuring
provides leakproof operation
The forces required to actuate a positive shifting force. The U
throughout entire pressure
the plunger are unaffected by cup offers friction free sealing for
range. The wafer/wiper style
pressures being controlled as- a positive shift.
seal also provides a low friction
suring positive shifting through-
profile.
out the entire range.
Air-Assisted
Spring Return
Air boosts spring
for positive valve
return.
High Performance Solenoid Actuator

All the C-316 Series solenoid valves utilize a
high performance solenoid pilot design. This
Fully Ported – High Flow design utilizes available media pressure/
Investment Cast Stainless Steel Internal flow area equal to or greater force to shift valve assuring positive shifting.
316 stainless steel components utilized for than the area of the corresponding This design also produces the lowest
superior corrosion protection in the harshest pipe/tube size. wattage requirements in the industry.
environments. Investment cast components
offer a first class finish while providing
weight savings and superior flow.
www.versa-valves.com 3
THE C-316 SERIES
Specifications
Flow Rate: Cv = 2.0 Materials:
NAMUR Cv = 1.6 Valve body and internal parts: 316L stainless steel
CMAP Cv = 1.5 Actuator caps: 316L stainless steel
Port Size: Inlet, cylinder and exhaust: ¼” NPT Valve seals: FKM (fluorocarbon)
Media: C-316 Pneumatic* Option Low Temp Nitrile (“-44“)
CMAP Pneumatic Screws: Stainless steel
Pilot: Inpilot & Expilot solenoid valves Solenoid internal parts: 304, 430F and 302 stainless steel
Temperature: -5 to 200°F (-20 to 93° C), Media and ambient Solenoid Coil housing: Depends on coil selected, see page 7
Low Temp (-44 option) Manual: -20 to 200°F (-29 to 93°C), Media and ambient
Pilot: -55 to 200°F (-48 to 93°C), Media and ambient
Solenoid: -40 (-40°C) to Max based on solenoid type
*For hydraulic service consult factory Repair kits Repair Kit Number
Prefix Suffix
Operating Pressure 3-Way 4-Way NAMUR
No. No.
CAG, CGA
Valve Function Minimum psi (bar) Maximum psi (bar) CAP, CPA
136PE C-3301-316-356AN C-4302-316-356AN *
Single Solenoid Spring Return 25 (1.8) 150* (10.3) 314E

CZA, CAZ C-3301-316-AZ C-4302-316-AZ *
357E
Dual Solenoid Detent 15 (1.0) 150* (10.3) CSI, CIS Standard
CSA, CAS 357E C-3301-316-S C-4302-316-S *
Expilot Spring Return (with and CSC,CCS Standard
See Controlled (inlet) Pressure chart below
without strong spring -S) CAI, CIA 150E
CZI, CIZ Standard C-3301-316-ZI C-4302-316-ZI *
*Exhaust restriction recommended for operating pressures over 125 psi (8.6 bar) CAI, CIA 173E
CAG, CGA 356B C-3321-316-356AN C-4322-316-356AN *
CAG, CGA
Controlled (inlet) Pressure CAP, CPA
356BN C-3321-316-356BN C-4322-316-356BN *
Pilot Operated CGG, CPP C-3321-316-GG C-4322-316-GG C-4322-316-GG-NE
psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar
Spring Return CSP,CPS Standard C-3321-316-SG *
25 1.7 30 1.2 50 3.4 70 4.8 90 6.2 110 7.6 130 9.0 150 10.3 C-4322-316-SP
CSG,CGS C-3321-316-SG C-4322-316-SG-NE
Minimum Pilot CAP, CPA 314E C-3301-316-AP C-4302-316-AP *
19 1.3 20 1.4 27 1.9 33 2.3 40 2.8 46 3.2 52 3.6 59 4.1 CSA, CAS 314E C-3301-316-SI C-4302-316-SI *
Pressure Required CIZ LOV C-3301-316-ZI-LOV C-4302-316-ZI-LOV *
*For NAMUR valve repair kits contact factory.
SELECTOR CHART & PRODUCT NUMBERING
Each letter and digit in the product number of a Versa Valve has a significant meaning, as explained below.
C S G 3 3 2 1 316 XX A120
Valve ACTUATING DEVICES Function Port Spool Details Suffix Details
Type of Body Material
Series Left Side* Right Side* (see Spool Details) Size (flow pattern) Mechanical Electrical
Series A Combination Actuators 2* Two-Way 2/2 3 1/4” 0 Expilot Body Three-Way ‘316’ -CA3 CMAP identifier Electrical
C-316 136PE, -150E, -173E, NPT with threaded 3/2 Valves indicates -NE_ NAMUR valve with 316 -HT High Temp coil
Valves -314E, -356B, -356BN, 3 Three-Way 3/2 side-ports that the mounting screws, -LA 0.85 Watt coil
1 Normally
-357E (for Manual, basic -NE1 10-28 -LB 1.8 Watt coil
Closed
see suffix column 4 Four-Way 5/2 construction -PC NEMA 4/4X
Pilot and Expilot material for -NE2 10-32
solenoid actuated 2 Normally -NE3 M5 -ST Stainless steel
C Cam Operator *Two-Way may valve parts
valves) Open -DG Dust Proof coil housing
be created by is AISI 316
G Solenoid-pilot plugging the Stainless -44 Low Temperature seals -U Upright solenoid
Four-Way end cap
exhaust port of 2 Inpilot Body Steel
5/2 Valves -U Up Right coil housing
I Hand Button three-way valve with threaded (Conforms -XDB_ Stainless Steel
(for panel mounting) bodies side-ports with 2 2-Position to NACE -ME Override, momentary housing,multi
internal drilling Standard contact Page 17 agency approvals
P Pressure-Pilot MR-01-75) Tagging -XX NEMA 7 & 9
to supply
inlet pressure to -NV28A, Stainless steel ID -XN ATEX
S Spring Return tag; see Page 17
Solenoid-pilot See page 5 for Suffix
(spring pushes actuator Combination Actuators specifications
valve spool) -136PE Palm Button, Spring
Rating Code:
3 Inpilot Manifold Return Page 9 & 11 A= 60Hz frequency
Z 2-Position Detent mounted with -150E Pilot-2-Position D= Direct Current (DC)
(for 2-position manually internal drilling Detent Page 12 E= 50Hz frequency
operated valves) to supply inlet -173E Solenoid, 2-Position Three numbers follow the
pressure to Detent Page 9 Rating Code to indicate
Solenoid-pilot -314E Key Operated Actuator voltage:
*NOTE
“S” above is on left end actuator. Page 15 Examples:
NAMUR Valve -356B Button Actuator W/ Voltage Code
of valve looking at inlet 24V60 = 024
Latch – Reset Page 10
“G” above is on right end 13 & 19 120V60 = 120
of valve looking at inlet -356BN Actuator W/ Latch – 24VDC = 024
Reset No Button Page See Page 7 for specific
10, 12, 18 & 19 coil and codes.
-357E Rotary Switch-
2-Position Detent Page
14
THE C-316 SERIES
Hazardous Location Combination Suffix Details
Cross Reference Chart
Suffix Reference North American (-XX) (Cont.) ATEX (-XN) (cont.)
Suffix Description Combination
Included Suffix
Combination
Included Suffix
-CD 72” wire leads Suffix Suffix
-D14 Solenoid vent, water proof nut -XXK -XX, -HT, -LB, -PC, -ST -XNR -XN, -LB
-H2E 1/8” npt Solenoid vent -XXK4 -XX, -D14, -HT, -LB, -PC, -ST -XNS -XN, -LA, -ST
-HE ¼” npt Solenoid vent -XXL -XX, -PC -XNU -XN, -HT, -LB, -ST
-HT Class H coil -XXL4 -XX, -D14, -PC -XNV -XN, -LA
-L14 Solenoid vent dust nut -XXM -XX, -HT, -PC -XNX -XN, -LB, -PS
-LA 0.85 watt Solenoid -XXM4 -XX, -D14, -HT, -PC -XNWS -XN, -VJBT, -LB, -PS
-LB 1.8 watt Solenoid -XXN -XX, -LB, -PC
-LV 0.85 watt (World Solenoid) -XXN4 -XX, -D14, -LB, -PC World Solenoid (-XDB, -XV, -XT)
-LX 1.8 watt (World Solenoid) -XXQ -XX, -HT, -LB Combination
-LZ 0.5 watt (World Solenoid) Included Suffix
-XXQ4 -XX, -D14, -HT, -LB Suffix
-PC Potted coil; NEMA 4
-XXR -XX, -LB -XDBS1 -XDBS, -HT, -LX
-PS Potted coil, male conduit;
-XXR4 -XX, -D14, -LB -XDBS2 -XDBS, -HT, -LX, -H2E
-ST Stainless Solenoid housing
-VJBT Add on Junction Box -XXS -XX, -LA, -ST -XDBS3 -XDBS, -HT, -LX, -HE
-XDBS World Solenoid** -XXS4 -XX, -D14, -LA, -ST -XDBS4 -XDBS, -HT, -LX, -L14
-XDBT World Solenoid** -XXU -XX, -HT, -LB, -ST -XDBS5 -XDBS, -HT, -LX, -303D
-XN ATEX Solenoid -XXU4 -XX, -D14, -HT, -LB, -ST -XDBS6 -XDBS, -HT, -LX, -H2E, -303D
-XT World Solenoid** -XXV -XX, -LA -XDBS7 -XDBS, -HT, -LX, -HE, -303D
-XV World Solenoid; North America -XXV4 -XX, -D14, -LA -XDBS8 -XDBS, -HT, -LX, -L14, -303D
-XX North American Solenoid -XXW -XX, -CD, -HT, -H2, -PC, -ST -XDBS9 -XDBS, -HT, -LX, -D14
-303D Integral diode -XXW4 -XX, -D14, -CD, -HT, -PC, -ST -XDBS10 -XDBS, -HT, -LX, -D14, -303D
North American (-XX) -XDBT1 -XDBT, -HT, -LX
Combination ATEX (-XN) -XDBT2 -XDBT, -HT, -LX, -H2E
Included Suffix -XDBT3 -XDBT, -HT, -LX, -HE
Suffix Combination
Included Suffix -XDBT4 -XDBT, -HT, -LX, -L14
-XXA -XX, -HT Suffix
-XXA4 -XX, -D14, -HT -XNA -XN, -HT -XDBT5 -XDBT, -HT, -LX, -303D
-XXB -XX, -PS -XND -XN, -ST -XDBT6 -XDBT, -HT, -LX, -H2E, -303D
-XXB4 -XX, -D14, -PS -XNE -XN, -PC, -ST -XDBT7 -XDBT, -HT, -LX, -HE, -303D
-XXC -XX, -HT, -PS -XNE4 -XN, D14, -PC, -ST -XDBT8 -XDBT, -HT, -LX, -L14, -303D
-XXC4 -XX, -D14, -HT, -PS -XNF -XN, -HT, -ST -XDBT9 -XDBT, -HT, -LX, -D14
-XXD -XX, -ST -XNG -XN, -LB, -ST -XDBT10 -XDBT, -HT, -LX, -D14, -303D
-XXD4 -XX, -D14, -ST -XNH -XN-HT, -PC, -ST -XV1 -XV, -HT, -LX
-XXE -XX, -PC, -ST -XNJ -XN, -LB, -PC, -ST -XV2 -XV, -HT, -LX, -H2E
-XXE4 -XX, -D14, -PC, -ST -XNJ4 -XN, -D14, -LB, -PC, -ST
-XV3 -XV, -HT, -LX, -HE
-XXF -XX, -HT, -ST -XNK -XN, -HT, -LB, -PC, -ST
-XV4 -XV, -HT, -LX, -L14
-XXF4 -XX, -D14, -HT, -ST -XNL -XN, -PC
-XXG -XX, -LB, -ST -XV9 -XV, -HT, -LX, -D14
-XNL4 -XN, -D14, -PC
-XXG4 -XX, -D14, -LB, -ST -XNM -XN, -HT, -PC -XT1 -XT, -HT, -LX
-XXH -XX, -HT, -PC, -ST -XNN -XN, -LB, -PC -XT2 -XT, -HT, -LX, -H2E
-XXH4 -XX, -D14, -HT, -PC, -ST -XNN4 -XN, -D14, -LB, -PC -XT3 -XT, -HT, -LX, -HE
-XXJ -XX, -LB, -PC, -ST -XNP -XN, -HT, -LB, -PC -XT4 -XT, -HT, -LX, -L14
-XXJ4 -XX, -D14, -LB, -PC, -ST -XNQ -XN, -HT, -LB -XT9 -XT -HT, -LX, -D14
Recommended Hazardous Location Certification/Power
Solenoid Option Packages North American - CSA ATEX - IECEx - INMETRO

Enclosure/Wire Standard Power Low Watt* Standard Power Low Watt*
Steel, Electroless Nickel Plated, 24 Inch Leads -XXL4 -XXN4 -XNL4 -XNN4
Stainless Steel, High Performance 430 type, 24” wire leads -XXE4 -XV9 -XNE4 -XT9**
Stainless Steel, 316L type, Junction Box with Terminal Strip — -XDBT9** — -XDBS9**
*1.8 watt solenoid. Also available 0.5 and 0.85 watt. Consult factory for availability.
**All the –XDBS, -XDBT & -XT solenoids are “World Solenoids” certified for North America, ATEX, IECEx and INMETRO and more.
-XV solenoids certified for North America.
For complete solenoid specifications please see above and page 6-7.
Electrical
NON HAZARDOUS LOCATIONS OPERATORS
Suffix Protection Area Classification Certification- Ingress
Identification Classification and (Gas Grouping) (Conformance) Protection
None or NEMA 1,2,

General Purpose Indoor & Outdoor CSA
-HT, PC 3&4
-HC NEMA 4;
General Purpose Indoor & Outdoor CSA
-HCC (Shown) IP65
HAZARDOUS LOCATION SOLENOIDS

Agency Approvals North America World*
Protection Area Classification Ingress
Suffix* Zones Divisions Agency
Classification and (Gas Grouping) Protection
CL I, DIV 1, Grp (C & D)
CL II, DIV 1, Grp (E, F & G)
Hazardous Temp T3C UL NEMA
-XX — —
Locations CL I, DIV 2 Grp (A B C) CSA 7&9
CL II, DIV 2 Grp (E, F & G)
Temp T3C
Ex d IIB+H2 T3…T6 Gb IECEx

-XN (d) Flameproof — — IP66/67
II 2 G Ex d IIB+H2 T3…T6 Gb ATEX
NEMA
Hazardous 4, 4X,
-XV — — CSAUS
Locations C 6P,
IP66
CL I, DIV 1, Grp (B, C, D)
CL II, DIV 1,Grp (E, F , G)
CL III
-XT (d) Flameproof
CL I, DIV 2, Grp (A. B, C, D)
CL II, DIV 1, Grp (E, F, G)
CL III
CL, I, Zn 1 A/Ex de IIC T* Ex II 2 G D

-XDBT ATEX - IECEx
CL, II Zn, 21 AEx tD A21, A/Ex d e IIC T3…T6 Gb IP66/67/68
INMETRO
DIP A21 Ex tb IIIC T3…T6 Db
(d) Flameproof
(e) Increased
Safety
-XDBS —
(mb)
-XMAA Encapsulation
Ex e mb IIC T5, T6 Gb
-XMAF Ex tb IIIC T85ºC, T100ºC Db IECEx
(e)
— — TR CU IP67
Increased Safety
II 2 G Ex e mb IIC T5...T6 Gb ATEX
-XMFA II 2 D Ex tb IIIC T85ºC...T100ºC Db
-XMFF (tD)
Tight Dust
Ex (ia) IIC T4...T6 Gb
-XIFA (ia) Ex (ia) IIIC T130ºC...T80ºC Db IECEx
Intrinsic — — TR CU IP67
-XIFF Safe II 2 G Ex ia IIC T4...T6 ATEX
II 2 D Ex iaD 21 T130ºC, T80ºC
-HC-XISX6- ATEX
(Shown) CL I, DIV 1, Grp (A, B, C & D) IECEx
Intrinsic II 2 G Ex ia IIC T4…T6 Gb
— CL II, DIV 1, Grp (E, F, & G) TR CU IP65
Safe II 2 G Ex ia IIB T4…T6 Gb
CL III CSA
-HCC-XISX6
FM
*Recommended solenoid options. See page 5

COIL CODES: Identify the solenoid frequency Rating Code Voltage
and voltage consisting of a “Rating Code” and A = 60Hz frequency Indicated by three digits: A120 = AC,120Volts/60hz
“Voltage” as shown at right. Coil codes complete D = Direct Current (DC) e.g. 24 volts = 024
the part number for a solenoid operated valve. E = 50Hz frequency 120 volts = 120
Voltage Electrical
Miscellaneous
(Power) Characteristics
Class F epoxy molded coil
All usual 50 Hz & 60 Hz AC (7.3W) (155ºC).
All usual DC (9.5W) Continuous duty, 2 leads 24” Steel cover with 1/2 NPT conduit entry.
(60 cm).
24V60, 120V60, 240V60 (8.5W) Class F epoxy molded coil

24V50, 110V50, 220V50 (8.5W) (155ºC), with 3 spade terminals Mini DIN socket with PG9 cable gland (-HC) or 1/2” conduit
12VDC, 24VDC, 48VDC (10.5W) and mini DIN socket with PG9 connection (-HCC).
cable gland. Continuous duty.
Voltage Electrical
Miscellaneous
(Power) Characteristics
Plated steel coil housing with 1/2 NPT conduit entry.

50 Hz & 60 Hz AC (6W), DC (7.2W) & (1.8W) For additional (-XX) solenoid options see page 5.
AC: 12V60 (A012), 24V60 (A024), 48V60 Class F epoxy molded coil
(A048), 120V60 (A120), 240V60 (A120) (155ºC). continuous duty.
DC: 6VDC (D006), 12VDC (D012), 24VDC 3 leads 24” (60 cm).
(D024), 48VDC (D048) Plated steel coil housing with M20 x 1.5 conduit entry.
Ground terminal on cover.
For additional (-XN) solenoid options see page 5.
Suffix Detail Option Packabe

Stainless steel coil housing XV XT
1.8 watt
Standard (vent to atmosphere) -XV1 -XT1
1/8” Adapter (-H2E) -XV2 -XT2
AC: 120V60HZ (A120), 240V60HZ (A240) 1/4” Adapter (-HE) -XV3 -XT3
110V50HZ (E110), 220V50HZ (E230) Dust Nut (-L14) -XV4 -XT4
DC: 12VDC (D012), 24VDC (D024) Epoxy molded coils rated Water proof nut (-D14) -XV9* -XT9*
48VDC (D048), 120VDC (D120) for continuous duty, Class
H – 180°C. Stainless steel coil housing Suffix Detail Ordering Code
with internal Junction Box. M 20 Connection ½” Connection
1.8 watt standard. For 0.85 watt consult Internal and external ground
screw. No Diode Diode No Diode Diode
factory.
Standard (vent to atmosphere) XDBS1 XDBS5 XDBT1 XDBT5
1/8” Adapter (-H2E) XDBS2 XDBS6 XDBT2 XDBT6
1/4” Adapter (-HE) XDBS3 XDBS7 XDBT3 XDBT7
Dust Nut (-L14) XDBS4 XDBS8 XDBT4 XDBT8
Dust Excluder (-D14) XDBS9* XDBS10 XDBT9* XDBT10
Continuous duty coil &

24VDC (4W) rectifier, including surge
(Consult factory for other voltage options) suppression, potted within Thick wall epoxy coil housing with integral junction box. Internal
housing. ground terminal.
M20 x 1.5 conduit entry: (-XMAA), (-XMFA),
Continuous duty coil &
24VDC 10W inrush, 2.6W holding) 1/2 NPT conduit entry with adapter: (-XMAF), (-XMFF).
power controller potted
(Consult factory for other voltages)
within housing.
Requires the use of an approved safety barrier or isolator.
Continuous duty coil and Thick wall epoxy coil housing and integral junction box. Internal
24VDC (0.8W)
power controller potted ground terminal.
(Consult factory for other voltages)
within housing. M20 x 1.5 conduit entry: (-XIFA).
1/2 NPT conduit entry with adapter: (-XIFF).
Requires the use of an approved barrier or isolator.
Class F epoxy molded coil Maximum operating system voltage before barrier 28VDC.
24VDC (1.6 watt max.) Maximum pilot pressure 115 psi (8 bar).
(155ºC).
System voltage prior to barrier 3 spade terminals, ISO DIN 43650 Form “A” PG9 cable gland (-HC).
Continuous duty. 1/2 NPT conduit entry: (-HCC).
Low temperature Buna seals standard.
*Recommended solenoid options. See page 5
THE C-316 SERIES
Mounting Hole Dimensions Side Ported Valves
Ø D E Ø A
Mounting Hole A A
B C D E Ø
C Dimensions 3-Way 4-Way C
B
B Inches 1.0 1.25 1.13 0.56 0.41 0.41 0.17
mm 25.4 31.8 28.6 14.3 10.3 10.3 4.4
D E
A
Optional Upright Coil Housing

Manual Override Manual Override
Available as an option A B C D D* E E*
3-Way 4-Way 3-Way 4-Way
on side ported valves.
A Side Ported
⅛” NPT Expilot Port Recommended for use Inches 2.8 1.62 1.42 5.41 5.91 8.53 9.0
with -XDB_, -XMA_,
mm 72.1 41.1 36.1 137.5 150.1 217 288.6
C -XMF_ & XIF_ coils
⅛” NPT NAMUR
Expilot on NAMUR valves for
Port Inches 2.8 1.63 1.44 4.14 4.14 7.25 7.25
D/D* E/E* B mounting clearance.
Solenoid shown is hazardous location type -XX. For more options see page 6-7. mm 72.1 41.3 36.6 105.2 105.2 184.2 184.2
Body Ported Valves

SOLENOID OPERATED
Pilot
Side Ported Function Actuation Type Part Number Weight Flow Symbol
3-Way Single 2A
2-Position Inpilot CSG-3321-316-(*)
Solenoid 1.6 lbs
Normally
Spring 0.7 kg
Closed Expilot CSG-3301-316-(*)
3/2 Return 1 IN EX 3
3-Way Single 2A
2-Position- Inpilot CGS-3322-316-(*)
Solenoid 1.6 lbs
Normally
Spring 0.7 kg
Open Expilot CGS-3302-316-(*)
2A
3-Way Double Inpilot CGG-3321-316-(*)
2.5 lbs
2-Position Solenoid
1.1 kg
3/2 Detent Expilot CGG-3301-316-(*) 1 IN EX 3
Single B A
4-Way Inpilot CSG-4322-316-(*)
Solenoid 1.7 lbs
2-Position
Spring 0.8 kg
5/2 Expilot CSG-4302-316-(*)
Return EB IN EA
Inpilot CGG-4322-316-(*) B A
4-Way Double
2.6 lbs
2-Position Solenoid
1.2 kg
5/2 Detent Expilot CGG-4302-316-(*)
EB IN EA
* Add solenoid/coil voltages (page 7) & Suffix from Selector Chart (page 4)
Optional Manual Override Optional Manual Override
⅛” NPT Expilot Port ⅛” NPT Expilot Port

A B C D D* E E*
A 3-Way 4-Way 3-Way 4-Way
C Inches 2.8 1.62 1.42 5.41 5.91 8.53 9.0
mm 72.1 41.1 10.3 137.5 150.1 217 288.6
B D/D* E/E*
Solenoid shown is hazardous location type -XX. For more options see page 6-7.
THE C-316 SERIES
Body Ported Valves
SOLENOID, PALM BUTTON with SPRING RETURN
Pilot
3-Way Single 2A
Inpilot CAG-3321-316-136PE-(*)
2-Position Solenoid
2.0 lbs
Normally Palm Button
0.9 kg
Closed Spring Expilot CAG-3301-316-136PE-(*)
3-Way Single
2-Position Solenoid Inpilot CGA-3322-316-136PE-(*) 2A
2.0 lbs
Normally Palm Button
0.9 kg
Open Spring
3/2 Return Expilot CGA-3302-316-136PE-(*)
1 IN EX 3
Single Inpilot CAG-4322-316-136PE-(*) B A

4-Way Solenoid
2.1 lbs
2-Position Palm Button
1.0 kg
5/2 Spring
Expilot CAG-4302-316-136PE-(*) EB IN EA
Return
Optional Manual Override
⅛” NPT Expilot Port A B C C* D Ø Ø*
Ø 3-Way 4-Way Travel
A
Inches 2.3 1.62 8.08 8.58 .20 1.81 1.0
mm 58.4 41.2 205.2 217.9 5.08 46 25.4
D Ø* For mounting hole dimensions see page 8
B C/C*
Manual override see page 17
SINGLE SOLENOID, PALM BUTTON with DETENT

Pilot
3-Way Inpilot CIA-3321-316-173E-(*) 2A
Single
2-Position
Solenoid 2.1 lbs
Normally
Detent with 1.0 kg
Closed Expilot CIA-3301-316-173E-(*)
Button 1 IN EX 3
3/2
3-Way Inpilot CAI-3322-316-173E-(*) 2A
Single
2-Position-
Solenoid 2.1 lbs
Normally
Detent with 1.0 kg
Open Expilot CAI-3302-316-173E-(*)
Button 1 IN EX 3
3/2
Inpilot CAI-4322-316-173E-(*) B A
Single
4-Way
Solenoid 2.2 lbs
2-Position
Detent with 1.0 kg
5/2 Expilot CAI-4302-316-173E-(*)
Button EB IN EA
⅛” NPT Expilot Port
Ø
A B C C* D Ø Ø*
A 3-Way 4-Way Travel
Inches 2.3 1.62 7.92 8.42 .20 1.81 1.0
D Ø* mm 58.4 41.2 201.2 213.8 5.08 46 25.4

B C/C*
For mounting hole dimensions see page 8
THE C-316 SERIES
Body Ported Valves
LATCHING, SINGLE SOLENOID, SPRING RETURN without PALM BUTTON
Pilot
3-Way 2A
Single Inpilot CAG-3321-316-356BN-(*)
2-Position
Solenoid 1.9 lbs
Normally
Spring 0.9 kg
Closed Expilot CAG-3301-316-356BN-(*)
Return
3/2 1 IN EX 3
3-Way 2A
Single Inpilot CGA-3322-316-356BN-(*)
2-Position-
Solenoid, 1.9 lbs
Normally
Latching 0.9 kg
Open Expilot CGA-3302-316-356BN-(*)
Reset
3/2 1 IN EX 3
Inpilot CAG-4322-316-356BN-(*) B A
Single
4-Way
Solenoid 2.0 lbs
2-Position
Latching 0.9 kg
5/2 Expilot CAG-4302-316-356BN-(*)
Reset EB IN EA
* Add solenoid/coil voltages (page 7) & Suffix Details from Selector Chart (page 4 )

⅛” NPT Expilot Port
A A B C C* Ø*
3-Way 4-Way
Inches 2.3 1.62 6.5 7.0 1.0
B Ø* mm 58.4 41.2 165 177.8 25.4
C/C*
Solenoid shown is hazardous location type -XX. For more options see page 6-7. For mounting hole dimensions see page 8
LATCHING, SINGLE SOLENOID, SPRING RETURN with PALM BUTTON

Pilot
3-Way
Single Sole- Inpilot CAG-3321-316-356B-(*) 2A
2-Position
noid, Latching 2.0 lbs
Normally
Reset with 0.9 kg
Closed
Button Expilot CAG-3301-316-356B-(*)
3/2 1 IN EX 3
3-Way
Single Sole- Inpilot CGA-3322-316-356B-(*) 2A
2-Position-
Normally
Reset with 0.9 kg
Open
Button Expilot CGA-3302-316-356B-(*) 1 IN EX 3
3/2
Single Sole- Inpilot CAG-4322-316-356B-(*) B A

4-Way
2-Position
Reset with 1.0 kg
5/2
Button Expilot CAG-4302-316-356B-(*) EB IN EA
* Add solenoid/coil voltages (page 7) & Suffix from Selector Chart (page 4 )
Ø ⅛” NPT Expilot Port

A B C C* D Ø Ø*
A 3-Way 4-Way Travel
Inches 2.3 1.62 8.08 8.58 .20 1.81 1.0

Ø* mm 58.4 41.2 205.2 217.9 5.08 46 25.4
B D C/C*
Solenoid shown is hazardous location type -XX. For more options see page 6-7. For mounting hole dimensions see page 8
THE C-316 SERIES
Body Ported Valves
PILOT OPERATED
Pilot
3-Way 2A
2-Position Single Pilot
Remote 1.0 lbs
Normally Spring CSP-3301-316
Pilot 0.5 kg
Closed Return
1 IN EX 3
3/2
3-Way 2A
2-Position- Single Pilot
Remote 1.0 lbs
Normally Spring CPS-3302-316
Pilot 0.5 kg
Open Return
3/2 1 IN EX 3
1A
3-Way
Double Pilot Remote 1.3 lbs
2-Position CPP-3301-316
Detent Pilot 0.6 kg
3/2
1 IN EX 3
B A
4-Way Single Pilot
Remote 1.0 lbs
2-Position Spring CSP-4302-316
Pilot 0.5 kg
5/2 Return
EB IN EA
B A
4-Way
Double Pilot Remote 1.4 lbs
2-Position CPP-4302-316
Detent Pilot 0.6 kg
5/2
EB IN EA
⅛” NPT Pilot Port A B C D D* E E*

3-Way 4-Way 3-Way 4-Way
A C Inches 2.8 1.62 1.42 3.36 3.86 4.43 4.94
mm 72.1 41.1 10.3 85 98 112.4 125.4
B D/D* E/E*
PILOT, PALM BUTTON with SPRING RETURN

Pilot
3-Way
Single Pilot 2A
2-Position
Palm Button Remote 1.3 lbs
Normally CAP-3301-316-136PE
Spring Pilot 0.6 kg
Closed
Return
3/2 1 IN EX 3
3-Way 2A
Single Pilot
2-Position-
Normally CPA-3302-316-136PE
Spring Pilot 0.6 kg
Open
Return
3/2 1 IN EX 3
B A
Single Pilot
4-Way
2-Position CAP-4302-316-136PE
Spring Pilot 0.6 kg
5/2
Return EB IN EA
⅛” NPT Pilot Port

Ø Ø*
A B C C* D Ø Ø*
3-Way 4-Way Travel
A
Inches 2.3 1.62 7.88 8.38 .20 1.81 1.0
D
C/C* B mm 58.4 41.2 200.1 212.9 5.08 46 25.4
THE C-316 SERIES
Body Ported Valves
PILOT, PALM BUTTON with DETENT
Pilot
3-Way 2A
2-Position Single Pilot
Remote 1.5 lbs
Normally Detent with CAI-3301-316-150E
Pilot 0.7 kg
Closed Button
1 IN EX 3
3/2
3-Way 2A
2-Position- Single Pilot
Remote 1.5 lbs
Normally Detent with CIA-3302-316-150E
Pilot 0.7 kg
Open Button
3/2 1 IN EX 3
B A
4-Way Single Pilot
Remote 1.6 lbs
2-Position Detent with CAI-4302-316-150E
Pilot 0.7 kg
5/2 Button
EB IN EA
⅛” NPT Pilot Port Ø* Ø A B C C* D Ø Ø*

3-Way 4-Way Travel
A
Inches 1.42 1.62 5.86 6.36 .20 1.81 1.0
B C/C* D mm 36.1 41.2 149 161.4 5.08 46 25.4
LATCHING, PILOT, SPRING RETURN without PALM BUTTON

Pilot
3-Way 2A
Pilot,
2-Position
Latching, Remote 1.3 lbs
Normally CAP-3301-316-356BN
Spring Pilot 0.6 kg
Closed
Return 1 IN EX 3
3/2
3-Way
Pilot, 2A
2-Position-
Latching Remote 1.3 lbs
Normally CPA-3302-316-356BN
Spring Pilot 0.6 kg
Open
Return
3/2 1 IN EX 3
Pilot, B A
4-Way
2-Position CAP-4302-316-356BN
Spring Pilot 0.6 kg
5/2
Return EB IN EA
Ø ⅛” NPT
A B C C* Ø
A Pilot Port 3-Way 4-Way
D Inches 2.23 1.42 4.36 4.86 1.81
mm 56.6 36.1 117.5 123.4 46
B C/C*
THE C-316 SERIES
Body Ported Valves
LATCHING, PILOT, SPRING RETURN with PALM BUTTON
Pilot
3-Way 2A
Pilot,
2-Position
Normally CAP-3301-316-356B
Reset with Pilot 0.6 kg
Closed
Palm Button 1 IN EX 3
3/2
3-Way 2A
Pilot,
2-Position-
Normally CPA-3302-316-356B
Open
Palm Button
3/2 1 IN EX 3
B A
Pilot,
4-Way
2-Position CAP-4302-316-356B
5/2
Palm Button EB IN EA

A
Ø* D Ø
A B C C* D E Ø Ø*
3-Way 4-Way Travel
E
Inches 2.23 1.62 8.08 8.58 .20 2.3 1.81 1.0
D mm 56.6 41.2 205.2 217.9 5.08 58.4 46 25.4
B C/C*
MANUAL, PALM BUTTON, SPRING RETURN

Pilot
3-Way 2A
2-Position Palm Button
1.1 lbs
Normally Spring NA CSI-3301-316
0.5 kg
Closed Return
3/2 1 IN EX 3
3-Way 2A
2-Position- Palm Button
1.1 lbs
Normally Spring NA CIS-3302-316
0.5 kg
Open Return
3/2 1 IN EX 3
B A
4-Way Palm Button
1.3 lbs
2-Position Spring NA CSI-4302-316
0.6 kg
5/2 Return
EB IN EA
Ø* D Ø
A B C C* D Ø Ø*
3-Way 4-Way Travel
A
Inches 2.3 1.62 8.08 8.58 .20 1.81 1.0
C/C* mm 58.4 41.2 205.2 217.9 5.08 46 25.4

B
THE C-316 SERIES
Body Ported Valves
MANUAL, PALM BUTTON, DETENTED
Pilot
3-Way 2A
2-Position
Palm Button 1.3 lbs
Normally NA CZI-3301-316
Detent 0.6 kg
Closed
3/2 1 IN EX 3
3-Way 2A
2-Position-
Palm Button 1.3 lbs
Normally NA CIZ-3302-316
Detent 0.6 kg
Open 1 IN EX 3
3/2
B A
4-Way
Palm Button 1.4 lbs
2-Position NA CZI-4302-316
Detent 0.6 kg
5/2 EB IN EA
Ø* D Ø
A B C C* D Ø Ø*
3-Way 4-Way Travel
A
Inches 1.42 1.62 4.8 5.3 .20 1.81 1.0
mm 36.1 41.2 122 135 5.1 46 25.4
B C/C*
MANUAL, ROTARY, SPRING RETURN & DETENTED

Pilot
2A
3-Way Spring Return CSA-3301-316-357E 1.6 lbs

2-Position 0.7 kg
1 IN EX 3
Normally NA 2A
Closed Detent CZA-3301-316-357E(*) 1.8 lbs
3/2 0.8 kg
1 IN EX 3
2A
3-Way Spring Return CAS-3302-316-357E 1.6 lbs

2-Position 0.7 kg 1 IN EX 3
Normally NA 2A
Open Detent CAZ-3302-316-357E(*) 1.8 lbs
3/2 0.8 kg
1 IN EX 3
Spring Return CSA-4302-316-357E 1.8 lbs B A
0.8 kg
4-Way EB IN EA
2-Position Detent NA CAZ-3302-316-357E(*) 2.0 lbs
B A
5/2 0.9
EB IN EA
A B C C* Ø
3-Way 4-Way
Ø
A Inches 3.5 1.62 3.73 4.23 1.0
mm 90 41.2 95 107.4 25.4
B C/C*
THE C-316 SERIES
Body Ported Valves
MANUAL, KEY , SPRING RETURN & DETENT

Pilot
1.8 lbs
2A
3-Way Spring Return CSA-3301-316-314E(*)
2-Position 0.8 kg
1 IN EX 3
Normally NA 2A
Closed 1.9 lbs

Detent CZA-3301-316-314E(*)
3/2 0.9 kg 1 IN EX 3
3-Way Spring Return CAS-3302-316-314E(*) 1.8 lbs 2A
2-Position- 0.8 kg
1 IN EX 3
Normally NA 2A
Open 1.9 lbs

Detent CAZ-3301-316-314E(*)
3/2 0.9 kg 1 IN EX 3
B A
Spring Return CSA-4302-316-314E(*)

4-Way EB IN EA
2 lbs
2-Position NA 0.9 kg B A
5/2 Detent CAZ-4302-316-314E(*)

EB IN EA
*Key Number - Key number assigned by Versa
A B C C* D Ø
Ø 3-Way 4-Way
A
D Inches 3.5 1.62 3.73 4.23 2.8 1.0
mm 90 41.2 95 107.4 71.3 24.5
B C/C* For mounting hole dimensions see page 8
MANUAL, KEY, PILOT RETURN

Pilot
3-Way 2A
2-Position
Key Remote 2 lbs
Normally CPA-3301-316-314E(*)
Pilot Return Pilot 0.9 kg
Closed
3/2 1 IN EX 3
3-Way 2A
2-Position
Key Remote 2 lbs
Normally CAP-3302-316-314E(*)
Open
3/2 1 IN EX 3
B A
4-Way
Key Remote 2 lbs
2-Position CPA-4302-316-314E(*)
5/2 EB IN EA
*Key Number - Key number assigned by Versa
A
Ø A B C C* D Ø
3-Way 4-Way
D
Inches 3.53 1.62 8.08 8.58 2.8 1.0
B C/C* mm 90 41.2 205.2 217.9 71.3 24.5

THE C-316 SERIES
Body Ported Valves
MANUAL, LOCK - OUT
Pilot
3-Way 2A
2-Position
Palm Button 1.3 lbs
Normally NA CIZ-3301-316-LOVBE
Detent 0.6
Closed
3/2 1 IN EX 3
B A
4-Way
Palm Button 1.4 lbs
2-Position NA CIZ-4302-316-LOVEE
Detent 0.6
5/2
EB IN EA
Note: locks not included

D Ø*
A B C (3-Way) C* (4-Way) D (Travel) Ø Ø*
A Inches 2.3 1.62 8.08 8.58 .20 1.81 1.0
mm 58.4 41.2 205.2 217.9 5.08 46 25.4
C B For mounting hole dimensions see page 8
MANUAL, By Pass Valve

Pilot
CAU-430X-316-314E***-2039 BYPASS TEST NORMAL

1/4” NPT* Positions 3 2 1
5 3
4Way Key (*** = key code assigned at factory) 2 lbs
NA
3-Position Operated Add -9E Sffix Detail for Extended 0.9 kg
Plunger B4 A2
Optional
A B C D* E Ø
Ø Extended
Plunger Inches 3.53 1.62 5.14 4.7 2.8 1.0
Suffix -9E A
D mm 90 41.2 130 217.9 71.3 24.5
B C
The, basic valve is a 3 position manual valve. Operation is as follows:

Position 1. This position is the normal position or the regular operation mode.
Position 2. This position places the control circuit in the test mode. In this position the bypass valve allows
pressure to the circuit for testing while maintaining pressure on the actuator. With pressure to solenoid
inlet and solenoid circuit outlet blocked/isolated this position allows complete testing of solenoid circuit
while not shutting down the system.
Position 3. This position places the control system in a replace mode. Should it be determined that a
component in the control circuit needs to be repaired and or replaced this position allows total isolation
from pressure while still holding system pressure to actuator.
*1/2” NPT available; part number: VAU-450X-316-314E507-2039. See V-316 Series.
THE C-316 SERIES
Body Ported Valves
MANUAL, CAM
Pilot
3-Way Cam
2A
2-Position 1.0 lbs

Spring NA CSC-3301-316
Normally 0.5 kg
Closed 3/2 Return
1 IN EX 3
3-Way Cam
2A
2-Position 1.0 lbs

Spring NA CCS-3302-316
Normally 0.5 kg
Open 3/2 Return 1 IN EX 3
B A
4-Way Cam
1.0 lbs
2-Position Spring NA CSC-4302-316
0.5 kg
5/2 Return
EB IN EA
C C* D
B C/C*
D
A B (3-Way) (4-Way) (Travel)
E ( Over
Travel ) Ø
Standard Cam Inches 1.42 1.62 3.87 4.37 .20 0.19 1.0
Ø mm 58.4 41.2 110.9 217.9 5.08 4.8 25.4
A
D
E
B C/C*
Over Travel Cam Suffix -18E
Options
Override Stainless Steel Tag
ORDERING
INFORMATION
Order any B-316, C-316, T, V

or V-316 valve. As a separate
line item (listed directly under
valve part number to be tagged) list the tag part number P- 2002-16-NV28A. In
remarks field specify the tag marking instructions. If sequential numbering is required
provide the start and end numbers required in the sequence for the appropriate
-ME -ME -U number of valves.
Override Override
On Standard Solenoid Cap On Up Right Solenoid Cap
Engraving Options
Solenoid Vent Options Versa's engraved tags are available in two configurations.
Configuration one: is a simple text field 2.25”

consisting of two lines of text, 20 characters ABC OIL
0.5”
maximum per line. The text can be specified as P/N SV 966
alpha, numeric or both.
Configuration two: is a text field with sequential

numbering added. This option includes two ABC OIL
lines of text. Line one is text. Line two allows for P/N SV 966
Hydraulic Adapter Excluders sequentially numbering the tag, 20 characters Field for Sequential Characters
maximum per line.

-H2 ⅛” -L14 -D14
-H ¼” Dust Proof Water Tight
THE C-316 SERIES
NAMUR
Note: NAMUR, SOLENOID OPERATED
3-Way & 4-Way
NAMUR valves Pilot
look the same NAMUR Function Actuation Type Part Number Weight Flow Symbol
externally. 3-Way Single 2A
2-Position
Solenoid 1.7 lbs
Normally Inpilot CGS-3331-316-NE†-(*)
Spring 0.8 kg
Closed
3-Way Single 2A
2-Position-
Solenoid 1.7 lbs
Normally Inpilot CSG-3332-316-NE†-(*)
Spring 0.8 kg
Open
3/2 Return
1 IN EX 3
2A
3-Way Double
2.3 lbs
2-Position Solenoid Inpilot CGG-3331-316-NE†-(*)
1.0 kg
3/2 Detent
1 IN EX 3
Single B A
4-Way
Solenoid 1.7 lbs
2-Position Inpilot CGS-4332-316-NE†-(*)
Spring 0.8 kg
5/2
Return EB IN EA
B A
4-Way Double
2.3 lbs
2-Position Solenoid Inpilot CGG-4332-316-NE†-(*)
1.0 kg
5/2 Detent
EB IN EA
† Add mounting screw type from Selector Chart “Suffix” column (page 4) * Add solenoid/coil voltages (page 7) & Suffix from Selector Chart (page 4).
Optional Manual Override Optional Manual Override
A ⅛” NPT Expilot Port ⅛” NPT Expilot Port A B C D

C
Inches 2.3 1.62 5.7 8.8
mm 58.4 41.2 144 223
B D E
Solenoid shown is hazardous location type -XX. For more options see page 6-7. Manual override see page 17
NAMUR LATCHING, SOLENOID, SPRING RETURN without PALM BUTTON

Pilot
NAMUR Function Actuation** Type Part Number Weight Flow Symbol
3-Way Pilot, 2A
2-Position Latching 1.5 lbs
Normally Reset Inpilot CAG-3331-316-NE†-356BN-(*)
without 0.7 kg
Closed
3/2 Button 1 IN EX 3
3-Way Pilot, 2A
2-Position- Latching 1.5 lbs
Normally Reset Inpilot CGA-3332-316-NE†-356BN-(*)
without 0.7 kg
Open
3/2 Button 1 IN EX 3
Single B A
4-Way Solenoid,
Latching 1.5 lbs
2-Position Inpilot CAG-4332-316-NE†-356BN(*)
Reset 0.7 kg
5/2 without EB IN EA
Button
† Add mounting screw type from Selector Chart “Suffix” column (page 4 ). * Add solenoid/coil voltages (page 7) & Suffix from Selector Chart (page 8).
A ⅛” NPT Expilot Port A B C Ø*

**Consult
Inches 2.23 1.62 5.7 1
factory for other
configurations mm 56.6 41.2 144 25.4
Ø*
B C
Solenoid shown is hazardous location type -XX. For more options see page 6-7. Manual override see page 17
THE C-316 SERIES
CMAP Modular Air Package
Bill of Materials
Description Part Number
A Regulator ARFA-3111-316-CA3-GBG
Valve CAG-3321-316-356BN-CA3-XX-A120
M6 x .43 MM
full threads
3 mounting holes
INLET
B C
A B C EA 3 A2
Inches 8.44 4.0 3.85

mm 214 101.6 97.9
6 Mounting Holes
0.28” (7.2mm) Ø Bill of Materials
On center Vertical L to R
0.0 to 3.84“ to 1.16” Description Part Number
On center horizontal 1.25”
Regulator ARFA-3111-316-CA3-GBG
Valve CSG-3321-316-CA3-XDBS1-A120
A
Spacer CY-3209-32-316-CA3
Bracket 4302-99-316-CA3
Relief Valve RV-3-316-100
B C
INLET
A B C
Inches 9.39 6.0 3.85
EA 3 A2
mm 238 152.4 97.9
Air Prep Selection Part Number Weights

Regulator, Description 0-100 psi 0-150 psi lbs kg
Filter and No gauge ARFA-3112-316-CA3 ARFA-3111-316-CA3 2.7 1.22
manual 2" gauge liquid filled ARFA-3112-316-CA3-GBG ARFA-3111-316-CA3-GBG 2.9 1.32
drain* 2 1/2" gauge liquid filled ARFA-3112-316-CA3-GAG ARFA-3111-316-CA3-GAG 2.9 1.32
Valve Selection Part Number Weights ††
Description 3-way, normally closed † 3-way, normally open † lbs Kg
3/2 Pilot, Spring Return CSG-3321-316-CA3-** CGS-3322-316-CA3-** 1.9 0.86
3/2 Double Pilot, detented CGG-3321-316-CA3-** CGG-3322-316-CA3-** 2.5 1.13
3/2 Pilot, spring return w/ latch CAG-3321-316-CA3-356BN-** CGA-3322-316-CA3-356BN-** 2.2 0.99
3/2 Pilot, spring return w/ latch and button CAG-3321-316-CA3-356B-** CGA-3322-316-CA3-356B-** 2.3 1.04
3/2 Pilot, spring return CSP-3301-316-CA3 CPS-3302-316-CA3 1.3 0.59
Accessories Weights Notes:

Description Part Number lbs kg * For regulator auto drain, consult factory
Mounting bracket Add 4302-99-316-CA3 to bill of Material 0.5 0.23 ** Add voltage and Pilot options. See page 7
Auxiliary port plate Add CY-3209-32-316-CA3 to bill of Material 0.2 0.09 † For expilot change 3321 to 3301
†† Weight are for -XX type Pilots
Relief Valve (also specify Aux port plate) Add RV-3-316-*** to bill of Material 0.2 0.09
*** Add set pressure, for example
Speed Control, close only Add suffix -BC3 to Control Valve p/n 0.1 0.05 RV-3-316-080 for 80 psi
Speed Control, both open closed Add FCV-3-316 to bill of Material 0.5 0.23
Versa
has been
supplying the
oil and gas
industr y with
pneumatic
and hydraulic
components
for over 70
years. We
have built a
reputation
for quality
that is
unsur passed
in the market
for high
perfor mance
solenoids,
pneumatic
relays, resets
and pilot
valves
WARNINGS REGARDING THE DESIGN APPLICATION,

INSTALLATION AND SERVICE OF VERSA PRODUCTS
The warnings below must be read and reviewed before designing a system utilizing,
installing, servicing, or removing a Versa product. Improper use, installation or servicing of LIMITED WARRANTY DISCLAIMER
a Versa product could create a hazard to personnel and property. AND LIMITATION OF REMEDIES
DESIGN APPLICATION WARNINGS Versa’s Series products are warranted
Versa products are intended for use where compressed air or industrial hydraulic fluids are to be free from defective material and
present. For use with media other than specified or for non-industrial applications or other workmanship for a period of ten years
applications not within published specifications, consult Versa. from the date of manufacture, provided
Versa products are not inherently dangerous. They are only a component of a larger said products are used in accordance
system. The system in which a Versa product is used must include adequate safeguards with Versa specifications. Versa’s
to prevent injury or damage in the event of system or product failure, whether this failure liability pursuant to that warranty
be of switches, regulators, cylinders, valves or any other system component. System is limited to the replacement of the
designers must provide adequate warnings for each system in which a Versa product
is utilized. These warnings, including those set forth herein, should be provided by the Versa product proved to be defective
designer to those who will come in contact with the system. provided the allegedly defective
product is returned to Versa or its
Where questions exist regarding the applicability of a Versa product to a given use, inquiries authorized distributor. Versa provides
should be addressed directly to the manufacturer. Confirmation should be obtained directly
from the manufacturer regarding any questioned application prior to proceeding. no other warranties, expressed or
implied, except as stated above.
INSTALLATION, OPERATION AND SERVICE WARNINGS There are no implied warranties
Do not install or service any Versa product on a system or machine without first of merchantability or fitness for a
depressurizing the system and turning off any air, fluid, or electricity to the system or
machine. All applicable electrical, mechanical, and safety codes, as well as applicable particular purpose. Versa’s liability for
governmental regulations and laws must be complied with when installing or servicing a breach of warranty as herein stated is
Versa product. the only and exclusive remedy and in
no event shall Versa be responsible or
Versa products should only be installed or serviced by qualified, knowledgeable personnel
who understand how these specific products are to be installed and operated. The liable for incidental or consequential
individual must be familiar with the particular specifications, including specifications for damages.
temperature, pressure, lubrication, environment and filtration for the Versa product which
is being installed or serviced. Specifications may be obtained upon request directly from
Versa. If damages should occur to a Versa product, do not Operate the system containing
the Versa product. Consult Versa for technical information.
Versa Products Company, Inc. Versa BV

22 Spring Valley Road Prins Willem Alexanderlaan
Paramus, New Jersey 07652 1427
USA 7321 GB Apeldoorn
Phone: 201-843-2400 The Netherlands
Fax: 201-843-2931 Phone: 01131-55-368-1900 www.versa-valves.com
Fax: 01131-55-368-1909 email: [email protected]
V. WARRANTY LETTER,
VAS Válvulas y Actuadores, S.A. de C.V.
RFC: VVA190219FL2 FOLIO: 0218
Avenida Ayuntamiento No.168 Piso 3,
Tlalnepantla Centro, Tlalnepantla de Baz, Estado de México
CP-54000, Tel 55 53840977 con 10 líneas
e-mail: [email protected]
Cliente: ARES CONTROL, S.A. DE C.V.

Orden de Compra: 7711 REV 03
Orden de Venta: PV665
Fecha: 11/05/2023
CARTA GARANTÍA
ITEM MATERIAL DESCRIPCION CANTIDAD
1 VBT08R06FZDGY VALVULA BOLA TRUNNION 8" RF 600# A105N
1.1 8FP-BS6R-A105N-57666-NC-G 2
2 VBT08R06FZDYYB VALVULA BOLA TRUNNION 8" RF 600# ACT. SR
2.1 8FP-BS6R-A105N-57666-NC 1
2.2 G2016-SR2 1
VAS Válvulas y Actuadores, S.A. de C.V. garantiza que los bienes manufacturados están libres de defectos en
materiales y mano de obra.
VAS Válvulas y Actuadores, S.A. de C.V. garantiza el buen funcionamiento de los equipos por un periodo de 18
meses a partir de la fecha de entrega en sitio y/o 12 meses en operación, lo que ocurra primero.
La garantía no será válida si los equipos son manipulados, transportados, almacenados, instalados y operados
en forma diferente a lo indicado en los manuales de los fabricantes de cada elemento. Los trabajos de diagnostico
e instalación deberá ser por personal autorizado por VAS Válvulas y Actuadores, S.A. de C.V. para que esta
garantía sea efectiva.
Para hacer efectiva la garantía, el usuario deberá notificar por escrito a VAS Válvulas y Actuadores, S.A. de
C.V. de la falla, dentro de los 15 días calendario, siguientes a la fecha de ocurrencia de la misma.
VAS Válvulas y Actuadores, S.A. de C.V. reparará o reemplazará los equipos y/o servicios que haya
suministrado en la orden de compra de referencia.
Sólo se atenderán los reclamos que se notifiquen por escrito y que estén avalados por ARESCONTROL, S.A.
DE C.V.
Los bienes reparados y/o reemplazados dentro del período de garantía, permanecerán en garantía por el
tiempo restante del período de garantía original.
ATENTAMENTE
______________________________
Coordinación de Operaciones
No. PO PO15298
REV. DATE 2023-07-13

METERING SKID
6. FLOW COMPUTER
ARES CONTROL S.A. de C.V.
Circuito Cronistas No.208
Col. Ciudad Satélite, Naucalpan de Juárez
Estado de Mexico. C.P: 53100
T: (55) 5374 3577, (55) 5374 3578
F: (55) 5572 0910
CARTA GARANTÍA
Naucalpan, Estado de México a 05 de mayo del 2023
Ares Control S.A. de C.V., GARANTIZA el equipo abajo listado, contra defectos en los
materiales que los constituyen, mano de obra, defectos de fabricación y vicios ocultos, bajo
condiciones normales de almacenamiento, uso, operación y mantenimiento.
Constando que han sido controlados, revisados y supervisados durante su proceso de
fabricación, de acuerdo a los controles de calidad que nuestro proveedor mantiene
implementados.
La GARANTÍA se hace válida a partir del 05/05/2023 y hasta el 05/05/2024, esto de acuerdo
con lo comercialmente contratado, siendo: 12 meses a partir de la instalación del equipo o
por la garantía de 18 meses después de la fecha de entrega, lo que suceda primero.
DESCRIPCIÓN:
Cantidad: 1 pieza
Equipo: Computador de Flujo
Marca: ABB
Modelo: XFC G4 6200/6201 EX
Número de Serie: T203512974
Atentamente:
Ing. Abrahám David Fernández Zamudio

Gerencia de Control de Calidad
1
ARES CONTROL S.A. de C.V.
Circuito Cronistas No.208
Col. Ciudad Satélite, Naucalpan de Juárez
Estado de Mexico. C.P: 53100
T: (55) 5374 3577, (55) 5374 3578
F: (55) 5572 0910
Favor de Considerar las siguientes INSTRUCCIONES
1. Para hacer válida esta garantía es necesario que se comunique en primera instancia
con el responsable de su cuenta Ing. Edgar Vera Cano, para Atención a Clientes
comunicarse al correo: [email protected] y
[email protected] Teléfono: 55 53743577.
2. Es indispensable que se incluya:

a.) Descripción del problema
b.) Copia de carátula de esta póliza.
c.) Número de parte y No. de serie de la parte dañada (presentar de preferencia esta carta).
2
NOTES:
1. WARNING: This drawing does not
completely illustrate the installation
methods required for hazardous
locations. Prior to any installation in a
Classified Hazardous Location, verify
installation methods by the Control
Drawing referenced on the product’s
name tag and national and local codes.
Potentiometer
2 50
R1
Processor Card
CONTRAST 1 49
J1
1
SD CARD
J2
1 16
SD CARD
J3
JTAG
J5
1
4
J4 LITHIUM
XA1
JTAG Connector
Lithium Battery
L1 Connector SENSOR
13 1
14 2
J6
Sensor Connector
Motherboard Motherboard
Primary Component Side Secondary Component Side
REF:N/A
ACTION DOC TYPE TITLE DWG NO. REV SHEET
TOTALFLOW
Products L22126 UD XFCG4EX CIRCUIT BOARD ELEMENTS 2104217 AA 1 OF 3
NOTES:
completely illustrate the installation
Drawing referenced on the product’s
name tag and national and local codes.
J6 DI/PI J5 DO/AI2
Software configureable Uses J13 Jumper:
J3 AI/DO2
Jumper Pin1 to Pin 2 for DOUT
Uses J12 Jumper:
Jumper Pin 2 to Pin 3 for AI2
Jumper Pin1 to Pin 2 for AI
Jumper Pin 2 to Pin 3 for DOUT2
J3 J6 J5
IO Expansion Connector J9 Terminates RS-485
Interfaces with additional I/O on COMM1
mounted on an expansion board
+ AI - + DI - + DO -
J12 J13
1 3 1 3
RTD Probe J19
J8 COMM1
5 I/O EXPANSION
9
4 6 9 8
Security Switch 3
7
2 1 5
S2 6
1
J2 J9
On ETHERNET 5 1
RTD 4
Off
3 3
SECURITY J7 2 S3
USB Port 1
USB CLIENT RESET
2 - 2 50
J4 J21 1 +
PCCU connector J16

1 1 49
PWR
J1
MMI
J20 COMM2
1 2 3 4 5 6 7 8 9 Reset Button
G4
XFC 6200EX
POWER/TERM BOARD
2103344-XXX 1 3
J11
J11 Terminates RS-485 For Pinouts of Term Board

on COMM2 Connectors, SEE SHEET 3
Power Term Board Power Term Board

Primary Component Side Secondary Component Side
TOTALFLOW
NOTES:
completely illustrate the installation AIs/DIs/DOs
Drawing referenced on the product’s J13 Jumper:
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
name tag and national and local codes. Jumper Pin1 to Pin 2 for DOUT
J12 Jumper:
Jumper Pin1 to Pin 2 for AI
Jumper Pin 2 to Pin 3 for DOUT2 J9 Terminates RS-485
J3 J5
on COMM1
+ AI - + DI - + DO -
J12 J6 J13
1 3 1 3
J19
J8 COMM1
(WHT) RTD OUT 5 I/O EXPANSION 9 CTS/RBUS(-)
(WHT) RTD + 4 6 9 8 RXD/RBUS(+)
(BLK) RTD - 3 7 TXD/TBUS(-)
RTD PROBE (BLK) RTD IN 2 1 5
6 RTS/TBUS(+)
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET
RTD 4 1 OPERATE COMM1 COMM1
3 COMM1 SW (RS-232/RS-485)
3
SECURITY J7 2 GND
Note: S3
1 VBATT
Pinouts are shown to
USB CLIENT the outside for clarity, RESET
2 (-)
but all of the Phoenix
J4 J21 1 (+)
connectors are wired
and attached to the
inside. J16
1
PWR
MMI
J20 COMM2
XFCG46200EX
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
CTS/RBUS(-)
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
J11 Terminates RS-485 RRTS COMM2 COMM2

OPERATE COMM2
on COMM2 (RS-232/RS-485)
COMM2 SW
GND
VBATT
REF:N/A
TOTALFLOW
—
B A R T L E S V I L L E , O K , U S A , J U LY, 2 0 17
Measurement Canada Metrology

approval on the EX flow computer
After a tedious 28 months, ABB has finally obtained Category 3 with
Type B Event Logger metrology approval for the XFCG46200/6201EX
flow computer.
This approval allows the device to be utilized for custody transfer measurement in Canada. The previous approval
only allowed the end user to make changes IF the mechanical hard seal was broken and the security switch was
disabled. This resulted in the unit requiring reverification on site and resealing of the device. It involved
considerable coordination with approved inspectors or individuals and significant amount of paper work.
So what does this new Category 3, Type B approval do for our

Canadian customers?
• Category 3: this allows configuration capability, but access is controlled by a software switch or alternate
security means, as appropriate. The minimum method of sealing and securing is: An event logger is
required to secure legally relevant parameters that are accessible through the configuration capabilities
and access to the configuration capability shall be controlled by an appropriate security provision.
Previously, the event logger was not even recognized by Measurement Canada.
• Type B Event Logger: This allows the event records to be utilized as “security”. This was not previously
allowed. There are conditions as to how this is handled. Certain events have to be labeled as “Verification
Events” or “VTE”. These events are clearly identified and additional paperwork and process by the user must
be followed when such configurations etc. that may cause a “VTE” occur.
This approval is a big plus for our organization and future sales to the Canadian market. To my knowledge, this
is only the second flow computer to achieve this type of approval. Previously, a user could not even make an
orifice plate size change without technically requiring an official inspector to verify that the user did this
properly and entered the correct information. Not they can make many configuration changes and normal
maintenance without requiring a more burdensome effort. This approval, AG-0608 Rev 1, was officially signed
by Measurement Canada on June 27, 2017.
Thank you to each and every one that has been involved in the lengthy process of programming, testing,
shipping equipment, phone calls and emails with Measurement Canada, promptly reacting when additional
changes were required and re-testing, etc. Your work in finally achieving this goal, after more than 2 years, is so
gratefully appreciated.
1/1
Startup guide
XSeriesG4
6200/6201EX flow computer
Introduction
This is a quick start guide designed for typical installations only. Installations must be
performed by personnel knowledgeable with the Totalflow® XFCG4 6200/6201EX, the
XFCG4 6200/6201EX User’s Manual and with the installation requirements per local and
national electrical codes.
Read and understand the contents of this start-up guide prior to beginning installation of
the equipment. If for some reason there are questions that are not answered in this guide
or other documentation listed in the following section, call the local Totalflow
representative, or call the technical support number listed on the back page of this guide.
For the sake of this document, the XFCG4 6200/6201EX will be referred to as the G4 EX,
unless otherwise indicated.
Note: The startup guide does not address any requirements for installation of
product(s) in Classified Hazardous Locations. The XFCG4 6200/6201EX is rated for
Class I, Division 1, Classified Hazardous Locations. Refer to the XFCG4 6200/6201EX
User’s Manual for information on these types of installations. If purchased, the
Optional Equipment Unit (OEU) is rated for Class I, Division 2, Classified Hazardous
Locations. Refer to the XFCG4 6200/6201EX User’s Manual for information on
installations involving the OEU and Classified Hazardous Locations.
The nameplate on all certified units refers to the drawing that stipulates installation
specifications in hazardous areas. This drawing is provided electronically on the
document index included with every order or may be located on ABB’s website
(provided in the next section).
Additional reference material
Additional free publications for the XFCG4 6200/6201EX Flow Computer are available for
free download from www.abb.com/totalflow:
XFCG4 6200/6201EX Data Sheet 2104390DS

XFCG4 6200/6201EX Flow Computer User’s Manual 2104349MN
XFCG4 6200/6201EX Parts Replacement Guide 2104385MN
XFCG4 6200/6201EX AI to 2-Wire Transmitter User Drawing 2104334UD
XFCG4 6200/6201EX Circuit board Elements User Drawing 2104217UD
XFCG4 6200/6201EX Comm 1 & 2 Generic RS-232 Wiring 2104215UD
XFCG4 6200/6201EX Comm 1 & 2 Generic RS-485 Wiring 2104216UD
XFCG4 6200/6201EX Illustrated Parts Breakdown 2104346UD
XFCG4 6200/6201EX Pole-mount Bracket 2104424UD
XFCG4 6200/6201EX & µFLOG4 System Reset & RTD Input
TekBull197
Performance Deviation
Assumptions
As the G4 EX was designed for adaptability to a multitude of different scenarios, there can
be several different installation configurations that can be performed, based on the user’s
specific site needs. For the purpose of this guide, the following will look at one possible
standard configuration that is based on a common site scenario. If the presented scenario
differs from the user’s specific site needs, please reference the user’s manual for
additional scenario information.
Note: The G4 EX is shipped from the factory with the lithium battery disabled to
prevent power drainage. Please refer to 3.7 Lithium battery connection in this guide
for instructions on how to enable the lithium battery.
1 Health & safety

1.1 Safety precautions
Read, comprehend, and follow instructions contained in this guide, before and during
equipment installation. Failure to do so could result in bodily injury or equipment damage.
Note: Installation and maintenance must only be conducted by personnel authorized

to work on electrical installations, and in accordance with relevant national and local
codes.
1.2 Potential safety hazards

The G4 EX operates on 12 VDC. However, optional equipment may convert power from
AC to DC.
The G4 EX includes a lithium battery. Avoid physical damage to battery. Do not short
circuit the lithium battery. Improper use or damage to battery could create a risk of fire or
explosion.
2 2104263-001 (AD)
1.3 Safety conventions
Warning: A warning statement indicates a hazardous condition, improper access
method, or improper work technique that could lead to personal injury or death. The
warning text may state the hazard, what to do or not do to avoid the hazard, and what
the result would be if not followed.
Caution: A caution statement indicates an action that could result in equipment

damage or unfavorable results. The text may state the improper action, state what to
do or not do to avoid the equipment damage, and what the result would be if not
followed.
Note: A note is used to indicate useful information or to clarify a concept. It may also
provide information for improved equipment operation, longevity, or troubleshooting.
2 Unpacking and inspection

Unpack the G4 EX and any optional equipment if purchased. Inspect for damage and
missing or incorrect parts.
1. Unpack and inspect the XFCG4 6200/6201EX.
2. Unpack and inspect optional equipment, if purchased.
3. Check for missing, incorrect, or damaged parts.
Contact ABB Representative to replace missing, incorrect, or damaged parts.
3 Basic hardware installation

Although there are alternate methods of installation, it is recommended that technicians
perform the guide procedures in the presented order.
3.1 Mounting the unit
The following will detail the steps for mounting the G4 EX to a 2” mounting pipe. This
installation can be used for either a side pole mount or a stand-alone pole mount
configuration.
Determine where to mount the G4 EX and OEU. The G4 EX should be installed before
the OEU. The G4 EX comes supplied with a mounting kit assembly.
1. Attach the pole mount bracket to the top of the 2” pipe with the U-bolts. Use the
provided hex nuts, flat washers and spring load washers to tighten the pole mount
bracket to the 2” pipe (Fig. 1).
2. The G4 EX will be mounted to the pole bracket in one of three ways based on the
transducer supplied on the unit. Fig. 2 shows the three types of available
transducers. Locate the picture that most closely matches the unit’s transducer.
Proceed to the associated instructions for mounting that unit type.
2104263-001 (AD) 3
Pole
Pole-Mount
Bracket
Washer, Lock
Washer & Nut
(4 Places)
U-bolts (2 places)
Fig. 1: Pole Mount Bracket
Type A Type B Type C

Section 3.1.1 Section 3.1.2 Section 3.1.3
Fig. 2: Transducer Types/Mounting Options

3.1.1 Type A
1. Position and align the provided back clamp to the pole mount bracket (Fig. 3).
2. Set the G4 EX and transducer within the recessed grooves of the back clamp.
3. Attach the device to the brackets with the provided U-bolt and associated hardware.
4. Continue to 3.1.4 Orient the unit and attach pressure tubing.
4 2104263-001 (AD)
Pole-Mounted
Bracket
Mount flat bottom of

the unit flush against Washer, Lock
the bottom part of the Washer & Nut
bracket to ensure (2 Places)
additional support
XFCG4EX
U-Bolt
Fig. 3: Type A installation configuration

3.1.2 Type B
Note: The Type B installation configuration comes from the factory with the
transducer already enclosed in two attached mounting brackets.
1. Remove the lower two hex screws and associated hardware from the transducer’s
attached mounting brackets. Align the transducer’s bottom mounting holes with
those on the pole mount bracket (Fig. 4).
Pole-Mounted
Bracket
Washer, Lock
XFCG4EX Washer & Nut
(2 Places)
Bolts
(provided with the
XFCG4EX)
Note: The shorter (2)
bolts located on the
bottom of the Support
Brackets attach to the
Pole-mount Bracket.
Brackets
(provided with the XFCG4EX)
Fig. 4: Type B installation configuration
2104263-001 (AD) 5
2. Replace the hex screws and associated hardware through their respective mounting
holes on the mounting brackets and into the pole mount bracket and tighten.
3. Continue to 3.1.4 Orient the unit and attach pressure tubing.
Note: If the user received this type of configuration from the factory, there may be
additional parts within the provided mounting kit assembly that are not used.
3.1.3 Type C
1. Position and align the provided back clamp to the pole mount bracket (Fig. 5).
2. Set the G4 EX and transducer within the recessed grooves of the back clamp.
3. Attach the device to the brackets with the provided U-bolt and associated hardware.
Pole-Mounted
Bracket
Mount flat bottom of the unit Washer, Lock

flush against the bottom part of Washer & Nut
the bracket to ensure additional (2 Places)
support
XFCG4EX
U-Bolt
Fig. 5: Type C installation configuration

4. Continue to the next section.
3.1.4 Orient the unit and attach pressure tubing
1. To verify direction of flow, look at the (+) sign on the transducer tag. Plus (+)
indicates high side (upstream), while the opposite side will indicate the low side
(downstream); therefore, flow is from (+) to downstream. The user will not be able to
see these without removing the 4” bolt clamp. If this mounting causes the device to
face the wrong direction, loosen the Allen head set screw on the neck of the device,
and turn the unit clockwise until the unit is facing the correct direction. If the unit
becomes tight before achieving the correct position, turn counterclockwise (no more
than 360 degrees) until the correct position is obtained. Re-tighten the set screw.
2. Connect the stainless steel tubing from the manifold to the tap valve(s). Use large
bore, short, equal length gauge lines with a downward slope to taps (at least 1” per
foot). With the manifold equalized to avoid damaging the device’s transducer, apply
pressure to the manifold. Upon completion, check for leaks.
6 2104263-001 (AD)
3.2 Installing and wiring the RTD
RTD kits are available through ABB Totalflow. If the user orders the RTD but provides
their own thermowell, the U-length must be provided. Various sizes of thermowells are
available from Totalflow, but the U-length or insertion depth is required.
The following procedure assumes a Totalflow kit was provided.
1. Install the thermowell into the meter run, and tighten (Fig. 6). Install the ½” stainless
steel nipple into the thermowell, and tighten. Separate the union, and install the
female end of the union along with its nut onto the nipple. Once completed, tighten.
With the RTD head still loose, screw the male end of the union into the bottom of the
head, and tighten.
Fig. 6: RTD probe assembly

2. Insert the RTD sensor probe down through the top of the RTD head. Hold the sensor
probe from underneath the head, turn the probe and screw the spring into the
threaded hole in the terminal block. If the probe came with a terminal block, remove
it since there should be a terminal block already mounted inside the RTD head.
3. Guide the sensor probe down through the bottom half on the union. As the two
halves of the union come together, the user should feel some resistance when the
sensor probe contacts the bottom of the thermowell. The user should see the top of
the probe (3/4” max.) right above the terminal block as they push the two halves of
the union together. If the assembly is too long or too short, the user may need to
change-out the nipple for one of a differing length.
4. Slide the union nut up, and screw onto the top half of the union. Do not tighten. Align
the RTD head so that the connecting conduit or cable is pointing in the desired
direction, and then tighten the union.
5. Wire the RTD probe at the terminal block (Fig. 7). Install the probe wire spade lugs
under the small screw heads. One color (typically white) is one side of the RTD and
will go to the RTD Out & + connections on the G4 EX J8 connector. The other color
(typically red) is the other side of the RTD and will go to In & - connections on J8.
6. Remove J8 connector from the G4 EX termination board and begin field wiring (Fig.
11).
Warning: All wiring must meet local and national electrical codes.
2104263-001 (AD) 7
White - Customer
Connection
White - Customer
Connection
Red - Customer
Red - Customer
Connection
Connection
Fig. 7: RTD terminal block
3.3 Installing ABB OEU (optional)

The ABB OEU (if purchased) may contain the power supply, battery and any optional
communication equipment. If the user is providing their own power and/or communications
enclosure, refer Fig. 11 for field wiring.
Warning: All wiring between the G4 EX and the OEU must be installed per local and
national electrical codes.
1. Using the supplied installation kit, mount the OEU on a 2” pipe or flat surface.
Fig. 8: OEU pipe or panel mount

2. If using an external AC power supply, run the DC output wiring to the OEU. Remove
one of the rubber plugs, and using an approved cord connector, install DC cable into
the OEU. If using Totalflow’s external AC power supply, it can be connected directly
to the side of the enclosure. Refer to the User Manual listed in the front of this guide
for additional instructions if needed. Do not apply power.
3. Mount fully charged battery inside the optional enclosure or customer supplied
equipment if required (Fig. 9). Do not make the connection.
8 2104263-001 (AD)
Note: To extend the life of the battery pack, fully charge the battery prior to installation.
A system using solar panels may not fully charge the battery. Also, a fast charge,
which the solar panel cannot provide, improves the life of the battery.
DOOR
TO COMMUNICATIONS EQUIPMENT
RED
BRN
GRN
GRA
BLK
WHT
ORN
BLU
VIO
MTG
MTG
SHLD
YEL
ORN
YEL
BLU
VIO
GND
RED
BRN
GRN
GRA
GND
SHLD
BLK
WHT
FCU
TO
Battery (-)
Battery (+)
Solar Panel (-)
Solar Panel (+)
To Battery
Comm Output
To 6200EX
COMPARTMENT
BATTERY
COMMUNICATIONS
BRACKET
Fig. 9: OEU rotated 90 degrees for enlargement
2104263-001 (AD) 9
3.4 Installing solar panel (if applicable)
One solar panel and cable
Totalflow materials supplied Two U-bolts and fastening hardware
One solar panel bracket
Cable ties
Customer materials supplied One 9-inch or greater extension of 2-inch pipe
One 2-inch collar
Note: Step 1 is not required if the pipe is tall enough without the extension.
1. Attach 2-inch pipe collar and pipe extension to the top end of the OEU mounting pipe
or install mounting pipe (Fig. 10).
2. Install the solar panel on the mounting bracket with the provided hardware. Attach
the solar panel mounting plate to the top end on the 2-inch pipe with the U-bolts and
associated mounting hardware. Do not tighten the U-bolts until the solar panel has
been correctly oriented.
3. If needed, connect the solar panel power cable to the solar panel connector on the
back of the unit. Do not connect the other end of the solar panel wiring to the OEU
until all the steps are completed and the main battery pack has been connected.
4. Position the solar panel to face south in the northern hemisphere and north in the
southern hemisphere. Tighten the U-bolts securely to avoid movement by wind or
vibration.
5. Check the solar panel polarity using a digital voltmeter to insure that (+) and (-) wires
are properly identified.
Solar Panel
Mounting Bracket
U - Bolts
2 " Extension Pipe
Solar Panel
Cable
2 " Collar
Fig. 10: Solar panel mounting

6. Remove one of the hole plugs from the OEU, and install the cord connector. Remove
the nut, sealing ring and rubber grommet from the cord connector. Slide the nut,
sealing ring and rubber grommet over the cable, and insert the cable through the
body of the cord connector.
Note: To prevent moisture from entering the enclosure, allow the cable to dip below
and then rise to the access hole. This provides a path for rainwater away from the
access hole.
10 2104263-001 (AD)
7. Allow enough power cable to extend into the unit for connection to the Array Input +/-
terminals. Do not make connection.
8. Secure the solar panel cable using the grommet, sealing ring and nut.
3.5 Install conduit, cabling, and field wire connections
1. Run the appropriate conduit and wiring between the G4 EX and the OEU or
customer supplied equipment for power, IO, and optional communication equipment.
2. Verify the wiring is correct, per drawings. If the enclosed wiring interconnect
drawings (WIs) or user drawings (UDs) conflict with illustrations in this start-up guide,
the drawing should take precedence.
Warning: All wiring must meet local and national electrical codes.
3. Wire all connections inside of the G4 EX using Fig. 11, Table 1 and Table 2. This
may include communication to COMM1 (J19), COMM2 (J20), input/output (J3–J5),
optional IO expansion (J2), Ethernet (J7) and Power (J16).
4. Set appropriate communication terminations and onboard security to proper
positions.
J13 Jumper:
Jumpers for RS-485 Mode Only
AIs/DIs/DOs
If this is the last board on the bus, or if it is the
only board, jumper J9, Pin 1 to Pin 2.
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
There are a pair of jumper wires required for

RS-485 only: wire J19, Pin 9 to Pin 7 and
Wire Pin 8 to Pin 6 on the terminating board.
J12 Jumper:
Jumper Pin1 to Pin 2 for AI For all intermediate boards, Jumper J9, Pin 2
Jumper Pin 2 to Pin 3 for DOUT2 J5 to Pin 3
J3
+ AI - + DI - + DO -
J9 Terminates RS-485
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(BLK) RTD - 3
RTD PROBE 1 5
7 TXD/TBUS(-)
(BLK) RTD IN 2 6 RTS/TBUS(+)
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET 1
4 OPERATE COMM1
RTD
3 COMM2 SW
3
SECURITY J7 2 S3 GND
1 VBATT
USB CLIENT RESET

2 (-)
-
J4 J21 1 (+)
+
J16
1
PWR
MMI
J20 Note:
COMM2 Pinouts are shown to the outside for clarity,
but all of the Phoenix connectors are wired
XFCG46200EX and attached to the inside.
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
CTS/RBUS(-) Jumpers for RS-485 Mode Only
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
Fig. 11: G4 EX termination board
2104263-001 (AD) 11
3.6 Termination board, pin outs and communication
The following represents the G4 EX Termination board (2103344) communication pin
outs. Make any required connections for communication in both the G4 EX and inside the
optional OEU or customer supplied equipment.
Table 1: Comm 1 board pin outs
COMM1 (J19)
Comm 1 (J19) – RS232
RS485 RS422
Pin 1 VBATT (12V +) VBATT (12+)
Pin 2 Ground Ground
Pin 3 Switched Output Switched Output
Pin 4 Operate Operate
Pin 5 Mirror RTS Remote Request To Send
Pin 6 Request to Send (RTS) Transmit Bus + TBUS+ TBUS+
Pin 7 Transmit Data (TXD) Transmit Bus - TBUS- TBUS-
Pin 8 Receive Data (RTD) Receive Bus + RBUS+ RBUS+
Pin 9 Clear to Send (CTS) Receive Bus - RBUS- RBUS-
Table 2: Comm 2 Board pin outs

COMM2 (J20)
Comm 2 (J20) – RS232
RS485 RS422
Pin 1 VBATT (12V +) VBATT (12+)
Pin 2 Ground Ground
Pin 3 Switched Output Switched Output
Pin 4 Operate Operate
Pin 5 Mirror RTS Remote Request To Send
Pin 6 Request to Send (RTS) Transmit Bus + TBUS+ TBUS+
Pin 7 Transmit Data (TXD) Transmit Bus - TBUS- TBUS-
Pin 8 Receive Data (RTD) Receive Bus + RBUS+ RBUS+
Pin 9 Clear to Send (CTS) Receive Bus - RBUS- RBUS-
3.7 Lithium battery connection

The following are the steps for installing and verifying the connection on the lithium battery.
The lithium battery is disabled when shipped from the factory. The user will need to
connect the battery before continuing.
1. To connect the battery, locate battery connector behind and to the lower right side of
the display (Fig. 12).
2. On the G4 EX main electronic board, line up the lithium battery cord connection with
J5. Ensure the lithium (+) red is on top (pin 1) and the (-) black (pin 4) is on the
bottom. Slide the cable connector onto the pins carefully.
Note: For testing the battery voltage in a confined space, place the ground lead of a
voltmeter on bare metal, such as the plate behind the display, and put the positive lead
on the bottom solder pad. Be careful to not place the lead against ground.
12 2104263-001 (AD)
J5
1
4
LITHIUM
L1
Lithium Battery
Connector
Fig. 12: Lithium battery connection on main electronic board

3.8 Power up the G4 EX
1. Verify that the front and back covers are screwed onto the G4 EX.
2. Apply power:
a. If using optional OEU with battery power, connect battery to battery connector
mate.
b. If using optional external AC/DC power supply, connect DC power to charger
regulator inside the OEU. Apply external AC power to power supply.
c. If using customer supplied power to the G4 EX, make power connection.
3. Observe the LCD on the G4 EX; the display should power up, display Warm Start
information and then begin scrolling through the default display items. This insures
that the components and wiring are good. If the unit does not scroll as expected or
an alarm symbol is displayed, additional information is presented later in this guide.
4. If using the optional solar panel, connect the solar panel power cable to the Array
inputs on the charger/regulator inside the OEU.
4 PCCU configuration, setup, and startup

The following information details the steps that are necessary for the user to set up the
flow computer parameters within PCCU.
1. Connect the laptop running PCCU to the unit. Configure the G4 EX using Entry
mode in PCCU:
- Set the date/time
- ID
- Location
- AGA setup
2. In Calibration mode, verify the registers for static pressure (7.4.1), differential
pressure (7.4.0) and temperature (7.4.2).Select TF Device Connected and uncheck
Use Fixed TF, if a temperature input device is used.
Note: If calibration is needed or required by company policy, follow the calibration

procedure detailed in the User Manual via link provided under Additional reference
material inside the front cover of this guide.
3. Verify that the unit is calculating the volume correctly. Watch the display, or look at
the Current Values in the Entry mode of PCCU. Collect data, and review the event
and characteristic files to insure all parameters are set properly.
2104263-001 (AD) 13
4. Optional – When the user is sure that all setup and calibration has been completed
and the unit is on line and calculating volume, it is recommended that a Reset
Volume command be sent within PCCU Entry mode. This allows the unit to have a
starting point for good, live data. The Reset Volume will be recorded in the Events
file to mark the date and time.
5. Optional – If remote communication and/or onboard/expansion IO is used,
additional setup may be required in PCCU to make applications function properly.
PCCU Help files are available by clicking the Help button in the lower right corner of
each screen. Likewise, Help files may be searched by entering a search parameter
in the Help window search field.
5 General information
Note: To recharge a battery, a quick charge removes the buildup in the battery much
more effectively than a “trickle charge.” A battery slowly drained by low light conditions
on a solar charged system or setting in storage is less likely to recover than a battery
pack that was discharged quickly. Store batteries in a cool environment for less
drainage.
5.1 Wiring documentation

Specific wiring drawings are sent with each G4 EX, based on the options ordered. Many
wiring diagrams, including communications, are available on the internet at
http//:www.abb.com/totalflow. To see if a diagram is available, move to the web site, and
select Services. Next, click the Customer Service Download Section link and then the
Various Drawings link. Navigate to the desired drawing, and select.
5.2 Remote communication/WinCCU
The following information pertains to the communication between the G4 EX and the host
(typically, WinCCU).
To communicate with the host, the G4 EX uses the remote communications port (COMM
1) that can function as RS-232 or RS-485. If the 6270 OEU was ordered, the user has
several communication options to choose from.
After installation of the G4 EX, and with the communications path complete, the user
needs to enter the appropriate communication parameters. In most instances, the G4 EX
was shipped with COMM 1 set up for Totalflow (TF) Remote Protocol. If not, select the
protocol using the Entry mode within PCCU (Figure 10). The protocol must be selected
first for the appropriate communication parameters to be displayed. A blinking telephone
poll symbol " " in the annunciator position A8 (default) indicates that the COMM 1 port is
active. The symbol may not be visible, if the baud rate is above 2400. See the Alarms and
Status Codes section for a full description of the alarm characters, locations and
descriptions.
5.3 Other communication options
After selecting the protocol, verify the other communication parameters. All
communication parameters, with the exception of modems, are found on the Setup and
Advanced tabs (Fig. 13). Modem parameters have their own tab. Systems are shipped
with default settings for communications but may need fine tuning. The Schedule tab
parameters are only required if the user wants to power up the communication port and
communication device on and off at designated times to conserve power.
14 2104263-001 (AD)
Fig. 13: Communications Setup
5.4 Standard displays
Items that appear on the device’s display are user-configured; however, based on the
measurement application, units will be shipped with some default display items. The
following table is a typical set of default displays for an AGA-3 application. Engineering
units may vary from those shown, if the device supports the Selectable Units feature.
Description Standard display

DATE/TIME
Current Date and Time (24 hour clock)
MM/DD/YY HH:MM:SS
Yesterday’s Percent DP Low Limit Yest DP Low
Percent time below DP Low Set Point NN PERCENT
Yesterday’s Percent DP High Limit Yest DP High
Percent time above DP High Set Point NN PERCENT
Current Flow Rate Flow Rate
Programmable SCF, MCF or MMCF NNNNNN.N SCF/HR
Total Accumulated Volume Total Accum. Volume
Programmable SCF, MCF or MMCF NNNNNN.NN MCF
Battery Voltage
Battery Voltage (displayed in volts)
NN.N VOLTS
Station ID (ID of the box) Station ID
Differential Pressure Diff. Pressure
Inches H2O NNN.N IN. H2O
Static Pressure Absolute Static Pressure
PSIA NNN.N PSIA
Flowing Temperature Temperature
°F NN.N DEG. F
Yesterday’s Volume Yesterday’s Volume
Programmable SCF, MCF or MMCF NNNN.N MCF
Last Calc. Volume
Previous Calculation Period Volume
NNNN.N SCF
Device ID (Individual application ID) Device ID
Orifice Diameter
Orifice Diameter
N.NNNN Inches
2104263-001 (AD) 15
6 Troubleshooting information
6.1 Visual alarm and status codes
After the G4 EX completes recording the Log Period flow and operational records, the
LCD will display any alarm conditions that have occurred. Also, the date, hour and type of
alarm conditions are stored in the G4 EX’s memory. Status codes are also displayed when
the conditions exist. An alarm or status code can be a character, letter or symbol and will
appear on the lower right side of the LCD screen (Fig. 14). Descriptions of each code are
described in Table 3.
Note: Applications in a G4 EX device can be assigned to any annunciator. To verify

the current assignments, see Annunciator under Display in the PCCU Entry mode (Fig.
15).
4 characters high x 14 characters across
Name
Value
Unit A1 A7
B L
L L
A2 A8
Fig. 14: Annunciator locations
Fig. 15: Annunciator assignments
16 2104263-001 (AD)
Table 3: Visual alarm/status codes
Codes Description
System
Low Lithium Battery Alarm: When LL (low lithium) is displayed, the lithium
L
L battery voltage is below 2.5 VDC. A new lithium battery measures
approximately 3.6 VDC.
Communications
→ Transmitting Data.
← Receiving Data.
! Nak. Negative Acknowledgement w/packet list.
+ Ack. Positive Acknowledge of receipt of request.
Waiting for Ack. Waiting for response after transmission.
? Exception Alarm Processing.
ID Recognized.
Listen Cycle. Flashes if this remote port is active and running Totalflow
Remote Protocol. Flashes in sync with listening cycle that occurs at 1, 2
or 4 second intervals. May not be visible if baud rate is faster than 2400.
MODBUS ASCII: Modbus ASCII protocol is selected for the port
M
assigned to this annunciator.
MODBUS RTU: Modbus RTU protocol is selected for the port assigned
m
to this annunciator.
Local Protocol. Displayed when PCCU32 port is active and running
L
TOTALFLOW Local Protocol.
n Network (Ethernet)
u USB
Measurement application
B Back Flow Condition: Visible only when the DP variable is being
F displayed.
Zero Flow Condition: Visible only when the Flow Rate variable is being
Z
displayed.
Hold: Displayed when PCCU32 is in Calibration Mode and has a
H
measurement application in Hold mode.
Alarm Condition. Need to view alarm. The user may need to compare
A application limits to current values to determine where the alarm
condition is present.
A to D Failure. Displayed if A to D Converter’s Differential Pressure,
A Absolute Static Pressure or temperature readings exceed maximum
D
counts or are less than minimum counts.
Display Application
A number represents the Display Group number currently being
1
displayed.
The displayed item’s value is above the Data High Limit value specified
↑ on the display Item Setup screen.
The displayed item’s value is below the Data Low Limit value specified
↓ on the display Item Setup screen.
2104263-001 (AD) 17
6.2 G4 EX display does not scroll as expected
When power is first applied, the unit should quickly move through its startup routine and
begin cycling through the pre-programmed display items. If the display does not scroll
after startup and/or looks similar to the following (part numbers are example only), preform
the next steps.
XFC6200EX Prom
2101715-001
(Copyright)
1. Disconnect the main power, and then re-connect it.
2. After power is reconnected, the user should see something similar to the following:
Verifying Flash or COLD FLASH
XXXXX Flash 2101715-001
Checksum = Passed 6200EX Flash
XXXX = XXXX 2101715-001
(COPYRIGHT)
3. If the display still does not scroll, try disconnecting the power and re-connecting it
again.
4. If still no success, perform the following:
a. With PCCU, connect to the unit, and establish communication.
b. Move into Terminal mode, and type: 0.0.0=COLD. The unit should go through a
Cold Start procedure and then begin scrolling. If this does not happen, it may be
necessary to call a Totalflow customer service representative for additional
assistance. Refer to the contact information on the back of this guide.
6.3 Communications troubleshooting
A new radio or modem system that does not communicate is often difficult to troubleshoot
because proper operation has never been proven, and all the initial hardware and software
settings are suspect. More than one problem can be present. This causes component
replacement to be an inadequate troubleshooting technique. A checklist follows to serve
as an aid in pinpointing potential causes:
- Does the “ ” symbol flash (Totalflow Remote Protocol only) with the Listen
Cycle time in the A8 display (default position)? If no:
Note: The user may not see the “ ” symbol flashing where baud rates are set higher
than 2400. The user may need to set the baud rate to 1200 to see if the port is active
and then set it back to the desired baud rate.
− The protocol needs to be selected in the Entry mode using PCCU.

− Inadequate DC voltage (9 volts minimum) or as specified by the user in the
Station Setup of PCCU Entry mode.
− Insure the base radio is working for other locations.
− Verify the Station ID and Device ID matches with WinCCU and is the only
device with that ID.
− Verify baud rate, stop bits, security code and listen cycle time are the same
as WinCCU.
− Verify WinCCU is using packet protocol. The G4 EX only supports DB2
packet protocol.
18 2104263-001 (AD)
− Verify the wiring from the G4 EX to the OEU enclosure terminal strip and
terminal strip to radio (if used) or verify wiring from and to the customer
supplied equipment.
− Verify the cable from the radio to the antenna.
Note: To check for wiring shorts or opens with two or more wire connections, use a
multimeter set on continuity (resistance). Check two wires at a time from one device
to another. If the black and white wires are to be tested, disconnect both wires at both
ends, and put one probe on black and the other on white. The meter should read OL
or OFL (over range), if no shorts. Jumper the two wires at the other end. The meter
should read a low resistance, if no opens. This method requires only one end of the
wiring to be tested, no matter how far the devices are apart.
- If a radio is used, verify the directional antenna with the correct frequency
range is pointed toward the base +6°. The antenna should be mounted
vertically with the vanes perpendicular to the ground. Verify that the radio is
good with the same frequencies used to the base radio and remote.
- If a modem is used, verify the dial tone on line at the telephone company’s
termination box by checking Tip and Ring. Check the wiring from the phone
company’s box to the dial-up modem. If cellular, also check for proper Tip and
Ring voltage availability. Insure the phone number is correct in the G4 EX and
WinCCU.
Note: The telephone company uses a 48 volt power supply, so the typical on-hook
voltage between Tip and Ring wires should be something less than 48 volts.
Measuring another way, Tip to ground is approximately zero volts, and Ring to ground
is approximately -48 volts.
In the off-hook condition, Tip to ground will be approximately -20 volts, while Ring to
ground will be approximately -28 volts or approximately 8 volts between Tip and Ring.
6.4 Low power caused by communication drain

In situations where radio communication is required, the power requirements of some
radios might comprise the autonomy of the system. This problem can be handled in the
following ways:
- Upgrade to a 42-amp-hour battery or two 26-amp-hour batteries (or as
enclosure allows).
- Use low power radios such as the FreeWave® Spread Spectrum radio.
- Use radios that have a Sleep feature which allows the radio to go to sleep via a
control line going low and wakes up when the control line is driven high or
allowed to float. Totalflow has a Power Scheduler application that runs in the
G4 EX and switches an output called COM1SW on COMM 1 and COM2SW on
COMM 2. This is a FET output which, when turned ON, provides +12VDC.
6.5 Additional troubleshooting
Additional troubleshooting materials may be found in the user manual referenced earlier
in this guide.
2104263-001 (AD) 19
ABB Inc. Note
Measurement Products We reserve the right to make technical changes or
Main Office modify the contents of this document without prior
7051 Industrial Blvd. notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB does not accept any
Bartlesville, OK 74006 responsibility whatsoever for potential errors or
USA possible lack of information in this document.
Tel: +1 918 338 4888 The original US English version of this manual
+1 800 442 3097 shall be deemed the only valid version. Translated
Fax: +1 918 338 4699 versions, in any other language, shall be
maintained as accurately as possible. Should any
discrepancies exist, the US English version will be
considered final. ABB is not liable for any errors
ABB Inc. and omissions in the translated materials. Any and
Measurement Products all derivatives of, including translations thereof,
3700 W Sam Houston Pkwy South shall remain the sole property of the Owner,
Suite 600 regardless of any circumstances.
Houston, TX 77042 We reserve all rights in this document and in the
USA subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
Tel: +1 713 587 8000 utilization of its contents - in whole or in parts – is
Fax: +1 713 266 4335 forbidden without prior written consent of ABB.
Copyright© 2014 ABB
All rights reserved
2104263-001 (AD)
*2104263-001*
2104385-001 – rev. AA
G4 6200/6201EX Parts Replacement

Application Information
TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................. 1
1.1 Overview ..............................................................................................................1
1.2 Purpose ................................................................................................................1
2.0 INSTRUCTIONS.................................................................................................. 1
2.1 2104353–501/503 Motherboard Replacement .....................................................2
2.2 2103344–001 Termination Board Replacement...................................................6
2.3 2101650–002 Display Replacement ....................................................................8
2.4 2104199–001 Lithium Battery Assembly Replacement......................................10
2.5 I/O Daughter Card Replacement ........................................................................11
2.5.1 I/O Daughter Card Installation ........................................................................... 13
2.5.2 Generic Wiring Diagram..................................................................................... 13
2.6 EXIMV Replacement ..........................................................................................14
1.0 INTRODUCTION
1.1 Overview
The XFCG4 6200/6201EX (G4 EX) is a next generation solution for the pre-existing
generation 3 XFC 6200/6201EX. The G4 EX now incorporates the same 32-bit
technology currently used by the G4 XSeries products. By using 32-bit technology,
Windows® CE OS and memory capabilities, the G4 EX is a versatile product offering
for production automation and measurement projects.
Along with this new functionality, the hardware capabilities have been expanded to
meet the demands of targeted market applications in production automation and
natural gas distribution. These hardware features are utilized to enhance the system
integration capabilities with existing Totalflow products as well as existing third-party
control SCADA systems.
Additionally, the use of Bluetooth technology for local MMI connectivity is poised to
enhance the product for multi-tube application where this type of user interface has an
advantage in Class I, DIV 1 locations.
The G4 EX offers a product for differential (orifice) or linear (pulse) metering and
automation systems. The G4 EX is an accurate and reliable orifice gas flow computer
with the capability to measure and monitor gas flow in compliance with AGA, API and
ISO standards.
The G4 EX is a low power, microprocessor-based unit designed to meet a wide range
of measurement, control, monitor and alarming applications for remote gas systems.
The XFCG4 6200/6201EX system is certified as explosion-proof and flame proof for
installation in hazardous locations classified as either Class 1, DIV 1 or Class I, Zone
1.
1.2 Purpose
The following information presented in this document will detail the steps for replacing
various hardware component assemblies within the G4 EX. These hardware
components are as follows:
• 2104353–501/503 – (501) Motherboard with Engine Card flashed; (503)
Motherboard only.
• 2104199–001 – Lithium Battery Assembly
• 2101650–002 – Display Assembly
• 2103344–001 – Termination Board
• 2102955-xxx – I/O Daughter Card
• 2101465-xxx – EXIMV
2.0 INSTRUCTIONS
The following information will detail the steps for replacing the various assemblies as
they currently exist within the G4 EX.
2104385-001 Rev. AA Page 1

Remove power from the device, or insure the area is known to
be non-hazardous before removing any enclosure cover. For
further information, refer to the certification drawing indicated on
the device’s nametag, national and local electrical codes.
2.1 2104353–501/503 Motherboard Replacement

The G4 EX motherboard is mounted inside the front end cap, directly behind the
Display assembly.
User applicable connections on this board consist of the following:
• uSD Card (J3)
• Contrast Display Potentiometer (R1)
• LCD Display Connector (J2)
• Lithium Battery Connector (J5)
• Engine Card Connector (XA1)
• Sensor Interface Connector (J6)
• Termination Board Connector (J1)
The G4 EX transducer assembly utilizes a small electronic
board that contains the factory characterization data. This
allows the 2104353-501/503 or the EXIMV assembly to be
individually field replaceable in the event of failures.
Installation and/or maintenance of electric components

should follow guidelines stipulated in the certification
drawings shipped with this unit and adhere to local codes.
The default flash and configuration files that come with the
2104353-501/503 is Selectable Units. If the user requires
the US flash and configuration files, they will need to
contact Customer Service at 800-442-3097 or +1918-338-
4880.
1
41
Figure 2–1 G4 EX Motherboard
Page 2 2104385-001 Rev. AA

Figure 2–2 G4 EX Front End Exploded View
1) Collect data from the unit.

2) Back up the configuration files.
3) Verify that the “LL” battery alarm is not being displayed on the G4 EX LCD.
the device’s nametag and national and local electrical codes.
4) Gain access to the rear termination board by loosening the countersunk hex
socket locking set screw in the rear end cap. Use a 1/16” hex wrench to perform
this task. Upon completion, unscrew the end cap.
5) Disconnect the power connector (J16) from the board mounted connector.
2104385-001 Rev. AA Page 3

Figure 2–3 Termination Board
6) Gain access to the G4 EX motherboard by loosening the countersunk hex

socket locking set screw in the front end cap. Use a 1/16” hex wrench to
perform this task. When completed, unscrew the end cap.
7) After the end cap has been removed, gently pull the display overlay and graphic
overlay plate away from the snap-on standoffs.
8) Using a small slot head screwdriver, remove the four screws that hold the LCD
board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX motherboard, J2 connector.
Lift the board from the device.
Page 4 2104385-001 Rev. AA

Potentiometer
Processor Card (If
R1
Applicable)
CONTRAST
1
SD CARD
J2
1 16
SD CARD
J3
JTAG
J5
1
4
J4 LITHIUM
XA1
JTAG Connector
Lithium Battery
L1 Connector
Primary Component Side
Figure 2–4 G4 EX Motherboard
10) After the LCD board is disengaged, gently remove the lithium battery connector
(J5) from the G4 EX motherboard.
11) Upon removal of the lithium battery connector, snap the board out of the device.
Please note that the board is still connected to the device through the cables in
the back.
12) Unplug the sensor connector cable (J6) and the ribbon cable (J1) from the G4
EX motherboard. Remove the motherboard from the G4 EX device.
Figure 2–5 G4 EX Board Secondary Component Side.
2104385-001 Rev. AA Page 5

If the user has the 2104353–503 motherboard, they will need
to remove the processor card from the removed motherboard
and place it into the new one. This is accomplished by pulling
back the attachment brackets and gently unsnapping the
processor card from its housing. Once completed, take the
processor card and snap it into the replacement
motherboard. Continue to step 13.
13) Take the replacement G4 EX motherboard and attach the sensor cable and the
ribbon cable to their corresponding connectors.
Please note that both the sensor cable and ribbon cable pin
1 wire is red. The red edge (pin 1) of the cable should plug
into the outer most edge of the connector (pin 1).
14) Take the lithium battery cable and attach the cable to its corresponding
connector (J5).
15) Align the mounting holes on the G4 EX motherboard with the standoffs, and
snap the board into place within the device.
16) Once in place, line up the LCD board mounting holes to the G4 EX
motherboard. Gently connect the LCD board into the G4 EX motherboard via
the J2 connector.
17) Take a small slot head screwdriver and attach the LCD board to the G4 EX
motherboard using the four mounting screws.
2.2 2103344–001 Termination Board Replacement

The termination board is mounted inside of the G4 EX back end cap. To access and
remove the termination board, perform the following procedures:
Page 6 2104385-001 Rev. AA

Rear Cap
Term Board
Ribbon Cable
Note: The single red wire on the cable goes
to Pin 1 of both connectors
Stand-off
(4 places)
MMI Connector
Figure 2–6 G4 EX Back End Exploded View

5) Upon unscrewing the end cap, the user will see the termination board. Using a
¼” socket wrench, unscrew the four socket mounting screws that hold the
Termination board in place.
6) Depending on the configuration that the user selected from the factory, remove
either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21).
7) Next, remove the Comm 1 (J19), Comm 2 (J20) and power (J16) connectors.
2104385-001 Rev. AA Page 7

8) Upon completion, remove the ribbon cable from the J1 connector. This will
enable the user to remove the Termination board from the G4 EX device.
Figure 2–7 Termination Board Secondary Component Side
9) Take the replacement Termination board, and attach the ribbon cable to the J1
connector.
Please note that the ribbon cable pin 1 wire is red. The red
edge (pin 1) of the cable should plug into the outer most
edge of the connector (pin 1).
10) Depending on the configuration that the user selected from the factory, attach
either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21) to their
respective connection.
11) Next, attach the Comm 1 (J19), Comm 2 (J20) and power (J16) connections to
their respective connectors.
12) Upon completion, take the four socket mounting screws and attach the
Termination board in the G4 EX device.
2.3 2101650–002 Display Replacement

The G4 EX display has a dedicated interface to the motherboard from the 4x16 Liquid
Crystal Display (LCD) via a 14-pin connector.
The LCD board is mounted inside of the G4 EX front end cap. To access and remove
the display board, perform the following procedures:
Do not remove the lithium battery, since it provides power

to the RAM. It is recommended that historical flow data be
downloaded before accessing and removing the LCD board
to prevent the potential loss of stored data.
Page 8 2104385-001 Rev. AA

Figure 2–8 Display Assembly

Remove power from the device, or insure the area is known

to be non-hazardous before removing any enclosure cover.
For further information, refer to the certification drawing
indicated on the device’s nametag and national and local
electrical codes.
4) Gain access to the rear Termination board by loosening the countersunk hex
5) Disconnect the power connector (J16) from the board mounted connector.
6) Gain access to the LCD assembly by loosening the countersunk hex socket
locking set screw in the front end cap. Use a 1/16” hex wrench to perform this
task. When completed, unscrew the end cap.
2104385-001 Rev. AA Page 9

8) Using a small flat head screwdriver, remove the four screws that hold the LCD
board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX motherboard, J2 connector.
Lift the board from the device.
10) To reinstall the LCD board, repeat steps 8 through 9 in reverse order. Do not
over tighten screws.
11) Once the LCD board is reinstalled, apply power to the G4 EX (step 5), and
verify that the information displayed on the LCD is correct.
12) Adjust the contrast potentiometer, R1, for optimal display.
To adjust the display contrast, use an extra small screwdriver

to turn the potentiometer, R1, completely clockwise. After
completing this, turn the screw back counter clockwise until the
screen is readable.
13) Replace the graphic overlay plate that was removed earlier.
2.4 2104199–001 Lithium Battery Assembly Replacement

Do not remove power from the unit. Loss of power to the unit will
initiate a cold start. All data and configuration files will be lost.

2) Back up the configuration files following the instructions.
Remove power from the device, or insure the area is known to be

non-hazardous before removing any enclosure cover. For further
information, refer to the certification drawing indicated on the
device’s nametag and national and local electrical codes.
3) Gain access to the G4 EX motherboard by loosening the countersunk hex

socket locking set screw in the front end cap. Use a 1/16” hex wrench to
perform this task. When completed, unscrew the end cap.
5) Upon completion, gently remove the lithium battery connector (J5) from the G4
EX motherboard.
Page 10 2104385-001 Rev. AA

Figure 2–9 Lithium Battery Connector
6) Once the lithium battery connector is removed, snap the board out of the
device. Please note that the board is still connected to the device through the
cables in the back.
7) After the G4 EX motherboard has been partially removed, unplug the sensor
connector cable (J6) and the ribbon cable (J1) from the G4 EX motherboard.
This will allow the board to be completely removed from the device.
8) The user will now see a manufacturing plate. The lithium battery assembly is
located on the back of this plate in a small battery enclosure. Carefully remove
the plate from the snap-on standoffs.
9) The lithium battery assembly is attached to the manufacturing plate by a Velcro
strip. Gently remove the lithium battery from the Velcro strip.
10) Take the new lithium battery and attach the Velcro edge of the battery to the
Velcro strip in the battery enclosure on the manufacturing plate.
11) Once the lithium battery is attached to the manufacturing plate, snap the plate
back into the device using the appropriate standoffs.
12) Take the G4 EX motherboard and attach the sensor cable and the ribbon cable
to their corresponding connectors.
Please note that both the sensor cable and the ribbon
cable pin 1 wire are red. The red edge (pin 1) of the cable
should plug into the outer most edge of the connector (pin
1).
13) Attach the lithium battery cable to its corresponding connector.

14) Align the mounting holes on the G4 EX motherboard with the standoffs, and
snap the board into place within the device.
15) Replace the display and graphic overlays that were removed earlier.
2.5 I/O Daughter Card Replacement

The following information provides an outline for the installation and application of the
I/O daughter card within the G4 EX.
2104385-001 Rev. AA Page 11

The I/O daughter card may already be installed in new units, if configured, or can be
added as an upgrade kit to pre-existing units. The following information will address
the installation for the upgrade kit.
Do not install the I/O daughter card until told to do so in

these instructions. Installation prior to flashing the unit may
cause some older model units to not boot.
This card expands the capabilities of the explosion-proof flow computer by adding an
additional 12 points of fixed analog and digital I/O points. Specifications for the I/O
daughter card are as follows:
• Analog Points
3 each 0-10V (10K ohm impedance) analog inputs
1 each 0-20 mA (SINK mode) analog output
• Digital Points
4 each digital inputs/pulse inputs
4 each digital outputs (optically-isolated type 1A switches capable of
switching 200 mA of 48 VDC or 40 VAC)
If the unit is currently operating, data must be collected from the unit and the
configuration files saved prior to beginning this procedure.
Termination
Board
J21 PCCU
Connector
I/O Daughter
Card
Figure 2–10 I/O Daughter Card
Page 12 2104385-001 Rev. AA

2.5.1 I/O Daughter Card Installation
1) Gain access to the Termination board by loosening the countersunk hex socket
locking set screw in the rear end cap. Use a 1/16” hex wrench, and then
unscrew the end cap.
2) Remove the four existing 6-32 x .625 standoffs and washers (if installed). Do
not misplace as they will be needed later in this procedure.
3) Install the new standoffs (6-32 x .75”) and washers supplied in the kit into the
four corner mounting holes in the Termination board.
4) Center the I/O card over the Termination board (green phoenix connectors
facing out). Align the four screw holes at each corner. This should allow the I/O
card to interconnect with the I/O Expansion connection on the Termination
board. Gently apply pressure to the I/O card in the two areas located on either
side of the connector until the board is seated.
5) Using the four 6-32 x .625 standoffs removed previously, connect the I/O card to
the Termination board. Do not over tighten.
6) Reapply power to the unit.
2.5.2 Generic Wiring Diagram

This drawing does not completely illustrate the installation
methods required for hazardous locations. Prior to any
installation in a Classified Hazardous Location, verify the
installation methods by the Control Drawing referenced on the
product’s name tag and national and local codes.
2104385-001 Rev. AA Page 13

DB-9 Connector to XFCEX Board I/O
Expansion Connector (J2)
(Mounted on Back) XFCEX Board (Ref)
J3 J6 J5
The DI/PI inputs will accept sensor inputs
which meet the IEC-60947-5-6 electrical
SECURITY characteristics.
+ AI - + DI - + DO - ON
J8
J19
RTD IN I/O EXPANSION
J2 1 COMM1
RTD - 8
6 9 DI1(+)
RTD +
DI1(-)
RTD OUT 1 5 6
DI2(+)
SHIELD 5
J2 DI2(-) To Third Party
RTD 4
1 DI3(+) Digital Input Devices
AI1(+) 3
I/O Daughter Card DI3(-)
4 3 2 1
OFF 2
AI1(-) P/N: 2102458 DI4(+) 1
ON
AI2(+)
To Third Party AI2(-)
DI4(-) SW1
2
Analog Devices J21 AI3(+) 8J16 -
DO1(+)
DO2(+)
DO3(+)
DO4(+)
DO1(-)
DO2(-)
DO3(-)
DO4(-)
1
SEE SHEET 2 MMI
PWR +
AI3(-)
ON OFF
AOut(+) 4
1
AOut(-) 1 3 SW2 8
2
8 J3 1
J1
J20 COMM2
1 2 3 4 5 6 7 8
The Digital Outputs have a maximum “ON”

resistance of 2.5Ω which can switch 48V AC/
DC at up to 100mA. The outputs are isolated
To Third Party (AC voltage for 1 minute at 25°C, RH=60%
Digital Output Devices between input and output) from each other as
well as the control circuit by 1500Vrms.
Figure 2–11 I/O Daughter Card Generic Wiring
2.6 EXIMV Replacement

The EXIMV is specifically designed for the G4 EX device. The transducer
characterization files are stored in the G4 EX raw sensor interface board. As such,
replacement/repair involves removing both the transducer and the G4 EX raw sensor
interface board from the actual G4 EX device. Contact Totalflow to return the
assembly for replacement under warranty or for repair.
Entry into the interior of the transducer voids the transducer

warranty. If the transducer requires servicing, the entire
assembly must be removed from the unit, packaged
securely for shipping and returned to Totalflow. Contact
Totalflow Customer Service for instructions.
Page 14 2104385-001 Rev. AA

Figure 2–12 EXIMV Installation Overview

2) Back up the configuration files following the instructions listed previously in this
chapter.
3) Once the user has finished backing up the configuration and data files, they will
need to open the manifold high/low equalizer valves.
4) Using the orifice tap valves, close off both upstream and downstream. These
two valves connect the meter run high/low output lines to the transducer.
5) Open the vent valve to atmosphere.
6) Completely disconnect the high/low manifold lines from the transducer.
7) If the user is able to do so at this point, remove the external power that is
feeding the unit. If this can be done, skip to step 10; otherwise, continue to the
next step.
2104385-001 Rev. AA Page 15

Figure 2–13 G4 EX with Block Manifold

8) Gain access to the rear Termination board by loosening the countersunk hex
9) Disconnect the power connection (J16) from the Termination board mounted
connector.
10) Gain access to the G4 EX board by loosening the countersunk hex socket
locking set screw in the front end cap. Use a 1/16” hex wrench to perform this
task. When completed, unscrew the end cap.
overlay plate away from the snap on standoffs.
12) After the graphic overlay plate is off, gently remove the lithium battery connector
(J5) from the G4 EX board.
Page 16 2104385-001 Rev. AA

13) Upon removal of the lithium battery connector, snap the board out of the device.
Please note that the board is still connected to the device through the cables in
the back.
14) Unplug the raw sensor connector cable (J6) and the ribbon cable (J1) from the
G4 EX board.
15) Gently remove the board from the G4 EX device.
16) Loosen the 2” mounting pole U-bolts. Rotate/lower the unit a sufficient distance
so that the transducer can be removed.
17) Loosen the hex socket head set screws on the neck of the unit using a 3/32”
hex wrench. Continue until the transducer turns freely. Gently turn counter-
clockwise until the transducer is free from the enclosure.
18) Replace the transducer and raw sensor board with a new/repaired/spare unit of
the same type and pressure rating.
19) Reconnect the high/low manifold lines, and restore pressure.
20) Reassemble the unit by performing steps 10-14 in reverse order.
2104385-001 Rev. AA Page 17

©Copyright 2011 ABB, All rights reserved
Document Title
Application Information, G4 6200/6201EX Parts Replacement
Document No. Date & Rev. Ind. No. of Pages
2104385-001 AA 20
—
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Totalflow host software

System software products
2 T O TA L F L O W H O S T S O F T WA R E S Y S T E M S O F T W A R E P R O D U C T S | D S/ 2 1 0 1 1 9 8 - E N
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Introduction PCCU configuration and collection
No matter the size of a gas production, gathering or pipeline Setup Totalflow devices and collect data.
operation, there is ABB Totalflow software designed to • Windows application
support ongoing configuration, collection, operations, data • Local interface to all ABB Totalflow flow computers, RTU’s,
distribution and asset management. This is done more easily and chromatographs
and efficiently and more cost-effectively than most would • Calibrate and configure all IO
think possible. ABB Totalflow Software systems provide Total • Local data collection
Control solutions. • Local data graphing and reporting
• Configure remote communication ports
• Configure trend files in addition to standard EFM
historical files
— • Diagnostics/troubleshooting
Making sense of software • Monitor real time status
• Program analog and digital operations
Why do some hardware providers require the purchase of a • Program display and keypad functionality
third-party software system to operate their equipment? • Configure and troubleshoot NGC
That’s a bit like having to buy a car body from one dealer and • View chromatograms and configure cycle times
the engine from another. Everything about ABB Totalflow • Remote configuration capabilities
software systems is designed to make sense—logistical,
functional and economic sense—for every production,
gathering or pipeline operation. These remarkably easy-to-use
software systems provide real-time measurement and control
support right out of the box.
Users can quickly begin accessing and controlling facilities

from wherever they may be. These are open systems,
compatible not only with ABB hardware and software but also
with a wide range of non-ABB systems. Compatibility is a
commitment — compatible with all ABB hardware — whether
it’s the latest and greatest ABB product or the first Totalflow
model ever made.
The capabilities of ABB Totalflow software are continually

updated, never to render classic Totalflow equipment
obsolete. A very important point too, since ABB Totalflow
hardware is built to last a long, long time. ABB users deserve
software that keeps this hardware viable and productive.
Users also deserve accessible and effective support, which
comes standard with every ABB Totalflow system.
Even with software systems designed for easy set up and use,
there are still times when knowledgeable assistance can make
a difference. The ABB Totalflow support staff—including
project engineers with 20+ years’ experience—is always on
call to assist with any software or hardware issues. Take a look
at ABB Totalflow software systems to see which ones make
the most sense for any production, gathering or pipeline
operation.
T O TA L F L O W H O S T S O F T WA R E S Y S T E M S O F T W A R E P R O D U C T S | D S/ 2 1 0 1 1 9 8 - E N 3
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WinCCU – EFM host WebCCU
Complete gas volume/energy data management • WinCCU add-on works over internet or intranet
• API 21.1 compliant audit trail • Browser-based data presentation
• 13 standard reports (e.g. hourly/daily volume, missing data, • Microsoft .NET technology
field balance) • Post near real-time data to internet site
• User configurable variance reports • Standard WinCCU reports
• Flow data, alarms, events, characteristics, trends
• Demand polling
—
TF.net internet/intranet database
navigation and viewing
• Browser presentation capability for virtually any ODBC
database
• Microsoft .NET technology
• Access near real-time data from web site
• Multiple export formats (e.g. CSV, ASCII, PGAS, CFX5, 7)
• Graphical presentation of operational data
• Full featured gas volume editor
• Standard WinCCU reports (flow data, alarms, events,
• Microsoft Access or SQL server databases
characteristics, trends)
• LAN/WAN multi-user capability
• Flexible “active reports”
• Configurable status polls (templates) on demand
• Demand polling and configuration of field devices via
or scheduled
Totalflow TDS/OPC software
Remote communications
• Multiple communication port controller
• Radio, telco, CDPD, satellite, and cellular
• Automatic retry groups
• Exception reporting support
• TCP/IP socket interface
• Remote status monitoring (template)
Task scheduler
• Status polls, flow data collects, trend collects, alarms
• Batch configuration of field devices
• Reporting, emailing
— —
EZ Blocks VAS voice alarm messaging
• Provides intuitive, graphical way to create custom • Hardware + software solution
operations • Windows application
• Works with G4 devices • Dialogic speechboard management
• Similar to function block language in IEC-61131 • Call in/call out services
• Simple yet powerful library of blocks
• Offline development possible with simulator Supports up to 4 phone lines
• Built-in debugger • (2) call in, (2) call out
Comprehensive callout on alarm list

• Multiple regions
• Multiple receivers of call with priority
• Confirmation of authorized receiver of call

• Log records of callouts
• Call received confirmation
• Trigger callout from polled or exception alarms
— —
TDS32 OPC/DDE driver Plunger analysis software
• Totalflow protocol link to OPC-Read/DDE aware software Windows application for optimizing plunger control
systems parameters in a flow computer or RTU
• Coexist with WinCCU or as stand alone link to third party • Increase gas production volumes
systems • Reduce extended shut-ins due to liquid loading
• Retrieve exception reporting status from Totalflow devices • Lower operating costs
• Browse functionality • Characterize well conditions to optimize liquid production
• Persistent data retention
• Supports 50,000+ tags
— —
WellTell wireless utility WellTell local calibration software
• Configure radio settings to enhance wireless • Calibrate at the IO device location to eliminate the need for a
communications and troubleshoot field installations second person at the RTU or flow computer
• Set battery wake and sleep thresholds to protect from • Calibrations can be sent wirelessly to the RTU
permanent damage • 2,3 and 5 point calibrations of analog inputs
• Change channel and frequency settings to minimize • Calibration support for analog outputs and temperature
interference RTDs
• Adjust baud rates for adding multiple IO clients to a single
host
—
MasterLink
• Windows application for LevelMaster tank level sensor setup
• Configure communications
• Establish unique device ID
• Calibrate surface and interface levels
• View level and temperature
—
System requirements
Microsoft SQL Server 2005 or 2008 (R1, R2, X32, X64)

Hard Drive Memory (data storage excluded)
Windows Server 2008 5 (R1, R2, X32, X64)

Windows Server 2003 (R1, R2, X32, X64)
Windows Server 2012 5 (X64) (in test)
Microsoft SQL Server 2000

SVGA or higher resolution
Windows 8 5 X64 (in test)

Windows 8 5 X32 (in test)
9 pin serial port or USB
Windows Server 2000

Pentium IV, 2 GHz
Windows 7 5 X64
Windows 7 5 X32
Version Support
Windows Vista
CD ROM drive
Windows XP
Memory
Client software
PCCU ✓ 3 GB 1 GB ✓ ✓ ✓1 ✓ ✓ ✓ ✓ ✓ ✓3 7.18 and higher
Plunger Analysis ✓ 3 GB 1 GB ✓ ✓ ✓ 1
✓ ✓ ✓ ✓ ✓ 2.0 and higher
EZ Blocks ✓ 3 GB 1 GB ✓ ✓ ✓1 ✓ ✓ ✓ ✓ ✓ ✓ 1.0 to 2.0
EZ Blocks ✓ 3 GB 1 GB ✓ ✓ ✓1 ✓ ✓ ✓ ✓ ✓ ✓ 3.0 and higher
WellTell4 ✓ 3 GB 10 MB ✓ ✓ ✓ ✓ ✓ ✓ ✓ 1.0 and higher
MasterLink ✓ 3 GB 1 MB ✓ ✓ ✓ ✓ ✓ ✓ ✓ 1.0 and higher
Host software
WinCCU ✓ 3 GB 1 GB ✓ ✓ ✓1 ✓ ✓2 ✓ ✓ ✓ 6.08.0 to 6.11.4
WinCCU ✓ 3 GB 1 GB ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ 6.20.0 and higher
TF.net ✓ 3 GB 1 GB ✓ ✓ ✓ ✓ ✓ ✓ ✓ 3.0 and higher
WebCCU ✓ 3 GB 1 GB ✓ ✓ ✓ ✓ ✓ ✓ ✓ 3.0 and higher
VAS6 ✓ 3 GB 1 GB ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ 5.22 and higher
TDS ✓ 3 GB 1 GB ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ 5.28.0 to 6.0.1
TDS ✓ 3 GB 1 GB ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ 6.21.0 and higher
1. Edgeport1 recommended for USB to Serial conversion 5. Security settings must be correct for software to work
2. Requires manual installation correctly on Windows 7, Windows 8, Windows Server 2008,
3. NGC not supported and Windows Server 2012. DDE not available
4. Utility and local calibration software 6. VAS 5.22 requires Dialogic drivers Build 258 or higher for
X64 computers. See http://support.microsoft.com/
kb/917607 for help.
—
ABB Inc.
Measurement & Analytics Kansas Office Texas Office – Houston
Quotes: [email protected] 2705 Centennial Boulevard 3700 West Sam Houston
Orders: [email protected] Liberal, KS 67901 Parkway South, Suite 600
Training: [email protected] Ph: +1 620 626 4350 Houston, TX 77042
Support: [email protected] Ph: +1 713 587 8000
+1 800 442 3097 (opt. 2) Texas Office – Odessa
8007 East Business 20 Texas Office – Pleasanton
Main Office Odessa, TX 79765 150 Eagle Ford Road
7051 Industrial Boulevard Ph: +1 432 272 1173 Pleasanton, TX 78064
Bartlesville, OK 74006 Ph: +1 830 569 8062
Ph: +1 918 338 4888
www.abb.com/upstream
—
DS/2101198-EN Rev. AI 03.2019
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.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts – is forbidden without prior written consent of ABB.
© Copyright 2019 ABB.

All rights reserved.
—
A B B M E A S U R E M E N T & A N A LY T I C S | DATA S H E E T
XFCG4 6200/6201 EX
Flow computer
2 X F C G 4 6 2 0 0/6 2 0 1 E X F LO W C O M P U T E R | D S/ 2 1 0 4 3 9 0 - E N
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Overview
Based on ABB Totalflow XSeries technology, the XFCG4 6200EX Standard
series offers an explosion proof product for differential or • Explosion proof enclosure
linear metering and automation systems. The XFCG4 6200EX • LCD display (4 X 16)
series are accurate, reliable flow computers with the • Main electronics board
capability to measure and monitor gas flow in compliance • Engine card with 203 Mhz processor
with AGA, API and ISO standards. These units are expandable, • Termination board
provide exceptional control and meet many automation • 1 10BaseT Ethernet port (RJ45 on main board)
requirements. • 2 RS232/485 software selectable com ports for remote
communications
• 3 local configuration ports are available. Serial or USB are
— available to the optional external PCCU connection and
Description Class I Bluetooth is standard.
• Externally powered from 9 to 30 VDC
The XFCG4 6200EX includes an integrated high accuracy digital • Onboard User IO : 1 AI, 1 DI/PI, 1 DO
sensor (EXIMV) to measure differential pressure, static • Access to optional I/O daughter card
pressure and temperature from a single differential primary • 64MB FLASH (program storage/configuration)
measurement device. The XFCG4 6201EX includes an integrated • 32MB RAM (program execution/data storage)
high accuracy digital sensor to measure static pressure and • Integral multivariable transducer (EXIMV). DP/SP or SP only
temperature plus an onboard pulse input or serial input from a
single linear/ultrasonic or Coriolis primary measurement Optional
device. With the exception of the integrated sensors, both • Twelve (12) I/O point daughter card
models are identical (software, I/O, communications and • Manifold
electronics). • Externally accessible local communications fixture
(USB or Serial)
The XFCG4 6200EX series has multi-tube measurement • 100 ohm platinum RTD
capability. Up to 8 differential measurement applications per • Mounting Kit
RS-485 communications port when utilizing Modbus • Separate battery backup, power supply package
multivariable sensors (plus 1 tube type application utilizing
the integrated sensor) are possible. The number of linear Totalflow consistently provides new and innovative products
meter applications is limited by the available I/O and device and systems in support of accurate, reliable and auditable gas
configuration. Additional ‘tube’ or measurement applications measurement. As such, the XFCG4 6200/6201EX includes
are easily invoked with simple user or factory configuration. features grounded on a thorough understanding of the natural
gas industry’s custody transfer and measurement needs.
The XFCG4 6200EX series feature a powerful 203Mhz ARM920T
32 bit microprocessor, Windows CE operating system and
utilizes a unique ‘engine card’ design. The engine card contains
the processor, application firmware and memory components.
The processing and memory capability of this device, allows
the user to run more applications faster than ever before.
X F C G 4 6 2 0 0/6 2 0 1 E X F LO W C O M P U T E R | D S/ 2 1 0 4 3 9 0 - E N 3
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Features
• Low cost, high reliability design
• Cast aluminum enclosure, powder coated
• Low power consumption
• LCD 4 × 16 character display standard
• Stable time base (accurate integration)
• User selectable simple dual level security code data
protection or enhanced user configurable role based access
control (RBAC)
• Monitors operation limits for detection, and reporting of
abnormal conditions
• Complies with API 21.1 standard for custody transfer devices
• 40+ days historical records (user configurable for additional
hourly and daily data records)
• Full calculation of flow rates, volumes and energy in
accordance with AGA 3-85, AGA 3-92, ISO-5167 and
AGA-5 once per second
• Support for gas orifice, linear, coriolis primary elements
• Super compressibility calculations per NX-19, AGA8-92
gross or detail, ISO 12213-2
• Smart (temperature and pressure compensated) integral,
factory calibrated, multivariable smart sensor
• Flow retention during user sensor calibration
• Selectable 3 or 5 point user calibration; DP, SP and RTD (RTD
also supports single point bias/ offset adjustment).
• 100 ohm platinum RTD resistance curve fit with user
programmable single point offset or 3/5 point user
calibration for RTD input
• 100 ohm platinum RTD
• Programmable DP no flow cut-off
• Software selectable (RS232/RS485/RS422) communications
ports
• Hazardous area certifications: CSA C/US, ATEX and IECEx
• Type 3R/IP53 (with breather-drain option); Type 4X/IP66
without breather-drain option)
• Real time clock (lithium battery powered)
• Advanced embedded data logger
• Multi-tube capability
• Programmable alarm filtering and exception reporting
capabilities
• Multiple protocol options including Totalflow packet
protocol and various Modbus protocols
• User programmable Modbus registers
• User programmable math and logic (EZ Blocks)
• IEC 61131 user programming environment
• I/O expansion via optional daughter card
• Software control of power to communications equipment
— —
Hardware modularity Software modularity
Hardware functionality of the XFCG4 6200/6201EX can be The software platform represents significant modularization
extended in a flexible and simple way by adding an optional through use of object oriented design principles. Standard
I/O daughter card. The system recognizes the additional I/O Totalflow applications can be enabled in our factory or by the
automatically and configures the I/O Scanner subsystem user, one or more times on the same device. It is this
accordingly. framework that allows the support for multi-tube
measurement and allows the user to enable only the
applications that they may require.
Standard software applications include:

• AGA3 orifice measurement
• ISO 5167 orifice measurement
• VCone measurement
• AGA7 rotary/turbine/ultrasonic measurement
• Gas Coriolis measurement
• Trending; extremely flexible data logger, easily configured
by user
• PID control (AO only)
• RAMS (Alarming, Exception Reporting)
• EZ Blocks (graphical, similar to “function block”, simple
custom math / logic)
The I/O Daughter Card provides an additional 12 I/O points to • IEC 61131 (complex math / logic)
the G4 6200/6201EX. The I/O is fixed with a combination • Selectable Units (user selectable engineering units)
of Analog and Digital points. The analog point configuration is • Tank Level Application
comprised of three (3) 0-10V (10K ohm impedance) inputs and • Therms master application (Modbus master interface to gas
one (1) 0 to 20mA output. (The analog output is a “SINK” mode chromatograph)
and must be used in conjunction with an external power • Therms slave application (Modbus slave interface to gas
source) The digital point configuration is comprised of four (4) chromatograph)
digital inputs and four (4) digital outputs. The digital inputs • Totalflow NGC (gas chromatograph) Ethernet interface
also function as event counters and are capable of accepting • Multiple protocols: Totalflow native low power, Modbus slave
NAMUR type sensor signals. The digital outputs are optically- (RTU/ASCII), Modbus master (RTU/ASCII), LevelMaster,
isolated type 1A switches capable of switching 200 mA of 48 Enron Modbus (includes historical data)
VDC or 40 VAC at 60 °C (140 °F). • Advanced user configurable Plunger Lift applications
• Modbus Multivariable sensor interface
• Trending (extremely flexible and powerful user configurable
Div 1 or Zone 1 Non-hazardous area
data logger)
Div 1 or Zone 1 Non-hazardous area
• Pump controller (normally used in coal bed methane wells
to control “down hole” pumps)
RS-232 or RS-485 Communications
Communications Device
device
& switched
RS-232 or RS-485 &
power option
XFCG4EX
switched power option
Power Supply
9-30 Vdc power
Power supply
9-30 VDC power
—
General specifications
Dimensions
Electronics
Nominal diameter: 6 inches (15.24 cm)
Nominal length: 8 inches (20.32 cm) Power
External DC voltage 9 to 30 VDC
Weight
Nominal: 16.5 pounds (7.48 kg) Memory
• Program execution and data stored in 32MB PSRAM
Enclosure
(lithium battery backup)
Type 3R / IP53 with breather drain installed; Type 4X / IP66
• Windows® CE operating system, application programs,
without breather drain
and configuration files stored in 64MB Flash
Certification
Communications ports
CSA C/US Class 1, Div 1, Groups C, D T6; IECEx Ex d IIB T6;
• 3 - dedicated PCCU local configuration Ports;1- RS232,
ATEX II 2 G Ex d IIB T6; InMetro Brazil
1- USB (both ports available internally:
Mounting • user must specify which of these ports is to be utilized at
Pipe Mount the optional external MMI connection when ordering), and
standard Class I Bluetooth wireless
Operating temperature (ambient)
• 2 - remote: RS232, RS485 or RS 422 (software selectable)
-40 to 140 °F (-40 to 60 °C)
• 1 - 10BaseT Ethernet
Mechanical vibration
EX device current draw
Tested according to procedures derived from IEC 60068-2-6.
• Basic single differential measurement application without
Meets or exceeds 10-60 Hz 0.075 mm displacement
additional I/O ~25 mA @ 13.8 V (~345 mW)
amplitude / 60-500 Hz 1g specifications taken from IEC
• Bluetooth device enabled but not paired with host device:
61298-3.
~0 ma (~0 mW)
• Bluetooth device enabled and paired with host (not
EMC requirements
transferring data) ~8 mA @ 13.8 V (~110 mW)
Emissions: European regions: • Bluetooth device enabled, paired and communicating
EN55022 Class B emissions (radiated) with host ~15 mA @ 13.8 V in short bursts; not continually
(~207 mW)
Emissions: North America regions:
• Ethernet enabled: ~18.6 mA @ 13.8 V (~257 mW)
CFR 47, Part 15, Subpart B, Class B, FCC emissions
• I/O Daughter Card DO are optically isolated. ~5.1 mA
ICES-003 Issue 2, Rev. 1, Class B ITE emissions
@ 13.8 V per DO when closed (~71 mW)
Immunity: European regions:
LCD interface
EN 61000-6-1 Immunity:
• Dedicated interface for 4 x 16 Liquid Crystal Display (LCD)
EN61000-4-2:95, ESD, ±8 k V Air, ±4 k V Contact
EN61000-4-3:95 RF Immunity, 10 V/m Security switch
EN61000-4-4:95 EFT, 2 k V • On/Off dual-level on-board security switch; also supports
EN61000-4-6:95 conducted susceptibility, 10Vrms enhance role based access control (user configurable,
EN61000-4-8:93 power frequency magnetic field 3A/m multilevel, multi-user security)
Time base stability

• ± 7.5 ppm (parts per million)
Scan rate
• All Inputs Sampled at 1Hz Rate
AGA-3/AGA-7/ISO5167/VCone calculations
Calculations are tested to be within ± 50 ppm (parts per
million) as stated in API 14.3.4
—
Integral Multivariable (EX IMV)
specifications
Multivariable unit Differential pressure (XFCG4 6200EX
Temperature limits differential version only)
Compensated -20 to 140°F (-29 to 60°C)
Accuracy (including linearity, hysteresis & repeatability
Operational -40 to 140°F (-40 to 60°C)
at reference conditions)
Storage -40 to 185°F (-40 to 85°C)
± 0.075% of User Calibrated Spans from 20% to 100% of URL
Resolution
Ambient temperature effect within the operational
24 Bit analog-to-digital conversion (0.000012% FS)
temperature limit
(0.0012% FS effective signal resolution)
± 0.075% of URL ± 0.06% of Reading
Mounting specification
Stability (for 12 months)
Change from perpendicular (front to back / around x-axis)
± 0.1% of URL
≤ 0.5% URL (can be corrected with calibration)
Reproducibility
Static pressure ± 0.1%
Accuracy (including linearity, hysteresis, & repeatability at Static pressure effect (DP Zero)
reference conditions) ± 0.03% of URL per 1500 PSI (103.42 bar); 3200 PSI
± 0.075% of User Calibrated Spans from 20% to 100% of URL (220.63 bar) maximum
Ambient temperature effect within the operational Static pressure effect (DP Span)
temperature limit ± 0.1% of reading per 1500 PSI (103.42 bar); 3200 PSI
± 0.075% of URL ± 0.06% of Reading (220.63 bar) maximum
Reproducibility
Temperature
± 0.1%
Process range
-80 to +750°F (-62 to 399°C)
Accuracy (as shipped from factory)

± 0.35°F (± 0.2°C) over operating range
Accuracy (after single point field calibration)

± 0.2°F (± 0.12°C) repeatability over operating range
Sales Service Software

Available ranges
XFCG4 6200EX (differential version)
DP (inches
H 2 O)
AP (psia) 500 1500 3000
250
800
XFCG4 6201EX (linear version)
AP (psia) 500 1500
EX IMV sensors
Single seal rated (ANSI/ISA 12.27.01)
6200EX (DP/SP): PMax = 3000 psi
6201EX (SP): PMax = 1450 psi
• Wetted materials meet NACE MR0175/ISO 15156
• Process fluids: -62°C to 110°C
—
ABB Inc.
Measurement & Analytics
Quotes: [email protected]
Orders: [email protected]
Training: [email protected]
Support: [email protected]
+1 800 442 3097 (opt. 2)
Main Office
7051 Industrial Boulevard
Bartlesville, OK 74006
Ph: +1 918 338 4888
DS/2104390-EN – Rev. AH 07.2022
—
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.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts – is forbidden without prior written consent of ABB.
© Copyright 2017 ABB.

All rights reserved.
Totalflow product line
User manual
XSeries G4 6200/6201EX Flow Computer

2104349 ver. AD
2104349 (AD)
Proprietary information
© Copyright 2018 ABB, All rights reserved.
Intellectual property & copyright notice
©2018 by ABB Inc., Totalflow (“Owner”), Bartlesville, Oklahoma 74006, U.S.A. All rights reserved.
Any and all derivatives of, including translations thereof, shall remain the sole property of the Owner, regardless
of any circumstances.
The original US English version of this manual shall be deemed the only valid version. Translated versions, in
any other language, shall be maintained as accurately as possible. Should any discrepancies exist, the US
English version will be considered final.
Notice: This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by
Owner.
Inquiries regarding this manual should be addressed to ABB Inc., Totalflow Products, Technical
Communications, 7051 Industrial Blvd., Bartlesville, Oklahoma 74006, U.S.A.
Trademark Ownership
Windows® is a registered trademark of Microsoft
Teflon® is a registered trademark of Dupont
Table of contents
Introduction ........................................................................................................................................... x
Organization & style.................................................................................................................................. x
Getting help .............................................................................................................................................. x
Before you call ............................................................................................................................ x
Key symbols ............................................................................................................................................. x
Safety practices and precautions ............................................................................................................. xi
Safety guidelines ...................................................................................................................... xii
Safety first ................................................................................................................................ xii
Equipment markings ................................................................................................................. xiii
Grounding the product .............................................................................................................. xiii
Operating voltage ..................................................................................................................... xiii
Danger from loss of ground ......................................................................................................xiii
Safe equipment ....................................................................................................................... xiv
Fuse replacement .................................................................................................................... xiv
Compliance ............................................................................................................................................ xiv
EU Directive 2012/19/EU - Waste Electrical and Electronic Equipment (WEEE) .................... xiv
1 System description ............................................................................................................. 1–1
1.1 Overview ................................................................................................................................ 1–1
1.1.1 Capabilities............................................................................................................... 1–2
1.1.2 Functionality ............................................................................................................. 1–2
1.1.3 Flow computer calculations ...................................................................................... 1–3
1.1.4 Log period records ................................................................................................... 1–4
Display function ........................................................................................................ 1–5
1.1.6 Display annunciators ................................................................................................ 1–5
1.2 Computer hardware ................................................................................................................ 1–7
1.2.1 Enclosure ................................................................................................................. 1–8
1.2.2 G4 EX main processor board ................................................................................. 1–10
1.2.3 G4 EX termination board ........................................................................................ 1–12
1.2.4 Explosion proof multivariable transducer (EXIMV) ................................................. 1–17
1.2.5 Display assembly ................................................................................................... 1–19
1.2.6 Resistive temperature detector (RTD) .................................................................... 1–19
1.2.7 6270 Optional Equipment Unit (OEU) .................................................................... 1–20
1.2.8 Solar panel ............................................................................................................. 1–21
1.2.9 Lithium battery........................................................................................................ 1–22
1.3 G4 EX application licensing .................................................................................................. 1–22
1.3.1 Credit Key (USB).................................................................................................... 1–24
1.4 Laptop computer running PCCU32 ...................................................................................... 1–24
1.5 Local G4 EX connectors ....................................................................................................... 1–25
1.5.1 RS-232 serial PCCU cable (round military cable) .................................................. 1–25
1.5.2 PCCU32 USB connection ...................................................................................... 1–25
1.5.3 Bluetooth connectivity ............................................................................................ 1–26
1.5.4 Network connectivity (dynamic IP with router)........................................................ 1–26
2 Installation ............................................................................................................................ 2–1
2.1 Unpacking and inspection ...................................................................................................... 2–1
2.1.1 Unpacking ................................................................................................................ 2–1
2.1.2 Inspection ................................................................................................................. 2–1
2.1.3 Damaged components ............................................................................................. 2–1
2.2 2” Pole mount installation ....................................................................................................... 2–1
2.2.1 Type A ...................................................................................................................... 2–2
2.2.2 Type B ...................................................................................................................... 2–3
2.2.3 Type C ..................................................................................................................... 2–4
2.2.4 Manifold input lines .................................................................................................. 2–6
2104349– rev. AD Page iii

2.2.5 Standard RTD probe installation .............................................................................. 2–7
2.2.6 Explosion proof RTD probe assembly ...................................................................... 2–8
2.2.7 6270 Optional Equipment Unit (OEU) installation .................................................. 2–10
2.2.8 Battery Pack Installation ......................................................................................... 2–12
2.2.9 Lithium battery installation ...................................................................................... 2–13
2.2.10 Solar panel installation ........................................................................................... 2–14
2.2.11 AC charging unit installation ................................................................................... 2–16
2.2.12 Uninterrupted power supply (UPS) to the G4 EX ................................................... 2–18
3 G4 EX start-up ......................................................................................................................3–1
3.1 PCCU32 installation and setup ............................................................................................... 3–1
3.1.1 Step-by-step instructions .......................................................................................... 3–1
3.2 Establishing local communication ........................................................................................... 3–1
3.2.1 Connecting to a local port via a RS-232 cable ......................................................... 3–2
3.2.2 Connecting to local USB port ................................................................................... 3–3
3.2.3 Setup of the G4 EX for Bluetooth connectivity ......................................................... 3–5
3.2.4 Setup of the G4 EX for Ethernet connectivity ........................................................... 3–7
3.3 Setting up the G4 EX ............................................................................................................ 3–13
3.3.1 Date/time ................................................................................................................ 3–13
3.3.2 Station ID ............................................................................................................... 3–14
3.3.3 Location.................................................................................................................. 3–14
3.4 Security system .................................................................................................................... 3–14
3.4.1 Device legacy bi-level security ............................................................................... 3–14
3.4.2 WinCCU32 software security ................................................................................. 3–16
3.4.3 Role Based Access Control (RBAC) ...................................................................... 3–17
3.5 Application licensing Credit Key ........................................................................................... 3–25
3.5.1 Credit Key driver installation ................................................................................... 3–25
3.5.2 Access/view the Credit Key with PCCU32 7.0 (or later) ......................................... 3–25
3.5.3 Adding credits to the Credit Key by telephone ....................................................... 3–27
3.5.4 Transferring credits to the G4 EX from the Credit Key ........................................... 3–28
3.5.5 Transferring Credits to the Credit Key from the G4 EX .......................................... 3–29
3.6 G4 EX configuration ............................................................................................................. 3–30
3.6.1 Contact hour ........................................................................................................... 3–30
3.6.2 Log period .............................................................................................................. 3–31
3.6.3 Volume calculation period ...................................................................................... 3–31
3.6.4 Calculated method ................................................................................................. 3–31
3.6.5 Supercompressibility calculation (Fpv) ................................................................... 3–32
3.6.6 Constants ............................................................................................................... 3–33
3.6.7 Alarm Limits ........................................................................................................... 3–34
3.6.8 Reset Volume ......................................................................................................... 3–34
3.7 Start Up the G4 EX ............................................................................................................... 3–35
3.7.1 Putting the G4 EX On Line ..................................................................................... 3–35
3.7.2 Setting G4 EX Temperature Calculation ................................................................ 3–35
3.8 G4 EX Standard Displays ..................................................................................................... 3–35
3.8.1 Program Display ..................................................................................................... 3–35
4 G4 ex Maintenance...............................................................................................................4–1
4.1 Overview ................................................................................................................................ 4–1
4.1.1 Maintenance Support ............................................................................................... 4–1
4.1.2 How to Use This Chapter ......................................................................................... 4–1
4.1.3 Cleanliness............................................................................................................... 4–1
4.1.4 Front Mounted LCD .................................................................................................. 4–1
4.1.5 Returning Parts for Repair........................................................................................ 4–1
4.2 Backing Up Configuration Files .............................................................................................. 4–1
Page iv 2104349– rev. AD

4.3 Restoring Configuration Files ................................................................................................. 4–2
4.3.1 Step-by-Step Instruction ........................................................................................... 4–2
4.4 Performing a Warm Boot ........................................................................................................ 4–2
4.4.1 Hardware Warm Boot ............................................................................................... 4–2
4.4.2 Software Warm Boot ................................................................................................ 4–3
4.5 Performing a Cold Boot .......................................................................................................... 4–4
4.5.1 Hardware Cold Boot ................................................................................................. 4–4
4.5.2 Software Cold Boot .................................................................................................. 4–5
4.6 Changing the G4 EX Clock ..................................................................................................... 4–6
4.6.1 Clock Change Not Crossing an Hour Boundary ....................................................... 4–6
4.6.2 Forward Clock Change Crossing an Hourly Boundary ............................................. 4–6
4.6.3 Backward Clock Change Crossing an Hourly Boundary .......................................... 4–6
4.7 Replacing the G4 EX battery Pack ........................................................................................ 4–6
4.8 Replacing the G4 EX board .................................................................................................... 4–8
4.9 Replacing the G4 EX termination board ............................................................................... 4–13
4.9.1 Step-by-step instructions ........................................................................................ 4–13
4.10 Replacing the Liquid Crystal Display (LCD) board ............................................................... 4–15
4.11 Replacing the lithium battery ................................................................................................ 4–16
4.12 Replacing the transducer (EXIMV) ....................................................................................... 4–17
4.13 Calibration ............................................................................................................................ 4–19
4.13.1 Required test equipment ........................................................................................ 4–19
4.13.2 Hold mode .............................................................................................................. 4–20
4.13.3 Static pressure (SP) calibration checks .................................................................. 4–20
4.13.4 Differential pressure (DP) calibration checks ......................................................... 4–22
4.13.5 Calibrating static pressure (SP).............................................................................. 4–23
4.13.6 Calibrating differential pressure (DP) ..................................................................... 4–25
4.14 Onboard I/O calibration overview ......................................................................................... 4–26
4.14.1 Hold mode .............................................................................................................. 4–26
4.14.2 Calibrating onboard analog inputs.......................................................................... 4–26
4.14.3 Onboard pulse and digital inputs ............................................................................ 4–27
4.15 Zero transducer .................................................................................................................... 4–28
4.15.1 Static pressure ....................................................................................................... 4–28
4.15.2 Differential pressure ............................................................................................... 4–28
4.16 RTD calibration and bias ...................................................................................................... 4–28
4.16.2 Calibrating RTD temperature bias .......................................................................... 4–30
4.17 Changing the orifice plate ..................................................................................................... 4–30
4.17.1 Taking meter run out of service (simplex fitting) ..................................................... 4–30
4.17.2 Leaving meter run in-service procedure (senior fitting) .......................................... 4–31
5 Troubleshooting .................................................................................................................. 5–1
5.1 Overview ................................................................................................................................ 5–1
5.1.1 Troubleshooting support .......................................................................................... 5–1
5.1.2 Visual alarm codes ................................................................................................... 5–1
5.1.3 Sleep mode .............................................................................................................. 5–1
5.1.4 Solar panel ............................................................................................................... 5–1
5.1.5 Communication ........................................................................................................ 5–1
5.2 Troubleshooting visual alarm codes ....................................................................................... 5–2
2104349– rev. AD Page v

5.2.1 Troubleshooting a blank LCD screen ....................................................................... 5–4
5.2.2 Troubleshooting a Low Lithium alarm (LL) ............................................................... 5–4
5.2.3 Troubleshooting an Analog to Digital Failure alarm (AD) ......................................... 5–4
5.2.4 Resistive Temperature Detector (RTD) Continuity test ............................................ 5–6
5.2.5 RTD Current Source (Resistive) test ........................................................................ 5–6
5.2.6 RTD Impedance test ................................................................................................ 5–7
5.3 Power troubleshooting ............................................................................................................ 5–8
5.3.1 Overview .................................................................................................................. 5–8
5.3.2 Power supply test ..................................................................................................... 5–8
5.3.3 Charger Circuit test .................................................................................................. 5–9
5.3.4 Solar panel charging system test ........................................................................... 5–10
5.3.5 AC charging system unit test.................................................................................. 5–11
5.3.6 Auxiliary equipment isolation test ........................................................................... 5–12
5.3.7 Sleep mode ............................................................................................................ 5–13
5.3.8 Reset procedures ................................................................................................... 5–13
5.4 Communications troubleshooting ......................................................................................... 5–14
5.4.1 Overview ................................................................................................................ 5–14
5.4.2 Setting up communication ...................................................................................... 5–15
5.4.3 Transceiver supply voltage test .............................................................................. 5–16
5.4.4 6270 OEU supply voltage test ................................................................................ 5–16
5.4.5 Transceiver check .................................................................................................. 5–17
5.4.6 Termination board supply voltage test.................................................................... 5–17
5.4.7 RS-232 communication .......................................................................................... 5–18
5.4.8 RS-232 termination board test ............................................................................... 5–18
5.4.9 RS-232 OEU termination strip test ......................................................................... 5–19
5.4.10 RS-485 communication test ................................................................................... 5–20
5.4.11 RS-485 termination board test ............................................................................... 5–20
5.4.12 RS-485 OEU termination strip test ......................................................................... 5–22
6 Reference material .................................................................................................................23
6.1 Reference materials on ABB/Totalflow website ........................................................................ 23
6.2 I/O daughter card...................................................................................................................... 24
6.2.1 Materials supplied in the upgrade kit .......................................................................... 24
6.2.2 I/O daughter card specifications ................................................................................. 24
6.2.3 Installation .................................................................................................................. 24
6.2.4 Upgrading the flash .................................................................................................... 25
6.2.5 Unit operating status shut down instructions .............................................................. 26
6.2.6 Internal PCCU connector disassembly (if installed).................................................... 26
6.2.7 I/O daughter card installation ..................................................................................... 26
6.2.8 Internal PCCU connector reassembly (if previously installed) .................................... 28
6.2.9 Implementation ........................................................................................................... 28
6.3 4–20 milliamp transmitters ........................................................................................................ 34
6.3.1 Powering 4–20 Milliamp Transmitters ........................................................................ 34
6.3.2 Example 1 .................................................................................................................. 36
6.3.3 Example 2 .................................................................................................................. 36
6.3.4 Conclusion ................................................................................................................. 36
Page vi 2104349– rev. AD

Table of figures
Figure 1–1 Typical G4 EX installation ................................................................................................ 1–2
Figure 1–2 Liquid Crystal Display (LCD) and indicators ..................................................................... 1–6
Figure 1–3 G4 EX enclosure .............................................................................................................. 1–9
Figure 1–4 G4 EX enclosure left side ................................................................................................. 1–9
Figure 1–5 G4 EX enclosure right side............................................................................................. 1–10
Figure 1–6 G4 EX main processor board ......................................................................................... 1–11
Figure 1–7 G4 EX termination board ................................................................................................ 1–13
Figure 1–8 Typical DI point schematic ............................................................................................. 1–14
Figure 1–9 DI connection example ................................................................................................... 1–14
Figure 1–10 DI connection example ................................................................................................. 1–15
Figure 1–11 Typical DO point schematics ........................................................................................ 1–16
Figure 1–12 DO connection example ............................................................................................... 1–16
Figure 1–13 Typical AI point schematic............................................................................................ 1–17
Figure 1–14 AI example connections ............................................................................................... 1–17
Figure 1–15 Explosion proof multivariable transducer (EXIMV) ...................................................... 1–18
Figure 1–16 Liquid Crystal Display (LCD) assembly ........................................................................ 1–19
Figure 1–17 Explosion proof RTD .................................................................................................... 1–20
Figure 1–18 Optional communication enclosure .............................................................................. 1–21
Figure 1–19 Solar panel – typical installation ................................................................................... 1–22
Figure 1–20 RS-232 local communication cable .............................................................................. 1–25
Figure 1–21 USB local communication cable ................................................................................... 1–26
Figure 1–22 Ethernet communication cable ..................................................................................... 1–27
Figure 1–23 Ethernet connectivity diagram ...................................................................................... 1–27
Figure 2–1 Type A Installation Configuration ..................................................................................... 2–3
Figure 2–2 Type B Installation Configuration ..................................................................................... 2–4
Figure 2–3 Type C installation configuration ...................................................................................... 2–5
Figure 2–4 G4 EX EXIMV ports .......................................................................................................... 2–6
Figure 2–5 Thermowell installation into the meter run ....................................................................... 2–7
Figure 2–6 RTD probe wiring ............................................................................................................. 2–8
Figure 2–7 Explosion proof RTD overview ......................................................................................... 2–8
Figure 2–8 Explosion proof RTD disassembled ................................................................................. 2–9
Figure 2–9 RTD probe wiring ........................................................................................................... 2–10
Figure 2–10 6270 OEU pipe mounting installation ........................................................................... 2–11
Figure 2–11 6270 OEU wall mount installation ................................................................................ 2–12
Figure 2–12 6270 OEU enclosure .................................................................................................... 2–13
Figure 2–13 Lithium battery .............................................................................................................. 2–14
Figure 2–14 Solar panel installation ................................................................................................. 2–15
Figure 2–15 AC charger installed ..................................................................................................... 2–17
Figure 2–16 AC charger outlet box installation ................................................................................ 2–17
Figure 2–17 AC charger inside the conduit enclosure ..................................................................... 2–18
Figure 2–18 G4 EX to UPS .............................................................................................................. 2–19
Figure 3–1 System Setup Screen ....................................................................................................... 3–2
Figure 3–2 Windows found new hardware wizard .............................................................................. 3–3
2104349– rev. AD Page vii

Figure 3–3 Specific location selection window....................................................................................3–4
Figure 3–4 Specify location for USB driver (Totalflow.inf) ..................................................................3–4
Figure 3–5 System setup - Bluetooth ..................................................................................................3–6
Figure 3–6 Select a Bluetooth device dialog box ................................................................................3–6
Figure 3–7 System Setup dialog box - Bluetooth ...............................................................................3–7
Figure 3–8 Network tab .......................................................................................................................3–8
Figure 3–9 Communication setup .......................................................................................................3–9
Figure 3–10 System Setup window ..................................................................................................3–10
Figure 3–11 Windows desktop Shortcut dialog box ..........................................................................3–11
Figure 3–12 Network tab ...................................................................................................................3–12
Figure 3–13 System setup ................................................................................................................3–13
Figure 3–14 Station Setup tab ..........................................................................................................3–15
Figure 3–15 Security Setup dialog box .............................................................................................3–16
Figure 3–16 WinCCU32 Edit a Device ID dialog box .......................................................................3–17
Figure 3–17 Role administration menu path .....................................................................................3–18
Figure 3–18 Security Editor dialog box .............................................................................................3–18
Figure 3–19 Roles dialog box ...........................................................................................................3–19
Figure 3–20 User Name and Password dialog box ..........................................................................3–20
Figure 3–21 System Setup dialog box ..............................................................................................3–20
Figure 3–22 Send Role Based Access Control File dialog box ........................................................3–21
Figure 3–23 Totalflow-TCP Setup tab ...............................................................................................3–21
Figure 3–24 Login dialog box ............................................................................................................3–22
Figure 3–25 System Setup dialog box ..............................................................................................3–23
Figure 3–26 Security Log tab ............................................................................................................3–24
Figure 3–27 Credit Key License Utility ..............................................................................................3–26
Figure 3–28 Credit Key License Utility – Status ...............................................................................3–26
Figure 3–29 Application Credit Key entry screen .............................................................................3–27
Figure 3–30 Application Credit verification codes .............................................................................3–28
Figure 3–31 App Licensing tab .........................................................................................................3–29
Figure 3–32 Transfer to Credit Key ...................................................................................................3–30
Figure 4–1 Reset Button Location ......................................................................................................4–3
Figure 4–2 Lithium battery Connector .................................................................................................4–5
Figure 4–3 6270 OEU Configuration ...................................................................................................4–7
Figure 4–4 G4 EX Front End Exploded View......................................................................................4–9
Figure 4–5 Termination board ...........................................................................................................4–10
Figure 4–6 G4 EX board ...................................................................................................................4–11
Figure 4–7 G4 EX board Secondary Component Side. ....................................................................4–12
Figure 4–8 G4 EX Back End Exploded View ....................................................................................4–13
Figure 4–9 Termination board secondary component side ..............................................................4–14
Figure 4–10 EXIMV installation overview .........................................................................................4–17
Figure 4–11 G4 EX with block manifold ............................................................................................4–18
Figure 4–12 Calibration diagram .......................................................................................................4–22
Figure 4–13 RTD calibration screen .................................................................................................4–29
Figure 5–1 Troubleshooting flowchart .................................................................................................5–2
Page viii 2104349– rev. AD

Figure 5–2 LCD and indicators ........................................................................................................... 5–3
Figure 5–3 Power supply – G4 EX termination board ........................................................................ 5–4
Figure 5–4 G4 EX termination board .................................................................................................. 5–9
Figure 5–5 6270 OEU charger regulator .......................................................................................... 5–11
Figure 5–6 Current measurement troubleshooting cable ................................................................. 5–12
Figure 5–7 Communication troubleshooting flow chart .................................................................... 5–15
Figure 5–8 OEU termination strip ..................................................................................................... 5–20
Figure 6–1 Termination panel with I/O daughter card installed ............................................................ 25
Figure 6–2 32-Bit Loader screen .......................................................................................................... 25
Figure 6–3 I/O Interface screen ............................................................................................................ 27
Figure 6–4 I/O daughter card ............................................................................................................... 28
Figure 6–5 Generic Wiring Diagram ..................................................................................................... 29
List of tables
Table 1–1 XFC family genealogy ....................................................................................................... 1–1
Table 1–2 Typical G4 EX display options ........................................................................................... 1–5
Table 1–3 Default annunciator locations ............................................................................................ 1–6
Table 1–4 G4 EX status and alarm description .................................................................................. 1–6
Table 1–5 G4 EX main processor board specifications ................................................................... 1–11
Table 1–6 Explosion proof EXIMV specifications ............................................................................. 1–18
Table 1–7 Standard RTD probes ...................................................................................................... 1–20
Table 1–8 Standard Thermowells ..................................................................................................... 1–20
Table 3–1 Configurable calculation factors ...................................................................................... 3–31
Table 3–2 Fpv analysis data ............................................................................................................. 3–32
Table 3–3 Gas Orifice Constants ..................................................................................................... 3–33
Table 3–4 Alarm Limits ..................................................................................................................... 3–34
Table 3–5 G4 EX Displayed Items ................................................................................................... 3–35
Table 4–1 Calibration configurable parameters ............................................................................... 4–19
Table 5–1 Visual alarm codes ............................................................................................................ 5–3
Table 5–2 Specifications for solar panels ......................................................................................... 5–10
Table 5–3 RS-232 field wiring on the G4 EX termination board ...................................................... 5–18
Table 5–4 RS-485 field wiring on the G4 EX termination board ...................................................... 5–21
2104349– rev. AD Page ix

Introduction
This manual is designed to provide an experienced flow meter technician with the
requirements necessary to install, set up and operate a Totalflow XFCG4
6200/6201EX.
Organization & style

Each of the chapters in this manual presents information in an organized and
concise manner. Readers are able to look at the headings and receive a broad
picture of the content without reading every word. Also, there are overviews at the
beginning of each chapter that provides the user with an idea of what is in the
chapter and how it fits into the overall manual.
Readers will also note that each heading level number is formatted to include the
chapter, section, and subsection numbers. E.g. 4.15.2 indicates that the reader is
reading subsection 2 of section 15 in chapter 4.
Getting help
At Totalflow, we take pride in the ongoing support we provide our customers.
When you purchase a product, you receive documentation which should answer
your questions; however, Totalflow Technical Support provides you an 800
number as an added source of information.
If you require assistance, call:
USA: (800) 442-3097 International: 001-918-338-4888
Before you call

- Know your Totalflow’s model and serial number. Serial numbers can be
found on a plate located on each unit.
- Be prepared to give the customer service representative a detailed
description of the problem.
- Note any alarms or messages as they appear.
- Prepare a written description of problem.
- Know your software version, board and optional part numbers.
Key symbols
The following symbols may be used frequently in this manual. These are intended
to catch your eye and draw your attention to important information.
Intended to draw your attention to useful information or to

clarify a statement made earlier.
Intended to draw your attention to a fact that may be useful or

helpful in understanding a concept.
Page x 2104349– rev. AD

Intended to draw attention to a statement that might keep the
user from making a mistake, keep them from destroying
equipment or parts, or keep them from creating a situation that
could cause personal injury if caution is not used. Please refer
to the Safety Practices and Precaution section for additional
information.
Intended to draw attention to a statement regarding the

likelihood of personal injury or fatality that could result from
improper access or techniques used while working in
hazardous locations. Please refer to the Safety Practices and
Precaution section for additional information.
Intended to draw your attention to information regarding

security access to equipment, software security, or software
security features.
Intended to draw attention to a statement warning the user

about adverse effects of executing a particular procedure.
Adverse effects may include: service performance
degradation, loss of configuration, or complete service
disruption.
Indicates procedures that are only valid if system design

includes an Environmental Enclosure.
Intended to draw attention to information that may require

further investigation or consideration prior to continuing.
Safety practices and precautions

This manual contains information and warnings which have to be followed by the
user to ensure safe operation and to retain the product in a safe condition.
Installation, maintenance and repairs should only be performed by a trained and
qualified technician. Please refer to the certification drawings shipped with this unit
for specific guidelines. Extra copies of the certification drawings, referenced on the
unit’s name tag, can be obtained, free of charge, by contacting Totalflow Technical
Support at the number listed in the Getting Help section.
To ensure safe installation and operation of the equipment, the instructions that
are presented in this manual should be read carefully prior to their execution. As it
is impossible to cover every installation scenario that exists for a given device, the
instructions do not contain all possible details and do not take into account every
conceivable scenario. What is presented represents the most common scenarios
that a user will find in the field. If the information here does not cover the user’s
specific site scenario, call Totalflow Technical Support for further help in
implementing the installation.
2104349– rev. AD Page xi
Additionally, it should be pointed out that the following instructions are neither part
of nor provided for changing a previous existing agreement, promise or legal
relationship. The obligations adhered to by ABB Totalflow result from the
respective sales contract which also comprises the complete and solely valid
warranty clauses. These contractual warranty clauses will not be limited or
extended by the content of this manual.
Safety guidelines
- DO NOT open the equipment to perform any adjustments, measurements,
maintenance, parts replacement, or repairs until all external power supplies
have been disconnected.
- For assembly, electrical connection, installation and maintenance of the
device, only a qualified and authorized specialist should attempt these
tasks. A specialist would be one who is experienced in either assembly,
electrical connection, installation or maintenance of a given device and
holds the necessary qualifications for the task.
- When opening covers or removing parts, exercise extreme care "live parts
or connections can be exposed".
- Installation and maintenance must be performed by person(s) qualified for
the type and area of installation according to National and Local codes.
- Capacitors in the equipment can still be charged even after the unit has
been disconnected from all power supplies.
Safety first
Various statements in this manual identified as conditions or practices that could

result in equipment damage, personal injury or loss of life will be highlighted using
the following Icons.
Exercise caution while performing this task. Carelessness could

result in damage to the equipment, other property and personal
injury.
Page xii 2104349– rev. AD

STOP. Do not proceed without first verifying that a hazardous
condition does not exist. This task may not be undertaken until
proper protection has been accomplished, or the hazardous
condition has been removed. Personal injury or fatality could
result. Examples of these warnings include:
- Removal of enclosure cover(s) in a hazardous location must

follow guidelines stipulated in the Certification Drawings
shipped with this unit.
- If unit is installed or to be installed in a hazardous location,
technician must follow the guidelines stipulated in the
Certification Drawings shipped with this unit.
- Access to unit via PCCU cable in a hazardous location must
follow guidelines stipulated in the Certification Drawings
shipped with this unit.
- Connecting or disconnecting equipment in a hazardous location
for installation or maintenance of electric components
must follow guidelines stipulated in the Certification
Drawings shipped with this unit.
DANGER indicates a personal injury hazard immediately

accessible as one reads the markings.
CAUTION indicates a personal injury hazard not immediately

accessible as one reads the markings, or a hazard to property,
including the equipment itself.
Equipment markings
Protective ground (earth) terminal
Grounding the product
If a grounding conductor is required, it should be connected to the grounding

terminal before any other connections are made.
Operating voltage
Before switching on the power, check that the operating voltage listed on the
equipment agrees with the power being connected to the equipment.
Danger from loss of ground
A grounding conductor may or may not be required depending on the hazardous

classification. If required, any interruption of the grounding conductor inside or
outside the equipment or loose connection of the grounding conductor can result
in a dangerous unit. Intentional interruption of the grounding conductor is not
permitted.
2104349– rev. AD Page xiii

Safe equipment
If it is determined that the equipment cannot be operated safety, it should be taken

out of operation and secured against unintentional usage.
Fuse replacement
Fuses used on Totalflow electronic boards are surface mount and field repair
should not be attempted. Most fuses automatically reset themselves, but if a
known problem exists, the board should be sent in for repair or replacement.
Compliance
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.
Electrical and electronic equipment marked using the crossed-out wheeled bin symbol
shall not be mixed with general household waste. Correct disposal at a recycling
facility will help save valuable resources and prevent potential negative effects on
health and the environment. These steps ensure compliance with the Waste Electrical
and Electronic Equipment (WEEE) Directive.
Waste electrical and electronic equipment (WEEE) shall be treated separately using the national
collection framework available to customers for the return, recycling, and treatment of WEEE.
Page xiv 2104349– rev. AD

1 System description
1.1 Overview
The XFCG4 6200/6201EX (G4 EX) is a next generation solution for the pre-existing
generation 3 XFC6200/6201EX. The G4 EX now incorporates the same 32-bit
technology currently used by the G4 XSeries products. By using 32-bit technology,
Windows® CE OS and memory capabilities, the G4 EX is a versatile product
offering for production automation and DIV 1 custody measurement projects.
Along with this new functionality, the hardware capabilities are expanded to meet
the demands of targeted market applications in production automation and natural
gas distribution. These hardware features will be utilized to enhance the system
integration capabilities with existing Totalflow products as well as existing third-
party control SCADA systems. Additionally, the use of Bluetooth technology for
local MMI connectivity is poised to enhance the product for multi-tube and Class 1,
DIV 1 applications where this type of user interface is an advantage.
The G4 EX offers an explosion-proof product for differential (orifice) or linear
(pulse) metering and automation systems. The G4 EX is an accurate and reliable
gas flow computer with the capability to measure and monitor gas flow in
compliance with AGA, API and ISO standards.
The G4 EX is a low power, microprocessor-based unit designed to meet a wide
range of measurement, control, monitor and alarming applications for remote gas
systems located in DIV 1 hazardous areas.
See Table 1–1 for the XFC family genealogy. This highlights the main differences
between the various devices.
The XFC G4 6200/6201EX (G4 EX) is approved for installation

in Classified/Potential Hazardous Locations where an
explosive atmosphere may be present. Follow precautions and
requirements for installation, maintenance and service of
equipment according to Local and National Electrical Codes
and the “Warnings” contained in this manual.
Table 1–1 XFC family genealogy

Max.
XFC DIV Multi Orifice Pulse Battery Communication Max. TFIO
Battery
Model Class Tube Meter Meter Charger Equipment Modules
Capacity
12-Point I/O Opt.
6200EX 1 ● External External External
Expansion Card
12-Point I/O Opt.
6201EX 1 ● External External External
Expansion Card
6410 2 ● ● On board 26AH External N/A
6411 2 ● ● On board 26AH External N/A
6413 2 ● ● On board 26AH Internal 3
2104349 rev. AD Page 1–1

1.1.1 Capabilities
The G4 EX is packaged in a small, explosion-proof cast aluminum enclosure
which accommodates the processor board, termination board and display. The
power supply, charging source and radio communication applications must be
housed in separate accommodations. See Figure 1–1.
For the G4 EX, the integral multivariable transducer (EXIMV) is a separate unit
with no internal electronics and is attached to the bottom of the enclosure via a
threaded neck. This contains the wiring for the connection to the electronics that
are located in the enclosure.
The G4 EX defaults to the retention of daily and log period records for 40 days
and the retention of 200 events. These defaults can be extended, limited only by
the file storage spaces on the device.
The G4 EX may be used in conjunction with a laptop that is running PCCU32
software. PCCU32 is required for initial setup and setup of the advanced features.
The G4 EX maintains a history of alarms as well as average differential pressure
(DP), average static pressure (SP), average flowing temperature (Tf),
accumulated volume, energy and an average extension.
The G4 EX can be programmed to calculate flow rates and volumes in
accordance with AGA-3, AGA-7 or ISO-5167.
Supercompressibility calculations can be performed in accordance with either NX-
19, AGA-8 or ISO 12213-2.
Figure 1–1 Typical G4 EX installation
1.1.2 Functionality
Functions of the G4 EX reflect a design that is practical, straightforward and
efficient. It is simple to use and easy to learn. This functionality allows for saving
time that is usually allotted for calculations and report preparation. This flow
computer allows the user to perform the following with a minimum of effort,
maximum speed and greater accuracy.
Page 1–2 2104349 rev. AD

Complete log period flow and operational records that are reported hourly
(default), including:
- Average static pressure
- Average differential pressure
- Average flowing temperature
- Integral
- Corrected volume total
- Corrected energy total
- Operating status and alarms
- Flow time
Complete daily flow records, including:
- Average flowing temperature
- Average extension
- Corrected volume total
- Corrected energy total
- Operating status and alarms
Complete daily operation statistics, including:
- Percent flowing time
- Percent back flow time
- Percent out of limits (programmable) on SP, DP, Tf and flow rate
- Minimum and maximum values for SP, DP, Tf and flow rate
1.1.3 Flow computer calculations

The records and statistics generated are based on the following calculation
methods of the G4 EX:
- Calculation of flow rates and volumes in accordance with AGA 3–85, AGA
3–92, AGA-7 or ISO-5167.
- Calculation of flow rates and volumes in accordance with AGA-8 92 Gross
or Detail or NX-19 Supercompressibility Standards.
- Calculation of flow extension for the AGA3-92 equation is Dp* Sp ,

Tf  459.67
once per second.
- The flow extension reported for the log period is:
Dp* Sp
/ 3600 * flow time in sec onds
Tf  459.67
- Calculation of the flow extension for the AGA3-85 equation is Dp * Sp ,

once per second.
- Extrapolation of flow accumulation during transducer calibration or
calibration checks.
- Selection of all coefficients for calculation; the calculation of dynamic factors
(dependent upon DP, SP and Tf) using averages is based on one second
samples.
2104349 rev. AD Page 1–3

- Sample set of most recent calculations allowing subsequent verification.
- Monitoring of the operational limits, minimums and maximums to ensure
detection and reporting of malfunctions or abnormal site conditions.
- Acceptance and storage of system constants from the PCCU32 or remote
communications protocols.
- Storage of data records and operational events is determined by user
(based on available memory).
1.1.3.1 Additional features

Additional features of the Totalflow system’s flexibility include the following:
- Programmable differential pressure zero cutoff.
- Programmable bi-level security codes to prevent unauthorized access to
and configuration of the G4 EX or user-configurable Role Based Security
Access (RBAC).
- Internal 100 Ohm platinum RTD resistance curve fit with user-
programmable single point offset or 3/5-point user-calibration of the RTD
input.
- Quick, simple calibration procedures for transducer.
- Real-time clock providing a highly stable time base for the system.
- Proper battery and solar sizing is determined by geographic location of the
unit and total power consumption of the system. Totalflow project engineers
can select the appropriate battery and solar requirements for the user’s
specific application. Larger capacity batteries are available to increase
autonomy, if required.
- Three available power sources:
- External solar panel (standard)
- External AC or AC to DC power
- External 24/12 VDC power
- Liquid crystal display (LCD) programmable to allow monitoring of the G4 EX
operations and can display any variable that has a register (for example,
displays current static pressure).
- Three serial communication ports are available on the G4 EX: 1 dedicated
RS-232 Local and 2 user-programmable RS-232/RS-485 Remote
Communication ports.
- USB and 10Base T Ethernet port.
- USB or RS-232 serial may be ordered as local, externally accessible Local
Communication Interface port.
1.1.4 Log period records

Each record has entries that contain the following information (and more):
- Average flow temperature
- Calculated volume
1.1.4.1 Log period data entries

Log period data entries are made every 60 minutes, by default. The user may
change this period to any one of the seven (7) choices (1, 2, 5, 10, 20, 30, 60).
Page 1–4 2104349 rev. AD

Choosing a log period of less than 60 minutes will result in additional records
being logged. As a result, this requires more storage space to hold a full day’s
data. The log period must never be less than the volume calculation period.
1.1.4.2 Volume calculation period entries

Volume calculation period entries are made every second, by default. The user
may change this period up to 60 minutes. API 21.1 strongly suggests a volume
calculation period (QCP) of once per second.
The volume calculation period should never be greater than the log period and
should be evenly divisible into the log period.
Volume calculations are completed, following the top of the current period (i.e., top
of the hour, top of the minute, each second).
Display function
During operation, the front panel LCD continuously scrolls through the operating
parameters. Table 1–2 shows the typical displayed parameters; however, many
parameters with a register address can be displayed. The duration that the
parameter is displayed can vary from 1 to 255 seconds (default is five seconds); a
setting of zero seconds will set any item to Off. See the Program Display section
and the PCCU32 Help Files for additional information.
Table 1–2 Typical G4 EX display options

Display Description
DATE/TIME MM/DD/YY
Current date and time, 24 hour clock
HH:MM:SS
YEST DP LOW NN PERCENT Yesterday’s % time below DP Low Set Point
YEST DP HIGH NN PERCENT Yesterday’s % time below DP High Set Point
FLOW RATE NNNNNN.N SCF/HR Current flow rate, programmable SCF, MCF or MMCF
Total accumulated volume, programmable SCF, MCF
TOTAL ACCUM VOL NNNNNN.NN MCF
or MMCF
DIFF PRESS NNN.N IN. H2O Differential pressure, inches H2O
PRESSURE NNN.N PSIA Static pressure absolute, PSIA
FLOW TEMP NN.N DEG. F Flowing temperature, °F
Yesterday’s volume, programmable SCF, MCF or
YEST VOL NNNN.N MCF
MMCF
PERIOD VOL NNNN.N SCF Last volume calculation period volume
BATTERY VOLTAGE NN.N VOLTS Battery voltage as supplied by external unit
M_FLOWRATE NNNNNN.N SCF/HR Minute average flow rate
STATION ID ID of unit
ORIFICE DIAMETER N.NNNN INCHES Size of orifice plate
1.1.6 Display annunciators

Since a primary function of the G4 EX is to provide complete volume and
operational records, it is important to indicate unusual or alarm conditions as they
occur. This is supported on the LCD in the Annunciator display area shown in
Figure 1–2.
2104349 rev. AD Page 1–5

In the G4 EX computer, the status and alarm indicators are user programmable.
Table 1–3 identifies the default annunciator locations. Please consult the PCCU32
Help Files for additional instructions on programming the annunciators.
Whenever an alarm is indicated, the G4 EX records it in the appropriate log period
flow record. These are automatically retrieved when data is collected. Visual
alarms and status codes are described in Table 1-4.
Figure 1–2 Liquid Crystal Display (LCD) and indicators
Table 1–3 Default annunciator locations
Annunciator Application
A1 Measurement Tube 1
A2 CIM 0
A3 Valve Control
A4 COM2
A5 Plunger
A6 Local-COM0
A7 System
A8 TF Remote – COM1
Table 1–4 G4 EX status and alarm description
Indicator Description
System
LL Low Lithium Battery Alarm: When LL (low lithium) is displayed, lithium battery voltage is not
sufficient to maintain SRAM data. A new lithium battery measures approximately 3.6 VDC.
Display Application
1 A number represents the Display Group number currently being displayed.
The displayed item’s value is above the Data High Limit value specified on the display Item
↑
Setup screen.
The displayed item’s value is below the Data Low Limit value specified on the display Item
↓
Setup screen.
Page 1–6 2104349 rev. AD

Communications
 Transmitting Data: Sending a response.
 Receiving Data: Processing request.
! Negative Acknowledgement (Nak) w/packet list.
+ Positive Acknowledge (Ack) of receipt of request.
Waiting for Positive Acknowledgement: Waiting for response after transmission.
? Exception Alarm Processing.
ID Recognized: Recognized and receiving request.
Listen Cycle: Flashes if this remote port is active and running Totalflow Remote Protocol.
Flashes in sync with listening cycle that occurs at 1, 2 or 4 second intervals. May not be
visible if baud rate is faster than 2400. Annunciator will remain on if listen cycle is set to zero.
M MODBUS ASCII: MODBUS ASCII protocol selected for the port assigned to this annunciator.
m MODBUS RTU: MODBUS RTU protocol is selected for the port assigned to this annunciator.
L Local Protocol: Displayed when PCCU32 port is active and running Totalflow Local Protocol.
n Network (Ethernet).
u USB.
Measurement Application
BF Back Flow Condition: Visible only when DP variable displayed.
Z Zero Flow Condition: Visible only when Flow Rate displayed.
H Hold: Displayed when PCCU32 has entered Calibration mode on a Measurement Application.
Alarm Condition: Need to view alarm. The user may need to compare application limits to
A
current values to determine where the alarm condition is present.
A to D Failure: Displayed if A to D Converter’s differential pressure, absolute static pressure or
AD
temperature readings exceed maximum counts or are less than minimum counts.
1.2 Computer hardware

The G4 EX computers are housed in an explosion-proof enclosure. The
components that comprise this are as follows:
- G4 EX enclosure (3R/IP53 with breather drain installed; 4X/IP66 without
breather installed)
- G4 EX main processor board
- G4 EX termination board
- Lithium battery
- Engine Card
- G4 EX Liquid Crystal Display (LCD) Assembly
- PCCU Connector
- Internal Connector
- Explosion Proof External Connector – USB/Miltary (optional)
- Explosion Proof integral multivariable transducer with Raw Sensor board
Interface
- Resistive Temperature Detector
- Standard RTD (DIV 2)
- Explosion Proof RTD (DIV 1)
2104349 rev. AD Page 1–7

1.2.1 Enclosure
The custom-designed, explosion-proof enclosure consists of a cylinder shaped,
cast aluminum housing, powder coated, with front and rear end caps for access to
internal components (see Figure 1–3 through Figure 1–5). This enclosure may be
direct mounted, pipe mounted on the meter run using a pipe saddle or mounted on
a standalone pipe.
The enclosure features three (3) exterior hubs for wiring:
- Communication and power
- Resistive temperature detector (RTD)
- Input/output wires
The end caps have precision engineered threading and are susceptible to damage
if treated roughly. End caps are water tight, corrosion resistant and NEMA 4X
rated. Unauthorized removal of the end caps are protected with a 1/16”
countersunk hex head set screw on each end cap.

Do not attempt to loosen the end cap before loosening the set
screw. Doing so may damage threads on the unit.
1.2.1.1 Dimensions
Width
Unit w/o External w/ External Height Depth
PCCU PCCU
US 7.87” 9.50” 11.25” 8.34”
Metric 199.90 mm 241.30 mm 285.75 mm 211.84 mm
1.2.1.2 Installation and weight

W/ EX PCCU Pipe Mounted Direct Mounted
Unit Weight
Connector Depth Depth
US 15.65 lbs. 16.35 lbs. 9.69” 8.34”
Metric 5.84 kg 6.10 kg 246.13 mm 211.84 mm
Page 1–8 2104349 rev. AD

(9.50)
(7.87)
¾ NPT CONDUIT ENTRIES
¾ NPT CONDUIT ENTRIES
(01.53)
XFCG4 EX
(30º)
(01.84)
¾ NPT CONDUIT ENTRIES OPTIONAL EXTERNAL

PCCU FLAMEPROOF
HOUSING (2101416-001)
(3.76)
Figure 1–3 G4 EX enclosure
Figure 1–4 G4 EX enclosure left side
2104349 rev. AD Page 1–9

Figure 1–5 G4 EX enclosure right side
1.2.2 G4 EX main processor board

The G4 EX main processor board is mounted inside the front end cap, directly
behind the display assembly (see Figure 1–6 ).
User applicable connections on this board consist of the following:
- USD card (J3)
- Contrast display potentiometer (R1)
- LCD display connector (J2)
- Lithium battery connector (J5)
- Engine card connector (XA1)
- Sensor interface connector (J6)
- Termination board connector (J1)
The G4 EX transducer assembly utilizes a small electronic

board that contains the factory characterization data. This
allows the main electronics on the sensor assembly to be
individually field replaceable in the event of failures.
Installation and/or maintenance of electric components must

follow guidelines stipulated in the certification drawings
shipped with this unit and adhere to local codes.
Page 1–10 2104349 rev. AD

Figure 1–6 G4 EX main processor board
1.2.2.1 Engine card

An engine card plugs into the G4 EX board. All processor and memory
components reside on this engine card. The engine card uses a low power
processor running at 203 MHz with 16MB PSRAM for program execution and data
storage, 32MB Flash for application storage and 256 bytes of serial E2PROM. A
lithium backup battery is located on the main G4 EX board. Application programs
and configuration files are stored in non-volatile Flash.
1.2.2.2 G4 EX main processor board specifications

The G4 EX main processor board is designed as a general purpose motherboard
for the 6200/6201EX devices.
Table 1–5 G4 EX main processor board specifications
Component Description
Power 9 to 30 VDC
SWVBAT: 1 fused with 2.5 amp PTC
External Power
VBAT: 1 fused with 2.5 amp PTC
Charger No Charger
Application (Totalflow.exe) runs out of 16M SRAM. RAM memory has lithium
backup battery.
Memory Application and configuration files permanently stored in 32M Flash.
Registry (MAC address, etc.) is stored in 256 byte E2PROMSD Card
SD Card optional (512M/1G)
6 Ports Available
Dedicated PCCU/MMI (RS-232 or USB)
2 Onboard User Programmable RS-232/RS-422/RS-485 Ports
Comm. Ports USB (Client)
NOTE: A special cable is required, and the user must check with Totalflow for a
list of drivers to support Client peripherals.
Ethernet Bluetooth – Standard on the Main Electronics board
2104349 rev. AD Page 1–11

Component Description
Analog Inputs 1 (0-10 VDC)
1 (State Change or Pulse to 20 kHz) operating at a 50% duty cycle
Digital Inputs
with (Selectable De-bounce enabled 100 Hz)
Digital Outputs 1 FETs, sink = 2.5 Amp Max.Open Drain PTC, with 1500 W Transient protection
I/O Module Interface Optional plug-in I/O daughter card with 12 I/O (3 AI, 1 AO, 4 DI and 4 DO)
LCD Interface Dedicated interface for Liquid Crystal Display (LCD)
Security Switch On/Off Bi-level on-board Security (See Chapter 3 for details)
I/O Scan Rate 1 time per second
Time Base Stability  7.5 ppm (parts per million)
Pulse Input
Up to 20 KHz (Linear flow meter only)
Bandwidth
1.2.3 G4 EX termination board

The G4 EX termination board can be accessed by removing the rear end cap (see
Figure 1–7). All user connections should be routed through the cable entry hubs
and should adhere to local codes.
Located on the termination board, the user will find connectors for two (2)
communication ports: RS-232, RS-422 or RS-485 (software selectable). The user
should also note that there is a dedicated port for RS-232 local communications.
This is a plug type port and will connect to an internal PCCU connector or an
explosion proof external PCCU connector.
For more information on the explosion proof PCCU connector, see the
corresponding section. Additionally, for the internal PCCU connector, see the
section under Optional Equipment in this chapter.
Remote communication wiring for Port 1 is handled using the
COM 1 Port
J19 connector and the SW1 communication switch.
Remote communication wiring for Port 2 is handled using the
Com 2 Port
J20 connector and the SW2 communication switch.
The XFC G4 6200/6201EX (G4 EX) is approved for installation

in classified/potential hazardous locations where an explosive
atmosphere may be present. Follow precautions and
requirements for installation of equipment according to the
certification drawing indicated on the device’s nametag and
national and local electrical codes.
Page 1–12 2104349 rev. AD

Figure 1–7 G4 EX termination board
1.2.3.1 On-board I/O

The G4 EX termination board provides similar base I/O as earlier XSeries models
but with a reduced number due to enclosure restrictions. This includes:
- 1 user AI
- 1 user DO
- 1 user DI
- Interface for I/O daughter card: 3 AI, 1 AO, 4 DI (NAMUR rated) and 4 DO
1.2.3.2 Digital input

The G4 EX provides one digital/pulse input as a means to monitor external
equipment.
When connecting or disconnecting any wires to the G4 EX

boards, the user should remove all power sources and
insure that they are grounded properly.
The digital input reads an external contact. This is primarily used as a status input
to read external equipment. The contact must be closed to be considered “ON”.
The “ON” condition is recorded in the log period alarms and can trigger the action
of the G4 EX’s digital voltage output. OFF is defined as an open contact.
Selectable de-bounce can be enabled or disabled within PCCU32. See the
PCCU32 Help Files for additional information.
DI electrical specifications
- Open circuit voltage: 5 VDC (Internally pulled up to 5 VDC Nom.).
- Short circuit leakage current: -395 uA typical.
2104349 rev. AD Page 1–13

- Input capacitance: 0.1 ufd typical.
- Maximum allowable voltage range on input: -0.5 VDC to 15 VDC.
- Maximum frequency input: 100 Hz @ 50% duty cycle with de-bounce
enabled. 20 kHz @ 50% duty cycle with de-bounce disabled.
Input specifications
- Dry contact (form A), open collector or active voltage.
- Minimum contact resistance to activate input 1000Ω.
- Voltage threshold to deactivate the input: 3.1V (referenced to GND
terminal).
- Voltage threshold to activate the input: 0.5V (referenced to GND terminal).
- Conductor pairs must be shielded to prevent spurious signals.
Figure 1–8 Typical DI point schematic
Figure 1–9 DI connection example
Page 1–14 2104349 rev. AD

Figure 1–10 DI connection example
1.2.3.3 Digital output

The G4 EX provides one digital output (12 VDC or 24 VDC max.) as a means to
control external equipment.
When connecting or disconnecting any wires to the G4 EX

boards, the user should remove all power sources and
ensure that they are grounded properly.
The digital output can be used in conjunction with a measurement tube (AGA-3,
AGA-7 or liquid measurement) and triggered on the following measurement
parameters or conditions:
- Differential pressure over high limit
- Volume set point
- Differential pressure under low limit
- Flow temperature low
- Static pressure over high limit
- Flow temperature high
- Static pressure under low limit
- Flow rate low
- Low charger voltage
- Flow rate high
- Remote sense is on
- Trip on digital input
Custom programmable by Totalflow or user programmable with IEC 1131
programming language
DO electrical specifications
- Open circuit voltage: 0 VDC
- Short circuit leakage current: 0 uA typical
- Output capacitance: 1000 pF typical
- Maximum allowable voltage range on output: 0.5 VDC to 29.4 VDC
Output specifications
- Open drain FET type
2104349 rev. AD Page 1–15

- “ON” resistance (Including PTC fuse resistance): 0.1Ω Typical
- Maximum pulse current: 3A for 5 seconds
- Maximum continuous sink current: 1.2A at 60C or .75 at 85C
Typical DO point schematics
Figure 1–11 Typical DO point schematics

DO connection example
Figure 1–12 DO connection example
1.2.3.4 Analog input

The G4 EX provides one analog input as a means of receiving data, represented
by continuously varying voltage/current.
- Open circuit voltage: 0 VDC
- Short circuit leakage current: 0 uA typical
- Input impedance: 103.5KΩ typical (0 to 10V)
- Measurable input voltage range: 0 to 10.34 VDC
- Maximum voltage on input: 30 VDC
Page 1–16 2104349 rev. AD

Figure 1–13 Typical AI point schematic
Figure 1–14 AI example connections
1.2.4 Explosion proof multivariable transducer (EXIMV)

The EXIMV is an explosion proof version of the factory calibrated “smart” integral
multivariable transducer. The EXIMV is characterized over temperature so that
any changes occurring in the EXIMV or in the electronics can be compensated.
Providing the primary measurement capability for the G4 EX (see Figure 1–15 ),
the circuitry and characterization information are stored in the raw sensor board.
EXIMV specifications are discussed in Table 1–6.
2104349 rev. AD Page 1–17

The unit is designed to provide EMI/RFI protection of the low level signals and to
protect the circuitry from other environmental effects.
Figure 1–15 Explosion proof multivariable transducer (EXIMV)
Table 1–6 Explosion proof EXIMV specifications

Compensated: -20°F to 140°F (-29°C to 60°C)
Temperature limits Operational: -40°F to 140°F (-40°C to 60°C)
Storage: -40°F to 185°F (-40°C to 85°C)
Resolution 24 Bit A/D conversion (0.000012% FS) (0.0012% FS effective signal resolution)
Mounting spec. Change from perpendicular (front to back around X-axis) ≤0.5% URL
Static pressure
Linearity, Hysteresis and repeatability combined: ± 0.075% of user-calibrated spans from
Accuracy
20% to 100% of URL
Ambient temperature
effect within the
± 0.075% of URL +0.06% of Reading
operational
temperature limit
Stability ± 0.1% of URL (for 12 months)
Differential pressure
Linearity, Hysteresis and repeatability combined: ± 0.075% of user-calibrated spans from
Accuracy
20% to 100% of URL.
Ambient temperature
effect within the
± 0.075% of URL + 0.06% of Reading
operational
temperature limit
Stability ± 0.1% of URL (for 12 months)
Page 1–18 2104349 rev. AD

DP Zero per 1500 psi: ± 0.03% of URL (3200 psi maximum)
SP effect
DP Span per 1500 psi: ± 0.1% of Reading (3200 psi maximum)
Temperature
Operating range -80F to 750F (-62C to 339C)
± 0.35F (± 0.2C)over operating range (as shipped from factory)
Accuracy
± 0.2F (± 0.12C) repeatability over operating range (after single point field calibration)
1.2.5 Display assembly

The G4 EX display assembly (see Figure 1–16) has a dedicated interface to the
main processor board from the 4x16 LCD via a 14-pin connector.
The display utilizes four lines by 16 characters. The user can then customize the
annunciators based on their own specific needs. The alarm codes and
annunciators communicate a basic message(s) to the user and indicate a need for
further attention. These codes are location dependent and may mean different
things, based upon which character space the code appears in. These are also
user configurable.
Figure 1–16 Liquid Crystal Display (LCD) assembly
1.2.6 Resistive temperature detector (RTD)

Totalflow offers a choice of two RTD options. The 100 OHM Platinum RTD
measures real-time flowing temperature of the gas.
1.2.6.1 Standard RTD

The standard RTD is not DIV 1 approved; therefore, this RTD may only be
installed and used in general purpose areas.
2104349 rev. AD Page 1–19

1.2.6.2 Explosion proof RTD
The explosion proof RTD is available for use in DIV 1 areas (see Figure 1–17).
Two probe lengths are available: 10” and 16”. See Table 1–7 for standard probes,
based on Thermowell “U” lengths and Table 1–8 for standard Thermowells that
are based on thread diameter.
Figure 1–17 Explosion proof RTD
Table 1–7 Standard RTD probes
“U” Length Part Number “U” Length Part Number

2.00” 2101691–020 6.00” 2101691–060
2.50” 2101691–025 7.00” 2101691–070
3.00” 2101691–030 8.00” 2101691–080
4.00” 2101691–040 9.00” 2101691–090
5.00” 2101691–050 10.00” 2101691–095
Table 1–8 Standard Thermowells

Thread Diameter “U” Length Base Part Number
½” 2” through 10” 1622305
1” 2” through 10” 1622302
3/4” 2” through 10” 1622300
1.2.7 6270 Optional Equipment Unit (OEU)

The G4 EX unit is designed to be located in DIV 1 Hazardous areas; therefore,
many features and requirements of the unit are housed in a separate enclosure
that is located in DIV 2 or General Purpose areas.
Space is provided inside the enclosure to house a variety of remote
communication devices: transceiver, cellular phone, battery, changing source and
additional I/O (see Figure 1–18).
Page 1–20 2104349 rev. AD

The battery compartment shelf houses various optional battery packs that are
available for the OEU, from eight (8) ampere hours up to 26 ampere hours.
Installation of the battery is discussed later in the manual.
The 6270 OEU system with battery and solar panel is rated for
Class I, Division 2 locations only or can be installed in non-
hazardous locations.
Figure 1–18 Optional communication enclosure
1.2.8 Solar panel

A solar panel can be configured in the system to provide a charging source for the
battery. DIV 1 installations would require that the solar panel and battery pack be
installed in a General Purpose or DIV 2 area. Typically, the solar panel would be
connected through a charger regulator that is located in the 6270 OEU.
Depending upon power/charging requirements, the unit may be configured for a 5-
watt, 10-watt, 20-watt or 30-watt solar panel. The panel is designed to be mounted
on a 2-inch extension pipe.
2104349 rev. AD Page 1–21

Figure 1–19 Solar panel – typical installation
1.2.9 Lithium battery

The following information displays the technical information regarding the lithium
battery housed within the G4 EX.
When the G4 EX is in storage, it is recommended that the

lithium battery be disabled (unplugged from J5 connector) to
prevent power drainage. Not doing so can cause the battery to
lose power within six months.
Technical Data
Nominal capacity @
2.1 Ah
2 mA, to 2V
Rated voltage 3.6 V
Wires AWG 24
Enclosure UL 94V2
Mounting Hook and loop fastner
Operating
-55°C to +85°C/-67°F to +185°F
temperature range
1.3 G4 EX application licensing

The G4 (fourth generation) EX offers the user unrivaled power and flexibility. The
G4 EX units can support far more applications than the G3 (third generation)
devices. Various applications require that Totalflow pay a royalty to third party
vendors. As such, Totalflow has developed a credit system for handling
application loads beyond what would be required for a typical G3 meter run.
Application credits are required to enable many of the applications.
Page 1–22 2104349 rev. AD

From the factory, the G4 EX has four general credits installed. Several system
configurations are possible with these four general credits:
- AGA-3 with Plunger Lift and Trending (uses 3 general credits)
- Two AGA-3 (or AGA-7) tubes with Trending (uses 3 general credits)
- AGA-3 with Pad Control and Plunger Lift (uses 3 general credits)
Applications are divided into categories: standard, general, IEC and CO2. Other
application categories may be created in the future.
Standard applications typically support general applications as well as the basic
operation of the G4 EX unit. Standard applications do not require any credits to be
instantiated.
Standard applications include:
- System Application
- Communications
- I/O Subsystem
- Therms Master
- Therms Slave
- Analysis Trend System
- LevelMaster
- Pulse Accumulator
- NGC Client
- PID Controller
- Operations
- XMV Interface
- Holding Registers
- Units Conversion
- Host Interface
- Displays
General applications typically provide some type of measurement, control, logging
and/or archival function. General applications include:
- AGA-3 Measurement
- AGA-7 Measurement
- V-Cone Measurement
- Coriolis Gas
- Alarm System
- Shutdown
- Plunger
- PAD Controller
- Pump Interface
- Oil Custody Transfer Measurement
IEC applications are generally custom applications provided by Totalflow at the
customer’s request. This might include special control and/or measurement
algorithms required by the customer. Multiple IEC applications can be instantiated
with a single IEC credit.
- CO2 (NIST) applications each require a CO2 (NIST) credit.
2104349 rev. AD Page 1–23

1.3.1 Credit Key (USB)
The G4 EX comes with four general credits installed in the unit. If the system
configuration requires more application credits, they can be purchased from
Totalflow’s Order Entry (1-800-442-3097).
Credits (standard, general, IEC and CO2) are maintained on the credit key.
Credits can be purchased and kept on the USB credit key. The credit key is a
secure USB Flash drive (i.e., thumb drive). It cannot be written to or read by any
program other than PCCU32 7.0 or later. Credits can be added to the credit key
via a phone call to Technical Support or through email. Again, these credits are
used to run the various applications available in the G4 product line.
Credits can be transferred between the laptop and the G4 EX. If a G4 EX has
extra credits (more than required to be fully licensed), the extra credits can be
downloaded to the credit key to be used on other G4 units.
If the G4 controller is running an unlicensed application, that

fact is reflected in any reports generated from that
unlicensed meter. The meter will also log the fact that it is
unlicensed in the Event Log at the top of each contract day.
Unlicensed applications cause the meter to connect more
slowly.
1.4 Laptop computer running PCCU32

PCCU32 software running in a laptop Windows® environment offers the user the
most capabilities for programming the G4 EX. The Windows environment features
user friendly help files and easy to follow menus.
If configured with the USB option, the laptop computer connects via the cable
directly to the connector on the side of the G4 EX. Once this physical connection
has been made, the user may begin communicating through the software.
Remove power from device, or insure the area is known to

be non-hazardous before removing any enclosure cover.
electrical codes.
Connecting to the G4 EX meters with PCCU32 requires

version 7.05.5 or later.
Making a local connection to the meter may be accomplished one of three ways.
Traditionally, local connections have been made using the RS-232 PCCU cable
with the round military connector on one end and a serial port connector on the
other. The second method involves the local connection being made using a USB
cable. The third method utilizes the standard onboard Bluetooth wireless
connection. These methods are discussed below.
Page 1–24 2104349 rev. AD

1.5 Local G4 EX connectors
1.5.1 RS-232 serial PCCU cable (round military cable)
Remove power from device, or insure the area is known to

be non-hazardous before removing any enclosure cover.
electrical codes.
The local connection (serial military connector) requires an RS-232 serial port on
the host computer (generally a laptop). A PCCU cable is required to connect the
host computer to the meter’s round military connector (see Figure 1–20).
Connecting the PCCU cable to the meter will cause the annunciator in the LCD to
display an upper case letter “L” for local connect.
The G4 EX meter must be ordered to include serial

communication capability. A change over kit may be
purchased to adapt the G4 to USB capability.
Figure 1–20 RS-232 local communication cable
1.5.2 PCCU32 USB connection

The local USB connection requires use of a USB cable connected to the host
computer (generally a laptop). A USB PCCU cable is required to connect the host
computer to the meter’s client connector (see Figure 1–21). Connecting the PCCU
cable to the meter causes an annunciator in the LCD to display an upper case
letter “L” for local connect.
2104349 rev. AD Page 1–25

The G4 EX meter must be ordered to include USB
communication capability. A change over kit may be
purchased to adapt the G4 to serial capability.
Figure 1–21 USB local communication cable
1.5.3 Bluetooth connectivity

With the latest iteration of the G4 EX device, the user now has the option of
performing a local connecting using Bluetooth functionality. This option can be
accessed through PCCU32.
1.5.4 Network connectivity (dynamic IP with router)

When the user elects to operate the G4 EX in a network environment, using an
Ethernet is a practical solution. PCCU32 communication with the meter over an
Ethernet connection (TCP/IP) requires the use of a hub, switch or router along
with the appropriate cabling (see Figure 1–23). Ethernet (local) communication in
a remote area may also be utilized.
The Ethernet option is only available by removing the end

cap on the G4 EX device.
Page 1–26 2104349 rev. AD

Figure 1–22 Ethernet communication cable
Figure 1–23 Ethernet connectivity diagram
2104349 rev. AD Page 1–27

2 Installation
This chapter provides the user with the information for installation and setup of the
G4 EX. By the time the user has finished the chapter, they will have the G4 EX
unpacked, installed, field wired and ready for operation. For safe and trouble free
installation, follow all instructions and advisories.
Read through this chapter before beginning the installation.

This will give the user the ability to plan their specific
installation. Additionally, before beginning, refer to the wiring
diagrams delivered with the G4 EX. The user can store these
drawing under the Drawing tab in the back of the manual.
2.1 Unpacking and inspection
2.1.1 Unpacking
The G4 EX and RTD are shipped in a specially designed shipping carton which
contains the unit, mounting brackets, parts list and wiring and interconnect
diagrams. The solar panel and the battery pack with applicable hardware are
shipped in a separate carton.
Carefully remove the items from each carton.
2.1.2 Inspection
- Inspect the shipping carton for damage. If the shipping carton is damaged,
keep it until the contents have been inspected for damage.
- Inspect the unit’s exterior for dents, chipped paint, etc.
- Inspect the LCD window for breakage.
- Visually inspect the electronic boards, cables and EXIMV for damage.
2.1.3 Damaged components

If any components have been damaged or if there are noticeable defects, notify
the Totalflow representative. Keep all shipping materials for the carrier’s
inspection. Totalflow will arrange for immediate repair or replacement. See the
Getting Help section at the beginning of the manual.
2.2 2” Pole mount installation

The following information presented in this document will detail the steps for
mounting the G4 EX to a 2 inch mounting pipe using the mounting kit assembly
provided with the device. The G4 EX has three mounting types that can be
performed, based on the transducer that the user has received. It must be noted
that the transducer should be mounted above the meter run to allow adequate
slope between the manifold and the orifice fittings.
The installation instructions that follow can be used for either a side pole mount or
a stand-alone pipe mount configuration.
Before beginning these steps, review the procedures and the materials required
for installation.
2104349 rev. AD Page 2–1

2.2.1 Type A
2.2.1.1 Materials supplied

- G4 EX mounting kit assembly and associated hardware
2.2.1.2 Materials not supplied

- One 2” x 40” pipe
- Standard 3 or 5 valve manifold
- Stainless steel tubing
2.2.1.3 Step-by-step instructions
To install the G4 EX, it is recommended that two people

perform the installation. One to hold the unit in position and
the other to install and tighten the mounting brackets.
The method of installation must be consistent with the user’s

company policy.
1) Attach the pole mount bracket to the top of the 2” pipe with the U-bolts. Use
the provided hex nuts, flat washers and spring lock washers to tighten the
pole mount bracket to the 2” pipe.
Position the mounting bracket high enough on the pipe to

allow slope from the externally mounted manifold to the tap
valves.
2) Position the provided back clamp on the pole mount bracket, and align the
mounting holes between the two pieces.
3) Upon alignment, take the G4 EX and its attached transducer and set it
within the recessed groove on the back clamp.
4) Once the G4 EX and its transducer have been properly positioned, attach
the device to the brackets using the provided U-bolt. Use the hex nuts, flat
washers and spring lock washers to tighten the device to the mounting
brackets (see Figure 2–1).
Page 2–2 2104349 rev. AD

Back Clamp
Pole Mount Bracket
Figure 2–1 Type A Installation Configuration
2.2.2 Type B
The Type B installation configuration comes from the factory

with the transducer already enclosed in two attached
mounting brackets.




company policy.
2104349 rev. AD Page 2–3


valves.
6) Remove the lower two hex screws, hex nuts, flat washers and spring lock
washers from the transducer’s attached mounting brackets.
7) With the associated hardware removed, align the transducer’s bottom
mounting holes with those on the pole mount bracket.
8) Upon alignment, replace the hex screws, hex nuts, flat washers and spring
lock washers through their respective mounting holes on the mounting
brackets and into the pole mount bracket. Upon completion, tighten (see
Figure 2–2).
Figure 2–2 Type B Installation Configuration
It should be noted that if this is the type of installation

configuration that the user has received from the factory,
there may be additional parts within the provided mounting
kit assembly that are not used.
2.2.3 Type C


Page 2–4 2104349 rev. AD



company policy.

valves.
2) Position the provided back clamp on the pole mount bracket, and align the
mounting holes between the two pieces.
3) Upon alignment, take the G4 EX and its attached transducer and set it
within the recessed groove on the back clamp.
4) Once the G4 EX and its transducer have been properly positioned, attach
the device to the brackets using the provided U-bolt. Use the hex nuts, flat
washers and spring lock washers to tighten the device to the mounting
brackets (see Figure 2–3).
Back Clamp
Pole Mount Bracket
Figure 2–3 Type C installation configuration
2104349 rev. AD Page 2–5

2.2.4 Manifold input lines
The following instructions provide the procedural steps to install the manifold. The
meter run manifold high (+) and low (-) pressures terminate in the transducer’s
(EXIMV) + and – differential port cells. The differential port holes are located on
the bottom of the EXIMV (see Figure 2–4).

- Tubing fittings
A backup wrench should always be used when working with

stainless steel tubing and valves. This prevents the fitting from
turning and/or putting tension on stainless steel tubing.
Figure 2–4 G4 EX EXIMV ports

1) Install the isolation valves on the meter run.
2) Install the tubing between the meter run and the XFC. It should be noted
that the fittings are not supplied with the unit.
3) Leak check all connections.
Leaks in the tubing or manifold will introduce errors when

calibrating the transducer (EXIMV).
Page 2–6 2104349 rev. AD

2.2.5 Standard RTD probe installation
The standard RTD measures flowing gas temperature and should only be used if
the G4 EX is located in a General Purpose area, following local codes. The
procedures that are presented in this section will enable the user to install the
RTD into the meter run.
2.2.5.1 Optionally supplied materials

- RTD probe with 10’ of cable; optional lengths are 15’, 25’, 30’ 40’ and 50’
- One (1) Thermowell with ¾” npt threads; optional threads are ½” and 1”
- Nylon tie wraps

- Customer must specify Thermowell “U” length
- Teflon® tape

1) Install the Thermowell into the meter run (see Figure 2–5).
The power should be removed from the G4 EX before

performing any field wiring.
2) Using snap ring pliers, adjust the probe length so that it is spring loaded
against the bottom of the Thermowell.
3) Screw the probe connector into the Thermowell.
Figure 2–5 Thermowell installation into the meter run

4) At the G4 EX, remove the plug from the explosion proof RTD hub, and
screw the adapter bushing into the hub.
5) Remove the nut from the water tight cord connector. Leave the nylon
sealing ring in place.
2104349 rev. AD Page 2–7

6) Insert the wires through the cord connector, and continue through the
adaptor bushing into the enclosure (see Figure 2–6).
7) Screw the cord connector into the adaptor bushing, and tighten.
8) Inside of the G4 EX enclosure, begin by disconnecting the connector plug
from the RTD connection, J8, to begin field wiring.
Figure 2–6 RTD probe wiring

9) Using the supplied wiring instructions, make the field connections to the
connector plug, and re-insert into the J8 board connector.
10) Following the connection of the RTD Thermowell, secure the cable to the
meter run pipe with plastic tie wraps. Do not wrap cable around the meter
run pipe.
2.2.6 Explosion proof RTD probe assembly

If the G4 EX is installed in a DIV 1 area, the explosion proof RTD must be used
(see Figure 2–7). The following procedures assume that the explosion proof RTD
kit was purchased as an option. For additional information, refer to the Wiring
Interconnect and Application Instructions that were supplied with the kit.
HEAD
UNION
NIPPLE
THERMOWELL
CUSTOMER
SUPPLIED LINE
METER RUN
Figure 2–7 Explosion proof RTD overview

- RTD probe (see Table 1–7 in Chapter 1 for available parts)
- Optional Thermowell (see Table 1–8 in Chapter 1 for available parts)
- Explosion proof connection head
- Conduit union
- Nipple fitting
Page 2–8 2104349 rev. AD

- Certification tag
- Wiring instructions

- Teflon® tape
- Wiring cable/conduit from explosion proof RTD to flow computer (see local
codes for material specifications)
The following instructions assume that the Thermowell has

previously been installed. The end of the Thermowell should
penetrate the center 1/3 of the meter run.

1) Unpack the parts, and verify that all the supplied materials are present. If
parts are missing, contact Totalflow Customer Service at 800-442-3097 or
+1918-338-4880.
2) Screw the nipple fitting into the Thermowell, and tighten (see Figure 2–8).
3) Separate the top and bottom of the union. Screw the union bottom onto the
nipple fitting. Be aware that the union nut is on the union bottom. Tighten.
Figure 2–8 Explosion proof RTD disassembled

4) Screw the union top into the bottom of the connection head, and tighten.
5) Unscrew, and remove the cap from the explosion proof Connection Head.
6) Insert the RTD probe through the opening in the head. Holding the probe
from underneath, screw the spring clockwise down into the center of the
wiring block. Stop when the top edge of the spring is flush with the top of the
wiring block.
7) Insert probe and head assembly through the bottom half of the union that
was previously installed into the Thermowell. As the union halves meet, the
user should encounter some resistance. As the probe contacts the bottom
of the Thermowell, the user should see the top of the probe rise (3/4” max.).
If the probe assembly is too long or too short, the user may need
to change nipple lengths.
1) Lift the union nut up to the union top. Screw together.
2104349 rev. AD Page 2–9

2) Align the RTD head to the correct position for the conduit and wiring.
Tighten the union nut.
3) Using the supplied wiring interconnect drawings, wire the RTD probe at the
wiring block (see Figure 2–9).
4) Following local codes, run the RTD wiring to the G4 EX unit.
Figure 2–9 RTD probe wiring

5) Inside of the G4 EX enclosure, disconnect power from the termination
board. Remove the connection from J16.
6) Remove the connector plug from the RTD connection, J8, to begin field
wiring.
7) Using the supplied wiring instructions, make the field connections to the
connector plug. Re-insert into the J8 board connector.
8) Restore power to the unit.
2.2.7 6270 Optional Equipment Unit (OEU) installation

If the 6270 OEU enclosure is used, it may be configured to include other options,
including but not limited to, a battery pack to provide power to the G4 EX,
communication equipment and solar panel charger.
Following local codes for installation, this unit would normally be located in a DIV 2
or General Purpose area. The unit may be mounted on a 2” pipe or mounted on
flat surface such as a wall.
The battery and solar panel are packed and shipped separately from the 6270
OEU. Before installation, inspect all power cables where they terminate and
connectors for damage.
Before beginning, review the procedure and the materials required for installation.
The 6270 OEU system with battery and solar panel is rated for
Class I, Division 2 locations only or can be installed in non-
hazardous locations.
Page 2–10 2104349 rev. AD

2.2.7.1 Pipe mount
Enclosure mounting brackets and fastening hardware are supplied with the unit.
The customer must provide a 2” pipe of suitable length (see Figure 2–10).
If a charging source, such as a solar panel, is desired, this procedure may be
configured to mount the solar panel on the upper portion of the pipe.
Figure 2–10 6270 OEU pipe mounting installation

Step-by-step instructions
Instructions assume that the user has completed the installation of

the 2” pipe.
1) Using the instructions supplied with the mounting kit, attach the bracket to
the back of the enclosure unit.
2) Position the unit on the 2” mounting pipe, and secure in place with two U-
bolts, flat washers, lock washers and two bolts (see Figure 2–10).
2.2.7.2 Wall mount

Before beginning, review the procedures and the materials required for
installation. A typical installation should look similar to Figure 2–11.
The enclosure mounting brackets and fastening hardware are supplied with the
unit.
2104349 rev. AD Page 2–11

Figure 2–11 6270 OEU wall mount installation
1) Using the instructions supplied with the mounting kit, attach the bracket to
the back of the enclosure unit.
2) Prepare the wall surface for mounting, and mount the enclosure to the wall.
2.2.8 Battery Pack Installation

If the 6270 OEU is used (see Figure 2–12) and is configured to include a battery
pack, use the following procedures.
The battery is packed and shipped separately from the 6270 OEU. Before
installation, inspect the power cables that are located inside the 6270 OEU where
they terminate on the battery pack and the connector for breakage.
Before beginning, review the procedures and the materials required for
installation.
To extend the life of the battery pack, fully charge the battery
prior to installation. Systems using solar panels may not fully
charge the battery. Charging the battery fast will remove the
oxide buildup and will improve the life of the battery.
Do not over charge the battery pack.
Page 2–12 2104349 rev. AD

Figure 2–12 6270 OEU enclosure

1) Insert the battery pack into the battery compartment (see Figure 2–12) with
the long dimension of the battery facing outward.
2) Connect the battery pack connector to the battery connector mate that is
wired to the charger regulator.
3) If the G4 EX unit is already wired to the 6270 enclosure, the LCD screen
should display a warm start.
2.2.9 Lithium battery installation

The following are steps for installing and verifying the connection on the lithium
battery. The lithium battery is disabled when shipped from the factory. The user
will need to connect the battery before continuing.

1) To connect the battery, remove the front cover of the G4 EX. Look for the
battery connector behind and to the lower right side of the display (see
Figure 2–13).
2) On the G4 EX board, the lithium (+) red is on top (pin 1) and the (-) black
(pin 4) is on the bottom. It should be noted that this is a confined space. As
such, place the ground lead of a voltmeter on bare metal, such as the plate
behind the display, and place the positive lead on the bottom solder pad. Do
not place lead against ground.
2104349 rev. AD Page 2–13

Figure 2–13 Lithium battery
2.2.10 Solar panel installation

The solar panel is designed for outdoor mounting on a 2” extension pipe installed
on the upper end of the 6270 OEU 40” mounting pipe (see Figure 2–14). The solar
panel must be mounted within 12 feet of the 6270 enclosure (other lengths
available). For wall mounted enclosures, it can be mounted on the top or the side
of the meter house.
Do not connect the solar panel power cable to the charger

regulator that is located in the 6270 enclosure, unless the
main battery pack has been connected. Refer to the Battery
Pack Installation section.
Exercise caution when installing the solar panel so as not to

damage it.
For solar panel installations where the panel is mounted on

the top or to the side of a meter house, please insure that
the panel receives full sun all day. When mounted, the solar
panel will face up from the horizon at a 50° angle and face
in a southern direction.
The 6270 OEU system with battery and solar panel is rated
for Class I, Division 2 locations only or can be installed in
non-hazardous locations.

- One solar panel
- Two U-bolts and fastening hardware
- Solar panel cable (if not already attached)
- Solar panel mounting bracket (if not already attached to the solar panel)
- Pipe mounting kit

- Cable ties
Page 2–14 2104349 rev. AD

Figure 2–14 Solar panel installation

1) Attach the 2” pipe coupling to the top end of the 6270 OEU mounting pipe.
Securely tighten.
2) Install the 2” pipe extension into the coupling. Securely tighten.
3) Check the solar panel using the Digital Multi-meter to verify polarity and
output voltage. Voltage varies depending on the amount of sun, angle to the
sun, etc.
4) Install the solar panel on the mounting bracket, if required, with the provided
hardware. Install the solar panel cable, if required.
5) Attach the solar panel mounting plate to the top end of the 2” extension pipe
with U-bolts and associated mounting hardware. Do not tighten the U-bolts
until the solar panel has been correctly oriented.
6) For northern hemispheres, position the solar panel facing south; for
southern hemispheres, position the solar panel facing north. For optimum
charging, the solar panel should not be in shadows for any portion of the
day. The panel should be kept clean for maximum charging.
The sun’s orientation in the sky varies from summer to

winter. Keep this in mind when installing the solar panel to
make sure there are no obstructions during the entire year.
7) Do not connect the other end of the cable to the 6270 OEU until the main
battery pack has been connected and the user has been instructed to do so.
8) Remove the hole plug from the OEU, and install the cord connector.
2104349 rev. AD Page 2–15

9) Remove the nut, sealing ring and grommet from the cord connector. Slide
the nut, sealing ring and grommet over the end of the cable, and insert the
cable through the body of the cord connector. Leave enough of the cable on
the outside of the unit to allow the cable to dip below the level of the access
hole. This provides a path for moisture to run away from the unit to the
lowest point of the cable.
10) On the inside of the enclosure, allow enough cable to comfortably extend to
the input terminals on the charger regulator (see Figure 2–14).
11) Slide the nut, sealing ring and grommet to the cord connector on the side of
the unit, and tighten.
12) Before making connections to the charger regulator, trim the wire ends back
¼”.
13) Verify that the main battery pack is connected.
14) Loosen the securing screws on the charger regulator, insert the wire and
then retighten. Connect the solar panel (+) lead to the + terminal and the (-)
wire to the – terminal.
15) Following the connection of the solar panel power cable, secure the cable to
the 2” extension and mounting pipe cable with the provided plastic tie-
wraps.
2.2.11 AC charging unit installation

The AC power charging unit maintains a constant voltage charge on the installed
battery pack (see Figure 2–15).

- AC charging unit
- Pipe nipple

- Plastic cable ties
- AC wiring, conduit (rigid or flexible)
To maintain system certification, all wiring must comply with

NEC 501 code and applicable ABB certification drawings.
To prevent injury, only a licensed electrician should install

AC power wiring to the user supplied primary AC power
source.

1) The AC charging unit is shipped separately. When the unit is received,
unpack, and inspect all components for evidence of damage. Report
damage to the shipping carrier and to Totalflow’s Service Department.
2) Remove one of the plugs from the side of the 6270 OEU so that the AC
charging unit can be mounted without obstruction. See Figure 2–15.
Page 2–16 2104349 rev. AD

3) Remove the outside of the lock nut from the nipple. Leave the sealing ring
and inside lock nut.
Figure 2–15 AC charger installed
Figure 2–16 AC charger outlet box installation

4) Feed the AC charger’s DC power lines into the enclosure (see Figure 2–16).
2104349 rev. AD Page 2–17

5) Insert the nipple through the side of the enclosure, and install the removed
lock nut.
6) To prevent moisture from entering the enclosure after installing the AC
battery pack charger, be certain the “O” ring side of the metal backed
sealing “O” ring is against the enclosure.
7) Loosen the terminal screws, and insert the red wire into the plus (+) array
terminal and the black wire in the negative (-) array terminal (see Figure 2–
17). Retighten the screws.
8) Connect the green wire to one of the grounding screws that are located on
the bottom of the enclosure.
9) Pipe the conduit and associated AC wiring into the AC charger conduit box.
The AC charger is rated at either 120 VAC 60 Hz or 240 VAC 50 Hz.
Connect the 120 V hot and neutral or the two hot wires for 240 V to the
terminals of the AC charger. Connect the ground wire to the green screw.
10) Verify that the DC power wires are terminated properly inside the 6270 OEU
cabinet and that the main battery pack plug is already connected. Apply AC
power to the AC charger.
Figure 2–17 AC charger inside the conduit enclosure
2.2.12 Uninterrupted power supply (UPS) to the G4 EX

The G4 EX can be powered directly from any UPS that is supplying 9-30 VDC.
See Figure 2–18 for instructions on how to wire the G4 EX termination board to a
UPS.
Page 2–18 2104349 rev. AD

Figure 2–18 G4 EX to UPS
2104349 rev. AD Page 2–19

3 G4 EX start-up
The following chapter describes the steps required to get a newly installed G4 EX
system up and running. Specific information required to complete each step
(depending on equipment choice) is discussed more thoroughly in the PCCU32
Help Files.
All references in older materials to absolute pressure (AP)

have been converted to static pressure (SP). This reflects
the difference of including barometric pressure during
calibration.
3.1 PCCU32 installation and setup

Totalflow PCCU32 7.05.5 (or later) software is required to communicate with the
G4 EX. Previous versions of PCCU32 are not compatible.
PCCU32 software running in a laptop Windows® environment offers the user the
most capabilities for programming. 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.
3.1.1 Step-by-step instructions

1) Insert the PCCU32 disk into the PC drive. The Install Program should
automatically load (assuming the Auto Insert Notification has not been
turned off).
If the Install Program does not automatically load, click on Start and then
Run.
- Type the CD/DVD drive letter plus ‘setup. For example: E:setup.
- Click the OK button.
2) The Install Program will load followed by a Welcome message. Click the
Next button.
3) A screen will display that asks for user information. Complete entering in the
relevant information, and enter the serial number in the appropriate space
(the user needs to ensure that they enter both the numbers and dashes for
the serial number). Click the Next button.
4) Change the destination directory, if desired. Click the Next button.
5) Change the program folder, if desired. Click the Next button.
6) The installation process will load all the required software. If the install
program asks the user to restart the computer, the user will need to do so
before running the PCCU32 software.
7) If there is no message that asks for a restart of the computer, the installation
is complete. Click the Finish button.
3.2 Establishing local communication

As discussed previously, local communication can be established in different
ways: RS-232 MMI cable, Bluetooth or USB cable. The unit can be configured for
one or the other or all. TCP/IP is available but is designed for use over a network
setup.
2104349 rev. AD Page 3–1

With each selection, the user will see options that pertain only to that connection
method.
3.2.1 Connecting to a local port via a RS-232 cable

If the unit is configured to include the local RS-232 Communication port, the
connection is made using the RS-232 cable. This connects the laptop computer to
the local port on the meter.

1) Connect the MMI cable to the designated port on the PC (default is COM 0)
and to the local port located on the unit.
2) The user needs to open PCCU32. Upon selection, PCCU32 will open.
3) With the MMI cable connected, click the Connect icon on the PCCU32 main
toolbar. The Local Connect screen will display.
If the invalid security code screen displays, enter four zeroes

(0000) for the new code, and click the OK button. The G4 EX
should have defaulted to 0000 on start-up.
If the meter has been given a security code, the user needs to
ensure they have entered that code in PCCU32’s System Setup
screen (see Figure 3–1). However, if the meter has been cold
started, the security code will be reset to factory default, and
historical data will be lost.
Figure 3–1 System Setup Screen
Page 3–2 2104349 rev. AD

4) The Local Connect screen displays six buttons. From the button selections,
click Entry Setup to move to the Station Setup screen. Links within the
PCCU32 tree-view will move the user to screens for setup and daily
operations.
3.2.2 Connecting to local USB port

If the user’s unit is configured to include the local USB communication port, the
connection is made using the USB cable. This connects the laptop computer to
the Local port on the meter.
Before the user is able to communicate to the G4 EX using a USB cable, they
must install the Totalflow USB driver: Totalflow.inf.

1) If the G4 EX and laptop are powered up when the connection is made, the
user will receive the Found New Hardware Wizard screen (see Figure 3–2).
When this screen displays, the user needs to select the No, not this time
radio button. Click Next.
Figure 3–2 Windows found new hardware wizard

2) To install Totalflow.inf, select the Install from a list or specific location (i.e.,
the PCCU32 folder) radio button (see Figure 3–3). Click Next.
3) Select the Include this location in the search checkbox. Browse to the
PCCU32 folder. In Figure 3–4, the folder was named PCCU605 to draw
attention to the necessity to run PCCU32 version 7.05.5 or later with the G4
EX. After browsing to the folder that contains the Totalflow.inf, click the Next
button.
2104349 rev. AD Page 3–3

Figure 3–3 Specific location selection window
Figure 3–4 Specify location for USB driver (Totalflow.inf)
Page 3–4 2104349 rev. AD

4) At this point, the user may receive a Windows® message that warns that the
Totalflow USB driver has not passed Windows Logo testing. If the user
wishes to use their laptop’s USB port, they will need to click on Continue
Anyway, and proceed on with the installation.
5) The installation procedure begins loading the Totalflow.inf. This should only
take a few seconds. This will complete the Found New Hardware Wizard.
Click the Finish button. The Totalflow USB driver is now installed.
If the user sees the Found New Hardware Wizard on

subsequent connects to the meter, click the Cancel button.
6) The user will need to open PCCU32.

7) With the USB cable connected, click on the Connect icon within the
PCCU32 main toolbar. The Local Connect screen displays six buttons.
From the button selections, click Entry Setup to move to the Station Setup
screen. Links within the PCCU32 tree-view will move the user to screens for
setup and daily operations.
3.2.3 Setup of the G4 EX for Bluetooth connectivity

The following instructions will show the user how to set up the G4 EX for Bluetooth
connectivity.

1) Plug the Bluetooth adapter into the computer. Ensure that all the relevant
drivers are installed, and the device is working properly.
2) Open PCCU32. From the PCCU32 main toolbar, select the System Setup
icon. This will take the user to the System Setup dialog box.
3) The user will need to click the Bluetooth radio button to establish that this is
the method by which they are connecting.
4) Once this has been accomplished, the screen will populate with the relevant
fields that pertain to the Bluetooth connection method. If the Bluetooth
adapter is supported by the G4 EX, the Search for Bluetooth Devices button
is activated along with a drop-down list of Bluetooth devices that have
previously been selected (see Figure 3–5).
5) The user may select a previous Bluetooth device in the drop-down list or
search for a device (see Figure 3–6). If the user searches for a Bluetooth
device, the list will contain previously paired devices and not just the
devices in range.
6) The user may select the preferred Totalflow Bluetooth device, or if that one
was not found after the search, the user can initiate another search. Upon
selection, the device will be populated in the drop-down list in the System
Setup dialog box.
7) The user must provide the Bluetooth pairing code to automate the
connection. This is typically a 4-digit authentication code set in the device
and is defaulted to 0000.
2104349 rev. AD Page 3–5

Figure 3–5 System setup - Bluetooth
Figure 3–6 Select a Bluetooth device dialog box

8) The user can close out of the System Setup dialog box, and press the
Connect button. PCCU32 will attempt to pair with the selected Bluetooth
supported Totalflow device and establish communication with it.
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9) It should be noted that if the Bluetooth adapter plugged into the computer is
one that is not supported, the user will receive a different screen in the
System Setup dialog box (see Figure 3–7). At this point, the user must use
their Windows software that came with the Bluetooth adapter, and set up a
pair/connection to the preferred Totalflow Bluetooth-enabled device.
Figure 3–7 System Setup dialog box - Bluetooth

10) Once the pair/connection has been made, the user will need to assign a
communication port to it. After this is accomplished, the user can set the
com port in the drop-down list provided on the System Setup dialog box.
11) The user will then need to close the System Setup screen, and connect to
PCCU32 to communicate with the device.
3.2.4 Setup of the G4 EX for Ethernet connectivity

To set up the G4 EX for an Ethernet connection, the user must first connect locally
using either the RS-232 or USB cable. Using the local connection allows the user
to setup the device for Ethernet connectivity.
Currently, there are a variety of methods for completing this task. The following
will cover two such methods.
3.2.4.1 Method one

1) Connect locally using either the RS-232 instructions or the USB instructions
covered in the previous section(s).
2104349 rev. AD Page 3–7

2) In PCCU32 Entry mode, select Communications from the tree-view. Upon
selection, click on the Network tab (see Figure 3–8).
Figure 3–8 Network tab

3) The user will need to enter a Network ID, and set the Enable DHCP
parameter field value to Yes. The other fields within the tab will auto-
populate. Click the Send button.
4) Next, the user will need to locate the Totalflow – TCP selection under
Communications in the PCCU32 tree-view (see Figure 3–9). Once selected,
the user is taken to the Setup tab. In this tab, the user needs to set the
Protocol parameter value to Totalflow/TCP. When done, click the Send
button.
Page 3–8 2104349 rev. AD

Figure 3–9 Communication setup
5) While still in PCCU32, the user needs to click the Operate selection on the
main PCCU32 toolbar. From the drop-down menu, select Setup. From the
fly-out menu, select System Setup.
6) Within the System Setup dialog box (see Figure 3–10), click the TCP/IP
radio button. Next, enter the network ID or IP address for the meter in the
corresponding parameter field. The network ID is the same ID that the user
entered earlier within the meter setup.
7) Upon finishing, click the Close button.
2104349 rev. AD Page 3–9

Figure 3–10 System Setup window
8) Exit PCCU32 and the local connection.
9) With the Ethernet cabling installed, connecting to the meter is no different
than when using the PCCU cable or military connector. Click on the
Connect to Totalflow icon in the PCCU32 toolbar. To connect and move
directly to Entry mode, click on Entry instead of the Connect icon.
If the user has several meters on their network, they may find it
helpful to create a desktop shortcut for each meter. For
instructions on how to accomplish this task, follow steps 10 – 12;
otherwise, the user may continue on to the next section.
10) Create a desktop shortcut, and assign a name to it. For the sake of the
example, the following will use the meter’s ID for the shortcut name.
11) The user will now need to point to the version of PCCU32 that they want to
use (the user may have multiple versions of PCCU32 on their laptop). It
should be noted that it must be PCCU32 version 7.05.5 or later.
12) The user will then need to identify the network protocol to be used (TCP)
and the network ID (see Figure 3–11).
For example:
- Point to the folder with PCCU32 in it.
- Point to PCCU32.exe.
- Point to the protocol (TCP).
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- Point to the specific network address (XFC-148).
- String the enter address together: C:\PCCU605\pccu32.exe TCP:XFC-
148.
Figure 3–11 Windows desktop Shortcut dialog box
3.2.4.2 Method Two

1) Connect locally using either the RS-232 instructions or the USB instructions
covered in the previous section(s).
2) In PCCU32 Entry mode, select Communications from the tree-view (see
Figure 3–12). Upon selection, click on the Network tab.
3) In the Network tab, set the Enable DHCP parameter field value to No. Click
the Send button. The remaining parameter fields within the Network tab will
auto-populate.
2104349 rev. AD Page 3–11

Figure 3–12 Network tab
4) Move to the IP Address parameter field, and type in the IP address that is
reserved for the device. Click the Send button.
5) Close PCCU32.
6) Open the door to the unit, and locate the Reset button on the board. When
located, press the Reset button. This will set the IP address on the board.
7) The user will need to reopen PCCU32, but do not connect.
8) From the PCCU32 toolbar, click the Setup icon. This will take the user to the
System Setup dialog box (see Figure 3–13).
9) Within the System Setup dialog box, the user needs to select the TCP/IP
radio button.
10) Move to the Network ID or IP parameter field, and type in the IP address
that was established in step 4.
11) Click the Close button.
12) Reconnect to PCCU32, and move back into Entry mode. This establishes
the Ethernet connection.
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Figure 3–13 System setup
3.3 Setting up the G4 EX

Once the user has physically connected to the G4 EX, they must then instruct the
software of the programming device to connect to. At this time, the software will
actually read the device default values that are programmed at the factory. These
preset values are based on the type of product that the user has ordered and
programmed for the most widely used configuration.
Depending on the programming device that is being used, the following are
minimum required entries. Specific information required to complete each step is
discussed in the PCCU32 Help Files.
3.3.1 Date/time
The G4 EX date and time should be set before other tube parameters are entered.
This insures that events are properly dated and time tagged. Attention should be
given that the date and time are set correctly and should agree with the collection
equipment. PCCU32 or WinCCU can be used to update the date and time of the
device.
2104349 rev. AD Page 3–13

Description Format Note
Date MM/DD/YY Must enter 2 digits each
Time HH:MM:SS 24-hour clock
3.3.2 Station ID
The station identifier code should uniquely identify one G4 EX from that of any
others.
Station ID XXXXXXXXXX 10-digit alphanumeric
3.3.3 Location
The location field can hold up to 24 alphanumeric characters to describe its
location. An example would be the lease name, county name or road number.
Station ID XXXXXXXXXXXXXXXXXXXXXXXX 24-digit alphanumeric
There are additional fields stored in WinCCU for uniquely

identifying the meter, including fields for entering the lease
holder, producer, operator and buyer. These fields reside on
the host computer in the ID Manager not in the G4 EX.
3.4 Security system

Data and configuration security in the G4 EX is spread across three elements: the
flow meter, PCCU32 and WinCCU32. Currently, there are three types of security
that are possible:
- Device enforced legacy level 1-2 security
- WinCCU enforced legacy security
- Device and PCCU32 enforced Role Based Access Control (RBAC) security
The following sections will cover these security options.
3.4.1 Device legacy bi-level security

The G4 EX has a security switch (S2) on the termination board. Password security
is bi-level: read only (security code level 1) or read/write (security code level 2). To
establish meter security, the user must have the security switch in the OFF
position, and locally connect with PCCU32. Enter a four digit number level 1 and
level 2 security code, and click Send.
3.4.1.1 Establishing meter security

To establish a meter security, the user must have the security switch in the OFF
position, and locally connect with PCCU32.
1) Enter a four digit number for level 1 and level 2 security codes (see Figure
3–14), and click Send.
2) Turning the security switch (S2) ON will activate the security codes.
Page 3–14 2104349 rev. AD

Figure 3–14 Station Setup tab
The level 1 code (Figure 3–14, 1234) will allow data and configuration values to be
read but not altered. The level 2 code (in the above screenshot, 5678) will allow
full access to read and write.
These security codes must be entered into PCCU32 and WinCCU32 to provide
the appropriate access to the meters. However, WinCCU32 will always need the
proper security code, regardless of the position of the security switch (S2). Turning
the security switch off does not allow unprotected access for a WinCCU32
operator.
Modbus access to the meters is not protected by the security

codes.
3.4.1.2 PCCU32 software security

PCCU32 will require the appropriate security code to be entered.
1) To enter the security code, the user will need to move to System Setup in
PCCU32.
2) Enter the appropriate security code and select Close.
In the provided example (see Figure 3–15), the operator has been provided with
read only access to the meter.
The security code level of 1234 (per Figure 3-15) provides read only access to the
meter. If 5678 was entered, the user would have full read/write access to the
meter.
If the security level is breached, the meter will give no

indication. Any data that the user attempted to change will
simply remain unchanged.
2104349 rev. AD Page 3–15

Figure 3–15 Security Setup dialog box
If the Security Switch (S2) on the termination board is in the

Off position, no security code has to be entered to access
the operating parameters, even if there is one programmed
into the device.
3.4.2 WinCCU32 software security

WinCCU32 also requires the appropriate security codes be entered in the Device
ID (see Figure 3–16).
1) Highlight the appropriate meter in WinCCU, and click Edit ID.
2) Enter either the level 1 or level 2 security code.
3) Click OK.
Page 3–16 2104349 rev. AD

Figure 3–16 WinCCU32 Edit a Device ID dialog box
The security code level 2 of 5678 (per Figure 3–16) has been entered. This gives
the WinCCU32 user full read/write access to the meter.
Modbus access to the meters is not protected by the security

codes.
3.4.3 Role Based Access Control (RBAC)

Role Based Access Control (RBAC) is a feature in PCCU32 that is designed to
allow an administrator to designate roles and control access levels to various
applications and processes in G4 devices.
Beginning with a set of default roles, it is possible to duplicate, rename and delete
these items to create a working list of access roles that are relevant to the user’s
company hierarchy. From this role list, it is then possible to create user accounts
with various assigned roles. The user is also given the ability to take the newly
created configuration and save it in the form of a security file to their PC. The
security file can then be sent to a G4 device, where it is then implemented.
RBAC is enforced by both the device and the PCCU32

interface for G4 devices. Enforcement on devices is on a
port-by-port basis. When RBAC is enforced, type 1 and 2
security is superseded.
3.4.3.1 Security file configuration

RBAC configurations can be defined and saved in a security file. This mainly
includes Role Definition, User Configuration and Port Configuration.
The following instructions provide information for creating and editing a security
file.
2104349 rev. AD Page 3–17

1) After PCCU32 has been opened, move to the Security option under the
Operate menu option from the PCCU32 toolbar. Select Role Based Access
Control and then Role Administration from the fly-out menu (see Figure 3–
17).
Figure 3–17 Role administration menu path

2) Once Role Administration has been selected, the Security Editor dialog box
displays (see Figure 3–18).
Figure 3–18 Security Editor dialog box

RBAC security files are supported by G4 and NGC devices. The user is given the
ability to select the device type that the security file is specifically intended for.
For each role, it is possible to set the access level for each function that is listed.
The Entry View function sets the highest selectable level and has the options of
None, Basic, Advanced or Expert. Other functions have either a Yes | No option or
Page 3–18 2104349 rev. AD

a No Access | Read Only | Read/Write option. If an existing role definition does not
provide the proper capabilities, a new one can be created by clicking the Browse
button next to the Role drop-down list. This brings up the Roles dialog box (see
Figure 3–19).
Figure 3–19 Roles dialog box
3.4.3.2 Role definition

Default roles are automatically installed with PCCU32. These default roles are as
follows:
- Administrator
- Expert
- Advanced
- Basic
- File Admin
The Administrator role has the highest level access rights to all functions. Expert,
Advanced and Basic roles have decreasing levels of access rights.
The File Admin role has access rights of the Basic role plus minimum rights
required for sending/reading RBAC security files to and from G4 devices.
3.4.3.3 Role creation

The following instructions will walk the user through the steps for creating a new
role.
1) Select the row that has the corresponding access level that the user wants.
Upon location, click the Copy button.
2) A dialog box displays and asks for the name of the new role. Assign a name
to the role. The new role is then available in the Roles dialog box.
3) Modify the access levels to complete the modification of the created role:
- To change the name of an existing role, select the cell, and click the
Rename button.
- To delete an existing role, click the Delete button.
- The Default button resets the Role list to the factory defaults.
3.4.3.4 User configuration

When adding a new user, the default role is the one that is currently displayed in
the Role drop-down list at the time the Add User button is clicked. The following
dialog box displays to set the user name and password (see Figure 3–20).
2104349 rev. AD Page 3–19

Figure 3–20 User Name and Password dialog box
A security key is generated and displayed after the configuration is saved to a
security file. The Security Key file is displayed with “n/a will be generated on
save”, before a configuration is saved or after any modifications are made to a
saved configuration. The security key is logged in the Security Log every time the
security file is sent to a device or the device warm boots. Additionally, it can be
used to verify the security file on the device is the one created by the security
administrator.
The PC file name of the security file is saved in the security file and displayed in
the Security Editor dialog title bar, when the file is read from a device. It will also
be used as a default file name, suggested for saving.
The Open button opens a security file from the PC for editing (see Figure 3–18).
The New button clears all users and starts editing a new security configuration
with default roles and no users.
RBAC security files are saved with a unique extension (.rba), by default. There is
also a default directory that hosts these files. The directory is configurable by
selecting the menu item Operate > Setup > System Setup (Figure 3–21).
Figure 3–21 System Setup dialog box

When connected to a Totalflow G4 device, the Read button is enabled for all
users. Additionally, the Send button is enabled only for users with Administrator
rights. The Read button reads a security file from the device for editing. The Send
button is used to send and apply the security configuration to a device.
Another way to send a security file is to select the menu item (Operate > Security
> Role Based Access Control > Send Security File). This menu item is only
Page 3–20 2104349 rev. AD

enabled for users with Administrator rights. Clicking the menu item displays the
Send Role Based Access Control File dialog box (Figure 3–22).
In the dialog box, the user can click the Browse button to select the required file.
Upon selection, the user can click the Send button to send the security file.
Figure 3–22 Send Role Based Access Control File dialog box
3.4.3.5 Port configuration

Entry mode is available in the Advanced and Expert view modes and can be used
to configure RBAC for ports that are not specified in the security file or can be
used to override what is specified in the security file. Under each port which has a
protocol specified is a parameter field called Authentication. This parameter can
be set to Disabled, Enabled or Enable by Security Switch (See Figure 3–23).
- Disabled – Does not perform any RBAC functions on the port.
- Enabled – If the administrator name and/or password are lost or forgotten, it
will be necessary to use TfLoader to delete TfCold and TfData, and then
cold start the device to gain access. This will reset the device to the default
factory configuration.
- Enable by Security Switch – If the administrator name and/or password are
lost or forgotten, RBAC may be disabled using the legacy security switch.
By setting the switch to the Off position, a user may log in and reconfigure
the security access. This will not result in the loss of any data.
Figure 3–23 Totalflow-TCP Setup tab
2104349 rev. AD Page 3–21

3.4.3.6 User login
When the user tries to connect to an RBAC enabled port on a G4 device, they are
first asked to login (see Figure 3–24).
The user can elect to save the user name/password as default credentials to be
used for subsequent logins. To change or disable the default RBAC credentials,
select the menu item, Operate > Setup > System Setup (see Figure 3–25).
After a security file is sent to a Totalflow G4 device, the user is disconnected from
the device and asked to re-login under the following circumstances:
- RBAC security was not enabled on the connected port before the security
file is downloaded.
- The user is not defined in the new security file.
- The user has different access rights in the new security file.
Figure 3–24 Login dialog box
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Figure 3–25 System Setup dialog box
3.4.3.7 Security log

To track access to Totalflow G4 devices, a security log is kept that indicates the
date and time when a user logs in, the user name, the port where the access was
made and the actions taken before logout. Log entries are also generated when a
security file is downloaded and/or processed. Additionally, the results of applying
the configurations will also be logged every time a new security file is downloaded.
This tab is available in Advanced and Expert view modes (see Figure 3–26).
2104349 rev. AD Page 3–23

Figure 3–26 Security Log tab
3.4.3.8 Remote communications

While it is currently possible to enable RBAC on a remote port, this will block any
access to the port since no host software currently supports RBAC.
3.4.3.9 Access rights for common functions

Restricted applications
Applications not accessible to the currently connected user are not seen in the
left-hand tree-view within PCCU32. Functions that are restricted to the user are
disabled. When an application with Read Only functionality is accessed, the Send
button is also grayed out.
Calibration
In order for the user to perform a calibration, in addition to Calibration access
rights, a user must also have read/write access to the following applications:
- System
- Flow measurement
- I/O subsystem
- Display application
- For calibrating wireless I/Os, the user must have Read/Write access to the
Wireless I/O application and the Communication Ports application.
- For calibrating the XMV, the user must also have Read/Write access to the
XMV Interface application and the Communication Ports application.
Collection
In order to perform a collection, in addition to Collection access rights, a user must
also have Read access to the System application.
- For collecting tube data, the user must have Read access to the Flow
Measurement application.
- For collecting trend data, the user must have Read access to the Trend
application.
- For collecting analysis trend data, the user must have Read access to the
Analysis Trend application.
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- For collecting analyzer stream data, the user must have Read access to the
Analyzer Stream application and the Analyzer Operation application.
3.5 Application licensing Credit Key
3.5.1 Credit Key driver installation

1) Plug the USB credit key into an available USB port.
2) The Windows operating system will recognize the credit key as new
hardware and attempt to install the appropriate driver with the Found New
Hardware Wizard.
3) Click the Next button.
4) 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.
5) Upon location, click the OK button.
6) The software driver installation will begin. When it is completed, click the
Finish button.
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 port, if the user does not intend to use the same
USB port each time they use the credit key.
3.5.2 Access/view the Credit Key with PCCU32 7.0 (or later)
To access and view the credit key, the user must use PCCU32 7.0 (or later). The
credit key is a secure device and only accessible through PCCU32.

1) Install the credit key in an available USB port.
2) Open PCCU32, but do not connect to the unit.
3) Go to the Credit Key License Utility (Operate > File Utilities > Credit Key
License Utility).
To move to the Credit Key License Utility, the user cannot

be connected to the G4 EX. The user must have PCCU32
running and the initial Totalflow PCCU32 screen displayed.
4) When the Credit Key License Utility screen displays, click Load to view
available credits on the USB key (see Figure 3–27).
2104349 rev. AD Page 3–25

Figure 3–27 Credit Key License Utility
5) The number of credits will display.
This is the same dialog box that the user would use to add more
credits to the credit key.
Figure 3–28 Credit Key License Utility – Status
Page 3–26 2104349 rev. AD

3.5.3 Adding credits to the Credit Key by telephone
The user may have ordered the credit key from Totalflow with a specified number
of the various credits; however, the user may need to add more or different credits
in the future.
1) Open PCCU32 version 7.0 or later, but do not connect to the unit.
2) Go to the Credit Key License Utility (Operate > File Utilities > Credit Key
License Utility).
3) Insert the credit key into an available USB port.
4) Select Do Phone Update (see Figure 3–28).
5) The user is then asked to call Totalflow Order Entry. Insure that the credit
key is plugged in.
6) Upon connection with a Totalflow Order Entry representative, click the OK
button.
7) The representative will ask the user to read the five (5) encrypted codes that
appear directly beneath the Do Phone Update button. Read them from top
to bottom (see Figure 3–29).
Figure 3–29 Application Credit Key entry screen

8) The representative will give the user four codes to enter in the provided
fields.
9) After the codes have been entered (from top to bottom), click the Update
button (see Figure 3–30).
10) After the button has been clicked, three more codes are displayed directly
beneath the Do Phone Update button. The Totalflow representative will ask
the user to read the codes to verify that the credits have been properly
written to the credit key.
11) When completed, click the Update button.
2104349 rev. AD Page 3–27

Figure 3–30 Application Credit verification codes
3.5.4 Transferring credits to the G4 EX from the Credit Key

Credits can be transferred to the G4 EX. The user selects the type of credits and
the amount of those credits to be transferred.
If the G4 EX has a surplus of credits, these credits can be

transferred to the credit key to be used on the other meters. This
is discussed in a later section.
To transfer application credits to the G4 EX, the user will need to connect to the
G4 EX with PCCU32 7.0 or later.
1) Open PCCU32. Once open, move to the top of the tree-view, and click on
the App Licensing tab (see Figure 3–31).
3) Click the Load button to view the available credits.
This screen enables the user to see the licensing status of the G4
EX as well as the available credits on the credit key. The left pane
shows the type and amount of the available credits on the credit
key. The upper right pane is for information purposes only. It
shows the various available applications and the type/amount of
credits necessary to run the application. The standard credits (and
four general credits) are free with the purchase of the G4 EX. The
lower right pane displays the licensing status of the G4 EX. It
shows what credits are in the machine, what credits are being
used and any surplus or deficit of credits. A surplus of credits is
highlighted in green. A deficit of credits is highlighted in red.
Page 3–28 2104349 rev. AD

Figure 3–31 App Licensing tab
4) Select the Transfer to Device radio button.
5) From the Type drop-down menu, select the type of credit from the available
options.
6) Next, select the number of credits to transfer.
7) Upon completion, click the Transfer button.
3.5.5 Transferring Credits to the Credit Key from the G4 EX

As has been mentioned before, excess credits (credits beyond those that are
required to be fully licensed) can be taken from the G4 EX and returned to the
credit key to be used on other G4 devices.
Credits can be transferred from the G4 EX. The user selects the type of credit and
the amount of those credits to be transferred.
If the G4 EX has a surplus of credits, these credits can be

transferred to the credit key to be used on other meters.
If the G4 EX requires additional credits, these credits can be

transferred from the credit key. See the previous section for the
steps on how to accomplish this.
To transfer application credits to the G4 EX, the user needs to connect to the G4
EX unit with PCCU32 7.0 or later.
1) Open PCCU32. Once open, move to the top of the tree-view, and click on
the App Licensing tab.
3) Click the Load button to view the available credits.
2104349 rev. AD Page 3–29

This screen enables the user to see the licensing status of the G4
EX as well as the available credits on the credit key. The left pane
shows the type and amount of the available credits on the credit
key. The upper right pane is for information purposes only. It
shows the various available applications and the type/amount of
credits necessary to run the application. The standard credits (and
four general credits) are free with the purchase of the G4 EX. The
lower right pane displays the licensing status of the G4 EX. It
shows what credits are in the machine, what credits are being
used and any surplus or deficit of credits. A surplus of credits is
highlighted in green. A deficit of credits is highlighted in red.
4) Select the Transfer to Credit Key button (see Figure 3–32).

5) In the Type drop-down field, select the credit type from the available
selections.
6) In the Amount field, set the number of credits to transfer.
7) Upon completion, click the Transfer button.
8) The transferred credits will display to the left of the screen.
Figure 3–32 Transfer to Credit Key
3.6 G4 EX configuration
3.6.1 Contact hour

The user can program the G4 EX to begin the contact day based on their contract
or company standards. When the G4 EX first powers up, the contract is preset to
begin at midnight.
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Midnight is 00 o’clock. If any value entered is greater than
23, the user will receive an error message, and the G4 EX
forces the value to 00 (midnight).
3.6.2 Log period

The Log Period is the specified length of time between writing the calculated
accumulated volume to record. The user may record volumes as often as every
minute and as seldom as every hour. The default is 60 minutes. The G4 EX can
normally store 960 log periods (40 days x 24 logs). A five minute log period will
consume available memory in eight days.
Description Options
Log Period 1,2,5,10,20,30,60 (Minutes)
3.6.3 Volume calculation period

Volume Calculation Period is the specified length of time between volume
calculations. The Volume Calculation Period must be equally divisible into the Log
Period. The default is 1 second.
Description Options
1 sec, 2 sec, 5 sec, 10 sec, 20 sec, 30 sec
Volume Calculation Period 1 min, 2 min, 5 min, 10 min, 20 min, 30 min and 60 min.
It is recommended to leave at the default of 1 second.
3.6.4 Calculated method

When the G4 EX is initially powered up, the calculation method must be set. The
user has the option of setting the calculation method to AGA-3 1985, AGA-3 1992,
AGA-7 or ISO-5167. Once the calculation type has been determined, the user
may toggle specific factors on or off depending upon their availability (see Table
3–1).
Calculation types, and many of the factors involved with setting up

the calculations, are usually dictated by the user’s sales contract
or company policy.
Table 3–1 Configurable calculation factors
AGA-3 AGA-3
Calculation Parameter AGA-7 ISO-5167
1985 1992
Fpb (Pressure Base Factor) Yes N/A N/A N/A
Ftb (Temperature Base Factor) Yes N/A N/A N/A
Fg (Specific Gravity Factor) Yes N/A N/A N/A
Fb (Orifice Factor) Yes N/A N/A N/A
Ftf (Flowing Temperature Factor) Yes N/A N/A N/A
Y (Expansion Factor) Yes Yes N/A Yes
Fr (Reynolds Number) Yes N/A N/A N/A
Fa (Orifice Thermal Expansion
Yes N/A N/A N/A
Factor)
2104349 rev. AD Page 3–31

AGA-3 AGA-3
Calculation Parameter AGA-7 ISO-5167
1985 1992
Fpv (Supercompressibility Factor)1 Yes Yes Yes2 Yes3
Fw (Water Vapor Factor)4 Yes Yes Yes Yes
Faux (Full Well Stream Factor)5 Yes Yes Yes Yes
Cd (Coefficient of Discharge) N/A Yes N/A Yes
Fp (Fpv method = NX19 Fixed) Yes Yes Yes Yes
Ft (for Fpv method = NX19 Fixed) Yes Yes Yes Yes
Coefficient of Discharge Calc N/A Yes N/A Yes6
Fpc (Pressure Correction Factor) N/A N/A Yes N/A
Ftc (Temperature Correction Factor) N/A N/A Yes N/A
Fs (Fpv2 Compressibility Factor) N/A N/A Yes N/A
3.6.5 Supercompressibility calculation (Fpv)

When the G4 EX is powered up, the calculation method needs to be set. The user
has the option of changing the formula method to any one of several other choices
(see Table 3–2). Once the calculation has been determined, the user may toggle
specific parameters on or off depending upon whether they would like to use fixed
or live analysis data.
Many decisions involved with setting up the Fpv are dictated by

the user’s sales contract or company policy.
Table 3–2 Fpv analysis data

Default NX19 Fixed AGA-8 1992 All
Analysis Data Units
Value Ft/Fp Detail Others7
Fp (for Fpv method NX19 Fixed) 1.000 Yes No No
Ft (for Fpv method NX19 Fixed) 1.000 Yes No No
Heating Value8 1000.0000 BTU/SCF Yes Yes Yes
Argon 0.0000 mol % No Yes No
Carbon dioxide CO2 0.0000 mol % Yes Yes Yes
Carbon monoxide 0.0000 mol % No Yes No
Ethane 0.0000 mol % No Yes No
H2S 0.0000 mol % No Yes No
1 NX19 GCN, NX19 GCNM, AGA-8 1992 Gross and AGA-8 1992 Detail
2 See Fs for AGA-7 Fpv2
3 Only AGA-3 1992 Gross and Detail
4 Not an AGA factor. Fw is a factor which compensates for water vapor in the gas stream and its effect on volume
measurement.
5 Not an AGA factor. Faux is a user set multiplier to compensate for liquids in the gas stream. Defaults to 1.
6 Discharge Coefficient Type-only AGA-3 1992 and ISO-5167-1
7 NX19 GCN, NX19 GCNM, AGA-8 1992 Gross
8 Enter the Heating Value in Btu per SCF. Not used in volume calculations. Only used for calculating MMBTU for reports.
Page 3–32 2104349 rev. AD

Default NX19 Fixed AGA-8 1992 All
Analysis Data Units
Value Ft/Fp Detail Others7
Helium 0.0000 mol % No Yes No
Hydrogen 0.0000 mol % No Yes No
iButane 0.0000 mol % No Yes No
iPentane 0.0000 mol % No Yes No
Methane 100.000 mol % No Yes Yes
nButane 0.0000 mol % No Yes No
nDecane 0.0000 mol % No Yes No
nHeptane 0.0000 mol % No Yes No
nHexane 0.0000 mol % No Yes No
nitrogen N2 0.0000 mol % Yes Yes Yes
nNonane 0.0000 mol % No Yes No
nOctane 0.0000 mol % No Yes No
nPentane 0.0000 mol % No Yes No
Oxygen 0.0000 mol % No Yes No
Propane 0.0000 mol % No Yes No
Water H2O 0.0000 mol % No Yes No
Specific Gravity 0.6000 N/A Yes Yes Yes
3.6.6 Constants
On a single tube gas orifice meter, there are certain constants or parameters that
may need to be entered or changed from the default values. Table 3–3 displays
the list of these constants.
Table 3–3 Gas Orifice Constants

Default AGA-3 AGA-3
Parameters Units AGA-7 ISO-5167
Value 1985 1992
Configurable
Auxiliary Factor (Faux) 1.0 Yes Yes Yes Yes
Barometric Pressure PSIA Yes Yes Yes Yes
DP Zero Cutoff 0.0000 In H2O Yes Yes No Yes
Meter Factor (Fb Basic Orifice
210.2300 Yes No No No
Factor)
In per Deg.
Orifice Coefficient of Expansion 9.2500 No Yes No Yes
F
Orifice Diameter 1.0000 Yes Yes No Yes
Orifice Material Stainless Yes No No No
Inches per
Pipe Coefficient of Expansion 6.2000 No Yes No Yes
Deg. F
Pipe Diameter 2.0670 Yes Yes No Yes
Pressure Base (Contract) 14.7300 PSIA Yes Yes Yes Yes
Specific Heat Ratio 1.3000 Yes Yes No Yes
Tap Location Upstream Yes Yes No Yes
2104349 rev. AD Page 3–33

Default AGA-3 AGA-3
Parameters Units AGA-7 ISO-5167
Value 1985 1992
Flange
Tap Type Yes No No Yes
Taps
Temperature Base (Tb) 60.0000 Degrees F Yes Yes Yes Yes
Viscosity 0.0103 Centipoises Yes Yes No Yes
Z of Air at Base Condition 0.9996 No Yes No Yes
Fixed Cd .6 No Yes No Yes
Barometric Pressure 14.73 PSIA Yes Yes Yes Yes
K Factor (Vol. of Gas Per Pulse) 1.0 No No Yes No
3.6.7 Alarm Limits

The user has the ability to set the G4 EX alarm limits for the parameters listed in
Table 3–4. There are many purposes for setting these limits, i.e., controlling well
output or sending digital signals.
Table 3–4 Alarm Limits

AGA-3 AGA-3 ISO-
Parameter Default Value Units AGA-7
1985 1992 5167
Configurable
Dp High Limit 2047.9688 In H2O Yes Yes N/A Yes
DP Low Limit 0 In H2O Yes Yes N/A Yes
Flow Rate High Limit 1,000,000 SCF/Hr Yes Yes Yes Yes
Flow Rate Low Limit 0 SCF/Hr Yes Yes Yes Yes
RTD High Limit 420 Degrees F Yes Yes Yes Yes
RTD Low Limit 0 Degrees F Yes Yes Yes Yes
SP High Limit 2047.9688 PSIA Yes Yes Yes Yes
Uncorrected Vol High
ACF N/A Yes Yes Yes
Limit
Uncorrected Vol Low
ACF N/A Yes Yes Yes
Limit
3.6.8 Reset Volume

When the user resets the volume accumulator, the G4 EX will:
- Store time, date and previous accumulated partial calc period volumes into
the historical record file.
- Zero the remaining partial calc period accumulations.
- Complete all computations for the present flow file daily records.
- Begin a new flow file daily record.
- Zero total volume accumulator, and log the event with an accumulator value
before zeroing out the accumulator.
Page 3–34 2104349 rev. AD

Since the G4 EX volume calculations are made each vol calc
period, any changes that are made during the period would
effect the volume calculations (such as changing the orifice
plate size) and be introduced into the calculations. To avoid
introduced errors, it is recommended that the Reset Volume
command be used. This command forces the G4 EX to
perform volume calculations for the elapsed time since a
previous volume calculation was made. A new partial period
volume is added to the volume accumulator. This is logged
as an event before it is reset to zero (0).
3.7 Start Up the G4 EX
3.7.1 Putting the G4 EX On Line
To avoid a calibration shift, carefully follow these

instructions.

1) Open both the bypass valves, and close the vent to the atmosphere valve.
This stabilizes the pressure on both sides of the cell.
2) Begin to slowly open the high side orifice tap valve from the meter run.
3) Begin to slowly open the low side valve.
4) Once both the high and low sides are completely open, close both bypass
valves.
3.7.2 Setting G4 EX Temperature Calculation

The G4 EX temperature calculations can be set to the following conditions:
1) RTD Installed – This uses the RTD temperature input and stores the RTD
temperature unless the RTD fails. Additionally, it then uses and logs the
Fixed GF value.
2) Use Fixed TF – This uses and stores the fixed temperature.
3.8 G4 EX Standard Displays
3.8.1 Program Display

The single tube G4 EX comes from the factory with a set of default displays (see
Table 3–5). By default, each display item remains on the display for five seconds.
The user has the ability to change this default to zero (item not displayed) or any
value from 1 to 255 seconds. The user is also able to change the engineering
units and data format for display purposes. Further instructions on programming
the display system can be found in the PCCU32 Help Files. All display items and
item groups are user programmable and may be displayed by user defined
parameters.
Table 3–5 G4 EX Displayed Items
2104349 rev. AD Page 3–35

MM/DD/YY
DATE/TIME 24-hour clock
HH:MM:SS
Yesterday’s percent DP low limit percent time
YEST DP LO NN PERCENT
below DP low setpoint
Yesterday’s percent DP high limit percent time
YEST DP HI NN PERCENT
below DP high set point
Current flow rate programmable SCF or MCF
FLOWRATE NNNNNN.N SCF/HR
or MMCF
Total accumulated volume programmable SCF
ACCUM VOL NNNNNN.NN MCF
or MCF or MMCF
BATTERY NN.N VOLTS Battery voltage volts
DIFF PRESS NNN.N IN. H2O Differential pressure inches H2O
STATIC PRESSURE NNN.N PSIA Static pressure static PSIA
FLOW TEMP NN.N DEG. F Flowing temperature °F
Yesterday’s volume programmable SCF, MCF
YEST VOL NNNN.N MCF
or MMCF
Previous period volume last volume
PERIOD VOL NNNN.N SCF
calculation period volume
Orifice Diameter N.NNNN INCHES Diameter of installed orifice
STATION ID XXXXXXXXXX 10 character alphanumeric identifier
10 character alphanumeric application or tube
DEVICE ID XXXXXXXXXX
identifier
Page 3–36 2104349 rev. AD

4 G4 ex Maintenance
4.1 Overview
The following chapter will provide the user with standard maintenance information
and instructions on how to remove and install G4 EX components.
4.1.1 Maintenance Support

If installation, calibration and maintenance assistance is required, the user can
contact the Totalflow Service Department.
USA: (800) 442-3097 International: 001-918-338-4888
4.1.2 How to Use This Chapter

It is recommended that the user develop a regularly scheduled maintenance
program. By establishing a maintenance program, the G4 EX downtime can be
minimized.
Record all items within this chapter in the maintenance practice procedures.
Practical experience permits updating this schedule over a period of time. This
results in many maintenance items being handled on a routine basis before
potential problems result in a failure.
4.1.3 Cleanliness
Because a G4 EX installation is primarily exposed to external environmental
conditions, it is important that it be regularly inspected for cleanliness, both
externally and internally. Foreign contaminants can cause damage to interior
mounted components that can render the G4 EX inoperable.
4.1.4 Front Mounted LCD

The user is informed of operational problems and operational limit violations by
observing the alarm codes on the LCD display. Troubleshooting techniques for
dealing with these alarm codes is presented later in the manual.
4.1.5 Returning Parts for Repair

If a Totalflow component is to be returned to Totalflow for repair, securely wrap it
in protective anti-static packaging. Before returning a component, call Totalflow for
a Return for Authorization (RA) number. Affix this number to the outside of the
return package.
Part shipments must be prepaid by the customer. Any part that is not covered by
the original system warranty will be shipped to the customer, F.O.B.
4.2 Backing Up Configuration Files

Before beginning any maintenance on the G4 EX, the user should collect the data,
and back up all configuration files to the laptop’s hard drive or disk. This upload
safeguards data and allows the user to restart the unit without the obstacles
associated with reconfiguring the G4 EX should any problem arise.
Although there are Save buttons within the Entry mode screens in PCCU32 that
allow the user to back up Entry model data items, a complete system backup is
only accomplished by using the Save and Restore Utility or the 32-Bit Loader.
2104349 rev. AD Page 4–1

When using this utility to back up files, the user should also download the files to
the tfCold drive in the event of a cold start.

1) Collect the data from the unit.
2) While in PCCU32, click the Save and Restore Utility icon in the main
window toolbar.
3) When the Save and Restore window displays, click the Save Station Files
button. The Save Station Files dialog box will display.
4) When the Save Station Files dialog box displays, verify the default name
and path for the files. Click the OK button. This will save the tfData drive
files.
5) When finished saving the station files, a new dialog box offers the user the
option to Restore the Station Files to the tfCold drive. If the user selects
Yes, the station files will be downloaded to the tfCold drive.
4.3 Restoring Configuration Files

The Restore function enables the user to download configuration files to the G4
EX.
If prior to performing maintenance the Save Configuration Files was used, these
files were downloaded to the laptop’s hard drive or disk. The Restore function
downloads these files into the G4 EX’s tfCold drive. This safeguards the data and
allows the user to restart the unit without the obstacle of reconfiguring the G4 EX
should any problem arise.
4.3.1 Step-by-Step Instruction

1) While the user is in PCCU32, click the Save and Restore Utility icon on the
window’s main toolbar.
2) When the Save and Restore window displays, click the Restore Station
Files button. The Restore Station Files dialog box will display.
3) When the Restore Station Files dialog box displays, verify the default name
and file path. Click the OK button. This will restore the files to the tfCold
drive.
4) Verify that the unit is functioning properly.
4.4 Performing a Warm Boot

A warm boot signifies that the user has cycled power off the board without
disconnecting the lithium battery. This method enables the user to not lose any
stored data. A warm boot can be initiated from a hardware or software standpoint.
The following will take the user through the steps for both methods.
4.4.1 Hardware Warm Boot

There are two methods of warm booting the system from a hardware standpoint:
4.4.1.1 Method 1
1) The user will need to open the door to the unit. Locate the Reset button on
the G4 EX termination board.
Page 4–2 2104349 rev. AD

J19
COMM1
9
8
7
6
J9
5 1
4
3 3
2 S3
1
RESET
2 -
1 +
J16
PWR
Figure 4–1 Reset Button Location

2) Upon location, press the Reset button for approximately five seconds. The
unit will warm boot.
4.4.1.2 Method 2
1) Open the door to the unit. Ensure that there is voltage on the battery and
that the jumper is enabled.
If either of these conditions are not met, do not attempt a

warm boot. Continuing with this process without both
conditions being met will result in a cold boot and all
historical data will be lost.
2) Remove power to the board, and then reconnect. This will initiate a warm
boot.
4.4.2 Software Warm Boot

There are three methods of warm booting the system from a software standpoint:
4.4.2.1 Method 1
1) Open PCCU32. The user needs to ensure that they are not connected
initially and are at the Totalflow splash screen.
2) Click the 32-Bit Loader icon on the toolbar. This takes the user to the 32-Bit
Loader screen.
3) Within the screen, the user needs to select the Reload radio button.
4) Ensure that all of the checkmarks are removed from the various software
option. Once this has been accomplished, place a check in the options list
beside Shutdown Flash and Start Flash.
5) Select the needed connection type from the available drop-down menu.
6) Upon completion, click the Start button.
2104349 rev. AD Page 4–3

There is a chance that the user will see a PCCU32 dialog
box display that informs them that the Target Device Loader
is not working. The user will need to follow the dialog box
instructions to warm boot the system.
4.4.2.2 Method 2
The user must be in Expert view.
1) Move into Entry mode within PCCU32.

2) Upon completion, click on the Meter ID in the PCCU32 tree-view. By
default, this will take the user to the Station Setup tab.
3) Locate the System Shutdown/then Reset parameter field. Once located, set
the parameter value to Yes.
4) Click the Send button. This will initiate a warm boot.
4.4.2.3 Method 3
2) Once this has been completed, click the Terminal icon on the PCCU32
window toolbar. This will bring up the Terminal window.
3) Once in the Terminal window, move to the terminal prompt (->), and type in
the following: BOOT=WARM. Press Enter on the keyboard to initiate the
warm boot.
4.5 Performing a Cold Boot

A cold boot occurs when the user cuts power to the board, including the lithium
battery backup. This causes a loss of all historical data. A cold boot can be
initiated from a hardware or software standpoint. The following will take the user
through both methods.
4.5.1 Hardware Cold Boot

1) Open the door to the unit. Locate the lithium battery connector.
2) Upon location, disconnect the battery.
3) Press the Reset button for approximately five seconds. The unit will cold
boot.
Page 4–4 2104349 rev. AD

J5
1
4
LITHIUM
Lithium Battery
L1 Connector
Figure 4–2 Lithium battery Connector
4.5.2 Software Cold Boot

There are two methods for initiating a software cold boot:
4.5.2.1 Method 1
1) Open PCCU32. The user needs to insure that they are not connected
initially and are at the Totalflow splash screen.
2) Click the 32-Bit Loader icon on the toolbar. This takes the user to the 32-Bit
Loader screen.
3) Within the screen, the user needs to select the Reload radio button.
4) Make sure that all of the checkmarks are removed from the various software
options. Once this has been accomplished, place a check in the options list
beside Shutdown Flash, Delete tfData and Start Flash. A prompt will display
that warns that a cold boot is occurring. Click the Yes button to initiate a
cold boot.
There is a chance that the user will see a PCCU32 dialog

box display that informs them that the Target Device Loader
is not working. The user will need to follow the dialog box
instructions to cold boot the system.
4.5.2.2 Method 2
2) Once this has been completed, click the Terminal icon on the PCCU32
window toolbar. This will bring up the Terminal window.
3) Once in the Terminal window, move to the terminal prompt (->), and type in
the following: BOOT=COLD. Press Enter on the keyboard to initiate the
warm boot.
2104349 rev. AD Page 4–5

4.6 Changing the G4 EX Clock
When any measurement applications are instantiated on the G4 EX, changing the
clock could affect the time when log period entries are made. To protect the
integrity of the accounting audit trails, the G4 EX handles these types of clock
changes as follows:
4.6.1 Clock Change Not Crossing an Hour Boundary

When the next log period entry is made, the clock is not altered.
Example: If the present time is 4:14 pm and the clock is changed to 4:05 pm of
the same day, the daily flow record is the same. Entry reflects averages
accumulated over a 70 minute time period (15 minutes plus 55 minutes).
4.6.2 Forward Clock Change Crossing an Hourly Boundary

Forces a log period entry for part of the hour that has accumulated since the last
hourly entry. The G4 EX then advances to the newly defined data flow record
boundary and begins maintaining the balance of the day’s data in a newly defined
boundary.
the same day, the entry reflects only a 55 minute average accumulation. A new
flow record is then written. This period is also based on a 55 minute accumulation.
4.6.3 Backward Clock Change Crossing an Hourly Boundary

Hourly entry is made for part of the hour that has accumulated since making the
last hourly entry. This is the same as a Forward Clock Change Crossing an Hourly
Boundary. The G4 EX advances to a new day’s data flow record and maintains
the balance of the day’s data in a new record.
the same day, the log period entry reflects only a five minute average
accumulation. A new flow record is then written. This log period is based on a 60
minute accumulation.
A backward clock change uses two records to maintain data

integrity. This assures that previously recorded data is not
overwritten.
If it is necessary to make small backward time changes of

less than one (1) hour, the user should wait until the current
hour has progressed far enough to make a change that does
not cross an hour boundary.
4.7 Replacing the G4 EX battery Pack

This chapter presents the procedures for removal and installation of the G4 EX
battery pack that is located within the 6270 OEU. To access the battery pack,
open the door (see Figure 4–3). The battery pack is located in the upper portion of
the chamber.
Page 4–6 2104349 rev. AD

To extend the lift of the battery pack, fully charge the battery
prior to installation. A system using solar panels may not fully
charge the battery. Additionally, a fast charge, which the
solar panel cannot provide, improves the life of the battery.
To recharge a battery, a quick charge will remove buildup in

the battery much more effectively than a trickle charge. A
battery slowly drained by low light conditions on a solar
charged system or setting in storage will be less likely to
recover than a battery pack that was quickly discharged from
a short. Store batteries in a cool environment for less
drainage.
Figure 4–3 6270 OEU Configuration

1) Collect the data from the unit.
2) Back up the configuration files following the instructions listed previously in
this chapter.
3) Verify the “LL” alarm battery alarm is not being displayed on the G4 EX’s
display. This prevents any data stored in RAM from being lost when power
is removed.
4) Disconnect the charging source from the charger regulator.
2104349 rev. AD Page 4–7

5) Disconnect the battery pack cable connector going to the charger regulator.
6) Remove the battery pack from the battery compartment.
7) Remove the terminal lugs from the battery, and place it on the new battery.
Be sure to connect the red wire to the positive (+) side and the black wire to
the negative (-) side.
8) Insert the battery pack into the compartment. Insert the battery pack so that
its terminals are not touching any metal inside of the unit.
9) Reconnect the battery pack cable connector to the charger regulator.
10) Reconnect the charging source to the charger regulator.
11) Monitor the LCD for normal operational reading and battery voltage.
4.8 Replacing the G4 EX board

The G4 EX board is mounted inside of the G4 EX front end cap. To access and
remove the G4 EX board, perform the following procedures.

the device’s nametag, national and local electrical codes.
Installation and/or maintenance of electric components should

follow guidelines stipulated in the certification drawings shipped
with this unit and adhere to local codes.
Page 4–8 2104349 rev. AD

Figure 4–4 G4 EX Front End Exploded View

this chapter.

socket locking set screw in the rear end cap. Use a 1/16” hex wrench to
perform this task. Upon completion, unscrew the end cap.
5) Disconnect the power connector (J16) from the board mounted connector
(see Figure 4–5).
2104349 rev. AD Page 4–9

J13 Jumper:
AIs/DIs/DOs
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
J12 Jumper:
J3
+ AI - + DI - + DO -
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(BLK) RTD - 3 TXD/TBUS(-)
RTD PROBE 1 5
7
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET 1
4 OPERATE COMM1
RTD
3 COMM2 SW
3
SECURITY J7 2 GND
S3
1 VBATT
USB CLIENT RESET

2 (-)
-
J4 J21 1 (+)
+
J16
1
PWR
MMI
J20 Note:
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
Figure 4–5 Termination board

locking set screw in the front end cap. Use a 1/16” hex wrench to perform
this task. When completed, unscrew the end cap.
7) After the end cap has been removed, gently pull the graphic overlay plate
away from the snap on standoffs.
8) Using a small slot head screw driver, remove the four screws that hold the
LCD board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX board, J2 connector (see
Figure 4–6). Lift the board from the device.
Page 4–10 2104349 rev. AD

Potentiometer
R1
Processor Card
CONTRAST
1
SD CARD
J2
1 16
SD CARD
J3
JTAG
J5
1
4
J4 LITHIUM
XA1
Lithium Battery
L1 Connector
Primary Component Side
Figure 4–6 G4 EX board

10) After the LCD board is disengaged, gently remove the lithium battery
connector (J5) from the G4 EX board.
11) Upon removal of the lithium battery connector, gently snap the board out of
the device. Please note that the board is still connected to the device
through the cables in the back.
12) Unplug the sensor connector cable (J6) and the ribbon cable (J1) from the
G4 EX board (see Figure 4–7). Remove the board from the G4 EX device.
2104349 rev. AD Page 4–11

2 50
1 49
J1
SENSOR
13 1
14 2
J6
Sensor Connector
Secondary Component Side
Figure 4–7 G4 EX board Secondary Component Side.
If the user has the 2104353–503 motherboard, they will need

to remove the processor card from the removed
motherboard and place it into the new one. This is
accomplished by pulling back the attachment brackets and
gently unsnapping the processor card from its housing.
Once completed, take the processor card and snap it into
the replacement motherboard. Continue to step 13.
13) Take the replacement G4 EX board and attach the sensor cable and the
ribbon cable to their corresponding connectors.
Please note that both the sensor cable and ribbon cable pin
1 wire are red. The red edge (pin 1) of the cable should plug
into the outer most edge of the connector (pin 1).
14) Take the lithium battery cable and attach the cable to its corresponding
connector (J5).
15) Align the mounting holes on the G4 EX board with the standoffs,. Once
aligned, snap the board into place within the device.
16) Once in place, line up the LCD board mounting holes to the G4 EX board.
Gently connect the LCD board into the G4 EX board via the J2 connector.
17) Take a small slot head screwdriver and attach the LCD board to the G4 EX
board using the four mounting screws.
Page 4–12 2104349 rev. AD

4.9 Replacing the G4 EX termination board
The termination board is mounted inside of the G4 EX back end cap. To access
and remove the display board, perform the following procedures.
Rear Cap
Term Board
Ribbon Cable
Note: The single red wire on the cable goes
to Pin 1 of both connectors
Stand-off
(4 places)
MMI Connector
Figure 4–8 G4 EX Back End Exploded View

this chapter.

2104349 rev. AD Page 4–13

5) Upon unscrewing the end cap, the user will see the termination board (see
Figure 4–5). Using a ¼” socket wrench, unscrew the four socket mounting
screws that hold the termination board in place.
6) Depending on the configuration that the user selected from the factory,
remove either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21).
7) Next, remove the Comm 1 (J19), Comm 2 (J20) and power (J16)
connectors.
8) Upon completion, remove the ribbon cable from the J1 connector (Figure 4–
9). This will enable the user to remove the termination board from the G4
EX device.
2 50
1 49
J1
Figure 4–9 Termination board secondary component side

9) Take the replacement termination board and attach the ribbon cable to the
J1 connector.
Please note that the ribbon cable pin 1 wire is red. The red
edge (pin 1) of the cable should plug into the outer most
edge of the connector (pin 1).
10) Depending on the configuration that the user selected from the factory,
attach either the USB cable (J4), Ethernet cable (J7) or MMI cable (J21) to
their respective connection.
11) Next, attach the Comm 1 (J19), Comm 2 (J20) and power (J16) connections
to their respective connectors.
12) Upon completion, take the four socket mounting screws, and attach the
termination board in the G4 EX device.
Page 4–14 2104349 rev. AD

4.10 Replacing the Liquid Crystal Display (LCD) board
The LCD board is mounted inside of the G4 EX front end cap. To access and
remove the display board, perform the following procedures.
Do not remove the lithium battery, since it provides power to

the RAM. It is recommended that historical flow data be
downloaded before accessing and removing the LCD board
to prevent the potential loss of stored data.

this chapter.

further information, refer to the certification drawing indicated
on the device’s nametag and national and local electrical
codes.
5) Disconnect the power connector (J16) from the board mounted connector
(see Figure 4–5).
6) Gain access to the LCD assembly by loosening the countersunk hex socket
8) Using a small flat head screw driver, remove the four screws that hold the
LCD board to the G4 EX device.
9) Gently disconnect the LCD board from the G4 EX board, J2 connector (see
Figure 4–6). Lift the board from the device.
10) To reinstall the LCD board, repeat steps 8 through 9 in reverse order. Do
not over tighten screws.
11) Once the LCD board is reinstalled, apply power to the G4 EX (step 5), and
verify that the information displayed on the LCD is correct.
12) Adjust the contrast potentiometer, R1, for optimum display.
To adjust the display contrast, use an extra small screwdriver

to turn the potentiometer, R1, completely clockwise. After
completing this, turn the screw back counter clockwise until
the screen is readable.
13) Replace the graphic overlay plate that was removed earlier.
2104349 rev. AD Page 4–15

4.11 Replacing the lithium battery
Do not remove power to the unit. Loss of power to the unit

will initiate a cold start. All data and configuration files will be
lost.

this chapter.

5) Upon completion, gently remove the lithium battery connector (J5) from the
G4 EX board.
6) Once the lithium battery connector is removed, snap the board out of the
device. Please note that the board is still connected to device through the
cables in the back.
7) After the G4 EX board has partially been removed, unplug the sensor
connector cable (J6) and the ribbon cable (J1) from the G4 EX board. This
will allow the board to be completely removed from the device.
8) The user will now see a manufacturing plate. The lithium battery assembly
is located on the back of this plate in a small battery enclosure. Carefully
remove the plate from the snap on standoffs.
9) The lithium battery assembly is attached to the manufacturing plate by a
Velcro strip. Gently remove the lithium battery from the Velcro strip.
10) Take the new lithium battery, and attach the Velcro edge of the battery to
the Velcro strip in the battery enclosure on the manufacturing plate.
11) Once the lithium battery is attached to the manufacturing plate, snap the
plate back into the device using the appropriate standoffs.
12) Take the G4 EX board, and attach the sensor cable and the ribbon cable to
their corresponding connectors.
Please note that both sensor cable and ribbon cable pin 1
wire is red. The red edge (pin 1) of the cable should plug into
the outer most edge of the connector (pin 1).
13) Attach the lithium battery cable to its corresponding connector.
Page 4–16 2104349 rev. AD

14) Align the mounting holes on the G4 EX board with the standoffs, and snap
the board into place within the device.
15) Replace the display and graphic overlays that were removed earlier.
4.12 Replacing the transducer (EXIMV)

The EXIMV is specifically designed for the G4 EX device. The transducer
characterization files are stored in the G4 EX raw sensor interface board. As such,
replacement/repair involves removing both the transducer and the G4 EX raw
sensor interface board from the actual G4 EX device. Contact Totalflow to return
both pieces for replacement under warranty or for repair.
Entry into the interior of the transducer voids the transducer

warranty. If the transducer requires servicing, the entire
assembly must be removed from the unit, packaged
securely for shipping and returned to Totalflow. Contact
Totalflow Customer Service for instructions.
Figure 4–10 EXIMV installation overview

this chapter.
3) Once the user has finished backing up the configuration and data files, they
will need to open the manifold high/low equalizer valves.
4) Using the orifice tap valves, close off both upstream and downstream.
These two valves connect the meter run high/low output lines to the
transducer.
5) Open the vent valve to atmosphere.
6) Completely disconnect the high/low manifold lines from the transducer.
2104349 rev. AD Page 4–17

7) If the user is able to do so at this point, remove the external power that is
feeding the unit. If this can be done, skip to step 10; otherwise, continue to
the next step.
XFCG4EX
- +
HIGH SIDE
LOW SIDE EQUALIZER VALVE
EQUALIZER VALVE
VENT TO
ATMOSPHERE
Figure 4–11 G4 EX with block manifold

9) Disconnect the power connection (J16) from the termination board mounted
connector.

Page 4–18 2104349 rev. AD

11) After the end cap has been removed, gently pull the display overlay and
graphic overlay plate away from the snap on standoffs.
12) After the graphic overlay plate is off, gently remove the lithium battery
connector (J5) from the G4 EX board.
13) Upon removal of the lithium battery connector, snap the board out of the
device. Please note that the board is still connected to the device through
the cables in the back.
14) Unplug the raw sensor connector cable (J6) and the ribbon cable (J1) from
the G4 EX board.
15) Gently remove the board from the G4 EX device.
16) Loosen the 2” mounting pole U-bolts. Rotate/lower the unit a sufficient
distance so that the transducer can be removed.
17) Loosen the hex socket head set screws on the neck of the unit using a 3/32”
hex wrench. Continue until the transducer turns freely. Gently turn counter-
clockwise until the transducer is free from the enclosure.
18) Replace the transducer and raw sensor board with a new/repaired/spare
unit of the same type and pressure rating.
19) Reconnect the high/low manifold lines, and restore pressure.
20) Reassemble the unit by performing steps 10-14 in reverse order.
21) Following the instructions in section 4.3, restore the station files.
4.13 Calibration
The calibration mode allows the user to calibrate, check and zero the static and
differential pressure. Additionally, this mode allows the user to set the bias for the
resistance temperature detector (RTD). During the initial calibration, the
parameters shown in Table 4–1 will need to be configured.
Table 4–1 Calibration configurable parameters

Parameter Default Value Units
RTD Installed No
RTD Bias 0.00 Degrees F
Temperature Base (Tb) 60.000 Degrees F
Used Fixed Temperature (TF) No
4.13.1 Required test equipment

The following test equipment is required to calibrate the G4 EX EXIMV:
- PCCU32 version 7.17 or later
- Deadweight tester or equivalent calibration standard
- Test gauge capable of dual range measurement (PSIG and inches)
- Barometer or another means which can determine barometric pressure
- Nitrogen or compressed air source
2104349 rev. AD Page 4–19

If a method other than compressed nitrogen/deadweight
tester is used to calibrate the static pressure cell, the user
must ensure that the prescribed flange type valves are
blocked to prevent false differential pressure from being
applied to the DP cell. Additionally, ensure that both high and
low sides are pressured up during SP calibration.
4.13.2 Hold mode

When calibrating the transducer or setting up a fixed temperature, PCCU32 will
instruct the G4 EX to ignore live values for the flow calculations for the period of
time that the G4 EX is being calibrated. During this time, the G4 EX uses SP, DP
and temperature captured at the time that calibration mode was entered. This is
referred to as the Hold mode.
To exit Hold mode:
1) Exit Calibration mode.
2) Unplug the PCCU cable at the G4 EX connector.
Totalflow recommends performing a five point check before

and after calibration. The host software (WinCCU) is capable
of recalculating the volume based on the differences
between the previous five point check and the current five
point check.
After a secure audit trail is archived, WinCCU recalculates

the flow volumes based on the previous and current markers.
This allows more accurate results of the flow volume.
4.13.3 Static pressure (SP) calibration checks

The G4 EX allows the user to check the static pressure calibration and log
pressure marker check points. The user should perform this check prior to and
directly following the calibration.
During normal operation of the G4 EX, the display provides continuous SP
readouts; however, during this procedure, the G4 EX is placed in a temporary
Hold mode.
A minimum of three SP markers should be set; however, the user can enter as
many SP markers as they want. Recording too many markers could cause the G4
EX to overwrite existing older events. Only the last five checks are used by the
WinCCU editor for calibration adjustment. Enter a low, mid-low, mid, mid-high and
high value.
The resulting comparison pressure must not be greater than

the static pressure cell’s maximum pressure.

1) Enter the Calibration menu’s Checks screen. This will place the G4 EX on
Hold. Select the preferred measurement tube from the tree-view.
Page 4–20 2104349 rev. AD

2) Select SP from the Calibration drop-down menu to the left of the Pressure
Marker table.
3) Select the SP type: Absolute or Gauge.
Absolute will display values with the barometric pressure

added in. Additionally, entered values will need the
barometric pressure added. Gauge will display values in
gauge pressure. Additionally, entered values will need to be
in gauge pressure.
4) Click on the Enter Pressure Check Value, and select Continuous to update
the current reading.
5) Verify that the vent valve is closed (see Figure 4–12).
6) Open both the high and low equalizer valves.
7) Close both the downstream and upstream tap valves.
8) Open the atmospheric vent valve.
9) Enter a pressure marker for atmospheric pressure (PSIA). Enter zero if in
Gauge mode or the barometric pressure (or contract value) if in Absolute
mode. Click the OK button.
10) Close the atmospheric vent valve.
11) Click on the Enter Pressure Check Value.
12) Connect Calibration Standard to the calibration test port.
13) Pressure to the next preferred verification pressure.
14) When the current reading stabilizes, enter the pressure value from the
calibration source. Remember to add the barometric pressure if the
pressure type is Absolute. Click the OK button.
15) Repeat steps 11 through 14 for each pressure check value.
16) When all the static pressure markers have been set, determine if calibration
is required. If no calibration is required, return the manifold to service before
exiting Calibration mode.
For additional information regarding Static Pressure

Calibration Checks, see the PCCU32 Help Files.
2104349 rev. AD Page 4–21

Figure 4–12 Calibration diagram
4.13.4 Differential pressure (DP) calibration checks

As discussed in section 4.13.3, it is recommended that checks of the differential
pressure (DP) be performed prior to and directly following calibration.
A minimum of three differential pressure markers should be set; however, the user
may enter as many DP pressure markers as they prefer. Recording too many
markers may cause the G4 EX to overwrite existing older events. Only the last five
checks are used by the WinCCU editor for calibration adjustment. Enter a low,
mid-low, mid, mid-high and high value.
During normal operation of the G4 EX, the display provides continuous DP
readouts; however, during this procedure, the G4 EX is placed in a temporary
Hold mode.

1) Enter the Calibration menu’s Check screen. This places the G4 EX on
HOLD. Select the preferred measurement tube from the tree-view.
2) Select DP from the Calibration drop-down menu to the left of the Pressure
Marker table.
3) Click on Enter Pressure Check Value, and select Continuous to update the
current reading.
Page 4–22 2104349 rev. AD

8) Enter a pressure marker for differential pressure “0.0”. Click the OK button.
9) Close the high side equalizer valve, and verify that the low side is vented to
atmosphere.
10) Connect Calibration Standard to the calibration test port.
11) Pressure to the next preferred verification pressure.
12) When the current reading stabilizes, enter the pressure value from the
calibration source. Click the OK button.
13) Repeat steps 11 through 12 for each pressure check value.
14) When all the differential pressure markers have been set, determine if
calibration is required. If no calibration is required, return the manifold to
service before exiting Calibration mode.
For additional information regarding Differential Pressure

Calibration Checks, see the PCCU32 Help Files.
4.13.5 Calibrating static pressure (SP)

A three or five point pressure method is used to calibrate the G4 EX static
pressure cell. These different pressures are applied to the cell from a known,
traceable source. The resultant pressure values are entered into the G4 EX using
PCCU32 software.
When performing the following procedures, wait for the G4 EX display to stabilize.
If the G4 EX is not in Calibration mode, the display will not necessarily match
applied cell pressures.
The G4 EX uses an absolute static pressure (SP) cell.

Absolute pressure measures the pressure referenced to a
vacuum or sealed chamber. This is different than a gauge
cell which measures the pressure referenced to the
atmosphere.
Since the static pressure cell is an absolute device, it always

measures the true pressure relative to a vacuum or sealed
chamber. As such, when vented, it measures true
barometric pressure.
For other points of calibration, add the reading of PSI and

barometric pressure to arrive at PSIA. Upon completion,
enter this reading.
4.13.5.1 Absolute versus gauge

It is recommended that the initial calibration point be at vented conditions. When
this is done, the barometric reading (in PSI) should be used as the initial point.
When operating in PCCU32’s Absolute mode, other points of calibration are
arrived at by adding the PSI reading and the barometric pressure to arrive at
PSIA. Once this has happened, enter this reading.
When operating in PCCU32’s Gauge mode, readings may be entered in as read,
and then a barometric pressure reading is entered.
2104349 rev. AD Page 4–23

4.13.5.2 Calculating PSI
To convert barometric pressure measured from inches of mercury to barometric
pressure (PSI), perform the following calculation:
Barometric pressure, in inches of mercury x .4912 or (2.036) equals barometric
pressure in PSI.
1) Enter the Calibration menu’s Calibration screen. This places the G4 EX in
Hold. Select the preferred measurement tube from the tree-view.
2) Select SP from the Calibration drop-down box to the left of the Pressure
Marker table. Select 3 or 5 Point Calibration.
3) Set the Transducer SP Pressure Range in the Calibration window. This
should match the range reading from the tag or label attached to the
transducer.
4) Select the SP type: Absolute or Gauge.
Absolute will display values with the barometric pressure

added in. Additionally, entered values will need the
barometric pressure added. Gauge will display values in
gauge pressure. Additionally, entered values will need to be
in gauge pressure.
5) Enter the barometric pressure in the bottom window before proceeding.

9) Open the atmosphere vent valve.
10) Click on the Low Cal Point button. Verify the current reading is continuously
updated. This should represent the lowest calibration point.
11) When the current reading stabilizes, click the OK button; otherwise, enter a
different value, and then click the OK button.
12) When the previous reading was accepted, notice that the 100% Cal Point
button is activated. To select, press Enter.
13) Connect calibration standard to the calibration test port.
14) Close the atmosphere vent valve.
15) Pressure to 100% of the transducer range (100% of the target value).
16) When the current reading stabilizes, accept the target value already
showing in the window; otherwise, enter the pressure value from the
17) Again, notice that the next Cal Point is activated. To select, press Enter.
18) Pressure the transducer to the next target value as shown in the Calibration
window.
20) Repeat steps 17 through 19 until all calibration points have been entered.
Page 4–24 2104349 rev. AD

21) Upon completion of the SP calibration, new calibration markers should be
set.
22) Return the manifold to service before exiting Calibration mode.
4.13.6 Calibrating differential pressure (DP)

A three or five point pressure method is used to calibrate the G4 EX differential
pressure cell. These different pressures are applied to the cell from a known,
traceable source. The resultant pressure values are then entered in the G4 EX
using PCCU32 software.
During factory calibration, any differential pressure (DP) shift due to static
pressure effect is corrected. This is not user configurable and will not be modified
due to field or user calibration. This ensures that the readings received in the field
are accurate. The user may not change the factory set shift. If readings appear
incorrect, the user may need to check for leaks and then recalibrate the DP.
When calibrating, wait for the readings to stabilize before entering the new values.

1) Enter the Calibration menu’s Calibration screen. This places the G4 EX in
HOLD.
2) Select DP from the Calibration drop-down box to the left of the Pressure
Marker table. Select 3 or 5 Point Calibration.
3) Set the Transducer DP Pressure Range in the Calibration window before
proceeding. This should match the range reading from the tag or label
attached to the transducer. Target values based on the selected range will
display in the Calibration table.
8) Click on the Low Cal Point button. Verify the current reading is continuously
updated.
9) When the current reading stabilizes, click the OK button; otherwise, enter a
different value, and click the OK button.
10) When the previous reading was accepted, notice that the 100% Cal Point
button becomes activated. To select, press Enter.
11) Connect the Calibration Standard to the calibration test port.
12) Close the high side equalizer valve, and verify that the low side is vented to
atmosphere.
13) Pressure to 100% of the transducer range (100% of target value).
15) Again, notice that the next Cal Point is activated. To select, press Enter.
16) Pressure the transducer to the next target value as shown in the Calibration
window.
2104349 rev. AD Page 4–25

showing in the window; otherwise, enter the pressure value from calibration
source. Click the OK button.
18) Repeat steps 15 through 17 until all calibration ports have been entered.
19) Upon completion of the DP calibration, new calibration markers should be
set.
20) Return the manifold to service before exiting Calibration mode.
For additional information regarding Differential Pressure

Calibration mode, see PCCU32 Help Files.
4.14 Onboard I/O calibration overview

The Calibration mode enables the calibration of the analog inputs, analog outputs
and pulse inputs.
4.14.1 Hold mode

When calibrating, PCCU32 will instruct the G4 EX to ignore live values for the
period of time that the G4 EX is being calibrated. This prevents real-time G4 EX
calculations from being effected during calibration. During this time, the G4 EX
uses the last known value at the time Calibration mode was entered. This is
referred to as a Hold mode.
To exit Hold mode:
1) Exit Calibration mode.
2) Unplug the PCCU cable at the G4 EX connector.
4.14.2 Calibrating onboard analog inputs

The G4 EX comes standard with two analog inputs on the G4 EX board. As the
user enters Calibration mode, the G4 EX moves into Hold mode and displays the
current values.
When the user selects the Update checkbox, the Current Values section will
display the current values continuously. When different analog inputs are selected,
their assigned register numbers are displayed on the top of the screen.
Follow the instructions in the PCCU32 Help Files for specific software steps.
Generally, the user will need perform the following procedures:
If the user intends to use a 4-20 mA transmitter on the analog

input, please refer to Appendix X. Manufacturer’s
specifications can often lead to confusion. In some
instances, the manufacturer’s specifications will claim to
operate from 10 to 30 VDC. They are not always clear that
this 10-30 VDC must be applied across the 4-20 mA
transmitter only (and not across the transmitter/load resistor
series combination). Again, refer to the explanation in the
appendix.
Page 4–26 2104349 rev. AD

4.14.2.1 Calibration
1) Connect an accurate power source capable of 1-5 volts to the AI terminals
that are to be calibrated.
2) In Calibration window for the AI that is being calibrated, select either 3 or 5
Point calibration for the number of preferred calibration points. 3 Point for
low (50% and 100% values) and 5 Point for low (25%, 50%, 75% and 100%
values).
3) In the Current Value field, place a check in the Update checkbox. This
causes the AI to look for the source at the terminals instead of a test value.
4) Begin the calibration by starting with the first selection, Low Cal Point.
5) Apply one volt to the AI terminals.
6) Enter a value (typically zero) that represents the low calibration point and
represents the desired engineering units. Upon completion, click the OK
button.
The current reading value on the pop-up entry screens will

be placed in the Reading column and represent values from
the previous calibration. User entered values will be
displayed in the Entry column.
7) Move to the 100% Cal Point parameter field. Once there, apply five volts to
the AI terminals.
8) Enter a value that represents the full range and represents the desired
engineering units. Upon completion, click the OK button.
9) If 3 Point calibration was selected, move to the 50% Cal parameter field.
Once there, apply three volts to the AI terminals.
10) Enter a value that represents 50% and represents the preferred engineering
units.
If performing a 5 Point calibration, the user will need to add

additional values for both 25% and 75% calculation points.
4.14.3 Onboard pulse and digital inputs

The Totalflow G4 EX comes standard with one high speed pulse input on board.
This may also be used as a digital input. The following procedure will enable the
user to set the digital input.
Follow the instructions in the PCCU32 Help Files for specific software steps.

1) The user will need to click on the Calibrate icon in the PCCU32 main
toolbar. Once completed, click on the AGA-7 tube in the tree-view.
2) Click on the Setup tab.
3) If the device was ordered as a Pulse Input meter, the register addresses
(Static Pressure, Pulse Input and Temperature) are listed and fixed. If,
however, a new tube application was added by the user, they will need to
manually enter the register addresses.
2104349 rev. AD Page 4–27

4) Next, the user will need to click on the K-Factor button. Enter a value, and
click the OK button. Input pulses are multiplied by the K-Factor. To have a
one-to-one pulse count, user a factor of 1.
Please take into consideration that these inputs may have

the de-bounce enabled or disabled. This feature is
discussed in the PCCU32 Help Files and is also turned on
or off within PCCU32.
4.15 Zero transducer

During the process of setting pressure markers to determine the need for a
calibration of either the static pressure (SP) or the differential pressure (DP), the
user may conclude that the SP or the DP pressures are out of alignment at exactly
the same amount at each pressure marker (linear shift). When this occurs, the
user may either recalibrate the G4 EX or they can set the transducer to zero. The
preferred method is to recalibrate the G4 EX. This maintains the G4 EX records in
a manner that assures accountability and continuity when other measurement
issues arise. By using the Zero Transducer command, all references to previous
pressure markers are non-existent, eliminating the ability to adjust volumes based
on previous markers.
Using the Zero Transducer capability assumes that the shift

is linear. This means that at different levels of pressure the
transducer is off by exactly the same amount. If this is not
the case, the user needs to recalibrate the transducer
instead.
4.15.1 Static pressure

The SP can be zeroed without recalibrating. If the SP shifts, the user can enter a
new barometric pressure value. This shifts the SP transducer curve. After the Hold
state initiates, select Zero Transducer.
4.15.2 Differential pressure

The DP can be zeroed without recalibrating. If DP shifts, the user can enter a new
zero (0). This shifts the DP curve. After the HOLD state begins, select Zero
Transducer.
4.16 RTD calibration and bias

The Totalflow G4 EX has one onboard RTD input. The registers representing the
RTD input is normally assigned to a measurement tube. The RTD tab is located in
the Calibrate screen within the Onboard I/O tree-view. The user will need to click
the Analog Inputs sub-menu, and move to the RTD tab (see Figure 4–13).
Page 4–28 2104349 rev. AD

Figure 4–13 RTD calibration screen
The Current Value parameter will display the current value of the selected RTD by
placing a check mark in the Update field.

1) Connect the variable resistor or RTD calibration equipment to J7 on the G4
EX board.
Terminal J7
1 SHLD
2 Out
3 Plus (+)
4 Minus (-)
5 In
If the user elects to calibrate using an 100 OHM RTD probe,

refer to the PCCU32 Help Files to view resistance and
corresponding temperature readings.
2) Select the RTD tab within the Analog Inputs tab sub-menu under Onboard
I/O in the Calibration window.
3) Select whether to perform a 3 Point, 5 Point or Bias calibration. Note that if
a 3 Point is selected, there will be 3 Target values and 3 Cal Point buttons.
If 5 Point is selected, there will be 5 Target values and 5 Cal Point buttons.
2104349 rev. AD Page 4–29

4) Click inside the Range window, and enter a range. The range can be
anything and represent any units (percent, volts, etc.) that the user prefers.
Target values will be updated to reflect the new calibration range.
5) Click on the Low Cal Point button, and apply the voltage (typically 1 volt) for
the low calibration point. Verify the current reading on the Enter Low
Calibration Value screen is stable.
6) Enter the Target value for the Low Cal Point, and click the OK button.
7) Click on the 100% Cal Point button, apply the voltage (typically 5 volts) that
represents the full range and verify the current reading is stable.
8) Enter the Target value for the 100% Cal Point, and click the OK button.
9) Click on the next highest Cal Point button, and apply a voltage representing
its range. Verify the current reading is stable.
10) Enter the Target value for that Cal Point, and click the OK button.
11) Repeat Steps 9 - 10 for any remaining Cal Points. After the last point is
entered, PCCU32 will automatically calibrate the AI.
4.16.2 Calibrating RTD temperature bias

If the user elects to use Bias as a calibration method, select Bias from the
Calibration drop-down menu.
To change, click in the Bias parameter field. The RTD Bias dialog box will display.
This allows the user to enter a new value. The RTD's temperature will always be
biased by this value; however, the RTD Installed box on the Setup tab must be
checked for the RTD temperature and bias to be used. If the bias needs to be
negative, enter a minus sign (-) before the value. The current temperature value
under the Tf heading will increase or decrease to reflect the effect of the bias. The
bias does not affect the Fixed Temperature that is specified on the Setup tab. The
user can select Sp, Dp, etc., in the drop-down Calibration window to return to the
selected Calibration screen.
4.17 Changing the orifice plate

Use one of the following procedures when changing the orifice plate:
4.17.1 Taking meter run out of service (simplex fitting)

1) Take the meter run out of service.
2) Replace the physical orifice plate.
3) If the user wants to end the current log record and begin a new record with
the new orifice size (as stated in API21.1), they need to first move into Entry
mode within PCCU32. Next, select the preferred measurement tube, and
then click on the Commands tab. Change the value for the Reset Log
Period to Yes. This forces a new record to be written based on the old
orifice plate size. Additionally, if the user wants to simultaneously zero the
accumulated volume, they can use the Reset Volume command instead.
It is recommended to perform either the Reset Log Period or the Reset
Volume command to enhance the audit trail created by the event (API 21.1
requirement).
4) In PCCU32, enter the new orifice plate diameter.
5) Return the meter to service.
Page 4–30 2104349 rev. AD

4.17.2 Leaving meter run in-service procedure (senior fitting)
1) Place the G4 EX in HOLD by entering Calibration mode. This enables
constant SP, DP and Temperature values to be used, while the orifice plate
is being changed.
2) Replace the orifice plate.
3) Exit Calibration mode. This releases HOLD of the SP, DP and Temperature.
4) If the user wants to end the current log record and begin a new record with
the new orifice size (as stated in API 21.1), they need to first move into
Entry mode within PCCU32. Next, select the preferred measurement tube,
and then click on the Commands tab. Change the value for the Reset Log
Period to Yes. This forces a new record to be written based on the old
orifice plate size. Additionally, if the user wants to simultaneously zero the
accumulated volume, they can use the Reset Volume command instead.
It is recommended to perform either the Reset Log Period or the Reset
Volume command to enhance the audit trail created by the event (API 21.1
requirement).
5) In PCCU32, enter the new orifice plate diameter.
At the top of the Volume Calculation Period, the G4 EX will

perform calculations based on the new orifice plate diameter
for part of the period after the log was reset.
2104349 rev. AD Page 4–31

5 Troubleshooting
5.1 Overview
To serve as an aid in troubleshooting the G4 EX, the following chapter will provide
guidelines for the various subsystems within the device.
The chapter contains a troubleshooting flowchart (see Figure 5–1). As the user
follows the logic in this flowchart, they will be directed to specific test instructions
that are found in this chapter or may be directed to the Power Troubleshooting
section or the Communication Troubleshooting flowchart (see Figure 5–7). In
addition to the flowchart, this chapter contains step-by-step procedures for
troubleshooting the G4 EX with or without an installed radio communication unit.
5.1.1 Troubleshooting support

If troubleshooting instructions do not lead to a resolution and assistance is
required, the user can contact the Totalflow Service department:
USA: (800) 442–3097 International: 001-918-338-4880
5.1.2 Visual alarm codes

As noted in Chapter 1, the unit’s LCD annunciator displays many different status
indicators that are related to device operations. This section contains information
on those codes that reflect errors or provide information that is useful in
troubleshooting the device. Alarm codes indicate that an operational problem
exists.
The user is informed of operational problems and operational limit violations by
observing the alarm codes on the right side of the LCD display.
5.1.3 Sleep mode

Totalflow units are designed to move into a low power mode, Sleep, when an
insufficient supply voltage is present for a period of time. The issue that needs to
be addressed is the reason for the Sleep alarm; waking up the unit will be
insufficient for correcting the problem. As such, issues relating to the system’s
power supply should be investigated.
5.1.4 Solar panel

When a solar panel is attached to the 6270 OEU to provide a charging source for
the battery, cleanliness and positioning play an important part as do proper
electrical and cabling techniques. More detailed information on power
consumption can be found at www.abb.com/totalflow.
5.1.5 Communication
Troubleshooting the communications for this unit requires that both pieces of
equipment be tested: the G4 EX comm ports and the communication device. This
is discussed in more detail in the Communications Overview section. Other
communication troubleshooting information is shared in the following categories:
RS-232, RS-485, and RS-422 Communications.
2104349 rev. AD Page 5–1

Figure 5–1 Troubleshooting flowchart
5.2 Troubleshooting visual alarm codes

When a visual indicator is present (see Figure 5–2), the following section will
assist in determining the probable cause and the steps required to correct the
condition.
For the purposes of troubleshooting, only those codes considered alarms or codes
used to assist troubleshooting are discussed here. The entire list of status and
alarm codes can be found in Chapter 1. Table 5–1 contains a description of each
G4 EX alarm code. An alarm can be a word, character, letter or symbol.
Page 5–2 2104349 rev. AD

An application can be assigned to an annunciator, and any alarms or status codes
associated with that application will be displayed.
Figure 5–2 LCD and indicators
Table 5–1 Visual alarm codes

Indicator Description Alarm
I/O Subsystem
Low Lithium Battery Alarm: When displayed, the lithium battery voltage is
L
L below 2.5 VDC. If battery voltage is above 2.5 VDC, A1 appears shaded. A Y
new lithium battery measures approximately 3.6 VDC.
Low Charger: This is displayed if the G4 EX battery charging voltage is less
L
C than (+)0.4 VDC higher than the battery voltage. If charging voltage is (+)0.4 Y
VDC greater than the battery voltage, the annunciator is shaded.
Measurement Application
A to D Failure: Displayed if the A to D Converter absolute differential pressure,
A absolute static pressure or temperature readings exceed maximum counts or
D Y
are less than the minimum counts. If the A to D Converter readings are within
range, AD is shaded.
Communication Protocols
 Transmitting Data: Sending a response. N
 Receiving Data: Processing request. N
! Nak: Negative Acknowledgement w/packet list. N
+ Ack: Positive Acknowledgement of receipt request. N
Waiting for ACK: Waiting for response after transmission. N
? Exception Alarm Proceeding. N
ID Recognized: Recognized and receiving request. N
Listen Cycle: Flashes if this remote port is active and running Totalflow
Remote Protocol. Flashes in sync with listening cycle that occurs at 1, 2 or 4 N
second intervals.
MODBUS ASCII: MODBUS ASCII protocol selected for the port assigned to
M N
this annunciator.
MODBUS RTU: MODBUS RTU protocol is selected for the port assigned to
m N
this annunciator.
¥ ID Recognized: The ID has been recognized but is waiting for Sync. N
2104349 rev. AD Page 5–3

5.2.1 Troubleshooting a blank LCD screen
When the LCD is blank, this means that the unit has entered S mode. This
indicates that the battery voltage has dropped below 10.9 VDC.

1) Make a local connection with the G4 EX. This will wake the unit up so that
the user can check all alarm conditions and determine the problem.
2) Check the power supply cable. It must make a good, secure electrical
connection with the connector, J16 (see Figure 5–3).
3) If voltage is low, investigate power supply source.
Figure 5–3 Power supply – G4 EX termination board
5.2.2 Troubleshooting a Low Lithium alarm (LL)

When the Low Lithium alarm displays, the lithium battery should be replaced
immediately. Failure to replace the lithium battery could result in a loss of data
following a power loss. Instructions for replacing the lithium battery can be found
in Chapter 4.
5.2.3 Troubleshooting an Analog to Digital Failure alarm (AD)

The G4 EX must have a Measurement Tube application running to receive this
error. If the A to D Failure alarm is present or if the device is in Sleep mode but is
still receiving minimum voltage, it may be necessary to test the data link between
the main electronic board and the transducer. Use the following instructions to
check the transducer.
Probable causes of receiving the A to D failure include:
Page 5–4 2104349 rev. AD

- A/D Converter is over or under range (DP, SP or Tf)
- Loose wiring connections
- Faulty RTD probe
If the A to D Converter readings are within range, AD is shaded.

1) Begin by collecting data from the unit.
2) View the Event log in PCCU32 for codes (see PCCU32 Help Files for more
information).
- 99 A/D converter could not be read.
- 100 A/D converter could be read again.
3) If the event code is found, follow the guidelines for returning the transducer
to Totalflow for repair or replacement. If the event code is not found,
continue to the next step.
4) In the PCCU32 Entry screen, monitor the readings by clicking on the I/O
Subsystem in the tree-view and selecting Onboard and Analog Inputs.
Check SP, DP and temperature to determine which measurement channel
is causing the alarm.
- If the alarm is caused by the SP or DP channel, equalize and vent the
manifold.
- If the alarm disappears: the SP or DP cell is not ranged properly, or
the manifold may have blockage.
- If the alarm is still present, replace the transducer.
- If the alarm is caused by the temperature channel, move to Step 9;
otherwise, move to the next step.
5) Set the EXIMV back to Factory calibration. If this corrects the alarm,
recalibrate the EXIMV to correct field calibration. If the alarm is not
corrected, continue to the next step.
6) Perform a Warm start on the unit. Verify that the unit is not displaying a LL
(Low Lithium) alarm, and then remove power from the unit. Restore power
to the unit. If the A/D Failure alarm is not corrected, continue to the next
step.
7) Perform the Save and Restore function. Follow the procedure in Chapter 4
for backing up configuration files. The user must ensure that they restore
these files to the tfCold drive.
8) Following the reset procedures covered in this chapter, perform a Cold start
on the unit. If the problem is not corrected, continue to the next step.
9) Check the RTD wiring at the EXIMV.
10) Perform the following three procedures found next in this chapter.
- RTD Continuity Test
- RTD Resistive Test
- RTD Impedance Test
11) Contact Totalflow to repair or replace the EXIMV.
2104349 rev. AD Page 5–5

5.2.4 Resistive Temperature Detector (RTD) Continuity test
Should the readings from the RTD be suspect, follow the instructions below to test
the RTD probe.
5.2.4.1 Required equipment

- Digital Multi-meter (DMM) with alligator clip leads

1) Begin by disconnecting power and communications from the EXIMV.
2) Disconnect the RTD from the EXIMV.
3) Perform continuity test of the wires leading to the probe. Set DMM to 200
OHM or Continuity Audio.
4) Check the 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.
5) If there is continuity, move to step 7. If there is no continuity, verify the
wiring at the RTD head is correct.
6) If the wiring at the connection head is correct, the RTD is defective. Replace
the probe; otherwise, continue to the next step.
7) Check the continuity of the second wire pair (typically white) be connecting
one lead to each wire. The meter should read zero or close to zero.
8) Check the continuity of each wire (first pair either red or black, as identified
in step 4) to the probe or shield. If there is continuity, the RTD is defective.
Replace the probe. If there is no continuity, continue to the next step.
9) Check the continuity of each second wire pair (white, as identified in step 7)
to the probe or shield. If there is continuity, the RTD is defective. Replace
the probe. If there is no continuity, continue to the next step.
10) Check the continuity of each first wire pair (as identified in step 4) to each
second pair wire (as identified in step 7). The meter should read
approximately 100 to 140 OHMs. If this is the case, continue to the next
step. If not, the RTD is defective and should be replaced.
11) If the probe is still not functioning properly, recheck the wiring using the
supplied diagram. If no wiring error was found, perform the RTD Current
Source Troubleshooting test.
5.2.5 RTD Current Source (Resistive) test

If the readings from the RTD are still suspect following the RTD Probe Continuity
test, follow the instructions below to test the current source on the termination
board to verify that it is receiving power.

- Totalflow Diagnostics Kit
- Digital Multi-meter with alligator clip leads

1) Begin by disconnecting power and communications from the termination
board, if not already done.
Page 5–6 2104349 rev. AD

2) Disconnect the RTD from the termination board, if not already done.
3) Set the DMM to 200 mVDC.
4) Select the RTD test resistance value by selecting the resistor test
connection from the FCU Diagnostic kit, or make one using a resistor
appropriate for the unit.
- Substitute the RTD probe wiring by connecting either a 100 OHM or
123 OHM resistor across connector terminals 3 and 4.
- Connect a jumper wire between terminals 2 and 3.
- Connect a jumper wire between terminals 4 and 5.
5) Clip the positive lead of the DMM to the upper side of the RTD test resistor.
6) Clip the negative lead of the DMM to the lower side of the RTD test resistor.
7) Supply power to the unit.
8) Once running, the measured value across the RTD test resistor should be
either:
- 100 OHM Resistor – Min of 100mv to a maximum of 125mv
- 123 OHM Resistor – Min of 123mv to a maximum of 155mv
9) The RTD measurement temperature on the G4 EX display should read
either:
- 100 OHM Resistor – 31.0°F to 33.0°F
- 123 OHM Resistor – 140.8°F to 142.8°F
10) If either of the measured values are outside of the range, remove power and
replace the RTD.
11) Return power, and perform steps 9 and 10 again. If either of the measured
values are outside of range, remove power, and replace the main
termination board.
12) Return power, and perform steps 9 and 10. If either of the measured values
are outside of the range, remove power, and replace the EXIMV.
5.2.6 RTD Impedance test

If readings from the RTD are still suspect following the RTD Probe test, follow the
instructions below to test the current source on the termination board to verify that
it is receiving power.

- Ice Bath
- Digitial MultiMeter

1) Immerse RTD probe in ice bath.
2) Perform a continuity check between any two similarly colored wires.
Measured resistance should be 1 OHM or less.
3) Perform a continuity check between any two dissimilar colored wires.
Measured resistance should be approximately 100 OHMs.
4) Perform a continuity check between shield wire and any other wires.
Measured resistance should be in the Megohm range.
2104349 rev. AD Page 5–7

5) If any values are returned out of range, the RTD probe is defective. Replace
the RTD.
5.3 Power troubleshooting
5.3.1 Overview
This section focuses on determining what was has caused the G4 EX to lose
power. Generally, loss of power can be attributed to only the power supply
system. However, if the power supply system is used for powering a transceiver or
other peripheral equipment, a problem with that equipment may drain the battery
and cause the G4 EX to lose power.
The following procedures represent tests that the user can implement to deduce
the problem that exists with the powering of the unit.
5.3.2 Power supply test

Various equipment configurations will necessitate moving to one or more
additional tests from this location.

1) Check that the power supply voltage setting, the power supply current rating
and the cables used for the installation meet the recommended
requirements.
2) If this is a new installation and external power is being powered from the G4
EX, call Totalflow Technical Support for help in evaluating the cable and
power supply installation requirements.
3) Correct and retest, as necessary.
4) Check for a poor cable connection between the G4 EX board and the
lithium battery pack.
5) Verify that all field wiring screw terminals on the termination board are tight
(see Figure 5–4).
Page 5–8 2104349 rev. AD

J13 Jumper:
AIs/DIs/DOs
AI/DO2(+)
DO/AI2(+)
AI/DO2(-)
DO/AI2(-)
DI/PI (-)
DI/PI(+)
J12 Jumper:
J3
+ AI - + DI - + DO -
on COMM1
J12 J6 J13 COMM1
1 3 1 3
J19 (RS-232/RS-485)
J8 COMM1
(BLK) RTD - 3 TXD/TBUS(-)
RTD PROBE 1 5
7
S2
(DRAIN) SHIELD 1
J2 5 J9 RRTS COMM1
ETHERNET 1
4 OPERATE COMM1
RTD
3 COMM2 SW
3
SECURITY J7 2 GND
S3
1 VBATT
USB CLIENT RESET

2 (-)
-
J4 J21 1 (+)
+
J16
1
PWR
MMI
J20 Note:
POWER/TERM
BOARD 1 2 3 4 5 6 7 8 9
1 3
2103344-XXX J11
RXD/RBUS(+)
TXD/TBUS(-)
RTS/TBUS(+)
RRTS COMM2
OPERATE COMM2
on COMM2
COMM2 SW
GND
VBATT
COMM2
(RS-232/RS-485)
Figure 5–4 G4 EX termination board

7) Verify that there are no other devices that may drop and excessive voltage
across them in the power supply circuit to the G4 EX.
9) Replace the lithium battery with a known good battery using the Replacing
the Lithium Battery instructions in Chapter 4.
5.3.3 Charger Circuit test

If the system setup includes a battery pack, solar panel or AC charging source
connected to the 6270 Optional Equipment Unit (OEU) and the unit’s battery is not
remaining charged, the user will need to test the battery pack, AC charger and/or
the solar panel.
The following instructions contain the steps required to perform the circuit testing.

1) Disconnect power from the charger regulator located in the Optional 6270
enclosure.
2104349 rev. AD Page 5–9

2) Replace the battery with a known good battery using the Battery Pack
Installation procedure in Chapter 2.
3) Reconnect power to the charger regulator. If the battery pack is charged
through an AC charger, move to step 5; otherwise, continue to step 4.
4) Measure the charging voltage from the solar panel at the charger regulator.
Use a DMM that connects the (+) and (-) leads to the (+) and (-) solar panel
wires. Loaded voltage should be greater than or equal to the specifications
listed in Table 5–2. If the voltage is within range, the battery was bad.
If the loaded voltage is not above the minimum, perform the Solar Panel
Troubleshooting Test found within this chapter.
5) If the unit receives charging voltage from the AC charger, perform the AC
Charger Troubleshooting Test found within this chapter.
Table 5–2 Specifications for solar panels
Panel Max Volts @ PMax Open Circuit Load Resistance Loaded Voltage
5 4.5W 16.5V 20.5V 50 Ω 25W 13.5V
10 10W 16.8V 21V 30 Ω 25W 17.5V
20 20W 16.8V 21V 15 Ω 25W 17.8V
30 30W 16.8V 21V 10 Ω 40W 17.8V
5.3.4 Solar panel charging system test

If the system setup includes a solar panel charger connected to the 6270 Optional
Equipment Unit (OEU) and is not supplying the required voltage and current to the
G4 EX unit, the user may need to test the solar panel.
The following instructions contain the steps required to test the solar panel.

- Digital Multi-meter with 0-20 VDC range
- Required resistors for testing specific panels as listed in Table 5–2
In continuous low sunlight conditions, the unit may not

supply the required voltage. The solar panel should be
positioned so that it receives the most sunlight. Do not place
in a shaded area.

1) Measure the solar panel voltage at the charger regulator. Use a DMM
connecting the (+) and (-) leads to the (+) and (-) solar panel wires. Loaded
voltage should be greater than or equal to the specification listed in Table
5–2. If the solar panel is not above the minimum, replace the solar panel,
and continue to step 2.
2) Check the solar panel angle and direction. In the northern hemisphere, the
panel should face due south. In southern hemispheres, the panel should
face due north.
Page 5–10 2104349 rev. AD

3) Check the solar panel for any physical damage or obstructions to sunlight.
Sunlight obstructions prevent the solar panel from receiving enough sunlight
to charge the installed battery pack. Clear any debris from the cell face of
the panel.
4) Check the solar panel wiring to ascertain that it is correctly connected to the
associated termination pins that are located in the 6270 OEU enclosure
(see Figure 5–5).
5) Disconnect the solar panel from the field device.
6) Set the DMM to 20+ VDC.
7) Determine if the open circuit voltage is greater than or equal to the
specification listed in Table 5–2 by clipping the positive lead of the DMM to
the first wire and clipping the negative lead of the DMM to the second wire.
If the solar panel is not above the minimum, continue to the next step.
8) Using the selected resistor from Table 5–2 for the solar panel wattage,
attach the selected resistor between the two solar panel wires.
9) Clip the positive lead of the DMM to the upper side of the test resistor.
10) Clip the negative lead of the DMM to the lower side of the test resistor.
11) Determine if the loaded voltage is greater than or equal to the specification
listed in Table 5–2. If the solar panel is not above the minimum, replace the
solar panel, and return to Step 3.
Figure 5–5 6270 OEU charger regulator
5.3.5 AC charging system unit test

If the system setup includes an AC charger connected to the 6270 OEU Optional
Equipment Unit and is not supplying the required voltage to the G4 EX unit, the
user may need to test the AC charger.
2104349 rev. AD Page 5–11

The following instructions will take the user through the steps for performing this
task.

1) Check the AC charger wiring to the 6270 OEU enclosure termination board
connector. Ensure that the wiring is correct.
2) Check the input AC voltage to the external AC charging unit. Ensure that
the primary AC voltage is correct.
3) Correct, and retest as necessary.
4) If the input primary AC voltage level is correct, wiring to the 6270 OEU
enclosure termination board is correct, and there is no DC output from the
charger; replace the charger fuse.
6) If the fuse is not faulty or there is no charger DC output voltage after
replacing the fuse, replace the AC charging unit.
5.3.6 Auxiliary equipment isolation test

This test will need to be performed if the battery pack output voltage is not
remaining consistent and no errors were found during the previous Power Supply,
Solar Panel Charging System or AC Charging Circuit troubleshooting tests.

1) Disconnect the solar panel charger or AC charger located in the Optional
6270 enclosure.
2) Disconnect the battery pack cable from the charger regulator. This is
located in the Optional 6270 enclosure, and substitute know good battery.
3) Disconnect any auxiliary equipment that draws power from the G4 EX or
battery pack.
4) Connect the current measurement troubleshooting cable (see Figure 5–6) to
a known good battery, and reconnect to the charger regulator.
BLACK DMM CONNECTOR
TO CHARGER REGULATOR
RED DMM CONNECTOR
TO BATTERY CABLE
Figure 5–6 Current measurement troubleshooting cable

5) Using a DMM, connect to the troubleshooting cable, and measure the
average current. If it is equal to or greater than 80 mA at 12 VDC,
disconnect the battery pack, and reconnect one auxiliary item. Continue to
the next step.
Page 5–12 2104349 rev. AD

6) If the average current is equal to or greater than the specification, no
problem is found with the remote equipment. Return to the test sequence in
the Power Troubleshooting section.
7) Reconnect the known good battery pack using the troubleshooting cable.
8) Using the DMM, connect the troubleshooting cable, and measure the
average current during start up. If the current is higher than 33-40 mA,
return to the Power Troubleshooting section above, and continue. If the
current is within acceptable limits, continue to the next step.
9) When the unit reaches normal operating status, measure the average
current. If the current is higher than 26-30 mA, return to the test sequence in
the Power Troubleshooting section. Move past the sequential testing, and
go directly to the Remote Communications troubleshooting.
5.3.7 Sleep mode

The Sleep mode is a safety feature which maintains the RAM but discontinues
data measurement calculations and control functions. When the G4 EX is in Sleep
mode, the word Sleep is displayed on the LCD. If the G4 EX battery voltage falls
below 11 VDC, the G4 EX enters Sleep mode.
If the battery voltage is still below 10.9 VDC when the user disconnected locally,
the G4 EX returns to Sleep mode. If the battery voltage is above 11 VDC, the G4
EX remains awake.
The G4 EX has a real-time clock which maintains time and date during Sleep
mode and writes an event record when entering and leaving the Sleep mode.
Upon wake-up, the G4 EX performs the following functions:
- Stores present calculation period accumulations in the historical record.
- Zeroes present calculation period accumulations.
- Ends the current daily record and starts a new daily record.

1) Connect locally to the G4 EX. This should wake up the unit for the user to
determine the cause.
2) Check the lithium battery cable. Ensure that it has a good, secure electrical
connection to the G4 EX board.
3) If the lithium battery cable is securely connected, check the lithium battery.
If voltage is low, replace with another lithium battery.
5.3.8 Reset procedures

The G4 EX operating system can be reset through either a cold or warm start
procedure. The decision to use these procedures should only be made by an
experienced technician.
5.3.8.1 Cold start

A cold start clears all the data that is stored in RAM as well as resetting all entered
variables to their factory default values or to the values last written to the tfCold
drive by the Save and Restore utility. A cold start should be used for new G4 EX
installations. This will ensure that all memory is clear and the operating program is
at its default settings. Discretionary use of this procedure is advised.
2104349 rev. AD Page 5–13

Refer to Chapter 4 for steps on performing both a hardware and software cold
start.
5.3.8.2 Warm start

A warm start does not clear the data stored in RAM. The warm start will only reset
the G4 EX microprocessor and not disturb any data that has been stored in RAM.
A warm start should be used when taking a unit out of service to perform
maintenance or troubleshooting. A warm start can be used when a power or
communication interruption caused the G4 EX microprocessor to lock up.
Refer to Chapter 4 for steps on performing both a hardware and software warm
start.
5.4 Communications troubleshooting
5.4.1 Overview
These troubleshooting procedures are applicable to the G4 EX with an installed
radio in the optional 6270 OEU Enclosure unit. Use Figure 5–7 as an aid in
troubleshooting communication problems. The three basic types of radio
communication that can be used between the G4 EX and a radio receiver are:
- RS-232 Communications port programmable
The radio/modem may be powered one of two ways: always on or switched. The
user’s specific system set up will determine what steps are needed to power the
radio/modem.
When switching power to a radio with Inhibit (Sleep) mode, the communication 1
port or switched power line will move to the radio’s Inhibit(Sleep) mode input.
Power out will move to the radios.
It is important that the user disconnect the G4 EX battery

cable from the G4 EX board.
Page 5–14 2104349 rev. AD

START
Verify unit
ID#, Security
Code and
Protocol are
Correct.
Verify jumper
and terminal &
pin wiring are
correct.
NO
Does Unit Transceiver
YES NO Transceiver
Respond to Host Supply voltage Investigate
END Supply voltage
Comm Request? Test Transceiver
within Specs?
Issues
YES
Investigate NO
Voltage supply
Power Supply
from unit
Issues
> 11.9 VDC?
Figure 5-4
YES
Substitute
YES
Unit Respond to Communication
Host Comm Test Cable
Request?
NO
Contact
Is NO Is NO
Totalflow
Communication Communication Technical
RS-232? RS-485? Support
YES YES
RS-232 RS-485
Communication Communication
Test Test
Does Unit
Respond?
YES
NO
Transceiver
NO
Comm Check
Test Passed?
YES
Figure 5–7 Communication troubleshooting flow chart
5.4.2 Setting up communication

After the installation of the communication equipment and before placing the
communication system into operation, the user should note the following:
- Verify the field wiring terminations on the G4 EX termination board.
- Verify the field wiring from the G4 EX unit to the termination board inside the
6270 OEU enclosure.
- Verify the field wiring from the termination board to the radio.
2104349 rev. AD Page 5–15

- Check the G4 EX identifier (ID). Log the ID for future reference.
- Log G4 EX access security code, baud rate, listen cycle, protocol and
interface for future reference.
The following helpful hints will aid the user after the
communication equipment has been installed and set up:
- When the communication equipment is powered/switched

on, the G4 EX displays the  after it recognizes the
G4 EX ID.
- Check the baud rate of the G4 EX transmission and Listen
time settings. The baud rate and time settings can
be changed when PCCU32 is in Entry mode. Default
settings are 1200 baud, the listening time is 4
seconds and the communications interface is turned
off.
- Minimum power required for operating remote
communications is 11.9 VDC (default) or as set by
the user. Should the power fall below this level,
remote communications will be terminated.
- Test remote communications using the RS-232
troubleshooting cable. Use the RS-232 to RS-485
communication converter in conjunction with the RS-
232 troubleshooting cable to test RS-485 remote
communications.
5.4.3 Transceiver supply voltage test

Using the wiring information and guidelines supplied by the transceiver’s
manufacturer, verify that the transceiver is receiving the manufacturer’s suggested
voltage. If the unit is receiving sufficient voltage, continue to the 6270 OEU Wiring
Voltage Test.
If the transceiver is not receiving sufficient voltage,

investigate the power supply issues. These may involve
wiring irregularities at either the charger regulator,
termination board, terminal strip or at the power relay if using
relay for switching power to the radio.
5.4.4 6270 OEU supply voltage test

If the transceiver does not feature a Sleep mode and power is supplied through an
optional relay, begin with step 1.
If the transceiver features a Sleep mode or is continuously powered, begin with
Step 2.
Wire color/origination inside the 6270 enclosure should

comply with WI drawings. For the purposes of these
instructions, wire color name and designation should
coincide with the Totalflow drawings. The user may need to
adapt, as appropriate, for their individual installation.
Page 5–16 2104349 rev. AD

1) If the transceiver does not feature a Sleep mode and receives power
through an optional relay, activate COM1SW or COM2SW, and using a
Digital Multi-meter (DMM) set to Volts DC, measure the voltage at the relay
between the relay coil terminals.
If the voltage reads the same as the supplied voltage (12 VDC) and the
transceiver is still not receiving power, the relay may be incorrectly wired
(use normally open contacts), or the relay may be bad.
If the relay is not receiving power, continue to step 2.
2) If the transceiver features a Sleep mode or is continuously powered,
activate COMSW1 or COM2SW, and using a DMM set to Volts DC,
measure the voltage at the next supply junction. If the next junction is
located on the termination strip, verify the wiring is firmly connected;
otherwise, continue to the charger relay, and measure the voltage between:
Terminal 1 (Batt +) and Terminal 4 (Batt -)
Voltage should be greater than or equal to 11.9 VDC for this unit. If the
voltage is less than 11.9, return to the test sequence outlined in the Power
Troubleshooting section.
5.4.5 Transceiver check

1) If available, use a wattmeter to check the transceiver output power. Refer to
the manufacturer’s documentation for measuring instructions.
2) If available, use two hand-held transceivers, and verify the communication
path between the master and remote sites. Voice-activated interface can be
used, if available.
3) Verify that the transceiver is set to the correct frequency. Refer to the
manufacturer’s documentation for checking the frequency instructions.
4) If a directional antenna is used, verify the orientation to the antennae to the
master site.
If a communication problem still exists and the unit has

passed the transceiver check test, contact Totalflow
Technical Support for additional help.
5.4.6 Termination board supply voltage test

1) Using a DMM set to Volts DC, measure the power supply voltage from the
OEU enclosure to J16 on the termination board (see Figure 5–4) between:
Pin 1 (+) and Pin 2 (-)
Voltage should be equal to or greater than the amount specified as low
voltage input in PCCU32 for this unit (9 volt minimum, default is 11.9 VDC).
2) If the supplied voltage falls in the correct range, return to the test sequence
outlined in the Power Troubleshooting section.
2104349 rev. AD Page 5–17

5.4.7 RS-232 communication
The following test procedure is directed from Figure 5–7 and will assist the user in
what may be the possible cause for an indicated error message.
With the exception of the field wiring directly on the G4 EX termination board, all
other wiring is located inside the 6270 OEU enclosure; therefore, two separate
procedures are required for testing.
5.4.8 RS-232 termination board test

Before performing the voltage test on the termination board located inside the rear
end cap, verify that the wiring is correct (see Table 5–3).
Table 5–3 RS-232 field wiring on the G4 EX termination board
Description ABRV Description ABRV

J19 – COMM 1 J20 – COMM 2
Pin 1 V-Battery VBATT V Battery VBATT
Pin 2 Ground GND Ground GND
Pin 3 Switched VBATT COMM1SW Switched VBATT COMM2 SW
Pin 4 Operate Comm1 Operate Comm1 Operate Comm2 Operate Comm2
Mirror Request to Mirror Request to
Pin 5 RRTS COMM1 RRTS COMM2
Send Send
Pin 6 Request to Send RTS Request to Send RTS
Pin 7 Transmit Data TXD Transmit Data TXD
Pin 8 Receive Data RXD Receive Data RXD
Pin 9 Clear to Send CTS Clear to Send CTS
When troubleshooting RS-232 mode, verify the settings of

COMM 1 SW 1 and COMM 2 SW2 on the termination board
are configured properly (see Figure 5–4).
Voltage on the following steps may be hard to see using a

Digital Multi-meter (DMM). If available, an oscilloscope will
provide a more accurate reading. To verify, the WinCCU
software must be continuously polling the meter
Generally speaking, these tests performed on the

termination board will only verify incorrect or damaged
wiring. If all previous testing passed and all wiring, jumpers
and terminations have been verified correct, the board will
need to be replaced. Contact Totalflow Customer Service.
See the Getting Help section for instructions.
Page 5–18 2104349 rev. AD

1) Using an oscilloscope, measure the receiving data voltage on the
termination board, J19 or J20, between:
COMM 1, J19–Pin 2 (GND) and Pin 8 (RXD) or
COMM 2, J20–Pin 2 (GND) and Pin 8 (RXD)
When the unit is transmitting to WinCCU, the voltage should vary between -
5 VDC and +5 VDC. This would indicate that the unit is receiving data;
continue to step 2. If the unit is not receiving data, investigate the wiring
issues (see Table 5–3).
2) Using an oscilloscope, measure the request to send voltage on the
termination board J19 or J20 between:
COMM 1, J19–Pin 2 (GND) and Pin 6 (RTS) or
COMM 2, J20–Pin 2 (GND) and Pin 6 (RTS)
When the unit is communicating to WinCCU, the voltage should be +5
VDC and remain at +5 VDC until the G4 EX transmit stops. This
would indicate that the unit is transmitting data; continue to step 3. If the unit
is not receiving data, investigate the wiring issues (see Table 5–3).
3) Using an oscilloscope, measure the transmit data voltage on the termination
board, J19 or J20 between:
COMM 1, J19–Pin 2 (GND) and Pin 7(TXD) or
COMM 2, J20–Pin 2 (GND) and Pin 7 (TXD)
When the unit is transmitting to WinCCU, the voltage should vary between -
5 VDC and +5 VDC. This would indicate that the unit is transmitting data. If
the unit is still not responding, continue to the next test as directed in Figure
5–7.
5.4.9 RS-232 OEU termination strip test

termination strip will only verify incorrect or damaged wiring.
If all previous testing passed and all wiring, jumper and
terminations have been verified as correct, the termination
strip may need to be replaced but does not typically fail.
Contact Totalflow Customer Service. See the Getting Help
section for instructions.
Please note that NO wire colors are referenced. Individual

units may vary.
Voltage on the following steps may be difficult to see using a

Digital Multi-meter (DMM). If available, an oscilloscope will
provide a more accurate reading. To verify, the WinCCU
software must be continuously polling the meter.

1) Using a oscilloscope, if available, measure the receiving data on the G4 EX
side of the OEU termination strip (see Figure 5–8) between:
GND and RXD
2104349 rev. AD Page 5–19

When the data is being transmitted to the G4 EX unit, the voltage should
vary between -5 VDC and +5 VDC.
When the unit is receiving data from WinCCU, the voltage should vary
between -5 VDC and +5 VDC. This would indicate that the unit is receiving
data.
2) On the OEU G4 EX side of the termination strip (see Figure 5–8), measure
the request to send voltage between terminals:
GND and RTS
When the G4 EX is sending communication data to WinCCU, the voltage
should be +5 VDC.
3) On the OEU termination strip, measure the transmitting data voltage
between terminals:
GND and TXD
When the data is being transmitted from the G4 EX unit, the voltage should
vary between -5 VDC and +5 VDC.
4) Repeat steps 1 through 3 on the transceiver side of the termination strip.
5) If any inaccuracy exists, investigate wiring errors.
Figure 5–8 OEU termination strip
5.4.10 RS-485 communication test

The following RS-485 serial communication test procedure is directed from Figure
5–7 and will assist the user in what may be the possible cause for an indicated
error message.
With the exception of the field wiring directly on the G4 EX termination board, all
other wiring is located inside the 6270 OEU enclosure. As such, there are two
separate procedures required for testing.
5.4.11 RS-485 termination board test

Before performing this test on the termination board, verify that the wiring is
correct.
Page 5–20 2104349 rev. AD

Table 5–4 RS-485 field wiring on the G4 EX termination board
Description ABRV Description ABRV

J19 – COMM 1 J20 – COMM 2
Pin 1 V-Battery VBATT V Battery VBATT
Pin 2 Ground GND Ground GND
Pin 3 Switched VBATT COMM1SW Switched VBATT COMM2 SW
Pin 4 Operate Comm1 Operate Comm1 Operate Comm2 Operate Comm2
Mirror Request to Mirror Request to
Pin 5 RRTS COMM1 RRTS COMM2
Send Send
Pin 6 Receive Bus (+) TBUS(+) Receive Bus (+) TBUS(+)
Pin 7 Receive Bus (-) TBUS(-) Receive Bus (-) TBUS(-)
Pin 8 Receive Bus (+) RBUS(+) Receive Bus (+) RBUS(+)
Pin 9 Receive Bus (-) RBUS(-) Receive Bus (-) RBUS(-)
When troubleshooting RS-485 mode, verify the settings on

COMM 1 SW1 and COMM 2 SW2 on the termination board
are configured properly (see Figure 5–4).

Digital Multi-meter. If available, an oscilloscope will provide
a more accurate reading. To verify, the WinCCU software
must continuously be polling the meter.

termination board will only verify incorrect or damaged
wiring. If all previous testing passed and all wiring, jumper
and terminations have been verified correct, the termination
board may need to be replaced but does not typically fail.
Contact Totalflow Customer Service. See the Getting Help
section for instructions.
1) Using an oscilloscope, measure the line driver voltage on the termination

board, J19 and J20, between:
COMM1, J19–Pin 9 (BUS-) and Pin 8 (BUS+) or
COMM 2, J20–Pin 8 (BUS+) and Pin 9 (BUS-)
When the unit is receiving data from WinCCU, voltage should vary between
+5 VDC and 0 VDC. This indicates that the unit is receiving data.
2) Using an oscilloscope, measure the remote request to send voltage on the
termination board J19. On J20, RRTS is not directed:
COMM 1, J19–Pin 2 (GND) and Pin 5 (RRTS)
When the unit is transmitting receiving data, the voltage should vary
between -5 VDC and +5 VDC. This would indicate that the RRTS is working
correctly.
3) If any inaccuracy exists, investigate the wiring errors or damaged wires.
2104349 rev. AD Page 5–21

If a communication problem still exists and the unit has
passed the required test, additional testing is required.
5.4.12 RS-485 OEU termination strip test

Digital Multi-meter. If available, an oscilloscope will provide
a more accurate reading. To verify, the WinCCU software
must continuously be polling the meter.

termination strip will only verify incorrect or damaged wiring.
If all previous testing passed and all wiring, jumper and
terminations have been verified correct, the termination strip
may need to be replaced but does not typically fail. Contact
Totalflow Customer Service. See the Getting Help section for
instructions.
When designating the wire colors in the following

procedures, color/origination complies with Totalflow wiring
instruction drawings. For the purposes of these instructions,
the user may need to adapt for their individual installation.
1) Using an oscilloscope, if available, measure the line driver voltage on the

G4 EX side of the OEU termination strip (see Figure 5–8) between:
BUS+ and BUS-
When the unit is receiving data from WinCCU, the voltage should vary
between +5 VDC and 0 VDC. This indicates that the unit is receiving data.
2) Using an oscilloscope, measure the request to send voltage on the G4 EX
side of the OEU termination strip between:
GND and RRTS
When the data in the G4 EX is sending communication data to WinCCU, the
voltage should be +5 VDC for the duration of the transmission.
3) Using an oscilloscope, measure the transmitting data voltage on the G4 EX
side of the OEU termination strip between:
GND and BUS-
And
GND and Bus+
When data is being transmitted from the G4 EX unit, the voltage should vary
between +2 VDC and +5 VDC.
4) Repeat steps 1 through 3 on the transceiver side of the termination strip.
5) If any inaccuracy exists, investigate the wiring errors.
Page 5–22 2104349 rev. AD

6 Reference material
6.1 Reference materials on ABB/Totalflow website
Additional information about the ABB Explosion Proof Flow Computer can be
found on our website http://www.abb.com/totalflow. The following chart has direct
links to many documents on-line that the user may find helpful concerning this
product.
Item Description Part #

ABB document Location on the web for all documents available for
Download Center
download center downloads.(with search capabilities)
Data Sheet XFC G4 6200/6201EX OVERVIEW 2104390
Start-up Guide XFC6200/6201EX START-UP GUIDE 2104263
XFC G4 EX TERM BD COMM 1 & COMM 2
User Drawing 2104215
GENERIC RS232 WIRING
XFC G4 EX TERM BD COMM 1 & COMM 2
GENERIC RS-485 WIRING
XFC G4 EX (2103344 BD) COMM1 TO MICRO
MOTION 1700/2700 CORIOLIS (RS-485)
User Drawing XFC G4 EX CIRCUIT BOARD ELEMENTS 2104217
User Drawing XFC G4 EX ILLUSTRATED PARTS BREAKDOWN 2104346
User Drawing XFC G4 EX POLE-MOUNT BRACKET 2104424
XFC G4 EX (2103344BD) AI TO 2-WIRE
TRANSMITTER (ANALOG INPUT)
2104349 rev. AD Page 23

6.2 I/O daughter card
The following information provides an outline for the installation and application of
the I/O daughter card within the G4 EX.
The I/O daughter card may already be installed in new units, if configured, or can
be added as an upgrade kit to pre-existing units. The following information will
address the installation for the upgrade kit.
Do not install the I/O daughter card until told to do so in these

instructions. Installation prior to flashing the unit may cause
some older models units to not boot.
6.2.1 Materials supplied in the upgrade kit

- 1 each I/O Daughter Card
- 4 each #6 .25 OD Flat Washer
- 4 each #6 Flat Washer
- 4 each 6–32 x .625 ¼ Hex Female Spacer
- 4 each 6–32 x .75 LG, M-F Standoff
- 1 each I/O Daughter Card Generic Wiring Diagram
- 1 each CD-ROM with Specified Flash and Configuration Files
6.2.2 I/O daughter card specifications

This card expands the capabilities of the explosion-proof flow computer by adding
an additional 12 points of fixed analog and digital I/O points. Specifications for the
I/O daughter card are as follows:
Analog Points
- 3 each 0-10V (10K ohm impedance) analog inputs
- 1 each 0-20 mA (SINK mode) analog output
Digital Points
- 4 each Digital inputs/pulse inputs
- 4 each Digital outputs (optically-isolated type 1A switches capable of
switching 200 mA of 48 VDC or 40 VAC)
6.2.3 Installation
If the unit is currently operating, data must be collected from the unit and the
configuration files saved prior to beginning this procedure.
Page 24 2104349 rev. AD

Termination
Board
J21 PCCU
Connector
I/O Daughter
Card
Figure 6–1 Termination panel with I/O daughter card installed
6.2.4 Upgrading the flash

1) Open PCCU32, but do not connect.
2) Once PCCU32 has loaded, click on the 32-Bit Loader icon on the window’s
main toolbar. The 32-Bit Loader screen will display.
Figure 6–2 32-Bit Loader screen
2104349 rev. AD Page 25

3) Select the ExFC radio button to designate that the G4 EX is the device that
will receive the new Flash.
4) Next, select the Update radio button.
6.2.5 Unit operating status shut down instructions

2) Back up all of the configuration and data files.
3) While in PCCU32, click the Save and Restore Utility icon from the main
window toolbar. The Save and Restore Utility window will display.
4) Within the Save and Restore Utility, click the Save Station Files button.
5) When the Save Station Files dialog box displays, verify the default name
and path for the files. Click the OK button. This will save the tfData drive
files.
6) When finished saving the station files, a new dialog box will offer the option
to Restore the Station Files to the tfCold drive. Select No.
7) Remove power externally from the unit.
6.2.6 Internal PCCU connector disassembly (if installed)

1) Gain access to the termination board by loosening the countersunk hex

socket locking set screw in the rear end cap. Use a 1/16” hex wrench, and
then unscrew the end cap.
2) Remove the four 6-32 x .625 standoffs located at the four corners of the
termination board.
3) Gently lift the termination board out of the unit. Be careful to not disconnect
the PCCU ribbon cable from the termination board.
4) Disconnect the cable from the termination board.
6.2.7 I/O daughter card installation

1) Gain access to the termination board by loosening the countersunk hex

socket locking set screw in the rear end cap. Use a 1/16” hex wrench, and
then unscrew the end cap.
2) Remove the four existing 6-32 x 625 standoffs and washers (if installed). Do
not misplace as they will be needed later in this procedure.
3) Install the new standoffs (6-32 x .75”) and washers supplied in the kit into
the four corner mounting holes in the termination board.
Page 26 2104349 rev. AD

4) Center the I/O card over the termination board (green phoenix connectors
facing out). Align the four screw holes at each corner. This should allow the
I/O card to interconnect with I/O Expansion connection on the termination
board. Apply gentle pressure to the I/O card in the two areas located on
either side of the connector until the board is seated.
5) Using the four 6-32 x .625 standoffs removed previously, connect the I/O
card to the termination board. Do not over tighten.
6) Reapply power to the unit. Make the local connection using PCCU32 and
the MMI cable. Once physically connected, open PCCU32, and move into
Entry mode.
7) In the PCCU32 tree-view, select the I/O Interface application. Once
expanded, click on the 6200EX I/O Card sub-menu. If the user is
communicating properly, they will see the setup screens for the daughter
card.
Figure 6–3 I/O Interface screen

8) Disconnect, and remove power externally from the unit.
9) Perform field wiring following the diagrams in Chapter 3. If the internal
PCCU connector is being reinstalled, field wiring must be done prior to
installation.
2104349 rev. AD Page 27

DB-9 Connector to
Termination Board
(Mounted on back)
J2 1
DI1(+)
DI1(-)
DI2(+)
DI2(-)
1 DI3(+)
AI1(+) I/O Daughter Card DI3(-)
AI1(-)
DI4(+)
AI2(+)
DI4(-)
AI2(-)
AI3(+) 8
DO1(+)
DO2(+)
DO3(+)
DO4(+)
DO1(-)
DO2(-)
DO3(-)
DO4(-)
AI3(-)
AOut(+)
AOut(-) 1 8
8 J3
J1
Figure 6–4 I/O daughter card
6.2.8 Internal PCCU connector reassembly (if previously installed)

1) Connect the cable from the PCCU assembly to the termination board.
2) Reinstall the four mounting standoffs. This will secure the termination board
to the device.
6.2.9 Implementation
This drawing does not completely illustrate the installation

methods required for hazardous locations. Prior to any installation
in a Classified Hazardous Location, verify the installation methods
by the Control Drawing referenced on the product’s name tag and
national and local codes.
Page 28 2104349 rev. AD

DB-9 Connector to XFCEX Board I/O
Expansion Connector (J2)
(Mounted on Back) XFCEX Board (Ref)
J3 J6 J5
The DI/PI inputs will accept sensor inputs
which meet the IEC-60947-5-6 electrical
SECURITY characteristics.
+ AI - + DI - + DO - ON
J8
J19
RTD IN I/O EXPANSION
J2 1 COMM1
RTD - 8
6 9 DI1(+)
RTD +
DI1(-)
RTD OUT 1 5 6
DI2(+)
SHIELD 5
J2 DI2(-) To Third Party
RTD 4
1 DI3(+) Digital Input Devices
AI1(+) 3
I/O Daughter Card DI3(-)
4 3 2 1
OFF 2
AI1(-) P/N: 2102458 DI4(+) 1
ON
AI2(+)
To Third Party AI2(-)
DI4(-) SW1
2
Analog Devices J21 AI3(+) 8J16 -
DO1(+)
DO2(+)
DO3(+)
DO4(+)
DO1(-)
DO2(-)
DO3(-)
DO4(-)
1
SEE SHEET 2 MMI
PWR +
AI3(-)
ON OFF
AOut(+) 4
1
AOut(-) 1 3 SW2 8
2
8 J3 1
J1
J20 COMM2
1 2 3 4 5 6 7 8
The Digital Outputs have a maximum “ON”

resistance of 2.5Ω which can switch 48V AC/
DC at up to 100mA. The outputs are isolated
To Third Party (AC voltage for 1 minute at 25°C, RH=60%
Digital Output Devices between input and output) from each other as
well as the control circuit by 1500Vrms.
Figure 6–5 Generic Wiring Diagram
6.2.9.1 Analog Points

Analog Inputs
The input range is 0-10 volts for the three 0-5V analog inputs (AI1, AI2 and AI3).
The inputs have a low pass filter -3 dB point of 100Hz. The sourcing device must
be capable of driving 10K input impedance.
As shown below, an external 250-255 OHM resistor is required (across + and –
input) to convert a 0/4-20 mA signal to a 0/1-5V compatible input.
The analog inputs must be defined in PCCU32.
2104349 rev. AD Page 29

Analog Outputs
The 0-20.48 mA analog output circuit is SINK mode only and requires the use of
an external power supply.
The analog inputs must be defined in PCCU32.
Page 30 2104349 rev. AD

6.2.9.2 Digital/Pulse Points
The DI/PI inputs will accept NAMUR type sensor inputs which meet the IEC-
60947-5-6 electrical characteristics. The digital inputs also function as event
counters.
Digital Outputs
- Optically-isolated type 1A switches
- Have a maximum ON resistance of 2.5Ω which can switch 48V AC/DC at up
to 200 mA at 60°C
- The outputs are isolated (AC voltage for 1 minute at 25°C, RH=60%
between input and output) from each other as well as the control circuit by
1500Vrms
The digital inputs must be defined in PCCU32.
2104349 rev. AD Page 31

Digital or Pulse Inputs
- NAMUR: When in a low impedance, the state must draw more than 2.2 mA;
when in high impedance, the state must draw less than 1.0 mA. It should be
noted that in the NAMUR specification, a low impedance of less than 400
OHMS is considered a short (fault), and a high impedance of greater than
20K OHMS is an open (fault). These two conditions are not monitored.
- Open Collector (O.C.): The output transistor or FET must be capable of
sinking 8.2 mA. Total impedance of the circuit must be less than 1K OHM.
- Dry Contact (i.e., reed-switch): The device must be capable of sinking 8.2
mA. The total impedance, when active, must be less than 1K OHM. Note:
The pulse inputs on the 2102458-001 are designed to accept relatively high-
speed( approximately 20Khz) signals. Therefore, if a reed-switch or other
mechanical device subject to bouncing contacts is used, the application will
require the use of a capacitor across the contact of the switching device ( a
value of 0.1 uF should be a good starting place).
- Active Signal: Must be capable of being connected to a 1K load which is
tied to a 8.2V voltage source. When the output is driven high (above 8.8V),
the load will appear at 215 OHMS connected to a 8.8V. Note: The active
signal type input requires the use of an onboard DAC converter to adjust the
trip threshold of the comparator input. Example: A 0-5V signal will not cause
the input to transition through the NAMUR thresholds. The DAC will be set
to 1.35V (to a value of 69 decimal or 0x45). This will make the apparent
threshold, as seen at the input, to 2.5V.
The digital inputs and pulse inputs must be defined in PCCU32.
Page 32 2104349 rev. AD

2104349 rev. AD Page 33
6.3 4–20 milliamp transmitters
6.3.1 Powering 4–20 Milliamp Transmitters

4-20 milliamp (mA) transmitters are essentially variable constant current sources.
They need to have sufficient voltage applied to them to insure that they will be
able to drive 20 mA onto a 250 OHM load. Different transmitter technologies will
have different powering requirements.
Many 4-20 mA transmitters claim to be operational between 10 and 30 VDC, but
this can be somewhat misleading. If it is a two-wire (line powered) transmitter and
it is sourcing the maximum loop current of 20 mA, 5 VDC is dropped across the
250 OHM resistor. Dropping 5 VDC across the load resistor only leaves 5 to 20
VDC (of the aforementioned 10 to 30 VDC) to operate the transmitter. There is a
good chance that 5 VDC will not be enough to properly operate the transmitter at
its maximum output of 20 mA.
Example: Voltage dropped across the load resistor at the maximum loop current.
E = I x R = 20 mA x 250 OHM = 5 VDC
The figure below shows a 4-20 mA loop being powered by a 12 VDC source. This
could be a solar panel with battery backup. If the battery has been discharged to
12-volts, then only 7-volts would remain to operate the transmitter. This may not
be enough to fully operate the transmitter at higher loop currents.
Assume 20ma 4-20ma

VCC
Transmitter
AI - AI +
- + - +
250Ω
5VDC 7VDC 12VDC

remaining to source
operate Transmitter
The following discussion does not pertain to 1-5 VDC

transmitters.
Totalflow flow meters employ a 250 OHM resistor to convert the 4-20 mA
transmitter current loop to a 1-5 VDC signal. In some meters, this conversion is
made by attaching a 250 OHM resistor across the 4-20 mA input pins (see the
next figure – schematic A). Some meters use a small three-pin jumper to select an
onboard 250 OHM resistor (see the next figure – schematic B). Still, other meters
employ an electronic switch to select the 250 OHM resistor (see the next figure –
schematic C). In the figures , VCC represents the voltage source used to power
the transmitter. In many instances, VCC could be tied to the meter’s VBAT.
With a solar paneled system, such as many Totalflow installations, available
voltage to power the 4-20 transmitter can become an issue. 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.
Page 34 2104349 rev. AD

External to
Flowmeter
flowmeter VCC
2-wire (line powered)
AI +
4-20ma transmitter
To A/D Converter
User supplies 250Ω

A 250Ω
resistor and wires it
across the AI input
pins
AI -
External to
Flowmeter
flowmeter VCC
AI + 2-wire (line powered)
To A/D Converter
4-20ma transmitter
1 3
Onboard 250Ω
resistor selected
using three-pin
jumper
250Ω B
AI -
To PCCU Control Flowmeter External to VCC

flowmeter
To A/D Converter AI + 3-wire 4-20ma transmitter
Onboard 250Ω resistor is

selected in PCCU setup
250Ω
AI -
C
Again, the 4-20 mA transmitter that was selected by the user must be fully
operational at voltages as low as VCC – 5 VDC. Again, VCC is the source voltage
available at the user’s site, and 5 VDC represents the voltage dropped across the
meter’s 250 OHM resistor at the maximum loop current (20 mA).
Totalflow can provide a 12 to 24 VDC converter. This converter can be powered
from the meter’s VBAT (either comm ports or J16). The converter’s 24 VDC output
can then be used to power the 4-20 mA transmitter loop. In other words, VCC
would now be 24 VDC. Subtracting the 5-volts dropped across the 250 OHM
resister would leave 19 VDC to power the transmitter.
2104349 rev. AD Page 35

Another possible solution would be to reduce the 250 OHM
resistor to a small value, possibly 125 OHMs. An under-
powered transmitter could more easily drive 20 mA into the
lesser resister. Field calibrating the AI would negate any
differences between the 250 OHM and the 125 OHM
resistors. However, as the user reduces the size of the
resistor, they lessen the overall resolution.
6.3.2 Example 1
If the 4-20 mA transmitter can drive full range (20 mA through the 250 OHM
resistor), the user has essentially converted a 4-20 mA current range into a 1-5
VDC voltage range. The analog to digital (A/D) converter used in Totalflow
equipment expects a 1-5 VDC signal. During field calibration, the user might have
the 4 mA of loop current represent 10bbls of fluid per hour and 20 mA represent
100bbls. The conversion to voltage (using the 250 OHM resistor) would be as
follows:
1 VDC = 10bbls/hour
5 VDC = 100bbls/hour
Assuming that the A/D converter is ranged between 0 and 5 VDC and the
converter is resolving 15 bits, the user would expect to resolve about 150μ VDC
(or .0006 mA). These numbers translate to about .003 bbl (3 thousandths of a
barrel or about one half fluid ounce).
6.3.3 Example 2
If the 4-20 mA transmitter cannot drive full range (20 mA through the 250 OHM
resistor), the user may want to reduce the value of the resistor. For this example,
the following will drop it to 125 OHM (or half). A 4-20 mA current would now be
converted to a 5-2.5 VDC voltage range. Again, during field calibration, the user
would have the 4 mA current represent 10bbls per hour and the 20 mA signal
represent 100bbls per hour. The voltage conversion (using the 125 OHM resistor)
would be as follows:
.5 VDC = 10bbls/hour
2.5 VDC = 1000bbls/hour
The A/Ds full range is still 0-5 VDC; however, the user is only using about half of
its range capability. Just like the resistor value, the ability to resolve barrels of fluid
per hour has been cut in half. The overall accuracy remains unchanged, but the
user can only resolve about 0.006bbls (6 thousandths of a barrel or about one
fluid ounce).
6.3.4 Conclusion
If the 4-20 mA transmitter that is being used cannot drive a full 20 mA through the
250 OHM resistor, the user can reduce the resistive value. However, as the
resistive value is reduced, resolution (not overall accuracy) will be reduced
proportionally. If the user drops the resistive value by half (250 OHMs to 125
OHMs), the resolution will be reduced by half.
To reduce the resistive value of an onboard resistor, the user can add an external
resistor across the analog input pins. This places the two resistors in parallel with
one another. The parallel combination produces an equivalent resistance that is
Page 36 2104349 rev. AD

less than either of the two resistors alone. The value of the equivalent resistance
is calculated as shown in the figure below:
External to
Flowmeter
flowmeter VCC
Onboard 250 ohm
resistor selected using 2-wire (line powered)
4-20ma transmitter
three-pin shunt +
1 3
External resistor added
R2 across onboard resistor
R1 250 Ohm
250 Ohm
R1 x R2 250 x 250 62500

Equivalent Resistance = = = = 125 Ohms
R1 + R2 250 + 250 500
2104349 rev. AD Page 37

Contact us:
ABB Inc., Measurement & Analytics
Quotes: [email protected]
Orders: [email protected]
Training: [email protected]
Support: [email protected]
+1 800 442 3097 (opt. 2)
Main Office - Bartlesville Kansas Office - Liberal Texas Office – Odessa

7051 Industrial Blvd 2705 Centennial Blvd 8007 East Business 20
Bartlesville, OK 74006 Liberal, KS 67901 Odessa, TX 79765
Ph: +1 918 338 4888 Ph: +1 620 626 4350 Ph: +1 432 272 1173
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3700 W. Sam Houston Bakersfield 150 Eagle Ford Road
Parkway S., Suite 600 4300 Stine Road Pleasanton, TX 78064
Houston, TX 77042 Suite 405-407 Ph: +1 830 569 8062
Ph: +1 713 587 8000 Bakersfield, CA 93313
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NFE 2923 Q CE 001 - A Instruments and Valves Certificates

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REV. DATE 2023-07-13

INSTRUMENTS AND VALVES CERTIFICATES

REV. DATE REVISION ISSUED BY CHECKED BY APPROVED BY

REV. DATE 2023-07-13

REV. DATE 2023-07-13

1. ULTRASONIC FLOWMETER AND FLOW ALIGNER

1.1 Ficha técnica y dibujos

Approved measuring range according to MID 181

13.1 Performance data

Power consumption Measuring element: typical 7-9 W;

Interfaces RS 485 0 (for RMGViewUSM): 9600 / 19200 / 38400 / 57600 Baud

RS 485 1 9600 / 19200 / 38400 / 57600 Baud

RS 485 2 9600 / 19200 / 38400 / 57600 Baud

Manual USM GT400 · EN10 · May 2021

Current output Umax= 16 V Load resistance: max. 400 Ω

Pulse output Umax= 30 V fmax= 5 kHz

Flow velocity -40 to + 40 m/s

Gas temperature range -40 C to +80 C

Maximum operating observe the details on the type

Ambient conditions -40 C to +55 C

Manual USM GT400 · EN10 · May 2021

13.2 Approved gas types

13.2.1 Suitability and safety for natural gas containing H2

Manual USM GT400 · EN10 · May 2021

13.3 Approved measuring range according to MID

l780 3 77650 / 23000 5 / 175 (2,5 / 88) abi in preparation

100 4 1000 / 35320 8 / 208 (4 / 140) abcd in preparation

150 6 2400 / 84760 20 / 700 (10 / 350) bci in preparation

200 8 4200 / 148350 32 / 1130 16 / 560

250 10 6600 / 233100 50 / 1750 25 / 880

300 12 9400 / 332000 70 / 2450 35 / 1240

350 12 11400 / 403000 I90 / 3180 45 / 1590

400 16 15000 / 530000 120 / 4230 60 / 2120

450 12 19000 / 670700 150 / 1750 75 / 2650

500 20 23500 / 830000 180 / 6350 90 / 3180

600 24 34000 / 1201000 260 / 9175 130 / 4590

650 26 45000 / 1588000 340 / 12010 170 / 6000

700 28 52000 / 1834800 420 / 14335 210 / 7400

750 30 60000 / 2115000 460 / 16230 320 / 8100

800 32 68000 / 2399000 550 / 19250 550 / 19250

900 36 86000 / 3030000 700 / 24500 700 / 24500

1000 40 108000 / 3800000 850 / 29750 850 / 29750

*1 The extended measuring range only effects Qmin. It can be

Manual USM GT400 · EN10 · May 2021

13.4 Type plate

The following details can be found on the type plate:

Manual USM GT400 · EN10 · May 2021

13.4.1 Type plate ATEX / IECEx

Fig. 13.2: Type plate ATEX / IECEx

Manual USM GT400 · EN10 · May 2021

13.4.2 Type plate NEC (CSA)

Fig. 13.3: Type plate NEC (CSA / FM)

13.5 Weights and dimensions

Manual USM GT400 · EN10 · May 2021

13.5.1 NEC (CSA)

Manual USM GT400 · EN10 · May 2021

13.5.2 ATEX / IECEx