Ultrasonic Flow Processor (UFP)

Card configuration & replacement

Ultrasonic Flow Processor (UFP)

IPC-6606 AWS-8129H
UFP cards & card configuration

UFP card replacement

Calibration analogue inputs (AD-812 card)

Calibration frequency output (MP-103 card)

Calibration 4-20 mA output (MP-103 card)

UFP-V (IPC-6606 interior view)

CPU Card

RS-422/485 card

AD-812 card

MP 103 card
UFP-V (IPC-6606 interior view)

IDE Disk on module

(C-drive)

Compact Flash
card (D-drive)
 UFP-V (IPC-6606 back view)

230 / 110 VAC

24 VDC
VGA port
Power Switch

RS-485 port for

comms to UFC

AD-812 card

MP 103 card
UFP-V (CPU cards)

 PCA- 6154 (no longer available)

 PCA-6773 (no longer available)

 PCA-6780 (no longer available)

PCA-6781 (currently in use)

UFP CPU card (PCA-6154)

Disk on Chip
module (C-drive)

SRAM module Backup

(D-drive) battery
UFP-V (CPU card (PCA-6773))

• C drive (IDE Disk on module solid state)

• D drive Compact flash card
UFP-V (CPU card (PCA-6780))

• C drive (IDE Disk on module)

• D drive Compact flash card
UFP-V (CPU card (PCA-6781))
(PCA-6781)

• C drive (IDE Disk on module)

• D drive Compact flash card
UFP-V (CPU card (PCA-6773 jumper configuration))

DOM
SW1 DSTN 24bit
SW1 Panel Type 0000
1024x768
1
J01 COM2 Mode RS232

SSD
JP1 CMOS Select Normal
MEM

JP2 WDT Action System Reset

JP2 JP1 J01

MEM Memory Memory

DOM DiskOnModule DiskOnModule

SSD Solid State Disk Solid State Disk

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UFP-V (CPU card (PCA-6780 jumper configuration))
UFP-V (CPU card (PCA-6781 jumper configuration))

LVDS Panel Power Select (J1) : (1-2) +3.3V

LVDS VBR Select (J2): (1-2) Low
AT/ATX Power choose jumper (J3): (1-2) ATX Power
Clear CMOS (J4): (1-2) Normal
COM 2 RS-232/422/485 Select (J5): (1-2) RS-232

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UFP-V (PCL-745S RS422 / 485 card)

Two independent RS-

422/485 serial ports
Channel 1:
Dedicated to UFC
communication
Channel 2:
Modbus
communication

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UFP-V (PCL 745S RS422 / 485 card configuration )

SW1 CH1 COM3 Address 010000 3E8h

SW1 SW2 J04 SW2 CH2 COM4 Address 0100010 2E8h

1 1

J05 J06 J07 J08 J01 COM3 Interrupt IRQ 4

J01 Label 1
J02 COM4 Interrupt IRQ 3
Rev. 020402 R12 R9
U6 J04 COM3 Transmit Driver RTS

J09 J10 J11

J05 COM4 Transmit Driver RTS
J02
J06 COM3 Mode RS422
J07 COM3 TX Terminator 120Ohm
J08 COM3 RX Terminator not installed
Label 2

Rev. 020402
J09 COM4 Mode RS422
J10 COM4 TX Terminator 120Ohm
J11 COM4 RX Terminator 120Ohm

R12 R9 Replace Resistors R12 and R9 680Ohm/0.1W SMD

U6 Check Resistance Pin 8-6 and Pin 7-5 680Ohm
Label 1 Add Label with Revision Number Rev. 020402
Label 2 Add Label with Revision Number Rev. 020402

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UFP-V (PCL-812PG) + PCLD-780 terminal board ))

PCL-812PG PCLD-780 Terminal board

16 channel board

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UFP-V (Analogue I/O card (PCL-812PG))

16 channel multifunction board.

16 channel input (accuracy 0.015%
of reading +/- bit
(resolution 4-20mA=1638 pos).

PCL-812PG
16 channel multifunction board

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UFP-V (PCLD-780 terminal board )

• Terminal board
• (Allowing connection of 16
Analogue 4-20 mA inputs and 2
analogue outputs (0 -10 VDC)

PCLD-780 Terminal board

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UFP-V (AD I/O card (PCL-812PG) configuration

J09

SW1 Base Address 01110111 220h

J01 J01 Trigger Source INT

J04 J03
J02 CH0 Clock INT

J03 CH1 Reference Voltage INT

J02 J08
J04 CH2 Reference Voltage INT

J05 A/D Interrupt disabled

J05 SW1 J06

J06 DRQ disabled

1

J07 DACK disabled

J07

J08 D/A Internal Reference Voltage 10VDC

J09 A/D Maximum Input Voltage 5VDC

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UFP-V (PCLD-780 terminal board )

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 UFP-V MTL I/O Board - Front view

Replaces PCL-780 terminal board

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FP-V MTL I/O Board – Back view (230VAC version)

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FP-V MTL I/O Board – Back view (24 VDC version)

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UFP-V (MP103 Frequency output card )

· 4 digital inputs
(Max. 12 VDC TTL Compatible)
· 2 Frequency input channels
· (0-5000 Hz)
· 2 Frequency output channels
(1-2000 Hz. (Resolution max.:
0.016% of static output value.
· 1 analogue output : 4-20 mA
(puls width modulated, 14 bit).
· 4 Relay outputs (NO)

Frequency input (2x)

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UFP-V (IPC-6606 back view)

MP 103 card

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UFP-V (MP103 Frequency output card Rev. 3.39993.01)

J09
MC 1
J09 N.A. Function not installed

J03 J03 AD Output active passive

MC 2 J10 MC 1 Frequency Input 1 Function 33142102 Counter 33142101 Frequency

MC 2 Frequency Input 2 Function 33142101 Frequency
J01.. J07..
J07 Frequency Output 1 active passive
J06
J05 Frequency Output 2 passive active
J08

J10 Frequency Output Voltage 24VDC 12VDC

J01 Phase Shift Frequency Output 1-2 90o 0o

J04

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UFP cards & card configuration

UFP card replacement

Calibration analogue inputs (AD-812 card)

Calibration frequency output (MP-103 card)

Calibration 4-20 mA output (MP-103 card

 UFP-V (Card replacement Overview )

Defective card Corrective actions

RS-485 / 422 card Replace card with correct jumper configuration.

CPU Card (PCA-6773) Replace card with correct jumper configuration.

Correct UFP configuration needs to be downloaded.

AD Card (PCL-812PG) Replace card with correct jumper settings.

Recalibrate all AD inputs

MP103 Card Replace card with correct jumper settings.

Recalibrate Frequency output
 UFP cards & card configuration

UFP card replacement

Calibration analogue inputs (AD-812 card)

Calibration frequency output (MP-103 card)

Calibration 4-20 mA output (MP-103 card

UFP-V I/O overview

Accessible from the main screen <F10>, <F10>

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 UFP-V accessing AD calibration program

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Main Screen Control Screen Stop Measure mode

<F1> <F9> <F5>

Important!:
After pressing <F5> measurement of flow will stop. If flow is
not zero, loss of volume within the measurement will occur.
UFP-V (AD card calibration: DOS prompt (NON-MID version))

----
----
type AD to calibrate / verify AD card IO (AD-812)
type FR to calibrate / verify Frequency card IO (MP-103)
----
type CLNT to edit parameters on IO (Where to find IO, spans etc)
type COMS to edit communications setup (Modbus, BatchPrinter etc)
type HSET to edit parameters on hardware settings of the UFP
type TICK to edit the ticket (BOL) layout file
----
type MEAS to measure flow
----
----

c:\

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UFP-V (AD card calibration: DOS prompt (MID version))

POSSIBLE BATCH COMMANDS:

----
type AD to calibrate / verify AD card IO (AD-812)
type FR to calibrate / verify Frequency card IO (MP-103)
----
type CLNT to edit parameters on IO (Where to find IO, spans etc)
type COMS to edit communications setup (Modbus, BatchPrinter etc)
type HSET to edit parameters on hardware settings of the UFP
type TICK to edit the ticket (BOL) layout file
----
type TICKSS to set ticket (BOL) layout file to small layout (gross vol.)
type TICKSL to set ticket (BOL) layout file to large layout (standard vol.)
----
type BACKALL to make backup of flow config and OS to EMPTY floppy disk
type BACKFLOW to make backup of flow config only to EMPTY floppy disk
type BACKOS to make backup of Operating system OS to EMPTY floppy disk
type BACKZIP to make zipped backup of flow config and OS to EMPTY floppy disk
----
type MEAS to measure flow
----
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 UFP-V (AD card calibration:

1. Type: AD <enter> to start the AD calibration program

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UFP-V (AD card verification screen)

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 UFP-V (AD Card calibration (AD0300.exe)

1. Select the AD channel to calibrate <+>,<-> keys

2. Connect a calibrated 4-20mA simulator to the input
3. Press <Z> to select the 4mA point for calibration
4. Set simulator to 4 mA.
5. Use cursor keys to adjust the value of the input so that it is equal to the
simulated value.
6. Press <G> for calibration of gain point
7. Set simulator to 20 mA.
8. Repeat step 5.
9. When ready use <F10> to save adjustments
10. Press <esc>.
11. Select correct channel value with <+> & <-> keys.
12. Verify that adjustments which were made have been saved correctly
13. Press <esc> to exit ADcalibration / verification mode and return to DOS.
14. Type: MEAS <enter> to return to measurement mode.
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 UFP-V (Starting measurement after AD calibration)

1. If any adjustments where made in the AD calibration the UFP will display
the following:

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 UFP-V (Starting measurement after AD calibration)

1. Type: 1357 <enter>. The following will be displayed:

2. Press <1> to generate a new CRC checksum. The following screen will
be displayed

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 UFP-V (Starting measurement after AD calibration)

1. Type: 7531 <enter>. The program will return to the DOS prompt.
2. Type: MEAS <enter> to start the measurement mode.

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UFP-V (Starting measurement after AD calibration)

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UFP cards & card configuration

UFP card replacement

Calibration analogue inputs (AD-812 card)

Calibration frequency output (MP-103 card)

Calibration 4-20 mA output (MP-103 card

 UFP-V MP-103 calibration program

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Main Screen Control Screen Stop Measure mode

<F1> <F9> <F5>

Important!:
After pressing <F5> measurement of flow will stop. If flow is
not zero, loss of volume within the measurement will occur.
 UFP-V (MP-103 calibration program)
• Type: FR <enter> to start the MP-103 calibration program

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 UFP-V (MP-103 card calibration (FR0300.exe)

1. Press <F1> to switch to frequency output calibration mode

2. Connect a calibrated frequency counter to the frequency output
3. Use cursor keys to adjust the value on the frequency counter until it is
equal to 1000 Hz.
4. When ready use <F10> to save adjustments
5. Press <esc>.to access the verification screen.
6. Use the <2>, <4>, <6>, <8> keys to adjust to output value to 1000 Hz.
7. Verify that adjustments which were made have been saved correctly
8. Press <esc> to exit the MP-103 and return to DOS.
9. Type: MEAS <enter> to return to measurement mode.

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UFP-V (MP-103 verification screen)

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 UFP-V (Starting measurement after MP-103 calibration)

1. If any adjustments where made in the MP-103 calibration the UFP will
display the following:

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 UFP-V (Starting measurement after MP-103 calibration)

1. Type: 1357 <enter>. The following will be displayed:

2. Press <1> to generate a new CRC checksum. The following screen will
be displayed

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 UFP-V (Starting measurement after MP-103 calibration)

1. Type: 7531 <enter>. The program will return to the DOS prompt.
2. Type: MEAS <enter> to start the measurement mode.

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UFP-V (Starting measurement after MP-103 calibration)

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UFP cards & card configuration

UFP card replacement

Calibration analogue inputs (AD-812 card)

Calibration frequency output (MP-103 card)

Calibration 4-20 mA output (MP-103 card

 UFP-V (MP-103 calibration program)
• The MP-103 calibration program allows for 3 point adjustment of 4-20
mA output.

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 UFP-V MP-103 card calibration (FR0300.exe)

1. Connect a calibration current meter to the current output of the MP-103.

2. Press <F4> and use cursor keys to adjust reading for 4.00 mA
3. Press <F5> and use cursor keys to adjust reading for 12.00 mA.
4. Press <F6> and use cursor keys to adjust reading for 22.00 mA.
5. Press <F10> to save adjustments.
6. Press <esc> and use the verification screen to confirm if adjustments
were properly saved. (Use <a>, <w>, <d>, <x> keys to modify current
output value.
7. Press <esc> to exit to DOS.
8. Type MEAS <enter> to return to measurement mode.
9. Create a new CRC checksum as described in previous section for
calibration of AD & MP-103 card.

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Thank You
for your Attention!