Emerson ControlWave GFC Instruction manual

Instruction Manual
Doc Number CI-ControlWave GFC
Part Number D301387X012
November 2011
ControlWave Gas Flow Computer
Remote Automation Solutions
www.EmersonProcess.com/Remote
This page is intentionally left blank
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Contents
Chapter 1 – Introduction
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1-1 Scope of the Manual .................................................................................................................1-2 Physical Description ..................................................................................................................1-2 CPU/System Controller Board ..................................................................................................1-3 Power Options ...........................................................................................................................1-5 I/O Options ................................................................................................................................1-5 Software Tools ..........................................................................................................................1-6 Overview of the Gas Flow Measurement Application ...............................................................1-8 1.7.1 Data Acquisition – Static Pressure, Differential Pressure, Temperature Variables ......1-8 1.7.2 Flow and Volume Calculations ......................................................................................1-8 1.7.3 Flow Rate and Flow Time Calculations (AGA3)............................................................1-9 1.7.4 Flow Rate and Flow Time Calculations (AGA7)............................................................1-9 1.7.5 Extension Calculation and Analog Averaging ...............................................................1-9 1.7.6 Energy Calculation ......................................................................................................1-10 1.7.7 Volume and Energy Integration ..................................................................................1-10 1.7.8 Downstream Pressure Tap .........................................................................................1-10 1.7.9 Historical Data Storage (Audit Records/ Archive Files) ..............................................1-10 1.7.10 Run Switching .............................................................................................................1-12 1.7.11 Sampler and Odorizer .................................................................................................1-12 1.7.12 Chromatograph Interface ............................................................................................1-12 1.7.13 Nominations ................................................................................................................1-13 Chapter 2 – Installation
2-1 2.1 Site Considerations ...................................................................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations......................................................................2-4 2.2 Installation Overview .................................................................................................................2-5 2.2.1 Unpacking Components ................................................................................................2-6 2.2.2 Mounting the Housing ...................................................................................................2-6 2.2.3 Grounding the Housing ...............................................................................................2-11 2.2.4 Connecting to the Transducer (MVT or GPT) .............................................................2-12 Connecting to a Multivariable Transducer (MVT) ...................................................................2-12 Connecting to a Gage Pressure Transducer (GPT) ...............................................................2-14 2.2.5 Process Pipeline Connection (Meter Runs without Cathodic Protection) ...................2-14 2.2.6 Process Pipeline Connection (Meter Runs with Cathodic Protection) ........................2-16 2.3 Configuring the CPU/System Controller Board .......................................................................2-18 2.3.1 Setting DIP Switches on the CPU/System Controller Board ......................................2-19 2.3.2 Setting Jumpers on the CPU/System Controller Board ..............................................2-21 2.3.3 General Wiring Guidelines ..........................................................................................2-22 2.3.4 Wiring Power to the CPU/System Controller Board ....................................................2-23 2.3.5 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board.............2-25 2.3.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller
Board .........................................................................................................................2-30 2.3.7 Connections to the Ethernet Port on the CPU/System Controller Board ....................2-32 2.4 Radio-Ready and Case Mounted Modem or Radio ................................................................2-33 2.5 Mounting the Solar Panel ........................................................................................................2-34 2.6 Optional Display/Keypads .......................................................................................................2-37 Chapter 3 – I/O Configuration and Wiring
3-1 3.1 I/O Options ................................................................................................................................3-1 3.2 Process I/O Board .....................................................................................................................3-2 Issued Nov-2011
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.2.1 Setting Jumpers on the Process I/O Board .................................................................. 3-2 3.2.2 Setting DIP Switches on the Process I/O Board ........................................................... 3-2 3.3 I/O Wiring .................................................................................................................................. 3-4 3.3.1 Non‐Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board ................... 3-6 3.3.2 Non‐Isolated Discrete Outputs (DO) on TB3 of Process I/O Board.............................. 3-7 3.3.3 Non‐Isolated Analog Inputs (AI) on TB6 of Process I/O Board .................................... 3-8 3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board .................................. 3-9 3.3.5 Non‐Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Bd .. 3-10 3.3.6 Non‐Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on TB4 of Process I/O
Board .........................................................................................................................3-11 3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board ..... 3-12 3.3.8 Connections to a Bristol Model 3808 Transmitter ....................................................... 3-14 Chapter 4 – Operation
4-1 4.1 Powering Up/Powering Down the ControlWave GFC ............................................................... 4-1 4.2 Communicating with the ControlWave GFC ............................................................................. 4-2 4.2.1 Default Comm Port Settings ......................................................................................... 4-2 4.2.2 Collecting Data from the ControlWave GFC ................................................................. 4-3 4.3 Creating and Downloading an Application (ControlWave Project) ........................................... 4-3 4.4 Creating and Maintaining Backups ........................................................................................... 4-3 4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-4 4.4.2 Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-5 4.4.3 Backing up Data ............................................................................................................ 4-6 Chapter 5 – Service and Troubleshooting
5-1 5.1 Upgrading Firmware.................................................................................................................. 5-2 5.2 Removing or Replacing Components ....................................................................................... 5-6 5.2.1 Accessing Modules for Testing ..................................................................................... 5-6 5.2.2 Removing/Replacing the CPU/System Controller Board and the Process I/O Board .. 5-6 5.2.3 Removing/Replacing the Primary Battery System ........................................................ 5-7 5.2.4 Removing/Replacing the Backup Battery ..................................................................... 5-8 5.2.5 Enabling / Disabling the Backup Battery ....................................................................... 5-9 5.2.6 Removing/Replacing the Case-Mounted Radio or Modem .......................................... 5-9 5.2.7 Removing/Replacing the MVT or GPT Transducer .................................................... 5-10 5.3 General Troubleshooting Procedures ..................................................................................... 5-10 5.3.1 Checking LEDs ...........................................................................................................5-10 5.3.2 Checking LCD Status Codes ...................................................................................... 5-11 5.3.3 Wiring/Signal Checks .................................................................................................. 5-11 5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-12 5.4.1 Available Diagnostics .................................................................................................. 5-13 5.5 Core Updump .......................................................................................................................... 5-16 5.6 Calibration Checks .................................................................................................................. 5-17 Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations
A-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets
Z-1
Index
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IND-1 Contents
Issued Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave Gas
Flow Computer (GFC). For information about the software used with
the ControlWave GFC, refer to:
 ControlWave Flow Measurement Applications Guide (D5137),
 Getting Started with ControlWave Designer (D5085)
 ControlWave Designer Programmer’s Handbook (D5125)
 ControlWave Designer online help
This chapter provides an overview of the ControlWave GFC and its
components and details the structure of this manual
In This Chapter
1.1 1.2 1.3 1.4 1.5 1.6 1.7 Scope of the Manual ........................................................................1-2 Physical Description ........................................................................1-2 CPU/System Controller Board .........................................................1-3 Power Options .................................................................................1-5 I/O Options .......................................................................................1-5 Software Tools .................................................................................1-6 Overview of the Gas Flow Measurement Application......................1-8
ControlWave GFC is designed to perform as the ideal platform for
remote site automation, measurement, and data management in the oil
and gas industry. The ControlWave GFC measures differential pressure,
static pressure and temperature for a single meter run and computes
flow for both volume and energy.
Features ControlWave GFC has the following key features:
 Exceptional performance and low power consumption through use
of the ARM microprocessor
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
Revised Nov-2011
Very low power consumption to minimize costs of solar panel /
battery power systems
Two CPU / System Controller board configurations (see Table 1-1.)
Three process I/O board configurations (see Table 1-2.)
Two RS-232 and one RS-232/RS-485 asynchronous serial
communication ports
Optional 10/100 MB Ethernet port
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
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
Optional Display/Keypad
Wide operating temperature range: (–40 to +70C) (–40 to 158F)
Battery backup for Static RAM (SRAM) and real-time clock.
Nonincendive Class I, Division 2 (Groups C and D) Hazardous
Location approvals when installed in a suitable enclosure - see
Appendix A.

Cost-effective for small RTU/process controller applications.
Introduction
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Provides an overview of the hardware and
general information about the ControlWave GFC
and its application software.
Chapter 2
Installation
Provides information on mounting the
ControlWave GFC and setting CPU jumpers
and switches.
Chapter 3
I/O Configuration
Provides general information on wiring the
process I/O points.
Chapter 4
Operation
Provides information on day-to-day operation of
the ControlWave GFC.
Chapter 5 Service and
Troubleshooting
Provides information on service and
troubleshooting procedures.
1.2 Physical Description
The ControlWave GFC includes the following major components:

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
Enclosure with a local communication port and LCD
display/keypad.
CPU/system controller board (SCB) mounts on edge within the
enclosure – See Section 1.3
Optional I/O – see Section1.5.
Internal mounting brackets and battery
Multi-variable transducer (MVT) or gage pressure transducer (GPT)
Optional RTD probe
Radio/modem options
Figure 1-1. ControlWave GFC Enclosure (MVT Equipped) with 2-Button Display/Keypad
Assembly
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Introduction
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Enclosure The ControlWave GFC enclosure is a standard NEMA 3R rated
fiberglass enclosure. The enclosure consists of the body and the front
cover. A continuous gasket seals the unit when you close the front
cover. Two latches on the enclosure’s right side secure the cover.
The enclosure includes a weatherproof connector (local port) mounted
to the bottom of the cover and connected internally to RS-232 COM
port 1.
The enclosure includes a display or display/keypad for an operator or
technician to view process values locally.
Internal Mounting Internal mounting brackets support the various system components,
Brackets and Battery such as the battery, CPU/System Controller and Process I/O boards,
and the radio/modem option. These components attach to the one piece
mounting bracket which is secured to the inner rear wall of the
enclosure. A factory-supplied radio or modem mounts in front of the
battery on a battery cover/radio mounting plate.
Radio/Modem Options You can order the ControlWave GFC with a factory-installed modem
or spread spectrum radio. The unit supports a variety of MDS and
FreeWave radios and modems. Contact Emerson Remote Automation
Solutions for more information.
1.3 CPU/System Controller Board
The CPU (central processing unit) and System Controller Board (SCB)
contains the ControlWave GFC CPU, I/O monitor/control, memory, and
communication functions.
The CPU/System Controller board includes:


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

Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core, with a
system clock speed of either 14 MHz or 33 MHz.
two RS-232 communication ports
one communication port configurable by jumpers as either RS-232
or RS-485
optional 10/100baseT Ethernet port (See Table 1-1)
2 MB of battery backed Static RAM (SRAM),
512KB boot/downloader FLASH,
8MB simultaneous read/write FLASH memory
Board Variations The CPU/System Controller board has two basic variations: `
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Introduction
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Table 1-1. CPU/System Controller board Variations
CPU
Nominal
Input
Power
Ethernet
Port?
Solar
Regulator
?
Auxiliary
Power
Output?
RTD Input?
14MHz
ultra low
power
+6Vdc or
+12Vdc
No
Yes
Yes
Yes.
Connects to
100-ohm
platinum bulb.
Uses DIN
43760 curve.
33MHz
+12V or
+24Vdc
Yes
No
No
Yes (same as
ultra low
power)
Note: Each of the variants shown in Table 1-1 may be ordered with or
without special gas calculation firmware.
CPU Backup Battery The CPU/System Controller board has a coin cell socket that accepts a
3.0V, 300 mA-hr lithium battery. This 3.0V battery provides backup
power for the real-time clock and the system’s Static RAM (SRAM).
CPU Memory There are several different types of memory used by the CPU:
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The ControlWave GFC includes 8 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.
System Memory (SRAM)
The ControlWave GFC has 2 MB of static random access memory
(SRAM). During power loss periods, SRAM enters data retention mode
(powered by a backup 3.0V lithium battery). Critical system information
that must be retained during power outages or when the system has been
disabled for maintenance is stored here. This includes the last states of
all I/O points, audit/archive historical data (if not stored in FLASH), the
values of any variables marked RETAIN, the values of any variables
assigned to the static memory area, and any pending alarm messages not
yet reported.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
1.4 Power Options
You can power the ControlWave GFC by:


a factory-supplied 6V lithium battery
a factory-supplied 6V lithium battery pack (dual 6V lithium
batteries in parallel)
 a factory-supplied 6V, 7AH lead acid battery – used with a 1W, 6V
solar panel system
 a factory-supplied 6V, 7AH lead acid battery – used with a 5W, 6V
solar panel system
 a factory-supplied 12V, 7AH lead acid battery – used with a 5W,
12V solar panel system
 an external (user-supplied) power supply with either +5.4Vdc to
+16Vdc (nominal +6Vdc), +11.4Vdc to +16Vdc (nominal +12Vdc)
or +21.8Vdc to + 28.0Vdc (nominal +24Vdc)
If you connect solar panels to rechargeable battery systems to power the
ControlWave GFC, there is a secondary power input you can use to
provide power if there is no power from the solar panel/battery system.
1.5 I/O Options
ControlWave GFC comes with the following standard I/O:

2 Pulse Counter Inputs with a 1 second scan rate (can be configured
as discrete inputs (DI))
Optional I/O includes:
 Resistance Temperature Device (RTD) probe
 Either a Multi-Variable Transducer (MVT) or Gage Pressure
Transducer (GPT)
 Process I/O board. Three different versions of the optional process
I/O board are available:
Table 1-2. Process I/O Configurations
Revised Nov-2011
Type
Discrete
Input /
Output
(DI/DO)
Discrete
Input (DI)
Discrete
Output
(DO)
High Speed
Counter
(HSC)
A
2
4
2
2
B
2
4
2
2
3
C
2
4
2
2
3
Introduction
Analog
Input (AI)
Analog
Output
(AO)
1
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
1.6 Software Tools
The ControlWave programming environment consists of a set of
integrated software tools which allow you to create, test, implement,
and download complex control strategies for use with the ControlWave
GFC. Figure 1-2 graphically presents the programming environment.
Figure 1-2. ControlWave Programming Environment
The tools which make up the programming environment include:
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
1-6
ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave unit. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), and the ControlWave Designer
Programmer’s Handbook (document D5125).
The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O in the ControlWave and
configure the individual mapping of I/O points for discrete and
analog inputs and outputs. For information on the I/O Configurator
see the ControlWave Designer Programmer’s Handbook (document
D5125).
Introduction
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)

The ACCOL3 Firmware Library, available within ControlWave
Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see the
online help within ControlWave Designer.

OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).

OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).

A series of web page controls are available for retrieval of real-time
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. (See the
ControlWave Flow Measurement Applications Guide D5137)
Alternatively, developers can place the controls in third-party
ActiveX compatible containers such as Visual BASIC or
Microsoft® Excel. For information on the ActiveX controls, see the
Web_BSI Manual (document D5087).
User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).


Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).
Communication In addition to the Bristol Synchronous/Asynchronous Protocol
Protocols (BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port with serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
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1.7 Overview of the Gas Flow Measurement Application
Note: For detailed information on the gas flow measurement
application and web pages refer to the ControlWave Flow
Measurement Applications Guide (D5137).
You can purchase the ControlWave GFC with a pre-programmed flow
measurement application already loaded.
The ControlWave standard gas flow measurement application collects
static pressure, differential pressure and temperature data and computes
flow, energy, and volume for a station.
A station typically refers to a single flow computer and all its
associated meter runs. Each meter run refers to measurement of natural
gas through a single pipeline.
1.7.1 Data Acquisition – Static Pressure, Differential Pressure,
Temperature Variables
The application requires these process inputs for orifice measurement:
 static pressure (SP) collected once per second
 differential pressure (DP) collected once per second
 flowing temperature (T) collected once per second
The application requires these process inputs for measurement using a
positive displacement (PD), turbine, or ultrasonic meter:
 static pressure (SP) collected once per second
 frequency input collected once per second
 flowing temperature (T) collected once per second
The application also collects self-test and compensation variables at
intervals of four seconds or less.
Pressure data can come from any of the following sources:
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
Analog pressure transmitters connected to analog input points on a
process I/O module in the ControlWave flow computer.
Built-in multivariable transducer.
External multivariable transmitters (Bristol or Rosemount) using
BSAP or Modbus communications through an RS-485
communication port.
1.7.2 Flow and Volume Calculations
Flow and volume calculations conform to American Petroleum Institute
(API) and American Gas Association (AGA) standards.
Supported flow calculations include:
 AGA3-1985/NX-19
 AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
 AGA7/NX-19
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
 AGA7 with selectable AGA8 Gross or AGA8 Detail
 Auto-adjust AGA7/NX-19
 Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
The application performs a complete flow calculation using the process
variables every second. Each calculation includes instantaneous rate
according to API 14.3, compressibility according to AGA 8 Detail or
Gross method, and updates of all volumes, totals, and archive averages.
1.7.3 Flow Rate and Flow Time Calculations (AGA3)
For orifice flow measurement, the application compares the differential
pressure value to a low flow cutoff value every second. If the
differential pressure falls below the low flow cutoff value, flow is
considered to be zero for that second. Hourly and daily flow time is
defined to be the number of seconds for which the differential pressure
exceeded the cutoff value for the period.
The values for static and differential pressure and temperature are used
as inputs to the flow equations. You can select API 14.3 (AGA3, 1992)
and AGA8 calculations, with compressibility calculations according to
AGA Report No. 8, 1992 (with 1993 errata). The application supports
both the detail method and the two gross methods of characterization
described in AGA 8. Users may also select the AGA3, 1995 and NX-19
flow equations to calculate the rate of flow.
1.7.4 Flow Rate and Flow Time Calculations (AGA7)
When using PD meters, turbine meters or ultrasonic meters, the
application calculates flow rate by applying the correction factor
computed by the AGA7 calculations to the frequency of the input
pulses. When the frequency drops below 1 Hz, the application sets the
flow rate estimate to zero; however, volume calculations still
accumulate. The flow time recorded is the time for which the flow rate
is non-zero.
1.7.5 Extension Calculation and Analog Averaging
For orifice meters, the application calculates the flow extension every
second. The extension is the square root of the product of the absolute
upstream static pressure times the differential pressure. This extension is
used in the flow rate calculation. When there is no flow, the application
reports the arithmetic averages of static pressure and temperature. This
allows you to monitor static pressure and temperature during shut-in
periods.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
1.7.6 Energy Calculation
The application offers the option of using a fixed volumetric heating
value or calculating the energy content of the gas according to AGA
Report No. 5.
1.7.7 Volume and Energy Integration
The application integrates and accumulates volume and energy at the
end of every calculation cycle. The application calculates the volume
for a cycle by multiplying the calculated rate by the flow time for that
cycle. The application calculates the energy for a cycle by multiplying
the volume at base conditions by the heating value.
1.7.8 Downstream Pressure Tap
The multivariable transducer typically measures static pressure from an
integral tap on the upstream, high-pressure leg of the differential
pressure connection. The transducer can also measure static pressure at
the downstream pressure tap, with the measurement taken from the lowpressure side to the high-pressure side. In this installation, the
differential signal from the transducer is negative. If, while using the
integral smart multivariable transmitter (MVT) or an external MVT, you
select the downstream tap location during MVT configuration, the MVT
firmware changes the sign of the differential pressure to provide a
positive DP value.
1.7.9 Historical Data Storage (Audit Records/ Archive Files)
The ControlWave supports two distinct types of historical data storage –
audit records and archive files.
Where feasible, both forms of archive data conform to the requirements
of the API Chapter 21. Specifically, the averages of the process
variables stored in the data archive are for flowing periods, appropriate
to their usage in the equations, and any gas-related parameter designated
an event that is changed by an operator either remotely or locally causes
an entry in the audit log.
Audit Records
(Alarms and
Events)
The audit system maintains a history of alarms and certain events that
have an impact on the calculated and reported gas flow rates and
volumes.
The application stores the most recent 500 alarms and the most recent
500 events. As new alarms/events arrive, they overwrite the oldest
entries. Internally, the ControlWave stores alarms and events separately
to prevent recurring alarms from overwriting configuration audit data
events. The application reports alarms and events in the same log.
The following circumstances generate an audit record:
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 Any operator change to a configuration variable
 Any change in the state of an alarm variable
 A system restart
 Certain other system events
You can view audit records on-screen in the audit log.
See the Supplement to OpenBSI 5.8 Service Pack 1 documentation for
help on interpreting audit records.
Archive files store the value of process variables and other calculated
Archive Files
variables at specified intervals along with the date and time of each
(Averages,
totals, and other entry. This includes flow rates, volumes and other calculated values.
When archive files fill up, new values overwrite the oldest entries in the
values)
files.
The application displays archive file data in hourly, data, and periodic
logs you can view on screen.
Log Breaks
You can configure the application to support the "breaking" of a log
period when an operator-changes a parameter. When this occurs, the log
period in process closes out to make a log, and a new log begins.
Hourly Historical Data Log
Each meter run maintains an hourly data log that holds one record for
every contract hour. Hourly logs hold 840 entries or 35 days; this
ensures that the previous period of hourly data is always resident in
flash memory.
The hourly data log stores the following items:
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corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
Daily Historical Data Log
Each meter run maintains a daily data log that holds one record for
every contract gas day. You can change the contract hour the contract
gas day starts at some time other than midnight. The daily log holds 62
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
entries; this ensures that the previous calendar month of daily data is
always resident in flash memory.
The daily data log stores the following items:
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



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
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
Periodic Historical Data Log
Each meter run maintains a periodic data log that holds one record for
every log interval. Each log interval is 15 minutes. The periodic
historical data log holds 1440 records, or four days of 15 minute data.
The periodic historical data log stores the following items:




flowing differential pressure
flowing static pressure
flowing temperature
frequency
1.7.10 Run Switching
If you use multiple meter runs in the application, you can configure run
switching. Run switching (also known as meter run staging or tube
switching) allows changes to the number of meter runs currently active
to meet the gas flow demand for the station.
1.7.11 Sampler and Odorizer
Samplers are external devices which measure the quality of the gas
stream.
Because natural gas is odorless and colorless, devices called odorizers
inject an additive to the gas stream that allows people to detect the
presence of natural gas in the event of a gas leak.
1.7.12 Chromatograph Interface
If you use a chromatograph to measure gas component information you
can integrate this into the application. You can also specify fixed gas
component percentages to use if the chromatograph fails.
1-12
Introduction
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
1.7.13 Nominations
Nominations allow you to configure the ControlWave flow computer to
allocate precise amounts of gas flow during specific time periods, called
nomination periods.
Revised Nov-2011
Introduction
1-13
This page is intentionally left blank
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
GFC, considerations for installation, and instructions for setting
switches and jumpers.
In This Chapter
2.1 2.2 2.3 2.4 2.5 2.6 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations .............................2-4 Installation Overview........................................................................2-5 2.2.1 Unpacking Components .......................................................2-6 2.2.2 Mounting the Housing ..........................................................2-6 2.2.3 Grounding the Housing ......................................................2-11 2.2.4 Connecting to the Transducer (MVT or GPT) ....................2-12 Connecting to a Multivariable Transducer (MVT) ..........................2-12 Connecting to a Gage Pressure Transducer (GPT) ......................2-14 2.2.5 Process Pipeline Connection (Meter Runs without Cathodic
Protection) ........................................................................2-14 2.2.6 Process Pipeline Connection (Meter Runs with Cathodic
Protection) ........................................................................2-16 Configuring the CPU/System Controller Board .............................2-18 2.3.1 Setting DIP Switches on the CPU/System Controller Board2-19 2.3.2 Setting Jumpers on the CPU/System Controller Board .....2-21 2.3.3 General Wiring Guidelines .................................................2-22 2.3.4 Wiring Power to the CPU/System Controller Board ...........2-23 2.3.5 Connections to RS-232 Serial Port(s) on the CPU/System
Controller Board................................................................2-25 2.3.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the
CPU/System Controller Board ..........................................2-30 2.3.7 Connections to the Ethernet Port on the CPU/System Controller
Board ................................................................................2-32 Radio-Ready and Case Mounted Modem or Radio ......................2-33 Mounting the Solar Panel ..............................................................2-34 Optional Display/Keypads..............................................................2-37 2.1 Site Considerations
When choosing an installation site, check all clearances for the
enclosure, for the attached GPT/MVT, for the optional RTD probe, and
if applicable, for the solar panel. Ensure that you can open the front
cover of the ControlWave GFC (hinged on the left side) for wiring and
service. Make sure the display/keypad is accessible and visible.
See Figure 2-6 for a dimensional drawing of the NEMA 3R enclosure
with an MVT and Figure 2-7 for a dimensional drawing of the NEMA
3R enclosure with a GPT.
The ControlWave GFC is designed to operate in a Class I Division 2,
Groups C & D environment with a nonincendive rating (see Appendix
A). The ControlWave GFC can operate in an unprotected outdoor
environment.
Revised Nov-2011
Installation
2-1
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Caution
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:


Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
Figure 2-1. MVT Equipped ControlWave GFC (with MDS - Transnet Radio) (Internal View)
Component Identification Diagram
2-2
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Note: When equipped with a Gage Pressure Transducer, a GPT
Adapter Plate is mounted to the bottom of the enclosure.
Figure 2-2. GPT Equipped ControlWave GFC (with MDS - Transnet Radio) (Internal View)
Component Identification Diagram
Revised Nov-2011
Installation
2-3
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Specifications
for Temperature,
Humidity and
Vibration
 See document 1660DS-8c available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave GFC.
 Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
 Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave GFC is not
exposed to a level of vibration that exceeds that provided in the
technical specifications.
2.1.1 Class I, Div 2 Installation Considerations
Underwriters Laboratories (UL) lists the ControlWave GFC as nonincendive and suitable only for use in Class I, Division 2, Group C, and
D hazardous locations and non-hazardous locations. Read this chapter
and Appendix A carefully before you install a ControlWave GFC in a
hazardous location.
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 Group C and D environments.
When the ControlWave GFC is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
2-4
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.2 Installation Overview
Installing a ControlWave GFC involves several general steps:
1.
Unpacking, assembling, and configuring the hardware. This
includes:
a) Mounting the enclosure on site. (See Section 2.2.2)
b) Removing the CPU/System Controller board and optional
Process I/O board assembly so you can enable the backup
battery by setting jumper W3 on the CPU/System Controller
board to position 1 to 2. See Section 5.2.2 for instructions on
removing/replacing the board assembly, see Section 2.3.2 for
information on setting jumpers.
b) Setting other switches and jumpers on the CPU/System
Controller board (see Section 2.3.1 and Section 2.3.2) and on the
Process I/O board (see Section 3.2.1 and Section 3.2.2) and
placing both boards (as a single assembly) back into the chassis.
d) Connecting communication cables. (See Sections 2.3.5, 2.3.6,
and 2.3.7)
e) Wiring I/O. (See Section 3.3)
f) Connecting an external 3808 transmitter (see Section 3.3.8 if
required).
f) Installing a ground wire between the enclosure’s ground lug and
a known good Earth ground. (See Section 2.2.3)
g) Installing the solar panel (See Section 2.5) and rechargeable
battery (See Section 2.3.4 if applicable)
h) Connecting the RTD probe (if required). (See Section 3.3.7)
i) Wiring power to the unit. (See Section 2.3.4)
j) Turning on power. (See Section 4.1)
Revised Nov-2011
2.
Installing PC-based software (TechView).
3.
Establishing communications to perform calibration activities or
view data using the standard flow measurement application menus.
Installation
2-5
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Note: Steps 2 through 3 require that you install and use OpenBSI
TechView software to perform calibration and that you use the
standard menus. This manual focuses on hardware installation
and preparation. Software installation and configuration is
beyond the scope of this manual. Refer to the TechView User’s
Guide (D5131) and the ControlWave Flow Measurement
Applications Guide (D5137) for more information. If you are
not using the flow measurement application and plan to create
your own application, refer to the Getting Started with
ControlWave Designer Manual (D5085) and the ControlWave
Designer Programmer’s Handbook (D5125).
2.2.1 Unpacking Components
Packaging
ControlWave GFC gas flow computers ship from the factory with all
components wired and mounted except for the unit’s solar panel and
battery; these items are shipped separately.
2.2.2 Mounting the Housing


2-6
You must position the ControlWave GFC vertically with the
transducer (MVT or GPT) at its base. Make sure the front of the
assembly is visible and accessible for service, installation, and for
operator access to the LCD display.
If your unit requires a solar panel, make sure there is sufficient
clearance. You can mount the solar panel to the same 2” pipe that
secures the unit.
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Units with Multi- You can mount units with an MVT directly to the main (meter run)
Variable Transducer using a process manifold or you can mount them remotely to a panel, a
(MVT) wall, or to a vertical 2 inch pipe clamped at the rear of the unit with
two clamps and four bolts.
(1)
(3)
(5)
(7)
(9)
.5” Conduit Fitting - I/O wires
RTD Cable Assembly or Sealing Plug
Solar Pwr. Cable, Ext. Pwr. Cable, or Plug
Solderless Ground Lug
.880” hole for .75” Conduit Fitting (Plugged)
(2)
(4)
(6)
(8)
Local Port Connector
Battery Ventilation Assembly
Ant. Cable, Polyphaser, or Plug
Multivariable Transducer
Figure 2-3. ControlWave GFC Bottom View (Shown with MVT)
Revised Nov-2011
Installation
2-7
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Units with Gage You can mount units with a GPT remotely to a panel, a wall, or to a
Pressure Transducer vertical 2 inch pipe clamped at the rear of the unit using the two
(GPT) mounting brackets with two clamps and four bolts.
Caution
You cannot mount units with a GPT directly to the main (meter run).
(1) .5” Conduit Fitting - I/O wires
(3) RTD Cable Assembly or Sealing Plug
(5) Solar Pwr. Cable, Ext. Pwr. Cable, or Plug
(7) Solderless Ground Lug
(9) .880” hole for .75” Conduit Fitting (Plugged)
(2)
(4)
(6)
(8)
Local Port Connector
Battery Ventilation Assembly
Ant. Cable, Polyphaser, or Plug
Gage Pressure Transducer
Figure 2-4. ControlWave GFC (bottom view with GPT)
2-8
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Anchoring the Pipe If you mount to a 2 inch pipe, you must anchor the pipe in cement deep
enough to conform to local building codes associated with frost
considerations.
Figure 2-5. Side View of ControlWave GFC Mounted

Revised Nov-2011
Only connect power wiring after the unit is mounted and properly
grounded.
Installation
2-9
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)

I/O, power, and communication cabling enters the bottom of the unit
through conduit or special function fittings. You can also route I/O
wiring through the left side of the unit (when facing the front)
instead of the bottom; this requires that you remove the left side hole
plug and replace it with a ½” conduit fitting swapped out from the
bottom of the unit.
Refer to Figure 2-6 and Figure 2-7 for mounting dimensions.
Figure 2-6. ControlWave GFC (with MVT) - NEMA 3R Enclosure Dimensions
2-10
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-7. ControlWave GFC (with GPT) - NEMA 3R Enclosure Dimensions
2.2.3 Grounding the Housing
The ControlWave GFC enclosure includes a ground lug. If your unit has
an MVT, see Figure 2-1 to locate the ground lug. If your unit has a
GPT, see Figure 2-2 to locate the ground lug. Once you have installed
the unit, run a ground wire (#4 AWG max wire size) between the
ground lug and a known good earth ground. Connect the cases of
temperature transducers, pressure transmitters, and so on to the known
Revised Nov-2011
Installation
2-11
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
good earth ground. For more information on grounding see the
ControlWave Grounding Supplement (S1400CW):
Additional grounding guidelines include:




Use stranded copper wire (#4 AWG) to earth ground, and keep the
length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Using a high-wattage soldering iron, tin the wire ends with solder
before you insert them into the chassis ground lug.
Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.
2.2.4 Connecting to the Transducer (MVT or GPT)
Your unit can include either a multi-variable transducer (MVT) or a
gage pressure transducer (GPT).
Within the body of the transducer, metal diaphragms are exposed to the
gas. Solid-state strain gauge sensors in the neck of the transducer
measure the pressure applied to the diaphragms and produce
proportional electrical signals.
The neck of the transducer extends into the bottom of the enclosure,
with the body of the transducer outside the enclosure. The GPT/MVT
cable connector is factory mated with System Controller module
connector P1.
Connecting to a Multivariable Transducer (MVT)
Your ControlWave GFC may have an optional multivariable transducer
(MVT) secured to the bottom of the unit. The MVT is factory-connected
to connector P1 near the bottom of the CPU/System Controller board.
The MVT pressure assembly connects to the process manifold either
directly or by tubing.
Figure 2-8 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.
Arrangements are described as follows:

2-12
Standard Process Flange for MVT – Two process flanges
containing the connection ports are assembled to the differential
transducer. Port designations (L and H) are stamped on the body
between the flanges. Ports accept ¼-18 NPT pipe connections to 21/8 in. centers for connection to orifice taps or a standard threeInstallation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)

valve manifold. These process flange connections are illustrated at
the top of Figure 2-8.
Four bolts and nuts hold the two process flange assemblies in place.
When you remove the bolts, you can reposition the flanges so that
the connections can emanate from the front, rear or bottom of the
transducer. Take care not to damage the sensor module assembly
during this procedure. Once you position the flange, tighten the bolts
in an alternating sequence to about 20-30 foot-pounds of torque.
Figure 2-8. Process Flange and Optional Manifold Block Connectors

Revised Nov-2011
Optional Process Manifold Blocks – Process manifold blocks may
be installed on the transducers to permit the use of connector
assemblies having different connection centers. The manifold
blocks, which are oval in appearance, mate with the tranducer’s
Installation
2-13
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
process flange. The blocks may be installed in several positions to
achieve different connection centers as shown in Figure 2-8.
Connecting to a Gage Pressure Transducer (GPT)
You can secure an optional gage pressure transducer (GPT) to the
bottom of the enclosure instead of the MVT. Gage pressure transducers
are equipped with a ½-14 NPT male pipe fitting. The GPT connects to
the process manifold by tubing.
2.2.5 Process Pipeline Connection (Meter Runs without Cathodic
Protection)
Units equipped with an optional MVT may be mounted directly on the
pipeline or remotely on a vertical stand-alone two-inch pipe or on a wall
or panel. Units equipped with optional gage pressure transducers (GPT)
may only be mounted remotely, that is, on a vertical stand-alone twoinch pipe or on a wall or panel. The Earth ground must run between the
GFC’s ground lug and Earth ground (rod or bed) even though the
ControlWave GFC units equipped with a MVT or GPT may be
grounded to the pipeline. If any pressure transmitters or pulse
transducers are remotely mounted, connect their chassis grounds to the
pipeline or Earth ground.
Note: When installing the unit without cathodic protection, you do not
use the transducer to dielectric isolation kit.
2-14
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-9. ControlWave GFC Remote Installation without Cathodic Protection
Revised Nov-2011
Installation
2-15
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.2.6 Process Pipeline Connection (Meter Runs with Cathodic
Protection)
Dielectric isolators are available and are always recommended as an
added measure in isolating the ControlWave GFC from the pipeline
even though the enclosure does provide some galvanic isolation from
the pipeline and should not be affected by the cathodic protection or
other EMF on the pipeline. ControlWave GFCs equipped with an MVT
may be mounted directly on the pipeline (using a manifold block) or
remotely on a vertical stand-alone two-inch pipe. ControlWave GFCs
equipped with a GPT can only be remotely mounted on a vertical standalone two-inch pipe or on a wall or panel. It is recommended that
isolation fitting always be used in remotely mounted meter systems.
If the mounting 2-inch pipe (when used) is in continuity with the
pipeline you may need to electrically isolate it from the GFC. Use a
strong heat-shrink material such as RAYCHEM WCSM 68/22 EU
3140. This black tubing easy slips over the 2-inch pipe and then after
uniform heating (with a rosebud torch) it electrically insulates and
increases the strength of the pipe stand. See F1670SS-0a for information
on PGI direct mount systems and manifolds.
Install isolation fittings or gaskets between the following connections:



2-16
All conductive tubing that runs between the pipeline and mounting
valve manifold and/or the unit’s multivariable transducer (MVT).
All conductive connections or tubing runs between the ControlWave
GFC gas flow computer and a turbine meter, pulse transducer, or
any other I/O device that is mounted on the pipeline.
Any temperature transducer, pressure transmitter, etc. and their
mount/interface to the pipeline.
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-10. ControlWave GFC Direct Mount Installation with Cathodic Protection
Revised Nov-2011
Installation
2-17
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.3 Configuring the CPU/System Controller Board
The CPU/System Controller board mounts on edge inside the enclosure.
To configure the CPU/System Controller board, you need to set some
switches and jumpers.
NOTE: Ultra Low Power CPU/System
Controller Bds. don’t have an
Ethernet Port.
Solar Pwr. In and Aux. Power Out
are not available on units equipped
with an Ethernet Port.
Do Not Connect a 24V Solar Panel
to Connector TB1-1 & TB1-2!
1
2
Fuse:
F3 on
Non Intrinsically
Safe Units
3
Power
5
6
1
Power
2
F3
1
2
3
4
1
6
COM1
5
6
9
5
7
8
W1
W18
1
NOTE:
J11 normally used
3
4
5
W7
7
8
10/100
Base-T
Ethernet
Port
Transmit
LED
CR1
Watchdog
W3
Configuration
Options
Switch
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Idle
W7 - 1-2 = 12/24V Power Fail
Trip Point Hysterisis
2-3 = 6V Power Fail
Trip Point Hysterisis
W8 - 1-2 = 12V Power Fail
Trip Point
2-3 = 6/24V Power Fail
Trip Point
W12 - W16 - 1-2 = COM3 RS-232
2-3 = COM3 RS-485
W17 - 1-2 = 6V Input Power
2-3 = 12V Input Power
RJ-45
RJ-45
O
N
S1
O
N
RTD EXC
RTD+
RTD-
5
W13
W14
COM3
RS-232
RS-485
Radio
W12
3
4
SW3 - COM3 Config.
RS-485 Receiver Biasing & Termination
2-Wire, 4-Wire Selection
J5 - COM3
1
2
3
4
J5
Pulse
Input
J8
Emulation
Header
W17
1
2
3
NOTE:
J7, J8, J9
Factory Use
RTD
Input
LCD/
Keypad
RJ-45
Piggy-back
Radio Intf.
W16
PULSE 1
PULSE 2
GND
Output PULSE
PWR
Input
Input
1
2
W18: COM1 connector
selection
1 to 2 = J4 active
2 to 3 = J11 active
W15
RXD+
RXD-/RXD
TXD-/TXD
TXD+
GND
Recovery
Mode &
COM./Status
LEDs
1 2 3 4
1 2 3 4
Input
Input
Output
Output
W2
COM2
RS-232
6
Receive
LED
NOTE: Carefully
examine DIP
switches to verify
proper ON/OFF
position. Different
versions of the
board may have
different switch
positions.
COM1 for CW GFC and CW
RS-232 Express PAC only.
W8
2
GND
RXD
TXD
DCD
Input
RXD
Input
Output TXD
Output DTR
GND
Input
DSR
Output RTS
CTS
Input
3 2 1
W1 - 1-2 = COM1 CTS from Port
2-3 = COM1 CTS to RTS
W2 - 1-2 = COM2 CTS from Port
2-3 = COM2 CTS to RTS
W3 - 1-2 = Battery Enabled
2-3 = Battery Disabled
W5 - 1-2 = 12/24V Power Supply
Shut-down Hysterisis
2-3 = 6V Power Supply
Shut-down Hysterisis
W6 - 1-2 = 12V Power Supply
Shut-down
2-3 = 6/24V Power Supply
Shut-down
W6
4
W5
Solar Pwr. In +
GND
Power In +
GND
Aux. Power Out +
GND
Sec. Battery Input
GND
Input
DCD
Input
RXD
Output TXD
Output DTR
GND
DSR
Input
Output RTS
CTS
Input
J9
PLD JTAG
Header
J3
J3 - I/OBUS
Intf. to
CPU Board
J7
MSP430
JTAG
Header
CAUTION:
Damage WILL occur to
the CPU if the Ethernet
network is connected
to connector J2!
P1
WE
Figure 2-11. - CPU/System Controller Board Component I.D. Diagram
2-18
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.3.1 Setting DIP Switches on the CPU/System Controller Board
Before you install the CPU/System Controller board, you must
determine the settings for three banks of DIP switches. Refer to Figure
2-11 for the location of the DIP switch banks. Refer to Tables 2-1, 2-2,
and 2-3 for an explanation of the DIP switch positions.
Notes:


Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF. Different versions of the board may use
different switch positions.
Only switch combinations described have been tested.
Table 2-1. CPU/System Controller Board Switch SW1
SW1 Setting
Function
Mode
1&2
Recovery
Mode
Recovery Mode = Both SW1-1 and SW1-2 ON or both
SW1-1 and SW1-2 OFF
Local Mode =
SW1-1 OFF and SW1-2 ON (Factory
Default)
3
Force
Recovery
Mode
Enables recovery mode. Values are:
ON (enables recovery mode)
OFF (disables recovery mode). – This is the factory
default.
4
LED status
ON (Enable IDLE LED status indication)
OFF (Disable IDLE LED status indication)
Table 2-2. CPU/System Controller Board Switch SW2
Revised Nov-2011
SW2 Setting
Function
Mode
1
Watchdog
Enable
Controls whether the system enters a watchdog state
when a crash or system hang-up occurs and automatically
restarts. Values are:
ON (Enables watchdog circuit; factory default)
OFF (Disables watchdog circuit and prevents automatic
restart)
2
Lock/Unlock
Soft Switches
Controls the ability to modify soft switches, other
configurations, and flash files. Values are:
ON (Unlocks soft switches and flash files; factory
default).
OFF (Locks soft switches, configurations, and flash files)
3
Use/Ignore
Soft Switches
Controls the use of soft switches. Values are:
ON (Enable user-defined soft switches configured in flash
memory; factory default)
OFF (Disable soft switch configuration and use factory
defaults)
Installation
2-19
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
SW2 Setting
Function
Mode
Note: Setting both switch 3 and switch 8 to OFF (closed)
sets all serial communication ports to 9600 bps
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.
4
Core Updump
Causes the ControlWave GFC to perform a core updump,
provided you have set the SW1 switches to allow recovery
mode. Values are:
ON (Disables core updump; factory default)
OFF Core updump
5
SRAM Control
Manages SRAM contents following a low power situation
or a power outage. Values are:
ON (Retain values in SRAM during restarts; factory
default)
OFF (Reinitialize SRAM) – Data in SRAM lost during
power outage or re-start.
6
System
Firmware
Allows a remote download of system firmware (on units
equipped with boot PROM version 4.7 or higher and
system PROM version 4.7 and higher). Values are:
ON (Enable remote download of system firmware; factory
default)
OFF (Disable remote download of system firmware)
7
N/A
Not currently used.
8
Enable
WINDIAG
Suspends normal operation and allows diagnostic
routines. Values are:
ON (Permits normal system operation, including the boot
project, and disables the WINDIAG diagnostics from
running; factory default)
OFF (Allow WINDIAG to run test; disable boot project and
normal system operation.)
Note: Setting both switch 8 and switch 3 to OFF (closed)
sets all communication ports to 9600 bps operation.
All serial communication ports must be set at 9600
bps before WINDIAG can perform communication
tests.
Note: Table 2-3 describes switch settings for RS-485 port operation.
You may want to review Section 2.3.6 on RS-485 configuration
before you set these switches.
Table 2-3. RS-485 Configuration Switch SW3
Switch
Setting
1
2
2-20
Function
Mode
TX+ to RX+ Loopback / 2wire
ON (2-wire operation or loopback enabled)
TX- to RX- Loopback / 2-
ON (2-wire operation or loopback enabled)
Installation
OFF (4-wire operation and loopback
disabled)
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Switch
Setting
Function
Mode
wire
OFF (4-wire operation and loopback
disabled)
3
100 Ohm RX+ Termination
ON (End nodes only)
4
100 Ohm RX- Termination
ON (End nodes only)
5
N/A
Not currently used
6
N/A
Not currently used
7
RX+ Bias (End Node)
ON (4-wire = Both End nodes only; 2-wire=
One end node only)
OFF = No bias
RX- Bias (End Node)
8
ON (4-wire = Both End nodes only; 2-wire=
One end node only)
OFF = No bias
2.3.2 Setting Jumpers on the CPU/System Controller Board
The CPU has several jumpers.
 W1: COM1 CTS usage:
o 1-to-2 Installed = COM1 CTS source is from device.
o 2-to-3 Installed = COM1 RTS to CTS loopback
 W2: COM2 CTS usage:
o 1-to-2 Installed = COM2 CTS source is from device.
o 2-to-3 Installed = COM2 RTS to CTS loopback
Note: You must enable the backup battery by setting jumper W3 to
position 1-2.





Revised Nov-2011
W3: Enable/disable battery backup selection:
o 1-to-2 Installed = Enable battery backup.
o 2-to-3 Installed = Disable battery backup
W5: Power supply shut down selection:
o 1-to-2 Installed = 12/24V power supply shut down hysteresis
o 2-to-3 Installed = 6V power supply shut down hysteresis
W6: Power supply shut down selection:
o 1-to-2 Installed = 12V power supply shut down
o 2-to-3 Installed = 6/24V power supply shut down
W7: Power fail trip point hysteresis selection:
o 1-to-2 Installed = 12/24V power fail trip point hysteresis
o 2-to-3 Installed = 6V power fail trip point hysteresis
W8: Power fail trip point selection:
o 1-to-2 Installed = 12V power fail trip point
o 2-to-3 Installed = 6/24V power fail trip point
Installation
2-21
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)







W12: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W13: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W14: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W15: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W16: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W17: Input power selection (controls solar power shunt regulation.
Not applicable for +24Vdc CPUs:
o 1-to-2 Installed = 6V power
o 2-to-3 Installed = 12V power
W18: COM1 connector selection:
o 1-to-2 Installed = connector J4 (D connector) is active
o 2-to-3 Installed = alternate connector J11 is active
2.3.3 General Wiring Guidelines




ControlWave GFC terminal blocks use compression-type terminals
that accommodate up to #16 AWG wire.
When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the screw.
To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.
Note: Fuse F4 applies only for Class I Division 1 hazardous locations
with the intrinsically safe ControlWave GFC-IS. See Figure 2-11
to locate the fuse. See Supplement CW-GFC-IS for more
information on the intrinsically safe ControlWave GFC-IS.
2-22
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.3.4 Wiring Power to the CPU/System Controller Board
Caution
At this time you can connect power wiring. However; for safety reasons
and to prevent accidental damage to your bulk DC power supply, do not
connect the pluggable terminal block connectors TB1 and TB2 to the
CPU/System Controller board until after you install, wire, ground, and
configure the entire unit.
Follow the instructions in Section 2.3.3 General Wiring Guidelines when
wiring connections.
Power Supply Depending upon the CPU type, the ControlWave GFC accepts either a
Current 6Vdc, 12Vdc or 24Vdc bulk power input. You can estimate the
Requirements maximum current required for your ControlWave GFC using the
following equation:
Bulk +6/12/24 Vdc Supply Current = CPU/System Controller Board (with
options) + Process I/O Board + LCD
display/keypad + optional modem /
radio
Refer to Table 2-4 for ControlWave GFC power requirements based on
the CPU type.
Table 2-4. ControlWave GFC Bulk Power Requirements
CPU Type and Components
14 MHz Ultra Low Power CPU with LCD
display/keypad
33 MHz CPU with Ethernet and LCD
display/keypad
Bulk 6Vdc
Power
Supply
Bulk 12Vdc
Power Supply
Bulk 24Vdc
Power Supply
7 mA
without field supply
and with AO output
under range: 5 mA
Not Supported
Not
Supported
without process I/O
board: 80 mA
without process I/O
board: 47 mA
Note: If your ControlWave GFC includes a modem or radio, contact
the radio/modem manufacturer for power consumption
specifications.
Caution
Revised Nov-2011
If your ControlWave GFC is configured to use a solar panel to charge a
7AH (6V or 12V) battery for power, NEVER CONNECT THE SOLAR
PANEL/CHARGER WITHOUT ALSO CONNECTING THE BATTERY.
Connections without the battery present can damage power supply
components.
Installation
2-23
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Terminal Block Unplug removable connector TB1 from the CPU/System Controller
Connector TB1 board. We recommend you do not plug the connector back into the CPU
until the unit is already installed in the housing.
You can power the ControlWave GFC using a bulk DC power supply
using connections TB1-3 and TB1-4.
Nominal input source operating ranges for the DC power supply are:
 +6Vdc (+5.4Vdc to +16.0Vdc nominal operating range)
 +12Vdc (+11.4Vdc to +16.0Vdc nominal operating range)
 +24Vdc (+21.8Vdc to +28.0Vdc nominal operating range)
Not all ControlWave GFC CPUs support all DC power supplies.
Supported options are:

14MHz Ultra Low Power CPU: Supports +6Vdc or +12Vdc
nominal power supply.
 33MHz CPU with Ethernet: Supports +12Vdc nominal or +24Vdc
nominal power supply.
Alternatively, you can power low powered versions of the ControlWave
GFC using a solar panel connected to a user-supplied rechargeable 7AH
(6V/12V) lead acid battery.
TB1 connections are:

TB1-1: (Solar Power IN+): Power from a 1W – 6V, 5W – 6V or
5W – 12V solar panel (internally wired to recharge a factorysupplied battery). Not available on units with Ethernet.
 TB1-2 = Ground (GND) Not available on units with Ethernet.
 TB1-3 = Primary Power: Power from an internal factory-supplied
battery or from an external nominal +6Vdc , +12Vdc or +24Vdc
power supply, depending upon the CPU type.
 TB1-4 = Ground (GND)
 TB1-5 = Auxiliary Power Out+: for a radio or modem (if
supported). Aux power out enabled when DTR signal for COM2
goes high. Aux Power Out not available on units with Ethernet.
 TB1-6 = Ground (GND) for Aux power out.
Figure 2-12 shows the typical wiring at the TB1 block.
2-24
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-12. CPU/System Controller Board (TB1 & TB2) Power Wiring
Terminal Block The ControlWave GFC includes an alternative power connecter, TB2, to
Connector TB2 provide power if none is available at TB1. For example, you can
connect a bulk DC power supply to TB2 to handle situations where the
solar panel/battery system does not have sufficient power.
TB2 connections are:


TB2-1 = Power Input
TB2-2 = Ground (GND)
2.3.5 Connections to RS-232 Serial Port(s) on the CPU/System
Controller Board
An RS-232 port provides point-to-point, half-duplex and full-duplex
communications (for a maximum of 20 feet using data quality cable).
Your CPU includes two RS-232 ports and one port configurable for
either RS-232 or RS-485 operation.
Revised Nov-2011
Installation
2-25
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2- 13. PC Connected to ControlWave GFC via Circular Local Port
Notes:


RS-232 COM
Port Names and
Connectors
Cable part number 395402-01-8 = 10 foot communication cable.
Cable part number 395402-02-6 = 25 foot communication cable.
RS-232 COM ports use different connector types.
Table 2-5. RS-232 Connectors
Connector
Name
# Pins and Type
Notes
J4
COM1
9-pin male D-type
Choice of active connector for COM1
determined by jumper W18.
Ships from the factory connected to the local
port on the bottom of the front cover of the
unit.
J11
COM1
3-pin male
Choice of active connector for COM1
determined by jumper W18.
TB3
COM2
8-pin terminal block
Use this port for connection to a radio
mounted on the battery cover/radio mounting
plate.
2-26
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Connector
Name
# Pins and Type
Notes
TB4
COM3
5-pin terminal block
This port can be configured as either RS-232
or RS-485. See Section 2.3.6 for more
information.
RS-232 For the ControlWave GFC, half-duplex communications use Modbus or
COM1/COM2 BSAP protocol, while full-duplex communications use point-to-point
Port Cables protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 215) to connect with other devices (such as a PC, a printer, another
ControlWave [except the CW_10/30/35]) when the ControlWave GFC
uses the full-duplex PPP protocol.
Note: You can configure the ControlWave GFC as either a master or
slave node on a Modbus or BSAP network.
Figure 2-14 illustrates the CPU module’s male 9-pin D-type connector.
for COM1. Use the content provided in Table 2-6 to determine pin
assignments for the COM1 and COM2 ports.
Figure 2-14. Male DB9 9-Pin Connector
Table 2-6. RS-232 COM1 and COM2 Port Connector Pin Assignment
Pin
RS-232
Signal
1
DCD
Data Carrier Detect Input
1 (Green wire)
2
RXD
Receive Data Input
2 (Red wire)
3
TXD
Transmit Data Output
7 (White wire)
4
DTR
Data Terminal Ready Output
4 (Brown wire)
5
GND
Power Ground
6 (Black wire)
6
DSR
Data Set Ready Input
7
RTS
Request to Send Output
RTS connected to CTS at J4
of CPU for local port
communication cable.
8
CTS
Clear to Send Input
RTS connected to CTS at J4
of CPU for local port
communication cable.
9
Revised Nov-2011
Local Port Pin#
Local Port Notes:
RS-232 Description
Pin 4 connected to pin 4 at
TB5 of CPU = external power
for local communication port
cable.
N/A
Installation
2-27
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Use the “null modem” cable for full-duplex (PPP protocol)
communications when connecting a ControlWave GFC to a PC. (See
top part of Figure 2-15.)
Table 2-7. RS-232 COM1 (J11) Alternate Connector Pin Assignment
Pin
RS-232
Signal
1
GND
Power ground
2
RXD
Receive data input
3
TXD
Transmit data output
RS-232 Description
Figure 2-15. Full-duplex and Half-duplex Cable
Use the half-duplex cable (shown in the bottom part of Figure 2-15)
when connecting the ControlWave GFC to another ControlWave series
unit (again, with the exception of the CW_10/30/35).
When communicating with a Network 3000 series RTU 3305, RTU
3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of
the cables shown in Figure 2-16.
2-28
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-16. Full-duplex and Half-duplex Cable
Refer to Figure 2-17 when using COM2 of the ControlWave GFC to
connect with an case mounted modem or radio.
Figure 2-17. Connection from an Case Mounted Modem/Radio to
COM2 of the ControlWave GFC
When interfacing to the COM3 port of a ControlWave, or the COM5 or
COM6 port a ControlWaveEXP unit, use the cable presented in Figure
2-18 along with one of the cables shown in Figure 2-15 or Figure 2-16.
Figure 2-18. Full-duplex and Half-duplex Cable
Revised Nov-2011
Installation
2-29
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
RS-232 Cable
Guidelines
Observe the following guidelines when constructing RS-232
communication cables:





Ensure that DCD is high to transmit (except when dialing a modem)
Verify that each RS-232 transceiver has one active receiver while
disabled (in power down mode); connect the DCD signal to the
active receiver.
Set CTS to high to transmit.
If the port is set for full-duplex operation, RTS is always ON.
Ensure that DTR is always high when port is active; DTR enables
RS-232 transceivers.
Note: Control DTR using the PORTCONTROL function block and
the _Pn_AUTO_DTR system variable in your ControlWave
project. If you turn DTR off through these mechanisms, the
port remains off, even though hardware is fully configured.



When port is set for half-duplex operation, CTS must go low after
RTS goes low.
All RS-232 comm ports support RTS, DTR, CTS, DCD, and DSR
control signals.
All RS-232 comm port I/O signals are protected by surge protectors.
2.3.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the
CPU/System Controller Board
You use jumpers W12 through W16 to configure COM3 of the
ControlWave GFC for either RS-232 or RS-485 operation. See Section
2.3.2 for information on these jumpers.
Table 2-8. COM3 RS-485 Connector (TB4) on CPU/System Controller Board
Connector
Name
# Pins and Type
Notes
TB4
COM3
5-pin terminal block
This port can be configured as
either RS-232 or RS-485.
RS-485 COM3 Table 2-9 shows connector pin assignments for COM3.
Port Cables
Note: If you use COM3 for RS-232 operation, pins 1 and 4 do not
apply.
Table 2-9. COM3 Connector Pin Assignment
2-30
Pin
Signal
Description
1
RXD+
Receive Data + input (Not applicable for
RS-232 usage)
2
RXD–/RXD
Installation
Receive Data – Input
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Pin
Signal
Description
RXD- for RS-485 use
RXD for RS-232 use
3
TXD–/TXD
Transmit Data – Output
TXD- for RS-485 use
TXD for RS-232 use
4
TXD+
Transmit Data + Output (Not applicable for
RS-232 usage)
5
Power Ground
Ground
When serving as an RS-485 port, COM3 supports local network
communications to multiple nodes up to 4000 feet away.
Since the RS-485 port is intended for network communications, refer to
Table 2-10 for the appropriate connections for wiring the master, first
slave, and nth slave.
Essentially, the master and the first slave transmit and receive data on
opposite lines; all slaves (from the first to the nth) are paralleled (daisychained) across the same lines. Wire the master node to one end of the
RS-485 cable run using a 24-gauge paired conductor cable (such as a
Belden 9843).
Note: ControlWave GFC supports only half-duplex RS-485 networks.
Table 2-10. RS-485 Network Connections
From Master
To First Slave
To nth Slave
TXD+
RXD+
RXD+
TXD–
RXD–
RXD–
RXD+
TXD+
TXD+
RXD–
TXD–
TXD–
GND
GND
GND
To ensure that the “Receive Data” lines are in a proper state during
inactive transmission periods, you must maintain certain bias voltage
levels at the master and most distant slave units (end nodes). These end
nodes also require the insertion of 100Ω terminating resistors to
properly balance the network.
You must also configure switches at each node to establish proper
network performance. Accomplish this by configuring switches listed so
that the 100Ω termination resistors and biasing networks are installed at
the end nodes and are removed at all other nodes on the network. You
enable receiver biasing and termination (as well as 2-wire or 4-wire
selection) using an 8-position DIP switch located on the CPU/System
Controller board. See Table 2-3 for more information.
Revised Nov-2011
Installation
2-31
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.3.7 Connections to the Ethernet Port on the CPU/System
Controller Board
Caution
The RJ45 Ethernet port is connector (J1) located on the CPU/System
Controller board. The board also has one RJ45 port (J2) for the optional
Display/Keypad. Never connect Ethernet to J2 (the Display/Keypad port)
or damage will result.
The 33MHz ControlWave GFC can support one Ethernet port. This
port uses a 10/100Base-T RJ-45 modular connector (J1) that provides a
shielded twisted pair interface to an Ethernet hub.
A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with
port 8 having the capability to link either to another hub or to an
Ethernet communications port). Both ends of the Ethernet twisted pair
cable are equipped with modular RJ-45 connectors.
1
8
Looking into
receptacle
Figure 2-19. RJ-45 Ethernet Connector
These cables have a one-to-one wiring configuration as shown in
Figure 2-20. Table 2-11 provides the assignment and definitions of the
8-pin 10/100Base-T connectors.
Figure 2-20. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)
Table 2-11. Ethernet 10/100Base-T CPU Module Pin Assignments
Pin
2-32
Description
1
Transmit Data+ (Output)
2
Transmit Data– (Output)
3
Receive Data+ (Input)
4
Not connected
5
Not connected
6
Receive Data– (Input)
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Pin
Description
7
Not connected
8
Not connected
Note: You can swap TX and RX at the hub.
You can connect two nodes in a point-to-point configuration without
using a hub. However, you must configure the cable so that the TX+/Data pins connect to the RX+/- Data pins (swapped) at the opposite
ends of the cable (see Figure 2-21).
Figure 2-21. Point-to-Point 10/100Base T Ethernet Cable
The maximum length of one segment (CPU to hub) is 100 meters (328
feet). The use of Category 5 shielded cable is recommended.
2.4 Radio-Ready and Case Mounted Modem or Radio
The ControlWave GFC ships from the factory with a user selected radio
or modem installed within the enclosure (in front of the battery
mounting bracket) or as a radio-ready unit, in other words., ready for
field installation of a factory-supplied radio. The installer must ensure
that the remote antenna (associated with a case mounted radio) is
properly installed and connected.
See the ControlWave Radio-Ready Installation Guide (D5138) for
information on installing factory-supplied radios in the field.
See the ControlWave PSTN Modem Installation Guide (D5139) for
information on installing the 9600 bps PSTN modem.
Revised Nov-2011
Installation
2-33
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.5 Mounting the Solar Panel
Depending upon the type of power system you choose, your
ControlWave GFC may require a solar panel. The solar panel charges a
rechargeable 6V or 12V 7AH lead acid battery. Solar panel wires enter
the unit through a liquid tight conduit fitting and connect to TB1 on the
CPU/System Controller board.
Caution
If your ControlWave GFC is configured to use a solar panel to charge a
7AH (6V or 12V) battery for power, NEVER CONNECT THE SOLAR
PANEL/CHARGER WITHOUT ALSO CONNECTING THE BATTERY.
Connections without the battery present can damage power supply
components.
You can mount the solar panel to a 2” to 2-3/8” pipe using muffler
(pipe) clamps. You secure the pipe clamps using four ¼-20 nuts and
washers. (See Figure 2-22 and Figure 2-23.)
You must swivel the solar panel for optimum alignment with the sun. In
the northern hemisphere, face the panel due south (not magnetic south).
In the southern hemisphere, face the panel due north (not magnetic
north).
1 and 5 watt solar panel systems have adjustable tilt angles. Adjust the
tilt angle for maximum performance to accommodate the latitude of
your installation site. Table 2-12 shows the angle (from horizontal) at
which you should install the solar panel 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 winter.
Table 2-12. Solar Panel Tilt Angle
Latitude
0-4°
2-34
Tilt Angle
10° from Horizontal
5-20°
Add 5° to the Local Latitude
21-45°
Add 10° to the Local Latitude
46-65°
Add 15° to the Local Latitude
66-75°
80° from Horizontal
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-22. 1 Watt Solar Panel Mounting Diagram
Revised Nov-2011
Installation
2-35
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 2-23. 5 Watt Solar Panel Mounting Diagram
2-36
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2.6 Optional Display/Keypads
The ControlWave GFC supports two optional display/keypads and a
display without a keypad:


A 2-button keypad (shown in the left of Figure 2-24)
A 25-button keypad (shown in the right Figure 2-24)

Display only (no keypad) – (see Figure 2-25)
Figure 2-24. Optional 2-Button and 25-Button Keypads
Figure 2-25. Display with No Keypad
Both keypads use the same 4-line by 20-character LCD displays.
The Display without a keypad has a 2-line display with 10 characters on
the first line, and 6 characters on the second line. This display shows
variable values on line 1, and variable names on line 2.
Revised Nov-2011
Installation
2-37
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
You connect the Display/Keypad or Display to the ControlWave GFC
using a cable, one end of which has an RJ-45 jack (connected into the
RJ-45 equipped with two plugs. This cable connects between the RJ-45
display jack (J2) on the CPU/System Controller board and RJ-45 jack
(J1) on the remote Display or remote Display/Keypad assembly. A
potentiometer, provided on the keypad, allows you to set the contrast of
the LCD display.
Notes:


2-38
For information on the status codes which appear on the display, see
Section 5.3.2 Checking LCD Status Codes in Chapter 5.
For further information on the installation and use of the optional
keypads, refer to the ControlWave Display/Keypad Manual
(D5135).
Installation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Chapter 3 – I/O Configuration and Wiring
This chapter discusses setting I/O configuration switches and jumpers
and wiring I/O connections to the ControlWave GFC.
In This Chapter
3.1
3.2
3.3
I/O Options .......................................................................................3-1
Process I/O Board ...........................................................................3-2
3.2.1 Setting Jumpers on the Process I/O Board ..........................3-2
3.2.2 Setting DIP Switches on the Process I/O Board ..................3-2
I/O Wiring .........................................................................................3-4
3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O
Board ..................................................................................3-6
3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O
Board ..................................................................................3-7
3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O
Board ..................................................................................3-8
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O
Board ..................................................................................3-9
3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of
CPU/System Controller Board ..........................................3-10
3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on
TB4 of Process I/O Board .................................................3-11
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System
Controller Board................................................................3-12
3.3.8 Connections to a Bristol Model 3808 Transmitter ..............3-14
3.1 I/O Options
ControlWave GFC comes with the following standard I/O:
2 Pulse Counter Inputs with a 1 second scan rate (can be configured
as discrete inputs (DI))
 The 14 MHz CPU and the 33MHz CPU with Ethernet also includes
a Resistance Temperature Device (RTD) probe.
In addition, three different versions of the optional process I/O board are
available:

Table 3-1. Process I/O Configurations
Revised Nov-2011
Type
Discrete
Input /
Output
(DI/DO)
Discrete
Input (DI)
Discrete
Output
(DO)
High Speed
Counter
(HSC)
A
2
4
2
2
B
2
4
2
2
3
C
2
4
2
2
3
I/O Configuration and Wiring
Analog
Input (AI)
Analog
Output
(AO)
1
3-1
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.2 Process I/O Board
ControlWave GFC may include an optional Process I/O board.
The Process I/O board stands vertically on edge against the inner left
side of the enclosure and mounts to the CPU/System Controller board
using six nylon mounting posts.
To configure the Process I/O board, you need to set some switches and
jumpers. See Figure 3-1 for the location of the switches and jumpers.
3.2.1 Setting Jumpers on the Process I/O Board
The Process I/O board has several jumpers.
 JP1: AO output source (1-5V or 4-20mA):
o 1-to-2 Installed = 4-20mA analog output
o 2-to-3 Installed = 1-5V analog output
 JP3: AO power source:
o 1-to-2 Installed = system power
o 2-to-3 Installed = external power (+11 to +30 Vdc)
 JP4: AI field power configuration:
o 1-to-2 Installed = external power
o 2-to-3 Installed = bulk input supply (system power)
 JP5: AI1 input type (1-5V or 4-20mA)
o 1-to-2 Installed = 4-20mA analog input
o 2-to-3 Installed = 1-5V analog input
 JP6: AI2 input type (1-5V or 4-20mA)
o 1-to-2 Installed = 4-20mA analog input
o 2-to-3 Installed = 1-5V analog input
 JP7: AI3 input type (1-5V or 4-20mA)
o 1-to-2 Installed = 4-20mA analog input
o 2-to-3 Installed = 1-5V analog input
3.2.2 Setting DIP Switches on the Process I/O Board
The Process I/O board includes a single switch bank (SW1) to configure
the frequency for the high speed counters (HSC), the source current for
discrete inputs/counters, and the analog output.
Table 3-2. Process I/O Module Switch SW1
3-2
SW1
SW1-1
Function
Frequency for High Speed Counter1 (HSC1)
SW1-2
Frequency for High Speed Counter2 (HSC2)
I/O Configuration and Wiring
Mode
OFF = 10 kHz (high speed)
ON = 300 Hz (low speed)
OFF = 10 kHz (high speed)
ON = 300 Hz (low speed)
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
SW1
Function
SW1-3
DI/HSC 2mA source current
SW1-4
AO configuration
Mode
OFF = disabled
ON = enabled
OFF = current
ON = voltage
Figure 3-1. Process I/O Board Component Identification Diagram
Revised Nov-2011
I/O Configuration and Wiring
3-3
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Caution
Power down the ControlWave GFC before you perform I/O wiring. Shut
down any processes the ControlWave GFC may be managing (or switch
them over manually or handle with another controller). Perform any
hardware configuration (wiring, jumper configuration, and installation)
only when the ControlWave GFC is powered down.
Before any I/O connections can become operational, you must use
ControlWave Designer to configure and then download the application
(project).
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:


Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
3.3 I/O Wiring
The ControlWave GFC uses card edge terminal blocks to accommodate
field wiring. You route the wires into the enclosure/chassis through a ½
inch conduit fitting.
ControlWave GFC I/O uses compression-type terminals that
accommodate up to #16 AWG wire. Insert the wire’s bared end (approx.
¼” max) into the clamp beneath the screw and secure the wire. To
prevent shorts, ensure that no bare wire is exposed. If using standard
wire, tin the bare end with solder to prevent flattening and improve
conductivity. Allow some slack in the wires when making terminal
connections. Slack makes the wires more manageable and helps
minimize mechanical strain on the terminal blocks.
Shielding and Use twisted-pair, shielded and insulated cable for I/O signal wiring to
Grounding minimize signal errors caused by electromagnetic interference (EMI),
radio frequency interference (RFI), and transients. When using
shielded cable, ground all shields at only one point in the appropriate
system. This prevents circulating ground current loops that can cause
signal errors.
3-4
I/O Configuration and Wiring
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 3-2. Process I/O Board Wiring Diagrams
Revised Nov-2011
I/O Configuration and Wiring
3-5
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process
I/O Board
Process I/O Board terminal block connector TB2 provides interface to
four dedicated non-isolated discrete inputs DIs – DI1 through DI4. In
addition, terminal block connector TB3 provides two additional points
that can serve as either discrete inputs or discrete outputs (DI5 and DI6
when wired as inputs).
Table 3-3. Non-Isolated DI General Characteristics
Type
Discrete Inputs
(DI)
Number
Supported
4 on TB2
(optionally
2 on TB3)
Characteristics
 Supports dry contact inputs pulled
internally to 3.3 Vdc when field input is
open.
 Source current for DI1 to DI4 of either
60 μA or 2 mA based on switch SW13 setting. See Table 3-2.
 Source current for DI5 to DI6 of either
200 μA or 2.2 mA based on switch
SW1-3 setting. See Table 3-2.
 15 ms input filtering
Wiring See Figure 3-2 for wiring diagrams.
Software Configuration To use data from these DIs you must include a CWM_EIO board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this board.
Note: You must specify whether a discrete input/output is a DI or a
DO in ControlWave Designer’s I/O Configurator by
configuring a DI pin or a DO pin.
3-6
I/O Configuration and Wiring
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O
Board
Process I/O Board terminal block connector TB3 provides interface to
two dedicated non-isolated discrete outputs DOs – DO1 and DO2. In
addition, terminal block connector TB3 provides two additional points
that can serve as either discrete inputs or discrete outputs (DO3 and
DO4 when wired as outputs).
Table 3-4. Non-Isolated DO General Characteristics
Type
Number
Supported
Discrete Outputs
(DO)
2 to 4 (on
TB3)
Characteristics
 Supports 30V operating range. Can
sink 400 mA max at 30Vdc (open
drain).
 Maximum output frequency of 20Hz.
 Surge protection between signal and
ground.
Wiring See Figure 3-2 for wiring diagrams.
Software Configuration To use data from these DOs you must include a CWM_EIO board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this board.
Note: You must specify whether a discrete input/output is a DO or a
DI in ControlWave Designer’s I/O Configurator by
configuring a DO pin or a DI pin.
Revised Nov-2011
I/O Configuration and Wiring
3-7
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board
Process I/O Board terminal block connector TB6 provides interface to
three single-ended analog inputs (AIs).
Table 3-5. Non-Isolated AI General Characteristics
Type
Analog
Inputs (AI)
Number
Supported
Characteristics
3 (on TB6)
 Jumper-selectable using JP5, JP6, and
JP7 for either 4-20mA or 1-5V operation.
 Jumper JP4 determines whether AI field
power comes from system power (bulk
input supply applied to TB1-3 and TB1-4
on the CPU/System Controller Board) or
the external loop power source connected
to TB7-3 and TB7-4 on the Process I/O
board.
 2 Hz low pass filter for each AI.
 Surge Suppression.
 Self calibrating.
Setting Jumpers See Section 3.2.1 for details on setting jumpers.
Wiring Each AI includes three terminals (field power, AI# and DGND). See
Figure 3-2 for wiring diagrams. If using the ControlWave Loop Power
Supply, see document PIP-ControlWave-LS.
Notes:



You must connect cable shields associated with AI wiring to the
ControlWave GFC chassis ground.
Multiple shield terminations require you to supply a copper ground
bus. You must connect the ground bus to the ControlWave GFC
chassis ground lug using up to a #4 AWG wire size. The ground
bus must accommodate a connection to a known good Earth ground
(in lieu of a direct connection from the ControlWave GFC chassis
ground) and to all AI cable shields.
Use an appropriate terminal lug for shield wires and secure them to
the copper bus using industry rugged hardware (screw/bolt, lock
washer and nuts).
Software To use data from these AIs you must include a CWM_EIO board in
Configuration your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this board.
3-8
I/O Configuration and Wiring
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O
Board
Process I/O Board terminal block connector TB7 provides interface to a
single analog output (AO).
Table 3-6. Non-Isolated AO General Characteristics
Type
Analog
Output
(AO)
Number
Supported
Characteristics
1 (on TB7)
 Supports either 4-20mA or 1-5V operation.
Selection using jumper JP1 and switch SW14.
 Jumper JP3 determines whether AO field
power comes from system power (nominally
12 or 24V from bulk input supply applied to
TB1-3 and TB1-4 on the CPU/System
Controller Board) or from an external 24V
power source (+11 to +30Vdc connected to
TB7-3 and TB7-4) such as the ControlWave
Loop Power Supply.
 Maximum external load you can connect to a
4-20mA output is 250 ohms for an external
11V power source or 650 ohms for an
external 24V power source.
 Maximum external load current for the 1-5V
output is 5 mA (with an external 11 to 30 V
power source.)
 Factory-calibrated.
Setting See Section 3.2.1 for details on setting jumpers.
Jumpers
Wiring See Figure 3-2 for wiring diagrams. If using the ControlWave
Loop Power Supply, see document PIP-ControlWave-LS.
Note:
If your ControlWave GFC uses 6V bulk power, you
must provide external power for the AO.
Software To use data from this AO you must include a CWM_EIO board in
Configuration your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That
same manual includes an I/O Mapping section that describes, for
advanced users, the I/O map for this board.
Revised Nov-2011
I/O Configuration and Wiring
3-9
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of
CPU/System Controller Board
CPU/System Controller Board connector TB5 provides interface to two
internally sourced open collector pulse counter/discrete inputs (Pulse1
and Pulse2) with a 1 second scan rate. Pulse counters act like high speed
counters but cannot function with contact relays because they lack
contact debounce circuitry.
Table 3-7. Non-Isolated Pulse Counter/Discrete Inputs General
Characteristics
Type
Pulse Counter /
Discrete Inputs
Number
Supported
Characteristics
2 on TB5 of
CPU/Syste
m Controller
board
 Signal conditioning circuitry provides
20 microsecond filtering.
 Surge suppression.
 Maximum input frequency for each
pulse counter/discrete input circuit is
10 KHz.
Wiring Pulse counter/discrete inputs are field driven by open collector circuits
and are sourced for 3.3V (internally) with a 200μA source current. See
Figure 3-3 for information on the open collector wiring arrangement.
Figure 3-3. Pulse Input Wiring Diagram
Software Configuration To use data from these pulse counter/discrete inputs you must include
a CWM_ECPU board in your ControlWave project using
ControlWave Designer’s I/O Configurator, and then configure it. See
the ControlWave Designer Programmer's Handbook (D5125) for more
information. That same manual includes an I/O Mapping section that
describes, for advanced users, the I/O map for this board. To read a DI
value, look at the appropriate offset for the _STATE variable for the
board.
3-10
I/O Configuration and Wiring
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI)
on TB4 of Process I/O Board
Process I/O Board connector TB4 provides interface to two internally
sourced single-ended high speed counter/discrete inputs (HSC1 and
HSC2).
Table 3-8. Non-Isolated High Speed Counter/Discrete Inputs General
Characteristics
Type
High Speed
Counter /
Discrete Inputs
Number
Supported
Characteristics
2 on TB4
of Process
I/O board
 Surge suppression and signal
conditioning.
 HSCs can use dry contacts or open
collector field circuits.
 High speed counter switch-selectable
frequency of 10kHz or 300Hz.
 Sourced from 3.3Vdc and switch
selectable for a source current of
200μA (switch SW1-3 = OFF) or
2.2mA (switch SW1-3 = ON). Note:
These switches affect all DIs and
HSCs.
Wiring See Figure 3-2 for wiring diagrams.
Switch Settings See Table 3-2 for details on setting switches.
Software Configuration To use data from these high speed counter/discrete inputs you must
include a CWM_EIO board in your ControlWave project using
ControlWave Designer’s I/O Configurator, and then configure it. See
the ControlWave Designer Programmer's Handbook (D5125) for more
information. That same manual includes an I/O Mapping section that
describes, for advanced users, the I/O map for this board. To read a DI
value, look at the appropriate offset for the _STATE variable for the
board.
Revised Nov-2011
I/O Configuration and Wiring
3-11
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System
Controller Board
CPU/System Controller Board connector TB6 provides connection to a
3-wire 100 ohm platinum bulb RTD (using the DIN 43760 curve).
Wire the RTD according to Table 3-9 and Figure 3-4 and Figure 3-5. In
this configuration, the return lead connects to the RTD- terminal and the
two junction leads (Sense and Excitation) connect to the RTD+ and
RTD EXC terminals.
Caution
Never ground the RTD cable shield at both ends or allow it to come in
contact with metallic/conductive conduit because multiple ground paths
can cause RTD input errors.
Table 3-9. RTD Connections to CPU/System Controller Board
Connector TB6
TB6 Pin
Signal
Function
1
RTD EXC
Reference
2
RTD+
Sense
3
RTD-
Return
Figure 3-4. 3-Wire RTD Temperature Input Wiring
Installing the RTD To install the RTD probe, screw the fitting body into the thermowell
Probe with a 7/8” open-end wrench. While you apply pressure against the
sheath to force the tip of the RTD probe into the bottom of the
thermowell (so that the probe tip is in contact with the bottom of the
thermowell), tighten the 9/16” nut using an open-end wrench against
the 7/8” fitting body.
3-12
I/O Configuration and Wiring
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 3-5. RTD Probe Installation/Removal Diagram
Software Configuration To use data from the RTD you must include a CWM_ECPU board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this module.
Revised Nov-2011
I/O Configuration and Wiring
3-13
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3.3.8 Connections to a Bristol Model 3808 Transmitter
You can connect a Bristol 3808 transmitter (digital) to the ControlWave
GFC through either an RS-232 or RS-485 port. Communication
schemes and cable lengths determine the type of communication port
you need to use. In general RS-232 communications require that you
place the 3808 transmitter within 25 feet of the ControlWave GFC
(local communications). You can use RS-485 communications to reach
transmitters up to 4000 feet away (remote communications).
Figure 3-6 details RS-232 wiring connections required between the
ControlWave GFC and the 3808 transmitter.
Figure 3-6. 3808 Transmitter to ControlWave GFC RS-232 Comm. Cable Diagram
Figure 3-7 details RS-485 wiring connections required between the
ControlWave GFC and the 3808 transmitter.
Note: For loopback and termination control, use switch SW3 on the
CPU/System Controller board to configure COM3. See Table 23.
3-14
I/O Configuration and Wiring
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 3-7. 3808 Transmitter to ControlWave GFC RS-485 Comm. Cable
You can connect up to two 3808 transmitters to a ControlWave GFC
using a half-duplex RS-485 network. See Figure 3-8 for an illustration
of this type of network.
Figure 3-8. ControlWave GFC to 3808s - RS-485 Network Diagram
Revised Nov-2011
I/O Configuration and Wiring
3-15
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Chapter 4 – Operation
This chapter provides general operational details for using the
ControlWave GFC.
In This Chapter
4.1
4.2
4.3
4.4
WARNING
Powering Up/Powering Down the ControlWave GFC .....................4-1
Communicating with the ControlWave GFC ....................................4-2
4.2.1 Default Comm Port Settings .................................................4-2
4.2.2 Collecting Data from the ControlWave GFC ........................4-3
Creating and Downloading an Application (ControlWave Project) ..4-3
Creating and Maintaining Backups ..................................................4-3
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ............4-4
4.4.2 Saving Flash Configuration Parameters (*.FCP) .................4-5
4.4.3 Backing up Data ...................................................................4-6
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave GFC is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
See Appendix A for details on Class I Division 2 usage of this device.
4.1 Powering Up/Powering Down the ControlWave GFC
The ControlWave GFC receives power either from a solar panel and
user-supplied battery or from an external bulk power supply attached
using connector TB1 on the CPU/System Controller board. It can also
receive power through alternate connector TB2 on the same board.
Chapter 2 includes instructions for wiring power to the ControlWave
GFC. See Figure 2-3 for the location of these connectors.
Power Up To apply power to the ControlWave GFC, plug in connectors TB1 and
optionally TB2 on the CPU/System Controller board. If your
ControlWave project resides in flash memory, the project will load into
SRAM and begin execution. Depending upon the setting of the SRAM
control switch, retain variable values may load as well.
Revised Nov-2011
Operation
4-1
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Caution
When you disconnect power from the ControlWave GFC, your running
control strategy is erased from SRAM, as is any process data not stored
in retention mode. When configured for retention and the backup battery
remains good, SRAM stores the last states of all I/O points, audit/archive
data not residing in FLASH, the values of all variables marked RETAIN,
the values of variables stored in the static memory area, and any pending
unreported alarm messages.
Power Down To remove power from the ControlWave GFC, unplug connectors TB1
and TB2 from the CPU/System Controller board.
4.2 Communicating with the ControlWave GFC
You communicate to the ControlWave GFC by connecting a cable
between a port on your PC workstation and one of the ControlWave
GFC ports.
The port at the PC workstation must match the configuration of the
ControlWave GFC port.
4.2.1 Default Comm Port Settings
As delivered from the factory, ControlWave GFC communication ports
have default settings. Table 4-1 details these defaults.
Table 4-1. Default Comm Port Settings
Port
PCB
Default Configuration
COM1
CPU
RS-232; 115.2 Kbps using BSAP or ControlWave Designer
protocol. Note: The local port at the bottom of the door is
factory-wired to COM1.
COM2
CPU
RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM3
CPU
RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol. Intended for use with Bristol
3808 transmitters. You use jumpers W12 through W16 to
configure COM3 for either RS-232 or RS-485
Note: You can re-enable the factory communication settings at any
time by setting CPU module switch SW2-3 to OFF.
Ethernet
Using an optional Ethernet port (located on the 33MHz versions of the
CPU module), you can connect either directly or through a network to a
PC equipped with an Ethernet port. The default IP address and mask
for the Ethernet port is:
 ETH1 IP Address: 10.0.1.1 IP Mask: 255.255.255.
4-2
Operation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
4.2.2
Collecting Data from the ControlWave GFC
OpenBSI utilities such as DataView, Data Array Save/Restore and
Harvester allow you to collect real time data (values of variables, array
values, alarm messages) and historical data (audit records, archive files)
from the ControlWave. See the OpenBSI Utilities Manual (D5081) for
details. SCADA software such as OpenEnterprise can then present this
data to an operator in the form of graphical displays and reports.
4.3 Creating and Downloading an Application (ControlWave Project)
Most GFC users purchase the ControlWave gas flow measurement
application (ControlWave project) which ships pre-installed in the GFC
when it leaves the factory.
You can, however, create your own project using PC-based
ControlWave Designer software. Instructions for creating a
ControlWave project are beyond the scope of this manual. Please refer
to the following sources for information:
 Getting Started with ControlWave Designer (D5085)
 ControlWave Designer Programmer’s Handbook (D5125)
 ControlWave Designer online help
You must connect the GFC to a PC running ControlWave Designer
software and OpenBSI software.
Note: You can download an application either from ControlWave
Designer or from the OpenBSI 1131 Downloader.
1.
Connect a serial cable between your PC and COM1 of the
ControlWave GFC.
2.
Define the ControlWave project in ControlWave Designer, and
set communication and configuration parameters.
3.
Download the project according to instructions in the
Downloading section of the ControlWave Designer
Programmer's Manual (D5125).
4.4 Creating and Maintaining Backups
You should always maintain a current backup of each ControlWave
project and keep it in a safe place, preferably in a location physically
separate from the controller.
The reason we recommend you keep backup files is that if a disaster
occurs that damages or destroys your ControlWave hardware (flood,
lightning strike, etc.) you don’t want to also lose its control strategy
software programs. Otherwise, when the unit is repaired or replaced,
you’d have to create a new ControlWave project from scratch, which
might take a lot longer than replacing a few damaged modules.
Revised Nov-2011
Operation
4-3
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Always maintain a backup copy of your ControlWave project in a safe
place.
Caution
Anytime you modify your ControlWave project, be sure to create a new
backup of the new project.
Notes:


You may find it useful to maintain more than one backup copy in
case the backup media itself fails, for example, a CD-ROM becomes
unreadable because it melted in the sun or a thumb drive fails
because someone spilled coffee on it.
If you don’t keep more than one backup copy, it’s a good idea to
periodically test your backup copy to verify that the media has not
failed.
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup
Note: The .zwt file is a complete backup of your entire project
including code, comments and graphics. It may be stored on your
PC or removable storage media. It may also be downloaded and
archived to ControlWave Flash memory where it may be
uploaded at a later time for editing.
With your current ControlWave project open in ControlWave Designer,
perform the following steps:
1. Click File > Save Project As / Zip Project As.
Figure 4-1. Saving a Backup of Your Project
2. In the “Save/Zip project as” dialog box, specify a project name in
the File name field. In Figure 4-1 we chose the name mynewproj.
4-4
Operation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
3. In the Save as type field, choose Zipped Project Files (*.zwt).
4. In the Zip Options area, select which additional files you want to
include in the zwt file. Other than increasing the file size of the zwt,
it doesn’t hurt to check any or all of these options.
Zip Option
Description
Zip User-Libraries
If you created your own user-defined
functions or function blocks, you must
select this to preserve them.
Zip Frontend-Code
If you selected Zip User-Libraries you
should also select this option to include
compiled code for libraries in your zip file.
Otherwise, you need to re-compile your
user libraries with the project when you
unzip the zwt.
Zip FW-Libraries
This includes firmware libraries, such as
ACCOL3.FWL in your zwt.
Zip Pagelayouts
This includes pagelayout information for
printing your project, as well as graphical
elements used in certain 1131 languages.
5. Click Zip and a progress bar displays the percent complete of the
zipping process.
6. When the zip process completes, you’ll see a message box reporting
successful completion. Click OK.
7. Copy the resulting zwt file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the project, just open the zwt
file in ControlWave Designer, load libraries as needed, then compile
the project and download it into the ControlWave.
4.4.2 Saving Flash Configuration Parameters (*.FCP)
You must establish communications with the ControlWave GFC using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.
Note: For detailed information on using the Flash Configuration utility,
see Chapter 5 of the OpenBSI Utilities Manual (D5081).
1.
Revised Nov-2011
Start the Flash Configuration utility. To do this in NetView or
LocalView, right-click on the icon for this ControlWave and
choose RTU > RTU Configuration Parameters.
Operation
4-5
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
To do this in TechView, click Operations > Access Flash
Parameters or click the Access Flash icon
.
2.
Depending upon how your system is configured, the Flash
Configuration – Loading Options dialog box may open. If it
does, choose Load from device and wait for the utility to
retrieve all parameters from the ControlWave GFC, then skip to
step 4, otherwise, just proceed to step 3.
3.
Click
and wait for the utility to retrieve all
parameters from the ControlWave.
4.
Click
and specify a name for your FCP file,
then click Save. When the status line indicates successful
completion, your FCP file in done.
5.
Copy the resulting FCP file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the FCP parameters to the
controller, establish communications with the unit, start the
Flash Configuration utility, and load the FCP file using the Read
from FCP button, then choose the Write to RTU button.
4.4.3 Backing up Data
You can back up certain types of data and restore it if needed. There are
other types of data that you can only collect, but you cannot restore.



4-6
If you have certain variables that represent tuning parameters
(setpoints, for example) you can use tools such as the OpenBSI
DataView recipe feature to save those values to a recipe file on the
PC, and then restore them at a later time. See Chapter 8 of the
OpenBSI Utilities Manual (D5081).
You can store the contents of read/write data arrays using the
OpenBSI Data Array Save/Restore utility. See Chapter 13 of the
OpenBSI Utilities Manual (D5081).
You can collect alarms, and historical data (audit records, archive
files) but you cannot restore alarms or historical data.
Operation
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Chapter 5 – Service and Troubleshooting
This chapter provides general diagnostic and test information for the
ControlWave GFC as well as some common maintenance procedures.
In This Chapter
5.1 5.2 5.3 5.4 5.5 5.6 Equipment
Upgrading Firmware ........................................................................5-2 Removing or Replacing Components ..............................................5-6 5.2.1 Accessing Modules for Testing ............................................5-6 5.2.2 Removing/Replacing the CPU/System Controller Board and the
Process I/O Board ..............................................................5-6 5.2.3 Removing/Replacing the Primary Battery System ...............5-7 5.2.4 Removing/Replacing the Backup Battery ............................5-8 5.2.5 Enabling / Disabling the Backup Battery ..............................5-9 5.2.6 Removing/Replacing the Case-Mounted Radio or Modem .5-9 5.2.7 Removing/Replacing the MVT or GPT Transducer ...........5-10 General Troubleshooting Procedures ...........................................5-10 5.3.1 Checking LEDs...................................................................5-10 5.3.2 Checking LCD Status Codes .............................................5-11 5.3.3 Wiring/Signal Checks .........................................................5-11 WINDIAG Diagnostic Utility ...........................................................5-12 5.4.1 Available Diagnostics .........................................................5-13 Core Updump ................................................................................5-16 Calibration Checks.........................................................................5-17 You need the following equipment to perform the procedures described
in this chapter:
To run diagnostics software:
 PC with WINDIAG software, and either OpenBSI LocalView,
NetView, or TechView for communications
 Null modem interface cable
 Loop-back plug (See Figure 5-6 and Figure 5-7.)
To perform firmware upgrades:
 Null modem interface cable
 PC with the following software:
o OpenBSI LocalView
o OpenBSI System Firmware Downloader and either NetView,
LocalView, or TechView for communications.
o HyperTerminal (included in Windows®)
To replace the SRAM backup battery:
 Tweezers or needle-nose pliers
Miscellaneous other equipment:
 Needle-nose pliers
 Screw drivers
 Anti-seize compound (when replacing GPT/MVT)
Revised Nov-2011
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Note: When you service a ControlWave GFC on site, we recommend
that you close down (or place under manual control) any
associated processes. This precaution prevents any processes
from accidentally running out of control when you conduct tests.
Caution
Harmful electrical potentials may still exist at the field wiring terminals
even though the ControlWave GFC power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or
perform any wiring operations until you verify that all associated power
supply sources are turned off and/or disconnected.
Always turn off any external supply sources for externally powered I.O
circuits before you change any modules.
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave GFC is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
See Appendix A for details on Class I Division 2 usage of this device.
5.1
Upgrading Firmware
The ControlWave GFC ships from the factory with system firmware
already installed. If you need to upgrade the system firmware (stored in
Flash memory) to acquire new functionality or restore firmware, you
can use one of several methods.
System
Firmware
Downloader
Use this tool to download system firmware to an unattended remote
ControlWave GFC. To use this utility, you must set CPU/System
Controller board switch SW2-6 ON (the factory default position).
Note: For further information and detailed use instructions, refer to
Appendix J of the OpenBSI Utilities Manual (D5081).
LocalView
One of the standard OpenBSI utilities, LocalView requires OpenBSI
version 5.1 (or newer). If you have an older version of OpenBSI, use
HyperTerminal.
Note: For further information and detailed use instructions, refer to the
Flash Mode section of Chapter 5 of the OpenBSI Utilities
Manual (D5081).
5-2
Service & Troubleshooting
Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
HyperTerminal
HyperTerminal is a communications utility program included with
Microsoft® Windows® XP.
Notes:




Revised Nov-2011
If you are using a version of OpenBSI older than 5.1, or do not have
OpenBSI software, you can only perform a firmware upgrade using
HyperTerminal.
While HyperTerminal is included in Microsoft® Window® XP,
some newer versions of Window® do not include it.
The screens shown here may appear different depending upon the
version of HyperTerminal you use.
HyperTerminal requires *.BIN files; newer ControlWave firmware
upgrade files use *.CAB files. In cases such as those, you should use
the Remote System Firmware Downloader.
1.
Connect a null modem cable between COM1 of the
ControlWave GFC and any RS-232 port on the associated PC.
2.
Click Start > Programs > Accessories > Communications >
HyperTerminal
3.
If using HyperTerminal for the first time, set the communication
properties (for the PC port) via the Properties Menu as follows:
Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop
bits: = 1, and Flow control: = None and then click OK.
4.
Set CPU/System Controller board switch SW1-3 ON (ON =
Force Recovery).
5.
Apply power; to the ControlWave GFC. The resident BIOS
initializes and tests the hardware, this process is referred to as
POST (Power On Self Test). Unless there is a problem, the LCD
display should show RECOV. If you see a different status code,
see Section 5.3.1.
6.
From the HyperTerminal Mode menu (Figure 5-1), press the F
key to enter FLASH download. A message warns that the
FLASH is about to be erased; press the Y key at the prompt. The
screen displays dots as the system erases the flash memory; this
could take a few minutes.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 5-1. HyperTerminal Mode Menu
7.
When the FLASH is ready for download, HyperTerminal
repeatedly displays the letter C on the screen. In the
HyperTerminal menu bar click Transfer > Send File (see
Figure 5-2).
Figure 5-2. HyperTerminal (Ready to Download)
8.
5-4
In the Send File dialog box (see Figure 5-3), select 1KXmodem
for the protocol, enter the filename of the appropriate .bin file in
the format “E1Sxxxxx.bin” or “E3Sxxxxxx.bin” (where E1S
refers to 14 MHz CPUs, and E3S refers to 33 MHz CPUs and
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Revised Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
xxxxx varies from release to release) and click Send to start the
flash upgrade (see Figure 5-4). When you see the
HyperTerminal Mode Menu again, it means the download has
completed.
9.
Exit HyperTerminal and power down the ControlWave GFC. If
desired, you can disconnect the null modem cable between the
ControlWave GFC and the PC.
10.
Set switch SW1-3 to the OFF position (OFF = Recovery Mode
Disabled).
11.
Restore power to the ControlWave GFC.
Figure 5-3. Send File dialog box
CWEXP01
E1S0410.bin
Figure 5-4. HyperTerminal (Download in Progress)
Revised Nov-2011
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
5.2 Removing or Replacing Components
This section provides information on accessing ControlWave GFC
components for testing, as well as removal/replacement procedures.
Caution
Field repairs to the ControlWave GFC are strictly limited to the
replacement of complete boards. Replacing board components
constitutes tampering and violates the product warranty. Return
defective boards or housings to the factory for authorized service.
5.2.1 Accessing Modules for Testing
Only technically qualified personnel should test and/or replace
ControlWave GFC components. Read completely the disassembly and
test procedures described in this manual before starting. Any damage to
the ControlWave GFC resulting from improper handling or incorrect
service procedures is not covered under the product warranty
agreement. If you cannot properly perform these procedures, obtain
authorization and then return the device to the factory for evaluation and
repairs.
5.2.2 Removing/Replacing the CPU/System Controller Board and
the Process I/O Board
Use this procedure to remove or replace the CPU/System Controller
board and the Process I/O board.
5-6
1.
If the ControlWave GFC is running, place any critical control
processes under manual control.
2.
Open the cover and shut down the ControlWave GFC by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3.
Disconnect all removable card edge connectors from the
CPU/System Controller board and the Process I/O board. Label
or otherwise identify them so you can easily re-connect them
later.
4.
If present, disconnect the display/keypad from connector J2 on
the CPU/System Controller board.
5.
Loosen the upper and lower locking tabs and rotate them so you
can remove the boards together. Carefully slide the boards
toward the front of the unit and unplug the MVT cable from the
CPU/System Controller board connector P1.
6.
If you need to replace either the CPU/System Controller board
or Process I/O board, you need to separate the two boards. Use a
pair of needle-nosed pliers to squeeze the pair of tabs associated
with each of the six nylon mounting posts, while gently pulling
the CPU/System Controller board away from the Process I/O
board. Carefully unplug the boards from their interface
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
connectors. Align the replacement boards with each other and
press them together so that the interface connectors and
mounting posts properly mate; then squeeze together so that the
mounting post tabs capture the CPU/System Controller board.
7.
To install the replacement boards, power must be off. Align the
Process I/O board with the upper and lower guides so that the
CPU/System Controller board is on the right side. Slide the
boards (assembly) into the unit, making sure to re-connect the
MVT cable to CPU/System Controller board connector P1
before you fully insert the assembly.
8.
Rotate the upper and lower locking tabs to secure the boards.
9.
Replace all cables removed in steps 3 through 6.
Apply power and test the unit.
10.
5.2.3 Removing/Replacing the Primary Battery System
Notes:


Revised Nov-2011
The primary battery system attaches to the inside of the battery
cover/radio mounting plate.
Make sure the replacement battery is fully charged before you install
it.
1.
If the ControlWave GFC is running, place any critical control
processes under manual control.
2.
Open the cover and shut down the ControlWave GFC by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3.
Remove the battery wires from the CPU/System Controller
board connector TB1 (unplugged in step 2) making sure they
don’t contact each other.
4.
Loosen the four screws that secure the battery cover/radio
mounting plate to the one-piece mounting bracket.
5.
Slide the battery cover/radio mounting plate towards the top of
the unit so that its slots clear the mounting screws, and remove
it. If a radio or modem is present, carefully set the battery
cover/radio mounting plate to one side.
6.
Carefully remove the primary battery system (with cables
attached).
7.
To replace the primary battery system, reverse the steps you
performed from step 6 to step 3.
8.
Apply power and test the unit.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
5.2.4 Removing/Replacing the Backup Battery
Note: The CPU/System Controller board draws power from the battery
only if the board loses power. The system SRAM has a standby
current draw of 20 μA maximum for each part plus 2 μA for the
real time clock. For a ControlWave GFC containing 2MB of
SRAM, a worst-case current draw of 42 μA allows a battery life
of approximately 9,000 hours. This means you should not need
to replace a battery until the ControlWave GFC has been in
service for an extended period (normally many years).
The CPU/System Controller board accommodates a 3 V, 300 mA
lithium coin cell backup battery housed in a coin-cell socket (S1). A
supervisory circuit on the CPU switches to battery power when the
regulated 3.3 Vdc falls out of specification. The battery then provides
backup power for the real-time clock (RTC) and the system SRAM on
the CPU/System Controller board.
Note: If the real-time clock loses its battery backup, the ControlWave
system variable _QUEST_DATE turns ON. You can monitor
this to generate an alarm. See the System Variables section of the
ControlWave Designer Programmer's Handbook (D5125) for
more information.
Caution
You lose SRAM contents when you remove the backup battery.
If you replace a backup battery, wait at least one minute before repowering the system. This enables the SRAM to completely discharge.
After you install the new battery, ensure that you have placed jumper
W3 on pins 1-2 (to enable the battery).
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Removing /
Replacing the
Backup Battery
1. If the ControlWave GFC is running, place any critical control
processes under manual control.
2. Remove power from the ControlWave GFC.
3. Remove the CPU/System Controller board assembly from the
housing.
To remove the lithium battery, gently pry up the tab holding the battery
in the coin cell socket and remove the battery with a pair of tweezers or
needle-nosed pliers. Install the replacement battery.
4. Replace the CPU/System Controller board assembly in the housing.
5. Re-connect power to the ControlWave GFC.
6. Once the battery has been replaced, the unit executes its Flash-
based application (“boot project”) at power-up, but all of the
current process data is lost. At power-up, the ControlWave GFC
acts as though it had just been booted and reverts back to the initial
values specified in its application.
5.2.5
Enabling / Disabling the Backup Battery
For maximum shelf life, the CPU/System Controller board ships
from the factory with the installed lithium backup battery disabled.
You must enable it when you install the CPU/System Controller
board.
Enabling
To enable the battery, install jumper W3 on pins 1-2.
Disabling
For maximum shelf life, you can isolate the battery from the circuit by
placing jumper W3 on pins 2-3.
5.2.6 Removing/Replacing the Case-Mounted Radio or Modem
Revised Nov-2011
1.
If the ControlWave GFC is running, place any critical control
processes under manual control.
2.
Open the cover and shut down the ControlWave GFC by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3.
Disconnect (unplug/unscrew) all power and interface connectors
from the radio/modem.
4.
Disconnect the antenna cable from the modem.
5.
Loosen the four screws that secure the battery cover/radio
mounting plate to the one-piece mounting bracket.
6.
Slide the battery cover/radio mounting plate towards the top of
the unit, and remove it with the radio/modem installed.
7.
Remove the mounting screws from the inner side of the battery
cover/radio mounting plate to remove the radio/modem. Note: If
the unit has a Bristol 9600 bps PSTN modem you also have to
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
remove four screws that mount it to a plate which in turn mounts
to the radio/modem mounting plate.
8.
Replace the radio/modem, reversing the steps from 7 to 3.
9.
Apply power and test the unit.
5.2.7 Removing/Replacing the MVT or GPT Transducer
1.
If the ControlWave GFC is running, place any critical control
processes under manual control.
2.
Open the cover and shut down the ControlWave GFC by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3.
Remove the ControlWave GFC from its installation site and take
it to a repair area that supports proper ESD (electrostatic
discharge) control.
4.
Disconnect the MVT/GPT interface cable from CPU/System
Controller board connector P1.
5.
Remove the large mounting collar (nut) from the neck of the
MVT/GPT; then unscrew the four screws within the enclosure
that secure the MVT/GPT mounting plate to the bottom of the
enclosure. Remove the MVT/GPT.
6.
To install a replacement MVT/GPT, reverse steps 5 through 3.
Make sure the MVT/GPT O-ring seal is in place and apply antiseize compound as required. When you install an MVT at the
bottom of the enclosure, orient the flange for the desired high
and low settings.
5.3 General Troubleshooting Procedures
This section presents some procedures to troubleshoot problems with
the GFC.
5.3.1 Checking LEDs
The ControlWave GFC includes two red light emitting diodes (LEDs)
that provide operational and diagnostic functions.
You must open the chassis door to view these LEDs.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Table 5-1. LEDs on CPU/System Controller Board
LED
Color
Description
WD (CR1 right)
RED
ON = Watchdog condition – program crash; OFF = Normal operation
IDLE (CR1 left)
RED
ON = CPU has free time at end of execution cycle. Should be on
frequently.
OFF = CPU overloaded. Note: The idle LED may also be off if you
disabled it - see Table 2-1 in Chapter 2.
5.3.2 Checking LCD Status Codes
The following codes may appear on the LCD display:
Table 5-2. LCD Display Status Codes
LCD
Display
Blank
DIAG
R DIAG
FWXSUM
DEVERR
FLASH
FACT
BATT
STRTUP
INIT
RECOV
RAMERR
STOP
HALT
NO APP
BREAKP
POWERD
UPDUMP
NOTRUN
Indication
Definition
Application Running
Unit in Diagnostic Mode
Unit Running Diagnostics
Flash XSUM Error
Error Initializing Application Device
Flash Programming Error
Using Factory Defaults
Battery Failure Detected
Currently Loading the Boot Project
System Initialization in Progress
Waiting in Recovery Mode
Error Testing SRAM
Application Loaded
Stopped at a Break Point
No Application Loaded
Running with Break Points
Waiting for Power-down (after NMI)
Waiting for Updump to be Performed
Unit Crashed (Watchdog Disabled)
5.3.3 Wiring/Signal Checks



Revised Nov-2011
Check I/O field wires at the card edge terminal blocks and at the
field device.
Check wiring for continuity, shorts and opens.
Check I/O signals at their respective terminal blocks.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
5.4 WINDIAG Diagnostic Utility
The ControlWave GFC cannot execute your control strategy while it
runs diagnostic routines; place any critical processes controlled by the
ControlWave GFC under manual control before starting this procedure.
Caution
WINDIAG is a software-based diagnostic tool you use to test the
performance of I/O, CPU memory, communication ports, and other
system components. .
WINDIAG is a PC-based program, so the ControlWave GFC must be
attached to and communicating with a PC running WINDIAG. Establish
communication between the ControlWave GFC (with/without an
application loaded) and the PC with a local or network port under the
following conditions:



Set CPU module switches SW2-3 to OFF and SW2-8 to OFF.
Turning these switches off sets all serial ports on the ControlWave
GFC to 9600 baud in preparation for diagnostic testing and prevents
the boot project from running and also places the ControlWave GFC
in diagnostic mode.
Connect any ControlWave GFC serial communication port to the PC
provided their port speeds match. Use a null modem cable to
connect RS-232 ports between the ControlWave GFC and the PC;
use an RS-485 cable to connect the RS-485 port of the ControlWave
GFC and the PC. See Chapter 2 for information on cables.
Reserve the port running a diagnostic test for exclusive use; you
cannot use that port for any other purpose during testing.
Follow these steps:
5-12
1.
Start OpenBSI communications using NetView, TechView, or
LocalView, and select the RTU you want to test.
2.
Select Start >Programs > OpenBSI Tools >Common Tools >
Diagnostics. The Main Diagnostics menu (Figure 5-5) opens.
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Figure 5-5. WINDIAG Main Diagnostics Menu
3.
Select the component to be tested. See Section 5.4.1 for a
description of the tests. Enter any prompted parameters (slot #,
etc.). WINDIAG performs the diagnostics and displays pass/fail
results.
After performing all diagnostic testing, exit WINDIAG.
4.
Set switches SW2-3 and SW2-8 on the CPU module to ON. The
ControlWave GFC should resume normal operation.
5.4.1 Available Diagnostics
WINDIAG’s Main Diagnostics Menu (see Figure 5-5) provides the
following diagnostic selections:
Revised Nov-2011
Option
Tests
CPU & Peripherals
Checks the CPU/System Controller board except
for memory.
Analog Output
Checks the AO on the Process I/O board.
High Speed Counter
Checks HSCs on the Process I/O board and
Pulse Counter inputs on the CPU/System
Controller board.
Prom/Ram
Checks the SRAM and FLASH memory.
Analog Input
Checks AIs on the Process I/O board.
Communications
Checks serial communication ports COM1,
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Port Loop-back
Test
Option
Tests
COM2, and COM3. The External loop-back tests
require the use of a loop-back plug.
Discrete I/O
Checks DIs and DOs on the Process I/O board.
EEPROM
Checks the EEPROM.
Keyboard & Display
Checks the optional display/keypad hardware.
WINDIAG allows you to select the communication port to test.
Depending on the type of network (RS-232 or RS-485) and the port in
question, a special loop-back plug is required:

Port 1 - RS-232 uses a 9-pin female D-type loop-back plug (see
Figure 5-6).
Figure 5-6. COM1 & COM2 RS-232 Loop-back Plug/Wires


Port 2 - RS-232 use loop-back wires (see Figure 5-6).
Port 3 - RS-232 use loop-back wires (see Figure 5-7).
Figure 5-7. COM3 RS-232 & RS-485 Loop-back Wires
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Note: You can configure RS-485 loopback by setting CPU/System
Controller board switches SW3-1 & SW3-2 ON.

Port 3 - RS-485 use loop-back wires or CPU Switch SW3 (see
Figure 5-7).
These tests verify the correct operation of the communication ports.
Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
Test Procedure
Use this procedure to test the communication ports.
1.
Connect an external loop-back plug to the port on the CPU you
want to test. Valid ports are: COM1, COM2, or COM3.
2.
Select Communications on the WINDIAG Main Diagnostics
Menu. The Communications Diagnostic screen opens:
Figure 5-8. Communications Diagnostic Menu
Revised Nov-2011
3.
Enter 5 in the Number of Passes field.
4.
Select a port to test (click  to display all available ports).
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Note: The port you select must correlate to the port on which you
placed the loop-back plug in step 1.
5.
Select 115200 or ALL ASYNC as the baud rate (click  to
display all available rates).
6.
Click RUN to start the test. At the completion of the test (which
generally takes about 5 seconds), any failed results appear in the
Status field to the right of the RUN button: For example:


7.
TXD RXD Failure
CTS RTS Failure
Click Return to Menu to display the WINDIAG Main Menu.
5.5 Core Updump
In some cases—such as when a ControlWave GFC fails for no apparent
reason—you can upload a copy of the contents of SRAM and SDRAM
to a PC for support personnel and service engineers to evaluate. This
upload is called a “core updump.”
A core updump may be required if the ControlWave GFC
spontaneously enters a watchdog state that affects all system operation.
This occurs when the system crashes as a result of a CPU timeout
(resulting from improper software operation, a firmware glitch, and so
on). In some cases, the watchdog state can recur but you cannot
logically reproduce the conditions.
The CPU’s RAM contains “crash blocks,” a firmware function provided
specifically for watchdog troubleshooting. You can view and save the
crash blocks by viewing the Crash Block Statistic Web Page (see the
Web_BSI Manual, D5087). On request, you can forward crash block
files to our technical support personnel. If they need additional
information to evaluate the condition, the technical support group may
request a core updump. Once the core updump process generates a file,
you can forward that file to the support personnel for evaluation and
resolution.
Use the following steps to preserve the “failed state” condition at a
system crash and perform a core updump:
1.
Set switch SW2-1 on the CPU/System Controller board to OFF
(Disable Watchdog Timer). Set switch SW2-4 to OFF (Enable
Core Updump).
Note: The factory default setting for switch SW2-4 is OFF.
5-16
2.
Wait for the error condition (typically“NOTRUN” on the LCD
display).
3.
Connect the ControlWave GFC’s Comm Port 1 to a PC using a
null modem cable.
4.
Set the ControlWave GFC for Recovery Mode by setting both
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ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
SW1-1 and SW1-2 to either the ON position or both to the
OFF position..
5.
Start the PC’s HyperTerminal program (at 115.2 kbaud) and
generate a receive using the 1KX-Modem protocol. Save the
resulting core updump in a file so you can forward it later to the
technical support group.
By setting the CPU/System Controller board switches SW2-1 and SW24 both off before the ControlWave GFC fails you prevent the GFC from
automatically recovering from the failure and enable it to wait for you to
take a core updump.
Once you complete the core updump, set the CPU/System Controller
board’s switch SW2-1 to ON (Watchdog Enabled) and SW2-4 to ON
(Core Updump Disabled).
Additionally, set switch SW1-1 to OFF and SW1-2 to ON.
With these switches set, power up the ControlWave GFC and begin
standard operations.
5.6 Calibration Checks
The AO and AI on the Process I/O board are self-calibrating.
To calibrate the MVT/GPT and the RTD, use TechView software. See
the TechView User’s Guide (D5131) for more information.
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Special Appendix for ControlWave Gas Flow Computer Instruction Manual (CI-ControlWave GFC)
Appendix A – ControlWave GFC– Special Instructions for
Class I, Division 2 Hazardous Locations
1. The ControlWave GFC Gas Flow Computer is listed by
Underwriters Laboratories (UL) as nonincendive and is suitable for
use in Class I, Division 2, Groups C and D hazardous locations or
non-hazardous locations only. Read this document carefully before
installing a nonincendive ControlWave GFC Gas Flow Computer.
Refer to CI-ControlWave GFC for general information. In the event
of a conflict between the ControlWave GFC Customer Instruction
Manual (CI-ControlWave GFC) and this document, always follow
the instructions in this document.
2. The ControlWave GFC Gas Flow Computer includes both
nonincendive and unrated field circuits. Unless a circuit is
specifically identified in this document as nonincendive, the circuit
is unrated. Unrated circuits must be wired using Div. 2 wiring
methods as specified in Article 501-4(b) of the National Electrical
Code (NEC), NFPA 70 for installations in the United States, or as
specified in Section 18-152 of the Canadian Electrical Code for
installation in Canada.
3. The local communications port terminates in a circular 5-pin
connector on the bottom of the ControlWave GFC Gas Flow
Computer’s front cover. The wiring on this connector is unrated. No
connections may be made to this port unless the user ensures that the
area is known to be nonhazardous. Connections to this port are
temporary, and must be short in duration to ensure that flammable
concentrations do not accumulate while it is in use.
4. The optional power system (solar panel and battery) approved for
use with the nonincendive ControlWave GFC Gas Flow Computer
are described in the model specification. The connection to the solar
panel is approved as a nonincendive circuit so that Division 2 wiring
methods are not required. The nominal panel voltage must match the
nominal battery voltage (6V or 12V).
5. An RTD is normally supplied with the ControlWave GFC.
Connection to the RTD is approved as a nonincendive circuit, so
that Division 2 wiring methods are not required.
6. Signal connectors available for customer wiring are listed in Table
A-1. Network communications port and I/O wiring connections are
unrated and must be wired using Division 2 wiring methods.
Revised Nov-2011
Special Instructions for Class I, Division 2
A-1
Special Appendix for ControlWave Gas Flow Computer Instruction Manual (CI-ControlWave GFC)
7. The UL listed nonincendive ControlWave GFC may include
radio/modem communications (listed on the model specification)
that is used in conjunction with a 5W, 12V, 7AH lead acid battery
system. Connection to the radio or modem is approved as a
nonincendive circuit, so that Division 2 wiring methods are not
required.
WARNING
EXPLOSION HAZARD
Do not disconnect solar power from the battery
or any other power connections within the
ControlWave GFC enclosure or any power
connections to optional items such as
radio/modem, or cabling to the display/keypad
unless the area is known to be nonhazardous.
WARNING
EXPLOSION HAZARD
Substitution of components may impair
suitability for use in Class I, Division 2
environments.
WARNING
EXPLOSION HAZARD
The area must be known to be nonhazardous
before servicing/replacing the unit and before
installing or removing I/O wiring.
WARNING
EXPLOSION HAZARD
Do NOT disconnect equipment unless power
has been disconnected and the area is known
to be non-hazardous.
Table A-1. Module/Board Customer Wiring Connectors
Module/Item
CPU/System Controller board
Connector
TB1: 6-pin terminal block
CPU/System Controller board
TB3: COM2, 8-pin
terminal block RS-232
Wiring Notes
Solar power: User wired *
Primary power: Factory/User wired *
Auxiliary output: Factory/User wired *
Remote comm. port: For radio or external
network comm. Refer to model spec. and
item 6 of this document. When used for
network comm. use Div 2 wiring methods.
If COM2 is used in conjunction with a
radio/modem refer to item 7 of this
document.
CPU/System Controller board
TB4: COM3, 5-pin
terminal block RS-232/RS485
RS-232/485 comm. port: For external
network comm. Refer to model spec. and
item 6 of this document.
CPU/System Controller board
TB5: 4-pin terminal block
Pulse input field wiring: Field I/O wiring
A-2
Special Instructions for Class I, Division 2
Revised Nov-2011
Special Appendix for ControlWave Gas Flow Computer Instruction Manual (CI-ControlWave GFC)
Module/Item
Connector
pulse input interface
Wiring Notes
connector is unrated, use Div. 2 wiring
methods. *
CPU/System Controller board
TB6: 3-pin terminal block
RTD interface
Field wired: Refer to item 5 of this
document.
CPU/System Controller board
J1: 8-pin RJ-45 jack
10/100Base-T Ethernet
port
10/100Base-T Ethernet port jack for
external connection to an Ethernet hub.
Refer to model spec. and item 6 of this
document.
CPU/System Controller board
J2: 8-pin RJ-45 female
connector – display or
display/keypad interface
Factory wired *
CPU/System Controller board
P1: MVT interface
Factory wired *
CPU/System Controller board
J4: COM1, 9-pin male Dsub RS-232
RS-232 Comm. Port connectors: For
external network comm. Refer to model
spec. and item 6 of this document.
J11: COM1, 3-pin RS-232
Process I/O board
TB2: 6-pin terminal block
DI interface
Discrete input field wiring: Field I/O wiring
connector is unrated, use Div. 2 wiring
methods. *
Process I/O board
TB3: 8-pin terminal block
DO/DI interface
Discrete output/input field wiring: Field I/O
wiring connector is unrated, use Div. 2
wiring methods. *
Process I/O board
TB4: 8-pin terminal block
HSC interface
High speed counter field wiring: Field
input wiring connector is unrated, use Div.
2 wiring methods. *
Process I/O board
TB6: 9-pin terminal block
AI interface
Analog input field wiring: Field input wiring
connector is unrated, use Div. 2 wiring
methods. *
Process I/O board
TB7: 4-pin terminal block
AO interface
Analog output field wiring: Field output
wiring connector is unrated, use Div. 2
wiring methods. *
Front cover bottom
Local Port 5-pin female
circular connector
(Present version)
Local comm.. port – factory wired. Refer
to item 3 of this document. *
Note: * These wires should only be installed/removed when the item
(PCB) in question is installed / removed or when checking
wiring continuity. The area must be known to be nonhazardous
before servicing / replacing the unit and before installing or
removing PCBs, connectors, or individual I/O or power wires.
Refer to the warnings in this document. All input power and I/O
wiring must be performed in accordance with Class I, Division 2
wiring methods as defined in Article 501-4(b) of the National
Electrical Code, NFPA 70, for installations within the United
States, or as specified in Section 18-152 of the Canadian
Electrical Code for installation in Canada.
Revised Nov-2011
Special Instructions for Class I, Division 2
A-3
This page is intentionally left blank
ControlWave Gas Flow Computer Instruction Manual (CI-ControlWave GFC)
Appendix Z – Sources for Obtaining Material Safety Data
Sheets
This device includes certain components or materials which may be
hazardous if misused. For details on these hazards, please contact the
manufacturer for the most recent material safety data sheet.
Manufacturer
General
Description
DURACELL
http://www.duracell.com
3V lithium
manganese dioxide
battery
Emerson Part
Number
395620-01-5
P/N: DL 2450
TADIRAN
http://www.tadiranbat.com
7.2 Vdc battery
pack (each pack
composed of two
3.6V , 35AH
batteries)
395413-01-0
Individual battery
P/N:
TL-5137
POWER SONIC
http://www.power-sonic.com
6V, 7AH lead acid
battery – Used with
1W, 6V solar panel
or 5W, 6V solar
panel
395407-01-0
P/N: PS-670
POWER SONIC
http://www.power-sonic.com
12V, 7AH lead acid 395407-02-8
battery – Used with
5W, 12V solar panel
P/N: PS-1270
DOW CORNING
Silicone 200(R)
Fluid, 100 CST
http://www1.dowcorning.com
Pressure transducer
media fill
Revised Nov-2011
Appendix Z
Z-1
This page is intentionally left blank
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
Index
A
ACCOL3 Firmware Library ................................. 1-7
address
default IP ........................................................ 4-2
Analog averaging ................................................ 1-9
Analog Inputs ...................................................... 3-8
Analog Output ..................................................... 3-9
B
Backup battery
description ............................................... 1-4, 2-7
disconnecting.................................................. 5-9
jumper W3 .................................................... 2-21
removing/replacing ......................................... 5-8
Backups .............................................................. 4-3
Battery
replacing ......................................................... 5-8
Boot FLASH memory
amount............................................................ 1-4
C
Cables
RS-232 ......................................................... 2-27
RS-485 ......................................................... 2-30
Shielding ......................................................... 3-4
Checking
LEDs ............................................................. 5-10
Chromatograph ................................................. 1-12
Class I, Division 2 ........................................ 2-4, A-1
Communication Ports
defaults ........................................................... 4-2
Ethernet ........................................................ 2-32
RS-232 ......................................................... 2-25
RS-485 ......................................................... 2-31
Communications
Loop-back Test .................................... 5-14, 5-15
protocols supported ........................................ 1-7
ControlWave project
downloading ................................................... 4-3
Core Updump ................................................... 5-16
CPU/System Controller board
battery backup ................................................ 5-8
description ...................................................... 1-3
Jumpers ........................................................ 2-21
removing ......................................................... 5-6
switches ........................................................ 2-19
D
Defaults
Comm Ports.................................................... 4-2
Diagnostic software .......................................... 5-12
Issue: Nov-2011
Index
Disconnecting RAM Battery ................................ 5-9
Discrete Inputs .................................................... 3-6
Discrete Outputs ................................................. 3-7
Display/Keypad ................................................. 2-37
Downloading
the ControlWave project ................................. 4-3
E
Energy calculation............................................. 1-10
Energy integration ............................................. 1-10
Environmental specifications .............................. 2-4
Ethernet Port ..................................................... 2-32
Extension calculation .......................................... 1-9
F
Features .............................................................. 1-1
Field repair .......................................................... 5-6
Figures
1-1. ControlWave GFC Enclosure (MVTEquipped) with 2-Button Display Keypad Assy
...................................................................... 1-2
1-2. ControlWave Programming Environment 1-6
2-1. MVT- Equipped ControlWave GFC ......... 2-2
2-2. GPT- Equipped ControlWave GFC ......... 2-3
2-3. ControlWave GFC Bottom View w MVT . 2-7
2-4. ControlWave GFC Bottom View w GPT.. 2-8
2-5. Side View of ControlWave GFC Mounted2-9
2-6. ControlWave GFC (w MVT) dimensions 2-10
2-7. ControlWave GFC w GPT Dimensions . 2-11
2-8. Process Flange and Optional Manifold
Connectors ................................................. 2-13
2-9. ControlWave GFC Remote Installation
without Cathodic Protection........................ 2-15
2-10. ControlWave GFC Direct Mount
Installation with Cathodic Protection .......... 2-17
2-11. CPU/System Controller Board Component
I.D. Diagram ............................................... 2-18
2-12. CPU/ System Controller Board (TB1 &
TB2) Power Wiring ..................................... 2-25
2-13. PC Connected to ControlWave GFC via
Circular Local Port ...................................... 2-26
2-14. Male DB9 9-Pin Connector ................. 2-27
2-15. Full-duplex and Half-duplex Cable ...... 2-28
2-16. Full-duplex and Half-duplex Cable ...... 2-29
2-17.Connection from a Case Mounted
Modem/Radio to COM2 of the ControlWave
GFC ............................................................ 2-29
2-18. Full-duplex and Half-duplex Cable ...... 2-29
2-19. RJ-45 Ethernet Connector .................. 2-32
2-20. Standard 10/100Base-T Ethernet Cable
(CPU Module to Hub) ................................. 2-32
2-21. Point-to-Point 10/100Base T Ethernet
Cable .......................................................... 2-33
IND-1
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
2-22. 1 Watt Solar Panel Mounting Diagram 2-35
2-23. 5 Watt Solar Panel Mounting Diagram 2-36
2-24 Optional 2-Button and 25-Button Keypads
................................................................... 2-37
2-25 Display with No Keypad ....................... 2-37
3-1. Process I/O Board Component Identification
diagram ........................................................ 3-3
3-2. Process I/O Board Wiring diagrams........ 3-5
3-3. Pulse Input Wiring diagram ................... 3-10
3-4. 3-Wire RTD Temperature Input Wiring . 3-12
3-5. RTD Probe Installation/Removal diagram .313
3-6. 3808 Transmitter to ControlWave GFC RS232 Comm. Cable Diagram........................ 3-14
3-7. 3808 Transmitter to ControlWave GFC RS485 Comm. Cable ...................................... 3-15
3-8. ControlWave GFC to 3808s - RS-485
Network Diagram ....................................... 3-15
4-1. Saving a Backup of Your Project ............ 4-4
5-1. HyperTerminal Mode Menu .................... 5-4
5-2. HyperTerminal (Ready to Download)...... 5-4
5-3. Send File dialog box................................ 5-5
5-4. HyperTerminal (Download in progress) .. 5-5
5-5. WINDIAG Main Diagnostics Menu ........ 5-13
5-6. COM1 & COM2 RS-232 Loop-back
Plug/Wires .................................................. 5-14
5-7. COM3 RS-232 & RS-485 Loop-back Wires
................................................................... 5-14
5-8. Communications Diagnostic menu ....... 5-15
Firmware upgrade............................................... 5-2
HyperTerminal ................................................ 5-3
LocalView ....................................................... 5-2
System Firmware Downloader ....................... 5-2
FLASH memory
amount............................................................ 1-4
Flow calculations
supported ....................................................... 1-8
Flow rate calculations
AGA3 .............................................................. 1-9
AGA7 .............................................................. 1-9
Flow time calculations
AGA3 .............................................................. 1-9
AGA7 .............................................................. 1-9
I
I/O Configurator .................................................. 1-6
I/O Options .......................................................... 1-5
I/O Wiring ............................................................ 3-1
Installation ........................................................... 3-4
Class 1, Div 2 ................................................. 2-4
Overview......................................................... 2-5
IP address
default ............................................................. 4-2
J
Jumpers
CPU/System Controller Board...................... 2-21
Process I/O Board .......................................... 3-2
K
Keypad/Display ................................................. 2-37
L
LEDs
Checking....................................................... 5-10
disabling ....................................................... 2-19
LocalView............................................................ 5-2
Loop-back Test ........................................ 5-14, 5-15
M
Material Safety Data Sheets (MSDS)
how to obtain .................................................. Z-1
Memory
Boot FLASH.................................................... 1-4
FLASH amount ............................................... 1-4
SRAM amount ................................................ 1-4
Mounting the housing ......................................... 2-6
N
Nominations ...................................................... 1-13
O
Odorizer ............................................................ 1-12
Operator’s keypad/display ................................ 2-37
G
Grounding .................................................. 2-11, 3-4
H
Hazardous locations
special instructions for .................................... A-1
High Speed Counter/Discrete Inputs ................ 3-11
Historical data storage ...................................... 1-10
Humidity
specifications .................................................. 2-4
HyperTerminal .................................................... 5-3
IND-2
Index
P
Power
connecting or disconnecting ........................... 4-2
wiring ............................................................ 2-23
Power connector TB1 ....................................... 2-24
Power connector TB2 ....................................... 2-25
Power options ..................................................... 1-5
Pressure tap...................................................... 1-10
Process I/O board
replacing ......................................................... 5-6
Process I/O Board
configurations ................................................. 3-1
Jumpers .......................................................... 3-2
Issue: Nov-2011
ControlWave Gas Flow Computer (GFC) Instruction Manual (CI-ControlWave GFC)
switches .......................................................... 3-2
Process I/O board Configurations ...................... 1-5
Protocols
supported in ControlWave .............................. 1-7
Pulse Counter/Discrete Inputs .......................... 3-10
R
RAM Battery
Disconnecting ................................................. 5-9
Recovery mode switches .................................. 2-19
Repair in field ...................................................... 5-6
Resistance Temperature Device (RTD) ........... 3-12
RS-232 Ports .................................................... 2-25
Cables .......................................................... 2-27
RS-485 Ports .................................................... 2-31
Cables .......................................................... 2-30
configuration switch ...................................... 2-20
Run switching ................................................... 1-12
Running diagnostic software............................. 5-12
S
Sampler............................................................. 1-12
Site Considerations............................................. 2-1
Soft Switches
lock/unlock switch ......................................... 2-19
use/ignore switch .......................................... 2-19
Software Tools .................................................... 1-6
Specifications
for temperature, humidity, vibration ................ 2-4
SRAM memory
amount............................................................ 1-4
control switch ................................................ 2-20
Status codes ..................................................... 5-11
Switches
CPU .............................................................. 2-19
Process I/O board .......................................... 3-2
System Firmware Downloader............................ 5-2
U
Updump ............................................................ 5-16
switch ............................................................ 2-20
Upgrading firmware............................................. 5-2
V
T
Tables
1-1. CPU/System Controller board Variations 1-4
1-2.Process I/O Configurations ...................... 1-5
2-1. CPU System Controller Board Switch SW1
.................................................................... 2-19
2-2. CPU/System Controller Board Switch SW2
.................................................................... 2-19
2-3. RS-485 Configuration Switch (SW3) ..... 2-20
2-4. Power Requirements............................. 2-23
2-5. RS-232 Connectors on CPU ................. 2-26
2-6. RS-232 Port Connector Pin Assignment2-27
2-7. RS-232 Port Alternate Connector Pin
Assignment................................................. 2-28
2-8. RS-485 Connector on CPU ................... 2-30
Issue: Nov-2011
2-9. RS-485 Port Connector Pin Assignment2-30
2-10. RS-485 Network Connections ............. 2-31
2-11. Ethernet 10/100Base-T CPU Module Pin
Assignments ............................................... 2-32
2-12. Solar Panel Tilt Angle .......................... 2-34
3-1. Process I/O Configurations ..................... 3-1
3-2. Process I/O Module Switch SW1 ............ 3-2
3-3. Non-Isolated DI General Characteristics. 3-6
3-4. Non-Isolated DO General Characteristics3-7
3-5. Non-Isolated AI General Characteristics . 3-8
3-6. Non-Isolated AO General Characteristics 3-9
3-7. Non-Isolated Pulse Counter/Discrete Inputs
General Characteristics .............................. 3-10
3-8. Non-Isolated High Speed Counter/Discrete
Inputs General Characteristics ................... 3-11
3-9. RTD Connections to CPU/System Controller
Board Connector TB6................................. 3-12
4-1. Default Comm Port Settings (by PCB) .... 4-2
5-1. LEDs on CPU System Controller Board
board .......................................................... 5-11
5-2. LCD Display Status Codes .................... 5-11
A-1. Module/Board Customer Wiring Connectors
......................................................................... 2
TB1 Connector .................................................. 2-24
TB2 Connector .................................................. 2-25
Temperature
specifications .................................................. 2-4
Tools ................................................................... 5-1
Transmitters
connecting .................................................... 3-14
Troubleshooting .................................................. 5-1
general .......................................................... 5-10
Index
Vibration
specifications .................................................. 2-4
Volume calculations
supported ........................................................ 1-8
Volume integration ............................................ 1-10
W
W3 Backup battery jumper ............................... 2-21
Watchdog
enable switch ................................................ 2-19
WINDIAG .......................................................... 5-12
Wiring
I/O ............................................................ 3-1, 3-4
IND-3
November 2011
ControlWave Gas Flow Computer (GFC)
© 2011 Remote Automation Solutions, a business unit of Emerson Process Management. All
rights reserved.
Bristol, Inc., Bristol Canada, BBI SA de CV and Emerson Process Management Ltd, Remote
Automation Solutions (UK), are wholly owned subsidiaries of Emerson Electric Co. doing
business as Remote Automation Solutions, a business unit of Emerson Process Management.
FloBoss, ROCLINK, Bristol, Bristol Babcock, ControlWave, TeleFlow and Helicoid are trademarks
of Remote Automation Solutions. AMS, PlantWeb and the PlantWeb logo are marks of Emerson
Electric Co. The Emerson logo is a trademark and service mark of the Emerson Electric Co. All
other marks are property of their respective owners.
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
Remote Automation Solutions
The contents of this publication are presented for informational purposes only. While every
effort has been made to ensure informational accuracy, they are not to be construed as
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herein or their use or applicability. Remote Automation Solutions reserves the right to modify or
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