Emerson ControlWave GFC IStran Instruction manual

Instruction Manual
Document: CI-CW-GFC-ISTRAN
Part: D301647X012
November, 2009
ControlWave GFC IStran
ControlWave GFC IStran
Intrinsically Safe Communication Interface
Remote Automation Solutions
www.EmersonProcess.com/Remote
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any operation is
attempted. Improper use of this device in some applications may result in damage or injury. The
user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions division (RAS) for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may
leave an operating process without protection. Depending upon the application, this could result in
possible damage to property or injury to persons. It is suggested that the purchaser review the
need for additional backup equipment or provide alternate means of protection such as alarm
devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches,
etc. If additional information is required, the purchaser is advised to contact RAS.
RETURNED EQUIPMENT WARNING
When returning any equipment to RAS for repairs or evaluation, please note the following: The
party sending such materials is responsible to ensure that the materials returned to RAS are clean
to safe levels, as such levels are defined and/or determined by applicable federal, state and/or
local law regulations or codes. Such party agrees to indemnify RAS and save RAS harmless from
any liability or damage which RAS may incur or suffer due to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in
accordance with OSHA rules and regulations pertaining to "Design Safety Standards for Electrical
Systems," 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are in agreement
with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that
include electrically operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an
electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this
can result in erratic operation or complete failure of the equipment. Read supplemental document
S14006 for proper care and handling of ESD-sensitive components.
Remote Automation Solutions
A Division of Emerson Process Management
1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
Emerson Process Management
Training
GET THE MOST FROM YOUR EMERSON
INSTRUMENT OR SYSTEM

Avoid Delays and problems in getting your system on-line

Minimize installation, start-up and maintenance costs.

Make the most effective use of our hardware and software.

Know your system.
As you know, a well-trained staff is essential to your operation. Emerson offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at various locations. By participating in our training, your personnel
can learn how to install, calibrate, configure, program and maintain your Emerson products
and realize the full potential of your system.
For information or to enroll in any class, go to http://www.EmersonProcess.com/Remote and
click on “Training” or contact our training department in Watertown at (860) 945-2200.
BLANK PAGE
ControlWave GFC-IStran Instruction Manual
Contents
Chapter 1 – Introduction
1.1
1-1
Physical Description..................................................................................................................1-2
1.1.1 IStran PCB ....................................................................................................................1-3
Chapter 2 – Function and Electrical Characteristics
2.1
2.2
2.3
Hazardous and Non-Hazardous Characteristics.......................................................................2-1
2.1.1 Hazardous Interface......................................................................................................2-1
2.1.2 Non-Hazardous Interface ..............................................................................................2-3
Switched & Unswitched Modes.................................................................................................2-5
2.2.1 Configuring the Hazardous Interface for Switched Mode .............................................2-6
2.2.2 Configuring the Hazardous Interface for Unswitched Mode .........................................2-6
2.2.3 Configuring the Non-Hazardous Interface for Switched Mode .....................................2-6
2.2.4 Configuring the Non-Hazardous Interface for Unswitched Mode .................................2-6
Non-Hazardous Power Output ..................................................................................................2-6
Chapter 3 – System Wiring
3.1
3.2
3.3
3.4
3-1
Introduction to System Wiring ...................................................................................................3-1
Grounding..................................................................................................................................3-1
Cable Length .............................................................................................................................3-2
Field Wiring Diagrams...............................................................................................................3-2
Chapter 4 – Installation
4.1
4.2
4-1
Installation Overview .................................................................................................................4-1
Installation Notes.......................................................................................................................4-1
Chapter 5 – Specifications
5.1
5.2
2-1
5-1
Environment ..............................................................................................................................5-1
Operating Specifications ...........................................................................................................5-1
Index
Issued Nov-09
I-1
Contents
v
ControlWave GFC-IStran Instruction Manual
vi
Contents
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Chapter 1 – Introduction
The ControlWave GFC Intrinsically Safe IStran Communication
Interface (IStran) allows an intrinsically safe ControlWave Gas Flow
Computer / Corrector (CW-GFC-IS) to communicate with a device
located in a Division 2 or non-hazardous area.
Underwriter’s Laboratories (UL) approves the IStran interface with a
CW-GFC-IS unit when you use it with approved intrinsically safe
battery power/solar panel power, or when the CW-GFC-IS receives
external power through the IStran.
The IStran performs the following functions:





Replaces six intrinsic safety barriers for RS-232 signals (3 in, 3 out)
Provides 500V isolation between two devices
Operates at speeds up to 19,200bps
Allows the CW-GFC-IS to receive power from outside the Division
1 area
Allows the CW-GFC-IS to control power to a radio or modem
located outside the Division 1 area
You can also use the IStran for certain applications where intrinsic
safety is unnecessary, such as to provide isolation between two devices
or to allow multiple devices to share a single radio or modem.
Figure 1-1. IStran Front View
Issued Nov-09
Introduction
1-1
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
1.1 Physical Description
The IStran assembly measures 6.25 inches (length) by 4.50 inches
(width) by approximately 1 inch (depth). (See Figure 1-2, 1-3, and 1-4.)
The IStran assembly consists of the following major components:



One IStran printed circuit board (PCB) for the IStran assembly
Yellow alodined aluminum base plate (0.060 inch thick)
Black anodized cover (0.090 inch thick)
Figure 1-2. Physical Dimensions – IStran – Front View
Figure 1-3. Physical Dimensions – IStran – Edge (Side) View
1-2
Introduction
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Figure 1-4. IStran PCB Mounted on Base Plate (Cover removed)
1.1.1 IStran PCB
The IStran PCB provides two interfaces designated hazardous and nonhazardous. You configure each interface independently to operate in
either switched or unswitched mode.
Switched Mode Switched mode sets the TX drivers into a high-impedance state to
reduce power consumption.
Unswitched Mode In unswitched mode, the TX drivers are always active and they always
follow the corresponding RX inputs. In cases where power consumption
is not a key factor, configure the IStran for unswitched mode.
Issued Nov-09
Introduction
1-3
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
1-4
Introduction
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Chapter 2 – Function and Electrical Characteristics
You can use the ControlWave GFC Intrinsically Safe IStran
Communication Interface (IStran) in both hazardous and nonhazardous environments.
2.1 Hazardous and Non-Hazardous Characteristics
Table 2-1 provides the characteristics common to both the hazardous
and non-hazardous IStran interfaces:
Table 2-1. Common Characteristics for Hazardous and Non-Hazardous Interfaces
Description
Data Rate
Propagation Delay, any RX to
any TX
Output Enable Delay
(Switched Mode, enable to
TX valid)
RX Input High Level
Maximum:
Maximum:
Specification
19.2 Kbps
10 uS
Typical:
Maximum:
< 10 uS
50 uS
Minimum:
Maximum:
Minimum:
Maximum:
4.5 VDC
16 VDC
-16 VDC
0.5 VDC
RX Input Load Resistance
TX Output Load Resistance
Typical:
Minimum:
3.01 Kohm
3 Kohm
Quiescent Supply Current
(Both if in switched mode, all
TX off)
Idle Supply Current (Both if in
unswitched mode, all TX low)
Active Supply Current (Both if
active, worst case)
Maximum:
800 uA
Typical:
21 mA
Maximum:
43 mA
RX Input Low Level
2.1.1 Hazardous Interface
You connect the hazardous interface to an intrinsically safe device.
Table 2-2, identifies each connector position, the corresponding signal
name, and briefly describes each input/output point on the hazardous
interface.
Table 2-2. Hazardous Interface Connector
Position
Issued Nov-09
Name
Function
HJ2-4
HPOUT
Hazardous Power Output - connect to HJ1-3
(HPIN) for single supply applications
HJ2-3
HPIN
Hazardous Power Input
HJ2-2
HGND
Hazardous Interface Ground - connect to HJ21 (CGND) for single supply applications
HJ2-1
CGND
Enclosure Ground (Tied to NGND)
HJ1-8
HGND
Hazardous Interface Ground - (Reference for
Function and Electrical Characteristics
2-1
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Position
Name
Function
HPOUT and signals)
HJ1-7
HPOUT
Hazardous Power
HJ1-6
HRX3
Signal Input
HJ1-5
HRX2
Signal Input
HJ1-4
HJ1-3
HJ1-2
HJ1-1
HJP1-1
HJP1-2
HJP1-3
HRX1
HTX3
HTX2
HTX1
SW
COM
UNSW
Signal Input
Signal Output (Follows NRX3)
Signal Output (Follows NRX2)
Signal Output (Follows NRX1)
Jumper to COM for Switched Mode
Mode Selection Common
Jumper to COM for Unswitched Mode
Table 2-3 provides the characteristics of the hazardous interface.
Table 2-3. Hazardous Interface Characteristics
Description
2-2
Specification
HPOUT Voltage
Typical
Minimum:
Maximum:
6.3 VDC (No Load)
5.9 VDC (Max. Load)
6.4 VDC (No Load)
HPOUT Current Limit
Threshold
Minimum:
Maximum:
130 mA at 8 VDC
300 mA at 16 VDC
HPOUT Load Capacitance
Maximum:
100 uF
HPIN Quiescent Supply
Current
(Switched Mode,
Transmitters Off)
Maximum:
100 uA
HPIN Supply Current
(All TX Outputs High, 3 KW
Load
Maximum:
6 mA
HTX Output High Level
Minimum:
VDC
4.5 VDC,
Maximum:
5.0
HTX Output Low Level
Minimum:
VDC
0 VDC,
Maximum:
0.1
HJP1 Jumper Operation
If you don’t install a jumper, or if you install the
jumper between pins 1 and 2 (SW), the
hazardous interface operates in switched
mode. If you install the jumper between pins 2
and 3 (UNSW), the hazardous interface
operates in unswitched mode. Figure 2-1
shows the jumper in switched mode.
Function and Electrical Characteristics
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Figure 2-1. Setting Jumper HJP1
2.1.2 Non-Hazardous Interface
Typically you connect the non-hazardous interface to a radio or modem
located with the IStran assembly in a non-hazardous or Division 2 rated
area. Table 2-4 identifies each connector position and the corresponding
signal name, and provides a brief description of each I/O point on the
non-hazardous interface.
Table 2-4. Non-Hazardous Interface Connector
Position
Issued Nov-09
Name
Function
NJ3-1
NPOUT
Switched Power Output
NJ3-2
NGND
Local Ground reference
(Return for NPOUT)
NJ2-1
NPIN
Power Supply Input
NJ2-2
NGND
Local Ground
(Return for NPIN)
NJ1-1
NTX1
Signal Output (Follows HRX1)
NJ1-2
NTX2
Signal Output (Follows HRX2)
NJ1-3
NTX3
Signal Output (Follows HRX3)
NJ1-4
NRX1
Signal Input
NJ1-5
NRX2
Signal Input
NJ1-6
NRX3
Signal Input
NJ1-7
NGND
Local Ground
NJP1-1
SW
Jumper to COM for Switched Mode
NJP1-2
COM
Mode Selection Common
NJP1-3
UNSW
Jumper to COM for Unswitched Mode
Function and Electrical Characteristics
2-3
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Table 2-5 provides the characteristics of the non-hazardous interface.
Table 2-5. Non-Hazardous Interface Characteristics
Description
2-4
Specification
NPIN Voltage (When
HPOUT is not used)
Minimum:
Maximum:
5.4 VDC
16 VDC
NPIN Voltage (When
HPOUT is used)
Minimum:
Maximum:
8 VDC
16 VDC
NPIN Supply Current
(Switched Mode,
Transmitters Off)
Typical:
C)
Maximum:
< 500 uA at 12 VDC, 77 F (25
NPIN Supply Current (All
TX Outputs High, 3
KWLoads)
Maximum:
37 mA
NPOUT Leakage
Typical:
< 1 uA
NPIN to NPOUT OnResistance (NPIN ³ 12 V)
Typical:
Maximum:
< 0.3 ohm
0.5 ohm
NRX3 to NPOUT On
Typical:
< 10 uS
NPOUT Load Current
Maximum:
1.8 A Continuous
Maximum:
3.0 A Intermittent (Max 60
Seconds, 50% duty)
NTX Output High Level
Typical:
Minimum:
Maximum:
7.4 VDC into 3 Kohm Load
5.0 VDC
9.5 VDC
NTX Output Low Level
Typical:
Minimum:
Maximum:
-4.9 VDC into 3 Kohm Load
-9.5 VDC
-3.0 VDC
NJP1 Jumper Operation
If you didn’t install a jumper, or if you installed
a jumper between pins 1 and 2 (SW), the nonhazardous interface operates in switched
mode. If you install a jumper between pins 2
and 3 (UNSW), the non-hazardous interface
operates in unswitched mode. (Figure 2-2
shows the jumper in switched mode.)
Function and Electrical Characteristics
750 uA
Maximum: 100 uA
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Figure 2-2. Setting Jumper NJP1
2.2 Switched & Unswitched Modes
You can configure each IStran interface independently to operate in
switched or unswitched mode. In switched mode, the TX drivers can
enter a high-impedance state to reduce power consumption. The outputs
transition smoothly to and from the high-impedance state. Most modern
device inputs pull the high impedance IStran output to ground and
interpret it as a low, or mark state. Some devices may not properly
interpret the high-impedance signal, and in some systems it is
impractical for you to operate either or both interfaces in switched
mode. In these cases, or when power consumption is not a concern,
configure the interface(s) for unswitched mode. In unswitched mode,
the TX drivers are always active and they always follow the
corresponding RX inputs.
You enable or disable switched mode for the hazardous interface by
jumper position HJP1, and for the non-hazardous interface by jumper
position NJP1 (see Figures 2-1 and 2-2). When either interface is in
switched mode, the RX3 (NRX3 or HRX3) input of the opposite
interface turns it on or off.
Issued Nov-09
Function and Electrical Characteristics
2-5
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
2.2.1 Configuring the Hazardous Interface for Switched Mode
To configure the hazardous interface for switched mode, place the
supplied shorting jumper in the HJP1 position marked SW (short HJP1
pins 1 and 2 as shown in Figure 2-1). If you don’t install a jumper at
HJP1 the hazardous interface defaults to switched mode. When you
configure the hazardous interface for switched mode, the HTX outputs
are in a high-impedance state when NRX3 is low (or negative), and the
HTX outputs follow the NRX inputs normally when NRX3 is high
(positive).
2.2.2 Configuring the Hazardous Interface for Unswitched
Mode
To configure the hazardous interface for unswitched mode, place the
supplied shorting jumper in the HJP1 position marked UNSW (short
HJP1 pins 2 and 3). This is the opposite jumper position of that shown
in Figure 2-1. In unswitched mode, the HTX outputs remain on and
they always follow the corresponding NRX inputs.
2.2.3 Configuring the Non-Hazardous Interface for Switched
Mode
To configure the non-hazardous interface for switched mode, place the
supplied shorting jumper in the NJP1 position marked SW (short NJP1
pins 1 and 2 as shown in Figure 2-2). The non-hazardous interface is
also in switched mode by default if you don’t install a jumper at NJP1.
When you configure the non-hazardous interface for switched mode, the
NTX outputs are in a high-impedance state when HRX3 is low (or
negative), and the NTX outputs follow the HRX inputs normally when
HRX3 is high (positive).
2.2.4 Configuring the Non-Hazardous Interface for Unswitched
Mode
To configure the non-hazardous interface for unswitched mode, place
the supplied shorting jumper in the position marked UNSW (short NJP1
pins 2 and 3). This is the opposite jumper position of that shown in
Figure 2-2. In unswitched mode, the NTX outputs are always turned on
and they always follow the corresponding HRX inputs.
2.3 Non-Hazardous Power Output
The non-hazardous power supply is routed through a FET (field effect
transistor) from the power input to an output terminal. The power
supply comes in on the NPIN terminal and switched power goes out on
the NPOUT terminal.
2-6
Function and Electrical Characteristics
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
When hazardous interface signal input HRX3 is at a high (positive)
level, NPOUT turns on and can supply power to an external device.
When HRX3 is at a low (or negative) level, NPOUT turns off. You
determine the voltage drop between NPIN and NPOUT by multiplying
the NPOUT load current by the NPIN to NPOUT on-resistance. You
must also take into account the resistance of the associated field wiring
when you calculate the total drop between the power supply and the
load.
Caution
Issued Nov-09
In order to minimize resistance between NPIN and NPOUT, the IStran
does not provide over-current. You must install a fuse or other means of
over-current protection at the power source to prevent damage to the
IStran, power source, or load in case of a short circuit or other overcurrent condition.
Function and Electrical Characteristics
2-7
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
2-8
Function and Electrical Characteristics
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Chapter 3 – System Wiring
This chapter includes details on grounding and wiring for the IStran.
3.1 Introduction to System Wiring
The IStran connects a radio, modem, or other communications device to
a ControlWave GFC-IS Flow Computer/Corrector. An IStran can also
provide an intrinsically safe interface between an external power supply
and RS-232 signals associated with a radio, modem or ControlWave
RTU (in a non-hazardous area) and a ControlWave GFC-IS in a Class I,
Division 1 area.
3.2 Grounding
The IStran provides up to 500V of isolation between the hazardous and
non-hazardous interfaces. When using the ground isolation capability of
the IStran, devices on either side require separate power sources, and
each source must power the corresponding IStran interface. Refer to the
field wiring diagrams in Section 3.4 for systems with independent power
sources.
When isolation is not required, a single power source supplies both
IStran interfaces and, optionally, both connected devices. To power both
IStran interfaces using a single power source, connect the power source
between NPIN and NGND. Use connector HJ2 (see Figure 1-4) as a
jumper position to wire HPOUT to HPIN and HGND to CGND. Note
that CGND and NGND are internally connected, and that CGND is
connected to the IStran case. Refer to the field wiring diagrams in
Section 3.4 for systems with a single power source.
When a ground connection already exists between the power source and
the ControlWave or communications device, do not wire the ground
terminal on the IStran communications connector (NJ1 or HJ1). The
ground reference established on the IStran power connector (NJ2 or
HJ2) serves as both power supply return and signal ground reference.
Wiring the communications connector ground terminal may introduce a
ground loop and degrade the performance of the IStran under these
circumstances. The wiring diagrams in Section 3.4 illustrate the
recommended practices.
For intrinsic safety applications, you must use redundant earth grounds.
Both grounds must measure less than one ohm to earth. The NGND
terminal provides one ground, and the case provides the other. If the
mounting panel does not provide a suitable ground path, connect a
12AWG or larger ground conductor to one of the IStran mounting
screws.
Issued Nov-09
System Wiring
3-1
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
3.3 Cable Length
Underwriter’s Laboratories (UL) lists the IStran for use with cable
lengths up to 25 feet on either or both interfaces. Typically, you install
the IStran in close proximity to the communications device (connected
to the non-hazardous interface) and at some distance from the CWGFC-IS (connected to the hazardous interface). Because of cable
capacitance and inductance, 25 feet is the maximum cable length
allowable for use with a CW-GFC-IS located in a Division 1 area.
Warning
The cable length between a CW-GFC-IS operating in a Division 1 area
and the IStran must not exceed 25 feet.
3.4 Field Wiring Diagrams
Figure 3-1 illustrates a typical communication system. The power
source to the non-hazardous interface must not use or generate more
than 250V. If you install the IStran in a Division 2 area, you must make
power input and output connections using Division 2 wiring methods
described in Section 4.1.
In this example a single power source supplies both the communications
device and the CW-GFC-IS. The power supply input range for this
configuration is 8 to 16V. You connect the grounds of both devices
together through the IStran. The CW-GFC-IS power supply current
must be 120mA or less, and it must operate down to 5.9V. The IS
termination panel (part number 400135-01-9) contains the power and
communication connections.
Figure 3-1. Modem System with Single Power Source
3-2
System Wiring
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Figure 3-2 is similar to Figure 3-1 except it uses an MDS radio instead
of a modem.
Figure 3-2. Radio System with Single Power Source
Figures 3-3 and 3-4 illustrate an externally powered CW-GFC-IS
(without a modem or radio). In this example, the external power source
to the non-hazardous interface must not generate more than 16Vdc and
must be able to supply at least 8Vdc. If you install the IStran in a
Division 2 area, you must connect the power inputs and outputs using
Division 2 wiring methods. (See Section 4.1.)
Note: If you only require a modem or radio, refer to Figure 3-1 and
Figure 3-2. The only difference is that you can replace the 12V
battery by an external 8 to 16 Vdc power supply.
Figure 3-3. CW-GFC-IS with External Power Source
Issued Nov-09
System Wiring
3-3
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Figure 3-4. CW-GFC-IS with External Power Supply
3-4
System Wiring
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Chapter 4 – Installation
4.1 Installation Overview
The IStran and the communications device reside in a non-hazardous or
Division 2 rated area, while the CW-GFC-IS resides in a Division 1,
Division 2, or non-hazardous area.
You must provide a suitable enclosure for the IStran. When you mount
the IStran in a Division 2 area, you must make the non-hazardous
interface connections in accordance with Article 501-4(b) of the
National Electrical Code NFPA 70.
Caution
When you connect the IStran to a CW-GFC-IS mounted in a Division 1
area, wire all circuits according to wiring methods specified in article 504
of the National Electrical Code NFPA 70. Contact your IStran supplier for
assistance.
Warning
When you install the IStran in a Division 2 area, ensure that the area is
non-hazardous before you connect or disconnect the non-hazardous
interface.
4.2 Installation Notes
Use four #6 screws with lock washers to secure the IStran to a grounded
metal panel. Illustrations in Chapter 1 show the physical dimensions of
the IStran units. The four mounting holes/slots are 0.156" in diameter.
Total height is approximately 1". The case material is 5052 aluminum
with a black anodize finish. The thickness of the base is 0.060", and the
top is 0.090". The case hardware is stainless steel.
The IStran accepts stranded wires up to 14AWG. When you must insert
two wires in a single position, 18AWG is the maximum recommended
size. The recommended strip length is 1/4 inch, and the insulation must
not extend into the connector clamp. For cables, use 26AWG or larger
conductors and do not configure them as twisted pairs. If you use a
shield, connect it only at one end, closest to the system ground
reference. For optimum performance over long distances, use lowcapacitance cables. In the multi-drop configuration, keep all IStran units
in close proximity.
Secure all wiring before you apply power to the IStran or to the
associated devices. For intrinsic safety applications, use a single cable to
connect the IStran hazardous interface to the intrinsically safe device.
Maintain a minimum 2” separation between the intrinsically safe wiring
and all other wiring. Install the IStran hazardous interface near the point
where the intrinsically safe wiring exits the enclosure housing the
Issued Nov-09
Installation
4-1
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
IStran. Do not install any other wiring through the same hole or allow
other wires to share a cable or conduit with the intrinsically safe wiring.
Secure the intrinsically safe wiring and limit slack to ensure that, should
one of the intrinsically safe wires become dislodged from an IStran
terminal, it must still maintain a 2” separation with either the IStran
non-hazardous interface wiring or any other circuits except those on the
IStran hazardous interface.
Refer to Figures 3-1 through 3-4 in Chapter 3 when you connect wires
between an optional modem or radio and an IStran assembly.
Note: MDS and Freewave radios use different RXD/TXD naming
conventions. MDS uses RXD and TXD to mean “receive input”
and “transmit output” respectively, while Freewave uses RXD
for “transmit output” and TXD for “receive input.”
Refer to Chapter 3 when you connect wires between an externally
powered CW-GFC-IS and an IStran.
4-2
Installation
Issued Nov-09
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
Chapter 5 – Specifications
5.1 Environment
The IStran design supports operation inside a building or a weatherproof enclosure only.
5.2 Operating Specifications
Table 5-1 provides the operating specifications for the IStran:
Table 5-1. IStran Operating Specifications
Description
Operating
Temperature Range
Specification
-40oC to +70oC (-40oF to +158oF)
Operating Humidity
Range
15% to 95% RH (non-condensing)
Transient
Susceptibility
Field connected circuits designed to meet
requirements of ANSI/IEEE C37.90.1-1989
(formerly IEEE 472) for surge withstand capability.
Vibration Effect
10 to 500 Hz at 1 g on any axis per SAMA PMC-311 without damage or impairment.
ESD Susceptibility
Field connected circuits designed to meet the
requirements of IEC 801-2 for ESD withstand
capability up to 10KV.
EMI Compatibility
Designed to meet the susceptibility requirements of
IEC 801-3 level 2(3V/M) from 500kHz to 500MHz.
Designed to meet FCC Rules Part J, Subpart 15,
Class A for radiated emissions.
Hazardous Locations
Designed to meet NFPA and UL requirements for
installation in Class I, Division 2, Groups C and D
hazardous locations.
Designed to meet NFPA and UL requirements for
connection to intrinsically safe devices located in
Division 1 locations.
The intrinsically safe device must be designed
and/or approved for the intended connection.
Issued Nov-09
Specifications
5-1
ControlWave GFC IS Communication Interface Manual (CI-CW-GFC-ISTRAN)
5-2
Specifications
Issued Nov-09
WARRANTY
A.
Remote Automation Solutions (RAS) warrants that goods described herein and manufactured by RAS are
free from defects in material and workmanship for one year from the date of shipment unless otherwise
agreed to by RAS in writing.
B.
RAS warrants that goods repaired by it pursuant to the warranty are free from defects in material and
workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of
repaired goods, whichever is longer.
C.
Warranties on goods sold by, but not manufactured by RAS are expressly limited to the terms of the
warranties given by the manufacturer of such goods.
D.
All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused,
abused or otherwise damaged, (ii) repaired, altered or modified without RAS consent, (iii) not installed,
maintained and operated in strict compliance with instructions furnished by RAS or (iv) worn, injured or
damaged from abnormal or abusive use in service time.
E.
These warranties are expressly in lieu of all other warranties express or implied (including without limitation
warranties as to merchantability and fitness for a particular purpose), and no warranties, express or
implied, nor any representations, promises, or statements have been made by RAS unless endorsed
herein in writing. Further, there are no warranties which extend beyond the description of the face hereof.
F.
No agent of RAS is authorized to assume any liability for it or to make any written or oral warranties beyond
those set forth herein.
REMEDIES
A.
Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost
to Buyer of any goods or parts found by Seller to be defective if Buyer notifies RAS in writing of the alleged
defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above,
and if the Buyer returns such goods to the RAS Watertown office, unless the RAS Watertown office
designates a different location, transportation prepaid, within thirty (30) days of the sending of such
notification and which upon examination by RAS proves to be defective in material and workmanship. RAS
is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to RAS, the Buyer can arrange to have a RAS
service person come to the site. The Service person's transportation time and expenses will be for the
account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.
B.
Under no circumstances will RAS be liable for incidental or consequential damages resulting from breach
of any agreement relating to items included in this quotation from use of the information herein or from the
purchase or use by Buyer, its employees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Remote Automation Solutions (RAS) for repair, upgrade, exchange, or to verify
proper operation, Form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and
thus ensure an optimal lead time. Completing the form is very important since the information permits the RAS
Watertown Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-2220. A RAS Repair Dept. representative will
return the call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the RAS Web site (www.emersonprocess.com/remote) and sending it
via E-Mail to CustServe.RAS@Emerson.com . A RAS Repair Dept. representative will return E-Mail (or
other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Remote Automation Solutions
A Division of Emerson Process Management
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795
A RAS Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the RAS Repair Department at (860) 945-2442. A RAS Repair Department representative will
record a RA number on the form and complete Part I, send the form to the Customer via fax (or other
requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product
being returned. This will allow us to quickly track, repair, and return your product to you.
Remote Automation Solutions
Repair Authorization Form
(Providing this information will permit Remote Automation Solutions to effectively and efficiently process your return.
Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)
Date
____________
RA #
_________________
Standard Repair Practice is as follows: Variations to
this is practice may be requested in the “Special
Requests” section.
• Evaluate / Test / Verify Discrepancy/Repair/Replace
SH
Line No.
_________
Please be aware of the Non warranty standard
charge:
• There is a $100 minimum evaluation charge.
The party sending in material is responsible to ensure that the materials returned are clean to safe levels,
defined and/or determined by applicable federal, state and /or local law regulations or codes. Such party agrees
to indemnify Remote Automation Solutions harmless to any liability or damage which Remote Automation Solutions
may incur or suffer due to such party’s failure to so act.
Part I
Please complete the following information for single unit or multiple unit returns
Address No. _____________
Address No. ____________
Bill to : _____________________________________
Ship to: ___________________________________
____________________________________________
____________________________________________
____________________________________________
____________________________________________
Purchase Order: _________________________
Contact Name: _____________________________
Phone: _____________________
Part II
Fax: ______________________
E-Mail: ______________________
Please complete Parts II & III for each unit returned
Model No./Part No. _________________________ Description: __________________________________
Range/Calibration: _________________________ S/N: ___________________________________
Reason for return :
Failure
Upgrade
Verify Operation
Other __________________________
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.) ___________________
(Attach a separate sheet if necessary)
2.
Comm. interface used:
Standalone
RS-485
Ethernet
Other: ______________________________________
Modem (PLM (2W or 4W) or SNW)
3. What is the Firmware revision?_______________ What is the Software & version? _______________
Part III
If checking “replaced” for any question below, check an alternate option if replacement is not
available
A. If product is deemed not repairable would you like your product:
returned
replaced
B. If Remote Automation Solutions is unable to verify the discrepancy, would you like the product:
replaced
scrapped?
returned
*see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to
contact that has the most knowledge of the problem is: __________________ phone _________________
If we are unable to contact this person the backup person is:________________ phone _________________
Special Requests:
__________________________________________________________________________________________
Ship prepaid to:
Form GBU 13.01
Remote Automation Solutions, Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-2220
Rev. F 11/25/08
BLANK PAGE
ControlWave GFC-IStran Instruction Manual
Index
Non-Hazardous power output............................. 2-6
F
Field wiring diagrams.......................................... 3-2
Figures
1-1. Istran Front View ..................................... 1-1
1-2. Physical Dimensions - Istran Front View 1-2
1-3. Physical Dimensions – IStran Edge (Side)
View.............................................................. 1-2
1-4. Istran PCB Mounted on Base Plate ........ 1-3
2-1. Setting Jumper HJP1 .............................. 2-3
2-2. Setting Jumper NJP1 .............................. 2-5
3-1. Modem System with Single Power Source32
3-2. Radio System with Single Power Source 3-3
3-3. CW-GFC-IS with External Power Source 3-3
3-4. CW-GFC-IS with external power supply . 3-4
G
Grounding ........................................................... 3-1
H
Hazardous characteristics .................................. 2-1
Hazardous interface
configuring for Switched Mode ....................... 2-6
S
Specifications...................................................... 5-1
Switched Mode ............................................ 1-3, 2-5
configuring the Hazardous interface for ......... 2-6
configuring the non-Hazardous interface for .. 2-6
T
Tables
2-1. Common Characteristics for Hazardous and
Non-Hazardous Interfaces ........................... 2-1
2-2. Hazardous Interface Connector .............. 2-1
2-3. Hazardous Interface Characteristics ....... 2-2
2-4. Non-Hazardous Interface Connector ...... 2-3
2-5. Non-Hazardous Interface Characteristics2-4
5-1. IStran Operating Specifications............... 5-1
U
Un-Switched Mode....................................... 1-3, 2-5
configuring the Hazardous interface for ......... 2-6
configuring the non-Hazardous interface for .. 2-6
W
Wiring .................................................................. 3-1
field wiring diagrams....................................... 3-2
N
Non-Hazardous characteristics........................... 2-1
Issued Nov-09
Index
I-1
Customer Instruction Manual
CI-CW-GFC-ISTRAN
November, 2009
ControlWave GFC IStran
NOTICE
Emerson Process Management
Remote Automation Solutions
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Remote
Emerson Process Management
Remote Automation Solutions
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Remote
Emerson Process Management SA de CV
Calle 10 #145
Col. San Pedro de los Pinos
01180 Mexico, D.F.
Mexico
T +52 (55) 5809-5300
F +52 (55) 2614-8663
www.EmersonProcess.com/Remote
Emerson Process Management, Ltd.
Remote Automation Solutions
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969
www.EmersonProcess.com/Remote
Emerson Process Management AP Pte Ltd.
Remote Automation Solutions Division
1 Pandan Crescent
Singapore 128461
Phone: +65-6770-8584
Fax: +65-6891-7841
www.EmersonProcess.com/Remote
“Remote Automation Solutions (“RAS”), division of Emerson Process
Management shall not be liable for technical or editorial errors in this manual
or omissions from this manual. RAS MAKES NO WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THIS MANUAL AND, IN NO EVENT SHALL RAS BE LIABLE
FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL
DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION,
LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS
INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND
POWER, AND CLAIMS OF THIRD PARTIES.
Bristol, Inc., Bristol Babcock Ltd, Bristol Canada, BBI SA de CV and the Flow
Computer Division are wholly owned subsidiaries of Emerson Electric Co.
doing business as Remote Automation Solutions (“RAS”), a division of
Emerson Process Management. FloBoss, ROCLINK, Bristol, Bristol
Babcock, ControlWave, TeleFlow and Helicoid are trademarks of RAS. 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 trademarks are property of their respective owners.
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 warranties or guarantees, express or implied,
regarding the products or services described herein or their use or
applicability. RAS reserves the right to modify or improve the designs or
specifications of such products at any time without notice. All sales are
governed by RAS’ terms and conditions which are available upon request.
© 2009 Remote Automation Solutions, division of Emerson Process
Management. All rights reserved.