#)/2:#$8720$7,21#,1&

A Thermo Instruments Company

Publication No. 1-0485-008

December 1999

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Please contact the manufacturer if the information presented in

this manual does not match your equipment.

AutoPILOT GAS FLOW COMPUTER

INSTALLATION AND WIRING MANUAL

9303 W. Sam Houston Parkway South, Houston, TX 77099-5298 PH:(713)272-0404

Web Page: www.flowautomation.com

FAX:(713)272-2272

Click on the contents line to go to the desired section.

Click on the Table of Contents button to return.
AutoPILOT GAS FLOW COMPUTER
INSTALLATION AND WIRING MANUAL
CONTENTS
Section

Title

Page

1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 INTERNAL BATTERY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 EXTERNAL BATTERY ASSEMBLIES WITH CHARGING SOURCE . . . . . . . . . . . 4
2.3 EXTERNAL POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 LITHIUM BACK-UP BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 TRANSDUCER INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.0 ANALOG OUTPUT OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 SINGLE ANALOG OUTPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 DUAL ANALOG OUTPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.0 DISCRETE INPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.0 DISCRETE OUTPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.0 MEB DISCRETE INPUT AND DISCRETE OUTPUT OPTIONS . . . . . . . . . . . . . . . . . . 14
7.1 MEB 2DI/DO OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 MEB 4 DI OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 MEB 4 DO OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.0 SOLID STATE RELAY OUTPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.0 PULSE INPUT OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.1 AutoPILOT PULSE INPUT BOARD OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.2 MEB PULSE INPUT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.0 LOCAL COMMUNICATIONS PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11.0 AutoMITTER OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12.0 HOST COMMUNICATIONS PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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13.0 COMMUNICATION EXPANSION BOARD OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 33

14.0 DIV 1 COMM EXPANSION BOARD OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15.0 V.22/212A MODEM OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16.0 202 MODEM OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
17.0 RS-232/RS-485 CONVERTER BOARD OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
18.0 MDS RADIO OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
19.0 CELLULAR DATA TRANSCEIVER OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
19.1 INSTALLING THE TELEPHONE TO THE MOUNTING BRACKETS . . . . . . . . . 45
19.2 INSTALLING THE TELEPHONE IN THE ENCLOSURE . . . . . . . . . . . . . . . . . . . . 45
19.3 TELEPHONE ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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AutoPILOT GAS FLOW COMPUTER

INSTALLATION AND WIRING MANUAL

This document describes the installation and wiring of the AutoPILOT Gas Flow Computer in
Class I Division 2, Groups C and D, hazardous locations. Follow these procedures to ensure system
safety and to comply with the Underwriters Laboratories listing of this unit. The AutoPILOT has
an Operating Temperature Code of T3C, and may be used at an ambient temperature of -40 to +85
o
C (-40 to +185 oF).

1.0 GENERAL INFORMATION

For United States installations, wire all circuits connected to the flow computer (unless otherwise
specifically identified) using the Class I Division 2 Wiring Methods specified in Article 501-4(b)
of the National Electrical Code, NFPA 70. For Canadian installations, wire all circuits connected
to the flow computer (unless otherwise specifically identified) using the Class I Division 2 Wiring
Methods specified in Section 18-152 of the Canadian Electrical Code.
Caution
These circuits are not Nonincendive Field Wiring Circuits.
Wire these circuits as "power limited" circuits.

All external wiring routes through the side or bottom of the flow computer's enclosure and connects
to components and printed-circuit boards (PCBs) mounted in the enclosure. Maximum number and
type of externally-wired circuits are as follows:

&
&
&
&
&
&
&
&
&

&
&
&

External Power Connection

Three Analog Inputs
Ten optional Analog Outputs
Thirty optional Discrete Inputs
Thirty optional Discrete Outputs
Four optional Solid State Relay Outputs
Twelve optional Pulse Inputs
One RS-232 Local Communication Port
Up to three RS-232 or RS-485 Host Communication Ports
One Comm 3 Terminator connection to AutoMITTERs
One optional Telephone Jack Connection
Up to three optional Leased Line Connections
One optional Antenna connection to phone or radio

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WARNING:
CUSTOMER EQUIPMENT AND DEVICES MUST BE
SUITABLE FOR THE LOCATION WHERE THEY ARE
TO BE INSTALLED.

All wiring connections except the Local communication port, telephone jack and antenna terminate
in cage-clamp screw terminals that accept stranded-wire sizes up to 14 AWG. Strip wire ends
approximately 3/16 of an inch. Inspect the stripped wire for nicked and frayed ends. Insert the
stripped wire completely in the clamp, then tighten the clamp using a small common screwdriver.
Inspect each connection, ensuring no frayed strands protrude and no insulation is in the clamp.
The following connections are accessible from outside of the enclosure:

& One Local Communication Port (CHIT)

& One optional "N" style External Antenna or Coaxial Protector
& Optional Analog Input junction box assembly connections
WARNING:
CONNECT THE ENCLOSURE GROUND TERMINAL
TO EARTH GROUND BEFORE MAKING ANY OTHER
CONNECTIONS TO THE FLOW COMPUTER. THE
GROUND TERMINAL IS LOCATED ON THE SIDE OF
THE ENCLOSURE, AND IS MARKED WITH THE
GROUND SYMBOL INSIDE THE ENCLOSURE. USE A
MINIMUM OF AN 12-AWG STRANDED WIRE, AS
SHORT AS POSSIBLE.

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2.0 POWER CONNECTIONS

The flow computer is powered by an internal battery assembly with external solar panel, external
charging source and battery assembly, or an external power source. There is one internal battery
assembly option, and two external battery assemblies which can be used with several sizes of solar
panels or external charging sources.

2.1 INTERNAL BATTERY ASSEMBLY

There is one internal battery assembly available for the flow computer: a six-volt, twelveamperehour, rechargeable battery assembly with an external two-watt solar panel charging system.
The twelve-amperehour battery assembly sits in a bracket fastened to the flow computer internal
chassis, and connects to the six-position power distribution terminal block TB1, positions 1-3 (POS)
and 4-6 (NEG). The 2-watt solar panel assembly mounts external to the flow computer, is routed
through the bottom of unit's enclosure and connects to the two-position Molex connector of the
battery assembly.
When the battery needs to be changed, the entire battery assembly must be replaced. Order the
replacement assembly from Flow Automation (PN# 3-0485-029).
WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
REPLACING A BATTERY ASSEMBLY.

Caution
The flow computer PCB must be configured for the back-up
battery (B1) with jumper J1-1 installed to prevent loss of
software configuration and historical data.

To replace a battery assembly, disconnect the two wires to TB1 on the internal chassis equipment
panel, insulate the positive battery assembly lead, disconnect the solar panel assembly wires from
the two-position Molex connector of the battery assembly, then remove the battery assembly from
the enclosure. Place the new battery assembly in the battery bracket, connect the wires to TB1
observing correct polarity, then plug the solar panel wiring into the two-position Molex connector
of the battery assembly.

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2.2 EXTERNAL BATTERY ASSEMBLIES WITH CHARGING SOURCE

There are two external battery assemblies, each of which can be used with several solar panel sizes,
or with an external float charging system. The small battery assembly can contain up to a twelvevolt twenty-eight amperehour (12-V, 28-AH) rechargeable battery, and is typically used with the 5watt through 40-watt solar panels, or an external charger. The large battery assembly can contain
up to a 12-V, 105-AH rechargeable battery, and is typically used with the 10-watt through 60-watt
solar panels, or an external charger. For solar powered systems, the regulator for panel sizes 5-watt
and smaller is mounted inside the battery assembly, while the regulator for the 10-watt through 60watt panels is mounted in or on the junction box located on the rear of the solar panel itself. For both
battery assemblies, the 10-watt and larger solar panel or external charger output is wired into the
battery assembly enclosure, and terminated at TB1-4 (positive lead) and TB1-7 (negative lead) on
the terminal block inside the battery assembly. The 5-watt and smaller solar panel is terminated at
TB1-1 (positive lead) and TB1-7 (negative lead) on the terminal block inside the battery assembly.
External chargers and solar panel sizes 10-watt and above must be wired using Class I Division 2
Wiring Methods, and must be installed according to the manufacturers recommendations in the
proper area. See Section 1.0, General Information, for proper wiring guidelines.
WARNING:
CUSTOMER EQUIPMENT AND DEVICES MUST BE
SUITABLE FOR THE LOCATION WHERE THEY ARE
TO BE INSTALLED.

The wiring to the flow computer unit is the same for both battery assemblies. The connection
between the battery assembly and flow computer is routed into the bottom of the unit's enclosure and
must be made using Class I Division 2 wiring methods. See Section 1.0, General Information, for
proper wiring guidelines. The positive lead is wired from TB1-5 inside the battery assembly
enclosure to power distribution terminal block TB1 position 1-3 (POS) located on the internal
chassis equipment panel inside the flow computer enclosure. The negative lead is wired from TB1-8
of the battery assembly to TB1 position 4-6 (NEG) of the power distribution terminal block in the
flow computer enclosure. Power to the flow computer is current limited with a 5-ampere PTC
installed in the battery assembly.

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WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
CONNECTING OR DISCONNECTING THE BATTERY
ASSEMBLY CONNECTIONS.

Caution
The flow computer PCB must be configured for the back-up
battery (B1) with jumper J1-1 installed to prevent loss of
software configuration and historical data when external
power is removed.

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2.3 EXTERNAL POWER SOURCES

When using an external power source (+6 Vdc to +16 Vdc), the positive leg of the power source
must be protected with a 5-Ampere current limiting device. Install the power source and current
limiter in a non-hazardous area. Connect the power source and the flow computer with a 14 to 18AWG wire, following Class I Division 2 Wiring Methods. Route the power line from the source to
the flow computer through the bottom of the flow computer's enclosure. Connect the positive leg
of the power line to the power distribution terminal block located on the internal chassis equipment
panel to TB1 position 1-3 (POS) and the negative leg of the power line to TB1 position 4-6 (NEG).
Refer to Section 1.0, General Information, for proper wiring guidelines.
WARNING:
BEFORE MAKING OR BREAKING THE POWER
CONNECTION BETWEEN THE EXTERNAL POWER
SOURCE AND THE FLOW COMPUTER, DISCONNECT
THE POWER SOURCE IN THE NONHAZARDOUS
AREA.

Caution
The flow computer PCB must be configured for the back-up
battery (B1) with jumper J1-1 installed to prevent loss of
software configuration and historical data.

2.4 LITHIUM BACK-UP BATTERY

A lithium battery (B1) is soldered on the back of the flow computer's main PCB to maintain
configuration, memory and the real-time clock when power is removed from the unit. The in-circuit
connection of the lithium battery is set using Configuration Jumper J1-1. When the jumper is
installed, the battery is connected to the circuit. Loss of configuration or historical data with jumper
J1-1 installed may indicate that B1 needs to be replaced. This battery is not a field replaceable
item.
WARNING:
THE LITHIUM BATTERY MAY EXPLODE IF
MISTREATED; DO NOT RECHARGE, DISASSEMBLE,
OR BURN.

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3.0 TRANSDUCER INPUTS

The AutoPILOT main board has three analog inputs for single low-power (0-5 Vdc maximum range)
transmitters. Other transducers with voltage output ranges such as 0.8-3.2 V or 1-5 V units may be
used with software scaling provided the 0-volt minimum and 5-volt maximum limits are not
exceeded. Use of 4-20 mA current loop transmitters is not recommended for units powered from
small battery sources.
The AutoPILOT may also use direct or remote mounted combination transducers. Remote mounted
AutoMITTERs are connected through the Comm 3 Terminator board. See Section 11.0 for
AutoMITTER connection information. For direct mounted transducers, the appropriate transducer
interface board is required. The Rosemount 205 interface board is used with the Rosemont (0-250"
DP, maximum 3626 psi) transducer. The Honeywell interface board is used with the Honeywell
MXA125 (0-400 DP, maximum 750 psia), Honeywell MXA145 (0-400" DP, maximum 1500 psia)
or the Honeywell MXG170 (0-400" DP, maximum 3000 psig). The Honeywell transducer interface
board has station ID jumpers which may need to be user configured. If the flow computer software
version was initially developed to use the Rosemount 205, then jumpers J1 through J4 on the
Honeywell interface board must be installed. If the software version was developed to use a
Honeywell combination transducer, then J1 is removed, and J2 through J4 installed on the interface
board. J5 and J6 on the Honeywell Interface board are not installed for normal operation.
The AutoPILOT Analog Inputs have been evaluated as non-incendive field circuits for use with the
following single analog transmitters (differential pressure, static pressure, and temperature), which
may be connected to the flow computer using standard cabling and optional flexible conduit. All
transmitters are wired to TB4 of the Main Board, TB2 of the optional Digital I/O Expansion board,
or to an Analog Input junction box assembly with a maximum cable length of 25 Feet between the
AutoPILOT and each transmitter. The following single transmitters are included:

&
&
&
&
&

Druck Static Pressure Transmitter, Model PDCR143-8003 (25 to 3000 psi range)
Rosemount Static Pressure Transmitter, Model 3051C Low Power (3626 psi max)
Rosemount Differential Pressure Transmitter, Model 2024 (2000 psi max)
Rosemount Differential Pressure Transmitter, Model 3051C Low Power (3626 psi max)
Flow Automation RTD Temperature Transmitter, Model 465A

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Exhibit 3-1: Typical Analog Input Wiring Diagram (Direct Wired)

The following RTD probe assemblies, when connected to RTD1 (at TB5 of the Main Board), have
been evaluated as nonincendive connections using standard cabling and optional flexible conduit
with a maximum cable length of 25 feet:

& Flow Automation RTD Temperature Probe Assembly 3-0465-029

& Flow Automation RTD Temperature Probe Assembly 3-0465-033
Each AutoMITTER may also use one of the Temperature Probe assemblies. See Section 11.0 for
AutoMITTER connections.
Another type of RTD probe assembly with integral metal sheathing may connect to RTD1 (at TB5
on the main board) or to the AutoMITTER, using standard cabling, with up to 25 feet between the
probe body and the flow computer or AutoMITTER.
All other transmitters must be suitable for the area in which they are to be installed, and wired
according to Section 1.0, General Information, which specifies proper wiring guidelines.

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The Analog Inputs can be wired by the customer directly to the Main Board, or to a junction box
assembly located on the bottom of the enclosure. A single Analog Input may alternately be wired
to the optional Digital I/O Expansion Board. If wired directly to the Main Board or the Digital I/O
board, each analog input provides transmitter power (XPWR) at a nominal +9 V which power cycles
with the unit, a transmitter signal input (IN), and a transmitter power return (AGND). Refer to
Exhibit 3-1 for typical connections to the analog inputs wired directly to the Main Board. The
analog inputs are identified on the Main Board as follows:
INPUT

IN

AGND

XPWR

AI1
AI2
AI3

TB4-1
TB4-4
TB4-7

TB4-2
TB4-5
TB4-8

TB4-3
TB4-6
TB4-9

Analog Input 3 can alternately be wired to the optional Digital I/O board as follows:
INPUT

IN

AGND

XPWR

AI3

TB2-9

TB2-10

TB2-11

Six Analog Input junction box assemblies are available as options for customer wiring. The junction
box assemblies (PN# 3-0485-158, 3-0485-195 or 3-0485-255) used for transducers which cannot
power cycle (typically Rosemount 3051C types) have XPWR connected to the power distribution
terminal block at TB1 position 1-3 (POS), and AGND to TB1 position 4-6 (NEG). The junction box
assemblies used for power cycling transducers (PN# 3-0485-156, 3-0485-194 or 3-0485-254) supply
XPWR at a nominal +9 V from the Main Board at TB4-3 and AGND from TB4-2. Customer wiring
between the transmitters and any Analog Input junction box assembly is as follows:
JUNCTION BOX
TERMINAL

SIGNAL

1
2
3
4
5

Document 1-0485-008

AGND
XPWR
AI1-IN
AI2-IN
AI3-IN

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4.0 ANALOG OUTPUT OPTIONS

Two Analog Output option assemblies are available for the AutoPILOT. They are the Single Analog
Output described in Section 4.1 and the Dual Analog Output described in Section 4.2.

4.1 SINGLE ANALOG OUTPUT OPTION

This optional D/A board provides a single 4-20 mA output current under software control. Up to
two boards can be installed in each unit - mounted to the enclosure door behind the cover plate,
and/or mounted to the internal chassis equipment panel. The D/A board may be jumpered at J5
positions 1 to 2 for a 12V output when powered from the Main Board input power (used to drive
total loop resistance of 300 ohms or less) or assembled with the D/A Power Board mounted at J5 to
provide a 24 V maximum output (used to drive total loop resistance from 250 to 750 ohms). The
+24 V output from the optional 12/24 V Converter board can also be used as input power to the D/A
board to provide a 24 V output without the D/A Power Board. Refer to Section 1.0, General
Information, for wiring guidelines. The current loop output signal is connected at TB3-2, with the
current loop reference connected to TB3-1. If +24V input power is used, connect it at TB1-2 with
the input power reference connected to TB1-1, and install the J5 jumper between positions 1 and 2.
A unique address which determines the software configuration must be set consecutively using
jumpers J4 and J3 for each D/A Board installed in the unit. The D/A address jumpers are configured
as follows:
Jumper J4

Jumper J3

Board Number

Not Installed
Not Installed

Not Installed
Installed

1
2

See Exhibit 4-1 for typical output connections to the D/A board.

Exhibit 4-1: Typical Analog Output Wiring Diagram

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4.2 DUAL ANALOG OUTPUT OPTION

The optional 2D/A board provides dual 4-20 mA output currents under software control. Up to four
boards can be installed in each unit. The 2D/A board may be jumpered at J5 positions 1 to 2 for a
12V output when powered from a 12V input power source (used to drive total loop resistance of 300
ohms or less), or assembled with the D/A Power Board mounted at J5 to provide a 24 V maximum
output (used to drive total loop resistance from 250 to 750 ohms). The +24V output from the
optional 12/24 V Converter board can also be used as input power to the 2D/A board to provide a
24 V output without the D/A Power Board. Refer to Section 1.0, General Information, for wiring
guidelines. One current loop output signal is connected at TB3-2, with the current loop reference
connected to TB3-1. The second current loop output signal is connected at TB3-4, with the reference
connected to TB3-3. If the +24V input power option is used, connect it at TB1-2 with the input
power reference connected to TB1-1, and install the J5 jumper between positions 1 and 2.
A unique address which determines the software configuration must be set consecutively using
jumpers J6 and J7 for each 2D/A Board installed in the unit. The 2D/A address jumpers are
configured as follows:
Jumper J7

Jumper J6

Board Number

Not Installed
Not Installed
Installed
Installed

Not Installed
Installed
Not Installed
Installed

1
2
3
4

See Exhibit 4-2 for typical output connections to the 2D/A board.

Exhibit 4-2: Typical Dual Analog Output Wiring Diagram

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5.0 DISCRETE INPUT OPTION

When the optional Digital I/O Board is installed, the flow computer provides two discrete inputs for
customer input devices (reed relays, uncommitted transistor outputs, etc.; device must be DCresistive by nature). Additional discrete inputs may be provided by optional MEB expansion boards
as described in Section 7.0. Refer to Section 1.0, General Information, for proper wiring guidelines.
A +5 Vdc wetting voltage (internally limited to 0.1 mA maximum) is provided by the flow computer
for each signal input. Refer to Exhibit 5-1 for the typical discrete input wiring. The discrete inputs
are identified as follows:

INPUT

SIG

GND

DI1
DI2

TB2-5
TB2-7

TB2-6
TB2-8

Exhibit 5-1: Typical Discrete Input Wiring Diagram

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6.0 DISCRETE OUTPUT OPTION

When the optional Digital I/O Board is installed, the flow computer provides two discrete outputs
to drive low power customer supplied output devices (relays, solenoids, etc.; devices must be DCresistive by nature). Additional discrete outputs may be provided by optional MEB expansion boards
as described in Section 7.0. Refer to Section 1.0, General Information, for proper wiring guidelines.
Power for each discrete output is customer supplied and is independent of the flow computer's input
power, unless it is connected to an internal board. The customer's discrete output power must not
exceed 30 Vdc maximum or 250 mA maximum. Each signal provided by the board is an open drain
FET output contact closure detected as a level signal. Some optional boards may require the internal
use of one or more of the discrete outputs making them unavailable for customer use. Refer to
Exhibit 6-1 for the typical discrete output wiring. The discrete outputs are identified as follows:
OUTPUT

SIG

GND

DO1
DO2

TB2-1
TB2-3

TB2-2
TB2-4

Exhibit 6-1: Typical Discrete Output Wiring Diagram

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7.0 MEB DISCRETE INPUT AND DISCRETE OUTPUT OPTIONS

Optional Discrete Input and Discrete Output assemblies may be installed in the flow computer. Up
to seven boards may be installed in the unit.
The optional MEB 2 DI/DO Board provides two discrete inputs for customer input devices such as
reed relays, uncommitted transistor outputs, etc., and two discrete outputs to drive low power
customer supplied output devices such as relays, solenoids, etc. The 2DI/DO assembly is described
in Section 7.1.
The optional MEB 4 DI Board provides four discrete inputs for customer input devices such as reed
relays, uncommitted transistor outputs, etc. The MEB 4 DI assembly is described in Section 7.2.
The optional MEB 4 DO Board provides four discrete outputs to drive low power customer supplied
output devices such as relays, solenoids, etc. The MEB 4 DO assembly is described in Section 7.3.

7.1 MEB 2DI/DO OPTION

When the optional MEB 2 DI/DO Board is installed, the flow computer provides two discrete inputs
for customer input devices such as reed relays, uncommitted transistor outputs, etc., and two discrete
outputs to drive low power customer supplied output devices such as relays, solenoids, etc.
Customer devices must be DC-resistive in nature. Up to seven boards may be installed in the unit.
Refer to Section 1.0, General Information, for proper wiring guidelines.
A unique address which determines the software configuration must be set consecutively using
jumpers J1 through J3 for each MEB 2 DI/DO Board installed in the unit. The address jumpers are
configured as follows:
Jumper J3

Jumper J2

Jumper J1

Board Number

Not Installed
Not Installed
Not Installed
Not Installed
Installed
Installed
Installed

Not Installed
Not Installed
Installed
Installed
Not Installed
Not Installed
Installed

Not Installed
Installed
Not Installed
Installed
Not Installed
Installed
Not Installed

1
2
3
4
5
6
7

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A +5 Vdc wetting voltage (internally limited to 0.1 mA maximum) is provided by the flow computer
for each Discrete Input signal input. Refer to Exhibit 7-1-1 for the typical discrete input wiring. The
discrete inputs are identified as follows:
INPUT

SIG

GND

DI1
DI2

TB2-6
TB2-8

TB2-7
TB2-9

Exhibit 7-1-1: Typical MEB Discrete Input Wiring Diagram

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Power for each discrete output is customer supplied and is independent of the flow computer's input
power, unless it is connected to an internal board. The customer's discrete output power must not
exceed 30 Vdc maximum or 250 mA maximum. Each signal provided by the board is an open drain
FET output contact closure detected as a level signal. Some optional boards may require the internal
use of one or more of the discrete outputs making them unavailable for customer use. Refer to
Exhibit 7-1-2 for the typical discrete output wiring. The discrete outputs are identified as follows:
OUTPUT

SIG

GND

DO1
DO2

TB2-2
TB2-4

TB2-3
TB2-5

Exhibit 7-1-2: Typical MEB Discrete Output Wiring Diagram

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7.2 MEB 4 DI OPTION

When the optional MEB 4 DI Board is installed, the flow computer provides four discrete inputs for
customer input devices such as reed relays, uncommitted transistor outputs, etc. Customer devices
must be DC-resistive in nature. Up to seven boards may be installed in the unit. Refer to Section
1.0, General Information, for proper wiring guidelines.
A unique address which determines the software configuration must be set consecutively using
jumpers J1 through J3 for each MEB 4 DI Board installed in the unit. The address jumpers are
configured as follows:
Jumper J3

Jumper J2

Jumper J1

Board Number

Not Installed
Not Installed
Not Installed
Not Installed
Installed
Installed
Installed

Not Installed
Not Installed
Installed
Installed
Not Installed
Not Installed
Installed

Not Installed
Installed
Not Installed
Installed
Not Installed
Installed
Not Installed

1
2
3
4
5
6
7

A +5 Vdc wetting voltage (internally limited to 0.1 mA maximum) is provided by the flow computer
for each Discrete Input signal input. Refer to Exhibit 7-2 for the typical discrete input wiring. The
discrete inputs are identified as follows:

Document 1-0485-008

INPUT

SIG

GND

DI1
DI2
DI3
DI4

TB2-2
TB2-4
TB2-6
TB2-8

TB2-3
TB2-5
TB2-7
TB2-9

17

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Exhibit 7-2: Typical MEB 4 Discrete Input Wiring Diagram

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18

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7.3 MEB 4 DO OPTION

When the optional MEB 4 DO Board is installed, the flow computer provides four discrete outputs
to drive low power customer supplied output devices such as relays, solenoids, etc. Customer
devices must be DC-resistive in nature. Up to seven boards may be installed in the unit. Refer to
Section 1.0, General Information, for proper wiring guidelines.
A unique address which determines the software configuration must be set consecutively using
jumpers J1 through J3 for each MEB 4 DO Board installed in the unit. The address jumpers are
configured as follows:
Jumper J3

Jumper J2

Jumper J1

Board Number

Not Installed
Not Installed
Not Installed
Not Installed
Installed
Installed
Installed

Not Installed
Not Installed
Installed
Installed
Not Installed
Not Installed
Installed

Not Installed
Installed
Not Installed
Installed
Not Installed
Installed
Not Installed

1
2
3
4
5
6
7

Power for each discrete output is customer supplied and is independent of the flow computer's input
power, unless it is connected to an internal board. The customer's discrete output power must not
exceed 30 Vdc maximum or 250 mA maximum. Each signal provided by the board is an open drain
FET output contact closure detected as a level signal. Some optional boards may require the internal
use of one or more of the discrete outputs making them unavailable for customer use. Refer to
Exhibit 7-3 for the typical discrete output wiring. The discrete outputs are identified as follows:

Document 1-0485-008

OUTPUT

SIG

GND

DO1
DO2
DO3
DO4

TB2-2
TB2-4
TB2-6
TB2-8

TB2-3
TB2-5
TB2-7
TB2-9

19

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Exhibit 7-3: Typical MEB 4 Discrete Output Wiring Diagram

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8.0 SOLID STATE RELAY OUTPUT OPTION

The optional relay board used with the AutoPILOT provides up to four outputs which may be used
to drive customer supplied solenoids, valves, motor controllers or other equipment under software
control at higher power levels that can be controlled by the Discrete Outputs. Input power to the
board is 12V (wired internally from BAT) and optional 24-30 Vdc which is customer supplied and
must be current limited at 3-Amperes in a nonhazardous area. If the 24-30 Vdc input is used,
connect the positive to TB2-3 and ground to TB2-4. Refer to Section 1.0, General Information, for
required wiring information. Each normally open output is a DC level signal individually
jumperable for 6V (derived from 12V input), 12V or optional 24-30 V output at 2 A maximum
current per output (2 A total board current for 6V configuration). See Exhibit 8-1 for output
selection jumper positions. Each output has an independent jumpered return, and is controlled by
a Discrete Output signal generated by the optional Digital I/O Board or MEB expansion board under
software control. Power for the Discrete Outputs is provided on board from BAT connected at TB11, and each Discrete Output connected to the relay board is not available for customer use. See
Exhibit 8-2 for a typical wiring configuration. The outputs and control signals are identified as
follows:

OUTPUT
1
2
3
4

DO CONTROL
TB1-2
TB1-3
TB1-4
TB1-5

N - OPEN
OUTPUT

RET

TB3-1
TB4-1
TB5-1
TB6-1

TB3-2
TB4-2
TB5-2
TB6-2

WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
MAKING OR BREAKING ANY CONNECTIONS TO OR
CHANGING JUMPERS ON RELAY BOARD.
DISCONNECT THE OPTIONAL EXTERNAL POWER
SOURCE IN THE NON-HAZARDOUS AREA BEFORE
MAKING OR BREAKING ANY CONNECTIONS TO
THE RELAY BOARD.

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21

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Exhibit 8-1: Typical Output Select Jumper Positions

Exhibit 8-2: Typical Solid State Relay Output Wiring Diagram

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22

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9.0 PULSE INPUT OPTIONS

Two Dual Pulse Input assemblies may be used with the AutoPILOT. Section 9.1 details the
AutoPILOT Pulse Input Board option while Section 9.2 describes the MEB Pulse Input Option.

9.1 AutoPILOT PULSE INPUT BOARD OPTION

For each optional Pulse Input Board installed, the flow computer accepts two pulse inputs from
customer input devices (reed switches, slot sensors, magnetic pickup, uncommitted transistor
outputs, etc.). The optional AutoPULSE Indexer may use one of these inputs. No more than two
boards may be installed in the unit. A unique address which determines the software configuration
must be set consecutively using jumpers JP4 and JP2 for each Pulse Input Board installed in the unit.
The Pulse Input address jumpers are configured as follows:
Jumper JP4

Jumper JP2

Board Number

Not Installed
Not Installed

Not Installed
Installed

1
2

The AutoPULSE may be connected to the AutoPILOT with up to 25 feet of standard cabling and
optional flexible conduit. Refer to Section 1.0, General Information, for proper wiring guidelines
to other devices. A +5 Vdc wetting voltage provided by the flow computer may be selected for each
signal input. The pulse input device must be resistive or inductive in nature only, with a maximum
output of +15 volts if one of the +5 Vdc pull up modes is not selected. Each input has a sevenposition DIP configuration switch to select mode(s) of operation. Refer to Exhibit 9-1 for the typical
pulse input wiring. The pulse inputs are identified as follows:
INPUT
PI1
PI2

Document 1-0485-008

SIG

GND

SWITCH

TB3-1
TB3-3

TB3-2
TB3-4

SW2
SW1

23

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Exhibit 9-1: Typical Pulse Input Wiring Diagram

The function of each of the configuration switch positions in the "ON" position is as follows:

&
&
&
&
&
&
&

Position 1 - conditioning amplifier input

Position 2 - conditioning amplifier input bypass
Position 3 - 5 Vdc pull up (2.5-mA maximum)
Position 4 - 5 Vdc pull up (0.1-mA maximum)
Position 5 - conditioning amplifier output
Position 6 - conditioning amplifier output bypass
Position 7 - debounce, 400-Hz maximum input filter
WARNING:
DO NOT CHANGE SWITCH SETTINGS UNLESS THE
AREA IS KNOWN TO BE NON-HAZARDOUS.

Typical configuration switch settings for various inputs are as follows:

INPUT TYPE

SWITCH(S) ON

Slot Sensor
Magnetic
Contact Closure

Position 2, 3 and 6
Position 1 and 5
Position 2, 4, 6 and 7

The optional AutoPULSE indexer is configured as a contact closure type input.

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9.2 MEB PULSE INPUT OPTION

For each optional MEB Pulse Input Board installed, the flow computer accepts two pulse inputs from
customer input devices (reed switches, slot sensors, magnetic pickup, uncommitted transistor
outputs, etc.). The optional AutoPULSE Indexer may use one of these inputs. No more than four
boards may be installed in the unit. A unique address which determines the software configuration
must be set consecutively using jumpers JP1 and JP2 for each MEB Pulse Input Board installed in
the unit. The MEB Pulse Input address jumpers are configured as follows:
Jumper JP1

Jumper JP2

Board Number

Not Installed
Not Installed
Installed
Installed

Not Installed
Installed
Not Installed
Installed

1
2
3
4

The AutoPULSE may be connected to the AutoPILOT with up to 25 feet of standard cabling and
optional flexible conduit. Refer to Section 1.0, General Information, for proper wiring guidelines
to other devices. A +5 Vdc wetting voltage provided by the flow computer may be selected for each
signal input. The pulse input device must be resistive or inductive in nature only, with a maximum
output of +15 volts if one of the +5 Vdc pull up modes is not selected. Each input has a sevenposition DIP configuration switch to select the mode(s) of operation. Refer to Exhibit 9-2 for the
typical pulse input wiring. The pulse inputs are identified as follows:

Document 1-0485-008

INPUT

SIG

GND

SWITCH

PI1
PI2

TB3-1
TB3-3

TB3-2
TB3-4

SW2
SW1

25

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Exhibit 9-2: Typical MEB Pulse Input Wiring Diagram

The function of each of the configuration switch positions in the "ON" position is as follows:
& Position 1 - conditioning amplifier input
& Position 2 - conditioning amplifier input bypass
& Position 3 - 5 Vdc pull up (2.5-mA maximum)
& Position 4 - 5 Vdc pull up (0.1-mA maximum)
& Position 5 - conditioning amplifier output
& Position 6 - conditioning amplifier output bypass
& Position 7 - debounce, 400-Hz maximum input filter
WARNING:
DO NOT CHANGE SWITCH SETTINGS UNLESS THE
AREA IS KNOWN TO BE NONHAZARDOUS.
Typical configuration switch settings for various inputs are as follows:
INPUT TYPE

SWITCH(S) ON

Slot Sensor
Magnetic
Contact Closure

Positions 2, 3 and 6
Positions 1 and 5
Positions 2, 4, 6 and 7

The optional AutoPULSE indexer is configured as a contact closure type input.

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10.0 LOCAL COMMUNICATIONS PORT

The AutoPILOT provides an RS-232 compatible local communications port for calibration and
configuration of the unit using an laptop PC and Flow Automation configuration software. The
local port connection is made through the six-position polarized connector mounted in the bottom
of the flow computer enclosure. Flow Automation manufactures three optional cable assemblies for
connection between the AutoPILOT and a laptop PC. One assembly has coiled cable with a DB25
connector (PN# 3-0330-014). Two cable assemblies come with a DB9 connector in a 15-foot length
(PN# 3-0446-090) or a 25-foot length (PN# 3-0446-090-B).

WARNING:
THIS CONNECTION CAN ONLY BE USED WHEN THE
AREA IS KNOWN TO BE NON-HAZARDOUS.

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11.0 AutoMITTER OPTION

The AutoPILOT provides an optional connection through the Comm 3 Terminator board for up to
four remote mounted AutoMITTER transducers if any are mounted in a Division 1 area, or up to ten
AutoMITTERs if all are mounted in a Division 2 or non-hazardous area. Each AutoMITTER uses
one of the Honeywell combination transmitters to provide differential and static pressure
measurements, and an optional temperature input. All AutoMITTERs are wired in parallel to the
Comm 3 Terminator output, which provides a +6V power and RS-485 communication buss to and
from the AutoMITTERs, with a total cable length of 2250 feet or less. Each AutoMITTER also has
an optional RTD input, which may be wired using up to 25 ft. of standard cabling and optional
flexible conduit, to the 3-0465-029 or 3-0465-033 Temperature Probe assembly. Alternately, an
RTD probe assembly with integral metal sheathing up to 25 feet long may provide the optional RTD
input for the AutoMITTER.
Three different versions of the Comm 3 Terminator board may be used. For systems with a 6 V
power input as described in Section 2.1, Comm 3 Terminator assembly 3-0485-333 may be used for
United States or Canadian installations. For 12 V power input systems installed in the United States,
Comm 3 Terminator assembly 3-0485-183 must be used. For 12 V power input systems installed
in Canada, Comm 3 Terminator assembly 3-0485-334 must be used. Comm 3 Terminator assembly
numbers must be verified to ensure safety. If any of the AutoMITTERs are installed in a Class I
Division 1 hazardous location in the United States, all wiring to and from the AutoMITTERs is
intrinsically safe wiring, and must be made according Article 504 (Intrinsically Safe Systems) of the
National Electrical Code, NFPA 70. If any of the AutoMITTERs are installed in a Class I Division
1 hazardous location in Canada, all wiring to and from the AutoMITTERs is intrinsically safe wiring,
and must be made according to Sections 18-066 and 18-106 of the Canadian Electrical Code. Single
conductors, and multiple circuits in the same multiple conductor cable must have a minimum
insulation thickness of 0.01 inch (0.25 mm) on each conductor. If the Flow Computer and all
AutoMITTERs are in a Division 2 or non-hazardous area, connections between the Comm 3 output
and the AutoMITTERs may be made using standard cabling and optional flexible conduit as nonincendive field circuit wiring.
WARNING:
CONNECT THE AutoMITTER GROUND TERMINAL TO GROUND
BEFORE MAKING ANY OTHER CONNECTIONS TO THE UNIT.
USE A MINIMUM OF AN 12-AWG STRANDED WIRE, AS SHORT
AS POSSIBLE.

The Comm 3 Terminator is located on the lower right of the backpanel, and is partially covered with
a wire separator to partition the output from the other field wiring.

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28

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Connections between any of the AutoPILOT Comm 3 Terminators and each AutoMITTER are as
follows:
AutoMITTER
COMM 3
TX+ (TB2-5)
RX+ (TB1-1)
TX- (TB2-4)
RX- (TB1-2)
RX- (TB2-2)
TX- (TB1-3)
RX+ (TB2-1)
TX+ (TB1-4)
GND (TB2-6)
GND (TB1-5)
+6V (TB2-7)
BAT (TB1-6)
Shielded cable is recommended for use between the Comm 3 Terminator and the AutoMITTER(s),
with the drain wire connected to the Comm 3 Terminator at TB2-3.
WARNING:
REPLACE WIRING SEPARATOR AFTER MAKING
CONNECTIONS TO THE AutoMITTER.
The total cable length between the AutoPILOT and all AutoMITTERs must not exceed 2250 feet.
Refer to Exhibit 11-1 for typical system connection wiring between the AutoPILOT and
AutoMITTERs.
The RS-485 and power wiring routes through one side of the AutoMITTER enclosure. The RTD
wiring if provided is routed through the other side of the enclosure. Refer to Appendix B for
connections to the optional RTD probe assembly.

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The AutoMITTER address jumpers J1 through J4, which are located on the Honeywell Transducer
Interface board inside the AutoMITTER enclosure, must be configured to provide a unique
consecutive address for each AutoMITTER.
Unit Number
1
2
3
4
5
6
7
8
9
10

Jumper J1

Jumper J2

Jumper J3

Jumper J4

Not Installed
Installed
Not Installed
Installed
Not Installed
Installed
Not Installed
Installed
Not Installed
Installed

Installed
Not Installed
Not Installed
Installed
Installed
Not Installed
Not Installed
Installed
Installed
Not Installed

Installed
Installed
Installed
Not Installed
Not Installed
Not Installed
Not Installed
Installed
Installed
Installed

Installed
Installed
Installed
Installed
Installed
Installed
Installed
Not Installed
Not Installed
Not Installed

Jumpers J5 and J6 are not installed during normal operation.

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30

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Exhibit 11-1: AutoPILOT to AutoMITTER Connections

Notes:
1. Up to four AutoMITTERs may be connected if any are installed in a Division 1 area. If all AutoMITTERs are in
the Division 2 or non-hazardous area, up to ten AutoMITTERs may be connected.
2.

Maximum total cable length connected to the Comm 3 Terminator output and all AutoMITTERs is 2250 feet.

3.

Maximum cable length for each optional AutoMITTER temperature probe assembly is 25 feet.

4.

If any AutoMITTER is installed in the Division 1 area, all wiring to and from all AutoMITTERs is intrinsically safe
wiring, and must be installed according Article 504 of the National Electrical Code, NFPA 70, for United States
Installation, or Sections 18-066 and 18-106 of the Canadian Electrical Code for Canadian installations. If all
AutoMITTERs are in the Division 2 or non-hazardous area, wiring to all AutoMITTERs is non-incendive field
circuit wiring, which may be made using standard cabling and optional flexible conduit. Single conductors, and
multiple circuits run in the same multiple conductor cable must have a minimum insulation thickness of 0.01 inch
(0.25 mm) on each conductor.

5.

Comm 3 Terminator assembly numbers must be verified for proper use with the input voltage source and installation
location requirements.

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12.0 HOST COMMUNICATIONS PORT

The AutoPILOT Main Board provides one RS-232 Host Communications Port (TB2), which may
be wired internally to one of the communications options. Refer to Section 13.0 or 14.0 for
additional host port connections on the Communications Expansion Board options. If not used
internally, the communications port interfaces to any RS-232 compatible customer device (radio,
modem, etc.). Refer to Section 1.0, General Information, for proper wiring guidelines. Do not
exceed +15 Vdc on any of the communication lines. Refer to Exhibit 12-1 for typical wiring of the
Host Communications Port. The Host Communications Port RS-232 connections are as follows:

&
&
&
&
&
&

RX (Receive): TB2-1
CTS (Clear to Send): TB2-2
TX (Transmit): TB2-3
RTS (Request To Send): TB2-4
DCD (Data Carrier Detect): TB2-5
GND (Ground): TB2-8
WARNING:
CUSTOMER EQUIPMENT AND DEVICES MUST BE
SUITABLE FOR THE LOCATION WHERE THEY ARE
TO BE INSTALLED.

If required, the flow computer provides three different wetting-voltage sources for the
communications port:

& Auxiliary +9 (TB2-6): +9 Vdc nominal, 5-mA maximum load

& Auxiliary BAT (TB2-7): battery input voltage, 10-mA maximum load
& Auxiliary +5 (TB2-9): +5 Vdc nominal, 5-mA maximum load

Exhibit 12-1: Typical Host Communication Port Wiring

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13.0 COMMUNICATION EXPANSION BOARD OPTION

Flow Automation's optional Communication Expansion board is used to provide two additional Host
ports for the AutoPILOT. Each port can be configured for either the RS-232 or RS-485 (4-wire or
2-wire mode) buss interface. The RS-232 buss can drive up to 50 feet of cable, while the RS-485
buss can contain up to 32 devices (one master with up to 31 slaves), and drive up to 4000 feet of
cable. The Comm Expansion board is installed in the AutoPILOT enclosure mounted over the Main
Board behind the cover plate located on the door of the enclosure, and may not be used with the DIV
1 Comm Expansion Board option. The AutoPILOT Comm Expansion board connector P1 connects
to P5 of the AutoPILOT Main Board, while the connections to the Comm Expansion ports are made
at TB1 for Channel 4, and TB2 for Channel 5. Refer to Section 1.0, General Information, for wiring
guidelines. The Comm Expansion board is powered through the Main Board, and will power cycle
with the flow computer.
WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
CONNECTING OR DISCONNECTING THE
COMMUNICATION EXPANSION BOARD.

Each port must be configured for the mode of operation desired. In addition to the jumper positions
listed below, the RS-485 modes also require termination jumper configuration at J1 and J2 or J3 and
J4 which depend on the position of the port on the buss, and may require Transmit mode changes
at J12 or J9 for master versus slave configuration in the 4-Wire mode. The following jumper
selections are suggested for setting the mode of each channel:
PORT MODE
RS-232

CHANNEL 4

CHANNEL 5

Install jumpers J10B, J12C,

J13A, J14A
Remove jumpers J1A or B, J7,
J2A or B, J5A, J5B, J8

Install jumpers J11B, J9C,

J15A, J16A
Remove jumpers J3A or B, J4A or B,
J6A, J6B, J7, J8

RS-485 (4-Wire) Install jumpers J10A, J12A,

J13B, J14B
Remove jumpers J5A, J5B, J7,
J8

Install jumpers J9A, J11A, J15B,

J16B
Remove jumpers J6A, J6B, J7,
J8

RS-485 (2-Wire) Install jumpers J5A, J5B, J10A,

J12A, J13B, J14B
Remove jumpers J2A or B, J7, J8

Install jumpers J6A, J6B, J11A,

J9A, J15B, J16B
Remove jumpers J4A or B, J7, J8

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When configured in RS-232 mode, the serial communications signal connections to each port are
as follows:
RS-232 SIGNAL
CHANNEL 4
CHANNEL 5
RX
CTS
TX
RTS
DCD
GND
SHIELD

TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB1-8
TB1-9

TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-8
TB2-9

When configured in 4-Wire RS-485 mode, the RS-485 buss interface connections are as follows:
RS-485 SIGNAL

CHANNEL 4

CHANNEL 5

RXRX+
TXTX+
SHIELD

TB1-1
TB1-2
TB1-3
TB1-4
TB1-9

TB2-1
TB2-2
TB2-3
TB2-4
TB2-9

To connect the master port to the slave port(s) on the RS-485 buss, swap signals TX and RX, while
maintaining the correct polarity for each pair of signals. Each port must be configured with
termination jumper settings at J1 and J2 or J3 and J4. Generally, the ports at each end of the buss
are DC terminated on all lines (JX-B position), while the remaining ports on the buss are not
terminated (jumpers removed) to minimize power consumption and loading of the buss. AC
termination (JX-A position) may be used in special cases where DC termination produces excessive
buss loading. Typically, Transmit mode on the master port is set at J12B or J9B to "ON" mode,
while the slave port(s) are set at J12A or J9A to "AUTO" mode.
For many applications, the RS-485 port can be used in a two-wire configuration by installing
jumpers J5A and J5B, or J6A and J6B, with the following RS-485 buss connections to each port:
RS-485 SIGNAL

CHANNEL 4

CHANNEL 5

RX-/TXRX+/TX+
SHIELD

TB1-1
TB1-2
TB1-9

TB2-1
TB2-2
TB2-9

When the two-wire configuration is used, terminate the buss on the port at jumper J1 or J3 as
explained above under 4-Wire mode, and remove the jumper at J2A or B, or J4A or B. Transmit
mode is typically set to "AUTO" at J12A or J9A for all ports using the two-wire configuration.

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14.0 DIV 1 COMM EXPANSION BOARD OPTION

The DIV 1 Comm Expansion Board option may be used in the Division 2 AutoPILOT to provide
two additional synchronous or asynchronous RS-232 Host ports. The board mounts over the
AutoPILOT Main Board behind the cover plate located on the door of the enclosure, and may not
be used with the Communication Expansion Board option. Each port may be connected internally
to one of the communications options, or used to drive up to 50 feet of cable. Refer to Section 1.0,
General Information, for wiring guidelines. TB1 on the DIV 1 Comm Expansion Board provides
the field connections for Channel 4, while Channel 5 connects to TB2.
WARNING:
ENSURE THE AREA IS NONHAZARDOUS BEFORE
CONNECTING OR DISCONNECTING THE DIV 1
COMM EXPANSION BOARD.

The RS-232 signals at each port are as follows:

SIGNAL
RXD
CTS
TXD
RTS
DCD
GND

CHANNEL 4

CHANNEL 5

TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB1-8

TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-8

Each port also provides a +9 V wetting voltage of 5 mA maximum at TB1-7 for Channel 4, or TB2-7
for Channel 5, which can be used as a power cycle status input, or high impedance pull-up. For
asynchronous mode jumpers J1 and J2 are not installed. Some software versions also support
synchronous RS-232 operation. To configure Channel 4 for synchronous use, an external clock
must be supplied at TB1-6 (RXCA) referenced to GND, and jumper J1 must be installed. To
configure Channel 5 for synchronous use, an external clock must be supplied at TB2-6 (RXCB)
referenced to GND, and jumper J2 must be installed.

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15.0 V.22/212A MODEM OPTION

Flow Automation's optional V.22/212A Modem Card can be installed in the flow computer
enclosure on the internal chassis equipment panel. The modem provides communications between
the flow computer and customer equipment through the two-wire telephone interface. Refer to
Section 1.0, General Information, for proper wiring guidelines. The AutoPILOT Host
Communication Port is not available for customer use if the 212A modem option is installed. The
RS-232 serial communications signals are wired between the modem and the Host Communications
Port (TB2) on the flow computer's Main Board or Expansion Port using the AutoPILOT Active
Cable (PN# 3-0485-151) as follows:

MODEM
TX (J4-2)
RX (J4-3)
RTS (J4-4)
CTS (J4-5)
DCD (J4-8)
SG (J4-7)

MAIN BOARD
HOST PORT
TX (TB2-3)
RX (TB2-1)
RTS (TB2-4)
CTS (TB2-2)
DCD (TB2-5)
GND (TB2-8)
BAT (TB2-7)
+5 (TB2-9)

EXPANSION PORTS
CHANNEL 4
CHANNEL 5
TX (TB1-3)
RX (TB1-1)
RTS (TB1-4)
CTS (TB1-2)
DCD (TB1-5)
GND (TB1-8)

TX (TB2-3)
RX (TB2-1)
RTS (TB2-4)
CTS (TB2-2)
DCD (TB2-5)
GND (TB2-8)

WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
CONNECTING OR DISCONNECTING THE V.22/212A
MODEM CARD.

Refer to Exhibit 15-1 for the standard wiring configuration. Power for the modem is provided
through the power distribution terminal block TB1 mounted on the internal chassis equipment panel
as follows:
MODEM

PWR DIST TB

PWR (J5-1)
GND (J5-2)

TB1 position 1-3 (POS)

TB1 position 4-6 (NEG)

Connect a standard telephone line with a miniature six-position four contact RJ11C plug to the
phone-line connector (J6) of the modem.

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Exhibit 15-1: Flow Computer and 212A Modem Wiring Diagram

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16.0 202 MODEM OPTION

Flow Automation's optional 202 Modem can be installed in the flow computer enclosure mounted
on the internal chassis equipment panel or backpanel. Up to three modems can be installed in the
AutoPILOT enclosure. The modem provides communications between the flow computer and
customer equipment through lease lines, including multidrop applications. Refer to Section 1.0,
General Information, for proper wiring guidelines. The AutoPILOT Host Communication Port or
Expansion Port is not available for customer use if the 202 Modem option is connected. The RS-232
serial communications signals are wired between the modem and the Host Communications Port on
the AutoPILOT Main Board or Expansion Port as follows:

MODEM
HTX (J11-2)
HRX (J11-3)
HRTS (J11-4)
HCTS (J11-5)
HDCD (J11-8)
SG (J11-7)

MAIN BOARD
HOST PORT
TX (TB2-3)
RX (TB2-1)
RTS (TB2-4)
CTS (TB2-2)
DCD (TB2-5)
GND (TB2-8)

EXPANSION PORTS
CHANNEL 4
CHANNEL 5
TX (TB1-3)
RX (TB1-1)
RTS (TB1-4)
CTS (TB1-2)
DCD (TB1-5)
GND (TB1-8)

TX (TB2-3)
RX (TB2-1)
RTS (TB2-4)
CTS (TB2-2)
DCD (TB2-5)
GND (TB2-8)

WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
CONNECTING OR DISCONNECTING THE 202
MODEM CARD.

Refer to Exhibit 16-1 for typical interconnections between the flow computer Main Board and the
202 Modem. Power for the modem is provided through the power distribution terminal block
mounted on the internal chassis equipment panel (TB1) as follows:
MODEM

PWR DIST TB

PWR (J12-1)
GND (J12-2)

TB1 position 1-3 (POS)

TB1 position 4-6 (NEG)

Connect lease lines to the modem as follows:

RECEIVE LINE

TRANSMIT LINE

RXA (J13-1)
RXB (J13-2)

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TXA (J13-3)
TXB (J13-4)

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For customer equipment requiring contact closures (radio transmit key) connect across the modem
discrete output as follows (power must be externally limited to +18 Vdc maximum at 20 mA
maximum):
MODEM
CONNECTION

SIGNAL
C (positive)
E (negative)

J12-5
J12-6

Exhibit 16-1: Flow Computer and 202 Modem Wiring Diagram

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17.0 RS-232/RS-485 CONVERTER BOARD OPTION

Flow Automation's optional RS-232/RS-485 converter board is used to allow a flow computer port
or other RS-232 device to communicate with external equipment which supports a RS-485 buss
interface. The RS-232/RS-485 board is installed in the AutoPILOT enclosure mounted on the
internal chassis or backpanel. Multiple boards may be installed in the AutoPILOT. The AutoPILOT
Host Port connects to the converter board at the DB-25 connector P1, while the RS-485 buss is
connected at TB2. One master, and up to 31 slave devices may be attached to the same RS-485 buss,
with a maximum total cable length of 4000 feet. Refer to Section 1.0, General Information, for
wiring guidelines. The AutoPILOT Host Communication Port is not available for customer use if
the RS-232/RS-485 board is connected, while the Comm Expansion ports can be directly configured
for RS-485 use without using the converter board.
The RS-232 serial communications signals are wired between the converter board and the Host
Communications Port on the AutoPILOT Main Board as follows:
232/485
CONVERTER

HOST PORT

TX (P1-2)
RX (P1-3)
RTS (P1-4)
CTS (P1-5)
DCD (P1-8)
SG (P1-7)

TX (TB2-3)
RX (TB2-1)
RTS (TB2-4)
CTS (TB2-2)
DCD (TB2-5)
GND (TB2-8)

WARNING:
ENSURE THE AREA IS NON-HAZARDOUS BEFORE
CONNECTING OR DISCONNECTING THE
RS-232/RS-485 CONVERTER BOARD.

Power for the converter board is provided through the power distribution terminal block mounted
on the internal chassis equipment panel (TB1) as follows:
232/485
CONVERTER
PWR (TB1-1)
GND (TB1-2)

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PWR DIST TB
TB1 position 1-3 (POS)
TB1 position 4-6 (NEG)

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Each RS-232/RS-485 board typically provides four differential signals for the RS-485 buss interface
as follows:
SIGNAL

CONNECTION

RX+
RXTX+
TXDCD+
DCDRTS+
RTS-

TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-6
TB2-7
TB2-8

To connect the master board to the slave board(s) on the RS-485 buss, swap signals TX and RX, and
signals DCD and RTS, while maintaining the correct polarity for each pair of signals.
Each board must be configured with termination jumper settings at J8 through J11. Generally, the
boards at each end of the buss are DC terminated on all lines (JX-B position), while the remaining
boards on the buss are not terminated (jumpers removed) to minimize power consumption and
loading of the buss. AC termination (JX-A position) may be used in special cases where DC
termination produces excessive buss loading. Transmit Enable mode is set at J1, with the time delay
in milliseconds set at J2 if "AUTO DELAY" mode is selected at J1-C. Typically, the master board
is set at J1-A in "ON" mode, while the slave board(s) are set at J1-B in "AUTO" mode. For
applications when the converter board is to power cycle with the flow computer, install jumper J3,
and connect TB1-3 on the converter board to +5 (SBAT) on the AutoPILOT Main board at TB2-9.
Jumper J4 can be installed to provide indicator lights for troubleshooting purposes, but should be
removed during normal operation to conserve power.
For many applications, the RS-232/RS-485 board can be used in a two-wire configuration by
installing jumpers J5 through J7, with the following RS-485 buss connections on each board:
SIGNAL

CONNECTION

RX/TX +
RX/TX -

TB2-1 or 3
TB2-2 or 4

When the two-wire configuration is used, terminate the buss on the converter board, if needed, at
jumper J8 as explained above, and remove the jumper at J9. Transmit Enable mode is typically set
to "AUTO" at J1-B for the two-wire configuration.

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18.0 MDS RADIO OPTION

An optional MDS 2310A, 4310 or 4310A, 9310, or 9810 Series Radio, manufactured by Microwave
Data Systems and labeled with the UL Mark, can be installed in the flow computer enclosure inside
the internal chassis for United States installations. For Canadian installations, an optional MDS
4310A, 9310, or 9810 Series Radio manufactured by Microwave Data Systems and labeled with the
CSA Mark, can be installed in the flow computer enclosure inside the internal chassis. The radio
is mounted to the chassis using standard brackets supplied by the manufacturer with screws which
are accessible with the radio installed. The AutoPILOT Host Communication Port is not available
for customer use when connected to the MDS Radio Option.
WARNING:
BEFORE INSTALLING THE MDS 2310A, 4310, 4310A,
9310, OR 9810 SERIES RADIO IN THE FLOW
COMPUTER, ENSURE THE RADIO HAS THE UL
RECOGNIZED COMPONENT LABEL FOR UNITED
STATES INSTALLATIONS. ENSURE THE MDS 4310A,
9310, OR 9810 SERIES RADIO HAS THE CSA LABEL
FOR CANADIAN INSTALLATIONS. DO NOT
INSTALL AN MDS RADIO THAT DOES NOT HAVE
THE APPROPRIATE UL OR CSA RECOGNIZED
LABEL IN A FLOW COMPUTER BEING INSTALLED
IN A HAZARDOUS LOCATION.
The RS-232 cable connects the flow computer's Host Port or other RS-232 device to the radio
through a DB25P connector. An N-type bulkhead jack or optional coaxial protector is mounted on
the side of the enclosure and is connected to the radio antenna output through a coaxial cable and
an N-type plug. The RS-232 cable, power cable and antenna coax are installed with the radio in the
flow computer enclosure. Power is supplied to the radio through the radio's DC-power cable
connected to the power distribution terminal block or to the optional Radio Power Control Board as
follows:
RADIO IN
PWR DIST TB
or
RAD PWR CNTL BD
PWR (Red)
GND (Blk)

TB1 position 1-3 (POS)

TB1 position 4-6 (NEG)

TB2-1
TB2-2

WARNING:
ENSURE THAT THE AREA IS NONHAZARDOUS
BEFORE CONNECTING OR DISCONNECTING THE
RADIO.

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The optional Radio Power Control Board switches input power to the radio with solid state FET's
under software control. Input power to the board is wired from the power distribution terminal block
as follows:
RPCB INPUT

PWR DIST TB

TB1-1
TB1-2

TB1 position 1-3 (POS)

TB1 position 4-6 (NEG)

The control input to the Radio Power Control Board can be either one of the Discrete Outputs from
the Digital I/O board or MEB expansion board, an RS-232 level signal, or a 5V logic level signal
such as the FET outputs from the AutoPILOT Main Board. Either the Discrete Output or the FET
output are active under software control, but use of either makes one of the Discrete Outputs
unavailable for customer use. Typical connections for the control line are as follows:
RPCB CONTROL
TB1-3
TB1-4

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CONTROL SIGNAL
Discrete Output from Digital I/O or MEB board
AutoPILOT TB1-2 or TB1-3

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19.0 CELLULAR DATA TRANSCEIVER OPTION

An optional Flow Automation Cellular Data Transceiver, Model CDL100 Type FM4032F03 (ULRecognized for use in Class I Division 2, Groups C and D hazardous locations), can be installed in
the enclosure inside the internal chassis for United States installations. This option is not available
for Canadian units. The AutoPILOT Host Communication Port is not available for customer use if
connected to the Cellular Data Transceiver option. The phone bracket is permanently attached to
the flow computer internal chassis, and the phone is installed in the bracket and held in place with
a retainer which is accessible with the phone installed.
WARNING:
BEFORE INSTALLING THE CELLULAR DATA
TRANSCEIVER IN THE FLOW COMPUTER, ENSURE
IT HAS THE UL RECOGNIZED COMPONENT LABEL.
DO NOT INSTALL A CELLULAR TELEPHONE THAT
IS NOT UL RECOGNIZED IN A FLOW COMPUTER
BEING INSTALLED IN A HAZARDOUS LOCATION.

The RS-232 cable connects the flow computer's Host Port or other RS-232 device to the phone. The
antenna coax connects to the telephone's antenna connector and an N-type bulkhead jack or optional
coaxial protector mounted on the side of the enclosure. Power is supplied to the phone through the
DC-power cable connected to the power distribution terminal block or the Power Output of the
optional Radio Power Control Board. The RS-232 cable, coax, and DC-power cable are installed
with the phone in the flow computer enclosure.
WARNING:
ENSURE THAT THE AREA IS NONHAZARDOUS
BEFORE CONNECTING OR DISCONNECTING THE
TELEPHONE.

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19.1 INSTALLING THE TELEPHONE TO THE MOUNTING BRACKETS

Install the telephone to the mounting bracket as follows (refer to Exhibit 19-1):
1. Set the telephone bottom-side to the flat plate of the bracket (the telephone's bottom-side has
four rubber feet) with the telephone's long side, without the antenna connector, in the mounting
bracket's box-end. In this position, the telephone's antenna connector faces away from the
mounting bracket's box-end and the telephone's power connector is closest to the box-end.
2. Secure the telephone in mounting bracket with the L-shaped retainer bracket using a 6-32 nut and
washer.

Exhibit 19-1: Telephone and Mounting Bracket

19.2 INSTALLING THE TELEPHONE IN THE ENCLOSURE

The telephone bracket is permanently attached to the internal chassis in the flow computer enclosure.

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19.3 TELEPHONE ELECTRICAL CONNECTIONS

The telephone faceplate has the following electrical connections: the RS-232 connector, an external
microphone, the handset telephone connector, and the power connector. Refer to Exhibit 19-2.

Exhibit 19-2: Cellular Telephone Faceplate

Connect the telephone's RS-232 cable to the telephone's RS-232 connector. The cable (including
Active Cable PN# 3-0485-151) also connects to the flow computer's Host Port (TB2) or other RS232 device. The optional WHT and/or YEL wires may be connected to the AutoPILOT Main Board
FET Outputs or the Discrete Outputs on the optional AutoPILOT Digital I/O board or MEB
expansion board for some applications. Typical wiring of the RS-232 cable to the AutoPILOT Host
Port is as follows (refer to Exhibit 19-3):

Exhibit 19-3: Cellular Telephone's Active RS-232 Cable

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PHONE CABLE

HOST PORT

DCD (Violet)
RX (Orange)
RTS (Brown)
TX (Red)
CTS (Black)
GND (Blue, Shield)
BAT (Green)
+5 (Yellow)

DCD (TB2-5)
RX (TB2-1)
RTS (TB2-4)
TX (TB2-3)
CTS (TB2-2)
GND (TB2-8)
BAT (TB2-7)
+5 (TB2-9)

The external microphone connection to the telephone is not used.

Connect the telephone's power cable to the telephone's power connector. In addition to power, the
power cable provides a control line (Sense) to activate the telephone's low-power standby mode.
When the Sense line is set high or not connected, the telephone is in normal operation. When the
standby mode is desired, the Sense line connects to a discrete output of the optional Digital I/O
Board or MEB expansion board. Typical wiring of the power cable to the flow computer is as
follows (refer to Exhibit 19-4):

Exhibit 19-4: Cellular Telephone Power Cable

Power connections for Flow Computer without Radio Power Control Board are as follows:
TELEPHONE
+Vdc (Red)
GND (Blk)
Sense (Brn)

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PWR DIST TB
TB1 position 1-3 (POS)
TB1 position 4-6 (NEG)
No Connection
or

47

FLOW COMPUTER

Discrete Output from

Digital I/O or MEB board.

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Power connections for Flow Computer with Radio Power Control Board are as follows:
TELEPHONE

RADIO PWR. CNTL. BD

+Vdc (Red)
GND (Blk)
Sense (Brn)

PWR (TB2-1)
GND (TB2-2)
No Connection

The optional Radio Power Control Board switches input power to the phone with solid state FET's
under software control. Input power to the board is wired from the power distribution terminal block
located on the internal chassis as follows:
RPCB INPUT

PWR DIST TB

TB1-1
TB1-2

TB1 position 1-3 (POS)

TB1 position 4-6 (NEG)

The control input to the Radio Power Control Board can be either one of the Discrete Outputs from
the Digital I/O board or MEB expansion board, an RS-232 level signal, or a 5V logic level signal
such as the FET outputs from the AutoPILOT Main Board. Either the Discrete Output or the FET
output are active under software control, but use of either makes one of the Discrete Outputs
unavailable for customer use. Typical connections for the control line are as follows:
RPCB CONTROL
TB1-3
TB1-4

CONTROL SIGNAL
Discrete Output from Digital I/O or MEB board
AutoPILOT TB1-2 or TB1-3

The transceiver is primarily a data transfer device; however, if the optional handset is connected, the
unit can also provide standard cellular telephone voice communications. It is not intended for the
handset to be permanently installed with the transceiver, but to provide temporary, remote
communications during service/calibration operations.
WARNING:
DO NOT MAKE ANY CONNECTION TO THE
EXTERNAL MICROPHONE CONNECTOR, CHARGER
CONNECTOR, OR HANDSET CONNECTOR UNLESS
THE AREA IS KNOWN TO BE NON-HAZARDOUS.

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FLOW COMPUTER INSTALLATION

GROUNDING GUIDELINES
ADDENDUM - A

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GROUNDING PROCEDURES FOR FLOW COMPUTER INSTALLATIONS

A proper ground connection between the flow computer and an earth-ground connection protects the
meter run and the flow computer from natural and man-made electrical transients that may be present
on the system. Several factors determine the grounding configuration of the meter-run installation,
especially the flow-computer mounting and cathodic protection of the pipeline. The flow computer
may be mounted to a 2-inch vertical stand-pipe, using two 2-inch pipe clamps or U-bolts and saddle
brackets supplied with the system. The stand-pipe can be mounted directly on the pipeline using a
saddle, or be mounted in the ground. The selected method of mounting the flow computer and the
cathodic protection of the pipeline determines the grounding method to be used.
In all installations, the flow computer system must be grounded to a suitable earth-ground. The flow
computer provides a chassis ground lug located on the lower side of the flow computer enclosure.
The lug is marked with the ground symbol. The chassis-ground wire must be a minimum of an 12AWG stranded wire and as short as possible. The DC resistance from the lug to earth ground should
measure less than one ohm. Install the earth ground as outlined in Articles 250 (Grounding) and 501
(Class I Locations) of the National Electrical Code for United States installations. For Canadian
installations, install the earth ground as outlined in Sections 10 and 18 of the Canadian Electrical
Code.
This guideline deals with the following three installation configurations:

& Meter runs without cathodic protection

& Meter runs with cathodic protection using isolating flanges
& Meter runs with cathodic protection using isolating fittings

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Meter Runs without Cathodic Protection

Flow computer installation on meter runs without cathodic protection can be mounted directly on
the pipeline or on a stand-alone vertical stand-pipe. Refer to Exhibit 1. The ground conductor
connects between the flow computer and the earth ground. The Flow Automation Temperature
Transducer may be grounded through the pipeline. If any pressure/pulse transducers or
AutoMITTERs are remotely mounted, connect the cases of these transducers to the pipeline or earth
ground.

Exhibit 1: Meter-Run Installation without Cathodic Protection

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Meter Runs with Cathodic Protection Using Isolating Flanges

Isolating flanges can be used to electrically isolate the meter run (including the flow-computer
system, the orifice/turbine meters and AutoMITTERs) from the pipeline with cathodic protection.
The flow computer can be mounted directly on the isolated section of pipeline or on a stand-alone
vertical stand-pipe. Refer to Exhibit 2. The ground conductor connects between the flow computer
and the earth ground. Mount a ground strap to the isolated meter-run section and connect it to the
earth ground to protect the Temperature Transducer and any remotely mounted pressure/pulse
transducers. Connect any AutoMITTER grounds directly to earth ground.

Exhibit 2: Meter Run Installation with Isolating Flanges

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Meter Runs with Cathodic Protection Using Isolating Fittings

Isolating fittings can be used to electrically isolate the meter run from the pipeline with cathodic
protection. Refer to Exhibit 3. Install an isolated fitting or gasket between the following
connections:
& all metallic tubing runs between the orifice meter and pressure transducers/manifolds (including
remotely mounted units or AutoMITTERs)
& all metallic connections or tubing runs between the flow computer and turbine meter/pulse
transducers
& any Temperature Transducer and its pipe-mount, including those connected to AutoMITTERs.
Mount the flow computer on a stand-alone vertical stand-pipe. The ground conductor connects
between the flow computer and the earth ground. Connect the cases of the Temperature Transducer,
any remotely mounted pressure transducers, or AutoMITTER chassis grounds to the earth ground.

Exhibit 3: Meter Run Installation with Isolating Fittings

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RTD PROBE CUTTING

AND WIRING PROCEDURES
ADDENDUM - B

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There are two types of RTD probes which may be used with the AutoPILOT flow computer or
AutoMITTER. One has a composite or metal body with individual wires which connect inside a
condulet box to the cabling from the flow computer or AutoMITTER. A second type has a metal
probe body, and an integral flexible metal sheath covering the wires to the flow computer or
AutoMITTER enclosure.

1.0 RTD PROBE WITH INDIVIDUAL WIRES

One type of RTD probe has a composite or metal body with individual wires. This type of probe
may be cut to length, and installed with the wiring connected in a condulet box to the cable from the
flow computer or AutoMITTER.

1.1 CUTTING THE TEMPERATURE PROBE TO LENGTH

Flow Automation recommends the temperature probe length be measured from the inside bottom
surface of the RTD Housing to the desired depth in the thermowell. This measurement takes into
consideration the combined lengths of the thermowell and mounting hardware when the temperature
probe is installed on the pipeline. When installed in the thermowell, the tip of the probe must not
contact the bottom of the thermowell, to electrically isolate the probe from transient currents. Cut
the temperature probe as follows:
1. Measure or calculate the desired length of the temperature probe.
2. Remove the heat shrink from the top of the temperature probe.
3. Carefully, remove the small plastic sleeve from the top of the temperature probe. Caution: Do
not discard the small plastic sleeve. It protects the wires from the edge of the probe.
4. Measure and mark the body of the temperature probe to the desired length, measuring from the
tip of the temperature probe.
5. When using the standard Stark temperature probe, the composite-probe body is pre-scored.
Hand break the probe body at the desired score, then pull the portion to be removed from the
transmitter wires.
When using the optional stainless-steel temperature probe, score the metal body at the measured
mark using the tubing cutters, hand break the probe body at the score, then pull the cutoff portion
from the transmitter wires. Caution: When cutting the probe body and pulling the cutoff
portion from the transmitter wiring, be careful not to cut or skin the transmitter wires with
the tubing cutters or a sharp edge of the probe body.

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6. Re-install the small plastic sleeve over the transmitter wiring and insert at the top of the
temperature probe.

1.2 INSTALLING THE TEMPERATURE PROBE

1. Remove the cover of the RTD housing.
2. Carefully slide the temperature probe in the top of the housing through the bottom bushing, until
the top of the probe aligns approximately with the bottom inside surface of the housing.
3. Using the 5/64-inch Allen wrench, tighten the 8-32 set screw, securing the temperature probe in
place. Caution: When installing the Stark temperature probe, do not over-torque the set
screw so as not to break the composite-probe body.
4. Using the wire cutters, cut the transmitter wires approximately five inches long, measured from
the top of the temperature probe. Strip the end of the wires approximately 3/16 of an inch.
Inspect the wire for nicks or frayed ends.
5. For Temperature Probe assemblies 3-0465-029 or 3-0465-033, insert the stripped end of the
wires completely in the clamps of the four-position terminal block, then tighten the clamps using
a small screwdriver. Match the RTD probe wires to the RTD cable wiring as follows:
RTD Probe Wiring
White
White
Yellow, Jumper
Jumper

RTD Cable Wiring

Red
White
Black
Green

For the Model 465A Temperature Transmitter, insert the stripped end of the wires completely
in the clamps of the four position terminal block, then tighten the clamps using a small
screwdriver as follows:
& White conductor - Terminal Position #1
& White conductor - Terminal Position #2
& Yellow conductor - Terminal Position #3
Plug the terminal block into the RTD transmitter PCA. Using a dab of electrical RTV, secure
the probe wiring to the inside edge of the condulet.
Inspect each connection, ensuring no frayed strands protrude and no insulation is in the clamps.

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6. Install the cover of the RTD housing. If present, make sure that the gasket is properly seated.
7. It is recommended that the thermowell be installed in a vertical position on the pipeline, and be
filled with electrically nonconductive oil to cover the probe tip for maximum thermal transfer.

2.0 RTD PROBE WITH INTEGRAL METAL SHEATH

This type of RTD probe has a metal body with integral flexible metal sheath which covers the wires
to the flow computer or AutoMITTER enclosure. It must be positioned in the thermowell using a
fitting.

2.1 POSITIONING THE RTD PROBE

It is recommended that the thermowell be installed in a vertical position on the pipeline, and be
partially filled with electrically nonconductive oil to cover the probe tip for maximum thermal
transfer. When installed in the thermowell, the tip of the RTD probe must not contact the bottom
of the thermowell, to electrically isolate the probe from transient currents.
1. Measure or calculate the RTD probe length from the desired depth in the thermowell to the top
of the desired fitting. A standard fitting is supplied, while an isolating fitting may be required
for some applications.
2. Install the fitting at the top of the thermowell. The standard fitting connects to the thermowell
with the threaded portion. Loosen the clamp which will fit around the RTD probe body.
3. Measure the desired probe length from the tip of the temperature probe, and insert through fitting
to that depth.
4. Hand tighten the fitting around the probe body to secure the probe in position. Do not over
tighten, to avoid deforming the probe body.

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FLOW COMPUTER FIELD INSTALLATION

CONFIGURATION JUMPER SETTINGS
ADDENDUM - C

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AutoPILOT JUMPER CONFIGURATION GUIDE

The hardware of the AutoPILOT flow computer is configured by placing configuration jumpers in
connector J1 located in the lower, left-hand corner of the AutoPILOT Main Board. Remove the
cover plate from the enclosure door to locate the Main Board. The five positions of the configuration
connector J1 are defined as follows:
#1 Backup Battery Enable: When a jumper is installed in this position, the +3.6 Vdc Lithium
Backup Battery is connected to the AutoPILOT circuitry, maintaining historical/configuration
data in the system memory and powering the system's real-time clock when input power is
removed. Note: Remove this jumper when a unit is being stored, to prevent the battery
from being drained.
Caution
If this jumper is not installed in an operating unit and input
power is removed, all historical/configuration data is
destroyed.

#2 Watchdog Enable: When a jumper is installed in this position, the AutoPILOT's Watchdog
Circuitry is Enabled. Should be installed in all units.
#3 Constant Power/Sleep-Cycle: When a jumper is installed in this position, the circuitry is
constantly powered and the LCD display is constantly enabled. When the jumper is removed,
the AutoPILOT operates in the sleep-cycle mode. During the sleep-cycle mode, power is
removed from most of the AutoPILOT circuitry (except the system RAM and real-time clock,
maintaining historical and configuration data) for a software configurable duration of one to five
seconds. At the end of the sleep cycle, power is returned and the AutoPILOT collects new raw
input data, performs the flow calculations and stores the new data in system memory, then
returns to the sleep cycle. To preserve power, the constant power option is not recommended for
normal operation of the AutoPILOT with small power sources, including the 6-Vdc, 12 AH
rechargeable battery.
#4 No connection, used to store spare jumper.
#5 No connection, used to store spare jumper.

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