ControlWave® Intrinsically Safe Gas Flow Computer

CWGFC-IS
Product Data Sheet
D301635X012
October 2011
ControlWave® Intrinsically Safe Gas Flow
Computer (GFC-IS)
The ControlWave® Intrinsically Safe Gas Flow Computer
(GFC-IS) is an intrinsically-safe integrated “all in one box”
chart replacement. The intrinsically safe features of the
ControlWave GFC-IS are designed to prevent sparks or a
release of energy that could ignite a hazardous atmosphere.
The GFC-IS is UL approved as non-incendive for operation in
Class I, Division 1 hazardous areas.
The GFC-IS is delivered in a compact polycarbonate enclosure
that has provisions for a display/keypad, DP/P/T transducer
assembly, and 6 Volt battery/solar power system. The GFC-IS
includes a base API 21.1 flow measurement application
program, 2 user-configurable digital inputs (DI) or pulse
inputs (PI), a DP/P sensor assembly, an RTD interface, and a
shunt regulator for solar panel charging of an internal, lead
acid cell battery.
The CPU and I/O boards are located behind a shield in the
enclosure and all wiring termination blocks are on a
termination panel. You must wire all connections from the
terminal panel or from the ISProx board out through a
conduit on the right side of the GFC-IS enclosure in order to
preserve the integrity of the intrinsically-safe rating.
Hardware
ƒ
32-bit ARM9 platform capable of dual-run flow
computing and process automation operations
ƒ
Gauge pressure or DP/P sensor assembly can be
removed and replaced independently of the electronics
ƒ
Precision RTD interface provides accurate temperature
measurement
ƒ
Low power consumption minimizes costs
ƒ
Two serial communication ports
ƒ
Base I/O includes 2 DI/PI
ƒ
Optional I/O expansion includes 2 DI/DO, 4 DI, 2 DO,
2 High-speed Counter Inputs, and 3 AI (1-5 V)
Application Areas
The GFC-IS is appropriate to all flow computer and chart
replacements applications, including:
ƒ
Off-shore platforms
ƒ
Compressor stations
ƒ
Storage facilities
ƒ
Transmission metering stations
ƒ
Distribution/LDC metering/gate stations
ControlWave Intrinsically Safe
Gas Flow Computer
Communications
The GFC-IS has two built-in RS-232 communication ports and
one RS-485 port. One RS-232 port (Com 1) is factory wired to
the LOI port of the bottom of the GFC-IS enclosure.
Inputs and Outputs
The GFC-IS supports a variety of I/O options. The base unit
includes two I/O ports that are user-configurable as digital
inputs (DI) or pulse inputs (PI). Additional I/O modules may be
added including:
ƒ
2 DI/DO, 4 DI, 2 DO, 2 HSC, and 3 AI
ƒ
2 DI/DO, 4 DI, 2 DO, and 2 HSC
ƒ
RTD Input
Display/Keypad
The GFC-IS display is comprised of a four line by twenty
character liquid crystal display with adjustable contrast. The
display allows you to view and modify variable values and
associated status information via an ACCOL3 Function Block.
Variables include inputs, process variables, calculated variables,
constants, setpoints, tuning parameters, outputs, and alarm
state.
You can input data into the GFC-IS via a 2-button or 25-button
keypad. Each key on both keypads has a microswitch for
positive tactile feedback.
Remote Automation Solutions
CWGFC-IS
October 2011
IStran
Data Integrity
The IStran is the communications interface that allows the
GFC-IS to communicate with devices located outside of the
hazardous area. The IStran provides 500 V dc isolation
between the two devices, and also allows the GFC-IS to
receive power from outside the hazardous location. The
IStran allows the GFC-IS to control power to a radio or
modem located outside the Division 1 area, and operates at
up to 19200 bps.
The GFC-IS ensures data integrity, in the event of a
communication interruption, by storing critical time-stamped
alarm and historical data in the controller memory. This data is
then retrieved when communication is restored.
ISProx
The Intrinsically Safe Proximity Sensor Interface (ISProx)
provides an intrinsically safe interface to one or two variable
impedance proximity sensors (NAMUR Gap Sensors). The
ISProx conditions and converts incoming signals to open
drain outputs (DOs) which in turn drive digital inputs (DIs) or
high-speed counter inputs (HSCs).
TeleCounter
The TeleCounter is an optional pulse counting device and
odometer. The integrated TeleCounter assembly directly
mounts to a rotary positive displacement meter, and is
mounted to the bottom of the GFC-IS enclosure by a water
tight gasket. The TeleCounter can be configured to accept a
clockwise or counterclockwise turbine meter shaft rotation
with index rates of 1, 5, 10, 100, 1000 CF/Rev or 0.1, 1, 10,
100 M3/Rev.
Firmware/Software Features
ControlWave GFC is pre-programmed to meet API 21.1
requirements for a two-run metering station with
networking via BSAP or Modbus. Web-style menu pages are
pre-configured for all user operations.
ControlWave Designer is an IEC 61131-3 programming
environment that allows you to modify the base application
or create a completely customized program. ControlWave
Designer includes an extensive library of more than 200
basic IEC 61131-3 functions and function blocks common to
many IEC 61131-3 based products.
Sensor Assembly
Using the sensor assembly integrated in the instrument
package is the easiest implementation for a single meter run;
however, the base application program also allows use of
external transmitters, with or without the integrated sensor
assembly.
Most two-run systems use the integrated sensor assembly for
the first run and three 1-5 Volt transmitters for the second run.
Mounting
The GFC-IS can be remotely mounted on a wall, a panel, or a
two-inch pipe. It can also be mounted directly on the pipeline
by utilizing a manifold block.
Options
The GFC-IS supports the following:
ƒ
Integral, Bristol gauge pressure or multivariable (MVT)
DP/P sensor assembly and upper range limits.
ƒ
Pre-wired bendable RTD assembly.
ƒ
Thermowell.
ƒ
I/O card, including 2 DI/DO, 4 DI, 2 DO, 2 HSC/DI and,
optionally, an additional 3 AI.
ƒ
Choice of integral, battery and solar power systems.
ƒ
Stainless steel manifold adapters.
ƒ
A mounting bracket which affixes to the neck of the
housing and allows installation on a wall or 2” pipe.
ƒ
RS-232 interface PC cables are available in either 10 Ft. or
25 Ft lengths.
ƒ
6 Volt IS solar panel.
In addition to the basic functions and function blocks,
ControlWave Designer includes the ACCOL III function block
library. This library includes over sixty function blocks that
are valuable for use in oil & gas and process measurement &
control applications. The ACCOL III function block library is
designed to take full advantage of the significant features
offered by the ControlWave GFC-IS.
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CWGFC-IS
October 2011
ControlWave GFC-IS
Processor
Type
32-bit 14 MHz ARM9TDMI RISC Core Processor
Memory
Boot Flash
512KB
Holds boot/download code and soft switch configuration parameters
Flash
8MB
SRAM (External)
2MB battery-backed
Time Functions
Clock
Serial real-time clock accurate to 1 second/day at 25 ºC, battery backed
Communications
COM1
(this port can only be
connected to the LOI
port)
Type
RS-232
Connector
Physical Interface via 3-pin connector, which is internally linked to the
circular, Alden connector on the bottom of the enclosure door
Tx, Rx, GND with DCD asserted when external cable is plugged in
Note: Area must be declassified before making a physical connection
to the Alden connector.
COM2
(this port can only be
connected to an IStran
communications port)
Type
RS-232
Connector
8-pin terminal block
Supports RTS, CTS, DTR, DCD and DSR modem control signals
RS-232 transceivers are enabled by the port’s DTR
DCD input remains active even when the port is disabled
Note: Connections must be routed to IStran located in a nonhazardous area (25 foot maximum length).
COM3
(this port can only be
connected to an MVT
3808)
Type
RS-485
Connector
5-pin terminal block
Surge Suppression
All communication ports are transorb protected to ±15KV ESD
Inputs/Outputs
RTD
(interface only)
Type
The greater of ± 0.1 °C, or ± 0.1 % of reading
Conversion Accuracy
The greater of ± 0.1 °C, or ± 0.1 % of reading
Ambient Temperature
Effect
±0.01°C / ºC max
Long Term Stability at
Constant Conditions
±0.25 °C / month max
Note: RTD probe interchangeability can add ±0.7°C of uncertainty to the measurement.
Pulse/Discrete Inputs
Quantity
2
Type
Non-interrupting inputs
Maximum Scan Rate
Once per second
Input Filter
20 microseconds
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October 2011
Pulse/Discrete Inputs
(continued)
Input Current
200 μA nominal at 3.3V per input
Voltage Range
Internally sourced dry contact input - 3.3 Vdc
On-State Voltage
>1.86 V
Off-State Voltage
<1.5 V
Surge Suppression
16 V transorb between signal ground
Meets ANSI/IEEE C37.90-1978
Pulse Input
Digital Inputs
Quantity
Frequency
Range
0-10 kHz
Accumulator
16-bit
6 total: 4 DI and 2 selectable DI or DO
Note: Total DI points plus DO points cannot exceed eight
Type
Dry contact
Maximum Scan Rate
Once per 250 ms
Input Filter
15 ms
Input Current for DI
points 1 — 4 (those that
are DI-only)
Configurable as 60 μA for low power applications or 2 mA nominal at
3.3V per input
Input Current for DI
points 5 — 6 (those that
are selectable as DI or
DO)
Configurable as 200 μA for low power applications or 2.2 mA nominal
at 3.3V per input
On-State Voltage
>1.6 V
Off-State Voltage
<1.3 V
Isolation
None
Surge Suppression
30V transorb between signal and ground
Meets ANSI/IEEE C37.90-1978
Digital Outputs
Quantity
4 total; 2 DO and 2 selectable DI or DO
Note: Total DI points plus DO points cannot exceed eight
Type
Open Drain MOSFET
Maximum Scan Rate
Once per 250 ms
Operating Voltage
Range
10 Vdc
Maximum Load Current
250 mA
Isolation
None
Surge Suppression
30V transorb between signal and ground.
Meets ANSI/IEEE C37.90-1978.
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CWGFC-IS
Counter Inputs
October 2011
Quantity
2; also operable as DI points
Type
Dry contact
Frequency Range
Low-Speed
0 — 300 Hz
High-Speed
0 — 10 kHz
Input Range
Internally sourced dry contact input
Input Current
200 μA
Input Filtering
1 ms or 20 μs
Accumulator
16- bit
Maximum Scan Rate
Once per 250 ms
Signal Conditioning
Switch selectable high and low speed input
On-State Voltage
> 1.86 V
Off-State Voltage
< 1.5 V nominal
Isolation
None
Surge Suppression
30 V transorb between signal and ground
Meets ANSI/IEEE C37.90- 1978
Analog Inputs (optional)
Quantity
3
Type
Externally sourced, single—ended inputs, 1—5 V dc
Resolution
14-bit
Input Impedance
1 MΩ
Input Filtering
12 Hz
Maximum Scan Rate
Once per 250 ms
Channel Settling Time
600 ms to be within 0.01% of input signal
Input Accuracy
0.1% of span at 25˚C
0.2% of span at 40˚C to 70˚C
Surge Suppression
30 V transorb between signal and ground
Meets ANSI/IEEE C37.90- 1978
Power
Consumption
Base Unit
6 V dc: 10 mA
Input Voltage Range
5 V dc to 8.28 Vdc
Fuses
1.5 A from charge regulator, 0.125 A for battery input
Surge Suppression
16 V dc transorb between signal and ground
Meets ANSI/IEEE C37.90- 1978
Charge Regulator
Temperature-compensated charge control with cut-off
Threshold voltage for
shunt at 23ºC
7.2 V for a 6 V battery
Backup Battery
Backs up real-time clock and SRAM
300 mA-hour lithium coin cell, 9000 hour expected backup time
Power Consumption
(keypad)
2.5 mA @ 3.3 V (0.008 watts)
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CWGFC-IS
October 2011
Physical
Dimensions
Sensor
Keypad / Display
Housing
15.77” H x 7.8” W x 9” D
Clearance
Please allow at least 2.5” space underneath for cabling
MVT Assembly (optional)
3” H x 3.75” W x 2.5” D
Mounting
Can be pipe-mounted, wall-mounted, or direct-mounted (in the last
case, Emerson recommends PGI Direct Mount manifold products); a kit
for affixing to a 2” pipe or mast is available.
Diaphragm Material
316 Stainless Steel
Fill Medium
DC 200 Silicone
Flange Material
316 Stainless Steel
Flange Bolt Material DP
Units
316 Stainless Steel
Flange Process
Connections
¼” NPT female
4-line by 20-character backlit liquid crystal display with adjustable contrast
2-button or 25-button keypad with membrane keys with tactile feedback
Self-adhesive overlay mounts to the enclosure door or panel (ControlWave GFC package is
delivered with this assembly installed on the door)
Configuration via ACCOL III Function Block
Dimensions
7.4”H x 5.5”W (18.8cm x 14.4cm)
Window size
1.1” H x 3.1”W (2.8cm x 7.9cm)
Character size
4mm H x 3mm W
Wiring
Up to 16 gauge wire size at the terminal block
Weight
Minimum
10 lbs
Battery + MVT Assembly
18.5 lbs
Maximum with Radio
20 lbs
Externally Powered
-40 to 70ºC (-40 to 158ºF)
With Lead Acid Batteries
-20 to 60ºC (-4 to 140ºF)
Environmental
Operating Temp
Storage Temp
-40 to 85ºC (-40 to 185ºF)
Operating Humidity:
10 to 95% RH non-condensing
Immunity
In conformity with ENV 50140 Radio-frequency electromagnetic field amplitude modulated EMC
Electro-Static Discharge
Meets IEC EN 61000-4-2, EN 61326
Radiated Emissions
EN 55011:1998 Class A ITE emissions requirements (EU); ICES-003 Issue 3 Class A Digital Apparatus
emissions requirements (Canada); AS/NZS3548:1995/ CISPR Class A ITE emissions requirements
(Australia). EN 6100-4-3.
Vibration
Maintains proper operation while subjected to a 2.0g acceleration over 10- 150 Hz and 1.0 g
acceleration over 150-2000 Hz (ISA Process Mount).
NEMA Rating
Nema 3R (Nema 4x except with a battery vent)
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CWGFC-IS
October 2011
Approvals
Product Markings for
Hazardous Locations
(USA):
Class I Div. 1, Groups C & D
T3C
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October 2011
ControlWave GFC-IS
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Emerson Process Management
Remote Automation Solutions
11100 Brittmoore Park Drive
Houston, TX 77041 U.S.A.
T +1 713 827 6380
www.EmersonProcess.com/Remote
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