Description
Emerson FloBoss S600+ | Fiscal Flow Computer
Dynamic Product Introduction
A flow computer is not just another industrial controller. When the application is custody transfer, the calculation engine is directly tied to measured product quantity, proving, reporting, and commercial accountability. The FloBoss S600+ is designed specifically for this job: Emerson positions it for fiscal measurement, custody transfer, pipeline measurement, batch loading, meter proving, and flow control.
The FloBoss S600+ improves on the original S600 with a more powerful CPU and hardware floating-point processing. Its metering calculations use 64-bit double-precision floating point, while cumulative totals are maintained in three separate memory locations using a Tri-reg arrangement. That architecture matters when measurement integrity is more important than raw PLC scan speed.
For multi-stream installations, the FloBoss S600+ can handle up to 10 streams with optional expansion modules, including combinations of gas, wet gas, crude oil, refined products, LPG, and NGL measurement. A single unit can also accommodate both a liquid and a gas station.
FLOBOSS S600+
Key Technical Specifications
- Model: FloBoss S600+
- Product type: Panel-mounted fiscal flow computer
- Processor: ColdFire MPC8313, 333 MHz, with integrated floating-point processor.
- Operating system: Linux
- Calculation precision: 64-bit double-precision floating point
- Flow capacity: Up to 10 streams with optional expansion
- Stations: Up to 2 stations
- Analog input resolution: 24 bit
- Analog input accuracy: ±0.005% of full scale at 23°C
- Analog scan: All channels can be acquired in less than 1 second.
- Ethernet: 10/100 Mbps full duplex
- Ethernet protocol: Modbus/TCP or Modbus over Ethernet
- Serial protocols: ASCII and Modbus ASCII/RTU
- Serial baud rates: 2,400 to 57,600 baud
- Configuration software: Config600
- Configuration storage: Up to 20 user configurations, reducing recovery time when a replacement is required.
- Display: 128 × 64 pixel LCD, 8 lines × 20 characters
- Keypad: 29 keys
- Operating temperature: -10°C to +60°C according to Emerson’s current product page.
Global Sourcing & Live-Test SOP
For a surplus or replacement FloBoss +, “powers on” is a very low bar. A flow computer can boot normally while carrying an incorrect configuration, degraded battery, damaged I/O channel, or communications problem.
1. Inbound Verification
Record the physical identity before applying power:
- Exact FloBoss + model marking
- Serial number
- Hardware revision
- CPU/module configuration
- I/O module configuration
- Firmware/software identification
- Manufacturing labels
- Display and keypad condition
- Terminal and connector condition
The physical unit should also be checked for corrosion, evidence of moisture, cracked terminal blocks, damaged rear connectors, and unauthorized board modifications.
For custody-transfer equipment, configuration provenance matters almost as much as the hardware itself. A visually clean used unit with an unknown configuration is not equivalent to a documented tested spare.
2. Live Simulation
A proper test should use a compatible + test arrangement with representative instrumentation signals.
The test sequence should include:
- Stable DC power application
- Cold boot and restart
- Display/keypad operation
- CPU diagnostic verification
- Analog input simulation
- Pulse input simulation
- RTD/PRT simulation where applicable
- Digital I/O verification
- Analog output verification
- Serial communications
- Ethernet communications
- Configuration upload/download
- Alarm and event generation
The + provides a dedicated configuration port for Config600, while its Ethernet interfaces support Modbus/TCP and Modbus over Ethernet.
3. Measurement and Communications Diagnostics
For analog channels, use calibrated signal sources rather than simply shorting terminals. The documented analog architecture supports 0–5 V and current input ranges, with 24-bit conversion and high accuracy.
Communications should be tested at the actual intended protocol layer.
For Modbus, verify:
- Slave/master role
- Station address
- Register mapping
- Baud rate
- Data bits
- Parity
- Stop bits
- Response timing
- Ethernet addressing where applicable
The + Modbus specification documents 20 user-definable communication tasks, with individual links configurable for serial or network applications.
4. Extended Run and Final Prep
For high-value replacement inventory, perform an extended powered test rather than relying on a quick bench startup. Monitor CPU behavior, display operation, communication stability, I/O readings, and alarms.
The internal lithium battery deserves particular attention. Published specifications identify a 3 V, 1500 mAh lithium battery, with a typical service life of approximately 5–7 years.
Before shipment, record the observed firmware/configuration state, package the unit using ESD protection, protect the terminal hardware, and document the actual test performed. If the configuration has not been tested, say so.
The Field Engineer’s Pitfall Guide
❗ Do not confuse a CPU replacement with a configuration replacement. The + can store multiple user configurations, and Config600 is used to build, transfer, and maintain applications. Before removing the old controller, preserve the configuration whenever possible. I’ve seen metering jobs delayed because the replacement hardware was available but nobody had a verified copy of the running configuration.
❗ Watch the RS422/RS485 termination settings. The + provides jumper-selectable termination on its RS422/RS485 communications interfaces. A replacement unit may communicate perfectly on the bench and then fail on a multidrop network because the termination jumper was copied incorrectly—or not copied at all.
❗ Do not treat a similar -family unit as automatically interchangeable. Hardware generation, firmware, I/O expansion, communication interfaces, and application configuration all matter. The FloBoss + is a specific platform with its own processor, memory, I/O, and configuration environment. A two-hour troubleshooting session is easily created by assuming that physical fit equals functional compatibility.
Intent-Driven FAQ
What is the FloBoss + used for?
The FloBoss + is a fiscal flow computer intended for applications such as custody transfer, pipeline measurement, batch loading, meter proving, and flow control. It supports both gas and liquid measurement applications.
How many flow streams can a FloBoss + handle?
A standard + architecture supports multi-stream applications, with up to 10 streams using optional expansion modules. It can also support up to two stations, including configurations combining gas and liquid measurement.
Does the FloBoss + support Modbus?
Yes. The + supports Modbus ASCII and Modbus RTU over supported serial interfaces and Modbus/TCP or Modbus over Ethernet through its Ethernet interfaces.
Can I use the + for custody transfer?
Yes. Custody transfer is one of its primary intended applications. Emerson specifically describes the + for fiscal flow measurement and custody transfer, with support for major gas and liquid measurement standards including AGA, API, ASTM, GPA, ISO, and GERG-related standards.
What software is used to configure the FloBoss +?
The primary configuration environment is Config600. Emerson describes Config600 Pro as the engineering workbench for complex configurations and Config600 Lite as a tool for uploading, downloading, and editing existing configurations.
Can I hot-swap a FloBoss +?
Do not assume that you can. This is a panel-mounted flow computer rather than a conventional hot-swappable PLC I/O card. Follow the site’s approved shutdown and electrical isolation procedure unless the applicable Emerson documentation explicitly authorizes the particular maintenance operation.
What should I verify before buying a used FloBoss +?
At minimum, verify the exact + hardware configuration, serial number, firmware/software state, I/O modules, battery condition, display/keypad operation, communication interfaces, and configuration availability. For a custody-transfer application, I would also insist on documented functional testing rather than accepting a generic “tested” description.
Bottom Line
The FloBoss + is a specialized fiscal flow computer built around measurement accuracy, configurable flow calculations, communications, historical data, and proving—not merely general-purpose PLC control. Its 64-bit calculation engine, 24-bit analog conversion, multi-stream capability, Modbus/Ethernet communications, and Config600 environment make configuration integrity just as important as the physical replacement unit.
For procurement, buy the FloBoss + against the complete installed configuration, not just the enclosure label. That is the difference between receiving a spare and receiving hardware that can actually be commissioned.
