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Emerson ControlWave EFM 4710A Instruction Manual

Emerson electronic flow meter instruction manual
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Instruction Manual
CI-ControlWave EFM
Oct., 2006
ControlWave EFM
(Electronic Flow Meter)
www.EmersonProcess.com/Bristol
ControlWave EFM

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Summary of Contents for Emerson ControlWave EFM 4710A

  • Page 1 Instruction Manual CI-ControlWave EFM Oct., 2006 ControlWave EFM (Electronic Flow Meter) www.EmersonProcess.com/Bristol ControlWave EFM...
  • Page 2 IMPORTANT! READ INSTRUCTIONS BEFORE STARTING! Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.
  • Page 3 Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing. Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer.
  • Page 4 How to return material for Repair or Exchange Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Repair Dept.
  • Page 5 Bristol Inc. Repair Authorization Form (Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.) Date___________________ Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests”...
  • Page 6 GET THE MOST FROM YOUR BRISTOL BABCOCK INSTRUMENT OR SYSTEM • Avoid Delays and problems in getting your system on-line • Minimize installation, start-up and maintenance costs. • Make the most effective use of our hardware and software. • Know your system. As you know, a well-trained staff is essential to your operation.
  • Page 7 A Few Words About Bristol Inc. For over 100 years, Bristol ® and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
  • Page 8 software except for ControlWave and OpenEnterprise products, call (860) 945-2286. For technical questions about Network 3000 hardware, call (860) 945-2502. You can e-mail the Application Support Group at: bsupport@bristolbabcock.com The Application Support Group maintains an area on our web site for software updates and technical information.
  • Page 9 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter INSTALLATION FORWARD NOTE for all ControlWave EFM Installers: READ THIS SECTION FIRST! This manual has been designed for the following audience: • Customer Site Engineers, who must plan for the installation and implementation of the ControlWave EFM.

  • Page 10: Table Of Contents

    CI-ControlWave EFM ControlWave EFM Electronic Flow Meter SECTION TITLE Section 1 - ControlWave EFM INTRODUCTION GENERAL DESCRIPTION ... 1-1 ControlWave PROGRAMMING ENVIRONMENT ... 1-5 PHYSICAL DESCRIPTION... 1-7 1.3.1 Enclosure... 1-8 1.3.2 CPU Module ... 1-8 1.3.2.1 CPU Module Connectors ... 1-10 1.3.2.2 CPU Memory...
  • Page 11 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter SECTION TITLE Section 1 - ControlWave EFM INTRODUCTION (Continued) 1.5.3.2 Daily Historical Data Log ... 1-24 1.5.3.3 Periodic Historical Data Log ... 1-25 1.5.3.4 Alarm and Event Storage... 1-25 1.5.4 LCD Display... 1-25 1.5.5 Communications ...
  • Page 12 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter SECTION TITLE Section 2 - INSTALLATION & OPERATION (Continued) 2.3.1.1 Connection to the Multivariable Transducer (MVT) ... 2-10 2.3.1.2 Process Pipeline Connection (Meter Runs without Cathodic Protection) ... 2-11 2.3.1.3 Process Pipeline Connection (Meter Runs with Cathodic Protection)... 2-11 2.3.2 System Controller Module (SCM) Configuration...
  • Page 13 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter SECTION TITLE Section 2 - INSTALLATION & OPERATION (Continued) 2.4.2.3 Remote Upgrade of ControlWave EFM Firmware ... 2-58 2.4.3 Operation of the Mode Switch... 2-59 2.4.4 Soft Switch Configuration and Communication Ports ... 2-59 2.4.5 Optional Display/Keypad Assemblies...
  • Page 14 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter SECTION TITLE Section 4 - SPECIFICATIONS (Continued) 4.3.3 Power Supply External Power Monitor Specs..4-3 4.3.4 System Controller Module Connectors... 4-3 INPUT/OUTPUT MODULE SPECIFICATIONS... 4-4 4.4.1 Non-isolated Analog Input/Output Module... 4-4 4.4.2 Non-isolated Digital Input/Output Module...
  • Page 15 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter TABLE OF CONTENTS SECTION TITLE PAGE # REFERENCED OEM MANUALS (Continued) Expansion Comm. Module Piggy-back Modem/Radio OEM Manuals (Continued) Internal FreeWave Radio (wired to Polyphaser) - Spread Spectrum Data Transceiver FreeWave Spread Spectrum Wireless Data Transceiver User Manual - V5.0R (model FGR09CSU) Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the latest copy of the user manual.
  • Page 16 CI-ControlWave EFM ControlWave EFM Electronic Flow Meter TABLE OF CONTENTS SECTION TITLE PAGE # REFERENCED OEM MANUALS (Continued) External Modem/Radio OEM Manuals (Continued) MDS iNET 900 Ethernet Radio MDS iNET 900 Wireless IP/Ethernet Transceiver – User Guide = MDS 05-2806A01, Rev. D, Aug. 2003 (PDF = 2806D-iNET_User-web.pdf) for iNET 900 Ethernet Radio Center Insert (Installation Reference Chart) = (PDF = 2873D-iNET_Center_Sheet.pdf)

  • Page 17: Section 1 - Controlwave Efm Introduction

    ControlWave EFM INTRODUCTION 1.1 GENERAL DESCRIPTION ControlWave EFM electronic flow meters measure differential pressure, static pressure and temperature for a single run and compute flow for both volume and energy. In addition to operation in an unprotected outdoor environment, the ControlWave EFC electronic flow meter provides the following key features.
  • Page 18 generated on the CPU Module (derived from the regulated 3.3Vdc logic power). In addition to Idle and Watchdog LEDs, there are six status LEDs located on the SCM that will display run time status information. Figure 1-1 - ControlWave EFM Enclosure (with 25-Button Display/Keypad Assembly)(Shown with Circular Local Port) 1-2 / Introduction CI-ControlWave EFM...
  • Page 19 Figure 1-2A - 4-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with D-Type Local Port) CI-ControlWave EFM Introduction / 1-3...
  • Page 20 Figure 1-2B - 8-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with Circular Local Port) 1-4 / Introduction CI-ControlWave EFM...

  • Page 21: Controlwave Programming Environment

    Figure 1-3 - 8/4-Slot ControlWave EFM (Electronic Flow Meter) Base Assemblies (The 4-Slot Chassis is shown with ECM Modules in Slots 3 & 4) 1.2 ControlWave PROGRAMMING ENVIRONMENT The ControlWave programming environment uses industry-standard tools and protocols to provide a flexible, adaptable approach for various process control applications in the water treatment, wastewater treatment, and industrial automation business.
  • Page 22 ControlWave EFM units provide an ideal platform for remote site automation, measurement, and data management in the oil and gas industry. The control strategy file created and downloaded into the controller is referred to as a ControlWave project. The ControlWave EFM ships from Bristol Babcock with a standard ControlWave project, pre-configured for gas flow measurement, already loaded and ready to run.

  • Page 23: Physical Description

    function blocks accomplish various tasks common to most user applications including alarming, historical data storage, as well as process control algorithms such as PID control. The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows • real-time data access to any OPC [Object Linking and Embedding (OLE) for Process Control] compliant third-party software packages.

  • Page 24: Enclosure

    1.3.1 Enclosure ControlWave EFMs are housed in a standard Hoffman® Enclosure. External dimensions (excluding added hardware and Cover Latches) are approximately 14.56” high, by 12.97” wide, by 8.31” deep. When present, the Multivariable Transducer adds 2.89” to the height of the unit.
  • Page 25 Backup Battery Jumper JP1 (on the Battery Backup Board) from position 1 to 2 and then storing it on either pin. If the Real-time clock looses its battery backup a ControlWave Designer system variable bit (_QUEST_DATE) is set. This bit can be used to post a message or alarm to the PC (see the ‘Systems Variables’...

  • Page 26: Cpu Module Connectors

    1.3.2.1 CPU Module Connectors The CPU Modules contain up to seven connectors that function as follows (see Table 1-1): Table 1-1 - CPU Board Connector Summary Ref. # Pins 76-Pin Factory Debug 36-pin Card Edge Backplane I/O Bus Intf. 44-pin Card Edge Backplane SCM Intf.

  • Page 27: Cpu Module Configuration Jumpers

    memory is 32-bits wide. System Firmware and the Boot Project are stored here. No hardware write protection is provided for the FLASH array. System Memory (SRAM) The base version of the CPU Module has 2Mbytes of soldered-down static RAM, im- plemented with two 512K x 16 asynchronous SRAMs that are configured as a 512K x 32-bit array.

  • Page 28: Cpu Module Leds

    Table 1-3 - Assignment of CPU Bd. Switch SW1 Switch Function SW1-3 Force Recovery Mode Table 1-4 - Assignment of CPU Module Switch SW3 COM3 - Switch SW3-1 TX+ to RX+ Loopback SW3-2 TX- to RX- Loopback SW3-3 100 Ohm RX+ Termination SW3-4 100 Ohm RX- Termination SW3-7...
  • Page 29 The power supply operates from +4.5/+4.9 to +16Vdc or +9.6/10.3 to +16Vdc with the nominal input supply configuration (+6V or +12V) user configured via on-board jumpers. A supervisory circuit monitors the incoming power and the supply voltages. The isolated supplies are shut down when the incoming voltage drops below +4.5V for a +6V system or +9.6V, for a +12V system.

  • Page 30: Scm Mode Switch

    1.3.3.1 SCM Mode Switch SCM Module’s Mode Switch (SW1), is a 2-position piano type DIP-Switch that is utilized for recovery mode and core updump operations (see Sections 2.4.3 and 3.6) 1.3.3.2 SCM Board Fuse The SCM is fused to protect the entire system. 5x20mm Slow Blow Fuse F1 is rated at 1A. 1.3.3.3 SCM Board Connectors Connectors TB1, TB2, J1, J2 and P2 function as described below.

  • Page 31: Controlwave Efm Backplanes

    1.3.4 ControlWave EFM Backplanes 4-Slot or 8-Slot ControlWave EFM Backplanes provide for the electrical interconnection of the System Controller Module (SCM), CPU Module, Expansion Communication Modules (ECOMs) and/or I/O Modules. One or two Expansion Comm. Modules may be substituted for I/O Modules in Backplane slots 3 & 4. Backplane module slot connections that support Expansion Comm.

  • Page 32: Controlwave Efm I/O Modules

    The unit’s Base Assembly Chassis is mounted to the Fabrication Panel inside the Hoffman Enclosure. ControlWave EFM Chassis’ contain a Ground Lug that accommodates up to a #4 AWG Ground Wire. Grounding the unit is accomplished by connecting a ground wire between the Ground Lug and a known good Earth Ground.

  • Page 33: Non-Isolated Analog I/O & Analog Input Modules

    1.3.6.1 Non-isolated Analog I/O & Analog Input Modules (also see Section 2.3.4.5) ControlWave EFM AI/O Modules provide 6 Analog Inputs and optionally 2 Analog Outputs. All Analog Inputs are externally sourced, single-ended and individually Jumper configurable for either 4-20mA or 1-5Vdc. Analog Outputs are externally sourced and are individually Jumper configurable for 4-20 mA or 1-5 Vdc.

  • Page 34: Internal Mounting Brackets

    Figure 1-9 - ControlWave EFM Communications Module 1.3.8 Internal Mounting Brackets Internal mounting brackets that support the various system components, such as the Battery, ControlWave EFM Base Assembly, etc., are mounted on the ‘Fabrication Panel,’ which in turn is secured to the inner rear wall of the enclosure. An External radio or 1-18 / Introduction CI-ControlWave EFM...

  • Page 35: Multivariable Transducer

    modem will mount via a Radio/Modem Mounting Bracket (beneath the Battery Mounting Bracket on units equipped with a 4-Slot Chassis).. 1.3.9 Multivariable Transducer The Multivariable Transducer (MVT) pressure assembly is connected to the process manifold either directly or by tubing. In the body of the transducer, metal diaphragms are exposed to the gas.

  • Page 36: Power Supply Option

    Figure 1-11 - Digital To Relay I/O Board 1.3.12 21V Power Supply Option The 21V Power Supply is a continuous mode boost switching type power supply. It is based upon a low power, low noise circuit that produces 21 Volts from a 12V input. Power shutdown is not an option with this unit since it employs a Boost circuit;...

  • Page 37: Rtd Probe

    Solar panels mount to a 2" pipe and can be swiveled for optimum alignment with the sun and their tilt angle is adjustable for maximum performance to accommodate the latitude of the installation site. Solar panel wires enter the unit through a liquid tight conduit fitting on the bottom of the enclosure.

  • Page 38: Data Acquisition

    • AGA7 with selectable AGA8 Gross or AGA8 Detail • Auto Adjust AGA7/NX-19 • Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail • Includes run switching • Includes an auto-selector, PID flow/pressure control algorithm per run or per station •...

  • Page 39: Flow Rate And Flow Time Calculations (Aga3)

    totals, and archive averages. The user can select AGA3/NX-19 (1985), AGA3/AGA8, AGA7/NX-19 or AGA7/AGA8. 1.5.2.1 Flow Rate and Flow Time Calculations (AGA3) For orifice flow measurement, the differential pressure value is compared to a flow cutoff value every second. If the differential pressure is less than the flow cutoff value, flow is considered to be zero for that second.

  • Page 40: Archives

    or an external MVT, the user selects the downstream tap location during MVT configuration, the MVT firmware changes the sign of the differential pressure to provide a positive DP value. 1.5.3 Archives The ControlWave EFM stores two distinct types of archive data. The first type is Audit Trail data, which is a recording of the various events and alarms that have an impact on the calculated and reported rates and volumes.

  • Page 41: Periodic Historical Data Log

    The following items are stored in the Daily Data Log. • Corrected Volume • Uncorrected Volume • Accumulated Energy • Average Static Pressure • Average Temperature • Average Differential Pressure • Average Specific Gravity • Average Heating Value • Flow Time •...

  • Page 42: Communications

    1.5.5 Communications A ControlWave EFM can be configured as a Master or Slave node on either a MODBUS network or a BSAP network. Up to three communication ports are contained on the ControlWave EFM CPU Module and are designated as follows: CPU Module: COM1 - Port 1: CPU Bd.

  • Page 43: Bsap Message Support

    slave transmit and receive data on opposite lines; all slaves (from the first to the "nth") are paralleled (daisy chained) across the same lines. The master node should be wired to one end of the RS-485 cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used.

  • Page 44: Pulse Output For External Totalizer Or Sampler

    1.5.6.2 Pulse Output for External Totalizer or Sampler When the ControlWave EFM is configured to provide a pulse output based on volume, the operator provides a control volume and pulse duration. After each calculation cycle, an internal volume accumulator is compared to the control volume. If the accumulator exceeds the control volume then a pulse is output and the accumulator is reduced by the volume represented by the pulse.

  • Page 45: Product Overview

    PRODUCT FEATURES & OVERVIEW 1A.1 PRODUCT OVERVIEW ControlWave® products have been designed and integrated as a highly adaptable, high performance Distributed Open Controller family with exceptional networking capability that provides a complete Process Automation Management Solution. ControlWave EFM electronic flow meters have been designed with an emphasis on providing high performance with low power consumption, scalability and modularity.

  • Page 46: Product Family Compatibility

    • Full user programming environment, ControlWave Designer with ACCOL III, is available for modification of existing loads as well as creation of custom loads • Full suite of function blocks for flow calculations, audit trail, historical archive/data management, communication, and process control is included. •...

  • Page 47: Standard Application Program

    Briefly, this library includes function blocks for: • Average, Compare, Totalize • Scheduling & Sequencing • PID & Lead/Lag • AGA gas flow and liquids calculations • File handling In addition, ControlWave ensures data integrity, in the event of a communication interruption, by storing critical time-stamped alarm and historical data in the controller memory.

  • Page 48: 3.2 Openbsi Utilities

    other client applications communicate with the Bristol networks. OpenBSI supports both serial BSAP protocol and Ethernet Internet Protocol communication to ControlWave and Network 3000 RTUs and controllers. 1A.3.2 OpenBSI Utilities Above this communication layer are a group of applications known as OpenBSI Utilities. These client utilities communicate through the server to collect and manage data gathered from the network, generate files based on collected historical data, collect alarms, and monitor and control OpenBSI communications.

  • Page 49: 3.3.1 Activex Controls

    1A.3.3.1 ActiveX Controls • Security - 56-bit encryption - allows the user to sign on to the RTU • Signal Value - displays signal values in various formats • Comm. Statistics - works with a standard page that displays the RTU’s communication statistics •...

  • Page 50: Controlwave Open Network Connectivity

    class hardware and software with confidence in their interoperability. Our OpenBSI OPC Server was among the first to comply with the OPC Foundation alarm and event server specification. • OPC Data Access 1.0a & 2.0 compatible • Windows NT, 2000 & XP •...

  • Page 51: 4.1.2 Modbus Protocol

    • Global time-synchronization • Time-stamped Alarm reporting • Historical archive data transfer • Audit file transfer • On-line program editing • Diagnostics • Communication statistics 1A.4.1.2 Modbus Protocol Modbus - Modbus is often considered a de-facto standard protocol because broad usage as either the primary or a secondary offering in many measurement and control related products.
  • Page 52 BLANK PAGE...

  • Page 53: Section 2 - Installation & Operation

    Section 2 INSTALLATION & OPERATION 2.1 INSTALLATION IN HAZARDOUS AREAS Each ControlWave EFM electronic flow meter is furnished in a housing designed to meet the NEMA Type 3 specifications and to operate in a Class I, Division 2, Groups C & D environment with a nonincendive rating (see Appendix A).
  • Page 54 Figure 2-1B - 8-Slot ControlWave EFM (Shown with MDS - Transnet Radio & Circular Local Port) 2-2 / Installation & Operation CI-ControlWave EFM...
  • Page 55 Each ControlWave EFM Base Assembly (4/8-Slot) is housed in an open-faced Gold Irridite coated Aluminum Chassis assembly. Keyed cutouts in rear wall of the ControlWave EFM Base Assembly are provided for Wall or Panel mounting arrangements. The ControlWave EFM Base Assembly is mounted to the Fabricated Panel on the inner rear wall of the Hoffman Enclosure and is comprised of the following components: •...

  • Page 56: Site Location Considerations

    ControlWave EFM Modules that comprise the system are housed in a base assembly consisting of an open faced Gold Irridite coated Aluminum Chassis equipped with either a 4-Slot or 8-Slot Backplane. Dimensional drawings of the Base Assemblies are provided at the end of Chapter 4.
  • Page 57 1. Remove the unit from its carton and install it at the assigned work site (see Section 2.3.1). Dimensions are provided in Section 4.6 of this manual. 2. Remove the SCM Module and after configuring its jumpers, install it into Control- Wave EFM Base Assembly, chassis slot 1, i.e., the first slot from the left end of the Base Assembly Chassis (see Section 2.3.2).
  • Page 58 Step 3. Establish Communications using either LocalView or NetView, and Run the Flash Configuration Utility Communications must be established with the ControlWave EFM using either LocalView or NetView. The ControlWave EFM ships from the factory with a default Flash configuration. Most users will need to edit this configuration to set the BSAP local address (IP address if using PPP), user accounts, and port parameters.
  • Page 59 Once the program has been created, it is assigned to an executable task. The entire project is then saved and compiled. NOTE: From this point on, the order of steps may be varied, somewhat, depending upon the requirements of the user's application. NOTE: If you modify the standard EFM program, you may need to modify the standard web pages associated with it.

  • Page 60: Mounting The Controlwave Efm Enclosure

    2.3.1 Mounting the ControlWave EFM Enclosure When mounting one of these units, it is to be positioned in accordance with the following restrictions: The unit is to be positioned vertically with the Multivariable Transducer (MVT) at its base and is to be mounted to a wall or a vertical 2” pipe (clamed at the rear of the unit via two clamps and four bolts).
  • Page 61 There should be clearance for the optional Solar Panel (if required) (the Solar Panel may be mounted to the same 2” pipe that secures the unit. Power wiring should not be installed until the unit has been mounted and grounded at a designated work site.

  • Page 62: Connection To The Multivariable Transducer (Mvt)

    2.3.1.1 Connection to the Multivariable Transducer (MVT) One Multivariable Transducer (MVT) is provided with each ControlWave EFM and is secured to the bottom of the enclosure. Figure 2-5 details MVT process flange and optional manifold block connector mounting dimensions. The MVT provides connection ports on the process flange as the standard arrangement. Optional manifold blocks may also be specified.

  • Page 63: Process Pipeline Connection (Meter Runs Without Cathodic Protection)

    Optional Process Manifold Blocks: Process manifold blocks may be installed on the transmitter to permit the use of connector assemblies having different connection centers. The manifold blocks, which are oval in appearance, mate with the transmitter's process flange. The blocks may be installed in several positions to achieve different connection centers as shown in Figure 2-5.
  • Page 64 by cathodic protection or other EMF on the pipeline. ControlWave EFMs may be mounted directly on the pipeline (see Figure 2-6) or remotely on a vertical stand-alone two-inch pipe (see Figure 2-7). It is recommended that isolation fitting always be used in remotely mounted meter systems.

  • Page 65: System Controller Module (Scm) Configuration

    heating (e.g., with a rose-bud torch) it electrically insulates and increases the strength of the pipe stand. See Bristol Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds. 2.3.2 System Controller Module (SCM) Configuration System Controller Module’ (SCM) configuration jumpers must be set to configure bulk power (+6Vdc or +12Vdc nominally) and to enable or disable the Power Good LED (see Figure 2-8).

  • Page 66: Cpu Module & Ecom Module Configuration

    For safety reasons and to prevent accidental damage to a user supplied external bulk DC Power Supply, it is recommended that pluggable Terminal Block connector TB1 be discon- nected from the SCM until the entire unit has been wired, and hardware configured. Sections 2.3.9.1 &...
  • Page 67 SW2-3 set OFF forces the use of Soft Switches as set per factory default (see Section 2.4.4). For use of user defined Soft Switches, SW2-3 must be set to the ON position. Note: If both SW2-3 and SW2-8 are set OFF (closed), all communication ports will be set to 9600 bps operation (8-bits, no parity, 1 stop bit, BSAP Protocol).

  • Page 68: Communication Ports

    Table 2-3 - CPU Bd. Switch SW1 - Force Recovery Mode/Battery Enable Switch Function SW1-3 Force Recovery Mode Note: SW1-1, SW1-2 and SW1-4 are not used. 2.3.3.2 Communication Ports A ControlWave EFM can be configured as a Master or Slave node on either a MODBUS network or a BSAP network.

  • Page 69: Rs-485 Interfaces

    Up to three communication ports are contained on the ControlWave EFM CPU Module and are designated as follows: CPU Module: COM1 - Port 1: CPU Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232 - connected to Local Port COM2 - Port 2: CPU Bd. J4, PC/AT 9-Pin Male D-Sub - RS-232 - supports External Radio COM3 - Port 3: CPU Bd.
  • Page 70 Expansion Communications Module 1: Resides in Base Chassis Backplane Slot #3 COM4 - Port 1: ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - RS-232 COM5 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - RS-485 Expansion Communications Module 2: Resides in Base Chassis Backplane Slot #4 COM8 - Port 1: ECOM Bd.
  • Page 71 Figure 2-12 - Communication Port RS-232 Cable Wiring Diagram CI-ControlWave EFM Installation & Operation / 2-19...
  • Page 72 Table 2-4A - RS-232 Ports (1/2/4/8) and RS-485 Ports (3/5/9) Pin Assignments Signal Description: RS-232 RS-232 Signals Data Carrier Detect Input Receive Data Input Transmit Data Output Data Terminal Ready Output Signal/Power Ground Data Set Ready Input Request To Send Output Clear To Send Input * ISOGND on Isolated RS-485 Ports Only! Note: Pin-9 not used Table 2-4B - RS-232 Port (COM1) Connector Pin Assignments...
  • Page 73 Figure 2-13B - PC Connected to ControlWave EFM via Circular Local Port Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable RS-485 Ports ControlWave EFM can use an RS-485 communication port for local network com- munications to multiple nodes up to 4000 feet away.

  • Page 74: Piggy-Back Spread Spectrum Modem (Radio) Port

    by configuring CPU Bd. Switch SW3 and/or ECOM Switch SW1 (COM6/COM9) so that the 100-Ohm termination resistors and biasing networks are installed at the end nodes and are removed at all other nodes on the network (see Table 2-6). Table 2-5 - RS-485 Network Connections (see Table 2-4A ControlWave EFM RS-485 Port Pin # Assignments) From Master...

  • Page 75: Piggy-Back 56K Pstn Modem Port

    Installation steps 1 through 3 below support user installation and configuration of a Spread Spectrum Modem. 1. Mount the radio (Spread Spectrum Modem) onto the Expansion Comm. Module. Remove the nut and washer from the internal coaxial RF cable supplied with the ECOM Module. Remove the plug from the front of the ECOM Cover and insert the in-ternal coaxial RF cable’s SMA connector (straight end with flat area on top) through the rear of the ECOM Cover.
  • Page 76 Figure 2-14 - Expansion Comm. Module Radio/Modem Installation Diagram 2-24 / Installation & Operation CI-ControlWave EFM...
  • Page 77 Modems are supplied in kit form with all the hardware required for user installation onto an Expansion Communications Module. Figure 2-14 shows the modem mounted on the Expansion Comm. Module. Modems are user installed onto the ECOM Module (see Figure 2-14) and their associated Ports are setup during installation in the Ports Page of the Flash Configuration Utility.
  • Page 78 Complies with Part 68 FCC Rules. Contains device with FCC Registration Number: AU7-USA-25814-M5-E Ringer Equivalence Number (REN): 0.3B Note: The sum of all the RENs on your telephone lines should be less than five in order to assure proper service from the telephone company. In some cases, a sum of five may not be usable on a given line.

  • Page 79: Radio Ready And External (Case Mounted) Modem Or Radio

    Figure 2-16 - Wiring for Phone Cord Connector 2.3.3.6 Radio Ready and External (Case Mounted) Modem or Radio A wide selection of modems and radios are offered. The ControlWave EFM is factory shipped with a user selected radio or modem installed within the enclosure (beneath the Battery Mounting Bracket) or as a radio ready unit, i.e., ready for field installation of a Bristol supplied radio.
  • Page 80 removable Terminal Block connectors and field devices (see Figure 2-18). Use AWG 14 or smaller wire, (consult with the field device manufacturer for recom- mendations). Leave some slack and plan for wire routing, identification, main- tenance, etc. The bundled wires are to be routed in/out through the bottom of the I/O Module Assembly between the Terminal Block Assembly and the Terminal Housing Assembly.
  • Page 81 6. Using a PC equipped with ‘ControlWave Designer’ and ‘OpenBSI’ software, con- figure the ControlWave EFM to accept the new I/O Module (and any other modules that have been added or removed) and then download the application load into the ControlWave EFM CPU’s System FLASH and/or SDRAM (see Section 2.4.1).

  • Page 82: I/O Wire Connections

    2.3.4.2 I/O Wire Connections ControlWave EFM electronic flow computers utilize compression-type terminals that accommodate up to #14 AWG wire. A connection is made by inserting the wire’s bared end (1/4” max) into the clamp beneath the screw and securing the screw. The wire should be inserted fully so that no bare wires are exposed to cause shorts.

  • Page 83: Non-Isolated Analog Input/Output & Analog Input Modules

    Figure 2-19 - Non-Isolated DI/O Module Configuration Diagram 2.3.4.5 Non-isolated Analog Input/Output & Analog Input Modules (see Figure 2-20) Analog Input/Output Modules support six 4-20mA or 1-5 Vdc single ended analog inputs and optionally, two independently configurable 4-20mA or 1-5 Vdc analog outputs. AI/O Modules consists of an Analog Input/Output PCB with two 10-point Terminal Block Assemblies (for local termination), 12 Configuration Jumpers and a Cover Assembly.
  • Page 84 Each AI signal is channeled through signal conditioning circuitry (that provides a 2 Hertz low pass filter), a transorb for surge suppression, multiplexer, and an A to D Converter (ADC). Figure 2-20 - Non-isolated AI/O & AI Module Configuration Diagram 2-32 / Installation &...

  • Page 85: Analog Input/Output Configurations

    The Analog Output circuit consists of a 12-bit resolution Digital to Analog Converter (DAC), a V to I circuit, and a V to V circuit. The 12-bit DAC dives the V to I circuitry. A scaling circuit within the V to I circuit drives the V to V circuitry. V to I and V to V circuitry are powered by an external power source.
  • Page 86 Modules consists of a High Speed Counter PCB with two 10-point Terminal Block Assemblies (for local termination), 14 Configuration Jumpers, an LED Board with 4 Status LEDs (one for each point) and a Cover Assembly. The HSC Board mates with the Backplane PCB via a 36-pin gold plated card edge connector.

  • Page 87: High Speed Counter Configurations

    signals, or relay contacts. A serial EEPROM contains HSC Board serialization data. Each input of the HSCI Module is configured as a 16-bit high-speed counter. 2.3.4.6.1 High Speed Counter Configurations HSC Modules provide a total of 4 HSC inputs with surge protection. HSC Module Con- figuration Jumpers W1 through W14 must be set per Table 2-10.
  • Page 88 Figure 2-22 - Mixed I/O Module Wiring Diagram Mixed I/O Modules optionally support one externally powered (VEXT = 11 to 30Vdc) analog output. AO Circuitry consists of a 12-bit resolution Digital to Analog Converter (DAC), a V to I circuit, and a V to V circuit. The 12-bit DAC drives the V to I circuitry. A scaling circuit within the V to I circuit drives the V to V circuitry.

  • Page 89: Mixed I/O Module Configuration

    Figure 2-23 - Non Isolated Mixed I/O Module Configuration Diagram 2.3.4.7.1 Mixed I/O Module Configurations Mixed I/O Module Configuration Jumpers W1 through W28 must be set per Table 2-11. Table 2-11 - Non Isolated Mixed I/O Module Jumper Assignments Jumper Purpose Configures optional AO for Voltage or Current Output...

  • Page 90: Rtd Wiring

    Table 2-11 - Non Isolated Mixed I/O Module Jumper Assignments (Continued) Jumper Purpose Configures AI1 through AI4 W23 - W26 (respectively) AO Voltage Selection Set W27 Pins 2-3 ALWAYS HSC Circuitry Enable * = W1 located on optional AO Daughter Board 2.3.5 RTD Wiring A 3-wire RTD may be provided with the ControlWave EFM.

  • Page 91: Power Supply Option

    Figure 2-25 - RTD Probe Installation/Removal Diagram 2.3.6 21V Power Supply Option 21V Power Supplies are mainly used in conjunction with Temperature and Pressure Transmitters which require a higher than +12V but lower than +21.4V (±.8V) input supply to operate (such as Series 3508 Transmitters). Figure 2-26 - 21V Power Supply Board 21V Power Supply Boards contain two terminal blocks that accommodate power con- nections between the ControlWave EFM and remote transmitters.

  • Page 92: Digital To Relay I/O Board Option

    Table 2-13 - 21V Power Supply Board Terminal Designations 21VPS 21VPS TB NAME TB1-1 +12VIN TB1-2 12VGND TB1-3 CHASSISGND TB2-1 +21V TB2-2 21VGND TB2-3 +21V TB2-4 21VGND 2.3.7 Digital to Relay I/O Board Option Digital to Relay I/O Boards except up to two discrete input signals from an open drain MOSFET device and convert them to Form C relay output signals using Solid State Relay (SSR) logic.
  • Page 93 The commons associated with each form C Relay (R0COM and R1COM) have the option of being tied to the ControlWave EFM Power Ground or to a floating Ground. Jumper W1 is associated with Outputs R0A and R0B and W2 is associated with outputs R1A and R1B. When Jumper W1 is installed the common (C) associated with Outputs R0A and R0B is tied to ControlWave EFM Power ground;...

  • Page 94: Connection To A Model 3808 Transmitter

    Figure 2-28 - Digital to Relay I/O Board Wiring Diagram 2.3.8 Connection to a Model 3808 Transmitter A Model 3808 Transmitter (Digital) can be interfaced to a ControlWave EFM via either an RS-232 or an RS-485 communication scheme. Communication schemes and cable lengths are determined the type of communication port utilized.
  • Page 95 Note: For Loopback & Termination Control: Use SW3 on CPU Module to configure COM3. Use SW1 on ECOM Module to configure COM5 or COM9. Figure 2-30 - Model 3808 Transmitter to ControlWave EFM Figure 2-31 - ControlWave EFM to 3808s - RS-485 Network Diagram CI-ControlWave EFM RS-485 Comm.

  • Page 96: Power Wiring & Distribution

    Figures 2-29 and 2-30 detail the RS-232 and RS-485 wiring connections required between the ControlWave EFM and the Model 3808 Transmitter. Up to eight (8) Model 3808 Transmitters can be connected to a ControlWave EFM via a half duplex RS-485 Network. An illustration of this network is provided in Figure 2-31. 2.3.9 Power Wiring &...

  • Page 97: Bulk Power Supply Current Requirements

    Power Distribution Boards are provided with six (6) Terminal Connector Blocks that function as follows: TB1 - Primary Power Input: (three-conductor) (from user supplied bulk power source) TB1-1 = Power+ (Pos. input) TB1-2 = Power– (Neg. input) TB1-3 = Chassis (GND) TB2 - Main Power Output 1: (two-conductor) (to SCM Power Connector TB1) TB2-1 = PWR1+ to TB1-1 on SCM (+VIN) TB2-2 = PWR1–...

  • Page 98: Power Wiring

    Bulk +6/12Vdc Supply Current = CPU* + Sum of all ECOM Modules, I/O Modules, optional Boards & Optional External Modem/Radio This summation will accommodate steady state current draw. Table 2-16 provides detailed steady state power current requirements for each ControlWave EFM Base Assembly module.

  • Page 99: Mounting An Optional Solar Panel

    2.3.9.3 Mounting an Optional Solar Panel Solar Panels (used to charge the rechargeable lead acid batteries) are to be mounted to a 2” to 2-3/8” pipe as illustrated in Figure 2-35. Muffler (Pipe) Clamps, utilized for this purpose, are secured via four 1/4-20 nuts and washers. NOTE 1: To Attach item C to item D: Slide two bolts (A) through the top and bottom Solar Panel (Centered) Channel Holes.

  • Page 100: Tilt Angle

    2.3.9.3.2 Tilt Angle 30/40 Watt Solar Panel Systems (see Figure 2-35) have adjustable tilt angles. Table 2-17 shows the angle (from horizontal) at which the Solar Panel should be installed in order to maximize annual energy output. At most latitudes, performance can be improved by less of an angle during the summer and more of an angle during the winter.

  • Page 101: Controlwave Efm System Grounding

    1. Remove connector TB1 from the System Control Module (SCM) and remove the Battery/Power Harness from the Battery Charger/Power Manager Board. 2. Remove the Lead-acid Battery from its shipping carton. 3. Install the Lead-acid Battery (on end) as illustrated in Figure 2-36. Note: Make sure the Lead-acid Battery is fully charged before installing it.

  • Page 102: Installation Of A Bezel Assembly

    NOTE: If the Battery or is removed when power is off the contents of SRAM (on the CPU Module) will not be retained. Once a Battery has been removed, don’t install a replacement Battery for at least one minute unless SW2-5 on the CPU has been set OFF.

  • Page 103: Operational Details

    2.4 OPERATIONAL DETAILS ControlWave EFM electronic flow computers are shipped from the factory with firmware that allows the unit to be configured in conjunction with an IEC 61131, application program. This section provides information as follows: - Steps required to download the application load and place the unit into ‘Run’ mode. - Steps required to download system firmware.

  • Page 104: Using Localview To Upgrade Controlwave Efm Firmware

    Upgrade of system firmware via LocalView FLASH Mode requires OpenBSI 5.1 (or newer). If you have an older version of OpenBSI, FLASH upgrades are to be performed via HyperTerminal. You will need a binary (*.BIN) system firmware file, and that file should be defined in the Flash Master File (FLASH.MST).
  • Page 105 When the "Mode", "Name", and "Location" have been specified, click on the [Create] push button to activate the Communication Setup Wizard. Step 1 - Communication Setup Choose the communication port you want in the What port would you like to use: field. Click on the [Next] pushbutton to activate the next wizard.
  • Page 106 Step 3 - Flash Data Setup Complete the following fields in the Flash Data Setup Wizard: "Please enter the name of the binary file to Flash" To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file on your hard disk containing the firmware.

  • Page 107: Using Hyperterminal To Upgrade Controlwave Efm Firmware

    Once the Flash download has begun, you will NOT be allowed to shut down LocalView, unless you cancel the download, or it has been completed. The progress of the Flash download will be displayed in the window. Any mismatch in file versions, or if the type of .BIN file does not match the type of RTU, the download will be aborted.
  • Page 108 6. Close the HyperTerminal program. The null modem cable connected between the ControlWave EFM and the PC can be removed if desired. 7. Set the System Controller Module’s Mode Switch (SW1) for ‘Local Mode,’ i.e., SW1-1 in the OPEN (Right) position and SW1-2 in the CLOSED (Left) position. Switch Power OFF and then ON again.
  • Page 109 Once the ControlWave EFM running its application load, status codes are posted to the six Status LEDs on the PSSM. These Status LED (Hex) Codes are listed in Table 2-15 (see Figure 2-47. Figure 2-45 - HyperTerminal Flash Download (Send File Dialog Box - Enter Filename) Figure 2-46 - HyperTerminal FLASH Download (Download in Process) CI-ControlWave EFM Installation &...

  • Page 110: Remote Upgrade Of Controlwave Efm Firmware

    Table 2-18 - System Status LED Codes on System Controller Module Status In Hex Figure 2-47 - SCM Status LED Hexi-decimal Codes (See Table 2-18 for Definitions) 2.4.2.3 Remote Upgrade of ControlWave EFM Firmware It is possible to download system firmware into an unattended remote ControlWave EFM. This function can only be accomplished if CPU Board Switch SW2-6 (associated with the unit in question) is set in the ON position (factory default).

  • Page 111: Operation Of The Mode Switch

    2.4.3 Operation of the Mode Switch The System Controller’s Mode Switch (SW1) is a two position piano type DIP-Switch that functions as follows: Both switches set to the OPEN (Right) or CLOSED (Left) positions = Recovery Mode. Recovery Mode is used for either a firmware upgrade (see Section 2.4.2) or a core updump (see Section 3.6).

  • Page 112: Optional Display/Keypad Assemblies

    WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program. In lieu of the use of an RS-232 Port, an RS-485 cable (see Tables 2-4A & 2-5) can be connected between COM5 and the PC’s RS-485 Port.
  • Page 113 Figure 2-48 - Dual-Button Display/Keypad Assembly Installation Drawing CI-ControlWave EFM Installation & Operation / 2-61...

  • Page 114: Operation Of The Dual-Button Display/Keypad Assembly

    Figure 2-49 - 25-Button Display/Keypad Assembly Installation Drawing 2.4.5.1 Operation of the Dual-button Display/Keypad Assembly The Display will have a timeout of 20 minutes. If there has been no keypad activity for this time the display will “logout,” i.e., the display will be turned off and scrolling stopped until a key press occurs.
  • Page 115 If a shorter timeout of the display is needed for power savings, another timeout may be implemented. The processor connected to the display will control the timeout. When the timeout occurs the display will be blanked, but communications between the ARM and display processor will still occur.
  • Page 116 Manual Mode In Manual Mode the programmer is responsible for creating each screen and displaying the next desired screen, based on key inputs. The programmer has access to all lines of the display and can provide any string that he/she desires to display. Special formats that must be adhered to that allow the programmer to display what they want on the screen are provided in the description of iaScrnSruct in the ACCOL 3 Display function block within ControlWave Designer’s On-Line Help.

  • Page 117: Section 3 - Service

    3.1 SERVICE INTRODUCTION This section provides general, diagnostic and test information for the ControlWave EFM. The service procedures described herein will require the following equipment: 1. PC with null modem interface cable & Bristol’s WINDIAG Software 2. Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 3-9) 3.

  • Page 118: Removal/Replacement Of The Bezel Assembly

    3.2.2 Removal/Replacement of the Bezel Assembly Before I/O Modules can be removed, the Bezel Assembly, which covers them, must be removed. 1. Grasp the sides of the Bezel Assembly and gently lift it up and then pull it out and off its associated I/O Module Covers.

  • Page 119: Removal/Replacement Of An Expansion Comm. Module

    4. Press down on the Cover’s built-in top latch (with one hand) and up on the Cover’s built-in bottom latch (with the other hand). 5. Carefully slide the I/O Module out of the front of the Housing. If binding occurs, gently rock the I/O Module up and down to free it.

  • Page 120: Removal/Replacement Of A Power Distribution Board

    Figure 3-1 - Sealed Lead-acid Battery Mounting Diagram 3.2.8 Removal/Replacement of a Power Distribution Board 1. If the ControlWave EFM is running, place any critical control processes under manual control and shut down the unit by disconnecting power to the System Controller Module (SCM).

  • Page 121: Removal/Replacement Of A 21V Power Supply Board

    3.2.9 Removal/Replacement of a 21V Power Supply Board 1. If the ControlWave EFM is running, place any critical control processes under manual control (as required). 2. Unplug wiring harnesses from 21V Power Supply Board connectors TB1 and TB2. 3. Slide the 21V Power Supply Board toward the front of the unit and remove it from its Snap Track Holder.

  • Page 122: Led Checks

    +16Vdc), you can determine the point at which the unit turns off, i.e., the point at which the PWRGOOD LED on the SCM goes OFF (Vt-). If the value of the bulk power supply’s +6Vdc or +12Vdc output approaches the value of Vt+ or Vt- it should be replaced by a power supply with the correct +6V or +12V output.
  • Page 123 ControlWave EFM LED designations are provided in Table 3-1. Module Name SCM * IDLE SCM * 6 STATUS CPUM C1 RX (Comm 1) CPUM C1 TX (Comm 1) CPUM C2 RX (Comm 2) CPUM C2 TX (Comm 2) CPUM C3 RX (Comm 3) CPUM C3 TX (Comm 3) ECOM1...
  • Page 124 Table 3-2 - System Status LED Codes on System Controller Module (Continued) Status (Hex) * = Flashed at startup Figure 3-3 - System Controller Module Status LED Hexi-decimal Codes 3-8 / Service Error Testing SDRAM Error Testing SRAM Application Loaded Stopped at a Break Point No Application Loaded Running with Break Points...
  • Page 125 Figure 3-4 - CPU Module Communication Connector and LED Designations Figure 3-5 - ControlWave EFM Plus I/O Module LED Designations CI-ControlWave EFM Service / 3-9...

  • Page 126: Wiring/Signal Checks

    Figure 3-6 - Expansion Comm. Module - Comm. Connector and LED Designations 3.3.3 Wiring/Signal Checks Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check wiring for continuity, shorts & opens. Check I/O signals at their respective Terminal Blocks (see Table 3-3).

  • Page 127: Extent Of Field Repairs

    3.4.1 Extent of Field Repairs Field repairs to a ControlWave EFM are strictly limited to the replacement of complete modules. Component replacement on a ControlWave EFM Module constitutes tampering and will violate the warranty. Defective ControlWave EFM Housings or Modules must be returned to Bristol Inc.
  • Page 128 COM2: From the factory, RS-232 Communications Port COM2 on the CPU Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test COM2 using the WINDIAG program, it must not otherwise be in use and CPU Switch SW2-8 must be set OFF. COM3: RS-485 Communications Port COM3 on the CPU Board defaults to 9600 baud, 8- bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
  • Page 129 Figure 3-7 - Netview Startup Menu - Example with Multiple Networks Figure 3-8 - WINDIAG Main Diagnostics Menu CI-ControlWave EFM Service / 3-13...

  • Page 130: Diagnostics Using Windiag

    4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG will perform the diagnostics and display pass/fail results. 5. After all diagnostic testing has been performed, exit the WINDIAG program and then exit the Netview Program if there aren’t any other ControlWave EFM units to be tested.
  • Page 131 Figure 3-9 - RS-232 Loop-back Plugs Figure 3-10 - RS-485 Loop-back Plugs Figure 3-11 - WINDIAG’s Communications Diagnostic Menu 1. Type "1," "2," "3," or "4" for the port to test. 2. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5. CI-ControlWave EFM Service / 3-15...

  • Page 132: Core Updump

    3. Click on RUN button next to External loop-back. Test responses: a) Success - All sections of test passed b) Failure - TXD RXD Failure or CTS RTS Failure Execution time < 5 sec. 3.6 CORE UPDUMP In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for evaluation by Bristol Inc.

  • Page 133: Section 4 - Specifications

    4.1 CPU, MEMORY & PROGRAM INTERFACE Processor: Memory: Real Time Clock: Connectors: Table 4-1 - CPU Board Connector Summary Ref. # Pins 76-pin Factory Debug Connector 36-pin IOBUS Connector 44-pin SCM Connector 9-pin COM1 (RS-232) 9-pin male D-sub 9-pin COM2 (RS-232) 9-pin male D-sub 9-pin COM3 RJ-45 (RS-485) 10-pin...

  • Page 134: System Controller Module

    Table 4-2 - RS-232 Ports (COM1/2/4/8 and RS-485 Ports COM3//5/9 Signal Description: RS-232 RS-232 Signals Data Carrier Detect Input Receive Data Input Transmit Data Output Data Terminal Ready Output Signal/Power Ground Data Set Ready Input Request To Send Output Clear To Send Input Figure 4-1 - DB9 9-Pin Connector Associated with COM1, COM2, COM3, COM4, COM5, COM8 &...

  • Page 135: Power Supply Sequencer Specs

    Shutdown: 4.3.2 Power Supply Sequencer Specs. Signals Monitored: Sequencer Switchpoints: Sequencer Output Signals: PFDLYCLK Timing on power down 2msec after POWER- 4.3.3 Power Supply External Power Monitor Specs. Input Signal: Input Range: Resolution: Accuracy: 4.3.4 System Controller Module Connectors Table 4-3 - System Controller Module Connector Summary Ref.

  • Page 136: Input/Output Module Specifications

    Figure 4-2 - SCM - TB1 (Power Connector) 4.4 INPUT/OUTPUT MODULE SPECIFICATIONS 4.4.1 Non-isolated Analog Input/Output Module Non-isolated Analog Inputs Number of Inputs: Input Type: Input Impedance: Non-isolated Analog Outputs Number of Outputs: 4-20mA Output Compliance: 1-5V Output: General AI/AO Module Specs. Accuracy: 4-4 / Specifications 6 Single Ended Inputs (1-5V or 4-20Ma) individually...

  • Page 137: Non-Isolated Digital Input/Output Module

    Terminations: Data Transfer: 4.4.2 Non-isolated Digital Input/Output Module Non-isolated Digital Inputs Number of Inputs: Input Filtering: Input Current: ‘0’ State Voltage: ‘1’ State Voltage: Bus Access: Electrical Isolation: Surge Suppression: Status Indication: Non-isolated Digital Outputs Number of Outputs: Output Configuration: Maximum Load Current: Bus Access: Electrical Isolation:...

  • Page 138: Non-Isolated High Speed Counter Input Module

    Terminations: 4.4.3 Non-isolated High Speed Counter Input Module Number of Inputs: Input Configuration: Input Frequency: Input filtering: Signal Conditioning: ‘1’ State Voltage: ‘0’ State Voltage: Bus Access: Electrical isolation: Surge Suppression: Terminations: Status Indication: Power Consumption: 4.4.4 Non-isolated Mixed Input/Output Module Number of I/Os: 4-6 / Specifications mA @ 3.3Vdc: 12 DIs ON @ 66uA, CLK active...
  • Page 139 Terminations: Power Consumption: Non-isolated Mixed I/O Module Digital Inputs/Outputs Number of Points: Input Current: Input Configuration: Input Filtering: ‘0’ State Voltage: ‘1’ State Voltage: Bus Access: Surge Suppression: Status Indication: Output Configuration: Max. DO Load Current: Electrical Isolation: Power Consumption: Non-isolated Mixed I/O Module Analog Inputs Number of Inputs: Input Type:...
  • Page 140 Power Consumption: Non-isolated Mixed I/O Module Analog Output Number of Outputs: 4-20mA Output Compliance: 1-5V Output: Accuracy: Power Consumption: Non-isolated Mixed I/O Module High Speed Counter Inputs Number of Inputs: Input Configuration: Input Frequency: Input filtering: Signal Conditioning: ‘1’ State Voltage: ‘0’...

  • Page 141: Digital To Relay I/O Board Specification

    Electrical isolation: Surge Suppression: Status Indication: Power Consumption: 4.5 DIGITAL TO RELAY I/O BOARD SPECIFICATIONS Digital to Relay I/O Board General Specs. Terminations: Digital to Relay I/O Board Input Requirements Power Source Range: SSR Input Impedance: MOSFET Sink Current: Digital to Relay I/O Board Output Requirements Contact Ratings: Maximum Current: Maximum ON State:...

  • Page 142: Environmental Specifications

    Vibration: 21V Power Supply Board Performance Specifications Input Voltage (Vin): Input Current (Iin): Output Voltage (Vout): Output Current (Iout): Ripple/Noise: Efficiency: Fuses: 4.7 ENVIRONMENTAL SPECIFICATIONS Temperature: Relative Humidity: Vibration: RFI Susceptibility: ESD: 4.8 DIMENSIONS 4-Slot Base Chassis: 8-Slot Base Chassis: NEMA 3X Enclosure 4-10 / Specifications 1g for 10Hz to 500Hz per PMC-31-1 (without damage or...
  • Page 143 Figure 4-3 - 4-Slot ControlWave EFM Base Chassis Assembly Dimensions CI-ControlWave EFM Specifications / 4-11...
  • Page 144 Figure 4-4 - 8-Slot ControlWave EFM Base Chassis Assembly Dimensions 4-12 / Specifications CI-ControlWave EFM...
  • Page 145 Figure 4-5 - ControlWave EFM NEMA 3X Enclosure Dimensions CI-ControlWave EFM Specifications / 4-13...
  • Page 146 BLANK PAGE...

  • Page 147: Special Instructions For Class I, Division 2 Hazardous Locations

    Special Instructions for Class I, Division 2 Hazardous Locations Bristol, Inc.’s ControlWave EFM Electronic Flow Meter is listed by Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Group C and D hazardous locations or nonhazardous locations only.
  • Page 148 Special Instructions for Class I, Division 2 Hazardous Locations Table A1 -Module/Board Connector Customer Wiring Connectors (Continued) Module/Item SCM Module TB1 - Input Power SCM Module TB2 - RTD Interface Exp. Comm Module 1 J4 - COM4, 9-pin Male D-sub RS-232 J5 - COM5, 9-pin Male D-sub RS-485...

  • Page 149: Hardware Installation Guide

    Appendix C HARDWARE INSTALLATION GUIDE Hardware Configuration There are seven (7) main steps required to configure a ControlWave EFM. This appendix provides an overview of these steps with an emphasis on the installation and configuration of the hardware. This appendix is intended for users who have already installed at least one ControlWave EFM.
  • Page 150 Figure C-1B - 8-Slot ControlWave EFM (Internal View) SCM & CPUM Installed in Slots #1 & #2 (Respectively) of Base Assembly C-2 / Appendix C - Hardware Installation Guide CI-ControlWave EFM...
  • Page 151 Step 1. Hardware Configuration (Continued) 2. Remove the System Controller Module (SCM) and after configuring its configuration jumpers, install it in chassis slot 1, i.e., the first slot from the left end of the Base Assembly Chassis (see Section 2.3.2). WATCHDOG LED (Red) IDLE LED...
  • Page 152 Table C-1 - CPU Bd. Switch SW1 - Force Recovery Mode/Battery Enable Switch Function Force Recovery SW1-3 Mode Note: SCM Switch SW1 can also be used for Force Recovery Mode operation Table C-2 - CPU Bd. Switch SW2 - User Configurations Note: Except for SW2-4, ON = Factory Default Switch Function...
  • Page 153 A ControlWave EFM can be configured as a Master or Slave node on either a MODBUS network or a BSAP network. Up to three communication ports are contained on the ControlWave EFM CPU Module and are designated as follows: CPU Module: COM1 - Port 1: CPU Bd.
  • Page 154 Expansion Communications Module: COM4, COM5, COM6 & COM7 on 1 COM8, COM9, COM10 and COM11 on 2 COM4/8 - Port 1: ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - Both RS-232 COM5/9 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - Both RS-485 COM6/10 - Port 3: ECOM Bd.
  • Page 155 Radios are user installed onto the ECOM Module (see Figure C-4A) and their associated Ports are setup during installation in the Ports Page of the Flash Configuration Utility. The Flash Configuration Utility is accessed via NetView or LocalView. FreeWave® Spread Spectrum Wireless Data Transceiver: Operates in the 902 to 928 MHz range (20 miles).
  • Page 156 Figure C-4B - ECOM Module Component Identification Diagram #2 Microwave Data System Inc. MDS TransNET OEM™ Spread Spectrum Data Transceiver: Operates in the 902 to 928 MHz range (20 miles). Installation steps below support user installation and configuration of a Spread Spectrum Modem.
  • Page 157 Figure C-5 - Communication Port RS-232 Cable Wiring Diagram CI-ControlWave EFM Appendix C - Hardware Installation Guide / C-9...
  • Page 158 • For FreeWave Radio: Follow the Tuning Transceiver Performance” section of the FreeWave Technologies Inc. FreeWave Spread Spectrum Wireless Data Transceiver User Manual to configure the radio. For MDS Radio: Refer to section 3.3 “Initial Power-Up & Configuration” within the MDS TransNet OEM Integration Guide and if necessary for more information on connecting a PC terminal and preparing it for use, refer to section 9.0 “PROGRAMMING REFERENCE.”...
  • Page 159 Base Housings - Slots 3 & 4 (in lieu of Expansion Comm. Modules) & Slots 5 through 8 Expansion Housings - Any Slot Install I/O wiring to each I/O Module (see Figures C-6 through C-10). Install a communications cable between the ControlWave EFM and a Model 3808 Transmitter (Network of Transmitters) if required (see Figures C-11 &...
  • Page 160 Figure C-7 - Non-isolated AI/O Module Configuration Diagram C-12 / Appendix C - Hardware Installation Guide CI-ControlWave EFM...
  • Page 161 Figure C-8 - Non Isolated HSC Module Configuration Diagram Step 1. Hardware Configuration (Continued) 6. Install a ground wire between the Chassis Ground Lug and a known good Earth Ground (also see Supplement Guide S1400CW). ControlWave EFM Housings are provided with a Ground Lug that accommodates up to a #4 AWG wire size.
  • Page 162 connected to Chassis Ground when they have been installed and secured via their two Captured Panel Fasteners. As an extra added precaution, it is recommended that a #14 AWG wire be run from SCM Power Connector TB1-3 (Chassis Ground) to the same known good Earth Ground.
  • Page 163 Figure C-10 - Non-isolated Mixed I/O Module Wiring Diagram (see Figure C-9 for Mixed I/O Module Configuration Diagram) • Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is recommended that stranded copper wire is used and that the length should be as short as possible.
  • Page 164 • The wire ends should be tinned with solder prior to insertion into the Chassis Ground Lug. Note: Use a high wattage Soldering Iron. • The ground wire should be run such that any routing bend in the cable has a minimum radius of 12-inches below ground and 8-inches above ground Step 1.
  • Page 165 Figure C-12 - ControlWaveEFM to 3808s - RS-485 Network Diagram Step 2. Software Installation on the PC Workstation ControlWave Designer software will have to be installed on the PC if the ControlWave EFM is to be utilized in an application other than that supported by the standard load. This is accomplished by installing the ControlWave Designer Package from the Open BSI CD ROM.
  • Page 166 Step 3. Establish Communications using either LocalView or NetView, and Run the Flash Configuration Utility Communications must be established with the ControlWave EFM using either LocalView or NetView. The ControlWave EFM ships from the factory with a default Flash configuration. Most users will need to edit this configuration to set the BSAP local address (IP address if using PPP), user accounts, and port parameters.
  • Page 167 Once the program has been created, it is assigned to an executable task. The entire project is then saved and compiled. NOTE: From this point on, the order of steps may be varied, somewhat, depending upon the requirements of the user's application. If you modify the standard EFM program, you may need to modify the standard web pages associated with it.
  • Page 168 Downloading the Application Load Any ControlWave EFM must have a configured application load before it can be placed into operation. For units not shipped with the ‘Standard Load,’ this will require connection of the ControlWave EFM to a PC running Windows NT (4.0 or higher), Windows 2000 or Windows XP Professional and equipped with ControlWave Designer software &...
  • Page 169 Module Name SCM * IDLE SCM * 6 STATUS CPUM C1 RX (Comm 1) CPUM C1 TX (Comm 1) CPUM C2 RX (Comm 2) CPUM C2 TX (Comm 2) CPUM C3 RX (Comm 3) CPUM C3 TX (Comm 3) ECOM1 C1 RX (Comm 4) ECOM1 C1 TX (Comm 4)
  • Page 170 Figure C-13 - SCM Status LED Hexi-decimal Codes C-22 / Appendix C - Hardware Installation Guide CI-ControlWave EFM...

  • Page 171: Ecom Module Radio/Modem Installation Guide

    ECOM MODULE RADIO/MODEM INSTALLATION GUIDE D1.1 RADIO INSTALLATION & CONFIGURATION D1.1.1 Installing an Internal FreeWave Radio (FGR09CSU) FreeWave Radio Model GR09SCU is provided (for user installation) in a kit consisting of the following components: • 2-56 x .188” Pan Head Screw (Qty. 3) - Fig. D2 Reference = 1 •...
  • Page 172 Figure D1 – Expansion Comm. Module Component Identification Diagram D1.1.2 Configuring the FreeWave Radio (FGR09CSU) To configure a Model FGR09SCU Radio (installed on an Expansion Communication Module), perform the following eight (8) steps: 1. If required, remove the Exp. Comm. Module from the unit in question (see Figure. D1). 2.
  • Page 173 Figure D2 - FreeWave Radio Installation Diagram CI-CW MICRO/CW EFM Appendix D - Radio/Modem Installation Guide / D-3...
  • Page 174 4. Open Hyperterminal on the PC and set the PC communication port settings as follows: Bits per second: 19200 Data bits: Parity: None Stop bit: Parity Check: None/Off Carrier Detect: None/Off Flow Control: Xon/Xoff 5. Cycle power to the ControlWave MICRO/ControlWave EFM. The FreeWave configuration menu will appear in Hyperterminal.
  • Page 175 If In Slot #3 Comm. Port Assignments If In Slot #4 6/10 Cover Panel EMI Gasket Figure D4 - MDS Transnet OEM Radio Installation Diagram CI-CW MICRO/CW EFM NOTE: ECOM Module Comm. Ports 4/8 (RS-232) are wired the same as CPU Module Comm.
  • Page 176 To install a MDS Transnet OEM Radio onto an Expansion Comm. Module, perform the following nine (9) steps (referring to Figure D-4): 1. Remove the Expansion Comm. Module from the unit in question (see Figure D1). 2. Grasp the Expansion Comm. Module with one hand. Squeeze both sides of the Cover Panel (just below the unit’s top) and pull up and away to release the Cover Panel and EMI Gasket from the PCB (see Figure D2).
  • Page 177 Parity Check: None/Off Carrier Detect: None/Off Flow Control: Xon/Xoff 4. Cycle power to the ControlWave MICRO/ControlWave EFM. After hitting the escape (Esc) key and then the carriage return twice (at approximately half second intervals), the right arrow (>) will appear. 5.
  • Page 178 Figure D5 - MultiTech Modem Installation Diagram D-8 / Appendix D - Radio/Modem Installation Guide CI-CW MICRO/CW EFM...
  • Page 179 6. Snap the Cover Panel onto the Expansion Comm. Module PCB and insert the ECOM Module into the appropriate Backplane Slot, i.e., Slot 3 or 4. 7. Apply power and test the unit. D2.1.2 Configuring the MultiTech Modem (MT5634SMI) To configure a Model MT5634SMI Modem (installed on an Expansion Communication Module), perform the following nine (9) steps: 1.
  • Page 180 BLANK PAGE...

  • Page 181: Display/Keypad Assembly Guide

    Instruction Manual CI-ControlWave EFM & CI-ControlWave MICRO Oct., 2006 ControlWave EFM/MICRO DISPLAY/KEYPAD ASSEMBLY - GUIDE Appendix E www.EmersonProcess.com/Bristol ControlWave EFM & MICRO...
  • Page 182 ControlWave MICRO/EFM Display/Keypad Assembly Guide SECTION TITLE E1.1 OVERVIEW ... E-1 E2.1 DISPLAY FUNCTION BLOCK DESCRIPTION... E-2 E2.1.1 DISPLAY Function Block Parameters ... E-2 E3.1 PREPARING THE ControlWave PROJECT... E-3 E4.1 USING THE KEYPAD ... E-4 E4.1.1 Scrolling... E-5 E4.1.2 Signing-On ...

  • Page 183: E1.1 Overview

    Appendix E DISPLAY/KEYPAD ASSEMBLY GUIDE E1.1 OVERVIEW Bristol, Inc. Display/Keypad assemblies provide a built-in, local, user interface for the ControlWave MICRO or the ControlWave EFM. These assemblies allow an operator or engineer to view and modify variable values and associated status information, via an ACCOL3 Function Block.

  • Page 184: E2.1 Display Function Block Description

    Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode. Automatic Mode In Automatic Mode a set of screens (based on the application load) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for displaying the screens and responding to key presses.

  • Page 185: E3.1 Preparing The Controlwave Project

    Figure 2 - ACCOL3 DISPLAY Function Block Parameters E3.1 PREPARING THE ControlWave PROJECT In order for the keypad and display to operate, the ControlWave Designer project must include a properly configured Display Function Block. Once the Keypad is operating, a user who has signed on with a password can scroll through the names of variable lists and choose a list to read or change.

  • Page 186: E4.1 Using The Keypad

    Figure 3 - Creating the Identifier Message Step 2: Defining a Scroll List Once the keypad is operating properly, you can automatically scroll through a list of variables created via DISPLAY Function Block Parameters iiList2Scroll and iiListMode. Scrolling can be done without entering a password. The variables in the list are displayed one at a time and in the same order in which they were entered in the variable list.

  • Page 187: E4.1.1 Scrolling

    Note 1 : If your display shows something else, press the [F4] key until you see the words Login and Scroll on the bottom line. If your screen is blank, turn the brightness screw clockwise. This screw is located to the left of the Keypad (looking at the rear of the 25-Button Display/Keypad As- sembly (see Figure 17).

  • Page 188: E4.1.2 Signing-On

    variable name appears on the first line. The variable value appears on the second line and status information appears on the third line. An example is shown in Figure 6. When all variables in the list have been displayed, they will be shown again in the same order.

  • Page 189: E4.1.3 Using The Clock Functions

    Figure 7 - Logging On Once the correct password has been entered, the display will look like Figure 7C. When the second line shows READ/WRITE, you can read and write variable parameters. When it shows READ ONLY you cannot change variable parameters. You are only permit- ted to read variable information.

  • Page 190: E4.1.3.1 Changing The Time

    Figure 8 - Clock Display E4.1.3.1 Changing the Time From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third line. Enter the new time there and press [ENTER]. Valid times range from 00:00:00 to 23:59:59.

  • Page 191: E4.1.5 Moving Through A Variable List

    SCROLL function from the Initial Display. The variable name and value are presented from the Scroll List. This function is available to all users even without signing-on. The List Menu will show other groups of variable which you can choose to read. This in- formation will be more detailed than the Scroll List.
  • Page 192 Before making any changes, first check the signal inhibit status field (See Figure 12). When the display shows ME (manual enable) you can change variable parameters. When it shows MI (manual inhibit), you cannot alter the parameters of this variable. If the field indicates MI, press the OPER I/E key to change it to ME.
  • Page 193 1. Variable Name (Example 1: @GV.FLOW_RATE) (Example 2: @GV.TOTAL_FLOW_RATE) 2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be shown as asterisks. Analog values are displayed in floating point format, for example, 0.0125, 99.627, and 1287.66. When the value cannot be shown in floating point format, scientific format is used (1.287668E+10 or 1.25E-02 for example).

  • Page 194: E4.1.7 Signing-Off

    Notes for Figure 12 (Continued) Variables are shown below as they would appear in SNGL mode. 1) String SITE_NAME WEST SUNBURY PUMP STATION CE ME 2) Analog TOTAL_FLOW_RATE 1260.578 CE MI 3) Logical FLOW_ALARM CE MI AE NA E4.1.7 Signing-Off Once you have logged-on, use the [INIT] key at any time to log-off.

  • Page 195: E5.1 Keypad Identification & Installation Info

    E5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO. 5.50 3.13 1.13 7.38 4.19 4.69 Figure 14 – 25 Button Display/Keypad Assembly Installation Drawing CI-CW MICRO/CW EFM 1.25 2.13 2.00 1.25 .190 .170 .937 Appendix E - Display/Keypad / E-13 5.50 3.25 .313 2.750 TYP.
  • Page 196 Table 1 - 25 Button Keypad Keys Function keys will take on a variety of different functions depending on the F1, F2, F3, situation. The function of these keys is listed on the legend line (bottom line) of the display. INIT The INIT key is used to terminate the keyboard session and sign-off.
  • Page 197 Instruction Manual CI-ControlWave EFM Oct., 2006 Using ControlWave EFM WebBSI Web Pages Appendix F www.EmersonProcess.com/Bristol ControlWave EFM...
  • Page 198 BLANK PAGE...
  • Page 199 ControlWave EFM Using ControlWave EFM WebBSI Web Pages SECTION TITLE GENERAL OVERVIEW ...F-1 F.1.1 Viewing WebBSI ...F-1 INSTALLING WebBSI SOFTWARE & ControlWave EFM Web Pages ...F-1 F.2.1 Communication Connections ...F-2 WebBSI PROGRAM STARTUP...F-3 SECURITY CATEGORY FUNCTIONS ...F-3 F.4.1 Signing On/Off ...F-4 F.4.1.1 Selecting a Node and Signing ON...F-4 F.4.1.2...
  • Page 200 ControlWave EFM Using ControlWave EFM WebBSI Web Pages SECTION TITLE F.6.2 Meter Run I/O Configuration...F-23 F.6.2.1 Differential Pressure, Static Pressure and Temperature Inputs ...F-23 F.6.2.2 Frequency Input ...F-25 F.6.2.3 Heating Value Input...F-25 F.6.2.4 Alarm Configuration (Accessed via Meter Run I/O Configuration)...F-27 F.6.3 Flow Equations ...F-27 F.6.3.1...

  • Page 201: General Overview

    Using ControlWave EFM F.1 GENERAL OVERVIEW The ControlWave EFM is configured and monitored using WebBSI Web pages developed specifically for the standard application program. The Web pages are stored and displayed on a personal computer (PC), and use either OpenBSI Network edition or Local edition to interface to the ControlWave EFM.

  • Page 202: Communication Connections

    Control Wave Figure F-1 - ControlWave EFM Connected to PC via the Local Communications Cable F.2.1 Communication Connections The ControlWave EFM communicates with the PC through the Local Port as shown in Figures F-1 through 2B. The Local Port has been provided specifically for installation, startup and on-site configuration and data collection.

  • Page 203: Webbsi Program Startup

    Figure F-2B - PC Connected to ControlWave EFM (via Circular Local Port) Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable F.3 WebBSI PROGRAM STARTUP Ensure that the Local Communications Cable connections (at both the ControlWave EFM &...

  • Page 204: Signing On/Off

    F.4.1 Signing On/Off When the WebBSI Web pages for the ControlWave EFM are first accessed, the SIGN On/Off Web page is displayed. A user must select the RTU Name from the drop down menu. If using OpenBSI Network Edition, this drop down menu will include all nodes available on the network.

  • Page 205: Contacts

    The Node Locator Web page is accessible by clicking on the Security category button and choosing the Locate Nodes drop-down menu selection. Figure F-4 - Locate Nodes Web Page F.4.3 Contacts A list of Bristol Inc. offices is provided under the topic Contacts. The Contacts Page is accessible by clicking on the Security category button and choosing the Contacts drop-down menu selection.

  • Page 206: Sampler And Odorizer Configuration

    Figure F-5 - Station Summary Web Page F.5.2 Sampler and Odorizer Configuration See section F.5.2.1 for Sampler Configuration or F.5.2.2 for Odorizer Configuration. F.5.2.1 Sampler Configuration The user may enable or disable the Sampler by using the Enable/Disable button. If enabled, the Sampler will operate at a frequency set by the Pulse Frequency setpoint (in cubic feet).

  • Page 207: Mechanical Counter Configuration

    When the Digital Output Mode is used, the user must enter the frequency of the pulses per volume through the meter (in cubic feet). Figure F-6 - Sampler & Odorizer Configuration Web Page F.5.3 Mechanical Counter Configuration The Mechanical Counter Configuration section of the Sampler & Mechanical Counter Configuration Web Page is used to simulate a mechanical counter.

  • Page 208: Nomination

    Figure F-8 - Nomination Web Page F.5.4 Nomination Users configure the nominations control from the Nomination WebPage. Nominations functionally provide the user with the ability to set the ControlWave EFM to allocate precise amounts of gas flow during specific time periods. These periods are called “nomination periods.”...

  • Page 209: Nomination Operation

    arrive at the target (volume or energy) as quickly as possible without regard to the programmed end time. Flow Control The Flow Control method internally enables the PID flow control algorithm in order to hit the target volume/energy at exactly the programmed end time. The user programs the ControlWave EFM t(via the ‘Stop Mode’...
  • Page 210 this signal to end an in progress nomination immediately, or to start the next period immediately (see Manually Starting/Ending a Nomination Period). Stop Mode The Stop mode selection allows the user to automatically have the valve closed, i.e., shut-in on stop mode, or left in the last position upon reaching the target (or programmed end period).

  • Page 211: Beginning A Nomination Period

    Percent Delivered This signal provides the percentage of target delivered to this point in the current nomination period. NEXT NOMINATION PERIOD - This section allows the operator to set/view the following parameters associated with the next nomination which is to be programmed (has been programmed): Note: New entries must be made prior to the ending of the current nomination period.

  • Page 212: Ending A Nomination Period

    F.5.4.1.3 Ending a Nomination Period If shut-in on stop mode is in use, the current period will end when the target accumulation is reached. At this time, the ControlWave EFM attempts to close the control valve. If PID control is being used, the setpoint is set to 0.0, the current cycle will ramp down accordingly.
  • Page 213 property damage, and injury to persons. When setting the WebBSI Web Page parameters, make sure the associated process is observed and protected. Figure F-9 - Flow Control & Valve Control Web Page Setpoint (x1000) This field contains the operating point at which the flow rate is to be controlled. Set-point units are MSCFH with a default setting of 1000 MSCF per Hour.

  • Page 214: Pressure Override (Set One Or Both To Enable Override

    Max Flow Rate (x1000) Max Flow Rate represents the maximum flow rate allowed. If the number entered in the Setpoint field exceeds the Max Flow Rate value, the Max Flow Rate value will be used. To change the Max Flow Rate (x1000) value, right click on the field and select Change Signal Value.

  • Page 215: Run Switching

    entering a new value. When the mode is changed back to Automatic, the valve control starts from the last Manual value entered for Bumpless transfer. If the user selects Raise Lower Mode, the DO associated with raising the valve must be selected and a separate DO must be selected for lowering the valve.
  • Page 216 Figure F-10 - Run Switching Web Page F-16 / Appendix F CI-ControlWave EFM...

  • Page 217: Radio Control

    F.5.7 Radio Control The Radio Control Configuration Web Page is accessible for users by selecting Radio Control. Figure F-11 - Radio Control Web Page CI-ControlWave EFM Appendix F / F-...

  • Page 218: Radio Control Mode

    F.5.7.1 Radio Control Mode Enable/Disable Radio Control via a control button to the right of Radio Control Mode. F.5.7.2 Common Properties Local Address Local Address of the ControlWave EFM is set via the RTU Configuration Parameters Page in NETVIEW or LOCAL VIEW. Group Number Group Address of the ControlWave EFM.

  • Page 219: Daily Mode

    Re-Calculate Next On Time If the user makes any changes to the items that affect the On Time, it must re-calculate the Next On Time using this button. Next On Time Hour/Minute/Second When the Radio Control Mode is selected for Hourly, Daily or Daylight, these values represent the next time that the radio will be turned on.

  • Page 220: Aga3 - Orifice Meter

    Figure F-12 - Meter Run Type Configuration WebPage F.6.1.1 AGA3 - Orifice Meter If the meter is configured as an Orifice Meter the following Read Only items are displayed: Pipe Diameter & Orifice Diameter – To change these items, select Flow Equation from the left side menu section.
  • Page 221 Figure F-13B - Meter Run Overview (1992 AGA3 – Orifice Meter) Web Page DP (Differential Pressure), SP (Static Pressure) and T (Temperature) – Live Values from the Transmitters being used for calculation (selected via the I/O Configuration Page). Active Flow Calculation – (AGA3I (1992) or AGA3 (1985) – To change an item, select Flow Equation from the left side menu section.

  • Page 222: Aga7 Frequency Meter

    Reset Meter Run’s Measurement Type – This button (bottom of menu) allows the user to reset the meter run’s measurement type (if a mistatke hass occurred during configuration). F.6.1.2 AGA7 Frequency Meter If the meter is configured as a Linear Meter, following Read Only items are displayed: Active Flow Calculation –...

  • Page 223: Meter Run I/O Configuration

    There are five fields that allow the user to make changes: Contract Hour – Users enter the Contract Hour for the start of the Contract Day here. Current Heating Value (Units) – The user may select the Heating Value units from a drop down menu;...
  • Page 224 If a Zeros & Spans Button is pressed an Analog Input Configuration Web Pge Menu will appear (see Figure F16A). Zero, Span and Units can be configured for analog inputs 1 through 3. The Analog Input Configuration Web Page also allows the user to enable/disable the Damping function.

  • Page 225: Frequency Input

    F.6.2.2 Frequency Input The frequency input must be brought into one of the two high-speed counter (HSC) inputs on the I/O board. Users select the two I/O points to which the typical turbine, PD, or ultrasonic meter is connected. However; if using an Invensys Auto-Adjust Turbo-Meter, both HSC inputs are used to select the Auto-Adjust Algorithm.
  • Page 226 AGA5 is selected when the component mole % values are fed into the AGA5 equation. Source of the component mole % values is determined by settings made on the Chromatograph Setup Page. Figure F-16B - Auto-Adjust Configuration for Run# Web Page (Accessed from Meter Run I/O Configuration Web Page) F-26 / Appendix F CI-ControlWave EFM...

  • Page 227: Alarm Configuration (Accessed Via Meter Run I/O Configuration

    F.6.2.4 Alarm Configuration (Accessed via Meter Run I/O Configuration) Figure F-17 - Alarm Configuration Web Page (Accessed from Meter Run I/O Configuration Web Page) Enable/Disable - the alarm function on a per point basis. Units and Current Value - are read from the I/O source. Alarm Limit - are set via the appropriate alarm limit point.

  • Page 228: 1985 Aga3 Equation Configuration

    (1992) equation by toggling the push button labeled Click Here to select AGA3I (1992). F.6.3.1.2 1985 AGA3 Equation Configuration The user must configure the inputs to the equation. Pressure Tap – The user must select Pressure Tap type and location. The type is defined Flange or Tap and the location is defined as Upstream or Downstream.

  • Page 229: 1992 Aga3 Equation Configuration

    FPV - Supercompressibility Factor (FPV) is displayed here. Base Temperature - Required or Contract Base Temperature is entered here (Deg. F). Base Pressure - Required or Contract Base Pressure is entered here (psig). The following outputs from the AGA3 calculation are displayed: MSCF/H - Flow rate in thousands of standard cubic feet per hour Low Flow Cut Off - Cutoff (if the DP drops below the low flow cut off value) or OK C Prime - Orifice Flow Constant...
  • Page 230 Figure F-18B - (1992 AGA3) Orifice Flow Equation Setup Web Page Adjust Press. - Users enter Average Barometric Pressure here (psia). Diff. Press. - Actual value in use is displayed here. Static Pressure - Actual value in use is displayed here. Temperature - Actual value in use is displayed here.

  • Page 231: Frequency Flow Equation Setup

    Y - Expansion Factor Fpb - Pressure Base Factor Ftb - Temperature Base Factor Ftf - Flowing Temperature Facture Fpv - Supercompressibility Factor Fm - Additional Correction Factor Extension - Square Root of the product of Diff. Pressure and Static Pressure ( Reynolds Number - Computed Pipe Reynolds Number BCF - Base Correction (Zb/Zf) F.6.3.2 Frequency Flow Equation Setup...

  • Page 232: Supercompressibility Setup

    Density Switch - Users may select whether a density meter or Gravitometer is used as an input to the equation. Gravitometer Press. Switch - Users may save the default value for Pressure or Volume entered in the Gravitometer Press. Used field. Gravitometer Temp.
  • Page 233 If the Base Pressure or Base Temperature differ from Standard conditions (14.73 psia, 60 ºF) and the 1992 AGA3 calculation is in use, an AGA8 Detail or AGA8 Gross module will be executed to calculate standard compressibility Zs for the defined gas composition. The calculation of Zs will be done once per minute or whenever a related gas constant changes.

  • Page 234: Chromatograph Category Functions

    F.7 CHROMATOGRAPH CATEGORY FUNCTIONS The standard application program is configured for communicating with a Daniel 2251 Gas Chromatograph, via a serial MODBUS interface. Users will configure the Chromatograph interface from the “Chromatograph Setup” Web Page (Figure F-21). Figure F-21 - Chromatograph Setup Web Page F-34 / Appendix F CI-ControlWave EFM...

  • Page 235: Communication Settings

    F.7.1 Communication Settings Mode – Enabled/Disabled - When this signal is ENABLED, a chromatograph is present, and gas component data is provided by the chromatograph interface. When this signal is DISABLED, the fixed values for the gas component data are used. Common Fixed Data - When COMMON is selected fixed chromatograph values for all runs will come from the Stream 1 fixed values.

  • Page 236: Logs Category Functions

    Figure F-22 - Chromatograph Component Range Setup Web Page F.8 LOGS CATEGORY FUNCTIONS Two WebBSI Web Pages are accessible under the Logs Category Section of WebBSI; these are: • View Archives (Section F.8.1) • View Audit Trail (Section F.8.2) • View Signal List (Section F.8.3) •...

  • Page 237: Meter Run Archive Files

    F.8.1 Meter Run Archive Files When View Archive has been selected, the Meter Run Archive Files WebBSI Web Page will be displayed (see Figure F-23). Meter Run Archive Files Web Pages provide three types of archive files, i.e., Hourly, Daily & 15 Minute for each of the four runs. Figure F-23 - Meter Run Archive File Web Page (Hourly Archive Shown) Meter Run Archive File Web page pushbuttons allow the user to Collect Data, Save Parameters, Search Criteria, select Floating Point Format and show File Definition.

  • Page 238: View Signal List

    By clicking on the Floating Point Format button, the user may change the way Analog Values are displayed. By clicking on the File Definition button, the user can view how the archive file is configured. Additionally, the Meter Run Archive Web page provides the number of Fields Collected and Records Collected under the Stats field.

  • Page 239: Archive File Collection

    Figure F-25 - Signal List Web Page F.8.4 Archive File Collection When Collection is selected, an Archive File Collection Web Page (see Figure F.26) will be displayed. Log Break Configuration buttons are provided on the Archive File Collection Web Page to enable/disable log breaks for configuration changes and Gas Chromatograph operation and configuration.

  • Page 240: Load/Save Category Function

    F.9 LOAD/SAVE CATEGORY FUNCTION One WebBSI Web page is accessible under the Load/Save Category Section of WebBSI; this is called the Meter Run Save/Load Configuration Web page (see Figure F.27). This page allows a user to save configuration parameters from a ControlWave EFM or load a saved configuration down to a ControlWave EFM.

  • Page 241: Special Functions

    A user may download a previously saved configuration to the ControlWave EFM. Users would select the file to download to the unit by clicking on the Browse button to locate it. A user would then click on Load from File. This will update the recipe with the information from the file.
  • Page 242 Figure F-28 - Sync Date & Time Web Page Display F-42 / Appendix F CI-ControlWave EFM...
  • Page 243 Instruction Manual CI-ControlWave EFM Oct., 2006 ControlWave EFM RADIO READY INSTALLATION GUIDE Appendix G www.EmersonProcess.com/Bristol ControlWave EFM (P/N 721700-01-2)
  • Page 244 ControlWave EFM Radio Ready Installation Guide SECTION TITLE G1.1 GENERAL INTRODUCTION... G-1 G2.1 RADIO INSTALLATION ... G-2 G2.1.1 Installation of a Radio into a Radio Ready ControlWave EFM ... G-2 G2.2 ADDITIONAL FreeWave INFORMATION ... G-5 CI-ControlWave EFM APPENDIX G TABLE OF CONTENTS Appendix G - Radio Ready Installation Guide Contents / 0 - 1 PAGE #...

  • Page 245: G1.1 General Introduction

    Appendix G RADIO READY INSTALLATION GUIDE G1.1 GENERAL INTRODUCTION ControlWave EFM Electronic Flow Meters may be ordered "Radio Equipped," or “Radio Ready.” Radio Ready units contain all hardware required to field install a Bristol provided radio except the radio and radio installation hardware (such as screws, nuts and washers. Radio Ready units will include either an Internal RF Radio Cable with Bulk Head Antenna Connector or an Internal RF Radio Cable that mates to an optional Polyphaser (Surge/Impulse Suppresser).

  • Page 246: G2.1 Radio Installation

    G2.1 RADIO INSTALLATION Radios provided by Bristol, Inc. for use in the ControlWave EFM Electronic Flow Meters are approved for use in Class I, Division 2, Groups A, B, C & D hazardous locations. Radios may also be used in non- hazardous locations.
  • Page 247 Figure 1 - Radio Installation - Mounting Diagram CI-ControlWave EFM Appendix G - Radio Ready Installation Guide / G-3...
  • Page 248 Figure 2 - Radio Mounting Bracket - Radio Installation Diagram 7. Plug the Radio Interface Cable into the radio’s Comm. Port. The other end of this cable should already be installed into Comm. Port 2. of the CPU Module. In the case of the FreeWave Radio, power is also supplied via the Interface Cable.

  • Page 249: G2.2 Additional Freewave Information

    Figure 3 - Partial View - ControlWave EFM with/without Polyphaser Installed G2.2 ADDITIONAL FreeWave INFORMATION The FreeWave Spread Spectrum Data Transceiver Model FGRM-501X005 User Manual contains in-depth details on modem parameters, operation, installation, tuning transceiver performance, and more. Copies of the FreeWave Spread Spectrum Data Transceiver Model FGRM-501X005 User Manual can be obtained from FreeWave Technologies, Inc.
  • Page 250 Table 1 - Setup Menu Terminal Settings Baud Rate Data Rate Parity Stop Bits Parity Check Carrier Detect Figure 4 - Cable Diagram for Radio to PC Interface G-6 / Radio Ready Installation Guide PARAMETER SETTING 19,200 None None/Off None/Off CI-ControlWave EFM...
  • Page 251 Material Safety Data Sheets A Material Safety Data Sheet is provided herein to comply with OSHA’s Hazard Com- munication Standard, 29 CFR 1910.1200. This standard must be consulted for specific requirements. Material Safety Data Sheets are provided in the order listed in Table Z-1 below. MSDS for ControlWave EFM Instruction Manual Manufacturer General Description...
  • Page 252 BLANK PAGE...
  • Page 253 Gillette Environment Health and Safety MATERIAL SAFETY DATA SHEET NAME: DURACELL LITHIUM MANGANESE DIOXIDE COIN BATTERIES CAS NO: Not applicable A. — IDENTIFICATION Manganese Dioxide (1313-13-9) Propylene Carbonate (108-32-7) Lithium (7439-93-2) Graphite, synthetic (7440-44-0) 1,2-Dimethoxyethane (110-71-4) Lithium Perchlorate (7791-03-9) B. — PHYSICAL DATA Boiling Point °...
  • Page 254 D. — HEALTH HAZARD DATA Occupational Exposure Limits PEL’s, TLV’s, etc.) 8-Hour TWAs: Manganese Dioxide (as Mn) - 5 mg/m 1,2-Dimethoxyethane - 0.15 ppm (Gillette) Graphite (all kinds except fibrous) - 2 mg/m These levels are not anticipated under normal consumer use conditions. Warning Signals Not applicable Routes/Effects of Exposure...
  • Page 255 Page 3 of 4 F. — EXPOSURE CONTROL METHODS Engineering Controls General ventilation under normal use conditions. Eye Protection None under normal use conditions. Wear safety glasses when handling leaking batteries. Skin Protection None under normal use conditions. Use butyl gloves when handling leaking batteries. Respiratory Protection None under normal use conditions.
  • Page 256 H. — EMERGENCY PROCEDURES Steps to be taken if material is released to the environment or spilled in the work area Evacuate the area and allow vapors to dissipate. Increase ventilation. Avoid eye or skin contact. DO NOT inhale vapors. Clean-up personnel should wear appropriate protective gear. Remove spilled liquid with absorbent and contain for disposal.
  • Page 257 MATERIAL SAFETY DATA SHEET SECTION 1: PRODUCT AND MANUFACTACTURER Product name: Sealed maintenance-free lead acid batteries Manufacturer: B.B. Battery Co., Ltd. Address: Chengdong Trial Area, Huanggang, Raoping, Guangdong, P.R.China 515700 Tel: +86-768-7601001 or +86-768-7601002 Fax: +86-768-7601469 US Office: B&B Battery USA, Inc. Address: 6415 Randolph Street, Commerce, CA 90040 Tel: 323-278-1900 Fax: 323-278-1268...
  • Page 258 SECTION 4: PROTECTION EXPOSURE PROTECTION SKIN Rubber gloves, Apron, Safety shoes Protective equipment must be worn if battery is cracked RESPIRATORY Respirator (for lead) EYES Safety goggles, Face Shield SECTION 5: FLAMMABILITY DATA COMPONENTS FLASHPOINT EXPLOSIVE LIMITS COMMENTS Lead None None Sulfuric Acid None...
  • Page 259 SECTION 7: CONTROL MEASURES 1. Store lead/acid batteries with adequate ventilation. Room ventilation is required for batteries utilized for standby power generation. Never recharge batteries in an unventilated, enclosed space. 2. Do not remove vent caps. Follow shipping and handling instructions that are applicable to the battery type. To avoid damage to terminals and seals, do not double-stack industrial batteries.
  • Page 260 SECTION 9: SULFURIC ACID PRECAUTIONS INHALATION: Acid mist form formation process may cause respiratory irritation, remove from exposure and apply oxygen if breathing is difficult. SKIN CONTACT: Acid may cause irritation, burns or ulceration. Flush with plenty of soap and water, remove contaminated clothing, and see physician if contact area is large or if blisters form.
  • Page 261 Supplement Guide - S1400CW Issue: 04/05 SITE CONSIDERATIONS EQUIPMENT INSTALLATION, GROUNDING & WIRING A Guide for the Protection of Site Equipment & Personnel In the Installation of ControlWave Process Automation Controllers Bristol Babcock...
  • Page 262 NOTICE Copyright Notice The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol Babcock assumes no responsibility for any errors that may appear in this document. Request for Additional Instructions Additional copies of instruction manuals may be ordered from the address below per attention of the Sales Order Processing Department.
  • Page 263 Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE GENERAL INTRODUCTION ... 1-1 MAJOR TOPICS ... 1-1 PROTECTING INSTRUMENT SYSTEMS... 2-1 2.1.1 Quality Is Conformance To Requirements... 2-1 PROTECTING EQUIPMENT & PERSONNEL ... 2-1 2.2.1 Considerations For The Protection of Personnel ...
  • Page 264 Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE Section 5 - WIRING TECHNIQUES (Continued) 5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation)... 5-2 5.2.3 Grounding of Cable Shields..5-3 5.2.4 Use of Known Good Earth Grounds ...

  • Page 265: Section 1 - Introduction

    Section 1 - Overview 1.1 INTRODUCTION This document provides information pertaining to the installation of ControlWave systems; more specifically, information covering reasons, theory and techniques for protecting your personnel and equipment from electrical damage. Your instrument system affects the quality of service provided by your company and many aspects of its operational safety.

  • Page 266: Section 2 - Protection

    Section 2 - Protection 2.1 PROTECTING INSTRUMENT SYSTEMS Electrical instrumentation is susceptible to damage from a variety of natural and man made phenomena. In addition to wind, rain and fire, the most common types of system and equipment damaging phenomena are lightning, power faults, communication surges & noise and other electrical interference’s caused by devices such as radios, welders, switching gear, automobiles, etc.

  • Page 267: Considerations For The Protection Of Personnel

    2.2.1 Considerations For The Protection of Personnel Always evaluate the site environment as if your life depended on it. Make sure that you understand the physical nature of the location where you will be working. Table 2-1 provides a general guideline for evaluating an installation site. Table 2-1 - Installation Site Safety Evaluation Guide Indoor or outdoor –...

  • Page 268: Other Site Safety Considerations

    Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued) Is there an antenna in the immediate area? How close is other equipment? Can someone safely touch this equipment and a ControlWave simultaneously? Determine equipment ground requirements. How will the ControlWave and its related wiring be grounded? Consider Earth Ground, Circuit Ground, Conduit Ground, Site Grounds! Are there any obviously faulty or questionable power or ground...

  • Page 269: Section 3 - Grounding & Isolation

    Section 3 - Grounding & Isolation 3.1 POWER & GROUND SYSTEMS ControlWaves utilize DC power systems. AC power supplies are not provided with Con- trolWave units. ControlWave, ControlWave MICRO, ControlWave EFM/GFC/EFC, ControlWaveRED, ControlWaveREDIO and ControlWave I/O Expansion Racks are provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing a connection to Earth Ground.

  • Page 270: Soil Conditions

    not be suitable for a complex system of sophisticated electronic equipment. Conditions such as soil type, composition and moisture will all have a bearing on ground reliability. A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into conductive earth to a depth of about 7-feet as shown in Figure 3-1.
  • Page 271 ground has been established, it should be tested on a regular basis to preserve system integrity. Figure 3-2 - Basic Ground Bed Soil Test Setup Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5 ohms, the ground is good.

  • Page 272: Dry, Sandy Or Rocky Soil

    Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is indicated, one or more additional ground rods connected 10 feet from the main ground rod should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x ¼-20 cable clamps as illustrated in Figure 3-3).

  • Page 273: Ground Wire Considerations

    Figure 3-5 - Poor Soil Ground Bed Construction Diagram 3.3.2 Ground Wire Considerations ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, Control- WaveRED, ControlWave REDIO & ControlWave I/O Expansion Rack ControlWave Chassis are provided with a Ground Lug that accommodates up to a #4 AWG wire size.

  • Page 274: Other Grounding Considerations

    Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground Bus. The panel, lug or bus in turn must be connected to a known good Earth Ground via a #4 AWG wire.

  • Page 275: Isolating Equipment From The Pipeline

    For applications employing equipment that communicates over telephone lines, a lightning arrester Must Be provided. For indoor equipment the lightning arrester must be installed at the point where the communication line enters the building as shown in Figure 3-6. The ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.

  • Page 276: Meter Runs With Cathodic Protection

    grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely mounted, connect their chassis grounds to the pipeline or earth ground. Figure 3-8 - ControlWave EFM (Installation is similar to GFC/XFC) Remote Installation without Cathodic Protection 3.4.2 Meter Runs With Cathodic Protection Dielectric isolators are available from Bristol Babcock and are always recommended as an added measure in isolating the ControlWave EFM/GFC/XFC from the pipeline even though the ControlWave EFM/GFC/XFC does provide 500V galvanic isolation from the...
  • Page 277 • all conductive tubing that runs between the pipeline and mounting valve manifold and/or the units multivariable pressure transducer • all conductive connections or tubing runs between the ControlWave EFM/GFC and turbine meter, pulse transducer, or any input other device that is mounted on the pipeline •...
  • Page 278 See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds. Figure 3-10 – ControlWave EFM (Installation is similar to GFC/XFC) Remote Installation (with Cathodic Protection) S1400CW Page 3-10 Section 3 - Grounding & Isolation...

  • Page 279: Section 4 - Lightning Arresters & Surge Protectors

    Section 4 - Lightning Arresters & Surge Protectors 4.1 STROKES & STRIKES Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will average 18 KA for the first impulse and about half of that for the second and third impulses.
  • Page 280 Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the United States there is an average of 30 thunderstorm days per year. Any given storm may produce from one to several strokes. Data on the subject indicates that for an average area within the United States there can be eight to eleven strokes to each square mile per year.

  • Page 281: Antenna Caution

    modem has been interfaced to a ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP, or ControlWaveEXP the possibility of damage due to a lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower must be considered. It is recommended that the additional lightning protection considerations listed below be followed for units installed in areas with a high possibility or history of stroke activity.
  • Page 282 Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram For all systems it is best to have all communication equipment input/output grounds tied together. In the case of ControlWave units, this is accomplished via the unit’s Chassis Ground (Typically at a ground lug, ground bus or ground plate). However additional S1400CW Page 4-4 Section 4 - Lightning &...

  • Page 283: Ground Propagation

    communication equipment lightning arresters and surge suppressors should be tied to the same system ground. System ground consists of the tower leg grounds utility ground and bulkhead-equipment ground-stakes that are tied together via bare copper wire. 4.1.3 Ground Propagation As in any medium, a dynamic pulse, like R.F., will take time to propagate. This propagation time will cause a differential step voltage to exist in time between any two ground rods that are of different radial distances from the strike.

  • Page 284: Use Of Lightning Arresters & Surge Protectors

    i Watch out for dissimilar metals connections and coat accordingly. i Use bare wire radials together where possible with ground stakes to reduce ground system impedance. i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground system.

  • Page 285: Section 5 - Wiring Techniques

    Section 5 - Wiring Techniques 5.1 OVERVIEW This section provides information pertaining to good wiring practices. Installation of Power and “Measurement & Control” wiring is discussed. Information on obscure problems, circulating ground and power loops, bad relays, etc. is presented. Good wire preparation and connection techniques along with problems to avoid are discussed.

  • Page 286: Use Of Twisted Shielded Pair Wiring (With Overall Insulation)

    Figure 5-1 - Field Wired Circuits With & Without A Common Return 5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation) For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly recommended. This type of cable provides discrete insulation for each of the wires and an additional overall insulated covering that provides greater E.M.I.

  • Page 287: Grounding Of Cable Shields

    5.2.3 Grounding of Cable Shields DO NOT connect the cable shield to more than one ground point; it should only be grounded at one end. Cable shields that are grounded at more than one point or at both ends may have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O signals.

  • Page 288: High Power Conductors And Signal Wiring

    Remember loose connections, bad connections, intermittent connections, corroded connec- tions, etc., are hard to find, waste time, create system problems and confusion in addition to being costly. 5.2.7 High Power Conductors and Signal Wiring When routing wires, keep high power conductors away from signal conductors. Space wires appropriately to vent high voltage inductance.

  • Page 289: Secure Wiring Connections

    Discharge Units should be placed on the base of the antenna and at the point where the antenna lead (typically coax) enters the site equipment building. When a modem is used, a lightning arrester should be placed at the point where the phone line enters the site equipment building.
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  • Page 291 Please help us make our documentation more useful to you! If you have a complaint, a sug- gestion, or a correction regarding this manual, please tell us by mailing this page with your comments. It's the only way we know we're doing our job by giving you correct, complete, and useful documentation.
  • Page 292 U.S.A. Locations: Northern Region Gulf Coast Region Bristol Babcock Inc. Bristol Babcock Inc. 1100 Buckingham Street 2000 Governor's Circle Watertown, CT 06795 Suite F Phone: +1 (860) 945-2381 Houston, TX 77092-8731 Fax: +1 (860) 945-2525 Phone: +1 (713) 685-6200 NorthernUS@bristolbabcock.com Fax: +1 (713) 681-7331 SouthwestUS@bristolbabcock.com Helicoid Instruments...

  • Page 293: Care And Handling Of Pc Boards And Esd-Sensitive Components

    ESDS Manual S14006 4/15/92 CARE AND HANDLING PC BOARDS ESD-SENSITIVE COMPONENTS BRISTOL BABCOCK...
  • Page 294 BLANK PAGE...
  • Page 295 TOOLS AND MATERIALS REQUIRED ESD-SENSITIVE COMPONENT HANDLING PROCEDURE Introduction General Rules Protecting ESD-Sensitive Components Static-Safe Field Procedure Cleaning and Lubricating Completion TOOLS AND MATERIALS REQUIRED Tools Anti-Static Field kit. It is recommended that an anti-static field kit be kept on any site where solid-state printed circuit boards and other ESD-sensitive compo- nents are handled.

  • Page 296: Esd-Sensitive Component Handling Procedure

    ESDS Manual #S14006 4/15/92 Materials Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent) Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent) Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent) ESD-SENSITIVE COMPONENT HANDLING PROCEDURE Introduction Microelectronic devices such as PC boards, chips and other components are electro- static-sensitive.

  • Page 297: General Rules

    Means of Static Generation Walking across carpet Walking over vinyl floor Worker at bench Vinyl envelopes for work instructions Poly bag picked up from bench Work chair padded with poly foam General Rules ESD-sensitive components shall only be removed from their static-shielding bags by a person who is properly grounded.
  • Page 298 ESDS Manual #S14006 4/15/92 It is important to note when inserting EPROMS/PROMS, that the index notch on the PROM must be matched with the index notch on the socket. Before pushing the chip into the socket, make sure all the pins are aligned with the respective socket-holes.

  • Page 299: Protecting Esd-Sensitive Components

    Don't place ESD-sensitive components and paperwork in the same bag. The static caused by sliding the paper into the bag could develop a charge and Include a note, which describes the malfunction, in a separate bag along with each component being shipped. The repair facility will service the component and promptly return it to the field.

  • Page 300: Static-Safe Field Procedure

    ESDS Manual #S14006 4/15/92 Note: If a system checker is not available, use an ohmmeter connected to the cable ends to measure its resistance. The ohmmeter reading should be 1 megohm +/- 15%. Be sure that the calibration date of the ohmmeter has not expired. If the ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a new one.
  • Page 301 The components can now be handled following the general rules as described in the instruction manual for the component. Place the component in a static-shielding bag before the ground cord is disconnected. This assures protection from electrostatic charge in case the work surface is located beyond the reach of the extended ground cord.

  • Page 302: Cleaning And Lubricating

    ESDS Manual #S14006 4/15/92 If a component is to undergo on-site testing, it may be safely placed on the grounded work surface for that purpose. (10) After all component work is accomplished, remove the wrist straps and ground wire and place in the pouch of the work surface for future use. Cleaning And Lubricating The following procedure should be performed periodically for all PC boards and when a PC board is being replaced.
  • Page 303 Clean PC board connectors as follows: Review the static-safe field procedure detailed earlier. Following the ESD-sensitive component handling procedures, remove the connectors from the boards and remove the PC boards from their holders. Use cleaner to remove excessive dust build-up from comb connectors and other connectors.

  • Page 304: Completion

    ESDS Manual #S14006 4/15/92 Spray the connector liberally to flush out any contaminants. Remove any excess spray by shaking the connector or wiping with either a toothbrush, or a lint-free wiping cloth. Completion Replace any parts that were removed. Make sure that the component cover is secure. Return the system to normal operation.
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  • Page 306 ControlWave EFM (Electronic Flow Meter) Emerson Process Management Bristol, Inc. 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2262 Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol Emerson Electric Canada, Ltd. Bristol Canada 6338 Viscount Rd. Mississauga, Ont. L4V 1H3 Canada Phone: 905-362-0880 Fax: 905-362-0882 www.EmersonProcess.com/Bristol...

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