Part Number D301217X012 July 2017 ROC800-Series Remote Operations Controller Instruction Manual ROC809 ROC827 Remote Automation Solutions ROC800-Series Instruction Manual Revision Tracking Sheet July 2017 This manual may be revised periodically to incorporate new or updated information. The revision date of each page appears at the bottom of the page opposite the page number. A change in revision date to any page also changes the date of the manual that appears on the front cover. Listed below is the revision date of each page (if applicable): Page Revision All pages July-2017 All pages October-2016 All pages January-2016 All pages December-2015 All pages July-2014 All pages May-2013 All pages November-2010 All pages June-2009 Initial issue March-2006 ii Revised July-2017 ROC800-Series Instruction Manual Contents Chapter 1 – General Information 1-1 1.1 Scope of Manual .............................................................................................................................. 1-2 1.2 Series 1 versus Series 2 Architecture .............................................................................................. 1-3 1.3 Hardware .......................................................................................................................................... 1-5 1.3.1 Central Processor Unit (CPU) .............................................................................................. 1-9 1.3.2 Real-Time Clock (RTC) ........................................................................................................ 1-9 1.3.3 Diagnostic Monitoring ........................................................................................................... 1-9 1.3.4 Options ............................................................................................................................... 1-10 1.4 FCC Information ............................................................................................................................. 1-11 1.5 Firmware ........................................................................................................................................ 1-11 1.5.1 Historical Database and Event & Alarm Log ...................................................................... 1-15 1.5.2 Meter Runs and Stations .................................................................................................... 1-16 1.5.3 ROC800 Flow Calculations ................................................................................................ 1-16 1.5.4 ROC800L Flow Calculations .............................................................................................. 1-17 1.5.5 Automatic Self Tests .......................................................................................................... 1-17 1.5.6 Low Power Modes .............................................................................................................. 1-18 1.5.7 Proportional, Integral, and Derivative (PID) ....................................................................... 1-19 1.5.8 Function Sequence Table (FST) ........................................................................................ 1-19 1.6 ROCLINK 800 Configuration Software .......................................................................................... 1-20 1.7 ROC800L Software ........................................................................................................................ 1-22 1.8 DS800 Development Suite Software ............................................................................................. 1-23 1.9 Expansion Backplane ..................................................................................................................... 1-24 1.10 FOUNDATION™ Fieldbus Interface ................................................................................................ 1-24 1.11 Security Gateway ......................................................................................................................... 1-24 1.12 Additional Technical Information .................................................................................................. 1-25 Chapter 2 – Installation and Use 2-1 2.1 Installation Requirements ................................................................................................................. 2-1 2.1.1 Environmental Requirements ............................................................................................... 2-2 2.1.2 Site Requirements ................................................................................................................ 2-2 2.1.3 Compliance with Hazardous Area Standards ...................................................................... 2-3 2.1.4 Power Installation Requirements ......................................................................................... 2-4 2.1.5 Grounding Installation Requirements ................................................................................... 2-4 2.1.6 I/O Wiring Requirements ...................................................................................................... 2-5 2.2 Required Tools ................................................................................................................................. 2-5 2.3 Housing ............................................................................................................................................ 2-5 2.3.1 Removing and Replacing End Caps .................................................................................... 2-6 2.3.2 Removing and Installing Wire Channel Covers ................................................................... 2-6 2.3.3 Removing and Installing Module Covers ............................................................................. 2-7 2.4 Mounting the ROC800 on a DIN Rail ............................................................................................... 2-7 2.4.1 Installing the DIN Rail ........................................................................................................... 2-9 2.4.2 Securing the ROC800 to the DIN Rail ................................................................................. 2-9 2.4.3 Removing the ROC800 from the DIN Rail ......................................................................... 2-10 2.5 ROC800-Series Expansion Backplane (EXP) ............................................................................... 2-10 2.5.1 Attaching an Expansion Backplane ................................................................................... 2-11 2.5.2 Removing an Expansion Backplane .................................................................................. 2-12 2.6 Central Processing Unit (CPU) ...................................................................................................... 2-13 2.6.1 Removing the CPU Module................................................................................................ 2-17 2.6.2 Installing the CPU Module.................................................................................................. 2-17 2.7 License Keys .................................................................................................................................. 2-18 Revised July-2017 iii ROC800-Series Instruction Manual 2.7.1 Installing a License Key ..................................................................................................... 2-19 2.7.2 Removing a License Key ................................................................................................... 2-19 2.8 Startup and Operation .................................................................................................................... 2-20 2.8.1 Startup ................................................................................................................................ 2-20 2.8.2 Operation ........................................................................................................................... 2-21 Chapter 3 – Power Connections 3-1 3.1 Power Input Module Descriptions .................................................................................................... 3-1 3.1.1 12-Volt DC Power Input Module (PM-12) ............................................................................ 3-1 3.1.2 24-Volt DC Power Input Module (PM-24) ............................................................................ 3-3 3.1.3 30-Volt DC Power Input Module (PM-30) ............................................................................ 3-4 3.1.4 Auxiliary Output (AUX+ and AUX–) ..................................................................................... 3-8 3.1.5 Switched Auxiliary Output (AUXSW+ and AUXSW–) ........................................................ 3-10 3.2 Determining Power Consumption .................................................................................................. 3-11 3.2.1 Tuning the Configuration .................................................................................................... 3-15 3.3 Removing a Power Input Module ................................................................................................... 3-25 3.4 Installing a Power Input Module ..................................................................................................... 3-27 3.5 Connecting the ROC800 to Wiring ................................................................................................