Daniel Model 2500 Turbo Hardware Owner's manual

MANUAL ADDENDUM

HARDWARE

2500 TURBO FLOW COMPUTER

DANIEL INDUSTRIES, INC.

HOUSTON, TEXAS

Part Number: 9-9065-133

Revision F

May 2002

This addendum accompanies the Daniel Industries Model 2500 Hardware Manual (part number

3-9000-590) to addresses the features, installation, setup, and specifications of the Daniel

Industries 2500 Turbo Flow Computer. A 2500 Turbo upgrade or installation introduces

significant performance benefits, yet retains compatibility with the previous generation of the

Model 2500 Flow Computer.

NOTE: Also included in this addendum are selected 2500 Turbo drawings.

This addendum is organized into the following topics and sections.

Introduction ............................................... See section 1

Available Models and Kits ........................................ 1.1

Features and Capabilities ......................................... 1.2

Software Compatibility .......................................... 1.3

Installation ................................................ See section 2

Installing a New Complete-Unit Assembly ............................. 2.1

Upgrading an Existing Model 2500 .................................. 2.2

Connector Points ........................................... See section 3

Jumper and Switch Configurations .............................. See section 4

Serial Port 1 Jumper Settings ...................................... 4.1

Serial Port 2 Jumper Settings ...................................... 4.2

Turbine Inputs Jumper Settings ..................................... 4.3

2500 Turbo

NOV 1998

Digital Outputs Jumper Settings .................................... 4.4

Status Jumpers ................................................ 4.5

Password Protection Switch SW1 ................................... 4.6

Processor Jumpers .............................................. 4.7

Startup and Operation ....................................... See section 5

Recompiling a 2500 Turbo Application Program ......................... 5.1

Downloading a 2500 Turbo Application Program ........................ 5.2

Operation After Downloading ...................................... 5.3

Determining the Base25 EPROM Revision Level ........................ 5.4

Cold Starting the 2500 Turbo from Keypad ............................ 5.5

Specifications .............................................. See section 6

Main CPU Card Specifications ..................................... 6.1

Analog Inputs Specifications ...................................... 6.2

Analog Outputs Specifications ..................................... 6.3

Pulse Inputs / Frequency Inputs Specifications .......................... 6.4

Status Inputs Specifications ....................................... 6.5

Control Outputs Specifications ..................................... 6.6

Transient Protection Specifications .................................. 6.7

Calculation Accuracy Specifications ................................. 6.8

Communications Specifications ..................................... 6.9

RS232 Serial Communications Port ................................. 6.10

RS485 Serial Communications Port ................................. 6.11

Electrical Power Supply Specifications .............................. 6.12

Self Diagnostics Specifications .................................... 6.13

Environmental Specifications ..................................... 6.14

Approvals and Certifications ...................................... 6.15

2500 Turbo Drawings

Turbo 2500 Assembly Drawing ..................... DE-19456 (sheet 2 of 2)

Turbo 2500 P/S Assembly Drawing ............................. CE-19459

Minimodule/SSD Assembly Drawing, Turbo 2500 .................. BE-19561

Core Module/4DXi, Turbo 2500 ............................... BE-19711

Field Wiring Diagram, Model 2500 ............DE-10485 (sheets 1, 2, and 3 of 3)

2 2500 TURBO FLOW COMPUTER

2500 Turbo

NOV 1998

Year 2000 Warranty

The Company represents and warrants that computer programs in any medium, software,

firmware and combinations thereof ("Deliverables") manufactured by the Company and

incorporated into or supplied by the Company for use with goods manufactured by the Company

will, under normal use and care:

i) recognize and accept dates falling on or after 1 January 2000;

ii) recognize and accept the year 2000 and every succeeding fourth year as leap

years;

iii) recognize and accept 29 February in the year 2000 and every succeeding fourth

year;

iv) record, store, process, sequence, present and output calendar dates and data related

to dates falling on or after 1 January 2000, in the same manner and with the same

functionality as they do on or before 31 December 1999 and without errors or

omissions; and

v) lose no functionality with respect to the introduction into them of dates or data

related to dates falling on or after 1 January 2000;

provided that, in the case of any non-conforming Deliverables that are returned to the Company

promptly following discovery of the non-conformity, the Company will, at its option and cost,

repair or replace such Deliverable or refund to the Purchaser the purchase price therefor. This

shall be the Purchaser’s sole and exclusive remedy for breach of the foregoing warranty.

Notwithstanding the foregoing, the Company shall not, under any circumstances whatsoever, be

liable for any defects or errors caused by: materials or workmanship made, furnished or specified

by the Purchaser; non-compliance with the Company’s installation or operation requirements;

failure to install any revisions and/or upgrades to the Deliverables deemed mandatory by the

Company; any modifications to Deliverables not previously authorized by the Company in

writing; the use by the Purchaser of any non-authorized spare or replacement parts in connection

with the goods used in conjunction with the Deliverables; or the use of the Deliverables with any

hardware or software not supplied by the Company. The Purchaser shall at all times remain

solely responsible for the adequacy and accuracy of all information supplied by it. Any third

party content in Deliverables shall carry only the warranty extended by the original manufacturer.

ADDENDUM 9-9065-133 3

2500 Turbo

NOV 1998

THE FOREGOING CONSTITUTES THE COMPANY’S SOLE AND EXCLUSIVE

WARRANTY IN RELATION TO THE PERFORMANCE OF THE DELIVERABLES AS IT

RELATES TO THE CHANGE FROM YEAR 1999 TO YEAR 2000 OR THE OCCURRENCE

OF LEAP YEARS THEREAFTER, AND THE PURCHASER’S EXCLUSIVE REMEDY FOR

BREACH THEREOF. IN NO EVENT WILL THE COMPANY BE LIABLE FOR INDIRECT,

CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES, INCLUDING LOSS OF USE,

BUSINESS INTERRUPTION OR LOSS OF PROFITS, IRRESPECTIVE OF WHETHER THE

COMPANY HAD NOTICE OF THE POSSIBILITY OF SUCH DAMAGES.

The foregoing warranty shall remain valid until the later of December 31, 2000 or one year after

the date that the Deliverable was shipped.

4 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

SECTION 1

INTRODUCTION

1.1 AVAILABLE MODELS AND KITS

The Daniel Industries 2500 Turbo Flow Computer is available either as a complete, new

installation unit or as a kit to upgrade an existing Model 2500 Flow Computer.

2500 Turbo: New Installation Units

Like the Model 2500, the 2500 Turbo Flow Computer can be housed in a standard rack

(panel mount) enclosure, or it can be housed in any of these environmentally rated

enclosures:

Table 1. List of enclosures and model series for new 2500 Flow Computer

Enclosure** Daniel Model No. Series

Standard Rack Mount

2521 Series: one-board

2522 Series: two-board*

NEMA 13, painted steel, 20 x 20 inches 2530 Series: one- or two-board*

NEMA 12, stainless steel, 24 x 30 inches

2512 Series, one- or two-board*

NEMA 4X, stainless steel, 24 x 30 inches

Canada Box

NOTES:

* Two-board configuration provides more I/O capabilities (see Section 2, "Hardware

Options", of the Model 2500 Hardware Manual, Daniel part number 3-9000-590,

for details).

** See Section 2, "Enclosure", of the Model 2500 Hardware Manual, for more details

on enclosure options. Each enclosure is designed to be compliant with the NEMA

standard.

These power supply options are also available:

· 115/230 volts AC power supply

· 24 volts DC input

ADDENDUM 9-9065-133 5

2500 Turbo

FEB 1998

2500 Turbo: Upgrade Kit

To upgrade an existing Model 2500 to a 2500 Turbo Flow Computer, use this upgrade

kit:

· PC/104 Mother Board with CPU plug-in, high capacity power supply (Daniel part

number 3-2500-410).

NOTE: To upgrade a two-board Model 2500, you only need to replace the

CPU board. The second, or I/O board, is not replaced, as it is fully

compatible with the 2500 Turbo upgrade.

1.2 FEATURES AND CAPABILITIES

Increased Performance

The 2500 Turbo is designed to be a performance upgrade kit for existing users. With its

486/100 megahertz (MHz) 32-bit microprocessor, it will provide speed increases of over

20 times the original performance of the V20 microprocessor.

Improved Upgrade Paths for Future Applications

The 2500 Turbo uses a PC/104 motherboard that accommodates plug-in modules to help

maximize upgrade paths for future applications. PC convenience, instead of proprietary

microprocessor designs, makes it easier to adapt to virtually any flow measurement

programming challenge.

Improved Power Supply

The 2500 Turbo board has an onboard industry standard power supply that provides a

higher power output and a wide (18 to 36 volts DC) input voltage range. For installations

using 115 or 230 volts AC power, the onboard 2500 Turbo power supply receives input

voltage from an optional 115/230 volts AC power supply.

6 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

Compatibility

The 2500 Turbo upgrade kit fits into existing Model 2500 RTU enclosures. And the 2500

Turbo, whether new or upgraded, is compatible with existing Model 2500 applications via

the Daniel Industries Config25 software. This makes upgrading to 2500 Turbo a three-step

process:

1. Replace the existing 2500 CPU with a new 2500 Turbo card set.

2. Compile your existing applications with the new Config25 software program.

3. Download the application, and go back on line.

1.3 SOFTWARE COMPATIBILITY

To use existing Config25 applications with the 2500 Turbo, you will need the following:

· Daniel Config25 Turbo Configuration Program, revision 6.00 or later

· Base25 EPROMs, revision 6.05 or later

With the two above items installed, you can select the application and analyze the file in

preparation for a new download. This recompiles the application for the 32-bit microprocessor

of the 2500 Turbo. See the next section of this addendum, "Installation", for more details.

NOTES: To determine the revision level of the Base25 EPROMs installed

in a 2500 Turbo, follow the instructions provided in section 5.4,

"Determining the Base25 EPROM Revision Level", this addendum.

Further revisions of Config25 software and 2500 Turbo firmware

are currently under development. These revisions, when released,

represent the next step in realizing the full potential of the 2500

Turbo’s architecture and performance.

ADDENDUM 9-9065-133 7

2500 Turbo

FEB 1998

SECTION 2

INSTALLATION

2.1 INSTALLING A NEW COMPLETE-UNIT ASSEMBLY

If you are installing a new complete-unit assembly, and not upgrading an existing installation,

follow the instructions provided in Section 4, "Installation", of the Model 2500 Hardware Manual,

Daniel part number 3-9000-590.

Note these differences, though, between a new Model 2500 installation and a new 2500 Turbo

installation:

(1) Use Daniel Config25 Turbo Configuration Program revision 6.00, or later, to recompile

existing applications that are version K.2 through 5.xx for use with a 2500 Turbo Flow

Computer.

NOTE: New 2500 Turbo applications do not need recompiling before they

are downloaded to the flow computer. Only applications that are

revision K.2 to 5.xx need to be recompiled. You can determine an

application’s revision level by examining the application listing. In

the application listing, the revision level is printed in the top center

of each page header (as vK.2, for example).

(2) Applications can be downloaded to either serial port 1 or serial port 2 of the 2500 Turbo.

Default speeds are 9600 bps for serial port 1 and 2400 bps for serial port 2.

8 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

2.2 UPGRADING AN EXISTING MODEL 2500

To prepare for upgrading, have on hand the following tools and materials

:

· Flat blade screwdriver

· 5/16" wrench

· Serial cable for downloading Application Program from personal computer (PC)

to the flow computer (see drawing CE-10174, "Assembly, Cable to IBM

Computer", in the Model 2500 Hardware Manual, appendix H).

· Model 2500 Turbo Application Program

· Model 2500 Hardware Manual (Daniel part number 3-9000-590)

· Model 2500 Config25 Reference Manual (Daniel part number 3-9000-592)

· This guide, the Manual Addendum, Hardware, 2500 Turbo Flow Computer

(Daniel part number 9-9065-133)

ADDENDUM 9-9065-133 9

2500 Turbo

FEB 1998

To upgrade an existing Model 2500 to a 2500 Turbo, follow these steps:

(1) Turn off and disconnect electrical power from the Model 2500 Flow Computer.

(2) Access the Model 2500 Flow Computer chassis.

(3) Remove the card cage assembly from the flow computer’s chassis.

(a) Make note of all cable connections to the chassis, so that you can later consult

your notes, reinstall the card cage assembly, and accurately reconnect all cables.

(b) Disconnect the green ground wire from the lug on the chassis. (Use the flat blade

screwdriver and 5/16" wrench.)

(4) If board number 2 (for additional I/O capabilities) is installed, make sure the P2 cable is

disconnected from it, then remove board number 2 from the card cage assembly.

(5) Make sure the P1 and P2 cables are disconnected from board one (CPU board), then

remove the board from the card cage assembly.

(6) Install the new 2500 Turbo board in the card chassis slot for board number 1.

IMPORTANT: Before you install the new 2500 Turbo board,

make note of the EPROM label on U44, board number 2 (if

applicable), since it will identify the AGA8 equation type that will

be required for entry, upon startup.

(a) Before installing the new board, first ensure that all jumper settings are as desired

for serial port communications, turbine inputs, and digital outputs. (For

illustrations, see section 4, "Jumper and Switch Configurations", this addendum,

and the 2500 Turbo drawings at the end of this addendum.)

(b) Reconnect the P1 and P2 cables to the new 2500 Turbo board.

(7) Reconnect the green ground wire to the card chassis.

(8) Enable the new board’s battery by connecting the four-pin connector to the J7 connector

on the board.

10 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

(9) If board number 2 was installed, reinstall it now.

(a) Reconnect the P2 connector cable to board number 2.

(10) Reconnect any remaining disconnected cables to the board(s).

(11) Install onto the card chassis the new side plate that comes with the 2500 Turbo upgrade

kit.

(a) The new side plate has a printed list of field-wiring terminations that are

applicable to the 2500 Turbo. It is a replacement for the original side plate that

lists these terminations.

(12) Reinstall the card cage assembly into the flow computer’s chassis.

(13) To indicate the flow computer has been upgraded to 2500 Turbo, add the "Turbo" sticker

to the front panel of the flow computer.

(14) Reconnect and turn on electrical power to the flow computer.

NOTE: Board number 2’s EPROMs (for AGA8 applications, etc.) and

battery are now resident on the new 2500 Turbo CPU card. Do not

remove these items from board number 2 — they will not affect

the operation of the 2500 Turbo upgrade.

ADDENDUM 9-9065-133 11

2500 Turbo

FEB 1998

SECTION 3

CONNECTOR POINTS

The following is a list of the cable connector points on the 2500 Turbo board.

Table 2. List of cable connector points for 2500 Turbo

P1 display connector

P2 expansion board connector

P3 termination board 1

P6 termination board 2

P7 termination board 2

P102 PC-104 bus

P103 PC-104 bus

J1 power supply

J5 utility port to CPU module

J6 utility port to keyboard, reset, etc.

J7 3.6 volt lithium battery

J8 backup power for SSD (solid state disk)

module

12 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

SECTION 4

JUMPER AND SWITCH CONFIGURATIONS

4.1 SERIAL PORT 1 JUMPER SETTINGS

RS232

(default)

JP7 1-2

4-5

7-8

10-11

13-14

JP14 1-2

JP9 open

JP10 open

RS485

Full

Duplex

JP7 2-3

5-6

8-9

11-12

14-15

7-10

JP14 1-2

JP9 open

JP10 open

RS485

Half

Duplex

JP7 2-3

5-6

8-9

11-12

14-15

7-10

JP14 1-2

JP9 closed

JP10 closed

ADDENDUM 9-9065-133 13

2500 Turbo

FEB 1998

Figure 1. Serial port 1 jumper locations

14 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

Figure 2. Serial ports 1 and 2 jumpers, default settings (RS232)

ADDENDUM 9-9065-133 15

2500 Turbo

FEB 1998

4.2 SERIAL PORT 2 JUMPER SETTINGS

RS232

(default)

JP8 1-2

4-5

7-8

10-11

13-14

JP15 1-2

JP11 open

JP12 open

RS485

Full

Duplex

JP8 2-3

5-6

8-9

11-12

14-15

7-10

JP15 1-2

JP11 open

JP12 open

RS485

Half

Duplex

JP8 2-3

5-6

8-9

11-12

14-15

7-10

JP15 1-2

JP11 closed

JP12 closed

16 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

Figure 3. Serial port 2 jumper locations

ADDENDUM 9-9065-133 17

2500 Turbo

FEB 1998

4.3 TURBINE INPUTS JUMPER SETTINGS

Turbine Inputs

2048 cycles per sample (default)

JP13 1-2

Turbine Inputs

4096 cycles per sample

JP13 2-3

4.4 DIGITAL OUTPUTS JUMPER SETTINGS

Digital Outputs

supply system power (+24 volts)

diode clamping the open collector

digital outputs

JP6 open

4.5 STATUS JUMPERS

Jumpers JP1 - JP5 are used to configure software operations. These jumpers are not

normally used.

4.6 PASSWORD PROTECTION SWITCH SW1

Switch SW1, a three-position switch, determines the mode of password protection:

- Switch in DOWN position (toward the board edge): password protection is

disabled.

- Switch in MIDDLE position: a 5-minute timeout is allowed after password entry

for a parameter change.

- Switch in UP position (toward the board center): the front panel green LED is

off, and password is required for any parameter change.

18 2500 TURBO FLOW COMPUTER

2500 Turbo

FEB 1998

Figure 4. Digital outputs and turbine inputs jumper locations

ADDENDUM 9-9065-133 19

2500 Turbo

FEB 1998

4.7 PROCESSOR JUMPERS

Jumper blocks W2 through W7 on the Core Module CPU daughterboard (that is plugged

into the 2500 Turbo board number 1) should be set in the positions shown in Figure 5,

below, if a Minimodule Solid State Disk (SSD) daughterboard is also plugged into the

2500 Turbo board number 1.

Figure 5. Core Module CPU processor jumpers with Minimodule SSD also onboard

20 2500 TURBO FLOW COMPUTER

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Daniel Model 2500 Turbo Hardware Owner's manual

Daniel Model 2500 Turbo Hardware Owner's manual

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