Fisher ControlWave Gas Flow Computer-CLASSIC Guide

Instruction Manual
CI-ControlWave GFC-CL
Oct., 2006
ControlWave GFC Classic
(Gas Flow Computer)
www.EmersonProcess.com/Bristol
ControlWave GFC-CL
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 Bristol 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 in-formation is
required, the purchaser is advised to contact Bristol .
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol for repairs or evaluation, please note the
following: The party sending such materials is responsible to ensure that the materials
returned to Bristol 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 Bristol and save Bristol harmless from any liability or damage which Bristol 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 at the back of this manual for proper
care and handling of ESD-sensitive components.
Bristol Inc. 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
WARRANTY
A.
Bristol warrants that goods described herein and manufactured by Bristol are free from
defects in material and workmanship for one year from the date of shipment unless
otherwise agreed to by Bristol in writing.
B.
Bristol warrants that goods repaired by it pursuant to the warranty are free from defects
in material and workmanship for a period to the end of the original warranty or ninety
(90) days from the date of delivery of repaired goods, whichever is longer.
C.
Warranties on goods sold by, but not manufactured by Bristol, 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
Bristol's consent, (iii) not installed, maintained and operated in strict compliance with
instructions furnished by Bristol, 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 BRISTOL UNLESS ENDORSED HEREIN
IN WRITING. FURTHER, THERE ARE NO WARRANTIES WHICH EXTEND BEYOND
THE DESCRIPTION OF THE FACE HEREOF.
F.
No agent of Bristol 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 Bristol 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 Bristol's Watertown office, unless Bristol's Water-town office designates a
different location, transportation prepaid, within thirty (30) days of the sending of such
notification and which upon examination by Bristol proves to be defective in material and
workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstalllation of allegedly defective or defective goods. If a Buyer does not wish to ship the
product back to Bristol, the Buyer can arrange to have a Bristol 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 Bristol 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 Bristol for repair, upgrade, exchange, or to verify
proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very
important since the information permits the Bristol Repair Dept. 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) 945-3875. A Bristol Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)
and sending it via E-Mail to [email protected]. A Bristol Repair Dept.
representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795
A Bristol Repair Dept. representative will return call (or other requested method)
with a RA number.
D. Phone
Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Department representative will record a RA number on the form and complete Part I, then
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.
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
•
Avoid Delays and problems in getting your system on-line
•
Minimize installation, start-up and maintenance costs.
•
Make the most effective use of our hardware and software.
•
Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at three locations: Houston, Orlando and our Watertown, CT
headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol products and realize the full
potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 6856200.
A Few Words About Bristol Inc.
For over 100 years, Bristol® has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Inc. instruments, controllers, and systems running year-in and
year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Help Files / Release Notes
Many Bristol software products incorporate help screens. In addition, the software typically
includes a ‘read me’ release notes file detailing new features in the product, as well as other
information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about ControlWave call (860) 945-2394 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865
or e-mail: [email protected]
For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: [email protected]
The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/
For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-9464.
You can e-mail the Communication Technology Group at:
[email protected]
Telephone Support - Non-Technical Questions, Product Orders, etc.
Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed on the rear cover of
this manual) or to your Bristol-authorized sales representative.
Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office
covers your particular area.
Visit our Site on the World Wide Web
For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com
Training Courses
Bristol’s Training Department offers a wide variety of courses in Bristol hardware and
software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at (860) 945-2343 for course
information, enrollment, pricing, and scheduling.
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
INSTALLATION FORWARD
NOTE for all ControlWave GFC-CL Installers:
READ THIS SECTION FIRST!
This manual has been designed for the following audience:
• Customer Site Engineers, who must plan for the installation and implementation of the
ControlWave GFC-CL.
• Instructors who must become familiar with and teach Field Engineers/Technicians on
the installation, operation and repair of ControlWave GFC-CL.
• Field Engineers/Technicians who must install and service the ControlWave GFC-CL.
Installation of the ControlWave GFC-CL Gas Flow Computer is provided in two formats
as follows:
Section 2 - Installation & Operation provides a detailed overview of the installation and
operation of the ControlWave GFC-CL. Section 2 provides all the information required for
instructors who are training individuals unfamiliar with the ControlWave GFC-CL. It is
also intended to support anyone who needs to learn how to install and operate the ControlWave GFC-CL for the first time.
Appendix C - Hardware Installation Guide is intended for individuals who are already
familiar with the ControlWave GFC-CL but need the configuration information in a
concise format. Field Engineers/Technicians who have previously installed one or more
Control-Wave GFC-CL will find the necessary installation information logically sequenced
for their convenience.
NOTE:
A Windows driven diagnostic tool referred to as WINDIAG is provided on the
OpenBSI Software CDROM. WINDIAG is documented in instruction manual
D4041A – Window Diagnostics for Bristol Controllers. Bristol’s WINDIAG program
provides menu driven diagnostics that have been designed to assist a technician
or Process Engineer in troubleshooting the various ControlWave GFC-CL
circuits. A brief overview is provided in Section 3.5 of this manual. For more
detailed descriptions of ControlWave GFC-CL Windows Diagnostics than those
provided herein, see Document D4041A – Chapters 1 and 7C.
CI-ControlWave GFC-CL - Installation Forward
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 1 - ControlWave GFC-CL INTRODUCTION
1.1
1.2
1.3
1.3.1
1.3.2
1.3.2.1
1.3.2.2
1.3.2.3
1.3.2.4
1.3.2.5
1.3.3
1.3.3.1
1.3.3.2
1.3.3.3
1.3.3.3.1
1.3.3.3.2
1.3.3.3.3
1.3.3.3.4
1.3.3.4
1.3.4
1.3.5
1.3.6
1.4
1.5
1.5.1
1.5.2
1.5.2.1
1.5.2.2
1.5.2.3
1.5.2.3.1
1.5.2.3.2
1.5.2.4
1.5.3
1.5.3.1
1.5.3.2
1.5.3.3
1.5.3.4
1.5.4
1.5.5
1.5.5.1
1.5.6
1.5.6.1
1.5.6.2
1.5.6.3
1.5.7
GENERAL DESCRIPTION ........................................................................................... 1-1
ControlWave PROGRAMMING ENVIRONMENT .................................................... 1-4
PHYSICAL DESCRIPTION........................................................................................... 1-6
Enclosure......................................................................................................................... 1-6
CPU/System Controller Board....................................................................................... 1-7
CPU/System Controller Board Connectors ................................................................... 1-9
CPU Memory................................................................................................................. 1-10
CPU/System Controller Board Configuration Jumpers ............................................. 1-10
CPU/System Controller Board Configuration Switches............................................. 1-12
CPU/System Controller Board LEDs .......................................................................... 1-13
Battery Charger and I/O Board ................................................................................... 1-13
Battery Charger and I/O Board Connectors ............................................................... 1-14
Battery Charger and I/O Board Configuration Jumpers ........................................... 1-14
Battery Charger and I/O Board Field I/Os.................................................................. 1-17
Non-isolated Analog I/O ............................................................................................... 1-17
Non-isolated Digital I/O ............................................................................................... 1-17
Non-isolated High Speed Counter Inputs ................................................................... 1-17
Optional RTD Input Probe ........................................................................................... 1-17
Battery Charger and I/O Board Input Power Connections ........................................ 1-18
Multivariable or Gage Pressure Transducer............................................................... 1-18
Internal Mounting Brackets ........................................................................................ 1-18
Radio/Modem ................................................................................................................ 1-18
FIELD WIRING............................................................................................................ 1-19
FUNCTIONS................................................................................................................. 1-19
Data Acquisition ........................................................................................................... 1-20
Flow and Volume Calculations .................................................................................... 1-20
Flow Rate and Flow Time Calculations (AGA3) ......................................................... 1-20
Flow Rate Calculations and Flow Time Accumulations (AGA7) ............................... 1-20
Extension Calculation and Analog Averaging ............................................................ 1-21
Energy Calculation ....................................................................................................... 1-21
Volume and Energy Integration .................................................................................. 1-21
Downstream Pressure Tap........................................................................................... 1-21
Archives......................................................................................................................... 1-21
Hourly Historical Data Log.......................................................................................... 1-22
Daily Historical Data Log ............................................................................................ 1-22
Periodic Historical Data Log ........................................................................................ 1-22
Alarm and Event Storage............................................................................................. 1-23
LCD Display.................................................................................................................. 1-23
Communications ........................................................................................................... 1-23
BSAP Message Support................................................................................................ 1-24
Discrete and Analog I/O GFC Functionality ............................................................... 1-24
Flow Rate Control - DDC (jog control) using PID....................................................... 1-24
Pulse Output for External Totalizer or Sampler ........................................................ 1-25
Nominations.................................................................................................................. 1-25
Self Test & Diagnostics ................................................................................................ 1-25
CI-ControlWave GFC-CL
Contents / 0 - 1
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 1A - PRODUCT FEATURES & OVERVIEW
1A.1
1A.1.1
1A.1.2
1A.2
1A.2.1
1A.2.2
1A.2.3
1A.3
1A.3.1
1A.3.2
1A.3.3
1A.3.3.1
1A.3.3.2
1A.3.4
1A.3.5
1A.4
1A.4.1
1A.4.1.1
1A.4.1.2
1A.4.1.3
PRODUCT OVERVIEW .............................................................................................. 1A-1
Hardware Features...................................................................................................... 1A-1
Firmware and Software Features............................................................................... 1A-2
PRODUCT FAMILY COMPATIBILITY .................................................................... 1A-2
Open Standards for Programming, Network Config. and Communication ............. 1A-2
ControlWave Designer with ACCOL III................................................................... 1A-2
ACCOL III.................................................................................................................... 1A-2
STANDARD APPLICATION PROGRAM.................................................................. 1A-3
OpenBSI - Simply Creative......................................................................................... 1A-4
OpenBSI Utilities ........................................................................................................ 1A-4
Real-time ActiveX Controls......................................................................................... 1A-4
ActiveX Controls .......................................................................................................... 1A-5
Required Software ....................................................................................................... 1A-5
Historical Data Collection ........................................................................................... 1A-5
OPC Server .................................................................................................................. 1A-6
ControlWave OPEN NETWORK CONNECTIVITY................................................ 1A-6
Communication Protocols............................................................................................ 1A-6
BSAP Protocol.............................................................................................................. 1A-6
Modbus Protocol........................................................................................................... 1A-7
Generic Serial Interface .............................................................................................. 1A-7
Section 2 - INSTALLATION & OPERATION
2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.1.1
2.3.1.2
2.3.1.3
2.3.1.4
2.3.2
2.3.3
2.3.3.1
2.3.3.2
2.3.3.3
2.3.3.4
2.3.3.5
2.3.3.6
2.3.4
2.3.4.1
2.3.4.2
0 - 2 / Contents
INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1
SITE LOCATION CONSIDERATIONS........................................................................ 2-2
Temperature & Humidity Limits .................................................................................. 2-3
Vibration Limits ............................................................................................................. 2-3
ControlWave GFC-CL INSTALLATION/CONFIGURATION .................................. 2-3
Mounting the ControlWave GFC-CL Enclosure ........................................................ 2-6
Connection to the Multivariable Transducer (MVT) .................................................. 2-10
Connection to the Gage Pressure Transducer (GPT) ................................................. 2-11
Process Pipeline Connection (Meter Runs without Cathodic Protection) ................. 2-11
Process Pipeline Connection (Meter Runs with Cathodic Protection)....................... 2-11
Battery Charger and I/O Board Configuration ........................................................... 2-13
CPU/System Controller Board Configuration............................................................. 2-15
CPU/System Controller Board Switch Configuration ................................................ 2-15
Communication Ports ................................................................................................... 2-17
RS-232 & RS-485 Interfaces ........................................................................................ 2-18
Piggy-back Spread Spectrum Modem (Radio) Port .................................................... 2-22
Piggy-back 56K PSTN Modem Port............................................................................. 2-25
Radio Ready and External (Case Mounted) Modem or Radio.................................... 2-27
I/O Wiring...................................................................................................................... 2-27
I/O Wire Connections.................................................................................................... 2-28
Shielding and Grounding ............................................................................................. 2-28
CI-ControlWave GFC-CL
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 2 - INSTALLATION & OPERATION (Continued)
2.3.4.3
2.3.4.3.1
2.3.4.4
2.3.4.4.1
2.3.4.5
2.3.4.5.1
2.3.4.6
2.3.4.6.1
2.3.5
2.3.6
2.3.7
2.3.7.1
2.3.7.2
2.3.7.3
2.3.7.3.1
2.3.7.3.2
2.3.7.4
2.3.8
2.4
2.4.1
2.4.2
2.4.2.1
2.4.2.2
2.4.2.3
2.4.3
2.4.4
2.4.5
2.4.5.1
Non-isolated Discrete Input/Output Connector Block TB5........................................ 2-28
Discrete Input/Output Configurations ........................................................................ 2-28
Non-isolated Analog Input Connector Block TB8....................................................... 2-28
Analog Input Configurations ....................................................................................... 2-30
Non-isolated Analog Output Connector Block TB9 .................................................... 2-30
Analog Output Configurations..................................................................................... 2-30
Non-isolated High Speed Counter Input Connector TB6........................................... 2-31
High Speed Counter Configurations............................................................................ 2-31
RTD Wiring ................................................................................................................... 2-31
Connection to a Model 3808 Transmitter.................................................................... 2-32
Power Wiring & Distribution ....................................................................................... 2-34
Bulk Power Supply Current Requirements ................................................................ 2-35
Power Wiring ................................................................................................................ 2-35
Mounting an Optional Solar Panel .............................................................................. 2-36
Swivel (Directional Facing) .......................................................................................... 2-37
Tilt Angle....................................................................................................................... 2-37
ControlWave GFC-CL System Grounding ............................................................... 2-38
Operation of the Lithium Backup Coin-cell Battery .................................................. 2-38
OPERATIONAL DETAILS .......................................................................................... 2-39
Downloading the Application Load.............................................................................. 2-39
Upgrading ControlWave GFC-CL Firmware ........................................................... 2-40
Using LocalView to Upgrade ControlWave GFC-CL Firmware ............................. 2-40
Using Hyperterminal to Upgrade ControlWave GFC-CL Firmware...................... 2-43
Remote Upgrade of ControlWave GFC-CL Firmware ............................................. 2-46
Operation of the Mode Switch...................................................................................... 2-46
Soft Switch Configuration and Communication Ports ............................................... 2-47
Optional Display/Keypad Assemblies.......................................................................... 2-47
Operation of the Dual-button Display/Keypad Assembly .......................................... 2-52
Section 3 - SERVICE
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.3
3.3.1
3.3.2
3.3.3
3.4
3.4.1
SERVICE INTRODUCTION ........................................................................................ 3-1
COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1
Accessing Components For Testing ............................................................................... 3-1
Removal/Replacement of the CPU/System Controller Board ...................................... 3-2
Removal/Replacement of the Primary Battery System................................................ 3-2
Removal/Replacement of the Battery Charger & I/O Board ........................................ 3-2
Removal/Replacement of an External Radio/Spread Spectrum Modem ..................... 3-3
Removal/Replacement of the MVT or GPT Transducer ............................................... 3-3
TROUBLESHOOTING TIPS......................................................................................... 3-3
Battery Charger & I/O Board Voltage Checks.............................................................. 3-3
LED Checks .................................................................................................................... 3-4
Wiring/Signal Checks ..................................................................................................... 3-7
GENERAL SERVICE NOTES ....................................................................................... 3-8
Extent of Field Repairs................................................................................................... 3-8
CI-ControlWave GFC-CL
Contents / 0 - 3
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 3 - SERVICE (Continued)
3.4.2
3.4.3
3.5
3.5.1
3.5.1.1
3.5.1.2
3.6
3.7
Disconnecting RAM Battery .......................................................................................... 3-8
Maintaining Backup Files.............................................................................................. 3-8
WINDIAG DIAGNOSTICS ............................................................................................ 3-8
Diagnostics Using WINDIAG ...................................................................................... 3-11
Communications Diagnostic Port Loop-back Test ...................................................... 3-12
Serial Comm. Port Eternal Loop-back Test Procedure .............................................. 3-12
CORE UPDUMP........................................................................................................... 3-13
CALIBRATION CHECKS............................................................................................ 3-14
Section 4 - SPECIFICATIONS
4.1
4.2
4.3
4.3.1
4.3.2
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.5
4.6
CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1
COMMUNICATION PORTS ......................................................................................... 4-1
CPU/SYSTEM CONTROLLER BOARD ...................................................................... 4-3
Input Power Specs. ......................................................................................................... 4-3
Power Supply Sequencer Specs. .................................................................................... 4-4
BATTERY CHARGER & I/O BOARD SPECIFICATIONS.......................................... 4-4
External Power Monitor Specs. ..................................................................................... 4-4
Battery Charger & I/O Board Connectors..................................................................... 4-4
Non-isolated Digital Input/Output Circuitry Specs...................................................... 4-5
Non-isolated Analog Input/Output Circuitry Specs. .................................................... 4-6
Non-isolated High Speed Counter Input Circuitry Specs. ........................................... 4-7
ENVIRONMENTAL SPECIFICATIONS...................................................................... 4-7
DIMENSIONS ................................................................................................................ 4-8
APPENDICES/SUPPLEMENTAL INSTRUCTION
Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A
Reserved ............................................................................................................Appendix B
HARDWARE INSTALLATION GUIDE..........................................................Appendix C
PIGGY-BACK RADIO/MODEM INSTALLATION GUIDE.......................... Appendix D
DISPLAY/KEYPAD ASSEMBLY GUIDE.......................................................Appendix E
Using ControlWave GFC-CL WebBSI Web Pages ....................................... Appendix F
RADIO READY INSTALLATION GUIDE .................................................... Appendix G
MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z
Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW
Care and Handling of PC Boards and ESD-Sensitive Components ..................... S14006
REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS
WINDIAG - Windows Diagnostics for BBI Controllers........................................D4041A
ControlWaveMICRO Quick Setup Guide ............................................................. D5124
Open BSI Utilities Manual ...................................................................................... D5081
Getting Started with ControlWave Designer.......................................................... D5085
0 - 4 / Contents
CI-ControlWave GFC-CL
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS (Continued)
Web_BSI Manual ...................................................................................................... D5087
ControlWave Designer Reference Manual .............................................................. D5088
ControlWave Designer Programmer’s Handbook ................................................... D5125
TechView User’s Guide............................................................................................. D5131
REFERENCED OEM MANUALS
Expansion Comm. Module Piggy-back Modem/Radio OEM Manuals
MDS Transnet Radio wired to Polyphaser - Spread Spectrum Data Transceiver
MDS document MDS 05-3946A01, Rev. A April, 2003 (PDF = 3946A-TNET_OEM-web.pdf)
Internal FreeWave Radio (wired to Polyphaser) - Spread Spectrum Data Transceiver
FreeWave Spread Spectrum Wireless Data Transceiver User Manual - V5.0R (model FGR09CSU)
Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the
latest copy of the user manual.
MultiTech Systems wired to Surge Suppressor - Modem Module MT3334SMI & MT5634SMI
MultiTech Systems Developer Guide PN S000181C, version C 6/24/02 (PDF = S000181C.pdf)
External Modem/Radio OEM Manuals
MDS Transnet 900 - Spread Spectrum Data Transceiver
MDS TransNET 900 Spread Spectrum Data Transceiver Installation & Operation Guide – MDS Doc.
MDS 05-2708A01, Rev. C, Feb., 2004 (PDF = 2708C-TransNET-web.pdf) for MDS TransNet 900
MDS 4710A – Remote Data Transceiver (Radio)
MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver Installation and Operation Guide
– MDS Doc. 05-3305A01, Rev. B, Sept. 2000
(PDF = 3305B-710AC.pdf) for model MDS 4710A
MDS 4710B – Data Transceiver (Radio)
MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev.
E, Sept. 2000
(PDF = 3316E-x710B.pdf) for model MDS 4710B
MDS 9810 – Spread Spectrum Data Transceiver (Radio)
MDS 9810/24810 900 MHz/2.4GHz Spread Spectrum Transceivers Installation and Operation Guide
– MDS Doc. 05-3301A01, Rev. B, April 2000
(PDF = 3301B-x810.pdf) for model MDS 9810
CI-ControlWave GFC-CL
Contents / 0 - 5
CI-ControlWave GFC-CL
ControlWave GFC CLASSIC
Gas Flow Computer
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
External Modem/Radio OEM Manuals (Continued)
MDS 9710A Remote Data Transceiver (Radio)
MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver – MDS Doc. 05-3305A01, Rev. B,
Sept. 2000
(Installation & Operation) (PDF = 3305B-710AC.pdf) for model MDS 9710A
MDS 9710B Data Transceiver (Radio)
MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev.
E, Sept. 2000
(PDF = 3316E-x710B.pdf) for model MDS 9710B
MDS iNET 900 Ethernet Radio
MDS iNET 900 Wireless IP/Ethernet Transceiver – User Guide = MDS 05-2806A01, Rev. D, Aug.
2003
(PDF = 2806D-iNET_User-web.pdf) for iNET 900 Ethernet Radio
Center Insert (Installation Reference Chart) = (PDF = 2873D-iNET_Center_Sheet.pdf)
MDS iNET 900 Wireless IP/Ethernet Transceiver – Installation Guide = MDS 05-2873A01, Rev. D,
Aug. 2003
(PDF = 2873D-iNET-Install_web.pdf) for iNET 900 Ethernet Radio
MDS entraNET Extended Range IP Networking Transceivers
MDS entraNET Extended Range IP Networking Transceivers – System Guide = MDS 05-4055A01,
Rev. A, Oct. 2003
(Installation & Operation) (PDF = 4055A-entraNET-web.pdf) for MDS entraNET 900 System
FreeWave Radio - Spread Spectrum Data Transceiver Model FGRM-501X005
Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the
latest copy of the user manual.
0 - 6 / Contents
CI-ControlWave GFC-CL
Section 1
ControlWave GFC-CL INTRODUCTION
1.1 GENERAL DESCRIPTION
ControlWave GFC-CL gas flow computers have been designed to perform as the ideal
platform for remote site automation, measurement and data management in the oil and gas
industry. ControlWave GFC-CLs measure differential pressure, static pressure and
temperature for a single run and compute flow for both volume and energy. In addition to
operation in an unprotected outdoor environment, the ControlWave GFC-CL gas flow
computer provides the following key features.
Hardware/Packaging Features:
• 32-bit ARM9 processor (LH7A400) provides exceptional performance and low power
consumption
• Wide operating temperature range: (-40 to +70°C) (-40 to 158°F)
• Two Board Platform: (CPU/System Controller Bd. and Battery Charger & I/O Bd.)
• Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,
300mA-hr lithium coin cell battery located on the CPU Module
• Very low power consumption - minimizes costs of solar panel/battery power systems,
which are also integrated into the package
• Integral Multivariable Transducer (MVT) with “smart” performance (for DP or GP
measurement) or Gage Pressure Transducer (for GP measurement)
• Three serial communications ports (One RS-232, One RS-485 and One RS-232/485)
• Four line alphanumeric display (with dual-button Keypad or 25-button Keypad)
• Standard I/O includes: 2 Digital Inputs (DI), 2 High Speed Counter Inputs (HSC), and 2
Digital Outputs (DO)
• Optional I/O includes: 3 Analog Inputs (AI) and 1 Analog Output (AO)
• RTD input
• Nonincendive Class I, Div. 2, Groups C & D Hazardous Locations (see Appendix A)
• Broad selection of modem and wireless communications are instrument package options
• Cost effective for small RTU/Process Controller applications
Firmware/Software Features
• Preprogrammed to meet API 21.1 requirements for a two-run metering station (with
networking via BSAP or Modbus)
• Functions as a Process Controller or Remote Terminal Unit (RTU)
• Standard Application Program supports the following Flow calculations:
• Calculates AGA3-1995/NX-19
• AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
• AGA7/NX-19
• AGA7 with selectable AGA8 Gross or AGA8 Detail
• Auto Adjust AGA7/NX-19
• Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
• Instromet Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail
• Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail
• WebBSI Web pages are preconfigured for all user operations.
• Additional, standard application programs will be introduced on a continual basis.
• Using our ControlWave Designer IEC 61131-3 Programming Environment, any user or
third party can modify the standard application or create a completely customized
program – full support from Bristol Babcock is available, every step of the way.
• ControlWave GFC-CLs are compatible with Bristol Babcock’s TeleFlow-series in
software and networking solutions for SCADA and EFM (Electronic Flow Meter) data
editing/management, and are similar in all operations.
CI-ControlWave GFC-CL
Introduction / 1-1
ControlWave GFC-CL gas flow computers are furnished in a NEMA 3R rated enclosure.
The gas flow computer hardware is comprised of a CPU/System Controller Board (mounted
on the inside of the Instrument Front Cover), a Battery Charger & Input/Output Board
(mounted on edge within the enclosure) and either a Multivariable Transducer (MVT) or a
Gage Pressure Transducer (GPT) (mounted on the bottom of the enclosure). Sharp’s
LH7A400 System-on-Chip Advanced RISC Machine (ARM) microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) is the core of the CPU/System
Controller Board. In addition to the microprocessor and control logic, the CPU/System
Controller Board includes one fixed RS-232 Communication Port (COM1), one fixed RS-485
Communication Port (COM3), 1 configurable (RS-232/RS-485) Communication Port
(COM2), 2MB of battery backed Static RAM (SRAM), 512kB Boot/Downloader FLASH,
8MB simultaneous read/write FLASH, SPI I/O Bus Connector, Serial Real Time Clock,
Power Supply Sequencer, and Display/Keypad Interface. In addition to Idle, Watchdog,
Power Good, DCD, DTR and the various Comm. Port LEDs, there are six status LEDs
located on the CPU/System Controller Board that will display run time status information
Figure 1-1 - ControlWave GFC-CL Enclosure (MVT Equipped)
(with 25-Button Display/Keypad Assembly)
1-2 / Introduction
CI-ControlWave GFC-CL
Figure 1-2A - MVT Equipped ControlWave GFC-CL (with MDS - Transnet Radio)
(Internal View) Component Identification Diagram
Battery Charger & I/O Boards provide the circuitry and field interface hardware necessary
to interconnect the assigned field I/O circuits. Non-isolated power is generated and
regulated by the CPU/System Controller Board (C/SCB) that provides +3.3Vdc for all logic
and bulk power for I/O field circuits from either a bulk 6Vdc or bulk 12Vdc source. +1.8Vdc,
used by the ARM microprocessor, is generated on the CPU Module (derived from the
regulated 3.3Vdc logic power).
CI-ControlWave GFC-CL
Introduction / 1-3
Figure 1-2B – GPT Equipped ControlWave GFC-CL (with MDS - Transnet Radio)
(Internal View) Component Identification Diagram
Note: When equipped with a Gage Pressure Transducer, a GPT Adapter Plate is
mounted to the bottom of the enclosure.
1.2 ControlWave PROGRAMMING ENVIRONMENT
The ControlWave programming environment uses industry-standard tools and protocols to
provide a flexible, adaptable approach for various process control applications in the water
treatment, wastewater treatment, and industrial automation business.
ControlWave GFC-CL units provide an ideal platform for remote site automation,
measurement, and data management in the oil and gas industry.
1-4 / Introduction
CI-ControlWave GFC-CL
The control strategy file created and downloaded into the controller is referred to as a
ControlWave project. The ControlWave GFC-CL ships from Bristol with a standard
ControlWave project, pre-configured for gas flow measurement, already loaded and ready
to run.
The ControlWave programming environment consists of a set of integrated software tools
which allow a user to modify the standard gas flow measurement project to fit the needs of
their own particular application, as well as to create, test, implement, and download a
different ControlWave project, if desired.
The tools that make up the programming environment are:
•
ControlWave Designer load building package offers several different methods for
generating and debugging control strategy programs including function blocks, ladder
logic, structured languages, etc. The resulting process control load programs are fully
compatible with IEC 61131-3 standards. Various communication methods as offered,
including TCP/IP, serial links, as well as communication to Bristol’s Open BSI software
and networks.
Figure 1-3 - ControlWave - Control Strategy Software Diagram
•
The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,
allows you to define process I/O modules in the ControlWave and con-figure the
individual mapping of I/O points for digital and analog inputs and outputs.
•
The ACCOL3 Firmware Library which is imported into ControlWave Designer,
includes a series of Bristol Babcock specific function blocks. These pre-programmed
function blocks accomplish various tasks common to most user applications including
alarming, historical data storage, as well as process control algorithms such as PID
control.
CI-ControlWave GFC-CL
Introduction / 1-5
The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows
real-time data access to any OPC [Object Linking and Embedding (OLE) for Process
Control] compliant third-party software packages.
•
• A set of ControlWave GFC-CL web pages is provided to set configuration parameters
for the standard gas flow measurement project, running in the unit. These web pages
use Bristol ActiveX controls for retrieval of real-time data values and communication
statistics from the unit. The ActiveX controls are compatible with Microsoft® Internet
Explorer. Alternatively, developers can place the ActiveX controls in third-party ActiveX
compatible containers such as Visual BASIC or Microsoft® Excel.
• User-defined Web Pages – Users can place the same ActiveX controls into their own
web pages to provide a customized human-machine interface (HMI) to the ControlWave GFC-CL.
• Flash Configuration Utility – Parameters such as the BSAP local address, IP address, etc. are set using the Flash Configuration Utility, accessible via Open BSI
LocalView or NetView. The ControlWave GFC-CL ships with a standard Flash Configuration Profile (FCP) file, with default configuration parameters already set.
1.3 PHYSICAL DESCRIPTION
ControlWave GFC-CL gas flow computers are comprised of the following major
components:
•
•
•
•
Enclosure with Local Communications Port (RS-232) and LCD Display (Section 1.3.1)
CPU/System Controller Board (Section 1.3.2)
Battery Charger & I/O Board (Section 1.3.3)
Internal Mounting Brackets (Section 1.3.5)
ControlWave GFC-CLs can be factory configured with the following options:
•
•
•
Multivariable Transducer (MVT) or Gage Pressure Transducer (GPT) (Section 1.3.4)
RTD Probe (Section 1.3.3.3.4)
Radio/Modem (Section 1.3.6)
1.3.1 Enclosure
ControlWave GFC-CLs are housed in a standard NEMA 3R rated fiberglass enclosure.
External dimensions (excluding added hardware and Cover Latches) are approximately
11.73” high, by 9.08” wide, by 7.44” deep (without mounting brackets). When present, the
Multivariable Transducer adds 2.80” or the Gage Pressure Transducer adds approximately
1.60” to the height of the unit. The enclosure consists of two pieces, the body and the
Instrument Front Cover. A continuous gasket seals the unit when the Instrument Front
Cover is closed. A hinge on the left side (facing the front of the unit) is formed by molded
channels on the Instrument Front Cover and the body that capture a stainless steel pin.
Two latches on the enclosure’s right side secure the Instrument Front Cover when it is
closed.
A weatherproof communication connector (the Local Port) is mounted to the bottom of the
Instrument Front Cover and is connected internally to RS-232 Comm. Port 1. The Local
Port provides connection for a local communications device, typically a PC.
Communications rate is configurable 300 to 115.2 KB (115.2 KB - default).
1-6 / Introduction
CI-ControlWave GFC-CL
Enclosures are provided with either a 2-button 4 X 20 LCD display or a 4 X 20 LCD display
supported by a 25-button keypad. In normal operation, the display stays off after the unit
has been configured and placed into service. The operator may activate the display at any
time by pressing the appropriate front panel button.
1.3.2 CPU/System Controller Board
The multilayer CPU/System Controller Board provides ControlWave GFC-CL CPU, I/O
monitor/control, memory and communication functions. ControlWave GFC-CL
CPU/System Controller Boards operate over an extended temperature range with long-term
product reliability.
ControlWave GFC-CL CPU/System Controller Boards are based on a 32-bit ARM9TDMI
RISC Core Processor. The CPU/System Controller Board is specified to operate with an
input voltage range from 4.5 to 16.0 Vdc and with a system clock speed of 14 MHz. The
Microcontroller is packaged in a 256-pin Plastic Ball Grid Array. In addition to the
microprocessor and control logic, the CPU Board includes one fixed RS-232 communication
Port (COM1), one fixed RS-485 communication port (COM3) and a communication port that
can be configured for RS-232 (default), RS-485 (4-wire) or modem/radio operation. CPU
Memory consists of 2MB of battery backed Static RAM (SRAM), 512kB Boot/Downloader
FLASH and 8MB simultaneous read/write FLASH. Interface to field I/O is provided
through an I/O Bus Connector.
CPU/System Controller Boards are provided backup power via a coin cell socket that
accepts a 3.0V, 300mA-hr lithium battery. This 3.0V battery provides backup power for the
real-time clock and the system’s Static RAM (SRAM). Backup power is enabled when
Configuration Jumper W28 (adjacent to the battery) is installed.
If the 3.3Vdc that powers the unit goes out of specification, a supervisory circuit on the
CPU/System Controller Board switches the battery voltage to the VBAT3.3 hardware signal
(used by the CPU’s SRAM and RTC). This supervisory circuit also generates a
BATTERYGOOD signal when the battery voltage is above 2.2V.
The system SRAM is specified to have a standby current of 20:A maximum for each part
(plus 2uA for the RTC). For a system containing 2MB of System SRAM, a worst-case
current draw of 42:A allows a battery life of approximately 7142 hours.
The power supply operates from +4.5/+4.9 to +16Vdc or +9.6/10.3 to +16Vdc with the
nominal input supply configuration (+6V or +12V) user configured via on-board jumpers. A
supervisory circuit monitors the incoming power and the supply voltages. The isolated
supplies are shut down when the incoming voltage drops below +4.5V for a +6V system or
+9.6V, for a +12V system.
A supervisory circuit is used to switch to battery power when VCC falls out of specification.
For maximum shelf life, the battery may be isolated from the circuit by removing the
Backup Battery Jumper W28 from position 1 to 2 and then storing it on either pin. If the
Real-time clock looses its battery backup a ControlWave Designer system variable bit
(_QUEST_DATE) is set. This bit can be used to post a message or alarm to the PC (see the
‘Systems Variables’ section of the ControlWave Designer Programmer’s Handbook D5125).
CI-ControlWave GFC-CL
Introduction / 1-7
Figure 1-4 - ControlWave GFC-CL CPU/System Controller Board
1-8 / Introduction
CI-ControlWave GFC-CL
Basic CPU components and features are summarized as follows:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
LH7A400 System-on-Chip 32-bit ARM9TDMI RISC Core microprocessor
512KB FLASH Boot/Downloader, 29LV040B, 90 nS, 8-bit access
2MB SRAM, 3.3V, 512K x 32, with Battery Back-up
8MB simultaneous read/write FLASH, TSOP site
3 serial Comm. ports (COM1 & COM2 with modem control)
SPI I/O Bus Interface, three separate chip selects
Spread Spectrum clock for lower EMI
Serial Real Time Clock with battery backup
8-Position general-purpose switch bank plus a 4-Position recovery switch bank
Coin cell socket accepts a 3.0V, 300mA-hr lithium battery
Six Status LEDs, 6 Comm. Port LEDs plus DTR Active, DCD On, Watchdog, Idle and
Power Good LEDs
5.4V to 16V Power Supply with Fail Safe Sequencer
Display/Keypad Interface
Optional Modules: Isolated RS-485 Module, Modem Module & Radio Module
1.3.2.1 CPU/System Controller Board Connectors
The CPU/System Controller Boards are equipped with up to twenty-one (21) connectors
that function as follows (see Table 1-1):
Table 1-1 - CPU/System Controller Board Connector Summary
Ref.
P2
P3
J1
J2
J5
J6
J7
J8
J9
J10
J11
J12
J13
J14
J15
J18
J19
J21
TB1
TB2
TB3
# Pins
16-pin
76-pin
3-Pin
10-Pin
26-pin
20-pin
4-pin
4-pin
6-pin
10-pin
10-pin
8-pin
20-pin
3-pin
10-pin
10-pin
9-pin
10-pin
8-pin
8-pin
5-pin
Function
Display Intf.
Factory Debug
Power
25-Button Keypad Intf.
IOBUS
Emulator Connector
Modem connector
Modem connector
Modem/Phone Line connector
Modem connector
Modem connector
Modem Signal Debug
Radio Daughter Board
2-Key Pushbutton
PLD JTAG Header
PLD JTAG Header
9-pin Male D-type (COM1 - RS-232)
Isolated RS-485 Daughter Board
Term. Block (COM1 - RS-232)
Term. Block (COM2 - RS-232/485)
Term. Block (COM3 - RS-485)
Notes
Reverse Side of Board
Not shown or user accessible
Top Edge - see Figure 1-4
Intf. to Battery Charger & I/O Bd.
Factory Use
Piggy-back Modem
Piggy-back Modem
Tip & Ring used (Bottom Edge)
Piggy-back Modem
Piggy-back Modem
Not user accessible
Not user accessible
Not user accessible
Top Edge
N/A
see Table 2-3A or 4-2
see Table 2-3A or 4-2
see Table 2-3B or 4-3
CPU/System Controller Board Serial Comm. Port Connectors (see Section 1.5.5)
The CPU Module supports up to three serial communication ports (COM1, COM2 &
COM3). COM1 is supported by two connectors; J19 – (Male 9-pin D-Type) and TB1 (-8-pin
Term Block). COM2 utilizes an 8-pin Terminal Block and COM3 utilizes a 5-pin Terminal
Block. COM1 supports RS-232 communications, COM3 supports RS-485 communications
and COM2 can be configured to support RS-232 or RS-485 communications. RS-232 ports
CI-ControlWave GFC-CL
Introduction / 1-9
are protected with LCDA12C devices to ±4KV ESD. RS-485 ports are protected with
LCDA12C and LCDA05 devices to ±4KV ESD.
1.3.2.2 CPU Memory
Boot/downloader FLASH
Boot/download code is contained in a single 512Kbytes uniform sector FLASH IC. This
device resides on the local bus, operates at 3.3V and is configured for 8-bit access. 4Position DIP-Switch SW1’s position 3 allows start-up menu options to be displayed or bootup from system FLASH. If SW1-3 is closed when a reset occurs, the boot-up code will cause
a recovery menu to be sent out the COM1 serial port to a terminal program running on an
external host computer. Note: Recovery Mode will also be initiated if CPU/System
Controller Board Switch SW1 positions 1 and 2 are both set ON or OFF during a reset.
FLASH Memory
The base version of the CPU Module has 8Mbytes of 3.3V, simultaneous read/write (DL)
FLASH memory. Each CPU Board contains one 48-pin TSOP site that will each accept 4 or
8 Mbytes of 3.3V, (DL) FLASH IC, for a total of 4 or 8 Mbytes of memory. FLASH memory
is 16-bits wide. System Firmware and the Boot Project are stored here. No hardware write
protection is provided for the FLASH array.
System Memory (SRAM)
The base version of the CPU Module has 2Mbytes of soldered-down static RAM, implemented with one 1M x 16 asynchronous SRAM that is configured as a 1M x 16-bit array.
All random access memory retained data is stored in SRAM. During power loss periods,
SRAM is placed into data retention mode (powered by a 3.0V lithium battery). SRAMs
operate at 3.3V and are packaged in 44-pin TSOPs. Critical system information that must
be retained during power outages or when the system has been disabled for maintenance is
stored here. Data includes: Last states of all I/O, historical data, retain variables and
pending alarm messages not yet reported. The SRAM supports 16-bit accesses.
1.3.2.3 CPU/System Controller Board Configuration Jumpers
ControlWave GFC-CL CPU/System Controller Board are provided with 21 User Configuration Jumpers that function as follows:
• W2 -
Power On LED Enable/Disable Jumper
1 to 2 = Enable Power On LED
2 to 3 = Disable Power On LED
• W3 -
Power Supply Shut-down Selection
1 to 2 = 12V Power Supply Shut-down
2 to 3 = 6V Power Supply Shut-down
• W4 -
Power Supply Shut-down Selection
1 to 2 = 12V Power Supply Shut-down
2 to 3 = 6V Power Supply Shut-down
• W5 -
Power Fail Trip Point Hysterisis Selection
1 to 2 = 12V Power Fail Trip Point Hysterisis
2 to 3 = 6V Power Fail Trip Point Hysterisis
1-10 / Introduction
CI-ControlWave GFC-CL
• W7 -
Power Fail Trip Point Selection
1 to 2 = 12V Power Fail Trip Point
2 to 3 = 6V Power Fail Trip Point
• W8 -
Radio/Modem Configuration Selection (Store Config. Jumper when not in use)
1 to 2 = Configure Radio
2 to 3 = Configure Modem
• W9 -
Radio Selection
IN =
MDS Radio
OUT = FreeWave Radio or Modem or RS-232
• W10 - Radio/Modem DTR Control Selection
IN =
Power Always ON to Radio/Modem
OUT = Remove Power to Radio/Modem with DTR
• W11 - Radio/Modem Installation Selection
IN =
Modem Installed
OUT = Radio Installed or RS-232 Operation
• W12 - COM2 Configuration Selection
IN = COM2 is RS-485
OUT = COM2 is RS-232 or Radio or Modem
• W13 - Keypad/2-Button Display Selection
1 to 2 = 5x5 Keypad/Display
2 to 3 = 2-Button Display
• W15 - Enable/Disable SPI Receive Termination
IN =
Enable SPI Receive Termination
OUT = Disable SPI Receive Termination
• W16 - Status LED Enable/Disable Selection
IN =
Enable Status LEDs
OUT = Disable Status LEDs
• W19 - COM2 RS-232/RS-485 Modem/Radio Selection
1 to 2 = COM2 set for Modem or RS-485
2 to 3 = COM2 set for Radio or RS-232
• W20 - COM2 CTS Use Selection
1 to 2 = COM2 CTS Source is from Device
2 to 3 = COM2 RTS to CTS Loopback
• W21 - COM2 RS-232/Radio or RS-485 Selection
1 to 2 = COM2 set for RS-232 or Radio
2 to 3 = COM2 set for RS-485
• W22 - COM2 RS-232/Radio or RS-485 Selection
1 to 2 = COM2 set for RS-232 or Radio
2 to 3 = COM2 set for RS-485
CI-ControlWave GFC-CL
Introduction / 1-11
• W23 - COM2 RS-232/Radio or RS-485 Selection
1 to 2 = COM2 set for RS-232 or Radio
2 to 3 = COM2 set for RS-485
• W24 - COM2 RS-232/Radio or RS-485 Selection
1 to 2 = COM2 set for RS-232 or Radio
2 to 3 = COM2 set for RS-485
• W25 - Enable/Disable Comm. Status LED Selection
IN =
Enable Comm. Status LEDS
OUT = Disable Comm. Status LEDs
• W28 - Enable/Disable Battery Back-up Selection
IN =
Enable Battery Back-up
OUT = Disable Battery Back-up
1.3.2.4 CPU/System Controller Board Configuration Switches
Four user configurable DIP-Switches are provided on the CPU/System Controller Board;
eight-bit DIP-Switch SW2 is provided for user configuration settings while four-bit DIPSwitch SW1 provides forced recovery functions. Eight-bit DIP-Switch SW3 provides
loopback, termination control, and receiver bias settings for the RS-485 port (COM3). Eightbit DIP-Switch SW4 provides loopback, termination control, and receiver bias set-tings for
COM2 when configured for RS-485 port operation (via jumpers W19 & W21).
Table 1-2 - CPU/System Controller Bd. Switch SW2 Assignments
Note: Except for SW2-4, ON = Factory Default
SW#
Function
SW2-1
Watchdog Enable
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
SRAM Control
System Firmware
Load Control *
N/A
Setting - (ON = Factory Default)
ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Mode Switch (SW1)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote download of System Firmware
OFF = Disable remote download of System Firmware
ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)
* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher
SW2-8
Enable WINDIAG
Table 1-3 - CPU/System Controller Bd. SW1 Assignments
Recovery Mode/Local Mode Control
SWITCH
Setting
Both ON or OFF = Recovery Mode
SW1-1/2
Recovery/Local Mode *
SW1 OFF & SW2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
SW1-3
Force Recovery Mode
OFF = Recovery Mode disabled
* = Note: Only the Switch SW1 settings listed in this table, have been tested (SW1-4 = N/A).
1-12 / Introduction
Function
CI-ControlWave GFC-CL
Table 1-4 - CPU/System Controller Bd. Switch SW3/SW4 Assignments
RS-485 Loopback & Termination Control (COM3 = SW3 & COM2 = SW4)
SWITCH
#
RS-485 Function
Switch ON
SW3/4-1
TX+ to RX+ Loopback/2-Wire
SW3/4-2
TX− to RX− Loopback/2-Wire
SW3/4-3
SW3/4-4
SW3-6
(see Note 2)
100 Ohm RX+ Termination
100 Ohm RX− Termination
Slew Rate
ISO485 ONLY
SW3/4-7
RX+ Bias (End Nodes/Node)
SW3/4-8
RX− Bias (End Nodes/Node)
Setting
ON – 2-Wire Operation or Loopback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – 2-Wire Operation or Looback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – End Nodes Only
ON – End Nodes Only
ON – Slow Rate Enabled
OFF – Fast Rate Enabled
ON – 4-Wire = Both End Nodes
2-Wire = One End Node Only
OFF = No Bias
ON – 4-Wire = Both End Nodes
2-Wire = One End Node Only
OFF – No Bias
1.3.2.5 CPU/System Controller Board LEDs
ControlWave GFC-CL CPU/System Controller Boards are equipped with 17 LEDs. Table
1-5 provides CPU/System Controller Board LED assignments.
Table 1-5 - Assignment of CPU Module LEDs
LED Ref.
CR13
CR21
CR22
CR35
CR36
CR37
CR38
CR39
CR40
Function
Power Good
DCD ON (Modem)
DTR Active (Modem)
Status
Status
Status
Status
Status
Status
Color
Green
Red
Red
Red
Red
Red
Red
Red
Red
LED Ref.
CR41
CR42
CR43
CR44
CR45
CR46
CR47
CR48
Function
Watchdog
Idle
TX COM3
RX COM3
TX COM1
RX COM1
TX COM2
RX COM2
Color
Red
Red
Red
Red
Red
Red
Red
Red
Two red LEDs provide for the following status conditions when lit: WD (CR41 - Indicates a
Watchdog condition has been detected) & IDLE (CR42 - Indicates that the CPU has free
time at the end of its execution cycle. Normally, it should be ON most of the time. When the
Idle LED is OFF, it indicates that the CPU has no free time, and may be overloaded). The
green Power Good LED (CR13) is on when power is within specification. Six status LEDs
provide run time status codes.
1.3.3 Battery Charger and I/O Board
The Battery Charger and I/O Board mounts vertically on edge against the inner left side of
the enclosure. Interface to the CPU/System Controller Board is provided via a 26-pin ribbon
cable. In addition to solar panel charging circuitry, the Battery Charger and I/O Board
contains an MSP430 Microcontroller that handles the following functions:
•
•
Multivariable Transducer (MVT) or Gage Pressure Transducer (GPT) Interface
Analog to Digital circuitry that monitors an external RTD and the unit’s power source
CI-ControlWave GFC-CL
Introduction / 1-13
•
Process I/O circuitry consisting of the following:
• Three 1-5V or 4 to 20mA Analog Inputs (Optional)
• Two Discrete Inputs and Outputs
• Two High Speed Counters
• One Analog Output (1-5V or 4 to 20mA) (Optional)
An on-board solar charger is capable of charging a 7AH battery (6V or 12V) (with the
charging cycle controlled by the MSP430 Microcontroller. An internal feature of the
MSP430 that measures the IC temperature is used to calculate the maximum battery
voltage for the charging cycle. Charging circuitry provides failsafe control that can override
the MSP430 output when the battery voltage exceeds the maximum specified voltage.
When the MSP430 has lost control of the system (due to Master Clear being active or a
Watchdog State, the battery will be charged to a voltage allowable at 60°C (140°F).
A backup battery connector (TB3) accommodates uninterrupted power while the internal
battery is being charged. Charging circuitry does not support or control the backup battery
circuit. Primary Battery (TB2) and Backup Battery (TB3) inputs are diode or’d with the
resulting output supplying power to the CPU/System Controller, the on board 24V supply
(for AI’s and AO’s), and the field power for HSC devices.
1.3.3.1 Battery Charger and I/O Board Connectors
Battery Charger and I/O Boards are equipped with up to thirteen (13) connectors that
function as follows (see Table 1-6):
Table 1-6 - Battery Charger and I/O Board Connector Summary
Ref.
P1
P2
P3
TB1
TB2
TB3
# Pins
3-Pin
8-Pin
26-pin
2-pin
2-pin
2-pin
Function
Power
MVT or GPT Transducer Interface
IOBUS
Solar Power
Primary Power
Backup Battery Power
TB4
2-pin
Auxiliary Power
TB5
TB6
TB7
TB8
TB9
TB10
8-pin
8-pin
2-pin
9-pin
4-pin
3-pin
Discrete Inputs and Discrete Outputs
High Speed Counter Inputs
N/A
Analog Inputs
Analog Outputs
RTD Input
Notes
Top Edge (Rear)
See Figure 1-5 & Section 3.2.6
Intf. to Cpu/System Controller Bd.
see Section 2.3.9.3
see Section 2.3.9.2
see Section 2.3.9Powers External Radio/Modem (see
Section 2.3.9
see Section 2.3.4.4
see Section 2.3.4.7
N/A
see Section 2.3.4.5s
see Section 2.3.4.6
see Section 2.3.5s
1.3.3.2 Battery Charger and I/O Board Configuration Jumpers
ControlWave GFC-CL Battery Charger and I/O Boards are provided with 14 User
Configuration Jumpers that function as follows:
• JP1 - AI1 Input Type (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Input
2 to 3 = 1-5V Analog Input
1-14 / Introduction
CI-ControlWave GFC-CL
• JP2 - AI2 Input Type (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Input
2 to 3 = 1-5V Analog Input
• JP3 - AI3 Input Type (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Input
2 to 3 = 1-5V Analog Input
• JP4 - AO Output Source (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Output
2 to 3 = 1-5V Analog Output
• JP5 - AO Configuration Status (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Output
2 to 3 = 1-5V Analog Output
• JP6 - AO Power Source
1 to 2 = Internal 24V Supply
2 to 3 = +V External
• JP7 - HSC1 Debounce Enable/Disable
1 to 2 = Debounce Enabled
2 to 3 = Debounce Disabled
• JP8 - HSC2 Debounce Enable/Disable
1 to 2 = Debounce Enabled
2 to 3 = Debounce Disabled
• JP9 - System Power for +24V Supply Selection
1 to 2 = System Power ON
2 to 3 = System Power Open (OFF)
• JP10 - AI Field Power Configuration
1 to 2 = Output of JP6
2 to 3 = System Power through Polyfuse
• JP11 - HSC2/NAMUR Output Feed to One shot
1 to 2 = +HSC2 (Factory Default)
2 to 3 = NAMUR
• JP12 - NAMUR Field Connected to Daughter Bd.
1 = NAMUR Power Source
2 = GND
3 = NAMUR Signal
• JP13 - NAMUR Daughter Board Power Connection & Output
1 = 3.3V
2 = GND
3 = NAMUR - HSC
• JP14 - Bypass Intrinsically Safe (IS) Fuse (F5) – (for NI versions)
Installed = Bypass IS Fuse (F5)
CI-ControlWave GFC-CL
Introduction / 1-15
Figure 1-5 - ControlWave GFC-CL Battery Charger & I/O Board
1-16 / Introduction
CI-ControlWave GFC-CL
1.3.3.3 Battery Charger and I/O Board Field I/Os
Field I/O Wiring is supported by card edge Terminal Block Connectors as follows:
Non-isolated Analog Input/Output Connector (Section 1.3.3.3.1)
Non-isolated Digital Input/Output Connector (Section 1.3.3.3.2)
Non-isolated High Speed Counter Input Connector (Section 1.3.3.3.3)
Optional RTD Input Connector - Section 1.3.3.4
1.3.3.3.1 Non-isolated Analog I/O (also see Sections 2.3.4.5 through 2.3.4.6.1)
Edge connectors TB8 and TB9 provide interface to three single ended Analog Inputs and 1
Analog Output (respectively). Three field terminals (on TB8) are assigned for each Analog
Input. AI field power is applied to each Analog Input (controlled via jumpers JP10 and JP6)
can be supplied by the system battery, an external power source, or in the case of a 12V
system, from a ControlWave GFC-CL produced 24V field power supply. Each AI/O
channel can be individually configured for 4 to 20mA or 1-5V operation.
AIs are supplied with a two hertz low pass filter and surge suppression (via 30Vdc Transorbs for NI versions and 16Vdc Transorbs for IS versions).
Analog Output circuitry consists of a 12-bit resolution Digital to Analog Converter, a V to I
circuit and a V to V circuit. 4 to 20mA or 1-5V operation is jumper configured via JP4 and
JP5.
1.3.3.3.2 Non-isolated Digital I/O (also see Section 2.3.4.4)
Edge connector TB5 provides interface to 2 Digital Inputs and 2 Digital Outputs. All Digital
Inputs support dry contact inputs that are pulled internally to 3.3 Vdc when the field input
is open. Source current will be 60uA from the 3.3V supply. 15 millisecond input filtering
protects against contact bounce.
Digital Outputs have a 16V or 30V operating range and are driven by Open Drain FETs
that provide 100 mA (Max.) at 16Vdc for the 6V system or 100mA (Max.) at 30Vdc for the
12V system. The maximum output frequency is 20 Hz. Transorbs (16Vdc for IS versions &
30Vdc for NI versions) provide surge suppression between each signal and ground.
1.3.3.3.3 Non-isolated High Speed Counter Inputs (also see Sections 2.3.4.7)
Edge connector TB6 provides the interface to two externally sourced single ended High
Speed Counter Inputs (HSCI) with selectable debounce circuitry (JP7 for HSC1 & JP8 for
HSC2). Signal conditioning circuitry provides 20 microsecond filtering. All Input circuits
have surge suppression. HSC inputs can be operated as internally sourced dry contact or
externally generated internally sourced input signals.
High Speed Counter inputs are sourced from 3.3Vdc with a source current of 200uA and a
maximum input frequency of 10kHz.
1.3.3.3.4 Optional RTD Input Probe (also see Section 2.3.5)
Edge Connector TB10 provides connection to a 100-ohm platinum bulb (using the DIN
43760 curve). The common three-wire configuration is accommodated. In this con-
CI-ControlWave GFC-CL
Introduction / 1-17
figuration, the return lead connects to the RTD- terminal while the two junction leads
(Sense and Excitation) connect to the RTD+ terminals.
1.3.3.4 Battery Charger and I/O Board Input Power Connections
Four 2-position Terminal Blocks are provided for input power wiring as follows:
•
•
•
•
TB1 - Solar Power: Power from a 1W - 6V, 5W - 6V or 5W - 12V Solar Panel
TB2 - Primary Power: Power from an internal BBI supplied battery or an external 6V
or 12V supply (see Model Specification for list of batteries)
TB3 - External User supplied battery (6V or 12V). TB3 is diode or’d with TB2, but is
not supported by a charging circuit.
TB4 - Auxiliary Power Output for the optional BBI supplied external radio/modem
Power may be provided by a rechargeable 6/12V Lead Acid Battery (used in conjunction
with a Solar Panel), a rechargeable Lithium Battery, or power may be externally supplied.
Solar panels mount to a 2" pipe and can be swiveled for optimum alignment with the sun
and their tilt angle is adjustable for maximum performance to accommodate the latitude of
the installation site. Solar panel wires enter the unit through a liquid tight conduit fitting
on the bottom of the enclosure and are connected to TB1.
Internally the solar panel wires connect to the rechargeable battery via connector TB1 PWR (red wire) and GND (black wire) terminals.
1.3.4 Multivariable or Gage Pressure Transducer
The Multivariable Transducer (MVT) pressure assembly is connected to the process
manifold either directly or by tubing while the Gage Pressure Transducer (GPT) MUST
ONLY be connected via tubing. In 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 MVT/GPT Transducer extends into the bottom of the enclosure, with the
body of the transducer outside the enclosure. The MVT/GPT cable connector is factory
mated with System Controller Module connector P2.
1.3.5 Internal Mounting Brackets
Internal mounting brackets that support the various system components, such as the
Battery, ControlWave GFC-CL Battery Charger and I/O Board, and the optional external
radio/modem option, are mounted on the ‘Fabrication Panel,’ which in turn is secured to the
inner rear wall of the enclosure. A BBI supplied external radio or modem will mount in
front of the battery via a Battery Cover/Radio/Modem Mounting Bracket.
1.3.6 Radio/Modem
In lieu of an internal modem/radio an external modem or spread spectrum radio may be
factory installed within the enclosure. A listing of modem and radios is provided in the
Table Of Contents under the topic REFERENCED OEM MANUALS.
1-18 / Introduction
CI-ControlWave GFC-CL
1.4 FIELD WIRING
ControlWave GFC-CL gas flow computers support connection to external field devices
through its field wiring terminals on the Battery Charger and I/O Board. Connections to
the following types of external devices may be made:
•
•
•
•
•
RTD
Analog Inputs (AIs)
Digital Inputs (DIs)
Digital Outputs (DOs)
Relays
•
•
•
•
Pulse Inputs (HSCs)
Analog Outputs (AOs)
Battery/Power Supply/Solar Panel
Communications (RS-232, RS-485 and Ethernet)
1.5 FUNCTIONS
ControlWave GFC-CL can come with or without a base application program that satisfies
API 21.1 requirements for a meter station using up to two meter runs. Using ControlWave Designer, the user can readily modify this load to add or subtract functions, increase
the number of runs, etc. An overview of the base application load is provided below.
• Uses pre-configured web pages for user readings, configuration and maintenance. Web
pages can be modified and new pages configured to work with a modified application
load
• Application load is object oriented
• Standard configuration is a two-run station
• Each run can be orifice, turbine or ultrasonic meter type
• Flow calculations include the following:
• AGA3-1985/NX-19
• AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
• AGA7/NX-19
• AGA7 with selectable AGA8 Gross or AGA8 Detail
• Auto Adjust AGA7/NX-19
• Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
• Includes run switching
• Includes an auto-selector, PID flow/pressure control algorithm per run or per station
• Interfaces to a chromatograph and provides energy throughput as well as composition
information (requires the optional Expansion Communications Module)
• Resides on a BSAP SCADA network
• Supports samplers and odorizers
• Provides audit trail and archives
• Includes a nominations function
• Allows the user to select engineering units, including English and metric
The primary function of the ControlWave GFC-CL is to measure the flow of natural gas in
accordance with API (American Petroleum Institute) and AGA (American Gas Association)
standards. Items below implement and supplement the primary function:
•
•
•
•
•
•
•
Data acquisition
Flow calculations
Data archives
Audit trail archives
Local display
Communications
Control outputs
CI-ControlWave GFC-CL
(see Section 1.5.1)
(see Section 1.5.2)
(see Section 1.5.3)
(see Section 1.5.3.4)
(see Section 1.5.4)
(see Section 1.5.5)
(see Section 1.5.6)
Introduction / 1-19
•
•
Status inputs
Self test and diagnostics
(see Section 1.5.6)
(see Section 1.5.7)
1.5.1 Data Acquisition
The process inputs used by the ControlWave GFC-CL are static pressure, differential
pressure, and temperature for orifice measurement, or static pressure, temperature, and
frequency input for positive displacement (PD), turbine, or ultrasonic meters. Static
pressure and differential pressure may be obtained from the Multivariable Transducer
connected to the ControlWave GFC-CL Battery Charger & I/O Board. Static pressure may
also be obtained from a Gage Pressure Transducer (in lieu of a MVT) when the unit is so
equipped. Inputs may also be derived from external smart Multivariable Transmitters
using either the BSAP or MODBUS protocols. Alternatively, the inputs may be obtained via
the local I/O Modules using analog transmitters. The standard ControlWave GFC-CL
application program allows any combination of inputs to be selected, for up to two runs of
measurement.
Regardless of the operating mode or the calculation interval, the ControlWave GFC-CL
acquires samples as follows:
a.
b.
c.
d.
Differential pressure once per second
Static pressure once per second
Flowing temperature once per second
All self-test and compensation values at intervals of 4 seconds or less
1.5.2 Flow and Volume Calculations
The ControlWave GFC-CL 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. The user can select AGA3/NX-19 (1985), AGA3/AGA8,
AGA7/NX-19 or AGA7/AGA8.
1.5.2.1 Flow Rate and Flow Time Calculations (AGA3)
For orifice flow measurement, the differential pressure value is compared to a flow cutoff
value every second. If the differential pressure is less than the flow cutoff value, flow is
considered to be zero for that second. 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, temperature, and flow extensions are used
as inputs to the flow equations. Users may select API 14.3 (AGA3, 1992) and AGA8
calculations, with compressibility being calculated according to AGA Report No. 8, 1992
(with 1993 errata). Both the DETAIL method and the two GROSS methods of
characterization described in AGA8 are supported. Users may also select the AGA3, 1995
and NX-19 flow equations to calculate the rate of flow.
1.5.2.2 Flow Rate Calculations and Flow Time Accumulations (AGA7)
When using PD meters, turbine meters or ultrasonic meters, the flow rate is calculated 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 flow rate estimate is set to zero;
1-20 / Introduction
CI-ControlWave GFC-CL
however, volume calculations are still accumulated. The flow time recorded is the time for
which the flow rate is non-zero.
1.5.2.3 Extension Calculation and Analog Averaging
For orifice meters, a flow extension is calculated 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, arithmetic
averages of static pressure and temperature are reported. This allows monitoring of static
pressure and temperature during shut-in periods.
1.5.2.3.1 Energy Calculation
The ControlWave GFC-CL offers the option of using a fixed volumetric heating value or
calculating the energy content of the gas according to AGA Report No. 5.
1.5.2.3.2 Volume and Energy Integration
Volume and energy are each integrated and accumulated at the end of every calculation
cycle. The volume for a cycle is the calculated rate multiplied by the flow time for that cycle.
The energy for a cycle is calculated by multiplying the volume at BASE conditions by the
heating value.
1.5.2.4 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. Static pressure can be
measured at the downstream pressure tap, with the measurement taken from the low-pressure 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, the user selects the downstream tap location during MVT
configuration, the MVT firmware changes the sign of the differential pressure to provide a
positive DP value.
1.5.3 Archives
The ControlWave GFC-CL stores two distinct types of archive data. The first type is Audit
Trail data, which is a recording of the various events and alarms that have an impact on
the calculated and reported rates and volumes. The second type is historical data, which
includes records of rates and volumes and other signals over time. When an archive log
becomes full, new entries replace the oldest entries in the log.
Where feasible, both forms of archive data conform to the requirements of the API Chapter
21 (the Committee on Gas Measurement's GFC document). 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.
The ControlWave GFC-CL supports the "breaking" of a log period when an operatorentered parameter is changed. When this occurs, the log period in process is closed out, a
log is made, and a new log is begun. This feature is disabled by default and may be enabled
by the operator. Note: To prevent several very short logs from being created due to a series of
successive configuration changes, the ControlWave GFC-CL will not create a log which
CI-ControlWave GFC-CL
Introduction / 1-21
contains less than 60 seconds (flowing or otherwise) of data. Therefore if a user enters 15
configuration changes over a 2minute period, the log will only be broken twice.
1.5.3.1 Hourly Historical Data Log
The Hourly Data Log 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
ControlWave GFC-CL FLASH memory.
The following items are stored in the Hourly Data Log:
•
•
•
•
•
•
•
•
•
•
Corrected Volume
Uncorrected Volume
Accumulated Energy
Average Static Pressure
Average Temperature
Average Differential Pressure
Average Specific Gravity
Average Heating Value
Flow Time
Uncorrected Count
Each log entry also contains the date and time. The ControlWave GFC-CL has a Hourly
Historical Log for each of four runs.
1.5.3.2 Daily Historical Data Log
The Daily Data Log holds one record for every contract day. The contract hour may be
changed by the user. The daily log holds 62 entries; this ensures that the previous calendar
month of daily data is always resident in ControlWave GFC-CL FLASH memory.
The following items are stored in the Daily Data Log.
•
•
•
•
•
•
•
•
•
•
Corrected Volume
Uncorrected Volume
Accumulated Energy
Average Static Pressure
Average Temperature
Average Differential Pressure
Average Specific Gravity
Average Heating Value
Flow Time
Uncorrected Count
Each log entry also contains the date and time. The ControlWave GFC-CL has a Daily
Historical Log for each of the two runs.
1.5.3.3 Periodic Historical Data Log
The periodic data log holds one record for every log interval. Log interval is 15 minutes. The
Periodic Historical Data Log holds 1440 records, or four days of 15 minute data.
The following items are stored in the Periodic Historical Data Log:
1-22 / Introduction
CI-ControlWave GFC-CL
•
•
•
•
Flowing Differential Pressure
Flowing Static Pressure
Flowing Temperature
Frequency
Each log entry also contains the date and time. The ControlWave GFC-CL has a Periodic
Historical Data Log for each of four runs.
1.5.3.4 Alarm and Event Storage
The ControlWave GFC-CL keeps an Audit Trail Buffer capable of storing the most recent
500 Alarms and the most recent 500 Events. Internally, these buffers are maintained
separately to prevent recurring alarms from overwriting configuration audit data.
Externally, they are reported to the user as a single entity. Both operate in a circular
fashion with new entries overwriting the oldest entry when the buffer is full.
The following circumstances cause an entry to be made in the Audit Trail Buffer:
•
•
•
•
Any operator change to a ControlWave GFC-CL configuration variable
Any change in the state of a ControlWave GFC-CL alarm signal
A system restart
Certain other system events
1.5.4 LCD Display
In normal operation, the display stays off after the unit is configured and placed in service.
The operator may activate the display at any time by pressing the appropriate front panel
button (depending on the keyboard type). When activated, the display scrolls through a list
of current values. The list defaults to an appropriate set of values.
1.5.5 Communications
A ControlWave GFC-CL can be configured as a Master or Slave node on either a
MODBUS network or a BSAP network. Up to three serial communication ports are
contained on the ControlWave GFC-CL CPU/System Controller Board. RS-232
Communication Port COM1 is supported by three connectors as follows: J19 (9-pin D-Type
Male connector) and TB1 (8-pin Terminal Block) are situated on the CPU/System
Controller Board while the Local Port connector associated with COM1 is situated
externally on the bottom of the Instrument Front Cover. Note: The Local Port is factory
wired to COM1 via an internal harness that is plugged into TB1 on the
CPU/System Controller Board. Communication ports situated on the CPU/System
Controller Board are designated as follows:
CPU/System Controller Board:
COM1 - Port 1:
COM1 - Port 1:
COM2 - Port 2:
COM3 - Port 3:
J19 - 9-Pin Male D-Sub - RS-232)
TB1 - 8-Pin Term. Block - RS-232 (Factory connected to the Local Port)
TB2 - 8-Pin Term Block - RS-232/RS-485 (Configured via W12, W19, W20
W21 (SW4 is used when COM2 is set for RS-485 operation) (COM2
supports an Internal or External Modem or Radio option)
TB3 - 4-Pin Term Block - RS-485 (Configured via SW3)
Communication Ports COM1, COM2 & COM3 support serial asynchronous operation.
Communication Port COM1 supports RS-232 operation while COM3 supports RS-485
CI-ControlWave GFC-CL
Introduction / 1-23
operation. Communication Ports COM2 may be user configured for either RS-232 or RS-485
operation. Additionally, the CPU/System Controller Board may optionally contain a
56Kbaud PSTN Modem or a Spread Spectrum Modem (Radio). Any serial communication
port can be configured for local communications, i.e., connected to a PC loaded with
ControlWave Designer and OpenBSI software.
RS-232 Ports
An RS-232 interface supports Point to Point, half-duplex and full-duplex communications
(20 feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWave GFC-CL utilize MODBUS or BSAP protocol, while full-duplex is supported
by the Point to Point (PPP) protocol. ControlWave GFC-CL RS-232 ports utilize the “null
modem” cable (Figure 2-11A) to interconnect with other devices such as a PC, printer,
another ControlWave GFC-CL, ControlWave GFC, Express, ExpressPAC, MICRO,
EFM, or ControlWave unit, a ControlWave I/O Expansion Rack or a ControlWaveLP
unit when the Control-Wave GFC-CL is communicating using the full-duplex PPP
protocol.
RS-485 Ports
ControlWave GFC-CL can use an RS-485 communication port for network
communications to multiple nodes up to 4000 feet away. Essentially, the master and the
first slave transmit and receive data on opposite lines; all slaves (from the first to the "nth")
are paralleled (daisy chained) across the same lines. The master node should be wired to
one end of the RS-485 cable run. A 24-gauge paired conductor cable, such as Belden 9843
should be used. Note: Only half-duplex RS-485 networks are supported.
Comm. Port Defaults
From the factory COM1 defaults to 115.2 kbd using the BSAP Protocol. The remaining
serial communication ports, i.e., COM2 and COM3 default as follows:
COM2 – BSAP Slave @ 9600 Baud
COM3 – BSAP Master @ 9600 Baud (for use with Bristol Babcock 3808 MVT Transmitters)
1.5.5.1 BSAP Message Support
The ControlWave GFC-CL supports the same subset of BSAP messages as the other
ControlWave products.
1.5.6 Discrete and Analog I/O GFC Functionality
ControlWave GFC-CL gas flow computers are equipped with a variety of Inputs and
Outputs (see Sections 1.3.3.1 through 1.3.3.4). While using the standard application
program, inputs and outputs required for measurement and control are mapped to the
application using the configuration Web pages. Analog Alarm limits for variables required
by the standard application program are defined via the configuration Web pages. Discrete
Input alarms associated with the standard application program can be enabled or disabled
on a per point basis via the configuration Web pages. Control algorithms (flow control,
sampler control, odorant control, etc.) are selected via the configuration Web pages.
1.5.6.1 Flow Rate Control - DDC (jog control) using PID
When the user configures the ControlWave GFC-CL to perform flow rate control, the two
digital output signals are wired to the Open and Close inputs of a controller. The ControlWave GFC-CL uses a Proportional/Integral/Derivative (PID) algorithm to cause the
1-24 / Introduction
CI-ControlWave GFC-CL
measured rate of flow to match a user-entered setpoint. When the flow rate is below the
setpoint, the Open output is pulsed. When the flow rate is above the setpoint, the Close
output is pulsed. The PID equation calculates the duration of the Open or Close pulse. The
minimum pulse duration is 1.0 seconds. The user changeable parameters are:
•
•
•
•
•
•
•
•
Flow Setpoint in MSCFH
Deadband in % of setpoint
Proportional Gain
Integral Time in repeats/minute
Derivative Time in seconds
Valve Travel Time (full close to full open)
Process Control Limiting
Pressure Override Limits
The flow control algorithm runs once per second.
1.5.6.2 Pulse Output for External Totalizer or Sampler
When the ControlWave GFC-CL is configured to provide a pulse output based on volume,
the operator provides a control volume and a pulse duration. After each calculation cycle,
an internal volume accumulator is compared to the control volume. If the accumulator
exceeds the control volume then a pulse is output and the accumulator is reduced by the
volume represented by the pulse. The pulse output may be used to drive an external
totalizer, odorizer, gas sampler, or similar device.
1.5.6.3 Nominations
The nomination function allows a user to establish a time period over which an
accumulation count of volume or energy that is delivered during the period is monitored
and compared to a configured ‘nomination' value. When the nomination value is reached,
the system will perform an action (such as opening or closing a valve). Prior to nomination
being reached, the volume/energy will be compared to a configured alarm level and an
alarm will be generated when the volume/energy reaches or exceeds the defined (specified)
level.
1.5.7 Self Test & Diagnostics
The ControlWave GFC-CL periodically runs a series of diagnostics to verify the
operational status of various system components. The tests include transducer parameters,
main and backup battery voltages, software sanity checks, and other indications of system
health. An appropriate alarm is generated if any test fails.
Bristol’s WINDIAG program provides menu driven diagnostics that have been designed to
assist a technician or Process Engineer in troubleshooting the various ControlWave GFCCL circuits (see Document D4041A).
CI-ControlWave GFC-CL
Introduction / 1-25
BLANK PAGE
Section 1A
PRODUCT FEATURES & OVERVIEW
1A.1 PRODUCT OVERVIEW
ControlWave® products have been designed and integrated as a highly adaptable, high
performance Distributed Open Controller family with exceptional networking capability
that provides a complete Process Automation Management Solution. ControlWave GFCCL gas flow computers have been designed with an emphasis on providing high
performance with low power consumption, scalability and modularity. ControlWave GFCCL Housings support to 2 main circuit boards, i.e., the CPU/System Controller Board and
the Battery Charger and I/O Board.
ControlWave GFC-CL gas flow computers have been designed as an ideal platform for
remote site automation, measurement and data management within the oil & gas industry.
ControlWave GFC-CL units are extremely effective in Flow Computer, Process Controller
or Remote Terminal Unit capacities as follows:
•
API 21.1 EFM/Flow Computer application
ControlWave GFC-CL units offer a cost effective and competitive match to all industry
meters used in Electronic Flow Measurement and Flow Computer installations.
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•
For orifice and other differential meters, the ControlWave GFC-CL has been
designed to integrate a DP/P/T, smart Multivariable Transducer with excellent
performance over the full range of operating pressure and temperature conditions.
For static pressure meters, the ControlWave GFC-CL has been designed to integrate
a Gage Pressure Transducer with excellent performance over the full range of
operating pressure and temperature conditions.
For linear meters, such as turbine and ultrasonic meters, the ControlWave GFC-CL
doesn’t overlook the importance of pressure and temperature corrections and utilizes
smart P/T circuitry to provide high accuracy over the full range of operating
conditions.
Process Controller or Remote Terminal Unit (RTU) applications
Process Controller and RTU applications don’t suffer performance limitations of flow
computers with expanded hardware. User configurable I/O provides AI/O, DI/O and HSC
functionality. An optional piggy-back mounted radio or modem or an external Spread
Spectrum Modem/Radio may be mounted within the enclosure.
1A.1.1 Hardware Features
•
•
•
•
•
Wide operating temperature range (-40 to 70°C)
Nonincendive Class I, Div. 2 Hazardous Location approval & CE approval
ARM9 Processor provides exceptional performance and low power consumption
Standard three serial communication ports (One RS-232, One RS-232/485 & One RS485)
I/O siutuated on one circuit board provides cost effective I/O for small RTU applications
CI-ControlWave GFC-CL
Product Features & Overview / 1A-1
1A.1.2 Firmware and Software Features
•
•
•
•
•
•
Standard application load for up to two run, API 21.1 EFM operation
Additional application loads (e.g. well automation with plunger lift control) are also
available
Full user programming environment, ControlWave Designer with ACCOL III, is
available for modification of existing loads as well as creation of custom loads
Full suite of function blocks for flow calculations, audit trail, historical archive/data
management, communication, and process control is included.
File management, including video images
Fully supported by a complete HMI and network communication software suite:
Bristol’s OpenBSI
1A.2 PRODUCT FAMILY COMPATIBILITY
Not only is ControlWave GFC-CL scalable, it is also compatible with Bristol Babcock’s
ControlWave family. ControlWave GFC-CL is fully software-compatible with the original
ControlWave, which provides greater I/O capacity.
1A.2.1 Open Standards for Programming, Network Config. and Communication
Only ControlWave brings the perfect combination of industry standards to minimize
learning, engineering and implementation costs.
By adhering to such industry standards as Ethernet, TCP/IP, Microsoft Windows®,
COM/DCOM, FTP, OLE and ActiveX, ControlWave is able to achieve the highest degree of
openness in control system architecture and bring the optimal process efficiency and
productivity needed to ensure a successful system implementation.
1A.2.2 ControlWave Designer with ACCOL III
To minimize your engineering and development time, we have adopted the international
standard for PLC programming, IEC 61131-3. ControlWave Designer is a fully IEC 611313 compliant programming environment for the ControlWave family of products.
ControlWave Designer includes all five IEC 61131-3 process languages for batch,
continuous and discrete control. Function Block Diagram, Structured Text Sequential
Function Chart, Ladder Logic Diagram and Instruction List.
ControlWave Designer includes an extensive library of more than 200 basic IEC 61131-3
functions and function blocks common to many IEC 61131-3 based products. These include:
•
•
•
•
•
Flip-flops, Counters & Timers
Ladder diagram functions – coils and contacts, etc.
Numerical, Arithmetic & Boolean functions – Sine, Cosine, Add, Sub, Square Root, And,
Or, etc.
Selection & Comparison – Min, Max, Greater than, Equal, Less than, etc.
Type conversions – Integer to Real, Boolean to Word, etc.
1A.2.3 ACCOL III
In addition to the basic functions and function blocks, ControlWave Designer brings the
benefit of over twenty years of SCADA and plant control experience in Bristol Babcock’s
ACCOL III function block library. ACCOL III includes over sixty function blocks valuable
1A-2 / Product Features & Overview
CI-ControlWave GFC-CL
for use in oil & gas, water & waste and process measurement & control applications.
Further, ACCOL III is designed to take full advantage of the significant features offered by
ControlWave.
Briefly, this library includes function blocks for:
•
•
•
•
•
Average, Compare, Totalize
Scheduling & Sequencing
PID & Lead/Lag
AGA gas flow and liquids calculations
File handling
In addition, ControlWave ensures data integrity, in the event of a communication
interruption, by storing critical time-stamped alarm and historical data in the controller
memory. This data is then securely retrieved when communication is restored.
1A.3 STANDARD APPLICATION PROGRAM
ControlWave GFC-CL can come with or without a base, application program that satisfies
API 21.1 requirements for a meter station using up to four meter runs. Using ControlWave
Designer, the user can readily modify this load to add or subtract functions, increase the
number of runs, etc.
Overview of the base, application load:
•
•
•
•
•
Uses pre-configured web pages for user readings, configuration and maintenance-web
pages can be modified and new pages configured to work with a modified application
load
Application load is object oriented
Standard configuration is a four-run station
Each run can be orifice, turbine or ultrasonic meter type
Flow calculations include the following:
• AGA3-1985/NX-19
• AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
• AGA7/NX-19
• AGA7 with selectable AGA8 Gross or AGA8 Detail
• Auto Adjust AGA7/NX-19
• Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
• Instromet Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail
• Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail
• Includes run switching
• Includes an auto-selector, PID flow/pressure control algorithm per run or per station
• Interfaces to a chromatograph and provides energy throughput as well as
composition information
• Resides on a BSAP SCADA network
• Supports samplers and odorizers
• Provides audit trail and archives
• Includes a nominations function
• Allows the user to select engineering units, including English and metric
CI-ControlWave GFC-CL
Product Features & Overview / 1A-3
1A.3.1 OpenBSI - Simply Creative
OpenBSI (Open Bristol System Interface) is a set of network setup, communication
diagnostic, and data viewing utilities that provide access to both ControlWave and
Network 3000 controllers and RTUs. OpenBSI is the only product available in the industry
to bring such unique functionality and ease of use to the network level. At the core is the
communication interface, written as a Windows communication server API through which
other client applications communicate with the Bristol networks. OpenBSI supports both
serial BSAP protocol and Ethernet Internet Protocol communication to ControlWave and
Network 3000 RTUs and controllers.
1A.3.2 OpenBSI Utilities
Above this communication layer are a group of applications known as OpenBSI Utilities.
These client utilities communicate through the server to collect and manage data gathered
from the network, generate files based on collected historical data, collect alarms, and
monitor and control OpenBSI communications.
•
•
•
•
•
•
•
•
Communication engine for PC applications
Supports ControlWave and Network 3000 serial and IP protocols
RS 232, Dial-line, cellular, radio, CDPD, satellite, and Ethernet connections
Provides on-line download & signal variable changes
Allows network configuration through NetView
PC and Network communication diagnostics
OPC Server for interfacing to most HMI software
Harvester collects historical data on request or scheduled basis
NetView is the basic configuration and application interface for all network operations.
NetView uses a tree structure for network graphical display in the Windows Explorer style.
Network nodes can be added on-line by simply dragging the node Icon into the tree. This
invokes a configuration Wizard simplifying network setup. Through the NetView Wizard,
the necessary network parameters are entered for node and IP address, alarm and message
routing, and network communication media. Once configured, selecting any node allows
direct access to the common OpenBSI utilities to reprogram, download a new application to
the node, review communication statistics, view real-time data through DataViewer, and
edit controller/RTU properties.
Local Configuration Wizard allows local communication with any attached ControlWave controller or RTU to download system flashware upgrades, configure cold download
parameters, and configure IP and soft-switch parameters.
DataView is an on-line utility used to collect and display several types of process data,
including signal values, data array values, signal lists, and audit trail information.
Operators have the ability to alter signal values. Multiple DataView windows may be open
simultaneously.
1A.3.3 Real-time ActiveX Controls
One of the many benefits OpenBSI brings to you is our use of open standards such as
ActiveX Controls. ActiveX is another of the Microsoft standards, which allow plug and play
with any ActiveX container, using Microsoft ActiveX container technology such as Visual
Basic, HTML web pages, and Microsoft Excel.
1A-4 / Product Features & Overview
CI-ControlWave GFC-CL
The set of available ActiveX Controls provides the basic functions necessary to communicate and collect data from ControlWaves.
1A.3.3.1 ActiveX Controls
•
•
•
•
•
Security - 56-bit encryption - allows the user to sign on to the RTU
Signal Value - displays signal values in various formats
Comm. Statistics - works with a standard page that displays the RTU’s communication
statistics
Configuration Info - works with a standard page that displays and allows the user to
change RTU Configuration information
Historical - Collect and view historical archive and audit files
The IP compliant ControlWave opens the door for owner controlled access via web pages.
Any generic web page builder can be employed to create user defined pages to access
ControlWave. The web pages are populated with these pre-configured ActiveX controls and
are stored at the PC.
1A.3.3.2 Required Software
Microsoft Internet Explorer
Bristol Babcock ActiveX controls
OpenBSI LocalView or NetView
1A.3.4 Historical Data Collection
High Historical Data Integrity
The ControlWave Historical Data Collection system offers exceptional historical data
integrity by providing time-stamped historical data storage in ControlWave flash memory.
The historical data is collected, through OpenBSI, on a scheduled or demand basis and
converted to .CSV and ODBC compliant file formats for use in spreadsheets and reports. If
data is missed due to a communication failure, it is collected when the communication is
reestablished and the PC historical database is back-filled with the missing data. This
distributed historical database architecture provides the greatest data reliability and
integrity during communication or PC failure.
Another important historical feature is the Audit storage and collection system. The Audit
Trail is a file stored in ControlWave flash memory containing significant events and timestamped alarms. The alarms stored in the Audit system provide a historical archive in
addition to the real-time alarm reporting system.
This file is also collected through OpenBSI and presented as a text file in the PC. This
functionality is extremely useful in providing an event trail during communication or PC
downtime or other system problem.
•
•
•
•
Archive Collection - collection and storage to disk of the ControlWave archive data
Audit Collection - collection and storage to disk of the ControlWave audit data.
Exports data files to third party, CSV & ODBC applications
DDE compliant for use with other popular Windows applications
CI-ControlWave GFC-CL
Product Features & Overview / 1A-5
1A.3.5 OPC Server
With industry demand for open standards, ControlWave answers the call by embracing
technologies that open the door for maximizing your efficiency and productivity. The OPC
standard was developed by the OPC Foundation comprised of hardware and software
suppliers from the process control community. OPC allows the engineer to select best in
class hardware and software with confidence in their interoperability. Our OpenBSI OPC
Server was among the first to comply with the OPC Foundation alarm and event server
specification.
•
•
•
•
•
•
•
•
•
•
•
OPC Data Access 1.0a & 2.0 compatible
Windows NT, 2000 & XP
Compatible with both ControlWave and Network 3000 systems
32 bit multi-threading, multi-processor design
Automatic database builder
Integrated real-time data monitor
Supports OPC Browse interface
Supports both serial communications and IP Ethernet connections
Supports COM/DCOM & OLE Automation
Primary and Background polling scheme
OPC Alarm & Event Server support
1A.4 ControlWave OPEN NETWORK CONNECTIVITY
By embracing the open system network technologies available through TCP/IP, Ethernet,
OPC, and Microsoft DNA, as well as pseudo standards such as Modbus and Open Modbus,
ControlWave can provide a total Process Automation Management Solution for in-plant
LAN based networks and Wide Area Network SCADA systems.
With the exceptional connectivity provided by the ControlWave network, access to realtime data and operating conditions, historical data, maintenance and performance data are
all available to the global network. ControlWave provides the needed information to the
plant floor technician, operator, engineer, supervisor and corporate management, even
external customers.
1A.4.1 Communication Protocols
Like all Bristol products, ControlWave supports BSAP (Bristol Standard Asynchronous
Protocol), Modbus, DF1, DNP 3 (serial) and serial ASCII as standard functions. These
protocols are implemented in Flashware so no additional hardware is required to use any
one or a combination of all protocols.
1A.4.1.1 BSAP Protocol
BSAP - All Bristol Network 3000 and ControlWave RTU and controller products support
BSAP protocol. BSAP is widely accepted as providing exceptional data integrity and greatly
simplifies communication between controllers. BSAP is provided with interfaces for
Master/Slave, vertical networks and Client/Server, horizontal networks. In either case,
variable lists are created in each controller that are easily passed from server to client or
slave to master.
1A-6 / Product Features & Overview
CI-ControlWave GFC-CL
BSAP meets the definition of an industry-standard, open architecture protocol because if
conforms to ISO standards 2629, 1745 and 2111, it is not proprietary in that Bristol does
not charge a license fee and makes the protocol and documentation available to anyone.
While BSAP is an open protocol, the added functionality of the messages provides much
more capability than is found in other networks.
•
•
•
•
•
•
•
Global time-synchronization
Time-stamped Alarm reporting
Historical archive data transfer
Audit file transfer
On-line program editing
Diagnostics
Communication statistics
1A.4.1.2 Modbus Protocol
Modbus - Modbus is often considered a de-facto standard protocol because broad usage as
either the primary or a secondary offering in many measurement and control related
products. Even with its common use, Modbus protocol actually has many variations.
Consider Modbus RTU and Modbus ASCII, Master & Slave, Serial and TCP/IP Open
Modbus. In addition there are consideration regarding supported function codes, floating
point values and byte order. Bristol Babcock supports the following:
•
•
•
•
•
Modbus serial and TCP/IP Open Modbus (Ethernet)
Master and Slave
Modbus RTU and ASCII
Modes 1 - 7, 8, 15 & 16
Integer and IEEE 4 byte floating point
1A.4.1.3 Generic Serial Interface
The Generic Serial Interface is a user programmable Master and Slave protocol used to
send and receive messages typically with third party serial ASCII devices. This protocol can
be used to interface with such devices and message boards, card readers and many
measurement devices.
CI-ControlWave GFC-CL
Product Features & Overview / 1A-7
BLANK PAGE
Section 2
INSTALLATION & OPERATION
2.1 INSTALLATION IN HAZARDOUS AREAS
Each ControlWave GFC-CL gas flow computer is furnished in an enclosure designed to
meet the NEMA Type 3R specifications and to operate in a Class I, Division 2, Groups C &
D environment with a nonincendive rating (see Appendix A).
Figure 2-1A - MVT Equipped ControlWave GFC-CL (with MDS - Transnet Radio)
CI-ControlWave GFC-CL
Installation & Operation / 2-1
Figure 2-1B - GPT Equipped ControlWave GFC-CL (with MDS - Transnet Radio)
Dimensional drawings of the NEMA Enclosures are provided at the end of Chapter 4.
2.2 SITE LOCATION CONSIDERATIONS
Check all clearances when choosing an installation site. Make sure that the ControlWave
GFC-CL Instrument Front Cover (hinged on the left side) can be opened for wiring and
service. Make sure that the LCD/Keypad is visible and accessible to the on-site operator.
There should also be clearance for the optional Solar Panel (if required). The enclosed unit
measures 11.73” in height by 9.08” in width by 7.44” in depth (without the mounting
brackets). A Gage Pressure Transducer adds approximately 1.60” to the height of the unit
while a Multivariable Transducer adds 2.80” to the height of the unit.
2-2 / Installation & Operation
CI-ControlWave GFC-CL
Information on mounting the ControlWave GFC-CL assembly at an installation site is
provided in Section 2.3.1 Mounting the ControlWave GFC-CL Enclosure.
2.2.1 Temperature & Humidity Limits
ControlWave GFC-CL gas flow computers have been designed to operate over a -40°F to
+158°F (-40°C to +70°C) temperature range (with storage at up to +185°F (+85°C)) and a
0% to 95% Relative Humidity range. Make sure that the ambient temperature and
humidity at the measuring site remains within these limits. Operation beyond these ranges
could cause output errors and erratic performance. Prolonged operation under extreme
conditions could also result in failure of the unit.
2.2.2 Vibration Limits
Check the mounted enclosure, panel or equipment rack for mechanical vibrations. Make
sure that the ControlWave GFC-CL is not exposed to a level of vibration that exceeds
those given in the specifications. ControlWave GFC-CL vibration limits are 1g for 10 - 150
Hz & .5g for 150 - 2000 Hz.
2.3 ControlWave GFC-CL INSTALLATION/CONIGURATION
ControlWave GFC-CL gas flow computers are shipped from the factory with all
components (wired and mounted) except for the unit’s Solar Panel and Battery; these items
are shipped separately.
Overview of Configuration
An overview of the seven main configuration steps are provided herein.
Step 1. Hardware Configuration
This involves unpacking the ControlWave GFC-CL hardware, mounting the enclosure,
wiring I/O terminations, connecting any permanent communication cables, making proper
ground connections, connecting a communication cable to a PC workstation, setting
switches and setting jumpers. To install and configure the ControlWave GFC-CL, follow
Hardware Configuration steps 1 through 10 below:
1. Remove the unit from its carton and install it at the assigned work site (see Section
2.3.1). Dimensions are provided in Section 4.6 of this manual.
2. Remove the Battery Charger and I/O Board Assembly and after configuring its
jumpers, install it into the ControlWave GFC-CL Enclosure (see Section 2.3.2).
3. Make sure that the Lithium Backup Battery has been enabled, i.e., Backup Battery
Jumper W28 on the CPU/System Controller Assembly (on the inside of the
Instrument Front Cover) should be installed (on its jumper posts). Configure the
CPU/System Controller Board DIP-Switches and Jumpers (see Section 2.3.8).
4. Configure/Connect appropriate communication port(s) (see Section 2.3.3.2). Connect
COMM. Port 1 (Local Port) or 2 of the ControlWave GFC-CL (depending on
CPU/System Controller Board Switch SW2 settings - see Section 2.3.3.1) to a
Communication Port of a PC (typically PC COMM. Port 1). Note: Also see Section
2.4.4.
5. Install I/O wiring to the Battery Charger and I/O Board (see Section 2.3.4). Install a
communications cable to a Model 3808 Transmitter if required (see Section 2.3.6).
CI-ControlWave GFC-CL
Installation & Operation / 2-3
6. Install a ground wire between the Enclosure’s Ground Lug and a known good Earth
Ground (see Section 2.3.7.5).
7. If required, install the RTD Probe (see Section 2.3.5).
8. Install the Rechargeable Battery and Solar Panel (if provided) (see Sections (2.3.7
through 2.3.7.3.2).
9. Connect DC Power wiring to the ControlWave GFC-CL Battery Charger and I/O
Board (see Sections 2.3.7.1 & 2.3.7.2).
10. Apply power to the ControlWave GFC-CL. Now continue with Steps 2 through 7
below (and Section 2.4.1) and the ControlWave GFC-CL will be ready for on line
operation.
Step 2. Software Installation on the PC Workstation
ControlWave Designer software will have to be installed on the PC if the ControlWave
GFC-CL is being utilized in an application other than that supported by the standard load.
This is accomplished by installing the ControlWave Designer Package from the Open
BSI CD ROM.
You must install the Open BSI Network Edition. For information on minimum system
requirements and more details on the installation, see the installation procedure in
Chapter 2 of the Open BSI Utilities Manual (document # D5081).
If you have an older version of ControlWave Designer already installed:
Beginning with ControlWave Designer Version 3.3, the copy protection key (dongle) is
NOT required. Prior to installing ControlWave Designer 3.3 or newer, you MUST remove
the hardware dongle from the parallel port of your PC workstation. Otherwise, when you
subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will
limit the available system resources.
IMPORTANT:
When you start ControlWave Designer, you will be reminded to register the
software. Unregistered software can only be used for a maximum of 30 days. For
more information on the registration process, see Chapter 2 of the Open BSI
Utilities Manual (document# D5081).
Step 3. Establish Communications using either LocalView or NetView, and Run
the Flash Configuration Utility
Communications must be established with the ControlWave GFC-CL using either
LocalView or NetView.
The ControlWave GFC-CL ships from the factory with a default Flash configuration. Most
users will need to edit this configuration to set the IP address (if using PPP), BSAP local
address, user accounts, and port parameters. This can be done in one of two ways:
•
•
Either open the supplied Flash Configuration Profile (FCP) file and modify it, directly in
the Flash Configuration Utility, or in a text editor,
Or retrieve existing Flash Parameters directly from the unit, and edit them in the Flash
Configuration Utility.
2-4 / Installation & Operation
CI-ControlWave GFC-CL
Detailed information on the Flash Configuration Utility, and LocalView is included in
Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in
Chapter 6 of that same manual.
Step 4. Modification of the Application-Specific Control Strategy (OPTIONAL)
ControlWave GFC-CL gas flow computers are shipped with the GFC program already
loaded. However, you can create your own application-specific control strategy using
ControlWave Designer. This involves opening a new project using the ‘CWMicro’ template,
defining I/O points using the I/O Configurator, and creating a program using one or more of
the five supported IEC 61131 languages (FBD, ST, SFC, LD, or IL). Some of these
languages are text based, others use graphical diagrams. The choice is up to you, depending
upon your particular application.
The ControlWave MICRO Quick Setup Guide (document # D5124) includes a simple LD
example. Additional examples are included in the manual, Getting Started with
ControlWave Designer (document # D5085). More detailed information about
ControlWave Designer and IEC 61131 is included in the ControlWave Designer Reference
Manual (document # D5088).
The ACCOL3 Firmware Library, which is automatically accessible through the template
referenced above, includes a series of function blocks which perform a variety of process
control and communication functions. These can be included within your program to perform various duties including PID control, alarming, calculations, etc. Detailed information
about each function block is included in the ControlWave Designer on-line help files.
On the variables declaration page(s) in ControlWave Designer, you will need to mark any
variable you want to make accessible to external programs, such as Open BSI’s DataView
utility, as “PDD”. Similarly, any variables which should be collected into a database, or
exported using the OLE for Process Control (OPC) Server must be marked as “OPC.”
Variables marked as OPC can be built into a text file by the OpenBSI Signal Extractor.
The text file can then be used in the creation of a database for human machine interface
(HMI) software such as OpenEnterprise or Iconics’ Genesis. These HMI software packages
require that the "Datatype conversion enable" option be selected when generating the
file using Signal Extractor. Information about the OpenBSI Signal Extractor is included in
Chapter 12 of the Open BSI Utilities Manual (document # D5081).
Once the program has been created, it is assigned to an executable task. The entire project
is then saved and compiled.
NOTE: From this point on, the order of steps may be varied, somewhat,
depending upon the requirements of the user's application.
NOTE: If you modify the standard GFC-CL program, you may need to modify the
standard web pages associated with it. (See Step 5, below).
Step 5. Use Standard Web Pages Provided to Select Options in the Standard
Control Strategy or Create Your Own Application-Specific Web Pages
The ControlWave GFC-CL has a standard set of web pages for configuration purposes
(stored on a PC) that lets you enter parameters, and configuration options for the standard
GFC program (see Step 4, above). If you modify the standard GFC program, you may need
to modify the standard web pages. If you create your own application program (instead of
CI-ControlWave GFC-CL
Installation & Operation / 2-5
using the standard one), you may create your own web pages using Bristol ActiveX controls
discussed in the Web_BSI Manual (document # D5087).
You can use whichever HTML creation package you want to create the pages, however, all
ControlWave GFC-CL related web pages (whether standard or user-created) must be
viewed within Microsoft® Internet Explorer. Web pages are stored on a PC workstation.
Step 6. Create an Open BSI Network Containing the ControlWave GFC-CL, or
ADD the ControlWave GFC-CL to an Existing Open BSI Network
In order for the ControlWave GFC-CL unit to function as part of a Bristol network, it is
necessary to include it in the Bristol network.
If no Bristol network exists:
You need to run Open BSI’s NetView software on the PC workstation in order to define
a Bristol Babcock network. A series of software wizards are used to define a Network
Host PC, a network, and the RTUs (controllers) assigned to the network. Finally, communication lines must be specified which handle the address assigned to the ControlWave GFC-CL. Chapters 3 and 4 of the Open BSI Utilities Manual (document # D5081)
include ‘quick start’ examples for performing these steps. More detailed information is
included in the NetView chapter (Chapter 6) of D5081.
If a Bristol network already exists:
You will need to add the ControlWave GFC-CL to the existing network using NetView’s RTU Wizard. Chapter 6 of the Open BSI Utilities Manual (document # D5081)
includes different sub-sections depending upon whether you are adding the unit to a
BSAP network, or an IP network.
Step 7. If applicable, download new or modified control strategy (OPTIONAL)
If you modified the standard GFC program, or substituted your own program, compile and
download the new or modified program into the unit, using either ControlWave Designer, or
the Open BSI 1131 Downloader. In this case, you download the control strategy into the
BOOT project area of FLASH memory; this ensures that if the ControlWave GFC-CL is
reset, or if there has been a failure of the backup battery, the control strategy can be
restarted from the beginning, i.e. from the BOOT project in FLASH memory. To download
the project, see Section 2.4.1.
2.3.1 Mounting the ControlWave GFC-CL Enclosure
When mounting one of these units, it is to be positioned in accordance with the following
restrictions:
-
The unit is to be positioned vertically with the Transducer (MVT or GPT) at its base.
Only units equipped with a Multivariable Transducer may be mounted directly to the
‘Main’ (meter run) (utilizing a Process Manifold – see Figure 2-5) or they can be
mounted remotely to a panel or wall or to a vertical 2” pipe (clamed at the rear of the
unit via two clamps and four bolts – see Figures 2-3 and 2-6). Units equipped with a
Gage Pressure Transducer can ONLY be mounted remotely to a panel or wall or to a
vertical 2” pipe (clamed at the rear of the unit via two clamps and four bolts – see
Figure 2-3). If used, the 2” pipe is to be anchored in cement (deep enough to conform to
local building codes associated with frost considerations). The basic unit measures
11.73” in height by 9.08” in width by 7.44”in depth (without the mounting brackets). A
2-6 / Installation & Operation
CI-ControlWave GFC-CL
GPT Transducer adds approximately 1.60” to the height of the unit while a
Multivariable Transducer adds 2.80” to the unit’s height. Note: Units equipped
with a Gage Pressure Transducer CANNOT be directly mounted to the ‘Main’
(meter run).
(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 2-2A - ControlWave GFC-CL Bottom View (Shown with MVT)
CI-ControlWave GFC-CL
Installation & Operation / 2-7
-
The Multivariable Transducer (MVT) is bolted to a process manifold which in-turn is
connected to the main (meter run) directly or via two pipes (see Figures 2-5 - 2-7).
The unit must be positioned so that the front of the assembly is visible and the unit is
accessible for service, i.e., installing an option or replacement of the Lithium Battery,
or installation/removal of any ControlWave GFC-CL Module.
(1)
(3)
(6)
(8)
(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
Gage Pressure Transducer
Figure 2-2B - ControlWave GFC-CL Bottom View (Shown with GPT)
2-8 / Installation & Operation
CI-ControlWave GFC-CL
-
Make certain that the LCD Display/Keypad is accessible and visible to the on-site
operator.
There should be clearance for the optional Solar Panel (if required) (the Solar Panel
may be mounted to the same 2” pipe that secures the unit.
Power wiring should not be installed until the unit has been mounted and grounded at
a designated work site.
I/O wiring, external power wiring, RTD cabling, local comm. port, antenna cable, and
network (RS-232 and RS-485) comm. port cabling enter the bottom of the unit though
conduit or special function fittings. I/O wiring may be routed through the left side of
the unit (right when facing the front) in lieu of the bottom. This requires that the left
side hole plug be removed and replaced with a 1/2” Conduit Fitting (swapped out from
the bottom of the unit).
Figure 2-3 - Side View of ControlWave GFC-CL Mounted to a 2” Pipe
CI-ControlWave GFC-CL
Installation & Operation / 2-9
2.3.1.1 Connection to the Multivariable Transducer (MVT)
One optional Multivariable Transducer (MVT) (secured to the bottom of the enclosure) can
be provided with each ControlWave GFC-CL. Figure 2-5 details MVT process flange and
optional manifold block connector mounting dimensions.
The MVT provides connection ports on the process flange as the standard arrangement.
Optional manifold blocks may also be specified. Both arrangements are described as
follows:
Standard Process Flange. Two process flanges containing the connection ports are assembled to the transmitter. Port designations (L and H) are stamped on the body of the
flanges. Ports accept 1/4-18 NPT pipe connections on 2-1/8 in. centers for connection to
orifice taps or a standard three-valve manifold. These process flange connections are
illustrated at the top of Figure 2-5.
The two process flange assemblies are held in place by four bolts and nuts. When the bolts
are removed, the flanges can be repositioned so that the connections can emanate from the
front, rear or bottom of the transmitter. Care should be taken not to damage the sensor
module assembly during this procedure. Once the flange has been positioned, the bolts
should be tightened in an alternating sequence to about 20-30 foot-pounds of torque.
Figure 2-4 - Process Flange and Optional Manifold Block Connectors
2-10 / Installation & Operation
CI-ControlWave GFC-CL
Optional Process Manifold Blocks: Process manifold blocks may be installed on the
transmitter to permit the use of connector assemblies having different connection centers.
The manifold blocks, which are oval in appearance, mate with the transmitter's process
flange. The blocks may be installed in several positions to achieve different connection
centers as shown in Figure 2-4.
MVT Interface Cable: An interface, connected to the top of the MVT, is factory connected
to Connector P2 near the bottom of the Battery Charger & I/O Board. This cable is keyed to
simplify installation.
2.3.1.2 Connection to a Gage Pressure Transducer (GPT)
One optional Gage Pressure Transducer (GPT) (secured to the bottom of the enclosure) can
be provided with each ControlWave GFC-CL. Gage Pressure Transducers are equipped
with a 1/2-14 NPT male pipe fitting (see Figure 2-3B & 4-5B).
2.3.1.3 Process Pipeline Connection (Meter Runs without Cathodic Protection)
ControlWave GFC-CLs equipped with an optional Multivariable Transducer (MVT) may
be mounted directly on the pipeline or remotely on a vertical stand-alone two-inch pipe or
on a wall or panel. ControlWave GFC-CLs equipped with an optional Gage Pressure
Transducer (GPT) may ONLY be mounted remotely, i.e., on a vertical stand-alone two-inch
pipe or on a wall or panel. The Earth Ground Cable is to run between the ControlWave
GFC-CL’s Ground Lug and Earth Ground (Rod or Bed) even though ControlWave GFCCL units equipped with a MVT or GPT Transducer 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.
2.3.1.4 Process Pipeline Connection (Meter Runs with Cathodic Protection)
Dielectric isolators are available from Bristol Babcock and are always recommended as an
added measure in isolating the ControlWave GFC-CL from the pipeline even though the
enclosure does provide some galvanic isolation from the pipeline and should not be affected
by cathodic protection or other EMF on the pipeline. ControlWave GFC-CLs equipped
with an MVT may be mounted directly on the pipeline (utilizing a manifold block) (see
Figure 2-5) or remotely on a vertical stand-alone two-inch pipe (see Figure 2-6). Units
equipped with a GPT may only be remotely mounted, i.e., on a vertical stand-alone two-inch
pipe or on a wall or panel. It is recommended that isolation fitting always be used in
remotely mounted meter systems. An isolation fittings or gasket should be installed
between the following connections:
• all conductive tubing that runs between the pipeline and mounting valve manifold
and/or the units Multivariable Transducer (MVT)
• all conductive connections or tubing runs between the ControlWave GFC-CL 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.
Mount the ControlWave GFC-CL’s enclosure on a stand-alone vertical 2-inch pipe or on a
wall or panel or in the case of units equipped with a MVT directly to the pipeline (utilizing
a Manifold Bock). The ground conductor connects between the ControlWave GFC-CL’s
Chassis Ground Lug and a known good earth ground. Connect the cases of Temperature
Transducers, Pressure Transmitters, etc., to the known good earth ground. If the mounting
CI-ControlWave GFC-CL
Installation & Operation / 2-11
2-inch pipe (when used) is in continuity with the pipeline it may have to be electrically
isolated from the ControlWave GFC. Use a strong heat-shrink material such as RAYCHEM
WCSM 68/22 EU 3140. This black tubing will easily slip over the 2-inch pipe and then after
uniform heating (e.g., with a rose-bud torch) it electrically insulates and increases the
strength of the pipe stand. See BBI Specification Summary F1670SS-0a for information on
PGI Direct Mount Systems and Manifolds.
2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.
Transducer to Manifold
Dielectric Isolation Kit
Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Bottom Washers (4)
Mounting Bolts (4)
AWG 4 Ground Wire
Ground Rod or System
Figure 2-5 - ControlWave EFM (Similar to GFC-CL)
Direct Mount Installation (with Cathodic Protection)
Note: Installation of unit, without Cathodic protection, is similar to that of Figure
2-5 or 2-6 except it doesn’t utilize the Transducer to Manifold Dielectric Isolation
Kit.
2-12 / Installation & Operation
CI-ControlWave GFC-CL
Transducer to Manifold
Dielectric Isolation Kit
Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
AWG 4 Ground Wire
Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Isolating
Fittings
Bottom Washers (4)
Mounting Bolts (4)
2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.
Clamp(s)
Ground Rod or System
Figure 2-6 - ControlWave EFM (Similar to GFC-CL)
Remote Installation (with Cathodic Protection)
2.3.2 Battery Charger and I/O Board Configuration
Battery Charger and I/O Board jumpers must be set to configure field I/Os, the system
power (+24V or EXTPWR) used in conjunction with the Analog Output, and to
install/remove the intrinsically safe (IS) Fuse (F5) (see Figure 2-7).
For safety reasons and to prevent accidental damage to a user supplied external bulk DC
Power Supply, it is recommended that the pluggable Power Terminal Blocks TB1, TB2 and
TB3 on the Battery Charger and I/O Board be disconnected until the entire unit has been
wired, and hardware configured. Sections 2.3.7.1 & 2.3.7.2 provide details on DC Power
Connector wiring.
CI-ControlWave GFC-CL
Installation & Operation / 2-13
Figure 2-7 - Battery Charger & I/O Board Component Identification Diagram
2-14 / Installation & Operation
CI-ControlWave GFC-CL
2.3.3 CPU/System Controller Board Configuration
To configure the CPU/System Controller Board, Jumpers must be set (see Figure 2-8), DIPSwitches must be set (see Section 2.3.3.1) and Communication Ports must be wired (see
Sections 2.3.3.2 through 2.3.3.3). The CPU/system Controller Board is situated on the
inside of the Instrument Front Cover (see Figure 2-1).
2.3.3.1 CPU/System Controller Board Switch Configuration
ControlWave GFC-CL CPU/System Controller Board DIP-Switches must be set for the
desired performance options. Tables 2-1, 2-2 and 2-5 provide an overview of switch settings.
SW2-1 set OFF will disable the system from entering a watchdog state when a crash or
system hangup occurs. Setting SW2-1 OFF prevents the system from automatically
restarting.
SW2-2 set OFF prevents changing the Soft Switches, other configurations and FLASH files,
i.e., these items are locked. To change Soft Switch, configuration and FLASH files SW2-2
must be set to the ON position (see Section 2.4.4).
Table 2-1 – CPU/System Controller Bd. Switch SW2 - User Configurations
Note: Except for SW2-4, ON = Factory Default
SW#
Function
SW2-1
Watchdog Enable
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
SRAM Control
System Firmware
Load Control *
N/A
Setting - (ON = Factory Default)
ON = Watchdog circuit is Enabled
OFF = Watchdog circuit is Disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Mode Switch (SW1)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote download of System Firmware
OFF = Disable remote download of System Firmware
ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)
* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher
SW2-8
Enable WINDIAG
SW2-3 set OFF forces the use of Soft Switches as set per factory default (see Section 2.4.4).
For use of user defined Soft Switches, SW2-3 must be set to the ON position. Note: If both
SW2-3 and SW2-8 are set OFF (closed), all communication ports will be set to 9600 bps
operation.
SW2-4 set OFF and used in conjunction with Mode Switch (SW1) will cause the
ControlWave GFC-CL to perform a Core Updump (see Section 3.6).
SW2-5 set OFF forces the ControlWave GFC-CL to reinitialize SRAM when the unit
recovers from a low power or power outage condition. When set ON, the contents of SRAM
will be retained and utilized when the system restarts. Note: If the Battery is removed
from the CPU Module (CPU removed) CPU should not be installed (and power applied)
before one minute has passed unless SW2-5 on the CPU has been set OFF.
CI-ControlWave GFC-CL
Installation & Operation / 2-15
Figure 2-8 - CPU/System Controller Board Component Identification Diagram
2-16 / Installation & Operation
CI-ControlWave GFC-CL
SW2-6 set ON will enable the user to perform a remote download of System Firmware (on
units equipped with Boot PROM version 4.7 or higher and System PROM version 4.7 or
higher).
SW2-8 set OFF prevents the ‘Boot Project’ from running and places the unit into diagnostic
mode. SW2-8 must be set OFF to run the WINDIAG program resident on the local PC (see
Section 3.5). When SW2-8 has been set ON, diagnostics is disabled. SW2-8 must be set to
the ON position for normal system operation, i.e. for the Boot project to run. Note: If both
SW2-3 and SW2-8 are set OFF (closed), all communication ports will be set to 9600 bps
operation.
Table 2-5 in Section 2.3.3.3 provides CPU/System Controller Board Switch SW3 (COM3)
and SW4 (COM2) RS-485 communication port settings.
Table 2-2 - CPU/System Controller Bd. Switch SW1
Recovery Mode/Local Mode Control
SWITCH
Function
Setting
Both ON or OFF = Recovery Mode
SW1-1/2
Recovery/Local Mode *
SW1 OFF & SW2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
SW1-3
Force Recovery Mode *
OFF = Recovery Mode disabled
SW1-4
Not Used
N/A
* = Note: Only the Switch SW1 settings listed in this table, have been tested.
2.3.3.2 Communication Ports
A ControlWave GFC-CL can be configured as a Master or Slave node on either a
MODBUS network or a BSAP network. A variety of communication schemes are available.
An optional 56K PSTN Modem and Spread Spectrum Modem (Radio) can be piggy-back
mounted on the CPU/System Controller Board. Three communication ports are contained
on the standard CPU/System Controller Board. These communication ports are designated
as follows:
CPU/System Controller Board:
COM1 - Port 1: J19 (9-Pin Male D-Sub), TB1 (8-Pin Term Block) - RS-232 (TB1 is factory
connected to the Local Port)
COM2 - Port 2: TB2 (8-Pin Term. Block) RS-232/RS-485 - RS-485 Configured by SW4
(COM2 supports an Internal or External Modem or Radio option)
COM3 - Port 3: TB3 (5-Pin Term. Block) RS-485 - Configured by SW3
COM1 is also available as the Local Port. This is accomplished via either a 9-pin D-Type
male connector or a circular 5-pin female connector. The Local Port is located on the bottom
of the Instrument Front Cover.
Communication Ports COM1, COM2 and COM3 support serial asynchronous operation as
listed above. Any communication port (COM1, COM2 or COM3) can be configured for local
communications, i.e., connected to a PC loaded with ControlWave Designer and OpenBSI
software.
Diagram of RS-232/485 interfaces and connectors are shown in Figures 2-9 through 2-11B.
Hardware connector pin wiring assignments are provided in Tables 2-3A and 2-3B.
CI-ControlWave GFC-CL
Installation & Operation / 2-17
2.3.3.3 RS-232 & RS-485 Interfaces
ControlWave GFC-CL RS-232 & RS-485 communication schemes are discussed herein.
RS-232 Ports
An RS-232 interface supports Point to Point, half-duplex and full-duplex communications
(20 feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWave GFC-CL utilize MODBUS or BSAP protocol, while full-duplex is supported
by the Point to Point (PPP) protocol. ControlWave GFC-CL RS-232 ports utilize a “null
modem” cable (Figure 2-10A - Top) to interconnect with other devices such as a PC, printer,
another ControlWave series unit, when the ControlWave GFC-CL is communicating
using the full-duplex PPP protocol. A half-duplex cable (Figures 2-10A - Bottom) is utilized
when the ControlWave GFC-CL is connected to any ControlWave series or to another
ControlWave GFC-C. If communicating with a Bristol series 3305, 3310, 3330 or 3335
RTU/DPC, one of the cables shown in Figure 2-10B must be used. Refer to Figure 2-10C to
connect ControlWave GFC-CL serial RS-232 port COM2 to either an external modem or
external radio. When interfacing to Port COM3 of a ControlWave unit, or to COM5 or
COM6 of a ControlWaveEXP, the cable of Figure 2-10D must be used along with the one
of Figure 2-10A or 2-10B.
Illustrations of the Local Communication Port cable connections (Communication Port 1)
are provided in Figures 2-11A and 2-11B.
An illustration of the CPU/System Controller Module’s male 9-pin D-type connectors is
provided in Figure 2-9. Table 2-3A provides the connector pin assignments for ports COM1
and COM2 while Table 2-3B provides connector pin assignments for ports COM3.
Figure 2-9 - Male DB9 9-Pin Connector Associated with COM1
Note: The following facts regarding ControlWave GFC-CL RS-232 serial communication
ports should be observed when constructing communications cables:
•
•
•
•
•
•
•
•
DCD must be high to transmit (except when dialing a modem)
Each RS-232 transceiver has one active receiver while in power down mode
(disabled); the DCD signal is connected to the active receiver.
CTS must be high to transmit.
When port is set for full-duplex operation - RTS is always ON.
DTR is always high (when port is active); DTR enables RS-232 Transceivers.
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 LCDA12C surge protectors
to ±4KV ESD.
2-18 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-10 - Communication Ports – CPU Board RS-232 Cable Wiring Diagram
CI-ControlWave GFC-CL
Installation & Operation / 2-19
Figure 2-11A - PC Connected to CW GFC-CL via Local Port (D-Type Version)
(Use Null Modem Cable - Bristol Part Number 392843-01-3)
Table 2-3A1 - RS-232 Ports (COM1 & 2) and RS-485 Ports (COM2)
Connector Pin Assignments (All COM1 Connectors, i.e., D-Type Local Port, J19 &
TB1 and COM2 Connector TB2)
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
N/A
Signal
RS-485
RXD+
TXD+
Description:
RS-485 Signals
Receive Data + Input
Transmit Data + Output
N/A
N/A
Ground
Receive Data − Input
Transmit Data − Output
N/A
N/A
GND
RXD−
TXD−
Table 2-3A2 - RS-232 Port (COM1) Connector Pin Assignments
(COM1 Connectors, i.e., Circular Type Local Port & TB1)
Pin
#
1
2
3
4
5
6
7
8
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
Local Port
RS-232 Pin #
7 (WHT Wire)
2 (RED Wire)
6 (BLK Wire)
*
*
* RTS connected to CTS at TB1 of CPU for Local Port Comm. Cable
2-20 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-11B - PC Connected to ControlWave GFC-CL via Local Port
(Circular Port Version)
Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable
Table 2-3B - RS-485 Port (COM3)
Connector Pin Assignments (TB3)
Pin
#
1
2
3
4
5
Signal
RS-485
RXD+
RXD−
TXD−
TXD+
Power Ground
Description:
RS-485 Signals
Receive Data + Input
Receive Date − Input
Transmit Data − Output
Transmit Data + Output
Ground
RS-485 Ports
ControlWave GFC-CL can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for
network communications, Table 2-4 provides the appropriate connections for wiring the
master, 1st 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 (daisy
chained) across the same lines. The master node should be wired to one end of the RS-485
cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used. Note:
Only half-duplex RS-485 networks are supported.
Receiver biasing and termination as well as 2-wire or 4-wire selection are enabled by eightposition DIP-Switches situated on the CPU/System Controller Board as follows: COM3:
Switch SW3, COM2: Switch SW4.
CI-ControlWave GFC-CL
Installation & Operation / 2-21
Table 2-3A provides the connector pin assignments for CPU/System Controller Board port
COM2. Table 2-3B provides connector pin assignments for CPU/System Controller Board
port COM3. Table 2-5 provides the RS-485 termination and loopback control Switch
Settings for the RS-485 Ports.
To ensure that the “Receive Data” lines are in a proper state during inactive transmission
periods, certain bias voltage levels must be maintained at the master and most distant
slave units (end nodes). These end nodes also require the insertion of 100-Ohm terminating
resistors to properly balance the network. Secondary Communication Board switches must
be configured at each node to establish proper network performance. This is accomplished
by configuring CPU/System Controller Bd. Switch SW3 (COM3) and/or Switch SW4 (COM2)
so that the 100-Ohm termination resistors and biasing networks are installed at the end
nodes and are removed at all other nodes on the network (see Table 2-5).
Table 2-4 - RS-485 Network Connections
(see Table 2-3A/B ControlWave GFC-CL RS-485 Port Pin # Assignments)
From
Master
TXD+
TXD−
RXD+
RXD−
GND/ISOGND*
To 1st
Slave
RXD+
RXD−
TXD+
TXD−
GND/ISOGND*
To nth
Slave
RXD+
RXD−
TXD+
TXD−
GND/ISOGND*
* ISOGND with Isolated RS-485 Ports Only!
Note: Pins 1, 2, 3, 4 & 9 of Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485 Comm.
Ports are assigned as follows: 1 = TXD+, 2 = TXD-, 3 = RXD+, 4 = RXD- & 9 = ISOGND.
Table 2-5 - CPU/System Controller Bd. Switch SW3/SW4 Assignments
RS-485 Loopback & Termination Control (SW3 for COM3 – SW4 for COM2)
SWITCH
#
RS-485 Function
Switch ON
SW3/4-1
TX+ to RX+ Loopback/2-Wire
SW3/4-2
TX− to RX− Loopback/2-Wire
SW3/4-3
SW3/4-4
SW3-6
(see Note 2)
100 Ohm RX+ Termination
100 Ohm RX− Termination
Slew Rate
ISO485 ONLY
SW3/4-7
RX+ Bias (End Nodes/Node)
SW3/4-8
RX− Bias (End Nodes/Node)
Setting
ON – 2-Wire Operation or Loopback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – 2-Wire Operation or Looback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – End Nodes Only
ON – End Nodes Only
ON – Slow Rate Enabled
OFF – Fast Rate Enabled
ON – 4-Wire = Both End Nodes
2-Wire = One End Node Only
OFF = No Bias
ON – 4-Wire = Both End Nodes
2-Wire = One End Node Only
OFF – No Bias
Note 1: Closed = Switch set ON Note 2: Switch SW3-6 (COM3) = N/A
2.3.3.4 Piggy-back Spread Spectrum Modem (Radio) Port (see Appendix D)
An optional Spread Spectrum Modem (Radio) is available on the CPU/System Controller
Board and is assigned as COM2. There are two unique radios offered. These radios will only
communicate with their own brand of radio, i.e., FreeWave radios are not compatible with
2-22 / Installation & Operation
CI-ControlWave GFC-CL
MDS Transnet radios. DTE/DCE serial data can be clocked into (transmit) or out of
(receive) the radio at a rate up to 115.2kHz. These radios are supplied in kit form with all
the hardware required for user installation onto a CPU/System Controller Board. Figure 213 shows both versions of radios mounted on CPU/System Controller Board. A Radio is user
installed onto the CPU/System Controller Board (see Figure 2-12) and its associated Port is
setup during installation in the Ports Page of the Flash Configuration Utility. The Flash
Configuration Utility is accessed via NetView or LocalView.
FreeWave® Spread Spectrum Wireless Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
Microwave Data System Inc. MDS TransNET OEM™ Spread Spectrum Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
Installation steps 1 - 3 below support user installation and configuration of a Radio.
1. Mount the radio (Spread Spectrum Modem) onto the Radio Carrier Board and then
mount this combined assembly onto the CPU/System Controller Board. Install the Lshaped Bracket onto the lower right corner of the CPU/System Controller Board. Install
one end of the internal coaxial RF cable supplied with the radio in question onto the
radio’s RF SMA Connector. Connect the other end of the internal coaxial RF cable to the
L-shaped Bracket.
2. Install the user supplied coaxial RF cable between the unit’s RF antenna cable or
Polyphaser and the remote antenna.
3. For FreeWave Radio: Follow the Tuning Transceiver Performance” section of the
FreeWave Technologies Inc. FreeWave Spread Spectrum Wireless Data Transceiver
User Manual to configure the radio.
For MDS Radio: Refer to section 3.3 “Initial Power-Up & Configuration” within the
MDS TransNet OEM Integration Guide and if necessary for more information on
connecting a PC terminal and preparing it for use, refer to section 9.0
“PROGRAMMING REFERENCE.”
Note:
Whenever setting any Jumper or connecting/removing a communication cable to/from a PC, power should be turned OFF. To
invoke the setup program, connect the radio (via COM1) to a
terminal program (such as HyperTerminal) via a null modem
cable (see Figure 2-11), put the radio into setup mode and set the
parameters for the terminal to those of Table 2-6. The setup
program is invoked by connecting Pins 1 and 2 of CPU/System
Controller Board Jumper Post W8.
Table 2-6 - Radio Setup Menu Terminal Settings
PARAMETERS
Baud Rate
Data Rate
Parity
Stop Bits
CI-ControlWave GFC-CL
SETTINGS
19,200
8
None
1
PARAMETERS
Parity Check
Carrier Detect
Flow Control
SETTINGS
None/Off
None/Off
Xon/Xoff
Installation & Operation / 2-23
1 - RS-232
2 - RS-232
3 - RS-485
1 - RS-232
2 - RS-232
3 - RS-485
F
F B
A
G
B
A
H
F
E
F
A B
Q
L
Q
F
I
E
F
I
or
G
J
J
F
or
M
D
O
O
N
F
G
C
E
A/B/C
H
A
E
N
F
G
OPTION I/J/K
Populated
by
L
Order
E
K
E
I
B
J
M
D
Modem Kit Parts
Q = Modem
Q
O/P
MDS (Transnet) Radio Kit/Option Parts
A = 6-32 x .250 Pan Head Screw (Qty. 4)
B = 6-32 x .313 F/F Standoff (Qty. 4)
C = 6-32 x .188 Pan Head Screw (Qty. 4)
D = Transnet Radio Cable (with Nut and Washer)
E = Swaged Standoff (Qty. 4)
F = 4-40 x .250 Pan Head Screw (Qty. 4)
G = Radio Carrier Board
H = MDS Transnet Radio Module
N = L-shaped Bracket
O = Screw
P = Nut
Q
O/P
FreeWave Radio Kit/Option Parts
E = Swaged Standoff (Qty. 4)
F = 4-40 x .250 Pan Head Screw (Qty. 4)
G = Radio Carrier Board
I = 2-56 x 1/4 Pan Head Screw (Qty. 3)
J = 2-56 x .250 F/F Standoff (Qty. 3)
K = 2-56 x .188 Pan Head Screw (Qty. 3)
L = FreeWave Radio Module
M = FreeWave Radio Cable (with Nut & Washer)
N = L-shaped Bracket
O = Screw
P = Nut
Figure 2-12 - CPU/System Controller Board Radio/Modem Installation Diagram
2-24 / Installation & Operation
CI-ControlWave GFC-CL
2.3.3.5 Piggy-back 56K PSTN Modem Port (see Appendix D)
An optional 56K PSTN Hayes type Modem can be mounted piggy-back on the CPU/System
Controller Board and is assigned to COM2. The Model MT5634SMI Modem module is
manufactured by MultiTech System and can be user configured for PSTN operation.
DTE/DCE serial data can be clocked into (transmit) or out of (receive) the modem at a rate
up to 115.2kHz.
Modems are supplied in kit form with all the hardware required for user installation onto a
CPU/System Controller Board. Figure 2-12 shows the modem mounted on the CPU/System
Controller Board.
A Modem is installed onto the CPU/System Controller Board (see Figure 2-12) and its
associated Port is setup during installation in the Ports Page of the Flash Configuration
Utility. The Flash Configuration Utility is accessed via NetView or LocalView. A Terminal
Emulation program such as HyperTerminal is used to profile the modem via AT commands.
Users typically use AT commands only when checking the modem’s active or stored profile
or when reconfiguring a modem, e.g., to turn auto answer on or off, etc.
The following 7 steps should be taken to configure a MultiTech Modem (this should have
been done during factory installation):
• Enable modem setup by setting CPU/System Controller Board jumpers as follows: W8 to
2-3, W11 Installed, W19 to 1 to 2, and for DTR Power Control as follows: W10 Installed =
Power Always On
• Connect via HyperTerminal (Parameters = 9600, 8, N, 1, & None) to port COM1 (J19 on
the CPU/System Controller Board or the Local Port) using the null modem cable (see
Figure 2-11A or 2-12).
• Send Factory Default = AT&W1 ATZ
• Disable Flow Control = AT&K0
• Set Baud using AT Command: AT$SB9600, or whatever baud rate you require.
• Write to Memory = AT&W0
• Disable setup mode. Park Jumper W8 (no connection)
After completing the seven configuration steps (if required) use WebBSI to select the
“Radio/Modem Control Mode” on the Radio & Modem Control Configuration Web page.
Note:
Whenever setting any Jumper or connecting/removing a communication cable
to/from a PC, power should be turned OFF. The modem can be reconfigured via
AT commands using a terminal program (such as HyperTerminal). Connect Pins 2
and 3 of CPU/System Controller Board Jumper Post W8 via a Suitcase Jumper.
Connect the modem (via port COM1) to the PC via a null modem cable (see Figure
2-11).
Publicly Switched Telephone Network (PSTN) Hookup
A PSTN using a master and three remote Process Automation Controllers (each equipped
with a PSTN modem) is shown in Figure 2-13. A connection to the PSTN is made using a
cable having standard telephone connectors at each end. One end of the cable plugs into
CPU/System Controller Board RJ11 connector jack (J9) while the other end plugs into a
telephone company RJ11 wall jack. The telephone company provides the necessary
subscriber loops at its central system along with the phone numbers for each destination.
Warning
CI-ControlWave GFC-CL
Installation & Operation / 2-25
Only one modem should be connected to each drop. If an attempt is made to parallel two or
more modems across a single drop, an impedance mismatch will occur and the quality of the
signal will be adversely affected. Modems will not provide reliable communications under
these conditions.
Figure 2-13 - Field Connections for ControlWave GFC-CL on Basic PSTN
An application consisting of a single master and a single remote requires only one of the
remote connections shown in Figure 2-13.
The 56K PSTN Modem is FCC-approved for use with public telephone lines. Before placing
a modem in operation, the following items should be checked to insure that all FCC
requirements are met:
•
•
Connections to party line service is subject to state tariffs.
Connection to telephone company provided coin service (central office implemented
systems) is prohibited.
2-26 / Installation & Operation
CI-ControlWave GFC-CL
•
The equipment compliance information is summarized as follows:
Complies with Part 68 FCC Rules.
Contains device with FCC Registration Number: AU7-USA-25814-M5-E
Ringer Equivalence Number (REN): 0.3B
Note: The sum of all the RENs on your telephone lines should be less than five in
order to assure proper service from the telephone company. In some cases, a
sum of five may not be usable on a given line.
•
Any direct connections to PSTN lines must be made through standard plugs and
jacks as specified in the FCC rules. The PSTN line connector plugs into J1 on the
modem. Notify your telephone company that the jack (connector) required for your
device is one of the following: Note: The Jack provided on the Modem (J1) is a 6-Pin
TLECO RJ-11. The connections to the modem are Pin 3 PSTN-Tip, and Pin 4 PSTNRing.
USOC: RJ11C or USOC: RJ11W
•
After the telephone company has installed the above jack, connect the modem to
your equipment by inserting the appropriate equipment interface cable (plugs) into
the modem jack and the wall jack.
Figure 2-14 - Wiring for Phone Cord Connector
2.3.3.6 Radio Ready and External (Case Mounted) Modem or Radio
A wide selection of modems and radios are offered. The ControlWave GFC-CL is factory
shipped with a user selected radio or modem installed within the enclosure (in front of the
Battery Mounting Bracket) or as a radio ready unit, i.e., ready for field installation of a
Bristol supplied radio. The installer must ensure that the remote antenna (associated with
a case mounted radio) is properly installed and connected.
Information on operating and configuring a Bristol supplied radio or modem is contained in
documentation authored by the unit’s manufacturer. A list of reference manuals is provided
in the Table of Contents under the topic REFERENCED OEM MANUAS.
2.3.4 I/O Wiring
ControlWave GFC-CLs are provided with Card Edge Terminal Blocks that accommodate
field wiring. Wiring is routed into the enclosure through a 1/2” Conduit Fitting.
CI-ControlWave GFC-CL
Installation & Operation / 2-27
2.3.4.1 I/O Wire Connections
ControlWave GFC-CL gas flow computers utilize Terminal Blocks equipped with
compression-type terminals that accommodate up to #14 AWG wire. A connection is made
by inserting the wire’s bared end (1/4” max) into the clamp beneath the screw and securing
the screw. The wire should be inserted fully so that no bare wires are exposed to cause
shorts. 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. The slack makes the
connections more manageable and minimizes mechanical strain on the terminal blocks.
2.3.4.2 Shielding and Grounding
The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize
signal errors caused by electromagnetic interference (EMI), radio frequency interference
(RFI) and transients. When using shielded cable, all shields should only be grounded at one
point in the appropriate system. This is necessary to prevent circulating ground current
loops that can cause signal errors.
2.3.4.3 Non-isolated Discrete Input/Output Connector Block TB5 (see Figure 2-15)
ControlWave GFC-CL Battery Charger and I/O Boards contain field interface circuitry for
up to 2 Discrete (Digital) Inputs and 2 Discrete (Digital) Outputs. Surge Suppression and
signal conditioning is provided for each DI. DO circuits consist of an open drain MOSFETs
and Surge Suppression. DI/O circuitry utilizes an 8-point Terminal Block Assembly.
DI/O circuitry provides internally sourced DI operation for Dry Contacts pulled internally
to 3.3Vdc when the field input is open. Each DI is protected with a surge suppressor. DI
filtering is 15 milliseconds. DO circuitry utilizes open drain MOSFETs and surge suppressors. The DOs sink current to digital ground.
2.3.4.3.1 Discrete Input/Output Configurations
Terminal Block TB5 supports two non-configurable DIs and 2 non-configurable externally
powered DOs. Each DI provides a 60uA source current from 3.3Vdc. Open drain MOSFETs
associated with each DO provide up to 100mA each @ 16Vdc for a 6V system or 100mA @
30Vdc for a 12V system to an externally powered device. Field wiring assignments are
provided in Figure 2-15.
2.3.4.4 Non-isolated Analog Input Connector Block TB8 (see Figure 2-15)
Battery Charger and I/O Boards contain field interface circuitry for up to three (3) Analog
Inputs that are individually configurable for 4-20mA or 1 to 5V operation. Field power
source can be from the battery powered ControlWave GFC-CL, an external power source,
or in the case of a 12V version, from the 24V field source.
Each AI signal is channeled through signal conditioning circuitry (that provides a 2 Hertz
low pass filter), a transorb for surge suppression, multiplexer, and an A to D Converter
(ADC).
2-28 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-15 - Battery Charger and I/O Board Field I/O Wiring Diagrams
CI-ControlWave GFC-CL
Installation & Operation / 2-29
2.3.4.4.1 Analog Input Configurations
AI circuits are provided with Configuration Jumpers that accommodate configuration of
each of the three Analog Inputs. Analog Input can be individually configured for 1-5V or 420mA operation. Field wiring assignments are provided in Figure 2-15.
Note:
Cable shields associated with AI wiring should be connected to the ControlWave GFCCL’s Chassis Ground. Multiple shield terminations will require a user supplied copper
ground bus. This ground bus must be connected to the ControlWave GFC-CL’s Chassis
Ground Lug (using up to a #4 AWG wire size) and must accommodate connection to a
known good Earth Ground (in lieu of a direct connection from the Ground Lug) and to all
AI cable shields. Shield wires should use an appropriate Terminal Lug and should be
secured to the copper bus via industry rugged hardware (screw/bolt, lock washer and
nuts).
Table 2-7 - Analog Input Circuitry Jumper Assignments
Jumper
Purpose
Configures AI1 through
AI3 (respectively)
JP1 - JP3
JP6
AO/AI Power
JP10
AI Field Power
Notes
Pins 1-2 installed = 4-20mA AI
Pins 2-3 installed = 1-5V AI
Pins 1-2 installed = +24V Supply
Pins 2-3 installed = +V External
Pins 1-2 installed = Output of JP6
Pins 2-3 installed = System Power through Polyfuse
2.3.4.5 Non-isolated Analog Output Connector Block TB9 (see Figure 2-15)
Battery Charger and I/O Boards contain field interface circuitry for up to one Analog
Output that is configurable for 4-20mA or 1 to 5V operation. Field power source can be from
the battery powered ControlWave GFC-CL, an external power source, or in the case of a
12V version, from the 24V field source. The Analog Output circuit consists of a 12-bit
resolution Digital to Analog Converter (DAC), a V to I circuit, and a V to V circuit. A jumper
is used to set the status of the output mode, i.e., current or voltage. The 12-bit DAC dives
the V to I circuitry. A scaling circuit within the V to I circuit drives the V to V circuitry.
Analog Output circuitry is not populated on 6V versions of the ControlWave GFC-CL.
2.3.4.5.1 Analog Output Configurations
The Analog Output circuit utilizes three Configuration Jumpers that accommodate 1-5V or
4-20mA AO operation and AO Power selection, i.e., internal (24Vdc) or external power (11 30Vdc). The maximum external load that can be connected to the 4-20mA output is 250
ohms (with an external 11V power source) or 650 ohms (with an external 24V power
Source). The maximum external load current for the 1-5V output is 5mA (with an external
11 to 30 V power source). AO operation requires either an 11 to 30Vdc power source
connected to the EXTPWR terminal of the AO circuit Terminal Block (TB9-3) or the unit
supplied 24Vdc supply.
Table 2-8 - Analog Output Circuitry Jumper Assignments
Jumper
JP4
JP5
Purpose
AO1 Field Output Source
AO1 Output Status
JP6
AO/AI Power
2-30 / Installation & Operation
Notes
Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5V AO
Pins 1-2 installed = +24V Supply
Pins 2-3 installed = +V External
CI-ControlWave GFC-CL
2.3.4.6 Non-isolated High Speed Counter Input Connector TB6 (see Figure 2-15)
Non-isolated High Speed Counter Input (HSC) circuitry supports a total of 2 inputs
provided with surge suppression bandwidth limiting and 20 microsecond (50kHz) filtering.
In addition, HSCI circuitry contains conditioning circuitry consisting of a debounce circuit
followed by a one shot pulse circuit that generates a 65 microsecond ±10% pulse and limits
the maximum frequency of an input signal to 15kHz. HSC inputs may be individually field
configured with contact debounce circuitry enabled or disabled. When debounce circuitry is
enabled, spurious pulses caused by relay contact bounce do not affect the count. HSC
circuitry is supported by an 8-point Terminal Block Assembly (for local termination) and 3
Configuration Jumpers.
Field inputs can be driven signals, or relay contacts. Each HSC input is configured as a 16bit high-speed counter.
2.3.4.6.1 High Speed Counter Configurations
A total of 2 HSC inputs with surge protection are provided. HSC Configuration Jumpers
must be set per Table 2-9.
Table 2-9 - Non Isolated High Speed Counter Module Jumper Assignments
Jumper
JP7
JP8
Purpose
Configures HSC1
Configures HSC2
JP11
HSC2/NAMUR Output Feed
Notes
Pins 1-2 installed = Enables HSC Debounce
Pins 2-3 installed = Disabled HSC Debounce
Pins 1-2 installed = +HSC2 (Default)
Pins 2-3 installed = NAMUR – N/A
2.3.5 RTD Wiring
A 3-wire RTD may be provided with the ControlWave GFC-CL. Connector TB2 on the
System Controller Module accommodates a removable three-wire Terminal Block (TB10).
This connector accommodates a 100-ohm platinum bulb using the DIN 43760 curve.
ControlWave GFC-CL’s utilize the common three-wire con-figuration. In this
configuration, the Return lead connects to RTD- and the two junction leads (Sense and
Excitation), connect to RTD+ and RTD EXC. Connection between the RTD and System
Controller Module is wired as follows:
Table 2-10 - RTD Connections to System Controller Connector TB2
TB10 Pin
1
2
3
Signal
RTD EXC
RTD+
RTD-
Function
Excitation
Sense
Return
Never ground the RTD Cable Shield at both ends or allow it to come in contact with
conductive conduit as multiple ground paths could cause RTD input errors.
To install the RTD Probe, screw the Fitting Body into the thermowell with a 7/8”open-end
wrench. While applying 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 thermowell),
tighten the Nut (9/16” open-end wrench) against the 7/8” Fitting Body (see Figure 2-17).
CI-ControlWave GFC-CL
Installation & Operation / 2-31
Figure 2-16 - 3-Wire RTD Temperature Input Wiring
Figure 2-17 - RTD Probe Installation/Removal Diagram
2.3.6 Connection to a Model 3808 Transmitter
A Model 3808 Transmitter (Digital) can be interfaced to a ControlWave GFC-CL via
either an RS-232 or an RS-485 communication scheme. Communication schemes and cable
lengths are determined the type of communication port utilized. In general RS-232
communications are utilized when the Model 3808 Transmitter is situated within 25 feet of
the ControlWave GFC-CL, i.e., for local communications. Communications can be
achieved with transmitters up to 4000 feet away (remote communications) via the RS-485
scheme.
Figures 2-18 and 2-19 detail the RS-232 and RS-485 wiring connections required between
the ControlWave GFC-CL and the Model 3808 Transmitter.
Up to two (2) Model 3808 Transmitters can be connected to a ControlWave GFC-CL via a
half duplex RS-485 Network. An illustration of this network is provided in Figure 2-20.
2-32 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-18 - Model 3808 Transmitter to ControlWave GFC-CL
RS-232 Comm. Cable Diagram
Note: For Loopback & Termination Control:
Use SW3/SW4 on CPU/System Controller Board to configure COM3/COM4.
Figure 2-19 - Model 3808 Transmitter to CW GFC-CL RS-485 Comm. Cable
CI-ControlWave GFC-CL
Installation & Operation / 2-33
To +
To 1
1 = RX+
2 = TX+
6 = RX7 = TX-
TB2 = COM2
Figure 2-20 - ControlWave GFC-CL to 3808s - RS-485 Network Diagram
2.3.7 Power Wiring & Distribution
Primary Power is applied to Connector TB2 of the Battery Charger and I/O Board (TB2-1 =
+ & TB2-2 = GND) (GND = -) and may be provided as follows:
•
•
•
•
•
•
Bristol supplied 6V Lithium Battery
Bristol supplied 12V Lithium Battery Pack (Dual Lithium Batteries)
Bristol supplied 6V/7AH Lead Acid Battery – used with a 1W, 6V Solar Panel System
Bristol supplied 6V/7AH Lead Acid Battery – used with a 5W, 6V Solar Panel System
Bristol supplied 12V/7AH Lead Acid Battery – used with a 5W, 12V Solar Panel System
External (User Supplied) Power Supply (+4.5/+4.9 to +16Vdc or +9.6/10.3 to +16Vdc
Three other power interface connectors are provided on the Battery Charger and I/O Board
and (in all cases (Pin-1 = + & Pin-2 = GND) (GND = -) function as follows:
•
•
•
TB1 - Solar Power (1W - 6V, 5W - 6V or 5W - 12V) (TB2-1 = + & TB2-2 = -)
TB3 - Backup Battery (External User Supplied 6V or 12V) (Diode Or’d with TB2)
TB4 - Auxiliary Output Power - for External Radio/Modem.
ControlWave GFC-CL Terminal Blocks utilize compression-type terminals that
accommodate up to #14 AWG wire. A connection is made by inserting the wire’s bared end
(1/4” max) into the clamp adjacent to the screw and then securing the screw. The wire
should be inserted fully so that no bare wires are exposed to cause shorts. If using standard
wire, tin the bare end with solder to prevent flattening and improve conductivity. Allow
some slack in the wires when making connections. The slack makes the connections more
manageable and helps to minimize mechanical strain on the terminal blocks.
2-34 / Installation & Operation
CI-ControlWave GFC-CL
Note: Fuses F1 and F3 are provided for Class I, Div. 1 Hazardous Location use
Only (see Figure 2-7).
2.3.7.1 Bulk Power Supply Current Requirements
ControlWave GFC-CL gas flow computers are equipped with a CPU/System Controller
Board that accepts either 6Vdc or 12Vdc Bulk Power input. The maximum current required
for a particular ControlWave GFC-CL can be estimated as follows:
Bulk +6/12Vdc Supply Current = CPU/System Controller Board (with options) + Battery
Charger and I/O Board + LCD Display Keypad + Optional External Modem/Radio
This summation will accommodate steady state current draw. Table 2-11 provides detailed
steady state power current requirements for each ControlWave GFC-CL configuration.
Note: In the case of an external modem/radio, the unit’s manufacturer provides power
consumption specifications.
Table 2-11 - ControlWave GFC-CL Base Assembly Power Requirements
COMPONENTS
CPU + Battery Charger and I/O
+ LCD with 2/25-Button Keypad
CPU + Battery Charger and I/O
+ LCD with 2/25-Button Keypad
BULK 12Vdc Supply
W/O Field Supply & with AO
Output Under range
5mA
With Field Supply - Field
Supply Efficiency Varies from
40% @ 5mA Load to
80% @ 100mA Load
30mA Total Current (5ma
Load on Field Supply)
250mA Total Current (100mA
Load on Field Supply)
1mA
34mA
289mA
BULK 6Vdc Supply
6.2mA
6.2mA
RS-485 Comm Port is ON
2mA
Optional Piggy-back 56K Modem
67mA
Optional Piggy-back MDS Radio
577mA
Optional Piggy-back FreeWave
250mA
500mA
Radio
Optional External Modem/Radio
See Manufacturer’s Spec.
See Manufacturer’s Spec.
Note: Current consumption provided in Table 2-11 is based on the standard Gas Flow
Computer application load. For 3808 power consumption refer to CI-3808.
2.3.7.2 Power Wiring
DC Power is interconnected to the CPU/System Controller Board (J1) via a wiring harness
that originates on the Power Supply and I.O Board (P1). One Bulk DC supply can be
connected to the ControlWave GFC-CL CPU/System Controller Board. The Bulk DC
supply (nominally +6Vdc or +12Vdc) connected to TB2-1 (Power Supply and I/O Board) and
is converted, regulated and filtered by the CPU/System Controller Board to produce
+3.3Vdc. This CPU/System Controller Bd. circuit is fused at 1A (F1). The operating range of
the units +4.5/4.9Vdc to +16.0Vdc (nominal +6Vdc input source) or +9.6/10.3Vdc to
+16.0Vdc (nominal +12Vdc input source).
Power Supply and I/O Board Connector TB2 provides 2 input connections for bulk power:
TB2-1 = (+VIN) (+4.5/4.9V to +8V dc for +6V bulk) (+9.6/10.3V to +16V dc for +12V bulk)
TB2-2 = (-VIN) (Supply Ground)
CI-ControlWave GFC-CL
Installation & Operation / 2-35
Figure 2-21 - Battery Charger and I/O Board (TB2) Primary Power Wiring
2.3.7.3 Mounting an Optional Solar Panel
Solar Panels (used to charge the rechargeable lead acid batteries) are to be mounted to a 2”
to 2-3/8” pipe as illustrated in Figures 2-22 and 2-23. Muffler (Pipe) Clamps, utilized for
this purpose, are secured via four 1/4-20 nuts and washers.
Figure 2-22 - 5 Watt Solar Panel Mounting Diagram
2-36 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-23 - 1 Watt Solar Panel Mounting Diagram
2.3.7.3.1 Swivel (Directional Facing)
Solar Panels used in the Northern Hemisphere should face due south (not magnetic south)
while those used in the southern hemisphere should face due north (not magnetic north).
2.3.7.3.2 Tilt Angle
1 and 5 Watt Solar Panel Systems (see Figures 2-22 & 2-23) have adjustable tilt angles.
Table 2-12 shows the angle (from horizontal) at which the Solar Panel should be installed
in order to maximize annual energy output. At most latitudes, performance can be
improved by less of an angle during the summer and more of an angle during the winter.
CI-ControlWave GFC-CL
Installation & Operation / 2-37
Table 2-12 - Solar Panel Tilt Angle for Solar Panels
LATITUDE
0-4°
5-20°
21-45°
46-65°
66-75°
INSTALLATION ANGLE
10° from Horizontal
Add 5° to the Local Latitude
Add 10° to the Local Latitude
Add 15° to the Local Latitude
80° from Horizontal
2.3.7.4 ControlWave GFC-CL System Grounding
ControlWave GFC-CL Enclosures are provided with a Ground Lug that accommodates up
to a #4 AWG wire size. A ground wire must be run between the Enclosure’s Ground Lug
(see Figure 2-2) and a known good Earth Ground. The following considerations are provided
for the installation of ControlWave GFC-CL system grounds (see S1400CW):
• Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is recommended
that stranded copper wire is used and that the length should be as short as possible.
• This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
• The wire ends should be tinned with solder prior to insertion into the Chassis Ground
Lug. Note: Use a high wattage Soldering Iron.
• The ground wire should be run such that any routing bend in the cable has a minimum
radius of 12-inches below ground and 8-inches above ground.
2.3.8 Operation of the Lithium Backup Coin-cell Battery
CPU/System Controller Boards are equipped with a Coin-cell Socket (S1) that accommodates a 3.0V, 300 mA-hr lithium coin cell. A supervisory circuit on the CPU/System
Controller Board is used to switch to battery power when the regulated 3.3Vdc VCC falls
out of specification. The CPU/System Controller Board switches the battery voltage to the
VBAT3.3 hardware signal, which provides backup power for the real-time clock (RTC) and
the system SRAM on the CPU Module.
The system SRAM has a standby current draw of 20uA maximum for each part. For a unit
containing 2MB of SRAM, a worst-case current draw of 42uA allows a battery life of
approximately 7142 hours.
Jumper W28 on the CPU/System Controller Board must be installed to enable the battery.
For maximum shelf life, the battery may be isolated from the circuit by removing Jumper
W28. W28’s suitcase jumper can be stored on either of its pins.
CPU/System Controller Boards are shipped with the Lithium backup battery installed. To
remove the backup battery, pry up the Battery Securing Tab on the Coin-cell Battery
Socket and then remove the battery using a pair of tweezers or needle-nose pliers. Install
the replacement battery. Note: This step will not be required until units have been in
operation for an extended period of time (normally many years) as the battery life is
approximately 7142 hours of backup service. (Power is drawn from the battery when the
unit looses power).
NOTE:
If the Lithium backup battery is disconnected or removed when power is off the
contents of SRAM (on the CPU/System Controller Board) will not be retained.
2-38 / Installation & Operation
CI-ControlWave GFC-CL
Once a Lithium backup battery has been removed, don’t install a replacement
battery for at least one minute unless SW2-5 on the CPU/System Controller Board
has been set OFF.
2.4 OPERATIONAL DETAILS
ControlWave GFC-CLs are shipped from the factory with firmware that allows the unit to
be configured in conjunction with an IEC 61131, application program. This section provides
information as follows:
-
Steps required to download the application load and place the unit into ‘Run’ mode.
Steps required to download system firmware.
Operation of the CPU/System Controller Board’s Mode Switch (SW1)
Soft Switch Configurations and Communication Ports
Operational details on ControlWave GFC-CL LEDs and use of the Bristol WINDIAG
program for fault isolation are provided in Chapter 3.
2.4.1 Downloading the Application Load
Any ControlWave GFC-CL must have a configured application load before it can be placed
into operation. For units not shipped with the ‘Standard Load,’ this will require connection of
the ControlWave GFC-CL to a PC running Windows NT (4.0 or higher), Windows 2000 or
Windows XP Professional and equipped with ControlWave Designer software & OpenBSI
software. Configuration of the application load must be performed by an individual familiar
with the various programming tools. The following software user documentation is referenced:
Getting Started with ControlWave Designer Manual - D5085
ControlWave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Web_BSI Manual - D5087
An application load download can be initiated, i.e., from ControlWave Designer, or from the
OpenBSI 1131 Downloader for ControlWave GFC-CL Nodes.
1. Make sure that the CPU/System Controller Board’s Mode Switch (SW1) is set in ‘Local
Mode,’ i.e., SW1-1 set to the OFF position and SW1-2 set to the ON position.
Note:
From the factory, COM1 defaults to 115.2 kbd (RS-232) using the BSAP
Protocol. Don’t connect COM1 to a PC unless the PC’s RS-232 port in question
has been configured for BSAP operation.
2. Once the ControlWave GFC-CL project has been defined, communications and configuration parameters have been set, perform the download according to either
‘ControlWave Designer’ (see D5088 - chapter 11) or ‘The Open BSI 1131 Downloader’
(see D5081 - Chapter 7).
3. After the download has been completed leave the CPU/System Controller Board’s Mode
Switch (SW1) in the ‘Local Mode’ position.
CI-ControlWave GFC-CL
Installation & Operation / 2-39
2.4.2 Upgrading ControlWave GFC-CL Firmware
The ControlWave GFC-CL CPU ships from the factory with system firmware already
installed. If an upgrade of the system firmware is required, use one of the procedures below
to download the new or replacement firmware from the PC.
Upgrade of system firmware via LocalView FLASH Mode requires OpenBSI 5.1 (or newer).
If you have an older version of OpenBSI, FLASH upgrades are to be performed via
HyperTerminal. You will need a binary (*.BIN) system firmware file that is read as follows:
cwi0440.bin (where cwi is the product code and 0440 is the release #). Upgrade of an
unattended ControlWave GFC-CL can be accomplished from a remote PC. This capability
is introduced in Section 2.4.2.3.
2.4.2.1 Using LocalView to Upgrade ControlWave GFC-CL Firmware
NOTE
Your ControlWave GFC-CL must be set to Recovery Mode ENABLE (ON) prior to
performing the FLASH upgrade, then set to Recovery Mode DISABLE (OFF) after
the upgrade. On ControlWave GFC-CLs this is accomplished via the CPU/System
Controller Board’s Mode Switch SW1. Set SW1-3 to the ON position for Recovery
Mode. After setting SW1-3 to the ON position, turn power OFF and then ON again.
A null modem cable (see Figures 2-10A & 2-11A) must be connected to COM1 of the
ControlWave GFC-CL and to any RS-232 port on the associated PC. The PC’s RS-232 port
used for this purpose must be set to run at 115.2 Kbaud. ControlWave GFC-CL CPU
Switch SW1, position, 3 must be set ON.
Start LocalView, Choose FLASH, Enter A Name, Click on [Create]
Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView. The
New View Mode dialog box will appear (see Figure 2-24).
Figure 2-24 - Local View - New View Mode Menu
"Mode"
Choose 'Flash' for the mode.
"Name"
Enter a name for the View Mode File in the "Name" field.
"Location"
If you want to store the View Mode File in a directory other than that shown in the
"Location" field, enter the new location there, or use the [Browse] push button to find
the directory.
2-40 / Installation & Operation
CI-ControlWave GFC-CL
When the "Mode", "Name", and "Location" have been specified, click on the [Create] push
button to activate the Communication Setup Wizard.
Step 1 - Communication Setup
Choose the communication port you want in the What port would you like to use: field.
Click on the [Next] pushbutton to activate the next wizard.
Figure 2-25 - Communication Setup: Step 1 Menu
Step 2 - Flash RTU Setup
In the Flash RTU Setup Wizard, you need not set the RTU type or local address, since these
are unused in this mode. Click on the [Next] push button to activate the Flash Data Setup
Wizard.
Figure 2-26 - Flash RTU Setup Menu
Step 3 - Flash Data Setup
Complete the following fields in the Flash Data Setup Wizard:
CI-ControlWave GFC-CL
Installation & Operation / 2-41
"Please enter the name of the binary file to Flash"
To upgrade system firmware, you must specify the path and name of a binary (*.BIN)
file on your hard disk containing the firmware.
Click on [Finish] to install the specified BIN file in FLASH memory at the RTU.
Once the Flash download has begun, you will NOT be allowed to shut down LocalView,
unless you cancel the download, or it has been completed.
The progress of the Flash download will be displayed in the window. Any mismatch in file
versions, or if the type of .BIN file does not match the type of RTU, the download will be
aborted.
Figure 2-27 - Flash Data Setup Menu (Note: Substitute \cwi0420.bin for cwe04...)
Figure 2-28 - Local View Downloading System Firmware Menu
2-42 / Installation & Operation
CI-ControlWave GFC-CL
Once the download has completed, set SW1-3 to the OFF position and then turn power OFF
and then ON again.
2.4.2.2 Using HyperTerminal to Upgrade ControlWave GFC-CL Firmware
A null modem cable (see Figures 2-10A & 2-11A) must be connected to COM1 of the
ControlWave GFC-CL and to any RS-232 port on the associated PC. The PC’s RS-232 port
used for this purpose must be set to run at 115.2 Kbaud. ControlWave GFC-CL
CPU/System Controller Board Switch SW1, position, 3 must be set to the ON position.
1. If not already running, apply power to the associated PC.
2. Start the HyperTerminal program on the PC. Note: HyperTerminal is a Windows 95 (or
newer) application utility program. If using HyperTerminal for the first time, set the
communications properties (for the PC Port being utilized) 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.
3. Set the CPU/System Controller Board’s Mode Switch (SW1) for ‘Recovery Mode,’ i.e., set
CPU/System Controller Board Switch SW1-3 to the ON position.
4. Apply power to the ControlWave GFC-CL. The resident BIOS will initialize and test
the hardware, this process is referred to as POST (Power On Self Test).
Unless there is a problem status code 10 (Status LED #5 ON) will be posted to the
CPU/System Controller Board’s Status LEDs. Detection of a fault during POST will be
posted on the Status LEDs. When the Power On Self Test has completed, a system status
code will be posted to the Status LEDs (see Table 2-13 and Figure 2-33).
From the HyperTerminal Recovery Mode menu (Figure 2-29), press the ‘F’ key to enter
FLASH download. A message will be displayed warning that the FLASH is about to be
erased; press the ‘Y’ key at the prompt. The screen will display dots as the flash devices are
being erased; this could take a few minutes.
Figure 2-29 - HyperTerminal Recovery Mode Menu
CI-ControlWave GFC-CL
Installation & Operation / 2-43
5. When the FLASH is ready for download the letter C will be displayed on the screen. In
the HyperTerminal command bar click on Transfer and then Send File (see Figure 230). In the Send File Dialog Box (see Figure 2-31), select “1KXmodem” for the protocol,
enter the filename of the appropriate .bin file in the format “CWIxxxxx.bin” (where
xxxxx varies from release to release). Click on the Send button to start the download
(see Figure 2-31). When the HyperTerminal Recovery Mode Menu of Figure 2-29
appears, the download has completed.
Figure 2-30 - HyperTerminal FLASH Download Menu
(Ready to Download) - (Transfer/Send File Selected)
Figure 2-31 – HyperTerminal Flash Download (Send File Dialog Box)
6. Close the HyperTerminal program. The null modem cable connected between the
ControlWave GFC-CL and the PC can be removed if desired.
7. Set the CPU/System Controller Board’s Mode Switch (SW1) for ‘Local Mode,’ i.e., set SW13 OFF. Then switch power OFF/ON.
Once the ControlWave GFC-CL is running its application load, status codes are posted to the
six Status LEDs on the CPU/System Controller Board and to the LCD Display Assembly.
These Status LED (Hex) Codes are listed in Table 2-13 (see Figure 2-33).
2-44 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-32 - HyperTerminal FLASH Download (Download in Process)
(Note: Substitute \cwi0420.bin for cwe04...)
Figure 2-33 – CPU/System Controller Bd. Status LED Hexi-decimal Codes
(See Table 2-13 for Definitions)
CI-ControlWave GFC-CL
Installation & Operation / 2-45
Table 2-13 - System Status Codes on LCD Display & LEDs on CPU/System Cntrl. Bd.
LED
LED
LED
LED
LED
6
5
4
3
2
CR40
CR39
CR38
CR37
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
1
0
1
1
0
0
1
1
1
0
1
1
1
0
1
1
1
1
1
1
1
1
* = Flashed at startup
LED
CR36
CR35
1
Status
In Hex
LCD
Disp.
Indication
Definition
0
0
1
0
0
1
0
0
1
1
0
1
0
0
0
0
1
1
1
0
1
1
0
1
1
0
1
0
1
0
0
0
0
0
0
1
0
1
00
01
03
04
05
07
08
09
0A
0B
10
12
20
28
30
38
3B
3E
3F
Blank
DIAG
R DIAG
FWXSUM
DEVERR
FLASH
FACT
BATT
STRTUP
INIT
RECOV
RAMERR
STOP
HALT
NO APP
BREAKP
POWERD
UPDUMP
NOTRUN
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)
2.4.2.3 Remote Upgrade of ControlWave GFC-CL Firmware
It is possible to download system firmware into an unattended remote ControlWave GFCCL. This function can only be accomplished if CPU Board Switch SW2-6 (associated with
the unit in question) is set in the ON position (factory default). The procedure for
performing a remote download of system firmware is discussed in Appendix J of the Open
BSI Utilities Manual (document D5081). Note: Remote upgrade of ControlWave
GFC_CL Firmware requires Boot PROM version 4.7 or higher and System PROM
version 4.7 or higher.
2.4.3 Operation of the Mode Switch
The CPU/System Controller Board’s Mode Switch (SW1) is a four position DIP-Switch;
functions are listed in Table 2-14.
Table 2-14 - CPU/System Controller Bd. Mode Switch SW1 Assignments
Recovery Mode/Local Mode Control
SWITCH
Function
Setting
Both ON or OFF = Recovery Mode
SW1-1/2
Recovery/Local Mode *
SW1 OFF & SW2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
SW1-3
Force Recovery Mode *
OFF = Recovery Mode disabled
SW1-4
Not Used
N/A
* = Note: Only the Switch SW1 settings listed in this table, have been tested.
Recovery Mode: Recovery Mode is used for either a firmware upgrade (see Section 2.4.2) or
a core updump (see Section 3.6).
2-46 / Installation & Operation
CI-ControlWave GFC-CL
Local Mode: Local Mode should be selected for normal running operations.
2.4.4 Soft Switch Configuration and Communication Ports
Firmware defined soft switches that control many default settings for various system
operating parameters such as BSAP Local Address, EBSAP Group Number, three (3) communication port parameters, etc., can be viewed and, if desired, changed via the Flash
Configuration Utility, which is accessible from LocalView or NetView. When connecting the
ControlWave GFC-CL to the PC (local or network) for the first time you should be aware
of the communication port default parameter settings provided below (see Figures 2-8
through 2-13). Note: Communication port factory defaults can be enabled anytime by setting
CPU Board Switch SW2-3 to the OFF position. CPU Switch SW2-8 must be set OFF to run
the WINDIAG program.
COM1: From the factory, RS-232 Communications Port COM1 defaults to 115.2 kbd (RS232) using the BSAP Protocol. Note: By setting CPU Switch SW2-8 OFF, the boot
project will be prevented from running and the unit will be placed into diagnostic
mode. To test COM1 using the WINDIAG program, it must not otherwise be in
use. Connection to a PC requires the use of an RS-232 “Null Modem” cable (see
Figure 2-12).
COM2: From the factory, RS-232 Communications Port COM2 on the CPU Board defaults
to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol
operation. To test COM2 using the WINDIAG program, it must not otherwise be in
use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program.
COM3: RS-485 Communications Port COM3 on the CPU Board defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM3 using the WINDIAG program, it must not otherwise be in use Note: CPU
Switch SW2-8 must be set OFF to run the WINDIAG program. In lieu of the use of
an RS-232 Port, an RS-485 cable (see Tables 2-3 & 2-5) can be connected between
COM3 and the PC’s RS-485 Port.
2.4.5 Optional Display/Keypad Assemblies
Two Display/Keypad Assemblies are offered; one with a dual-button Keypad (see Figure 234) and one with a 25-button Keypad (see Figure 2-35). Both Display/Keypad Assemblies
utilize identical 4 x 20 LCD Displays. Each Display/Keypad Assembly employs a unique
microcontroller based Display/Keypad Interface Circuitry (situated on the CPU/System
Controller Board) that drive the 4 x 20 LCD Display and interfaces the Keypad. Interface to
the Display Assembly is accomplished via a 16-pin connector (Plug on CPU/System
Controller Board and Jack on rear of Display Ass’y.). Interface between the CPU/System
Controller Board and the applicable keypad is accomplished via a ribbon cable that plugs
into CPU/System Controller Board Connector Jack J2 (in the case of the 25-button Keypad)
or Connector Jack J14 (in the case of the Dual-button Keypad). A potentiometer (R164)
used to set the contrast of the LCD Display is provided on the CPU/System Controller
Board.
Figure 2-36 provides mounting hardware information for the Dual-button Display/Keypad
Assembly. Operation of the Dual-button Display/Keypad Assembly is discussed in section
2.4.5.1.
CI-ControlWave GFC-CL
Installation & Operation / 2-47
Figure 2-37 provides mounting hardware information for the 25-button Display/Keypad
Assembly. Information on configuring the ‘Display Function Block’ (required to configure
the Display associated with the 25-button Display/Keypad Assembly) is provided in
ControlWave Designer’s On-Line Help.
Note: Operation of the 25-button Display/Keypad Assembly is discussed in Appendix E.
Figure 2-34 - ControlWave GFC-CL
(with Dual-Button Display/Keypad Assembly)
2-48 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-35 - ControlWave GFC-CL
(with 25-button Display/Keypad Assembly)
CI-ControlWave GFC-CL
Installation & Operation / 2-49
Figure 2-36 - Dual-button Display/Keypad Assembly Installation Drawing
2-50 / Installation & Operation
CI-ControlWave GFC-CL
Figure 2-37 - 25-Button Display/Keypad Assembly Installation Drawing
CI-ControlWave GFC-CL
Installation & Operation / 2-51
2.4.5.1 Operation of the Dual-button Display/Keypad Assembly
The Display will have a timeout of 20 minutes. If there has been no keypad activity for this
time the display will “logout,” i.e., the display will be turned off and scrolling stopped until
a key press occurs. When a key press occurs after a timeout the display will return to the
opening screen.
If a shorter timeout of the display is needed for power savings, another timeout may be
implemented. The processor connected to the display will control the timeout. When the
timeout occurs the display will be blanked, but communications between the ControlWave
GFC-CL CPU and display processor will still occur. The display processor will ignore
posting the messages to the screen when in the low power mode. When a key is pressed the
display processor will return to displaying information to the display.
Displays are organized into screens as follows:
Opening Screen:
User defined strings
List Selection Screen:
List Name
List Number
<Blank Line>
<Blank Line>
The List Selection screen is entered from the main opening screen by pressing the right
arrow. Once here the operator can select which list is to be viewed. The operator can
traverse though different list numbers by pressing the down arrow key. When the list to be
scrolled is shown on the display, pressing the right arrow key will bring the operator to the
Display Element screen.
Display Element Screen: <Blank Line>
<Blank Line>
Variable Name
Variable Name
The Display Element screen is entered from the list selection screen by pressing the right
arrow. Once here the operator can view the variables in the list. Once entered the first
element of the list is displayed and then next element will be displayed after the scroll
timeout occurs. The scrolling will continue displaying the next element in the list and then
wrapping around to the beginning of the list. The down arrow key will toggle the display
through hold and scroll mode. Pressing the right arrow key will bring the operator to the
list selection screen.
Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode.
Automatic Mode
In Automatic mode a set of screens (based on the application load) are displayed. The
application programmer provides strings for the opening screen. From there the firmware is
responsible for displaying the screens and responding to key presses. Screens are fixed and
start off with an opening screen, which displays user information passed into the function
block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled
has been selected, the user can scroll through the list by pressing the down arrow key. List
elements will be displayed automatically, scrolling at a predetermined rate (determined by
2-52 / Installation & Operation
CI-ControlWave GFC-CL
iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing
the right arrow key again will cause the list to start scrolling again.
The essence of Automatic mode is that the user can supply inputs into the function that will
determine which list can be displayed, but cannot change the menu or display. The user is
allowed to select a list and to start/stop scrolling.
Manual Mode
In Manual Mode the programmer is responsible for creating each screen and displaying the
next desired screen, based on key inputs. The programmer has access to all lines of the
display and can provide any string that he/she desires to display. Special formats that must
be adhered to that allow the programmer to display what they want on the screen are
provided in the description of iaScrnSruct in the ACCOL 3 Display function block within
ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode
does not support reading Keypad keypresses. Note: Manual Mode operation requires
ControlWave Firmware 4.50 or newer.
CI-ControlWave GFC-CL
Installation & Operation / 2-53
BLANK PAGE
Section 3
SERVICE
3.1 SERVICE INTRODUCTION
This section provides general, diagnostic and test information for the ControlWave GFCCL.
The service procedures described herein will require the following equipment:
1. PC with null modem interface cable & Bristol’s WINDIAG Software
2. Loop-back plugs/wires (for RS-232 and RS-485) (see Figure 3-9)
The following test equipment can be used to test the Power Supply/Sequencer Module:
1. DMM (Digital Multimeter): 5-1/2 digit resolution
2. Variable DC Supply: Variable to 30Vdc @ 2.5A (with vernier adjustment)
When ControlWave GFC-CL gas flow computers are serviced on site, it is recommended
that any associated processes be closed down or placed under manual control. This precaution will prevent any processes from accidentally running out of control when tests are conducted.
Warning
Harmful electrical potentials may still be present at the field wiring terminals
even though the ControlWave GFC-CL’s power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or perform any
wiring operations until all the associated supply sources are turned off and/or
disconnected.
Warning
Always turn off the any external supply sources used for externally powered
I/O circuits, before changing any printed circuit boards.
3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES
This section provides information on accessing ControlWave GFC-CL components for testing, as well as removal/replacement procedures.
3.2.1 Accessing Components For Testing
Testing and replacement of ControlWave GFC-CL components should only be performed
by technically qualified persons. Familiarity with the disassembly and test procedures described in this manual are required before starting. Any damage to the ControlWave GFCCL resulting from improper handling or incorrect service procedures will not be covered
under the product warranty agreement. If these procedures cannot be performed properly,
the unit should be returned to Bristol (with prior authorization from Bristol Inc.) for factory
evaluation and repairs.
CI-ControlWave GFC-CL
Service / 3-1
3.2.2 Removal/Replacement of the CPU/System Controller Board
1. Open the Instrument Front Cover.
2. If the ControlWave GFC-CL is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the Battery
Charger & I/O Board Assembly at TB1, TB2 and TB3.
3. Disconnect all CPU/System Controller Board communication cables, making sure
they are identified so they can be returned to their assigned Comm. Ports.
4. Disconnect the I/O Bus cable from connector J5.
5. Disconnect the Power cable from connector J1.
6. Disconnect the Keypad cable from connector J2 or the 2-Key Pushbutton cable from
connector J14.
7. While securing the CPU/System Controller Board, remove the six screws that secure
it to the six mounting standoffs. Carefully slide the Keypad/2-Key Pushbutton cable
through the board’s slotted cutout area and remove the CPU/System Controller
Board assembly from the Instrument Front Cover.
8. If the CPU/System Controller Board is to be replaced, remove any optional piggyback mounted printed circuit boards.
9. To replace a CPU/System Controller Board, power must be off. Install the appropriate optional hardware and the LCD Display/Keypad hardware. Open the Instrument
Front Cover. Carefully slide the Keypad/2-Key Pushbutton cable through the board’s
slotted cutout area (rear to front). Align the CPU/System Controller Board with its
six mounting standoffs and install the six mounting screws.
10. Replace all cables removed in steps 3 through 6. Apply power and test the unit.
3.2.3 Removal/Replacement of a Primary Battery System
1. If the ControlWave GFC-CL is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the Battery
Charger & I/O Board Assembly at TB1, TB2 and TB3.
2. Loosen the four screws that secure the Radio/Modem Mounting Bracket to the Battery Mounting Bracket.
3. Slide Radio/Modem Mounting Bracket toward the top of the unit and remove it. If a
Radio or Modem is installed, carefully set the Radio/Modem Mounting Bracket to
one side.
4. Carefully remove the Primary Battery System (with cables attached).
5. To replace the Primary Battery System, follow steps 4 through 2 in reverse order.
Replace Power cables (TB1, TB2 and TB3) and test the unit. Note: Make sure the
Primary Battery is fully charged before installing it.
3.2.4 Removal/Replacement of the Battery Charger & I/O Board
1. Open the Instrument Front Cover.
2. If the ControlWave GFC-CL is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the Battery
Charger & I/O Board Assembly at TB1, TB2 and TB3.
3. Unplug all Card Edge field wiring Terminal Blocks in use, i.e., TB4 through TB10.
4. Remove the Primary Battery System (see Section 3.2.3)
5. Slide the Battery Charger & I/O Board forward until you can remove the large screw
that secures the System Ground Cable to it. Remove the large System Ground Cable
Screw.
6. Continue to slide the Battery Charger & I/O Board forward until the CPU/System
Controller Interface cable can be removed from connector P3 on its rear (left side).
3-2 / Service
CI-ControlWave GFC-CL
7. Unplug the MVT Interface cable from P2.
8. Remove the Battery Charger & I/O Board and unplug the System Power cable from
connector P1.
9. To replace the Battery Charger & I/O Board, follow steps 8 through 2 in reverse order.
10. Replace Power cables (TB1, TB2 and TB3) and test the unit.
3.2.5 Removal/Replacement of an External Radio/Spread Spectrum Modem
1. If the ControlWave GFC-CL is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the Battery
Charger & I/O Board Assembly at TB1, TB2 and TB3.
2. Disconnect (unplug) all connectors (power and interface) from the Radio/Modem.
3. Disconnect the antenna cable from the Radio/Modem.
3. Loosen the four screws that secure the Radio/Modem Mounting Bracket to the Battery Mounting Bracket.
4. Slide Radio/Modem Mounting Bracket toward the top of the unit and remove it with
the Radio or Modem installed.
5. Remove the mounting screws from the bottom (inside) of the Radio/Modem Mounting Bracket and remove the Radio/Modem.
6. Replace the Radio/Modem in the reverse order from which it was removed.
7. Replace Power cables (TB1, TB2 and TB3) and test the unit.
3.2.6 Removal/Replacement of the MVT or GPT Transducer
1. If the ControlWave GFC-CL is running, place any critical control processes under
manual control.
2. Shut down the unit by disconnecting power to the Battery Charger & I/O Board Assembly at TB1, TB2 and TB3. Remove the ControlWave GFC-CL from its installation site and take it to a depot repair area that supports proper ESD control.
3. Disconnect the MVT/GPT Interface Cable from the Battery Charger & I/O Board Assembly.
4. Remove the large Mounting Collar (Nut) from the neck of the MVT/GPT; then unscrew the four screws (from within the enclosure) that secure the MVT to the GPT
Mounting Plate to the bottom of the enclosure and remove the MVT/GPT Transducer.
5. To install a replacement MVT’GPT, follow steps 4 through 1 in reverse order. Make
sure the MVT/GPT O-Ring Seal is in place and apply anti-sieze compound as required. When installing a MVT into the bottom of the enclosure, orient the Flange
for the desired High and Low settings.
3.3 TROUBLESHOOTING TIPS
3.3.1 Battery Charger & I/O Board Voltage Checks
One bulk power source or an internal battery (Primary Power System) can be connected to
the Battery Charger & I/O Board Assembly. Connector TB2 provides 2 input terminal connections for bulk power (see Figure 3-3):
TB2-1 = (+VIN) (+4.5/4.9V to +8Vdc for +6V supply) (+9.6/10.3V to +16Vdc for +12V supply)
TB2-2 = Chassis Ground - CHASSIS
CI-ControlWave GFC-CL
Service / 3-3
Bulk supply voltages can be checked at TB2 using a voltmeter or multimeter. Battery
Charger & I/O Board Assemblies are factory configured for use with a nominal 6Vdc or
12Vdc bulk power supply. The maximum and minimum input power switch-points can be
tested with the use of a Variable dc Power Supply connected between TB2-1 (+) and TB2-2
(-). By increasing the input voltage (starting at less than +4.5Vdc or less than +9.6Vdc) for
+6V or +12V units respectively, you can determine the point at which the unit will turn on,
i.e., the point at which the green PWRGOOD LED on the CPU/System Controller Board
comes ON (Vt+). By decreasing the input voltage (starting at 8Vdc or +16Vdc), you can determine the point at which the unit turns off, i.e., the point at which the PWRGOOD LED
on the CPU/System Controller Board goes OFF (Vt-). If the value of the Primary Power System (battery) or bulk power supply’s +6Vdc or +12Vdc output approaches the value of Vt+
or Vt- it should be replaced by a battery/power supply with the correct +6V or +12V output.
3.3.2 LED Checks
ControlWave GFC-CL CPU/System Controller Boards contain light emitting diodes
(LEDs) that provide operational and diagnostic functions. With the exception of the
Ethernet Port transmit and receive LEDs (green and yellow respectively) and the Power
Good LED (CR13) which is green all LEDs are red.
A brief synopsis of the individual CPU/System Controller Board LEDs (CR#) is provided as
follows:
CR13
CR21
CR22
CR35
CR36
CR37
CR38
CR39
CR40
CR41
CR42
CR43
CR44
CR45
CR46
CR47
CR48
Power Good
DCD ON
DTR Active
Status LED 1 (see Table 3-1 and Figures 3-1 & 3-2)
Status LED 2 (see Table 3-1 and Figures 3-1 & 3-2)
Status LED 3 (see Table 3-1 and Figures 3-1 & 3-2)
Status LED 4 (see Table 3-1 and Figures 3-1 & 3-2)
Status LED 5 (see Table 3-1 and Figures 3-1 & 3-3)
Status LED 6 (see Table 3-1 and Figures 3-1 & 3-2)
Watchdog LED - ON = Watchdog Condition - OFF = Normal Operation
Idle LED - ON = Idle
Comm. Port 3 - TX - ON = Transmit Activity
Comm. Port 3 - RX - ON = Transmit Activity
Comm. Port 1 - TX - ON = Transmit Activity
Comm. Port 1 - RX - ON = Transmit Activity
Comm. Port 2 - TX - ON = Transmit Activity
Comm. Port 2 - RX - ON = Transmit Activity
3-4 / Service
CI-ControlWave GFC-CL
Figure 3-1 - CPU/System Controller Board Component Identification Diagram
CI-ControlWave GFC-CL
Service / 3-5
Table 3-1 - System Status Codes LCD Display & LEDs on CPU/System Cntrl. Bd.
LED
LED
LED
LED
LED
LED
6
5
4
3
2
CR36
1
CR35
Status
In
Hex
LCD
Disp.
Indication
Definition
0
0
1
0
0
1
0
0
1
1
0
1
0
0
0
0
1
1
1
0
1
1
0
1
1
0
1
0
1
0
0
0
0
0
0
1
0
1
00
01
03
04
05
07
08
09
0A
0B
10
12
20
28
30
38
3B
3E
3F
Blank
DIAG
R DIAG
FWXSUM
DEVERR
FLASH
FACT
BATT
STRTUP
INIT
RECOV
RAMERR
STOP
HALT
NO APP
BREAKP
POWERD
UPDUMP
NOTRUN
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 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)
CR40
CR39
CR38
CR37
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
1
0
1
1
0
0
1
1
1
0
1
1
1
0
1
1
1
1
1
1
1
1
* = Flashed at startup
Figure 3-2 - CPU/System Controller Board Status LED Hexi-decimal Codes
(See Table 3-1 for Definitions)
3-6 / Service
CI-ControlWave GFC-CL
3.3.3 Wiring/Signal Checks
Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check wiring for continuity, shorts & opens. Check I/O signals at their respective Terminal Blocks
(see Figure 3-3).
Figure 3-3 - Battery Charger & I/O Board Field Wiring Diagram
(Note: See Figure 2-7 for Battery Charger & I/O Board Component Identification)
CI-ControlWave GFC-CL
Service / 3-7
3.4 GENERAL SERVICE NOTES
Certain questions or situations frequently arise when servicing the ControlWave GFC-CL.
Some items of interest are provided in Sections 3.4.1 through 3.4.4.
3.4.1 Extent of Field Repairs
Field repairs to a ControlWave GFC-CL are strictly limited to the replacement of complete modules. Component replacement on a ControlWave GFC-CL Module constitutes
tampering and will violate the warranty. Defective ControlWave GFC-CL components
(printed circuit boards, LCD Displays, Multivariable Transducer (MVT, etc.) must be returned to Bristol for authorized service.
3.4.2 Disconnecting RAM Battery
The ControlWave GFC-CL’s Lithium RAM battery cannot be replaced while power is on.
Once the RAM battery has been replaced, the unit will still execute its FLASH-based application load (Boot Project) upon power-up, but all of the current process data will have been
lost. Upon power-up, the unit will act as though it had just been booted and it will revert
back to the initial values specified in its application load. The battery may be disabled by
removing the CPU/System Controller Board’s Battery Backup Board Jumper, W28.
3.4.3 Maintaining Backup Files
It is essential to maintain a backup disk of each application load file to guard against an
accidental loss of process configuration data. Without a backup record, it will be necessary
to reconfigure the entire application load; that can be a very time consuming procedure.
Always play it safe and keep backup copies of your operating system loads. A copy of the
application load can be loaded into ControlWave GFC-CL FLASH memory and/or saved to
a PC’s Hard Drive as a ZIP file.
3.5 WINDIAG DIAGNOSTICS
Bristol Babcock’s WINDIAG program provides menu driven diagnostics that have
been designed to assist a technician or Process Engineer in troubleshooting the
various ControlWave GFC-CL circuits. For more detailed descriptions of ControlWave GFC-CL Windows Diagnostics than those provided herein see Document
D4041A – Chapters 1 & 7C.
Bristol’s WINDIAG Software is a diagnostic tool used for testing ControlWave GFC-CL
electronics including, I/O circuitry, CPU memory, communications ports, etc., for proper
performance. The ControlWave GFC-CL must be communicating with a PC equipped
with the WINDIAG program. CPU/System Controller Board configuration switch SW2-8
must be set to the OFF (Closed) position to enable diagnostics. Communication between the
ControlWave GFC-CL (with/without application loaded) and the PC can be made via a Local or Network Port with the following restrictions:
•
CPU/System Controller Board Switch SW2-8 must be OFF to run the WINDIAG program. Setting SW2-8 OFF will prevent the ‘Boot Project’ from running and will place the
unit into diagnostic mode.
•
Any ControlWave GFC-CL communication port can be connected to the PC (Process
Engineer’s Interface) provided their port speeds and configuration match, e.g., baud
3-8 / Service
CI-ControlWave GFC-CL
rate, parity, stop bits, protocol, etc. This can be accomplished via user defined Soft
Switches.
•
Setting CPU/System Controller Board Switch SW2-3 OFF will force ports COM2 and
COM3 to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol
operation.
•
Communication port COM1 is only forced to 9600 bps operation when CPU/System Controller Board Switches SW2-3 and SW2-8 have both been set OFF. COM1 can also be set
to 9600 bps operation via user defined Soft Switches.
•
Setting CPU/System Controller Board Switches SW2-3 and SW2-8 OFF prevents the
‘Boot Project’ from running, places the unit into diagnostic mode and forces communication ports COM1, COM2 and COM3 to operate at 9600 baud.
COM1: From the factory, RS-232 Communications Port COM1 defaults to 115.2 kbd (RS232) using the BSAP Protocol. Note: Port COM1 will be configured for RS-232 operation (at 9600 baud) by setting CPU/System Controller Board Switches SW2-3
and SW2-8 OFF. This will prevent the boot project from running and places the
unit into diagnostic mode. CPU/System Controller Board Switch SW2-8 must be
set OFF to run the WINDIAG program. Connection to a PC requires the use of an
RS-232 “Null Modem” cable (see Figure 2-11 or 2-12).
Communication Port COM1 has three (3) physical locations. Only one of these
connectors can be connected to a PC or other devise. Com1 connectors are identified as follows:
A 9-pin male D-type connecter (J19) on the CPU/System Controller Board.
An 8-position Terminal Block (TB1) on the CPU/System Controller Board. From
the factory, a wiring harness connects TB1 to the Local Port (situated on the bottom of the Instrument Cover.
Either a 9-pin male D-type connecter or a 3-pin circular connector situated on the
bottom of the Instrument Cover.
COM2: From the factory, RS-232/RS-485 Communications Port COM2 (8-position Terminal Block TB2) on the CPU/System Controller Board defaults to 9600 baud, 8-bits,
no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation (RS-232).
Note: COM2 is assigned to either an optional Radio/Spread Spectrum Modem or a 56K PSTN Modem (mounted piggy-back on the CPU/System Controller Board). If one of these options is present, connector TB2 should
not be used. In lieu of one of the piggy-back mounted communication options, an external Radio/Spread Spectrum Modem may be mounted inside
the unit on the Radio Mounting Bracket. An external Radio/Spread Spectrum Modem is interfaced to COM2 via connector TB2 on the CPU/System
Controller Board.
COM3: RS-485 Communications Port COM3 on the CPU/System Controller Board (5position Terminal Block TB3) defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ControlWave Designer protocol operation. In lieu of the use of an RS-232
CI-ControlWave GFC-CL
Service / 3-9
Port, an RS-485 cable (see Tables 2-3 & 2-5) can be connected between COM3 and
a PC’s RS-485 Port.
To use the WINDIAG program place any critical process (associated with the ControlWave GFC-CL unit in question) under manual control. WINDIAG cannot be run while the
ControlWave GFC-CL application is running. Set the CPU/System Controller Board Switch
SW2-8 to the OFF position. Perform steps 1 through 6 below.
1. Start the OpenBSI NetView Program. A menu similar to Figure 3-4 will appear.
Figure 3-4 - Netview Startup Menu - Example with Multiple Networks
2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI Tools,
then select Utilities Programs and then select Diagnostics.
3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 3-5 will appear.
4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG
will perform the diagnostics and display pass/fail results.
5. After all diagnostic testing has been performed, exit the WINDIAG program and then
exit the Netview Program if there aren’t any other ControlWave GFC-CL units to be
tested.
3-10 / Service
CI-ControlWave GFC-CL
When you close the Netview program you will be prompted as to whether or not you
want to close the OpenBSI program; select Yes.
6. Set ControlWave GFC-CL CPU/System Controller Board Switch SW2-8 to the ON
(Open) position. The ControlWave GFC-CL should resume normal operation.
Figure 3-5 - WINDIAG Main Diagnostics Menu
3.5.1 Diagnostics Using WINDIAG
ControlWave GFC-CL electronics can be tested using the WINDIAG program. From
WINDIAG’s Main Diagnostics Menu (see Figure 3-5) the following diagnostic tests can be
performed:
CPU & Peripherals Diagnostic:
Checks the CPU/System Controller Board [except for
RAM & PROM (FLASH)].
PROM/RAM Diagnostic:
Checks the CPU/System Controller Board’s RAM and
PROM (FLASH) hardware.
Communications Diagnostic:
Checks Comm. Ports 1, 2 and 3 - The External loop-back
tests require the use of a loop-back plug.
Analog Output Diagnostic:
Checks AOs on the Battery Charger & I/O Board.
Analog Input Diagnostic:
Checks AIs on the Battery Charger & I/O Board.
Discrete I/O Diagnostic:
Checks DIs or DOs on the Battery Charger & I/O Bd.
High Speed Counter Diagnostic:
Checks HSCs on the Battery Charger & I/O Board.
Keyboard & Display Diagnostics Checks Keyboard/Keypad & Display hardware
3.5.1.1 Communications Diagnostic Port Loop-back Test
CI-ControlWave GFC-CL
Service / 3-11
WINDIAG’s Communications Diagnostic Menu (see Figure 3-8) provides for selection of the
communication port to be tested. Depending on the type of network (RS-232 or RS-485) and
the port in question, a special loop-back plug is required as follows:
Port 1 - RS-232 use a 9-pin female D-type loop-back plug or loop-back wires (see Fig. 3-6).
Port 2 - RS-232 use loop-back wires (see Figure 3-6).
Port 2 - RS-485 use loop-back wires (see Figure 3-7)
Port 3 - RS-485 use loop-back wires (see Figure 3-7).
This group of tests verifies the correct operation of the Communication Interface. COM1,
COM2 and COM3 can be tested with this diagnostic. The ControlWave GFC-CL communication port that is connected to the PC (local or network and used for running these
tests) can’t be tested until diagnostics has been established via one of the other ports, i.e., to
test all ControlWave GFC-CL communication ports (via WINDIAG), communications with
the PC will have to be established twice (each time via a different port). It should be noted
that the ControlWave GFC-CL communication port that is connected to the PC (RS-232,
RS-485 or Ethernet) must be functional for WINDIAG to run the Communications Diagnostics
3.5.1.2 Serial Comm. Port External Loop-back Test Procedure
Connect an external loop-back plug or loop-back wires to the Communications Port to be
tested (see Figures 3-6 and 3-7).
DCD
1
RXD
4 = DTR
TXD
8 = CTS
DTR
3 = TXD
7 = RTS
2 = RXD
RTS
1 = DCD
CTS
TB1/TB2
COM1/COM2
Shown with RS-232
Loop-back Wires
COM1
RS-232
Loop-back Plug
Figure 3-6 - RS-232 Loop-back Plug/Wires
RXD+
1
TXD+
RXD+
1
RXD+
RXD-
RXD-
RXD-
TXD-
TXD-
TXD-
TXD+
TXD+
TB2
COM2
Shown with RS-485
Loop-back Wires
TB3
COM3
RS-485
Loop-back Wires
1
TB1 (Isolated RS-485 Bd.)
COM3
RS-485
Loop-back Wires
Figure 3-7 - RS-485 Loop-back Wires (Note TB1 N/A)
3-12 / Service
CI-ControlWave GFC-CL
Figure 3-8 - WINDIAG’s Communications Diagnostic Menu
1. Type "1," "2," "3," or "4" for the port to test.
2. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5.
3. Click on RUN button next to External loop-back.
Test responses:
a) Success - All sections of test passed
b) Failure - TXD RXD Failure
- CTS RTS Failure
Execution time < 5 sec.
3.6 CORE UPDUMP
In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for
evaluation by Bristol Babcock Inc. (BBI) engineers. This upload is referred to as a ‘Core
CI-ControlWave GFC-CL
Service / 3-13
Updump.’ A Core Updump may be required if the ControlWave GFC-CL electronic flow
meter repeatedly enters a ‘Watchdog State’ thus ill effecting system operation. A Watchdog
State is entered when the system crashes, i.e., a CPU timeout occurs due to improper
software operation, a firmware glitch, etc. In some cases the Watchdog State may reoccur
but may not be logically reproduced.
‘Crash Blocks’ (a function of firmware provided for watchdog troubleshooting) are stored in
CPU RAM. The user can view and save the ‘Crash Blocks’ by viewing the Crash Block
Statistic Web Page (see Chapter 4 of the Open BSI Technician’s Toolkit - D5087). Crash
Block files should be forwarded to Bristol for evaluation. If additional information is
required to evaluate the condition, a Core Updump may be requested by Bristol. Once the
file generated by the Core Updump has been forwarded to Bristol, it will be evaluated and
the results will be provided to the user.
Follow the five steps below to perform a Core Updump.
1. Set CPU/System Controller Board Switch SW2-1 OFF (Disable Watchdog Timer). If
Switch SW2-4 is ON, set it to OFF (Enable Core Updump). Note: The factory default
setting for SW2-4 is OFF.
2. Wait for the error condition (typically 3F on SCM Status LEDs).
3. Connect ControlWave GFC-CL Comm. Port 1 to a PC using a Null Modem Cable (see
Figures 2-11 and 2-12).
4. Set CPU/System Controller Board Switch (SW1- Recovery) so that SW1-1 and SW1-2
are both in either the UP (ON) position or the DOWN (OFF) position.
5. Start the PC’s HyperTerminal Program (at 115.2kbaud) and generate a file using the
1KX-Modem protocol. Save the resulting Core Updump in a file to be forwarded to BBI
for evaluation.
When the Core Updump has been completed, set the CPU/System Controller Board’s
Recovery Switch as follows: SW1-1 is in the DOWN position & SW1-2 is in the UP position.
Enable the Watchdog Timer by setting CPU/System Controller Board’ SW2-1 ON.
3.7 CALIBRATION CHECKS
Calibration of the MVT/GPT and the RTD are performed using OpenBSI’s TechView
Program (see document # D5131 – TechView User’s Guide).
3-14 / Service
CI-ControlWave GFC-CL
Section 4
SPECIFICATIONS
4.1 CPU, MEMORY & PROGRAM INTERFACE
Processor:
Sharp’s LH7A400 32-bit
ARM9TDMI RISC Core
System-on-Chip
with
32-bit
Memory:
8 Mbytes of simultaneous read/write FLASH
2 Mbyte of on-board SRAM
512 Kbytes FLASH Boot/Downloader
Real Time Clock:
A Semtech SH3000 support IC provides a full BCD clock
calendar with programmable periodic/wakeup interrupt and
a programmable clock generator with adjustable spectrum
spreading.
Connectors:
(see Table 4-1 and referenced Tables)
Table 4-1 - CPU/System Controller Board Connector Summary
Ref.
P2
P3
J1
J2
J5
J6
J7
J8
J9
J10
J11
J12
J13
J14
J15
J18
J19
J21
TB1
TB2
TB3
# Pins
16-pin
76-pin
3-Pin
10-Pin
26-pin
20-pin
4-pin
4-pin
6-pin
10-pin
10-pin
8-pin
20-pin
3-pin
10-pin
10-pin
9-pin
10-pin
8-pin
8-pin
5-pin
Function
Display Intf.
Factory Debug
Power
25-Button Keypad Intf.
IOBUS
Emulator Connector
Modem connector
Modem connector
Modem/Phone Line connector
Modem connector
Modem connector
Modem Signal Debug
Radio Daughter Board
2-Key Pushbutton
PLD JTAG Header
PLD JTAG Header
9-pin Male D-type (COM1 - RS-232)
Isolated RS-485 Daughter Board
Term. Block (COM1 - RS-232)
Term. Block (COM2 - RS-232/485)
Term. Block (COM3 - RS-485)
Notes
Reverse Side of Board
Not shown or user accessible
Top Edge - see Figure 1-5
Intf. to Battery Charger & I/O Bd.
Factory Use
Piggy-back Modem
Piggy-back Modem
Tip & Ring used (Bottom Edge)
Piggy-back Modem
Piggy-back Modem
Not user accessible
Not user accessible
Not user accessible
Top Edge
N/A
see Table 2-x or 4-x
see Table 2-x or 4-x
see Table 2-x or 4-x
4.2 COMMUNICATION PORTS
Connector/Port:
CI-ControlWave GFC-CL
CPU/System Controller Board
J19 - 9-Pin D-Type - COM1 (RS-232)
TB1 - 8-Pos. Term. Block - COM1 (RS-232)
TB2 - 8-Pos. Term. Block - COM2 (RS-232/RS-485)
TB3 - 5-Pos. Term. Block - COM3 (RS-485)
J9 - 6-Pin RJ-45 - COM2 - PSTN Modem*
Specifications / 4-1
Bottom of Front Cover (one or the other)
9-Pin D-Type - COM1 (RS-232)
3-Pin Circular - COM1 (RS-232)
Baud Rate:
300 to 115Kbps for RS-232 or RS-485
Up to 56Kbps for Modem
Table 4-2A - RS-232 Ports (COM1 & 2) and RS-485 Port (COM2)
Connector Pin Assignments (All COM1 Connectors, i.e., J19 & TB1 and COM2
Connector TB2 – Located on CPU/System Controller Bd.)
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Signal/Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
N/A
Signal
RS-485
RXD+
TXD+
Description:
RS-485 Signals
Receive Data + Input
Transmit Data + Output
GND
RXD−
TXD−
Ground
Receive Data − Input
Transmit Data − Output
N/A
N/A
Table 4-2B - RS-232 Port (COM1) Connector Pin Assignments
(Local Port on Bottom of Front Cover & TB1 on CPU/System Controller Bd)
TB1
Pin #
2
3
5
Signal
RS-232
RXD
TXD
GND
Description:
RS-232 Signals
Receive Data Input
Transmit Data Output
Power Ground
Local Port
RS-232 Pin #
7 (WHT Wire)
2 (RED Wire)
6 (BLK Wire)
Figure 4-1A - DB9 9-Pin Connectors Associated with COM1
Located on CPU/System Controller Bd. or Bottom of Front Cover (Local Port)
Figure 4-1B - Circular Local Port Connector Associated with COM1
Located on Bottom of Instrument Front Cover
4-2 / Specifications
CI-ControlWave GFC-CL
Figure 4-2 - 8-Position Terminal Block TB1 & TB2 Associated with COM1 & COM2
Located on CPU/System Controller Board
Table 4-3 - RS-485 Port (COM3) Connector Pin Assignments
TB3 - Located on CPU/System Controller Board
Pin
#
1
2
3
4
5
Signal
RS-485
RXD+RXDTXD−
TXD+
Power Ground
Description:
RS-485 Signals
Receive Data + Input
Receive Date - Input
Transmit Data − Output
Transmit Data + Output
Ground
1
Figure 4-3 - 5-Position Terminal Block Associated with COM3
TB3 Located on CPU/System Controller Board
4.3 CPU/SYSTEM CONTROLLER BOARD
4.3.1 Input Power Specs.
Note: Voltages are dc unless otherwise specified.
Operating Range:
+4.5/4.9V to +16.0V (+6V Input Supply) (Shutdown occurs
at +4.72/4.33V nominal)
+9.6/10.3V to +16.0V (+12V Input Supply) (Shutdown
occurs at +10.29/9.56V nominal)
Output Voltages:
+3.3Vdc ±1%
Output Current:
1A Max. @ 3.3Vdc
Output Ripple P/P:
+3.3V Output: 10mV
Fusing:
1A Slow Blow 5x20mm Fuse
Electrical Isolation:
None
CI-ControlWave GFC-CL
Specifications / 4-3
Surge Suppression:
16V Transorb to DGND and Chassis
Meets ANSI/IEEE C37.90-1978
Terminations:
Shutdown:
Pluggable, maximum wire size is 16 gauge
+6V System:
Max. ON Switchpoint = 4.90V
Min. OFF Switchpoint = 4.33V
+12V System:
Max. ON Switchpoint = 10.3V
Min. OFF Switchpoint = 9.28V
4.3.2 Power Supply Sequencer Specs.
Signals Monitored:
Input Power
Sequencer Switchpoints:
+3.3V Max. ON Switchpoint = +3.15V
+3.3V Min. OFF Switchpoint = +3.00V
+1.8V Max. ON Switchpoint = +1.72V
+1.8V Min. OFF Switchpoint = +1.64V
Sequencer Output Signals: PFDLYCLK Timing on power down 2msec after POWERFAIL
VIN100M timing on power Up 1200msec delay for Good
Power
POWERGOOD incoming power, 3.3V & 1.8V in Spec.
4.4 BATTERY CHARGER & I/O BOARD SPECIFICATIONS
4.4.1 External Power Monitor Specs.
Input Signal:
Input power after fuse, before Diode
Input Range:
0 to 8Vdc (6V System), 0 to 16Vdc (12V System)
Resolution:
12 Bit
Accuracy:
Calibrated: ±0.65% @ +25°C (+77°F)
Calibrated: ±0.91% over -40 to +85°C (-6.2 to +185°F)
4.4.2 Battery Charger & I/O Board Connectors (see Figure 4-4, Tables 4-4 & 4-5)
Table 4-4 – Battery Charger & I/O Board User Connector Summary
Ref.
P1
P2
P3
TB1
TB2
TB3
TB4
TB5
4-4 / Specifications
# Pins
3-pin
8-pin
26-pin
2-pin
2-pin
2-pin
2-pin
8-pin
Function
System Power Intf. Connector
MVT Interface Connector
CPU/System Controller Intf. Connector
Solar Power Terminal Block
Primary Battery Terminal Block
Backup Battery Terminal Block
Auxiliary Power Terminal Block
DI & DO Terminal Block
CI-ControlWave GFC-CL
Table 4-4 – Battery Charger & I/O Board User Connector Summary (Continued)
Ref.
TB6
TB7
TB8
TB9
TB10
# Pins
8-pin
2-pin
9-pin
4-pin
3-pin
Function
HSC Terminal Block
NAMUR Terminal Block (N/A)
AI Terminal Block
AO Terminal Block
RTD Interface Terminal Block
Table 4-5 - System Controller Module Input Power Terminal Block Assignments
TERM. #
TB1-1
TB1-2
NAME
+VIN
-VIN
FUNCTION
+6Vdc or +12Vdc (nominal) Input
Supply Common (Ground)
Figure 4-4 - Battery Charger & I/O Board (TB2) (Primary Power Connector)
4.4.3 Non-isolated Digital Input/Output Circuitry Specs.
Non-isolated Digital Inputs
Number of Inputs:
2 DI - Internally Sourced (Dry Contact) operation
Input Filtering:
15 milliseconds
Input Current:
60uA nominal
‘0’ State Voltage:
below 1.5V
‘1’ State Voltage:
above 1.5V
Bus Access:
SPI
Electrical Isolation:
None
Surge Suppression:
Transorb between signal and ground (16V for 6V Version,
31V for 12V Version)
Meets ANSI/IEEE C37.90-1978
Status Indication:
None
Non-isolated Digital Outputs
Number of Outputs:
2 DO
Output Configuration:
Open Drain (Externally Powered)
Maximum Load Current:
100mA each @ 16/30Vdc (6/12V System)
CI-ControlWave GFC-CL
Specifications / 4-5
Bus Access:
SPI
Electrical Isolation:
None
Surge Suppression:
Transorb between signal and ground (16V for 6V Version,
31V for 12V Version)
Meets ANSI/IEEE C37.90-1978
General DI/DO Circuitry Specs.
Terminations:
Pluggable, max wire size is 14 gauge for local terminations Two 14-pin mass termination headers are provided for
remote terminations.
4.4.4 Non-isolated Analog Input/Output Circuitry Specs.
Non-isolated Analog Inputs
Number of Inputs:
3 Single Ended Inputs (1-5V or 4-20mA) individually
jumper configurable
Input Type:
(Externally Powered) Voltage Input: 1-5 Vdc
(Externally Powered) Current Loop: 4-20mA
Input Impedance:
1 Meg ohm for 1-5V inputs
250 ohm for 4-20mA inputs
Non-isolated Analog Outputs
Number of Outputs:
4-20mA Output
Compliance:
1 AO (1-5V or 4-20mA) individually jumper configurable
250 ohm load with 11V External Power Source
650 ohm load with 24V External Power Source
1-5V Output:
5mA maximum output current into external load with
external voltage range of 11 to 30 Vdc
Internal Power for AI/O
24Vdc
General AI/AO Circuitry Specs.
Accuracy:
Analog Input
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
Analog Output
Current Output:
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -20ºC to +70ºC (-4ºF to 158ºF)
0.3% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
4-6 / Specifications
CI-ControlWave GFC-CL
Voltage Output Compliance (Iloadmax = 5mA):
(see Note1 & Note2)
0.1% of Span + X @ +25ºC (+77ºF)
0.2% of Span + X @ -20ºC to +70ºC (-4ºF to +158ºF)
0.3% of Span + X @ -40ºC to +70ºC (-40ºF to 158ºF)
where X = [(2.5 ohms x Iload)/4.4V x 100]
Note1: Does not include error due to inductors
Note2: 2.5 ohm uncompensated series resistance with
Inductors
Terminations:
Pluggable - Max. wire size is 14 gauge
Data Transfer:
SPI
4.4.5 Non-isolated High Speed Counter Input Circuitry Specs.
Number of Inputs:
2 HSC Inputs per Module
Input Configuration:
Internally Sourced Dry Contact, individually Jumper
selectable Debounce Circuitry
Input Frequency:
10kHz Max.
Input filtering:
20 microseconds
Signal Conditioning:
Debounce circuit for contact closures and bandwidth
limiting
‘1’ State Voltage:
‘0’ State Voltage:
below 1.5V
above 1.5V
Bus Access:
SPI
Electrical isolation:
None
Surge Suppression:
Transorb between signal and ground (16V for 6V Version,
31V for 12V Version)
Meets ANSI/IEEE C37.90-1978
Terminations:
Pluggable, max wire size is 14 gauge for local terminations Two 14-pin mass termination headers are provided for
remote terminations
Status Indication:
None
Power Consumption:
Additional Current per Input
200uA per HSCSET or HSCRST Input (ON State)
4.5 ENVIRONMENTAL SPECIFICATIONS
Temperature:
CI-ControlWave GFC-CL
Operating:
Storage:
-40 to +158 °F (-40 to +70 °C)
-40 to +158 °F (-40 to +70 °C)
Specifications / 4-7
Relative Humidity:
0-95% Non-condensing
Vibration:
2g for 10 - 150 Hz
1g for 150 - 2000 Hz
RFI Susceptibility:
In conformity with the following standards:
IEC 1000-4-3 (Level 2): 3V/meter - 80MHz to 1000MHz
ESD:
Field connected circuits meet the requirements of IEC
1000-4-2 for ESD withstand capability up to 4KV
4.6 DIMENSIONS
NEMA 3R Enclosure
4-8 / Specifications
ControlWave GFC-CL with MVT (see Figure 4-5)
ControlWave GFC-CL with GPT (see Figure 4-6)
CI-ControlWave GFC-CL
Figure 4-5 - ControlWave GFC-CL (with MVT) - NEMA 3R Enclosure Dimensions
CI-ControlWave GFC-CL
Specifications / 4-9
3.84”
3.04”
1.49”
5.26”
7.68”
2.18”
9.08”
5.16”
7.80”
14.21”
14.555”
11.73”
11.61”
1.583”
.345”
Figure 4-6 - ControlWave GFC-CL (with GPT) - NEMA 3R Enclosure Dimensions
4-10 / Specifications
CI-ControlWave GFC-CL
ControlWave GFC-CL
Special Instructions for Class I, Division 2 Hazardous Locations
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Bristol’s ControlWave GFC-CL Gas Flow Computer is listed by Underwriters Laboratories (UL) as
nonincendive and is suitable for use in Class I, Division 2, Group C and D hazardous locations or
nonhazardous locations only. Read this document carefully before installing a nonincendive
ControlWave GFC-CL Gas Flow Computer. Refer to the ControlWave GFC-CL Gas Flow Computer
User's Manual for general information. In the event of a conflict between the ControlWave GFC-CL Gas
Flow Computer User's Manual and this document, always follow the instructions in this document.
The ControlWave GFC-CL 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.
The local communications port terminates in either a D-Type connector or a circular 3-pin connector on
the bottom of the ControlWave GFC-CL Gas Flow Computer instrument 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.
The optional power system (solar panel and battery) approved for use with the nonincendive ControlWave GFC-CL 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).
WARNING: EXPLOSION HAZARD - Do Not disconnect Solar Power from the Battery or any
other power connections within the ControlWave GFC-CL Enclosure (including connectors
TB1 through TB4 and connector P1 on The Battery Charger & I/O Board, or connector J1 on
the CPU/System Controller Board, 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 major 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 nonhazardous.
An RTD is normally supplied with the ControlWave GFC-CL. Connection to the RTD is approved as a
nonincendive circuit, so that Division 2 wiring methods are not required.
Signal connectors available for customer wiring are listed in Table A1. I/O Connections are unrated and
must be wired using Div. 2 wiring methods.
The UL listed nonincendive ControlWave GFC-CL may include radio/modem communications (listed on
Model Spec.) 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.
Table A1 -Module/Board Connector Customer Wiring Connectors
Module/Item
Connector
CPU/System Controller
Board
J19: COM1, 9-pin Male D-sub
TB1: COM1, 8-pin Term. Block
CPU/System Controller
Board
TB2: COM2, 8-pin Term Block
RS-232/RS-485
TB3: COM3, 5-pin Term Block
CPU/System Controller
Board
CPU/System Controller
Board
CPU/System Cntrl. Bd.
J2: 25-Button Display Intf.
10-pin Inline Male Connector
J14: 2-Button Display Intf.
3-pin Inline Male Connector
J9: RJ11 Female Connector
04/28/2006
Wiring Notes
RS-232 Comm. Port Connectors: For external
Network Comm. Refer to Model Spec. and ¶ 10
of this document.
Remote Comm. Port: For Radio or external
Network Comm. Refer to Model Spec. and ¶ 10
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 ¶ 11 of this document. If COM3 is used in
conjunction with a modem refer to ¶ 11 of this
document.
Factory Wired - *
Factory Wired - *
Modular connection to Phone Co. equipment.
Appendix A, Document CI-ControlWave GFC-CL
Page 1 of 2
ControlWave GFC-CL
Special Instructions for Class I, Division 2 Hazardous Locations
Table A1 -Module/Board Connector Customer Wiring Connectors (Continued)
Module/Item
CPU/System Cntrl. Bd.
CPU/System Cntrl. Bd.
CPU/System Cntrl. Bd.
Battery Charger & I/O
Board
Battery Charger & I/O
Board
Connector
Wiring Notes
J20: RJ45 Female Connector
J5: I/O Bus Cable Connector
J1: 3-pin Molex Male Connector
P1: 3-pin Molex Male
Connector
Modular connection Ethernet 10/100BaseT
I/O Interface Bus - Factory Wired
Power Interface - Factory Wired
P2: MVT Interface
Factory Wired - *
Battery Charger & I/O
Board
TB1: 2-pin Term. Block
TB2: 2-pin Term. Block
TB3: 2-pin Term. Block
TB4: 2-pin Term. Block
Battery Charger & I/O
Board
TB5: 8-pin Term. Block
DI & DI Interface
Battery Charger & I/O
Board
TB6: 8-pin Term. Block
HSC Interface
Battery Charger & I/O
Board
Solar Power: User Wired - *
Primary Power: Factory/User Wired - *
Backup Battery: User Wired - *
Auxiliary Output: Factory Wired - *
Discrete Input/ Output Field Wiring: Field I/O
wiring connector is unrated, use Div. 2 wiring
methods. *
High Speed Counter Field Wiring: Field Input
wiring connector is unrated, use Div. 2 wiring
methods. *
TB7: 2-pin Term. Block
Battery Charger & I/O
Board
TB8: 9-pin Term. Block
AI Interface
Battery Charger & I/O
Board
TB9: 4-pin Term. Block
AO Interface
Battery Charger & I/O
Board
TB10: 3-pin Term. Block
RTD Interface
Local Port 9-pin Male D-sub
Connector (Early Version)
or
Local
Port
3-pin Female
Circular Connector (Present
Version)
Front Cover Bottom
Power Interface - Factory Wired - *
N/A: No Connection Permitted
Analog Input Field Wiring: Field Input wiring
connector is unrated, use Div. 2 wiring
methods. *
Analog Output Field Wiring: Field Output
wiring connector is unrated, use Div. 2 wiring
methods. *
Field Wired: Refer to 9 of this document
Local Comm. Port - Factory Wired. Refer to ¶
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 ¶ 6, 7 & 8 of 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.
04/28/2006
Appendix A, Document CI-ControlWave GFC-CL
Page 2 of 2
Appendix C
HARDWARE INSTALLATION GUIDE
Hardware Configuration
There are seven (7) main steps required to configure a ControlWave GFC-CL. This
appendix provides an overview of these steps with an emphasis on the installation and
configuration of the hardware. This appendix is intended for users who have already
installed at least one ControlWave GFC-CL.
Figure C-1A - ControlWave GFC-CL (with MVT & MDS - Transnet Radio)
(Internal View) Component Identification Diagram
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-1
Figure C-1B - ControlWave GFC-CL (with GPT & MDS - Transnet Radio)
(Internal View) Component Identification Diagram
Step 1. Hardware Configuration
This involves unpacking the ControlWave GFC-CL hardware, mounting the enclosure,
wiring I/O terminations, connecting any permanent communication cables, making proper
ground connections, connecting a communications cable to a PC work-station, setting
switches and setting jumpers. To install and configure the ControlWave GFC-CL, follow
Hardware Configuration steps 1 through 10 below:
1. Remove the unit from its carton and install it at the assigned work site (see Section
2.3.1 and associated subsections). Dimensions are provided in Section 4.6 of this
manual.
2. Remove the Battery Charger & I/O Board Assembly and after configuring its
configuration jumpers, install it into ControlWave GFC-CL Enclosure (see Figure C-2).
3. Make sure that the Lithium Backup Battery has been enabled, i.e., Backup Battery
Jumper W28 on the CPU/System Controller Board (on the inside of the Instrument
Front Cover) should be installed (on its jumper posts). Configure the CPU/System
C-2 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
Controller Board’s DIP Switches and Jumpers. Tables C-1 through C-3 provides
overviews of the Switch Settings (see Figure C-2).
Table C-1 - CPU/System Controller Bd. Switch SW1
Recovery Mode/Local Mode Control
SWITCH
Function
Setting
Both UP or DOWN = Recovery Mode
SW1-1/2
Recovery/Local Mode *
SW1 DOWN & SW2 UP = Local Mode
ON = Force Recovery Mode (via CW Console)
SW1-3
Force Recovery Mode *
OFF = Recovery Mode disabled
SW1-4
Not Used
N/A
* = Note: Only the Switch SW1 settings listed in this table, have been tested.
Table C-2 - CPU/System Controller Bd. Switch SW2 - User Configurations
Note: Except for SW2-4, ON = Factory Default
SW#
Function
SW2-1
Watchdog Enable
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
SRAM Control
System Firmware
Load Control *
N/A
Setting - (ON = Factory Default)
ON = Watchdog circuit is Enabled
OFF = Watchdog circuit is Disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Mode Switch (SW1)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote download of System Firmware
OFF = Disable remote download of System Firmware
ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)
* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher
SW2-8
Enable WINDIAG
Table C-3 - CPU/System Controller Bd. Switch SW3/SW4 Assignments
RS-485 Loopback & Termination Control (SW3 for COM3 – SW4 for COM2)
SWITCH
#
RS-485 Function
Switch ON
Setting
ON – 2-Wire Operation or Loopback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – 2-Wire Operation or Looback Enabled
SW3/4-2
TX− to RX− Loopback/2-Wire
OFF – 4-Wire Operation & Loopback Disabled
SW3/4-3
100 Ohm RX+ Termination
ON – End Nodes Only
SW3/4-4
ON – End Nodes Only
100 Ohm RX− Termination
SW3-6
Slew Rate
ON – Slow Rate Enabled
(see Note 2) ISO485 ONLY
OFF – Fast Rate Enabled
ON – 4-Wire = Both End Nodes
SW3/4-7
RX+ Bias (End Nodes/Node)
2-Wire = One End Node Only
OFF = No Bias
ON – 4-Wire = Both End Nodes
SW3/4-8
2-Wire = One End Node Only
RX− Bias (End Nodes/Node)
OFF – No Bias
Note 1: Closed = Switch set ON Note 2: Switch SW3-6 (COM3) = N/A
SW3/4-1
TX+ to RX+ Loopback/2-Wire
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-3
Figure C-2 - ControlWave GFC-CL CPU/System Controller Board
Component Identification Diagram
C-4 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
Figure C-3 - Battery Charger & I/O Board Component Identification Diagram
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-5
Step 1. Hardware Configuration (Continued)
4. Configure/Connect appropriate communication port(s) (see Sections 2.3.3.2). Connect
COMM. Port 1 or 2 of the ControlWave GFC-CL (depending on CPU/System
Controller Board’s Switch SW2 settings - see Tables C-2 & C-3 and Figures C-4A
through C-5) to a Communication Port of a PC (typically PC COMM. Port 1). Note: Also
see Section 2.4.4.
A ControlWave GFC-CL can be configured as a Master or Slave node on either a
MODBUS network or a BSAP network. A variety of communication schemes are
available. An optional 56K PSTN Modem and Spread Spectrum Modem (Radio) can be
piggy-back mounted on the CPU/System Controller Board. Three communication ports
are contained on the standard CPU/System Controller Board. These communication
ports are designated as follows:
CPU/System Controller Board:
COM1 - Port 1: J19 (9-Pin Male D-Sub), TB1 (8-Pin Term Block) - RS-232 (TB1 is
factory connected to the Local Port)
COM2 - Port 2: TB2 (8-Pin Term. Block) RS-232/RS-485 - RS-485 Configured by SW4
(COM2 supports an Internal or External Modem or Radio option)
COM3 - Port 3: TB3 (5-Pin Term. Block) RS-485 - Configured by SW3
COM1 is also available as the Local Port. This is accomplished via a 9-pin D-Type male
connector (on earlier models) or a circular 3-pin female connector (on currently
manufactured models). The Local Port is located on the bottom of the Instrument Front
Cover.
Communication Ports COM1, COM2 and COM3 support serial asynchronous operation
as listed above. Any communication port (COM1, COM2 or COM3) can be configured for
local communications, i.e., connected to a PC loaded with ControlWave Designer and
OpenBSI software. The pin labels for the various RS-232/485 interface connectors are
provided in Tables C-4A1 through C-4B.
RS-232 & RS-485 Interfaces
ControlWave GFC-CL RS-232 & RS-485 Comm. schemes are discussed herein.
RS-232 Ports
An RS-232 interface supports Point to Point, half-duplex and full-duplex
communications (20 feet maximum, using data quality cable). Half-duplex communications supported by the ControlWave GFC-CL utilize MODBUS or BSAP
protocol, while full-duplex is supported by the Point to Point (PPP) protocol.
ControlWave GFC-CL RS-232 ports utilize a “null modem” cable (Figure C-5 - Top) to
interconnect with other devices such as a PC, printer, another ControlWave series unit
when the ControlWave GFC-CL is communicating using the full-duplex PPP protocol.
A half-duplex cable (Figures C-5A - Bottom) can be utilized when the ControlWave
GFC-CL is connected to another ControlWave series unit. If communicating with a
Bristol series 3305, 3310, 3330 or 3335 RTU/DPC, one of the cables shown in Figure C5B must be used. Refer to Figure C-5C to connect ControlWave GFC-CL serial RS-232
port COM2 to either an external modem or external radio. When interfacing to Port
COM3 of a ControlWave unit, or to COM5 or COM6 of a ControlWaveEXP, the cable
of Figure C-5D must be used along with the one of Figure C-5A.
C-6 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
Step 1. Hardware Configuration (Continued)
Tables C-4A1 through C-4B provides the connector pin assignments for ports COM1,
COM2, COM3.
Figure C-4A - PC Connected to ControlWave GFC-CL Local Port
(D-Type Connector Version)
(Use Null Modem Cable - Bristol Part Number 392843-01-3)
Figure C-4B - PC Connected to ControlWave GFC-CL Local Port
(Circular Port Version)
Bristol Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Part Number 395402-02-6 = 25 Foot Comm. Cable
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-7
Figure C-5 - Communication Port RS-232 Cable Wiring Diagram
C-8 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
Step 1. Hardware Configuration (Continued)
Note: The following facts regarding ControlWave GFC-CL RS-232 serial communication ports should be observed when constructing communications cables:
•
•
•
•
•
•
•
•
DCD must be high to transmit (except when dialing a modem)
Each RS-232 transceiver has one active receiver while in powerdown mode
(disabled); the DCD signal is connected to the active receiver.
CTS must be high to transmit.
When port is set for full-duplex operation - RTS is always ON.
DTR is always high (when port is active); DTR enables RS-232 Transceivers.
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 LCDA12C surge protectors to
±4KV ESD.
Table C-4A1 - RS-232 Ports (COM1 & 2) and RS-485 Ports (COM2)
Connector Pin Assignments
(All COM1 Connectors, i.e., Local Port, J19 & TB1 and COM2 Connector TB2)
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
N/A
Signal
RS-485
RXD+
TXD+
Description:
RS-485 Signals
Receive Data + Input
Transmit Data + Output
GND
RXD−
TXD−
Ground
Receive Data − Input
Transmit Data − Output
N/A
N/A
Table C-4A2 - RS-232 Port (COM1) Connector Pin Assignments
(COM1 Connectors, i.e., Circular Local Port & TB1)
Pin
#
1
2
3
4
5
6
7
8
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
Local Port
RS-232 Pin #
7 (WHT Wire)
2 (RED Wire)
6 (BLK Wire)
*
*
* RTS connected to CTS at TB1 of CPU for Local Port Comm. Cable
RS-485 Ports
ControlWave GFC-CL can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for
network communications, Table C-5 provides the appropriate connections for wiring the
master, 1st 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 (daisy
chained) across the same lines. The master node should be wired to one end of the RS-485
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-9
cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used. Note:
Only half-duplex RS-485 networks are supported
Step 1. Hardware Configuration (Continued)
Table C-4B - RS-485 Port (COM3)
Connector Pin Assignments (TB3)
Pin
#
1
2
3
4
5
Signal
RS-485
RXD+
RXD−
TXD−
TXD+
Power Ground
Description:
RS-485 Signals
Receive Data + Input
Receive Date − Input
Transmit Data − Output
Transmit Data + Output
Ground
Receiver biasing and termination as well as 2-wire or 4-wire selection are enabled by eightposition DIP-Switches situated on the CPU/System Controller Board as follows: COM3:
Switch SW3, COM2: Switch SW4.
Table C-4A1 provides the connector pin assignments for CPU/System Controller Board port
COM2. Table C-4B provides connector pin assignments for CPU/System Controller Board
port COM3. Table C-3 provides the RS-485 termination and loopback control Switch
Settings for the RS-485 Ports.
To ensure that the “Receive Data” lines are in a proper state during inactive transmission
periods, certain bias voltage levels must be maintained at the master and most distant
slave units (end nodes). These end nodes also require the insertion of 100-Ohm terminating
resistors to properly balance the network. Secondary Communication Board switches must
be configured at each node to establish proper network performance. This is accomplished
by configuring CPU/System Controller Bd. Switch SW3 (COM3) and/or Switch SW4 (COM2)
so that the 100-Ohm termination resistors and biasing networks are installed at the end
nodes and are removed at all other nodes on the network (see Table C-5).
Table C-5 - RS-485 Network Connections
(see Table C-4A/B ControlWave GFC RS-485 Port Pin # Assignments)
From
Master
TXD+
TXD−
RXD+
RXD−
GND/ISOGND*
To 1st
Slave
RXD+
RXD−
TXD+
TXD−
GND/ISOGND*
To nth
Slave
RXD+
RXD−
TXD+
TXD−
GND/ISOGND*
* ISOGND with Isolated RS-485 Ports Only!
Note: Pins 1, 2, 3, 4 & 9 of BBI Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485 Comm.
Ports are assigned as follows: 1 = TXD+, 2 = TXD-, 3 = RXD+, 4 = RXD- & 9 = ISOGND.
Spread Spectrum Modem Port
An optional Spread Spectrum Modem (Radio) is available on the CPU/System Controller
Board and is assigned as COM2. There are two unique radios offered. These radios will only
communicate with their own brand of radio, i.e., FreeWave radios are not compatible with
C-10 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
MDS radios. DTE/DCE serial data can be clocked into (transmit) or out of (receive) the
radio at a rate up to 115.2kHz.
Step 1. Hardware Configuration (Continued)
These radios are supplied in kit form with all the hardware required for user installation
onto a CPU/System Controller Board. A Radio is user installed onto the CPU/System
Controller Board (see Figure C-6) and its associated Ports is setup during installation in the
Ports Page of the Flash Configuration Utility. The Flash Configuration Utility is accessed
via NetView or LocalView.
FreeWave® Spread Spectrum Wireless Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
Microwave Data System Inc. MDS TransNET OEM™ Spread Spectrum Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
Installation steps below support user installation and configuration of a Spread Spectrum
Modem.
•
Mount the radio (Spread Spectrum Modem) onto the Radio Carrier Board and then
mount this combined assembly onto the CPU/System Controller Board. Install the Lshaped Bracket onto the lower right corner of the CPU/System Controller Board. Install
one end of the internal coaxial RF cable supplied with the radio in question onto the
radio’s RF SMA Connector. Connect the other end of the internal coaxial RF cable to the
L-shaped Bracket.
•
Install the user supplied coaxial RF cable between the unit’s RF antenna cable or
Polyphaser and the remote antenna.
•
For FreeWave Radio: Follow the Tuning Transceiver Performance” section of the
FreeWave Technologies Inc. FreeWave Spread Spectrum Wireless Data Transceiver
User Manual to configure the radio.
For MDS Radio: Refer to section 3.3 “Initial Power-Up & Configuration” within the
MDS TransNet OEM Integration Guide and if necessary for more information on
connecting a PC terminal and preparing it for use, refer to section 9.0
“PROGRAMMING REFERENCE.”
Note:
Whenever setting any Jumper or connecting/removing a communication cable
to/from a PC, power should be turned OFF. To invoke the setup program, connect
the radio (via COM1) to a terminal program (such as Hyperterminal) via a null
modem cable (see Figure C-5), put the radio into setup mode and set the
parameters for the terminal to those of Table C-6 below. The setup program is
invoked by connecting Pins 1 and 2 of CPU/System Controller Board Jumper Post
W8.
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-11
1 - RS-232
2 - RS-232
3 - RS-485
F
F B
A
G
B
A
H
F
E
F
A B
Q
1 - RS-232
2 - RS-232
3 - RS-485
L
Q
F
I
E
F
I
or
G
J
J
F
or
D
M
O
O
N
F
G
C
E
A/B/C
H
A
E
N
F
G
OPTION I/J/K
Populated
by
L
Order
E
K
E
I
B
J
M
D
Modem Kit Parts
Q = Modem
Q
O/P
MDS (Transnet) Radio Kit/Option Parts
A = 6-32 x .250 Pan Head Screw (Qty. 4)
B = 6-32 x .313 F/F Standoff (Qty. 4)
C = 6-32 x .188 Pan Head Screw (Qty. 4)
D = Transnet Radio Cable (with Nut and Washer)
E = Swaged Standoff (Qty. 4)
F = 4-40 x .250 Pan Head Screw (Qty. 4)
G = Radio Carrier Board
H = MDS Transnet Radio Module
N = L-shaped Bracket
O = Screw
P = Nut
Q
O/P
FreeWave Radio Kit/Option Parts
E = Swaged Standoff (Qty. 4)
F = 4-40 x .250 Pan Head Screw (Qty. 4)
G = Radio Carrier Board
I = 2-56 x 1/4 Pan Head Screw (Qty. 3)
J = 2-56 x .250 F/F Standoff (Qty. 3)
K = 2-56 x .188 Pan Head Screw (Qty. 3)
L = FreeWave Radio Module
M = FreeWave Radio Cable (with Nut & Washer)
N = L-shaped Bracket
O = Screw
P = Nut
Figure C-6 - CPU/System Controller Board Radio/Modem Installation Diagram
C-12 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
Step 1. Hardware Configuration (Continued)
Table C-6 - Radio Setup Menu Terminal Settings
PARAMETERS
Baud Rate
Data Rate
Parity
Stop Bits
Parity Check
Carrier Detect
Flow Control
SETTINGS
19,200
8
None
1
None/Off
None/Off
Xon/Xoff
56K PSTN Modem Port
An optional 56K PSTN Hayes type Modem can be mounted piggy-back on the CPU/System
Controller Board and is assigned to COM2. The Model MT5634SMI Modem module is
manufactured by MultiTech System and can be user configured for PSTN operation.
DTE/DCE serial data can be clocked into (transmit) or out of (receive) the modem at a rate
up to 115.2kHz.
Modems are supplied in kit form with all the hardware required for user installation onto
an Expansion Communications Module. Figure C-6 shows the modem mounted on the
CPU/System Controller Board.
A Modems is user installed onto the CPU/System Controller Board and its associated Port
is setup during installation in the Ports Page of the Flash Configuration Utility. The Flash
Configuration Utility is accessed via NetView or LocalView. A Terminal Emulation
program such as Hyperterminal is used to profile the modem via AT commands. Users
typically use AT commands only when checking the modem’s active or stored profile or
when reconfiguring a modem, e.g., to turn auto answer on or off, etc.
For additional installation information see section 2.3.3.5 of this manual.
Step 1. Hardware Configuration (Continued)
5. Install I/O wiring to the Battery Charger & I/O Board Assembly (if required see Section
2.3.4) (see Figure C-3). Install a communications cable between the ControlWave GFCCL and a Model 3808 Transmitter (Network of Transmitters) if required (see Figures C7 through C-9).
6. Install a ground wire between the Chassis Ground Lug and a known good Earth Ground
(also see Supplement Guide S1400CW).
ControlWave GFC-CL Enclosures are provided with a Ground Lug that accommodates
up to a #4 AWG wire size. A ground wire must be run between the Chassis Ground Lug
and a known good Earth Ground. The following considerations are provided for the
installation of ControlWave GFC-CL system grounds.
•
Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is
recommended that stranded copper wire is used and that the length should be as
short as possible.
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-13
Step 1. Hardware Configuration (Continued)
•
This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
•
The wire ends should be tinned with solder prior to insertion into the Chassis
Ground Lug. Note: Use a high wattage Soldering Iron.
•
The ground wire should be run such that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above ground
Figure C-7 - Model 3808 Transmitter to ControlWave GFC-CL
RS-232 Comm. Cable Diagram
Figures C-7 and C-8 detail the RS-232 and RS-485 wiring connections required between the
ControlWave GFC-CL and the Model 3808 Transmitter.
Up to two (2) Model 3808 Transmitters can be connected to a ControlWave GFC-CL via a
half duplex RS-485 Network. An illustration of this network is provided in Figure C-9
C-14 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
Note: For Loopback & Termination Control:
Use SW3/SW4 on CPU/System Controller Board to configure COM3/COM4.
Figure C-8 - Model 3808 Transmitter to CW GFC-CL - RS-485 Comm. Cables
To +
To 1
1 = RX+
2 = TX+
6 = RX7 = TX-
TB2 = COM2
Figure C-9 - ControlWave GFC-CL to 3808s - RS-485 Network Diagram
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-15
Step 1. Hardware Configuration (Continued)
7. Install RTD (wiring and Probe) (see Section 2.3.5 of this manual).
8. Install the Rechargeable Battery and Solar Panel (if provided) (see Sections 2.3.8 and
2.3.7.3).
9. Connect DC Power wiring to the ControlWave GFC-CL Battery Charger & I/O Board
assembly (see Section 2.3.7.1 and 2.3.7.2).
SCM Connector TB1 provides 2 input connections for bulk power as follows:
TB1-1 = (+VIN) (+4.5/4.9V to +8V dc for +6V bulk) (+9.6/10.3V to +16.0V dc for +12V)
TB1-2 = Chassis Ground - CHASSIS
10. Apply power to the ControlWave GFC-CL. Continue with Steps 2 through 7 below
(and Section 2.4.1) and the ControlWave GFC-CL will be ready for on line operation.
Step 2. Software Installation on the PC Workstation
ControlWave Designer software will have to be installed on the PC if the ControlWave
GFC-CL is being utilized in an application other than that supported by the standard load.
This is accomplished by installing the ControlWave Designer Package from the Open
BSI CD ROM.
You must install the Open BSI Network Edition. For information on minimum system
requirements and more details on the installation, see the installation procedure in
Chapter 2 of the Open BSI Utilities Manual (document # D5081).
If you have an older version of ControlWave Designer already installed:
Beginning with ControlWave Designer Version 3.3, the copy protection key (dongle) is
NOT required. Prior to installing ControlWave Designer 3.3 or newer, you MUST remove
the hardware dongle from the parallel port of your PC workstation. Otherwise, when you
subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will
limit the available system resources.
IMPORTANT:
When you start ControlWave Designer, you will be reminded to register the
software. Unregistered software can only be used for a maximum of 30 days. For
more information on the registration process, see Chapter 2 of the Open BSI
Utilities Manual (document# D5081).
Step 3. Establish Communications using either LocalView or NetView, and Run
the Flash Configuration Utility
Communications must be established with the ControlWave GFC-CL using either
LocalView or NetView.
The ControlWave GFC-CL ships from the factory with a default Flash configuration. Most
users will need to edit this configuration to set the IP address (if using PPP), BSAP local
address, user accounts, and port parameters. This can be done in one of two ways:
C-16 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
•
Either open the supplied Flash Configuration Profile (FCP) file and modify it, directly in
the Flash Configuration Utility, or in a text editor,
•
Or retrieve existing Flash Parameters directly from the unit, and edit them in the Flash
Configuration Utility.
Detailed information on the Flash Configuration Utility, and LocalView is included in
Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in
Chapter 6 of that same manual.
Step 4. Modification of the Application-Specific Control Strategy (OPTIONAL)
ControlWave GFC-CL gas flow computers are shipped with the GFC program already
loaded. However, you can create your own application-specific control strategy using
ControlWave Designer. This involves opening a new project using the ‘CWMicro’ template,
defining I/O points using the I/O Configurator, and creating a program using one or more of
the five supported IEC 61131 languages (FBD, ST, SFC, LD, or IL). Some of these
languages are text based, others use graphical diagrams. The choice is up to you, depending
upon your particular application.
The ControlWave MICRO Quick Setup Guide (document # D5124) includes a simple LD
example. Additional examples are included in the manual, Getting Started with
ControlWave Designer (document # D5085). More detailed information about
ControlWave Designer and IEC 61131 is included in the ControlWave Designer Reference
Manual (document # D5088).
The ACCOL3 Firmware Library, which is automatically accessible through the template
referenced above, includes a series of function blocks which perform a variety of process
control and communication functions. These can be included within your program to perform various duties including PID control, alarming, calculations, etc. Detailed information
about each function block is included in the ControlWave Designer on-line help files.
On the variables declaration page(s) in ControlWave Designer, you will need to mark any
variable you want to make accessible to external programs, such as Open BSI’s DataView
utility, as “PDD”. Similarly, any variables which should be collected into a database, or
exported using the OLE for Process Control (OPC) Server must be marked as “OPC.”
Variables marked as OPC can be built into a text file by the OpenBSI Signal Extractor.
The text file can then be used in the creation of a database for human machine interface
(HMI) software such as OpenEnterprise or Iconics’ Genesis. These HMI software packages
require that the "Datatype conversion enable" option be selected when generating the
file using Signal Extractor. Information about the OpenBSI Signal Extractor is included in
Chapter 12 of the Open BSI Utilities Manual (document # D5081).
Once the program has been created, it is assigned to an executable task. The entire project
is then saved and compiled.
NOTE: From this point on, the order of steps may be varied, somewhat,
depending upon the requirements of the user's application. If you modify the
standard GFC-CL program, you may need to modify the standard web pages
associated with it. (See Step 5, below).
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-17
Step 5. Use Standard Web Pages Provided to Select Options in the Standard
Control Strategy or Create Your Own Application-Specific Web Pages
The ControlWave GFC-CL has a standard set of web pages for configuration purposes
(stored on a PC) that lets you enter parameters, and configuration options for the standard
GFC program (see Step 4, above). If you modify the standard GFC-CL program, you may
need to modify the standard web pages. If you create your own application program (instead
of using the standard one), you may create your own web pages using Bristol Babcock
ActiveX controls discussed in the Web_BSI Manual (document # D5087).
You can use whichever HTML creation package you want to create the pages, however, all
ControlWave GFC-CL related web pages (whether standard or user-created) must be
viewed within Microsoft® Internet Explorer. Web pages are stored on a PC workstation.
Step 6. Create an Open BSI Network Containing the ControlWave GFC-CL, or
ADD the ControlWave GFC-CL to an Existing Open BSI Network
In order for the ControlWave GFC-CL unit to function as part of a Bristol network, it is
necessary to include it in the Bristol network.
If no Bristol network exists:
You need to run Open BSI’s NetView software on the PC workstation in order to define
a Bristol network. A series of software wizards are used to define a Network Host PC, a
network, and the RTUs (controllers) assigned to the network. Finally, communication
lines must be specified which handle the address assigned to the ControlWave GFCCL. Chapters 3 and 4 of the Open BSI Utilities Manual (document # D5081) include
‘quick start’ examples for performing these steps. More detailed information is included
in the NetView chapter (Chapter 6) of D5081.
If a Bristol network already exists:
You will need to add the ControlWave GFC-CL to the existing network using NetView’s RTU Wizard. Chapter 6 of the Open BSI Utilities Manual (document # D5081)
includes different sub-sections depending upon whether you are adding the unit to a
BSAP network, or an IP network.
Step 7. If applicable, download new or modified control strategy (OPTIONAL)
If you modified the standard GFC program, or substituted your own program, compile
and download the new or modified program into the unit, using either ControlWave
Designer, or the Open BSI 1131 Downloader. In this case, you download the control
strategy into the BOOT project area of FLASH memory; this ensures that if the
ControlWave GFC-CL is reset, or if there has been a failure of the backup battery, the
control strategy can be restarted from the beginning, i.e. from the BOOT project in
FLASH memory. To download the project, see Section 2.4.1. To download the application load, see Section titled Downloading the Application Load.
Downloading the Application Load
Any ControlWave GFC-CL must have a configured application load before it can be placed
into operation. For units not shipped with the ‘Standard Load,’ this will require connection of
the ControlWave GFC-CL to a PC running Windows NT (4.0 or higher), Windows 2000 or
Windows XP Professional and equipped with ControlWave Designer software & OpenBSI
C-18 / Appendix C - Hardware Installation Guide
CI-ControlWave GFC-CL
software. Configuration of the application load must be performed by an individual familiar
with the various programming tools. The following software user documentation is referenced:
Getting Started with ControlWave Designer Manual - D5085
ControlWave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Web_BSI Manual - D5087
An application load download can be initiated, i.e., from ControlWave Designer, or from the
OpenBSI 1131 Downloader for ControlWave GFC-CL Nodes.
1. Make sure that the CPU/System Controller Board’s Mode Switch (SW2) is set in ‘Local
Mode,’ i.e., SW1-1 in the DOWN position and SW1-2 in the UP position.
Note: From the factory, COM1 defaults to 115.2 kbd (RS-232) using the BSAP
Protocol. Don’t connect COM1 to a PC unless the PC’s RS-232 port in
question has been configured for BSAP operation.
2. Once the ControlWave GFC-CL project has been defined, communications and
configuration parameters have been set perform the download according to either
‘ControlWave Designer’ (see D5088 - chapter 11) or ‘The Open BSI 1131 Downloader’ (see
D5081 - Chapter 7).
3. After the download has been completed leave the CPU/System Controller Board’s Mode
Switch (SW1) set in ‘Local Mode,’ i.e., SW1-1 in the DOWN position and SW1-2 in the UP
position.
LED Checks
ControlWave GFC-CL CPU/System Controller Boards contain light emitting diodes
(LEDs) that provide operational and diagnostic functions. With the exception of the Power
Good LED (CR13) which is green, all LEDs are red. A brief synopsis of the individual
CPU/System Controller Board LEDs (CR#) is provided as follows:
CR13
CR21
CR22
CR35
CR36
CR37
CR38
CR39
CR40
CR41
CR42
CR43
CR44
CR45
CR46
CR47
CR48
Power Good
DCD ON
DTR Active
Status LED 1 (see Table 3-7 and Figure 3-10)
Status LED 2 (see Table 3-7 and Figure 3-10)
Status LED 3 (see Table 3-7 and Figure 3-10)
Status LED 4 (see Table 3-7 and Figure 3-10)
Status LED 5 (see Table 3-7 and Figure 3-10)
Status LED 6 (see Table 3-7 and Figure 3-10)
Watchdog LED - ON = Watchdog Condition - OFF = Normal Operation
Idle LED - ON = Idle
Comm. Port 3 - TX - ON = Transmit Activity
Comm. Port 3 - RX - ON = Transmit Activity
Comm. Port 1 - TX - ON = Transmit Activity
Comm. Port 1 - RX - ON = Transmit Activity
Comm. Port 2 - TX - ON = Transmit Activity
Comm. Port 2 - RX - ON = Transmit Activity
CI-ControlWave GFC-CL
Appendix C - Hardware Installation Guide / C-19
Figure C-10 - SCM Status LED Hexi-decimal Codes
Table C-7
System Status Codes on LCD Display and LEDs on CPU/System Controller Board
LED
LED
LED
LED
LED
LED
6
5
4
3
2
CR36
1
CR35
Status
In
Hex
LCD
Disp.
0
0
1
0
0
1
0
0
1
1
0
1
0
0
0
0
1
1
1
0
1
1
0
1
1
0
1
0
1
0
0
0
0
0
0
1
0
1
00
01
03
04
05
07
08
09
0A
0B
10
12
20
28
30
38
3B
3E
3F
Blank
DIAG
R DIAG
FWXSUM
DEVERR
FLASH
FACT
BATT
STRTUP
INIT
RECOV
RAMERR
STOP
HALT
NO APP
BREAKP
POWERD
UPDUMP
NOTRUN
CR40
CR39
CR38
CR37
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
0
1
0
0
0
1
0
1
0
1
1
0
0
1
1
1
0
1
1
1
0
1
1
1
1
1
1
1
1
* = Flashed at startup
C-20 / Appendix C - Hardware Installation Guide
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)
CI-ControlWave GFC-CL
Appendix D
PIGGY-BACK RADIO/MODEM
INSTALLATION GUIDE
D1.1 RADIO INSTALLATION & CONFIGURATION
D1.1.1 Installing an Internal FreeWave Radio (FGR09CSU)
FreeWave Radio Model GR09SCU is provided (for user installation) in a kit consisting of
the following components:
•
•
•
•
•
•
•
•
•
2-56 x .188” Pan Head Screw (Nylon) (Qty. 3) - Fig. D1 Reference = K
2-56 x .250” F/F Standoff (Nylon) (Qty. 3) - Fig. D1 Reference = J
2-56 x .250” Pan Head Screw (Qty. 3) - Fig. D1 Reference = I
4-40 x .250” Pan Head Screw (Qty. 4) - Fig. D1 Reference = F
Swaged Standoff (Qty 4) - Built into CPU/System Controller Bd. - Fig. D1 Reference = E
Radio Carrier Board - Fig. D1 Reference = G
FreeWave Radio Module - Fig. D1 Reference = L
FreeWave Radio Cable - Fig. D1 Reference = M
FreeWave Radio Cable Mounting Hardware - Fig. D1 Reference: N = L-shaped Bracket,
O = Screw and P = Nut
To install a Model FGR09SCU Radio onto a CPU/System Controller Board, perform the
following eight (8) steps (referring to Figure D-1):
1. Install the three (3) 2-56 x .250 F/F standoffs (item J) onto the front of the Radio Carrier
Board (Item G). These standoffs are secured via three (3) 2-56 x .188 Pan Head Screws
(item K) that pass through the rear of the Radio Carrier Board.
2. Align the FreeWave Radio Assembly (item L) with the Radio Carrier Board (item G).
Press the two assemblies together and secure them via three (3) 2-56 x .250 Pan Head
Screws (item I).
3. Align the Radio Carrier Board (with FreeWave Radio installed) with the four (4) built-in
Swaged Standoffs (item E) on the CPU/System Controller Board and secure this
assembly via four (4) 4-40 x .250 Pan Head Screws (item F).
4. Secure the L-shaped Antenna Cable Bracket (item N) to the lower right corner of the
front of the CPU/System Controller Board via the remaining screw (item O) and nut
(item P)
5. Plug the radio end of the Antenna Cable (item M) into the FreeWave Radio’s RF
Connector.
6. Install the antenna end of the Antenna Cable (item M) through the L-shaped Bracket
(item N - installed in step 4). Secure the Antenna Cable to the Cover Panel via the
Antenna Cable’s washer and nut.
7. Set the CPU/System Controller Board Radio/Modem Jumpers as follows:
CI-ControlWave GFC-CL
Appendix D - Radio/Modem Installation Guide / D-1
W8: set Jumper to storage position, i.e., parked (no connection)
W9: set Jumper to storage position, i.e., parked (no connection)
W10: set Jumper for DTR Power Control
Removed = Remove Power with DTR OFF
Installed = Power Always ON
W11: set Jumper to storage position, i.e., parked (no connection)
W12: set Jumper to storage position, i.e., parked (no connection)
W19: set Jumper onto posts 2 to 3
W21: set Jumper onto posts 1 to 2
W22: set Jumper onto posts 1 to 2
W23: set Jumper onto posts 1 to 2
W24: set Jumper onto posts 1 to 2
8. Apply power and test the unit.
D1.1.2 FreeWave Radio (FGR09CSU) Configuration Guidelines
To configure a Model FGR09SCU Radio (installed on a CPU/System Controller Board),
perform the following seven (7) steps:
1. Place the radio into configuration mode by setting CPU/System Controller Board
Jumper W8 onto pins 1 and 2. This will enable configuration of the radio through
Comm. Port 1.
2. Connect a Modem Cable (see Figures D2A & D2B) between a PC and the Local Port, i.e.,
Comm. Port 1.
F
F
G
I/J/K
F
L
I
G
J
E
K
E
L
E
I
FreeWave Radio Kit/Option Parts
E = Swaged Standoff (Qty. 4)
F = 4-40 x .250 Pan Head Screw (Qty. 4)
G = Radio Carrier Board
I = 2-56 x 1/4 Pan Head Screw (Qty. 3)
J = 2-56 x .250 F/F Standoff (Qty. 3)
K = 2-56 x .188 Pan Head Screw (Qty. 3)
L = FreeWave Radio Module
M = FreeWave Radio Cable
(with Nut and Washer)
N = L-shaped Bracket
O = Screw
P = Nut
F
J
I
J
F
M
or
M
O
O/P
N
Figure D1 - FreeWave Radio Installation Diagram
D-2 / Appendix D - Radio/Modem Installation Guide
CI-ControlWave GFC-CL
3. Open HyperTerminal on the PC and set the PC communication port settings as follows:
Bits per second:
Data bits:
Parity:
Stop bit:
Parity Check:
Carrier Detect:
Flow Control:
19200
8
None
1
None/Off
None/Off
Xon/Xoff
4. Cycle power to the ControlWave GFC-CL. The FreeWave configuration menu will
appear in Hyperterminal.
5. In the configuration menu, set the radio as a multipoint slave. Go to the edit book and
type in the serial number of the Master Radio to which you want to communicate. Make
sure the Baud Rate matches that of the Master Radio. Once settings have been
implemented, press the Esc Key to exit the configuration menu.
6. Set CPU/System Controller Board Configuration Jumper W8 into a storage position, i.e.,
parked (no connection). Apply power and test the unit.
7. Using HyperTerminal at the Master Radio, inter configuration mode and set the radio
as a multipoint master. Using the edit book (in configuration mode) make sure that no
serial number is set. Verify that the baud rate matches that of the Slave Radio.
Figure D2A - PC Connected to ControlWave GFC-CL via Circular Local Port
Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable
CI-ControlWave GFC-CL
Appendix D - Radio/Modem Installation Guide / D-3
Figure D2B - (Internal Radio/Modem Configuration) Bristol P/N 392843-01-3
Full-duplex Null Modem Cable Diagram
D1.1.3 Installing an Internal MDS Transnet OEM Radio
MDS Transnet OEM Radio is provided (for user installation) in a kit consisting of the
following components:
•
•
•
•
•
•
•
•
•
6-32 x .250” Pan Head Screw (Qty. 4) - Fig. D3 Reference = A
6-32 x .313” F/F Standoff (Qty. 4) - Fig. D3 Reference = B
6-32 x .188” Pan Head Screw (Qty. 4) - Fig. D3 Reference = C
Transnet Radio Cable (with Nut and Washer- Fig. D3 Reference = D
Swaged Standoff (Qty 4) - Built into CPU/System Controller Bd. - Fig. D3 Reference = E
4-40 x .250” Pan Head Screw (Qty. 4) - Fig. D3 Reference = F
Radio Carrier Board - Fig. D3 Reference = G
MDS Transnet Radio Module - Fig. D3 Reference = H
MDS Transnet Radio Cable Mounting Hardware - Fig. D3 Reference: N = L-shaped
Bracket, O = Screw and P = Nut
To install a Transnet OEM Radio onto a CPU/System Controller Board, perform the
following eight (8) steps (referring to Figure D-3):
1. Install the four (4) 6-32 x .313 F/F standoffs (item B) onto the front of the Radio Carrier
Board (Item G). These standoffs are secured via four (4) 6-32 x .188 Pan Head Screws
(item C) that pass through the rear of the Radio Carrier Board.
2. Align the MDS Transnet OEM Radio Assembly (item H) with the Radio Carrier Board
(item G). Press the two assemblies together and secure them via four (4) 6-32 x .250 Pan
Head Screws (item A).
3. Align the Radio Carrier (with MDS Transnet OEM Radio installed) with the four (4)
built-in Swaged Standoffs (item E) on the CPU/System Controller Board and secure this
assembly via four (4) 4-40 x .250 Pan Head Screws (item F).
D-4 / Appendix D - Radio/Modem Installation Guide
CI-ControlWave GFC-CL
4. Secure the L-shaped Antenna Cable Bracket (item N) to the lower right corner of the
front of the CPU/System Controller Board via the remaining screw (item O) and nut
(item P)
5. Plug the radio end of the Antenna Cable (item D) into the MDS Transnet OEM Radio’s
RF Connector.
6. Install the antenna end of the Antenna Cable (item D) through the L-shaped Bracket
(item N - installed in step 4). Secure the Antenna Cable to the Cover Panel via the
Antenna Cable’s washer and nut.
7. Set the CPU/System Controller Board Radio/Modem Jumpers as follows:
W8: set Jumper to storage position, i.e., parked (no connection)
W9: set Jumper to storage position, i.e., parked (no connection)
W10: set Jumper for DTR Power Control
Removed = Remove Power with DTR OFF
Installed = Power Always ON
W11: set Jumper to storage position, i.e., parked (no connection)
W12: set Jumper to storage position, i.e., parked (no connection)
W19: set Jumper onto posts 2 to 3
W21: set Jumper onto posts 1 to 2
W22: set Jumper onto posts 1 to 2
W23: set Jumper onto posts 1 to 2
W24: set Jumper onto posts 1 to 2
8. Apply power and test the unit.
D1.1.4 MDS Transnet OEM Radio Configuration Guidelines
To configure a MDS Transnet OEM Radio (installed on a CPU/System Controller Board),
perform the following seven (7) steps:
1. Place the radio into configuration mode by setting CPU/System Controller Board
Jumper W8 onto pins 1 and 2. This will enable configuration of the radio through
Comm. Port 1.
2. Connect a Modem Cable (see Figures D2A & D2B) between a PC and the Local Port, i.e.,
Comm. Port 1.
3. Open HyperTerminal on the PC and set the PC communication port settings as follows:
Bits per second:
Data bits:
Parity:
Stop bit:
Parity Check:
Carrier Detect:
Flow Control:
19200
8
None
1
None/Off
None/Off
Xon/Xoff
4. Cycle power to the ControlWave GFC-CL. After hitting the escape (Esc) key and then
the carriage return twice (at approximately half second intervals), the right arrow (>)
will appear.
CI-ControlWave GFC-CL
Appendix D - Radio/Modem Installation Guide / D-5
5. In the configuration menu, set the radio mode using either the MODE M (master) or
MODE R (remote) command. Note: There can be only one Master radio per
network. Go to the edit book and type in the serial number of the network’s Master
Radio. Set a unique Network Address (1 - 65000) using the ADDR command. Note: All
radios on the network must have the same Network Address. Make sure the Baud
Rate of any Remote Radio matches that of the Master Radio. Set the radio’s data
interface parameters (bps: 1200 – 114200 bps), Data Bits: (8). Parity (N), Stop bits: (1).
Once settings have been implemented, press the Esc Key to exit the configuration menu.
F
G
F B
A
G
B
A
H
E
F
E
B
A B
Q
C
E
A/B/C
H
A
F
D
or
D
O
MDS (Transnet) Radio
Kit/Option Parts
A = 6-32 x .250 Pan Head Screw (Qty. 4)
B = 6-32 x .313 F/F Standoff (Qty. 4)
C = 6-32 x .188 Pan Head Screw (Qty. 4)
D = Transnet Radio Cable (with Nut & Washer)
E = Swaged Standoff (Qty. 4)
F = 4-40 x .250 Pan Head Screw (Qty. 4)
G = Radio Carrier Board
H = MDS Transnet Radio Module
N = L-shaped Bracket
O = Screw
P = Nut
O/P
N
Figure D3 - MDS Transnet OEM Radio Installation Diagram
6. Set CPU/System Controller Board Configuration Jumper W8 into a storage position, i.e.,
parked (no connection).
7. Apply power and test the unit.
D2.1 MODEM INSTALLATION & CONFIGURATION
D2.1.1 Installing an Internal MultiTech Modem (MT5634SMI)
MultiTech Modem Model MT5634SMI is provided (for user installation) in a kit consisting
of the following components:
•
MultiTech Modem Module - Fig. D4 Reference = Q
To install a Model MT5634SMI Modem onto a CPU/System Controller Board, perform the
following three (3) steps (referring to Figure D4):
D-6 / Appendix D - Radio/Modem Installation Guide
CI-ControlWave GFC-CL
1. Mount the MultiTech Modem (item Q) to the CPU/System Controller Board making
sure that the interface connectors (J7, J8, J10 & J11) align with those on the rear of the
modem.
Q
Modem Kit Parts
Q = Modem
Q
Figure D4 - MultiTech Modem Installation Diagram
2. Set the CPU/System Controller Board Radio/Modem Jumpers as follows:
W8: set Jumper to storage position, i.e., parked (no connection)
W9: set Jumper to storage position, i.e., parked (no connection)
W10: set Jumper for DTR Power Control
Removed = Remove Power with DTR OFF
Installed = Power Always ON
W11: Install Jumper
W12: set Jumper to storage position, i.e., parked (no connection)
W19: set Jumper onto posts 1 to 2
W21: set Jumper onto posts 1 to 2
W22: set Jumper onto posts 1 to 2
W23: set Jumper onto posts 1 to 2
W24: set Jumper onto posts 1 to 2
3. Apply power and test the unit
D2.1.2 Configuring the MultiTech Modem (MT5634SMI)
To configure a Model MT5634SMI Modem (installed on a CPU/System Controller Board),
perform the following seven (7) steps (this should have been done during factory
installation):
CI-ControlWave GFC-CL
Appendix D - Radio/Modem Installation Guide / D-7
1. Place the modem into configuration mode by setting CPU/System Controller Board
Jumper W8 onto pins 2 and 3. This will enable configuration of the modem through
Comm. Port 1.
2. Connect a Modem Cable (see Figures D2A & D2B) between a PC and the Local Port, i.e.,
Comm. Port 1.
Open HyperTerminal on the PC and set the PC communication port settings as follows:
Bits per second:
Data bits:
Parity:
Stop bit:
Flow Control:
9600
8
None
1
None
3. Send Factory Default = AT&W1 ATZ.
4. Disable Flow Control = AT&K0.
5. Set baud rate using AT Command: AT$SB9600, or whatever baud rate you require.
6. Write to memory = AT&W0.
7. Set CPU/System Controller Board Configuration Jumper W8 into a storage position, i.e.,
parked (no connection).
After completing the seven configuration steps (if required) use WebBSI to select the
“Radio/Modem Control Mode” on the Radio & Modem Control Configuration Web page.
D-8 / Appendix D - Radio/Modem Installation Guide
CI-ControlWave GFC-CL
Instruction Manual
CI-ControlWave GFC-CL
Oct., 2006
ControlWave GFC-CL
ControlWave GFC-CL DISPLAY/KEYPAD
ASSEMBLY - GUIDE
Appendix E
www.EmersonProcess.com/Bristol
APPENDIX E
ControlWave GFC-CL
Display/Keypad Assembly Guide
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
E1.1
E2.1
E2.1.1
E3.1
E4.1
E4.1.1
E4.1.2
E4.1.3
E4.1.3.1
E4.1.3.2
E4.1.4
E4.1.5
E4.1.6
E4.1.7
E5.1
OVERVIEW ................................................................................................................... E-1
DISPLAY FUNCTION BLOCK DESCRIPTION......................................................... E-2
DISPLAY Function Block Parameters ......................................................................... E-2
PREPARING THE ControlWave PROJECT................................................................ E-3
USING THE KEYPAD .................................................................................................. E-4
Scrolling.......................................................................................................................... E-5
Signing-On ..................................................................................................................... E-6
Using the Clock Functions ............................................................................................ E-7
Changing the Time ........................................................................................................ E-8
Changing the Date......................................................................................................... E-8
Choosing a Variable List from the List Menu.............................................................. E-8
Moving Through a Variable List................................................................................... E-9
Changing Variable Parameters .................................................................................... E-9
Signing-Off ................................................................................................................... E-12
KEYPAD IDENTIFICATION & INSTALLATION INFO......................................... E-13
NOTE:
The Dual-button Display/Keypad Assembly is discussed at the end of Chapter 2
(see Section 2.4.5.1).
CI-ControlWave GFC-CL
Appendix E – Display/Keypad Contents / 0 - 1
Appendix E
DISPLAY/KEYPAD ASSEMBLY GUIDE
E1.1 OVERVIEW
Bristol Display/Keypad assemblies provide a built-in, local, user interface for the
ControlWave GFC-CL These assemblies allow an operator or engineer to view and modify
variable values and associated status information, via an ACCOL3 Function Block.
Variables can include inputs, process variables, calculated variables, constants, setpoints,
tuning parameters and outputs used in a measurement or control application. Status bits
include alarm state, alarm acknowledge, control, manual, and questionable data.
Setting up the Display/Keypad is a simple matter of configuring a Display Function Block
in the ControlWave Designer project.
The Display/Keypad is comprised of a four line by twenty character liquid crystal display,
with adjustable LCD Contrast, and a 25 button membrane key matrix. Each key has a
microswitch for positive tactile feedback. This means that as you firmly depress the keys,
you will feel it click as it engages. In the case of the ControlWave GFC-CL, the
Display/Keypad is located in the Instrument Front Cover and is installed at the factory.
Figure 1 - Display/Keypad Assembly – 25 Button Keypad & 4 X 20 Display
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-1
Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode.
Automatic Mode
In Automatic Mode a set of screens (based on the application load) are displayed. The
application programmer provides strings for the opening screen. From there the firmware is
responsible for displaying the screens and responding to key presses. Screens are fixed and
start off with an opening screen, which displays user information passed into the function
block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled
has been selected, the user can scroll through the list by pressing the down arrow key. List
elements will be displayed automatically, scrolling at a predetermined rate (determined by
iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing
the right arrow key again will cause the list to start scrolling again.
The essence of Automatic Mode is that the user can supply inputs into the function that
will determine which list can be displayed, but cannot change the menu or display. The
user is allowed to select a list and to start/stop scrolling.
Manual Mode
In Manual Mode the programmer is responsible for creating each screen and displaying the
next desired screen, based on key inputs. The programmer has access to all lines of the
display and can provide any string that he/she desires to display. Special formats that must
be adhered to that allow the programmer to display what they want on the screen are
provided in the description of iaScrnSruct in the ACCOL 3 Display function block within
ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode
does not support reading Keypad keypresses. Note: Manual Mode operation requires
ControlWave Firmware 4.50 or newer.
If you're setting up the keypad, follow the configuration instructions provided in Section E3
of this appendix.
If your keypad has already been set up, Section E4 will tell you how to use the keypad and
interpret the display.
E2.1 DISPLAY FUNCTION BLOCK DESCRIPTION
Keypad and display control/configuration are handled by the DISPLAY Function Block.
This function block allows an operator to view/change variable data or to be allowed to
scroll through lists of variable data based upon their login privileges.
In order for the keypad and display to operate, the ControlWave Designer project must
include a properly configured DISPLAY Function Block. Use ControlWave Designer to
configure this function block and assign the parameters according to the four steps covered
in Section 3.
E2.1.1 DISPLAY Function Block Parameters
Referring to Figure 2, various DISPLAY Function Block Parameters are available. For
information on configuring the Display Function Block, please reference on-line help in
ControlWave Designer.
E-2 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
Figure 2 - ACCOL3 DISPLAY Function Block Parameters
E3.1 PREPARING THE ControlWave PROJECT
In order for the keypad and display to operate, the ControlWave Designer project must
include a properly configured Display Function Block. Once the Keypad is operating, a user
who has signed on with a password can scroll through the names of variable lists and
choose a list to read or change. Use Up Arrow and Down Arrow keys to select the Username
and use the numeric keys to enter your password. The steps that follow describe how to
configure this function block.
Step 1: Creating the Identifier Display
The Identifier Display is the first display to appear when the Display Function Block is
initialized and begins to execute. This display will look similar to Figure 3. Each of the first
three lines of the display contains the text value of a string variable. These string variables
are created utilizing iaScrnStruct parameters of the Display Function Block (See Figure 2)
and your computer keyboard. Since this is the first display that the user will see, you may
want the display to contain general information such as the node name of the controller or
the process that the controller is monitoring.
The bottom line on the display is called the legend line. It shows which function keys are
currently active and their purpose. Function keys are those keys on the Keypad that are
marked ([F1] through [F4]). Function key assignments are preconfigured and cannot be
changed. Using function keys is described in Section 4, Using the Keypad.
The legend line in Figure 3 shows that the user has two choices: to Log-in (using [F1]) or
scroll (using [F2]).
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-3
Figure 3 - Creating the Identifier Message
Step 2: Defining a Scroll List
Once the Keypad is operating properly, you can automatically scroll through a list of
variables created via DISPLAY Function Block Parameters iiList2Scroll and iiListMode.
Scrolling can be done without entering a password. The variables in the list are displayed
one at a time and in the same order in which they were entered in the variable list.
Later, we'll discuss other variable lists that can be accessed with the keypad. To distinguish
this list from others, let's call this variable list the Scroll List.
Enter the number of a variable list to be scrolled. This variable list becomes the Scroll List.
The Scroll List can contain different types of variables (that is, logical, analog and string).
You can create a specific scroll variable list or use any list in the ControlWave Project.
Each variable in the Scroll List will be displayed for the number of seconds defined by the
iiScrollTime parameter. If you don't specify a time for this parameter, the hold time will be
two seconds. If you signed-on and then started scrolling you will be signed-off in 20 minutes
if no keys are pressed. If you don’t want to automatically stop scrolling after 20 minutes,
sign-off (INIT key) before starting scrolling.
Step 3: Assigning Passwords
A valid RTU username/password combination must be entered to go beyond the initial
displays. Passwords can be any combination of numbers up to 16 digits in length, from
0000000000000000 to 9999999999999999. If none are specified, the default values are
system for User-name and 666666 for Password (read/write access).
Step 4: Status Information
Enter a variable name on the odiStatus terminal.
See On Line Help in ControlWave Designer for Status Values.
The next section describes how to use the Keypad to access variable information.
E4.1 USING THE KEYPAD
The Identifier Display is the starting point from which you can go to other displays. It
shows an identification message and the words Login and Scroll at the bottom of the screen
(see Note 1). The identification message may contain the name of the controller, the plant
equipment it is monitoring, or the variables you can expect to see when you use this
display.
E-4 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
Note 1 : If your display shows something else, press the [F4] key until you see the words
Login and Scroll on the bottom line.
If your screen is blank, turn the brightness screw clockwise. This screw is located to
the left of the Keypad (looking at the rear of the 25-Button Display/Keypad Assembly (see Figure 17). If no letters appear, the controller has not been programmed properly to operate the keypad.
The words Login and Scroll at the bottom of the screen are on the legend line. It tells you
which function keys (that is, key [F1] through [F4]) are active and their purpose at that
time.
Up to four legends can appear on the legend line. The legend on the far left corresponds to
the function of the [F1] key. The assignment for the [F4] key is on the far right. Keys [F2]
and [F3] are described to the left and right of center. When no legend appears, that function
key is not active at that time. For example, in Figure 4 only [F1] and [F2] are active.
Figure 4 - The Identifier Display
From the Identifier Display, you have two choices. Pressing [F1] will allow you to sign-on if
you have a password. By pressing [F2] you can activate automatic scrolling through a list of
variables.
Figure 5 - Identifier Display Legends and Corresponding Keypad Alignment
for 25 Button Membrane Key Matrix Keypad System
E4.1.1 Scrolling
To begin automatic scrolling, press [F2] from the Identifier Display (Figure 4). Variable information will appear on the screen and remain there for 1 to 30 seconds (default = 2). The
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-5
variable name appears on the first line. The variable value appears on the second line and
status information appears on the third line. An example is shown in Figure 6.
When all variables in the list have been displayed, they will be shown again in the same
order. This is called Single Variable Mode.
Pressing Mlti [F2] activates Multiple Variable Mode. Multiple Variable Mode displays up to
three (3) variables and their values on the screen simultaneously. Pressing Sngl [F2]
terminates Multiple Variable Mode and returns you to Single Variable Mode.
Figure 6 - Scrolling
Press HOLD [F1] to halt scrolling. Changing variable values will continue to be displayed.
Press GO [F1] to resume scrolling.
Press EXIT [F4] to return to the Identifier Display (Figure 4).
E4.1.2 Signing-On
To access the List Menu, you must first sign-on with a proper password. From the
Identifier Display (Figure 4), press [F1]. The screen will look like Figure 7A or 7C. If the
display looks like Figure 7C:
Someone else has already signed on. Go to the paragraph below that starts "Once you
have successfully signed on,…".
If the display looks like Figure 7A:
Select the Username (default = system) by using the Up and Down Arrow Keys. If the
Username system is displayed and no other Username is available (i.e., no others have
been assigned), press [ENTER].
Enter a password using the 0 to 9 keys. For security, asterisks will appear as you enter
the digits. If you make a mistake, press [F1] and try again or use the delete key to
delete the previously pressed key action. The default password is 666666 (used when a
password is not known or no password has been assigned). After typing the password,
press [ENTER].
If your password is not recognized, the asterisks will be erased after you press
[ENTER]. Check your password and try again.
E-6 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
Figure 7 - Logging On
Once the correct password has been entered, the display will look like Figure 7C.
When the second line shows READ/WRITE, you can read and write variable parameters.
When it shows READ ONLY you cannot change variable parameters. You are only permitted to read variable information. If your display shows READ ONLY and you want to
change variable values, sign-off (press the [INIT] key) and log on with a username and
password that provides Read/Write privileges.
Once you have successfully signed on, the legend line will show that you have four options.
You can view and change the time and date of the local clock, access more variable lists,
Scroll, or return to the Identifier Display. Use function keys F1 through F4 to select the
next menu (F1 = Clock, F2 = Menu, F3 = Scroll list & F4 = Exit). Let's start by setting the
local clock.
E4.1.3 Using the Clock Functions
From the Logged-On Display (Figure 7C), press [F1]. The screen will show the present date
and time and will look like Figure 8. Follow the instructions below to change the time or
date. When you're finished, press [F4] to exit.
Today's date is shown in the first line in the format month/day/year.
The current time is shown in the form of hours:minutes:seconds.
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-7
Figure 8 - Clock Display
E4.1.3.1 Changing the Time
From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third
line. Enter the new time there and press [ENTER]. Valid times range from 00:00:00 to
23:59:59. Invalid entries will be ignored. The display will be updated to show the new time.
Figure 9 - Time Set Display
If you make a mistake while entering the new time, use [DEL] to backspace and delete one
character at a time.
E4.1.3.2 Changing the Date
From the clock display (Figure 8, press [F1]. Slash marks (/) will appear on the third line.
Enter the new date there and press [ENTER].
Figure 10 - Date Set Display
If you make a mistake while entering the new date, use [DEL] to back space and delete one
character at a time. Press [F4] to return to the Logged-On Display (Figure 7C).
E4.1.4 Choosing a Variable List from the List Menu
The List Menu is another area where variable information can be seen. As explained earlier
in this section, your first opportunity to read variable information is by choosing the
E-8 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
SCROLL function from the Initial Display. The variable name and value are presented
from the Scroll List. This function is available to all users even without signing-on.
The List Menu will show other groups of variable which you can choose to read. This information will be more detailed than the Scroll List.
To get to the List Menu, choose MENU (press [F2]) from the Logged-On Display (Figure
7C).
Figure 11 - Using the List Menu Display
The first variable list number in the menu will appear on the second line.
Press PREV (F1) and NEXT (F2) to see the other variable lists that are available in the List
Menu. You can also use the Up and Down Arrow Keys to scroll through the various lists. To
move directly to a list, enter the list number, then press [ENTER].
E4.1.5 Moving Through a Variable List
After READ (F1) or WRITE (F2) has been pressed, the display will show the first variable
in the list. An example is shown in Figure 12. Each time NEXT (F2) is pressed; the display
will show the next variable in the list. PREV (F1) will show the previous variable. You can
also use the Up and Down Arrow Keys to move through a list.
Automatic wraparound occurs in either direction. When you reach the end of the list, [F1]
will display the first variable again. At the top of the list, [F2] will display the last variable.
E4.1.6 Changing Variable Parameters
From Figure 11, you can change variable parameters by pressing F2 [Write]. Then follow
the directions summarized below (see Note 2).
Note 2: If your display does not contain the legend Write in the legend line, your password
will only allow you to read variables. If you want to change variable values at this
time, you must first log-off and then log-on using the correct password. See your
Systems Engineer for the correct password.
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-9
Before making any changes, first check the signal inhibit status field (See Figure 12). When
the display shows ME (manual enable) you can change variable parameters. When it shows
MI (manual inhibit), you cannot alter the parameters of this variable. If the field indicates
MI, press the OPER I/E key to change it to ME.
To change an analog value:
Press CHNG (F3) to clear the third line. Use the number keys 0 through 9 to enter the
new value. The minus sign and period are also permitted. Press [ENTER].
If you make a mistake, press CHNG (F3) and enter the number again or use the [DEL]
key to erase a character.
Another way to enter new values is by using the arrow up and arrow down keys (located
below the [F3] key and left of the [INIT] key). These keys will raise and lower the value
by 1% of the displayed amount.
To change the status of a logical variable:
Press CHNG (F3), then use either the down and up arrow keys or the [0/OFF] and
[1/ON] keys to change the state of a logical variable. If the [0/OFF] and [1/ON] keys are
used, you must also press [ENTER].
Figure 12 - Interpreting Variable Information
To acknowledge an alarm:
Press [ALM ACK].
To change the alarm enable/inhibit status for alarm variables:
Press [ALM I/E] key. (Note: This will only inhibit alarm reporting, and not alarm level
detection.)
E-10 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
Notes for Figure 12
1. Variable Name (Example 1: @GV.FLOW_RATE) (Example 2: @GV.TOTAL_FLOW_RATE)
2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be
shown as asterisks.
Analog values are displayed in floating point format, for example, 0.0125, 99.627, and 1287.66.
When the value cannot be shown in floating point format, scientific format is used
(1.287668E+10 or 1.25E-02 for example).
3. Questionable Data Status - for analog variables, column 1 will be clear if the status is valid. It
will display a question mark if the status is questionable.
4. Variable Inhibit Status
CE (Control Enable) means this variable can be updated by the ControlWave project.
CI (Control Inhibit) means the variable cannot be updated by the ControlWave project.
ME (Manual Enable) means the variable can be changed manually.
MI (Manual Inhibit) means the variable cannot be changed manually.
5. Alarm Enable (for alarm variables only)
AE - variable is alarm enabled (changes will be reported).
AI - variable is alarm inhibited (changes will not be reported).
6. Alarm State
For Analog Variables:
HH - high-high alarm
HI
- high alarm
LO - low alarm
LL - low-low alarm
For Logical Variables:
TA - true alarm
FA - false alarm
CA - change-of-state alarm
! - alarm is unacknowledged
Notes for Figure 12 (Continued)
7
Multiple Signal Display
In Read Mode, pressing MULT (F3) will display the variable name extension, value, and units
for three variables at one time. These variables include the variable displayed when NEXT (F2)
was pressed and the next two variables in the list. Press SNGL [F3] to return to viewing one
variable at a time (see Figure 12A).
Figure 12A - Example of MULT Display in READ Mode
Variables are shown below as they would appear in SNGL mode.
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-11
1) String
SITE_NAME
WEST SUNBURY PUMP STATION
CE ME
2) Analog
TOTAL_FLOW_RATE
1260.578
CE MI
3) Logical
FLOW_ALARM
OFF
CE MI AE NA
E4.1.7 Signing-Off
Once you have logged-on, use the [INIT] key at any time to log-off. When this key has been
pressed, the screen will look like Figure 13. Press Yes (F1) to sign-off. You are signed-off
when the Identifier Display (Figure 3C) appears.
If you do not want to log-off, press Exit (F4) to leave the Log-Off Display.
Once you are signed-on an automatic sign-off will occur if 20 minutes has elapsed since the
last key was pressed.
Figure 13 - Log-Off Display
E-12 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
E5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO.
10
1
5.50
5.50
3.25
3.13
.19
1.13
.313
.31
TYP
1.25
.75
2.750
.43
7.38
.06
2.13
2.00
.25
MAX
TYP.
.25
1.25
4.19
.06
6.500
.50
.75
10
.190
.170
4.69
7.38
1
3.625
.937
Figure 14 - 25-Button Display/Keypad Assembly Installation Drawing
CI-ControlWave GFC-CL
Appendix E - Display/Keypad / E-13
Figure 15 - 25 Button Keypad
Table 1 - 25 Button Keypad Keys
KEY
F1, F2, F3,
F4
INIT
0 to 9, -, .
Δ
∇
ALM I/E
ALM ACK
A/M
OPER I/E
DEL
ENTER
FUNCTION
Function keys will take on a variety of different functions depending on the
situation. The function of these keys is listed on the legend line (bottom line) of the
display.
The INIT key is used to terminate the keyboard session and sign-off.
These keys are used to change the value of analog variables in the
CONFIGURATION mode. The 0/OFF and 1/ON keys are used to change the state
of logical variables.
Each press of this key will raise an analog variable value by 1% of the displayed
value or turn a logical variable ON.
Each press of this key will lower an analog variable value by 1% of the displayed
value or turn a logical variable OFF.
Use this key to enable or inhibit alarm variables.
Use this key to acknowledge alarms.
Toggle between AUTO (CE) and MANUAL (CI) with this key.
Toggle between manual inhibit (MI) and enable (ME) with this key.
Use this backspace key to erase digits that have been entered on the keypad.
This key is used to enter new data from the display into the controller, e.g.,
password or variable values.
E-14 / Appendix E - Display/5x5Keypad
CI-ControlWave GFC-CL
Instruction Manual
CI-ControlWave GFC-CL
Oct., 2006
ControlWave GFC-CL
Using ControlWave GFC Classic
WebBSI Web Pages
Appendix F
www.EmersonProcess.com/Bristol
BLANK PAGE
APPENDIX F
ControlWave GFC Classic
Using ControlWave GFC Classic
WebBSI Web Pages
TABLE OF CONTENTS
SECTION
TITLE
F.1
F.1.1
F.2
F.2.1
F.3
F.4
F.4.1
F.4.1.1
F.4.1.2
F.4.2
F.4.3
F.5
F.5.1
F.5.2
F.5.2.1
F.5.2.2
F.5.3
F.5.4
F.5.4.1
F.5.4.1.1
F.5.4.1.2
F.5.4.1.3
F.5.4.1.4
F.5.4.1.5
F.5.5
F.5.5.1
F.5.5.2
F.5.5.3
F.5.5.4
F.5.6
F.5.6.1
F.5.6.2
F.5.7
F.5.7.1
F.5.7.2
F.5.7.3
F.5.7.4
F.5.7.5
F.5.7.6
F.5.7.7
F.6
F.6.1
F.6.1.1
F.6.1.2
GENERAL OVERVIEW .................................................................................................F-1
Viewing WebBSI .............................................................................................................F-1
INSTALLING WebBSI SOFTWARE & ControlWave GFC Web Pages......................F-1
Communication Connections .........................................................................................F-2
WebBSI PROGRAM STARTUP.....................................................................................F-3
SECURITY CATEGORY FUNCTIONS ........................................................................F-3
Signing On/Off ................................................................................................................F-4
Selecting a Node and Signing ON..................................................................................F-4
Signing Off from the Node .............................................................................................F-4
Locating Nodes................................................................................................................F-4
Contacts...........................................................................................................................F-5
STATION CATEGORY FUNCTIONS...........................................................................F-5
Station Summary............................................................................................................F-5
Sampler and Odorizer Configuration ............................................................................F-6
Sampler Configuration ...................................................................................................F-6
Odorizer Configuration...................................................................................................F-7
Mechanical Counter Configuration ...............................................................................F-7
Nomination......................................................................................................................F-7
Nomination Operation....................................................................................................F-8
Enabling the Nomination Function ...............................................................................F-8
Beginning a Nomination Period...................................................................................F-11
Ending a Nomination Period........................................................................................F-11
Changing the Nomination Target................................................................................F-11
Manually Starting/Ending a Nomination Period........................................................F-11
Flow Control & Valve Control......................................................................................F-12
Nomination....................................................................................................................F-12
Flow Control..................................................................................................................F-12
Pressure Override (set one or both to enable override) ..............................................F-14
Valve Control ................................................................................................................F-14
Run Switching...............................................................................................................F-15
Common Properties ......................................................................................................F-15
Run1 & Run2 Properties ..............................................................................................F-15
Radio & Modem Control ...............................................................................................F-16
Radio/Modem Control Mode.........................................................................................F-16
Common Properties ......................................................................................................F-16
Radio Sensing Mode .....................................................................................................F-17
Hourly Mode..................................................................................................................F-17
Daily Mode ....................................................................................................................F-17
Day Light Mode ............................................................................................................F-18
Statistic .........................................................................................................................F-18
METER RUN CATEGORY FUNCTIONS ..................................................................F-18
Meter Run Overview ....................................................................................................F-18
AGA3 - Orifice Meter....................................................................................................F-18
AGA7 Frequency Meter................................................................................................F-20
CI-ControlWave GFC-CL
PAGE #
Appendix F - Using ControlWave GFC-CL WebBSI Web Pages / 0 - 1
APPENDIX F
ControlWave GFC Classic
Using ControlWave GFC Classic
WebBSI Web Pages
TABLE OF CONTENTS
SECTION
TITLE
F.6.2
F.6.2.1
F.6.2.2
F.6.2.3
F.6.2.4
F.6.3
F.6.3.1
F.6.3.1.1
F.6.3.1.2
F.6.3.1.3
F.6.3.2
F.6.4
F.7
F.7.1
F.7.2
F.7.3
F.7.4
F.7.5
F.8
F.8.1
F.8.2
F.8.3
F.8.4
F.9
F.10
Meter Run I/O Configuration.......................................................................................F-21
Differential Pressure, Static Pressure and Temperature Inputs ..............................F-22
Frequency Input ...........................................................................................................F-23
Heating Value Input.....................................................................................................F-23
Alarm Configuration (Accessed via Meter Run I/O Configuration)...........................F-24
Flow Equations .............................................................................................................F-25
Orifice Flow Equation Setup........................................................................................F-25
Differential Measurement............................................................................................F-25
1985 AGA3 Equation Configuration............................................................................F-25
1992 AGA3 Equation Configuration............................................................................F-27
Frequency Flow Equation Setup..................................................................................F-29
Supercompressibility Setup .........................................................................................F-30
CHROMATOGRAPH CATEGORY FUNCTIONS......................................................F-31
Communication Settings ..............................................................................................F-31
Stream Assignment and Setup ....................................................................................F-32
Analysis Data................................................................................................................F-32
Gas Components ...........................................................................................................F-32
Chromatograph Component Range Setup ..................................................................F-33
LOGS CATEGORY FUNCTIONS ...............................................................................F-33
Meter Run Archive Files ..............................................................................................F-33
Meter Run Audit Trial..................................................................................................F-34
View Signal List............................................................................................................F-35
Archive File Collection .................................................................................................F-35
LOAD/SAVE CATEGORY FUNCTION ......................................................................F-36
SPECIAL FUNCTIONS ...............................................................................................F-38
CI-ControlWave GFC-CL
PAGE #
Appendix F - Using ControlWave GFC-CL WebBSI Web Pages / 0 - 2
Appendix F
Using ControlWave GFC-CL
WebBSI Web Pages
F.1 GENERAL OVERVIEW
The ControlWave GFC-CL is configured and monitored using WebBSI Web pages
developed specifically for the standard application program. The Web pages are stored and
displayed on a personal computer (PC), and use either OpenBSI Network edition or Local
edition to interface to the ControlWave GFC-CL. Web pages provide:
* Sign-on to the ControlWave GFC-CL
* Invoke menus to configure the ControlWave GFC-CL for operation
* Read current gas flow and total information
* Set the ControlWave GFC-CL Date and Time
* Change the ControlWave GFC-CL network address
* Collect & Display the Daily, Hourly, Periodic, & Audit Logs
F.1.1 Viewing WebBSI
WebBSI is best viewed under these conditions:
• The Internet Explorer window should be maximized or be viewed full-screen.
• The resolution of the monitor should be at least 800x600 or above (preferably 1024x768 or
above).
• The color depth should be at least 16 bit high color or above (preferably 24 bit true color or
above).
• The text size of Internet Explorer should be "Medium" or smaller (preferably "Medium").
• JavaScript and ActiveX Controls should be enabled in Internet Explorer.
Pop-up Help windows for WebBSI Web pages can be accessed by clicking the Help button
on the left side of WebBSI Web pages. The help windows must be closed in order to open
another.
On pages that contain tables of controls:
• A white background on a control means that it is read/write.
• A beige background on a control means that it is read only.
F.2 INSTALLING WebBSI SOFTWARE & ControlWave GFC-CL
Web Pages
The WebBSI software requires a PC (computer) running either OpenBSI Network Edition
or OpenBSI Local Edition, with the WebBSI ActiveX controls installed and registered on
the PC (see appropriate document for details).
ControlWave GFC-CL Web pages will be installed in the following directory as the
default: C:\OpenBSI\WebGFC_CL\ and the default startup page will be
CW_MICRO_GFC.htm
CI-ControlWave GFC-CL
Appendix F / F-1
Figure F-1 - ControlWave GFC-CL
Connected to PC via the Local Communications Cable
F.2.1 Communication Connections
The ControlWave GFC-CL communicates with the PC through the Local Port as shown in
Figures F-1 through F-2B or through the Network if configured. The Local Port has been
provided specifically for installation/startup and on-site configuration and data collection.
For ControlWave GFC-CLs equipped with a Local Port that utilizes a D-Type connector,
local communications between the ControlWave GFC-CL and the PC is provided over a
standard ControlWave null-modem cable (see Figure F-2A). Units equipped with the
circular 3-pin Local Port utilize a special cable as illustrated in Figure F-2B.
Figure F-2A - ControlWave GFC-CL
Null Modem Cable (Bristol P/N 392843-01-3) Connection Diagram
Note: Connector J19 on the CPU/System Controller Board also = the Local Port
F-2 / Appendix F
CI-ControlWave GFC-CL
Figure F-2B - PC Connected to ControlWave GFC-CL via Local Port
(Circular Connector Version)
Bristol Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Part Number 395402-02-6 = 25 Foot Comm. Cable
F.3 WebBSI PROGRAM STARTUP
Ensure that the Local Communications Cable connections (at both the ControlWave GFCCL & the PC) are secure.
If the WebBSI Web pages for the ControlWave GFC-CL have been assigned as the default
Web pages for a node in OpenBSI, they can be invoked either from OpenBSI by right
clicking on the appropriate RTU and selecting RTU -> WebPage Access. Web pages are also
accessible by selecting Start -> Programs-> OpenBSI Tools-> WebPage Access -> CW GFCCL Pages.
Seven Category Functions are provided as follows:
Section F.4 (Security)
Section F.5 (Station)
Section F.6 (Meter Run)
Section F.7 (Chromatograph) Section F.10 (Special Functions)
Section F.8 (Logs)
Section F.9 (Load/Save)
F.4 SECURITY CATEGORY FUNCTIONS
Three Web pages are accessible from the Security category section of WebBSI.
• Sign On/Off
• Locate Nodes
(Section F.4.1)
(Section F.4.2)
CI-ControlWave GFC-CL
• Contacts
(Section F.4.3)
Appendix F / F-3
F.4.1 Signing On/Off
When the WebBSI Web pages for the ControlWave GFC-CL are first accessed, the SIGN
On/Off Web page is displayed. A user must select the RTU Name from the drop down
menu. If using OpenBSI Network Edition, this drop down menu will include all nodes
available on the network. If using OpenBSI Local Edition, only the default node (RTU) will
be available.
Figure F-3 - Sign On/Off Web Page
F.4.1.1 Selecting a Node and Signing On
The user must choose the Node they want to sign-on to from the RTU Name list box. The
user must enter the Username and Password. The user must then click on the Sign On
button. If the sign-on attempt is successful, the message Access Granted will appear (in
green text) within the message area. Failure messages appear in red text and informational
messages appear in black text.
F.4.1.2 Signing Off from the Node
To sign off from a Node, the user must click on the [Sign Off] push button. If the sign-off
attempt is successful, the message “Sign Off Successful” will appear in green (failures are
in red).
Note: For Security Maintenance functions refer to CW MICRO Quick Setup Guide – D5124
– Part 2 – Configuring User Accounts & Privileges.
F.4.2 Locating Nodes
The user may identify which node(s) they would like to communicate with by using the
Locator page. The Nodes can be identified either by loading a proxy file, or by loading Open
BSI information. In either case, they will be displayed as icons in a tree on the left side of
the page.
F-4 / Appendix F
CI-ControlWave GFC-CL
The Node Locator Web page is accessible by clicking on the Security category button and
choosing the Locate Nodes drop-down menu selection.
Figure F-4 - Locate Nodes Web Page
F.4.3 Contacts
A list of Bristol Inc. offices is provided under the topic Contacts.
The Contacts Page is accessible by clicking on the Security category button and choosing
the Contacts drop-down menu selection.
F.5 STATION CATEGORY FUNCTIONS
The standard application program for the ControlWave GFC-CL allows the user to
configure a station with up to four meter runs. Users must configure Station parameters
from the Station Configuration category section of WebBSI. Seven Web Pages are
accessible from the Station Configuration category section of WebBSI.
•
•
•
•
•
•
•
Station Summary
Sampler & Odorizer
Mechanical Counter
Nominations
Flow Control
Run Switching
Radio & Modem Control
(Section F.5.1)
(Section F.5.2)
(Section F.5.3)
(Section F.5.4)
(Section F.5.5)
(Section F.5.6)
(Section F.5.7)
F.5.1 Station Summary
Station Summary Web Pages display corrected and uncorrected flow rates and volumes
for the station and each run. Corrected Volumes, Uncorrected Volumes and Accumulated
Energy totals are displayed for the previous hour and previous day.
CI-ControlWave GFC-CL
Appendix F / F-5
Figure F-5 - Station Summary Web Page
F.5.2 Sampler and Odorizer Configuration
See section F.5.2.1 for Sampler Configuration or F.5.2.2 for Odorizer Configuration.
Figure F-6 - Sampler & Odorizer Configuration Web Page
F.5.2.1 Sampler Configuration
The user may enable or disable the Sampler by using the Enable/Disable button. If
enabled, the Sampler will operate at a frequency set by the Pulse Frequency setpoint (in
cubic feet). Users must select which Digital Output (DO) Point will be used. A running
count of samples taken will be displayed. Users may reset this count by pressing the Reset
Count button.
F-6 / Appendix F
CI-ControlWave GFC-CL
F.5.2.2 Odorizer Configuration
Users may enable or disable the Odorizer by using the Enable/Disable button. The user
also selects the Output Mode, i.e., Analog Output or Digital Output. If the Analog Output
Mode is selected, Analog Point ID 1 is assigned. If the Digital Output Mode is selected, the
Digital Output Point to be used is selected via the DO Point ID field.
When the Analog Output Mode is selected, the user must set the Scale Factor. The Scale
Factor is a ratio of the amount of odorant to be injected per cubic foot of gas. Users must
know the maximum output of the Odorizer and calculate the ratio accordingly.
The Current Odor Demand is the raw value of the odorant required. If this value is greater
than that which is allowed by the AO Zero and Span, the actual odorizer output will be
clamped to the maximum AO value.
When the Digital Output Mode is used, the user must enter the frequency of the pulses per
volume through the meter (in cubic feet).
F.5.3 Mechanical Counter Configuration
The Mechanical Counter Configuration section of the Sampler & Mechanical
Counter Configuration Web Page is used to simulate a mechanical counter. An
Enable/Disable button is used to activate/deactivate this function. Synchronization of the
ControlWave GFC-CL Counter with an external Mechanical Counter is achieved via the
Initial Count field. Determination of the volume of gas per pulse is performed utilizing the
Pulse Frequency field. Current Count is the actual number of pulses received by the unit.
Users must select which HSC Input will be used with the Mechanical Counter.
Figure F-7 - Mechanical Counter Configuration Web Page
F.5.4 Nomination
Users configure the nominations control from the Nomination WebPage. Nominations
functionally provide the user with the ability to set the ControlWave GFC-CL to allocate
precise amounts of gas flow during specific time periods. These periods are called
“nomination periods.” A nomination may be set for any duration of time (not to exceed one
month). The volume to be delivered (nominated) during a nomination period is the target.
Targets may be specified in terms of volume or energy. Users set a nomination period by
keying in the desired day of the month and hour to begin the period and the desired day of
CI-ControlWave GFC-CL
Appendix F / F-7
the month and hour to end the period. The daily nomination feature is used if the user
desires the same start/stop times every day. A unit programmed with a daily nomination,
will ignore the programmed start and end day numbers and will perform the nomination in
question at the same time once per day.
The delivery of the nominated quantity (volume or energy during the nomination period)
may be performed via one of the two unique schemes listed below.
Valve Control
The Valve Control method overrides PID flow control and allows the valve to be
independently controlled, thus permitting full flow of gas through the meter in order to
arrive at the target (volume or energy) as quickly as possible without regard to the
programmed end time.
Flow Control
The Flow Control method internally enables the PID flow control algorithm in order to hit
the target volume/energy at exactly the programmed end time.
The user programs the ControlWave GFC-CL (via the ‘Stop Mode’ button) to either close
the valve upon reaching the target or leave it in its last position.
F.5.4.1 Nomination Operation (See sections F.5.4.1.1 through F.5.4.1.5)
Figure F-8 - Nomination Web Page
F.5.4.1.1 Enabling the Nomination Function
The nomination function runs once per calculation cycle after the volume and energy
accumulations have been updated by the ControlWave GFC-CL. To setup and enable this
feature follow the steps below.
1. Setup of the nominations feature depends on the desired control mode selection, i.e., the
Fast approach mode or PID mode. Fast approach mode is the default mode for
nominations. If the desired control mode is the Fast approach mode, proceed to step 2;
however, if the desired control mode selection is the PID mode, you must first program
all the PID tuning parameters such as gain and integral. Note: DON’T enable the PID
flow control algorithm or the ControlWave GFC-CL will automatically disable
F-8 / Appendix F
CI-ControlWave GFC-CL
nomination. When properly configured the ControlWave GFC-CL will automatically
enable the PID flow control algorithm during nomination periods.
2. Select the Nomination Web Page (Figure F-8) via the Nomination button under the
Station Category Function (also see Figure F-9).
A description of the menu entries (Figure F-8) used to implement the nomination function follows:
NOMINATION CONTROL – In addition to the Time, this section of the Nomination
Web Page provides the following eight areas for nomination setup/selection:
Main function
The Main function selection is used to enable/disable the nomination function. If this
signal is set to the disable state, nomination will not occur.
Quantity units
The Quantity units selection is used to set the target units as MCF or MMBTU.
Control mode
Control mode provides for the selection of either the Valve Control or Flow Control
modes of nomination operation.
Status
The Status signal is an output of the nominations algorithm that indicates whether
there is currently a nominations period in progress. The user may change the state of
this signal to end an in progress nomination immediately, or to start the next period
immediately (see Manually Starting/Ending a Nomination Period).
Stop Mode
The Stop mode selection allows the user to automatically have the valve closed, i.e.,
shut-in on stop mode, or left in the last position upon reaching the target (or
programmed end period).
Daily Only Mode
When Daily mode is enabled, only the programmed start and end hours are used by the
ControlWave GFC-CL; the Start/Stop days are ignored, i.e., nomination begins and
ends within a 24 hour period every day.
Alarm at a level of %
The Alarm at a level of % setting can be configured as percentage of Volume (MCF) or
Energy (MMBTU). This feature allows the ControlWave GFC-CL to provide an alarm
(logical nomination alarm) or indication to an operator or computer that a specified
amount of target has been reached. The number entered (1 to 100) sets the percentage
at which the logical nomination alarm will occur. The status of this setting, i.e., whether
or not a nomination alarm has occurred, can be determined via the Alarm Status signal
(see Figure F-8).
Alarm Status
When the amount specified in ‘Alarm at a Level of (%)’ is reached, the value of the
signal will be set true.
CI-ControlWave GFC-CL
Appendix F / F-9
CURRENT NOMINATION PERIOD - This section allows the operator to view the
following information associated with a nomination which is currently in progress:
Start: day/hour
The actual time and day of the month when the current nomination period started is
displayed. This may be the programmed time or the time at which an operator manually
started a period.
Stop: day/hour
The programmed end time and day of the month at which the current nomination
period will end. If using the Fast approach mode, the period may end sooner, i.e., when
the target is reached. If using the daily nomination feature, the stop date (day) will
show 0 to indicate that only the hour matters.
Target value (x 1000)
The Target value provides the value of Volume/Energy to be delivered during this
period.
Amount Delivered (x 1000)
The Amount Delivered reading provides the actual amount of volume/energy delivered
so far during this period.
Percent elapsed time
This signal shows the percentage of time which has elapsed for the current nomination
period, e.g., 4 hours into a 100 hour nomination period would cause this value to be 4.0.
Percent Delivered
This signal provides the percentage of target delivered to this point in the current
nomination period.
NEXT NOMINATION PERIOD - This section allows the operator to set/view the
following parameters associated with the next nomination which is to be programmed
(has been programmed): Note: New entries must be made prior to the ending of the
current nomination period.
Start: day/hour
The actual start day of the month (1-31) and start hour (0-23) when the next nomination
period is to start is displayed or entered. The start day is ignored if the daily nomination
feature is enabled.
Stop: day/hour
The actual stop day of the month (1-31) and stop hour (1-23) when the next nomination
period is to end is displayed or entered. The stop day is ignored if the daily nomination
feature is enabled.
Target Value (x 1000)
The Target value is used to set the value of Volume/Energy to be delivered during the
next nomination period.
LAST NOMINATION PERIOD - This section allows the operator to view information
associated with the last nomination period which was completed. Information displayed
remains valid until the next time a nomination period ends (when the information is upgraded to reflect the new "last" nomination period). Start and end times stored here
F-10 / Appendix F
CI-ControlWave GFC-CL
indicate the actual time that the nomination period ended, which is not necessarily the
programmed time (because of the time required to close/open valves or complete other
actions). The days are valid even if the daily nomination mode is active.
3. Program all the configuration items for the NEXT Nomination Period such as start
and stop times and target value.
4. Set the desired parameters for NOMINATION CONTROL such as Quantity units,
Control mode, Stop mode, Daily only mode and Alarm at a level of and then set the Main
function signal to the Enable State.
5. If a radio or modem is to be used in conjunction with a "logical nomination alarm,"
access the Radio & Modem Control Configuration Web Page (see Figure F-11) via the
Radio Control button. See Section F.5.6 to configure the radio or modem for logical
nomination alarms.
F.5.4.1.2 Beginning a Nomination Period
When no nomination period is in progress, the ControlWave GFC-CL compares the NEXT
start date and time to the current time. If the date and time match (or time only for the
daily nomination mode), a new period is begun. The current time is copied into the
CURRENT START signals, and the next target is copied into the current target. The accumulators for the current period are zeroed and the current stop time is set to the next
start time. If the PID mode is selected, a new flow setpoint is calculated and stored in the
setpoint signal. The PID setpoint is recalculated every 15 minutes and whenever any
parameter is changed.
F.5.4.1.3 Ending a Nomination Period
If shut-in on stop mode is in use, the current period will end when the target accumulation
is reached. At this time, the ControlWave GFC-CL attempts to close the control valve. If
PID control is being used, the setpoint is set to 0.0, the current cycle will ramp down
accordingly. When the flow rate reaches 0.0, the current cycle accumulations and the actual
end time are copied into the LAST signals. If the valve fails to close, the volume will
continue to accumulate until the programmed end time. If the shut-in on stop mode is not
in use, the nomination period continues until the programmed end time.
F.5.4.1.4 Changing the Nomination Target
To change the target of the next period, the user should change the NEXT TARGET signal.
F.5.4.1.5 Manually Starting/Ending a Nomination Period
When a Nomination Period is not in progress, the user can immediately begin the NEXT
period by setting the Status signal to the ON state. The current start time will reflect the
time that the user started the cycle. The target and stop times used will be those of the
NEXT period. The user may immediately end a nomination period which is in progress by
setting the Status signal to the OFF state. The current time will be stored as the LAST stop
time.
CI-ControlWave GFC-CL
Appendix F / F-11
F.5.5 Flow Control & Valve Control
The Flow Control & Valve Control Web Page (Figure F-9) is accessible via the Flow
Control button. The PID Controller is utilized in the ControlWave GFC-CL for Flow Rate
Control. Sections F.5.5.1 through F.5.5.4 provide information on the four major functions
accessible from the Flow Control & Valve Control Web Page (see Figure F-9).
Figure F-9 - Flow Control & Valve Control Web Page
Users are cautioned to test the regular override controller actions to verify correct valve
movement for all expected conditions.
F.5.5.1 Nomination
Function
The Nominations Function provides for enabling/disabling the nominations feature (see
Section F.5.3). If this signal is set to the disable state, no nomination will be performed.
Status
The Status signal is an output of the nominations algorithm that indicates whether there is
currently a nominations period in progress. The user may change the state of this signal to
end an in progress nomination immediately, or to start the next period immediately (see
Manually Starting/Ending a Nomination Period in Section F.5.3).
F.5.5.2 Flow Control
Enable
Pressing the button to the right of Enable will allow the operator to toggle between PID
Flow Control Enabled and Disabled. It is recommended that GAIN, INTEGRAL and
DERIVATIVE adjustments be checked before turning a controller ON.
F-12 / Appendix F
CI-ControlWave GFC-CL
Warning
Do not enable PID Flow Control without first checking the external process control
loop. The initial values displayed on the PID Menu may drive some critical
processes beyond the extremes of safe limits. This could result in fire, explosion,
property damage, and injury to persons. When setting the WebBSI Web Page
parameters, make sure the associated process is observed and protected.
Setpoint (x1000)
This field contains the operating point at which the flow rate is to be controlled. Set-point
units are MSCFH with a default setting of 1000 MSCF per Hour. To change the Setpoint
value, right click on the field and select Change Signal Value.
Gain
Gain controls the amount of output change resulting from a change of the measured
variable. The default value of 1.00 is typically used as a starting point; final gain is usually
less. To change the Gain value, right click on the field and select Change Signal Value.
Integral
Integral determines the time it will take the PID to correct an error in the measured
variable. The number of times the output is adjusted in a given time period is specified in
seconds. An entry of 60 seconds can be used as a starting point; this would provide one (1)
repeat per minute. To change the Integral value, right click on the field and select Change
Signal Value.
Derivative
Derivative compensates for a rapidly changing measured variable. The time is specified in
seconds (SECS) and most applications will use a setting of zero (0). To change the
Derivative value, right click on the field and select Change Signal Value.
Deadband
Deadband provides a means of specifying a 'window' in which the variable does not affect
the output. This entry is in percent (%) of the SETPOINT signal. As an example, a 5% entry
would mean that the controller output must exceed the present setpoint by 5% before the
output is changed. To change the Deadband value, right click on the field and select Change
Signal Value.
Max Flow Rate (x1000)
Max Flow Rate represents the maximum flow rate allowed. If the number entered in the
Setpoint field exceeds the Max Flow Rate value, the Max Flow Rate value will be used. To
change the Max Flow Rate (x1000) value, right click on the field and select Change Signal
Value.
Valve Travel Time
Valve Travel Time is the amount of time it takes a Control Valve to go from being fully
open to fully closed (or visa-versa). The default value is 30 Seconds. To change the Valve
Travel Time value, right click on the field and select Change Signal Value.
Current Data Flow Rate (x1000)
The Flow Rate value is Read Only data; it is the present calculated flow rate per hour.
CI-ControlWave GFC-CL
Appendix F / F-13
F.5.5.3 Pressure Override (set one or both to enable override)
When the PID controller is active in flow-control mode, it will adjust a pressure valve to
maintain the established flow rate setpoint. Pressure override is used in situations where
full line pressure should not be applied to the downstream equipment or in circumstances
where a minimum pressure must be maintained.
Maximum & Minimum
A Maximum and Minimum pressure can be configured which set the PID controller to
switch to pressure control mode whenever the line pressure attempts to go outside the
defined limits. The pressure override mode becomes active when either or both limits are
set to a non-zero value.
Pressure Tap Location Relative to the Control Valve
The Pressure Tap location is specified as either upstream UPSTRM or downstream
DNSTRM with respect to the control valve. The action of the override controller depends on
the configured Tap location. When the pressure tap is configured as Downstream of the
control valve, pressure will rise as the valve opens to increase the flow rate. Increasing
demand will cause the valve to open more. Should conditions occur that cause the pressure
to exceed the maximum pressure limit, the override will take control and close the valve to
maintain the configured maximum pressure. Should the valve attempt to close and reduce
pressure below the configured minimum pressure, the override will take control to
maintain the minimum pressure. When the pressure tap is configured as Upstream, the
action is reversed, i.e., when the maximum pressure is exceeded the valve will open to lower
the pressure. When the minimum pressure is exceeded the valve will be closed.
F.5.5.4 Valve Control
A user may select the Valve Control type, i.e., Analog Output or Raise/Lower control via the
Digital Outputs. If the operator selects Analog Output control, Analog Output 1 will be
used by default. Current Data will show the value of the Analog Output in percent (4mA =
0%, 20mA = 100%).
Users may set the valves Output Control into either Manual or Automatic (Auto). When
Manual Mode has been selected, the current value of the Analog Output will be frozen.
Users may change the Manual Analog Output value, by right clicking on the field and
entering a new value. When the mode is changed back to Automatic, the valve control
starts from the last Manual value entered for Bumpless transfer.
If the user selects Raise Lower Mode, the DO associated with raising the valve must be
selected and a separate DO must be selected for lowering the valve. When the Raise Lower
Mode is being used, the Current Data section will display if the Raise DO is Off’ or Raising
and it will display the Lower DO state, i.e., Off or Lowering.
In the Manual Control mode, users may select whether to Raise or Lower the valve by using
the Manual Raise or Manual Lower Output buttons. If the valve is raising and the operator
pushes the Manual Lower Output button, the Raise Output will be automatically set to Off.
If the valve is lowering and the Manual Raise Output button, is pressed, the Lower DO
will automatically be set Off.
When switching back and forth between the Automatic and Manual Modes, both Raise and
Lower DOs will be set to Off.
F-14 / Appendix F
CI-ControlWave GFC-CL
F.5.6 Run Switching
Sections F.5.6.1 and F.5.6.2 provide information on run switching properties (see Figure F10). Enable/Disable Run Switching via a button to the right of Run Switching.
F.5.6.1 Common Properties
Current Rank shows how many runs are required to be open. Maximum Rank is selected by
the user (from 1 to 2). Process Variable (PV) Selection can be Differential Pressure,
Frequency or Flow Rate. The Transition Time is the amount of time required to allow run
switching to access (opening or closing a run). Valve Settle Time is the amount of time
allowed after the Transition Time for the process variable (PV) to settle, before allowing
another run switching action to occur.
Figure F-10 – Run Switching Web Page
F.5.6.2 Run1 & 2 Properties
When a run is in Manual Mode (selected by the Run Auto/Manual button), the valve may
be opened or closed by right clicking on the field to the right of the Current Valve Command
and toggling the valve. When a run is in Auto Mode and Run Switching is enabled, the
valve is controlled by the run switching logic. If the Target Rank of a run is 1, the valve will
always be open. The Call Next Run Setpoint (SP) is the value if the process variable (DP,
Frequency or Flow Rate) that will cause the next run to open. The process variable for
calling runs is the PV from the run selected as Target Rank 1. If the run with Target Rank
1 is open, and the run with Target Rank 2 is not open when the PV for Target Rank 1
exceeds the Call Next Run SP, the Target Rank 2 will be opened. Likewise, if the PV for
Target Rank 2 drops below the Call Prev Run SP, the highest ranked run that is open will
be closed.
Call Next Deadband is the amount of time that the PV has to be greater than the Call Next
Run SP value before the next run will be opened.
Call Previous Deadband is the amount of time that the PV has to be less then the Call Prev
Run SP value before the lowest rank run will be closed.
CI-ControlWave GFC-CL
Appendix F / F-15
Valve Control DO Point is the digital output point used for valve control.
F.5.7 Radio and Modem Control
The Radio & Modem Control Configuration Web Page is accessible for users by
selecting Radio & Modem Control.
Figure F-11 – Radio and Modem Control Configuration Web Page
F.5.7.1 Radio/Modem Control Mode
Enable/Disable Radio/Modem Control via a control button to the right of Radio/Modem
Control Mode.
F.5.7.2 Common Properties
Local Address
Local Address of the ControlWave GFC-CL is set via the RTU Configuration
Parameters Page in NETVIEW or LOCAL VIEW.
Group Number
Group Address of the ControlWave GFC-CL. This is set via the RTU Configuration
Parameters Page in NETVIEW or LOCAL VIEW.
Activate Radio/Modem on Local Port Active
When using any of the radio/modem port scheduling modes (Radio Sensing, Hourly, Daily
or Daylight) Port 2 (the Radio/Modem Port) is inactive unless communications are
scheduled. However, by enabling the Activate Radio on Local Port Active mode, Port 1 (the
Local Port) can be used to control the state of Port 2.
F-16 / Appendix F
CI-ControlWave GFC-CL
F.5.7.3 Radio Sensing Mode
Radio sensing allows a user to activate the radio for very short time intervals (specified in
milliseconds under Listen Time Out) every so many milliseconds (specified in seconds
under Listen Interval) to 'sense' a valid BSAP message on the radio's carrier frequency. If a
message is not detected, the radio is deactivated. If a message is detected, the radio is left
activated until it responds, after which it remains ON for another listen time interval. If no
more valid messages are detected, the radio returns to 'sense' mode. This mode allows the
system to use as little energy as possible to detect traffic throughout the day. Energy usage
depends on the activation time and activation rate (INTERVAL). Assuming a 1 watt radio
then a 200 millisecond listening period every 5 seconds is equivalent to .04 watts. Users can
configure the Interval and Rate (Listening period) to suit their energy needs. Radio Sensing
occurs between the START HOUR and END HOUR specified by the operator.
F.5.7.4 Hourly Mode
Start Time Offset Into Hour Seconds
Start Time Offset Into Hour Seconds specifies a user supplied offset which is used when
computing the radio/modem On Time. Start Time Offset is a factor used to calculate the On
Time.
Poll Time Per Node Seconds
Poll Time Per Node Seconds sets the duration of time (seconds) allocated for communications per node. Poll Time Per Node time is also used to calculate the On Time.
Poll Time Per Group Seconds
Poll Time Per Group Seconds sets the duration of time (seconds) allocated for communications per group. Poll Time Per Group time is also used to calculate the On Time.
Listen Time Seconds
Listen Time Seconds is the amount of time (in seconds) that the radio/modem will be
enabled for (at the scheduled time, i.e., the enabled time before it will shut off due to the
lack of communications.
Re-Calculate Next On Time
If the user makes any changes to the items that affect the On Time, it must re-calculate the
Next On Time using this button.
Next On Time Hour/Minute/Second
When the Radio/Modem Control Mode is selected for Hourly, Daily or Daylight, these
values represent the next time that the radio will be turned on.
Turn Off Delay Seconds
Turn Off Delay Seconds is the amount of time (in seconds) that the radio/modem will
remain enabled after successful communications have been established and completed. The
radio will remain active for the time period specified at the Turn Off Delay.
F.5.7.5 Daily Mode
Daily Mode Hour Offset
When the Daily Mode is selected, the radio/modem will be turned on once during the day.
The Daily Mode Hour Offset determines which hour (0 - 23) that the radio will be turned
on. On Time Minutes and On Time Seconds are calculated.
CI-ControlWave GFC-CL
Appendix F / F-17
F.5.7.6 Day Light Mode
A user may want to conserve battery power by using the radio/modem only during day light
hours. This is accomplished by selecting Daylight as the Radio/Modem Control Mode. Users
select the start of day light using the Day Light Mode Start Hour and Day Light Mode Start
Minute fields. Users select the end of day light using the Day Light Mode End Hour and
Day Light Mode End Minute field.
F.5.7.7 Statistic
Current/Previous Hour Radio On Time
Current/Previous Day Radio On Time
Current/Previous Month Radio On Time
F.6 METER RUN CATEGORY FUNCTIONS
Up to four WebBSI Web Pages are accessible under the Meter Run Category Section of
WebBSI; these include:
• Overview
• I/O Configuration
(Section F.6.1)
(Section F.6.2)
• Flow Equation
• Compressibility Setup
(Section F.6.3)
(Section F.6.4)
The Web Page of Figure F.12 will appear when either the ‘Overview’ or ‘Flow Equation’
category has been selected, if a Meter Run Type (Differential or Linear) has not been
configured.
F.6.1 Meter Run Overview
See section F.6.1.1 for AGA3 Orifice Meters or F.6.1.2 for AGA7 Frequency Meters.
F.6.1.1 AGA3 - Orifice Meter
If the meter is configured as an Orifice Meter the following Read Only items are displayed:
Figure F-12 - Meter Run Type Configuration WebPage
Pipe Diameter & Orifice Diameter – To change these items, select Flow Equation from
the left side menu section.
F-18 / Appendix F
CI-ControlWave GFC-CL
Figure F-13A - Meter Run Overview (1985 AGA3 – Orifice Meter) Web Page
Figure F-13B - Meter Run Overview (1992 AGA3 – Orifice Meter) Web Page
DP (Differential Pressure), SP (Static Pressure) and T (Temperature) – Live Values
from the Transmitters being used for calculation (selected via the I/O Configuration Page).
Active Flow Calculation – (AGA3I (1992) or AGA3 (1985) – To change an item, select
Flow Equation from the left side menu section.
CI-ControlWave GFC-CL
Appendix F / F-19
Current Heating Value – The instantaneous value is provided.
Flow Rate (x1000) – The instantaneous value is provided.
Accumulated Volume and Accumulated Energy ‘Read Only’ fields are provided for the
Current Hour and Current Day:
Accumulated Volume, Accumulated Energy, Avg. Static Pressure, Avg. Temperature, Avg.
Diff. Pressure, Avg. Specific Gravity, Avg. Heating Value and Flow Time ‘Read Only’ fields
are provided for the Previous Hour and Previous Day:
The following five fields accommodate user changes:
Meter ID – a string signal identifying the meter run (default is ‘Run n,’) (n = the Run #).
Contract Hour – The user enters the Contract Hour for the start of the current day here.
Current Heating Value (Units) – The user may select the Heating Value units from a
drop down menu; default units are BTU/Ft3.
Flow Rate (Units) – The user may select the Flow Rate units from a drop down menu;
default units are Ft3/Hour.
Energy Rate (x1000000) – The user may select the Energy Rate - Energy Units from a
drop down menu; default units are BTU. The user may select the Energy Rate - Rate Units
from a drop down menu; default units are HOUR.
Reset Meter Run’s Measurement Type - This button (bottom of menu) allows the user
to reset the meter run’s measurement type (if a mistake has occurred during configuration).
F.6.1.2 AGA7 Frequency Meter
If the meter is configured as a Linear Meter, following Read Only items are displayed:
Active Flow Calculation – Always AGA7
Corrected Flow Rate – Instantaneous Value
Uncorrected Flow Rate – Instantaneous Value
Current Heating Value – Instantaneous Value
Energy Value – Instantaneous Value
The following information is displayed for the Current Hour and Current Day:
Corrected Volume
Uncorrected Volume
Accumulated Energy
The following information is displayed for the Previous Hour and Previous Day:
Corrected Volume
Uncorrected Volume
Accumulated Energy
Average Static Pressure
Average Temperature
F-20 / Appendix F
CI-ControlWave GFC-CL
Average Specific Gravity
Average Heating Value
Flow Time
Figure F-14 - Meter Run Overview (AGA7 - Frequency Meter) Web Page
There are five fields that allow the user to make changes:
Meter ID – a string signal identifying the meter run (default is ‘Run n,’) (n = the Run #).
Contract Hour – Users enter the Contract Hour for the start of the Contract Day here.
Current Heating Value (Units) – The user may select the Heating Value units from a
drop down menu; default units are BTU/Ft3.
Flow Rate (Units) – The user may select the Flow Rate units from a drop down menu;
default units are Ft3/Hour.
Energy Rate (x1000000) – The user may select the Energy Rate - Energy Units from a
drop down menu; default units are BTU. The user may select the Energy Rate - Rate Units
from a drop down menu; default units are HOUR.
Reset Meter Run’s Measurement Type - This button (bottom of menu) allows the user
to reset the meter run’s measurement type (if a mistake has occurred during configuration).
F.6.2 Meter Run I/O Configuration
Retrieving Configuration Please Wait will initially be posted on the WebBSI Web Page
when I/O Configuration has been selected followed by the Meter Run I/O Configuration
Web Page (see Figure F-15).
CI-ControlWave GFC-CL
Appendix F / F-21
The Meter Run I/O Configuration Web Page provides the mechanism for assigning the
source for the inputs to the meter run calculations. From this page, the user would assign
specific transmitters and meters to a meter run. The user may select from analog
transmitters connected to I/O points, or from Smart Transmitters using BSAP or MODBUS
connected via an RS-485 serial port. In addition, the user would select the source of the
heating value, whether it is from a chromatograph and analog inputs or manually entered.
Figure F-15 - Meter Run I/O Configuration Web Page
F.6.2.1 Differential Pressure, Static Pressure and Temperature Inputs
To select the source for pressure, differential pressure, and temperature, the user selects
‘Source,’ ‘Point ID’ and either the ‘BSAP Address,’ or ‘MODBUS Address.’
Analog Input is used when a transmitter is connected to the ControlWave GFC-CL via a
4-20mA or 1-5Vdc signal. The user must then select the Point ID on the I/O board to which
the transmitter is physically connected. In addition, the zero and span settings and the
engineering units must be assigned by clicking the ‘Zeros & Spans’ link.
Wet End is used when the internal transmitter is used. No other configuration is required.
‘BSAP’ is selected when an external Bristol Smart Transmitter (either the TeleTrans or the
MVT) is used via RS-485 communications. The only configuration required is to assign the
BSAP address (1-127) of the Bristol Smart Transmitter connected to the RS-485 port.
F-22 / Appendix F
CI-ControlWave GFC-CL
Figure F-16A – Analog Input Configuration Web Page
(Accessed from Meter Run I/O Configuration Web Page)
‘MODBUS’ is selected when an external Smart Transmitter is used via RS-485
communications. The MODBUS interface supports the register list of the Rosemount 3095
smart multivariable transmitter. No additional configuration is required. Note: This functionality is only available when the Expansion Communications Module is used.
If a Zeros & Spans Button is pressed an Analog Input Configuration Web Page Menu will
appear (see Figure F16A). Zero, Span and Units can be configured for analog inputs 1
through 3. The Analog Input Configuration Web Page also allows the user to enable/disable
the Damping function.
F.6.2.2 Frequency Input
The frequency input must be brought into one of the two high-speed counter (HSC) inputs
on the I/O board. Users select the two I/O points to which the typical turbine, PD, or
ultrasonic meter is connected. However; if using an Invensys Auto-Adjust Turbo-Meter,
both HSC inputs are used to select the Auto-Adjust Algorithm. To select the Auto-Adjust
Algorithm, the user will toggle the push button under Source from High Speed Counter to
Auto Adjust Module. In this case, the user selects which point will be used for the Main
Rotor and which point will be used for the Sense Rotor.
Further configuration of the Auto-Adjust Turbine Meter is performed via the Auto-Adjust
Configuration Page. (For a description of the items on the Auto-Adjust Configuration Page,
see the ACCOL3 Function Block Help Documentation).
If the user selects the Auto-Adjust Configuration button the Auto-Adjust Configuration for
Run # Web Page will appear (see Figure F-16B). This page provides Calibration Data,
Configuration Data and Calculated Factors.
F.6.2.3 Heating Value Input
The user has three options for the source of the heating value, Manual Entry,
Chromatograph or AGA5.
Manual Entry is selected when the heating value will be directly entered. This value may
be entered via the Meter Run I/O Configuration Web Page, or may be written to a signal
externally.
CI-ControlWave GFC-CL
Appendix F / F-23
Chromatograph is selected when the heating value is read directly from the chromatograph
via the MODBUS interface.
AGA5 is selected when the component mole % values are fed into the AGA5 equation.
Source of the component mole % values is determined by settings made on the
Chromatograph Setup Page.
Figure F-16B – Auto-Adjust Configuration for Run# Web Page
(Accessed from Meter Run I/O Configuration Web Page)
F.6.2.4 Alarm Configuration (Accessed via Meter Run I/O Configuration)
Enable/Disable - the alarm function on a per point basis.
Units and Current Value - are read from the I/O source.
Alarm Limit - are set via the appropriate alarm limit point.
Deadband - dead bands represent a range just below the high limits or just above the low
limits in which the alarm variable remains in an alarm state, despite the fact that its value
no longer exceeds the alarm limit. Should the alarm variable rapidly fluctuate above and
below the alarm limit (without the use of dead band settings), the system will be flooded
with alarm messages.
F-24 / Appendix F
CI-ControlWave GFC-CL
Figure F-17 - Alarm Configuration Web Page
(Accessed from Meter Run I/O Configuration Web Page)
F.6.3 Flow Equations
When the user pushes the Flow Equation button (on the left side of the menu) the Flow
Equation Setup Web Page that is appropriate for the meter type will appear. If the meter
type has not been configured, the screen shown for Figure F.12 will appear. A user must
then select the Meter Run Type to be used.
F.6.3.1 Orifice Flow Equation Setup
F.6.3.1.1 Differential Measurement
If the user configures the meter as a Differential Measurement type, the Flow
Equation defaults to the AGA3 (1985) equation. Users may change to the AGA3
(1992) equation by toggling the push button labeled Click Here to select AGA3I
(1992).
F.6.3.1.2 1985 AGA3 Equation Configuration
The user must configure the inputs to the equation.
Pressure Tap - The user must select Pressure Tap type and location. The type is defined
Flange or Tap and the location is defined as Upstream or Downstream. Pressure Tap is
selected as follows:
1
2
3
4
DOWNSTREAM FLANGE
UPSTREAM FLANGE
DOWNSTREAM PIPE
UPSTREAM PIPE
CI-ControlWave GFC-CL
Appendix F / F-25
Figure F-18A - (1985 AGA3) Orifice Flow Equation Setup Web Page
Low Flow Cut Off - When the differential pressure drops below the low flow cut off value,
the flow rate will be set to zero. Default units are “inches of water.”
Orifice Diameter - Orifice diameter is entered here. Default units are “inches.”
Pipe Diameter - Diameter of the pipe is entered here. Default units are “inches.”
Orifice Constant - K (AGA3 1985) - Orifice constant is entered here.
Adjust Press. - Users enter Average Barometric Pressure here.
Diff. Pressure - Actual value of Differential Pressure (Inches H2O) are displayed here.
Static Pressure - Actual value of Static Pressure (psig) are displayed here.
Temperature - Actual value of Temperature (Deg. F) are displayed here.
Specific Gravity - Specific Gravity of the gas being measured is displayed here.
FPV - Supercompressibility Factor (FPV) is displayed here.
Base Temperature - Required or Contract Base Temperature is entered here (Deg. F).
Base Pressure - Required or Contract Base Pressure is entered here (psig).
The following outputs from the AGA3 calculation are displayed:
MSCF/H - Flow rate in thousands of standard cubic feet per hour
Low Flow Cut Off - Cutoff (if the DP drops below the low flow cut off value) or OK
C Prime - Orifice Flow Constant
Fb - Basic Orifice Factor
F-26 / Appendix F
CI-ControlWave GFC-CL
Fr - Reynolds Number Factor
Y - Expansion Factor
Fpb - Pressure Base Factor
Ftb - Temperature Base Factor
Ftf - Flowing Temperature Facture
Fg - Specific Gravity Factor
Extension - Square Feet of the Product of Differential Pressure and Static Pressure
F.6.3.1.3 1992 AGA3 Equation Configuration
The user must configure the inputs to the equation.
Pressure Tap - The user must toggle between pressure tap settings Flange/Upstrm and
Flange/Dnstrm.
Low Flow Cut Off - When the differential pressure drops below the low flow cut off value,
the flow rate will be set to zero. Default units are inches of water (H2O).
Orifice Diameter - Orifice diameter is entered here. Default units are inches.
Pipe Diameter - Diameter of the pipe is entered here. Default units are inches.
Figure F-18B - (1992 AGA3) Orifice Flow Equation Setup Web Page
Orifice Temp. Coefficient - Orifice coefficient of thermal expansion is entered here
(Inches per Inch-degree F).
CI-ControlWave GFC-CL
Appendix F / F-27
Pipe Temp. Coefficient - Pipe coefficient of thermal expansion is entered here (Inches per
Inch-degree F).
Isentropic Exponent - Gas Isentropic Exponent is entered here. This should not be
changed unless the Gas Isentropic Exponent is known to be other than the 1.3 value given
in the 1992 American Gas Association (AGA3) Report.
Adjust Press. - Users enter Average Barometric Pressure here (psia).
Diff. Press. - Actual value in use is displayed here.
Static Pressure - Actual value in use is displayed here.
Temperature - Actual value in use is displayed here.
Spec. Gravity - Specific Gravity of the gas being measured is displayed here.
Z Flowing - Flowing compressibility Factor, Zf, generated from the AGA8 calculation
referenced to upstream conditions.
Z Base - Base compressibility Factor from the AGA8 Gross calculation.
Base Temperature - Required and Contract Base Temperate is entered here (Deg. F).
Base Pressure - Required or Contract Base Pressure is entered here (psia).
The following outputs from the AGA3 calculation are displayed:
MSCF/H - Flow rate in thousands of standard cubic feet per hour
Low Flow Cut Off - Cutoff (if the DP drops below the low flow cut off value) or OK
C Prime - Orifice Flow Constant
Fn - Numeric Conversion factor which includes Ev (the velocity of approach factor)
CD - Orifice Coefficient of Discharge
Y - Expansion Factor
Fpb - Pressure Base Factor
Ftb - Temperature Base Factor
Ftf - Flowing Temperature Facture
Fpv - Supercompressibility Factor
Fm - Additional Correction Factor
Extension - Square Root of the product of Diff. Pressure and Static Pressure (
)
Reynolds Number - Computed Pipe Reynolds Number
F-28 / Appendix F
CI-ControlWave GFC-CL
BCF - Base Correction (Zb/Zf)
F.6.3.2 Frequency Flow Equation Setup
If the user configures a meter as a linear meter, the AGA7 Calculation page appears (see
Figure F-19).
Figure F-19 - Frequency Flow Equation Setup Web Page
Densisty Switch - Users may select whether a density meter or Gravitometer is used as
an input to the equation.
Gravitometer Press. Switch - Users may save the default value for Pressure or Volume
entered in the Gravitometer Press. Used field.
Gavitometer Temp. Switch - Users may use the default temperature value of the value
entered in the Gravitometer Temp. Used field.
Specific Gravity - Specific Gravity of the gas being measured is displayed here.
FPV - Supercompressibility Factor is displayed here.
K Factor Units - Users may select whether the factor is in units of CuFt/Count or
Counts/CuFt.
K Factor - Actual Gas Volume represented per count is entered here. The relationship is
controlled by the K Factor Units switch. If the K Factor Units switch is set to CuFt/Count,
and each pulse from the meter represents 100 cubic feet, the K Factor is entered as 100. If
the K Factor Units switch is set to Counts/CuFt and each pulse from the meter represents
100 cubic feet, the K Factor is entered as 1/100 or 0.01.
Frequency Input - The frequency from the meter (Hz) is displayed here.
Frequency Input Max - If the frequency input exceeds the Frequency Input Max value,
the Frequency Input Max value is used in the flow equation.
CI-ControlWave GFC-CL
Appendix F / F-29
Static Pressure - Actual values in use for the calculation
Temperature - Actual values in use for the calculation
Pressure Adjustment - Average Barometric Pressure (psia)
Base Pressure - Required or Contract base pressure (psia)
Base Temperature - Required or Contract base temperature (Deg. F)
Calibration Factor - Sometimes referred to as Meter Factor, this is an adjustment factor
issued by the meter manufacturer to account for known meter adjustments. The default 1,
i.e., no adjustments required.
MSCF/H - Flow rate in thousands of standard cubic feet per hour.
MSCF/H (Max) - The maximum flow value allowed through the meter at the maximum
frequency input.
F.6.4 Supercompressibility Setup
When the 1985 AGA3 calculation is selected, the Supercompressibility (Fpv) value is
calculated using the NX-19 equations. When the 1992 AGA3 calculation is used the Flowing
(Zf) and Base (Zb) compressibility factors are calculated using either the AGA8 Detail or
AGA8 Gross module. The AGA8 Gross module provides either (G, C, N) or (HV, G, C)
modes.
Figure F-20 - Supercompressibility Configuration Web Page
If the Base Pressure or Base Temperature differ from Standard conditions (14.73 psia @ 60
ºF) and the 1992 AGA3 calculation is in use, an AGA8 Detail or AGA8 Gross module will be
executed to calculate standard compressibility Zs for the defined gas composition. The
calculation of Zs will be done once per minute or whenever a related gas constant changes.
F-30 / Appendix F
CI-ControlWave GFC-CL
Users may select which Supercompressibility equation to use on a per run basis. The user
will click on the appropriate button to select the calculation equation to be used. The
selected compressibility calculation will be shown.
When using the AGA8 Gross Calculation, the user must select the Gross Mode1 or the
Gross Mode2 calculation. The user may change the Base Pressure and the Base
Temperature for this screen.
Flowing Static Pressure, Flowing Temperature, BTU and Specific Gravity in use are
displayed on this page.
Values of the gas components used to calculate the Supercompressibility are displayed
along with the FPV, Zflowing and ZBase values calculated by the Supercompressibility
equation in use.
F.7 CHROMATOGRAPH CATEGORY FUNCTIONS
The standard application program is configured for communicating with a Daniel 2251 Gas
Chromatograph, via a serial MODBUS interface. Users will configure the Chromatograph
interface from the “Chromatograph Setup” Web Page (Figure F-21).
Figure F-21 - Chromatograph Setup Web Page
F.7.1 Communication Settings
Mode – Enabled/Disabled - When this signal is ENABLED, a chromatograph is present,
and gas component data is provided by the chromatograph interface. When this signal is
DISABLED, the fixed values for the gas component data are used.
Common Fixed Data - When COMMON is selected fixed chromatograph values for all runs
will come from the Stream 1 fixed values. When INDIVIDUAL is selected, fixed
chromatograph values will come from the individual stream assigned to each run.
CI-ControlWave GFC-CL
Appendix F / F-31
Port Number - When a chromatograph is present, this is the port number on the ControlWave GFC-CL to which the chromatograph is connected. Default Port in the load is Port 3.
MODBUS Address - When a chromatograph is present, this is the MODBUS Address (1246) of the chromatograph.
Serial or IP - Select the appropriate Interface for the Chromatograph.
IP Address - Enter the IP Address of the Chromatograph in dotted decimal format, e.g.,
(xxx.xxx.xxx.xxx).
F.7.2 Stream Assignment and Setup
The Daniel 2251 can provide gas properties for up to 4 individual streams. The standard
application program allows the user to assign any stream to any meter run (up to two
streams and two runs). Each meter run may be assigned to the same stream, or each may
be assigned to a different stream.
In the event of a chromatograph failure, the user may assign either fixed values to use for
each gas component, or the last good values retrieved from the chromatograph. This mode
is selectable on a per stream basis.
F.7.3 Analysis Data
The Raw values of BTU and Specific Gravity from the Chromatograph will be displayed for
each stream. Fixed values for BTU and Specific Gravity may be entered for each stream.
F.7.4 Gas Components
The Raw value of each gas component from the chromatograph will be displayed for each
stream. Fixed values for each gas component may be entered for each stream.
Figure F-22 - Chromatograph Component Range Setup Web Page
F-32 / Appendix F
CI-ControlWave GFC-CL
F.7.5 Chromatograph Component Range Setup
Values of BTU, Specific Gravity and each gas component of each stream are compared to
user configured (high and low) allowable limits. These limits are set from the
Chromatograph Component Range Setup Web Page, accessible from the Chromatograph
Setup Web Page. If a component is found to be outside the user defined limits, the value
will be clamped at the closest configured limit.
It also checks the sum of the components; if the sum is outside the configurable limits, a
Boolean signal is set indicating so. If any component or the total is out of range, either fixed
or last values will be used.
F.8 LOGS CATEGORY FUNCTIONS
Four WebBSI Web Pages are accessible under the Logs Category Section of WebBSI; these
are:
•
•
•
•
View Archives
View Audit Trail
View Signal List
Collection
(Section F.8.1)
(Section F.8.2)
(Section F.8.3)
(Section F.8.4)
F.8.1 Meter Run Archive Files
When View Archive has been selected, the Meter Run Archive Files WebBSI Web Page
will be displayed (see Figure F-23). Meter Run Archive Files Web Pages provide three
types of archive files, i.e., Hourly, Daily & 15 Minute for each of the two runs.
Figure F-23 - Meter Run Archive File Web Page (Hourly Archive Shown)
Meter Run Archive File Web page pushbuttons allow the user to Collect Data, Save
Parameters, Search Criteria, select Floating Point Format and show File Definition. Users
can select one of the following Archive Collection Parameters: File Number To Collect,
Select from oldest record or Freeze Date/Time. Users can select the archive file, (Hourly,
CI-ControlWave GFC-CL
Appendix F / F-33
Daily or 15 Minutes) for the run in question by entering a number from 1 to 12 in the field
adjacent to File Number:.
Meter
Run
Run ID
1
2
Run 1
Run 2
Hourly
Archive
Number
1
4
Daily
Archive
Number
2
5
15 Minute
Archive
Number
3
6
The Web page opens by default configured to view Archive 1 (R1_HOURLY). To view
another archive, the user will enter the desired archive number in the File Number: field
and then press the Collect Data button.
To save the collected archive data, the user would press the Save Parameters button. A
Save Parameters dialog box will appear which will allow the user to select the file name to
save the data as, and select the folder to save the data in. After selecting the file Name and
Path (each box) and checking Save Archive Data, the file will be saved by clicking OK on
the Save Parameters Dialog. The file saved is a binary file. To view the file, the user may
use the Data File Conversion Utility or the UOI Dump Utility (UOIDMP.exe).
By clicking on the Floating Point Format button, the user may change the way Analog
Values are displayed. By clicking on the File Definition button, the user can view how the
archive file is configured. Additionally, the Meter Run Archive Web page provides the
number of Fields Collected and Records Collected under the Stats field.
F.8.2 Meter Run Audit Trail
The ControlWave GFC-CL keeps an Audit Trail Buffer capable of storing the most recent
500 Alarms and the most recent 500 Events. Internally, these buffers are maintained
separately to prevent recurring alarms from overwriting configuration audit data.
Externally, they are reported to the user as a single entity. Both operate in a circular
fashion with new entries overwriting the oldest entry when the buffer is full.
Figure F-24 - Meter Run Audit Trail Web Page (Both Alarms & Events Selected)
F-34 / Appendix F
CI-ControlWave GFC-CL
When View Audit Trail is selected, the Meter Run Audit Trail Web Page (see Figure
F.24) will be displayed. Meter Run Audit Trail Web page buttons allow the user to
Collect Data, Save Parameters, Search Criteria, and Show Statistics. Additionally, the
Meter Run Audit Trial Web page posts the Total # of Records Collected near the top right
side of the page. When the page is initially opened, only the 24 most recent records are
gathered. To view more records, the user may scroll down using the Vertical Scroll Bars.
F.8.3 View Signal List
Signal List Information:
Number - List Number to be viewed
Start Index - List Element to start collecting
Max Signals to Collect – Number of Signals to collect
Collect List:
Starts list collection
Floating Point Format:
Select this button to change the appearance of Floating Point
Values
Figure F-25 - Signal List Web Page
F.8.4 Archive File Collection
When Collection is selected, an Archive File Collection Web Page (see Figure F.26) will be
displayed. Log Break Configuration buttons are provided on the Archive File Collection
Web Page to enable/disable log breaks for configuration changes and Gas Chromatograph
operation and configuration. Log Breaks are ‘Disabled’ by default.
CI-ControlWave GFC-CL
Appendix F / F-35
Figure F-26 - Archive File Collection Web Page
F.9 LOAD/SAVE CATEGORY FUNCTION
One WebBSI Web page is accessible under the Load/Save Category Section of WebBSI; this
is called the Meter Run Save/Load Configuration Web page (see Figure F-27).
This page allows a user to save configuration parameters from a ControlWave GFC-CL or
load a saved configuration down to a ControlWave GFC-CL. The page opens from defaults
and the information displayed is retrieved from the following file:
(C:\OpenBSI\WebGFC\Config\DefaultMGFC.RCP).
The information displayed is returned from this file. If a user has made changes to the
configuration of the unit, upgrade of the values can be changed by clicking on Load from
RTU. The values in the configuration now reflect the actual configuration of the unit.
Users may save their configuration to a file. First the user should select the file where the
configuration should be save. This is done by clicking on Browse, and selecting an existing
file, or by typing in a new file name to save the configuration. After the file has been
selected, the date is saved by clicking on Write to File.
A user may download a previously saved configuration to the ControlWave GFC-CL.
Users would select the file to download to the unit by clicking on the Browse button to
locate it. A user would then click on Load from File. This will update the recipe with the
information from the file. To load the configuration to the ControlWave GFC-CL, the user
would click on Write to RTU. By defaults the RCP files are stored in the following folder:
(C:\OpenBSI\WebGFC\Config).
F-36 / Appendix F
CI-ControlWave GFC-CL
Figure F-27 - Meter Run Save/Load Configuration Web Page
The RCP file can be edited with a text editor such as WordPad. Users may save a
configuration from one meter, use a text editor to change the configuration parameters for a
different meter and read the configuration from the file, and download the modified
configuration to a new meter.
Users may modify the value of a signal from the Meter Run Save/Load Configuration
page. A user would highlight the signal that needs to be modified and then click on the
Modify Signal button. A dialog box will open with the Signal Name and Value. Users may
either enter the new value for String Signals and Analog Signals or select the new value
from the drop down menu (for logical signals). To write the change down to the
ControlWave GFC-CL, the user must click on Write to RTU. To ensure a saved
configuration, the user must click on Write to File.
Typical Steps:
1. Open Page – Values from DefaultMGFC.RCP are shown. If there is another configuration that the user would like to use, skip to Step 7.
2. Update Values with actual settings by clicking on Load from RTU.
3. Review settings and make modifications as required using the Modify Signal button.
CI-ControlWave GFC-CL
Appendix F / F-37
4. Click on Write to RTU.
5. Select the file to save the configuration to by clicking on Browse. Find an existing file to
update or enter the name of a new file to create.
6. Click on Write to File. - FINISHED
7. Select another file to use by clicking on Browse and the desired .RCP file.
8. Click on Load from File. - Return to Step 2.
F.10 SPECIAL FUNCTIONS
A special Sync Date & Time web page (see Figure F-28) is accessible from the Special
Functions Category Section of WebBSI.
Figure F-28 - Sync Date & Time Web Page Display
F-38 / Appendix F
CI-ControlWave GFC-CL
Instruction Manual
CI-ControlWave GFC-CL
Oct., 2006
ControlWave GFC-CL
Radio Ready Installation Guide
P/N 721700-02-0
Appendix G
www.EmersonProcess.com/Bristol
APPENDIX G
ControlWave GFC Classic
Radio Ready Installation Guide
TABLE OF CONTENTS
SECTION
TITLE
G1.1
G2.1
G2.1.1
G2.2
GENERAL INTRODUCTION....................................................................................... G-1
RADIO INSTALLATION .............................................................................................. G-2
Installation of a Radio into a Radio Ready ControlWave GFC-CL............................. G-2
ADDITIONAL FreeWave INFORMATION ................................................................. G-7
CI-ControlWave GFC-CL
PAGE #
Appendix G - Radio Ready Installation Guide Contents / 0 - 1
Appendix G
RADIO READY INSTALLATION GUIDE
G1.1 GENERAL INTRODUCTION
ControlWave GFC-CL Gas Flow Computers may be ordered "Radio Equipped," or “Radio
Ready.” Radio Ready units contain all hardware required to field install a Bristol provided
radio except the radio and radio installation hardware (such as screws, nuts and washers.
Radio Ready units will include either an Internal RF Radio Cable with Bulk Head Antenna
Connector or an Internal RF Radio Cable that mates to an optional Polyphaser (Surge/Impulse Suppresser).
Radios are shipped with all necessary installation hardware and are to be secured to the
factory installed Radio Mounting Bracket which in turn mounts to the ControlWave GFCCL Battery Bracket.
ControlWave GFC-CL Gas Flow Computers may be equipped with one of the external
radios listed below or may be shipped with the hardware necessary to install one of these
radios at a future date. The term “external radio,” refers to those radios that mount on a
Radio Mounting Bracket instead of piggy-back on the CPU/System Controller Board
Assembly.
MDS 4710A Remote Data Transceiver (Radio)
MDS 4710B Data Transceiver (Radio)
MDS 9710A Remote Data Transceiver (Radio)
MDS 9710B Data Transceiver (Radio)
MDS 9810 Spread Spectrum Data Transceiver (Radio)
MDS entraNET 900 Extended Range IP Networking Transceivers
MDS iNET 900 Ethernet Radio
MDS Transnet 900 Spread Spectrum Data Transceiver
FreeWave Radio Spread Spectrum Data Transceiver Model FGRM-501X005
Radios are shipped with the following additional hardware:
MDS 4710A/B, MDS 9710A/B & MDS 9810 models are provided with four (4) 6-32 x 5/16
Countersunk Screws, a Power Cable and a Radio Interface Cable.
MDS entraNET 900 Serial Remote and Ethernet Remote models are provided with four (4)
6-32 x 5/16 Countersunk Screws, a Power Cable and a Radio Interface Cable.
MDS entraNET 900 Access Point and MDS iNET 900 (Remote Serial Gateway, Remote
Ethernet Bridge or Access Point/Remote Dual Gateway) models are provided with four (4)
6-32 x 5/16 Countersunk Screws, a Power Cable and a Radio Interface Cable.
MDS TRANSNET radios are provided with four (4) 6-32 x 5/16 Countersunk Screws, four
(4) #6 Flat 5/16 O.D. Washers and four (4) 6-32 Hex Nuts and a Power Cable and a Radio
Interface Cable.
FreeWave radios are provided with eight (4) 6-32 x 5/16 Pan Head Screws and four (4) 6-32
x .500 F/F Standoffs, four (4) 6-32 x 5/16 Countersunk Screws and a Radio Intf. Cable.
CI-ControlWave GFC-CL
Appendix G - Radio Ready Installation Guide / G-1
G2.1 RADIO INSTALLATION
DANGER
Radios provided by Bristol for use in the ControlWave GFC-CL Gas Flow
Computers are approved for use in Class I, Division 2, Groups A, B, C & D
hazardous locations. Radios may also be used in non-hazardous locations.
The installer must be familiar with hazardous location installation
guidelines before installation or maintenance is undertaken. Do not begin
radio installation or service to the ControlWave GFC-CL unless the area is
known to be non-hazardous.
NOTE
Only the external radios listed on page 1 of this document may be used in
Class I, Division 2, Groups A, B, C & D hazardous locations! Use of other
external radios in Class I, Division 2, Groups A, B, C & D hazardous
locations is not allowed!
AVOID OPERATING EQUIPMENT DURING AN ELECTRICAL STORM. AN
IMPULSE SUPPRESSOR MAY SAVE EQUIPMENT FROM DANGER, BUT
SHOULD NOT BE CONSIDERED AS BEING SAFE FOR PERSONNEL.
G2.1.1 Installation of a Radio into a Radio Ready ControlWave GFC-CL
Radio Ready ControlWave GFC-CL Gas Flow Computers contain all the hard-ware
required (except the radio and securing hardware) to accommodate installation and
operation of the radio option.
1. Open the Instrument Front Cover.
2. Remove the Radio Mounting Bracket. To do this, loosening the four Pane Head Screws
that secure it to the Battery Bracket and then slid it upward until it can be removed.
3. Using the mounting hardware provided with the radio, mount and secure the radio to
the Radio Mounting Bracket removed in step 2 (see Figures 1 through 5 as required).
4. Re-install the Radio Mounting Bracket to the Battery Bracket using the four 10-32 x 3/8
Pan Head Screws that were loosened in step 2.
5. Connect the radio’s RF cable to the radio. The other end of the radio’s internal RF cable
should already be installed onto either a Polyphaser or a RF Bulk Head/Antenna
Interface connector.
6. Connect the user supplied antenna cable to either the Polyphaser or Bulk Head antenna
cable connector jack on the bottom of the ControlWave GFC-CL (see Figure 6).
G-2 / Radio Ready Installation Guide
CI-ControlWave GFC-CL
FRONT VIEW (Mounted)
MDS Radios
Models:
4710A, 4710B,
9710A, 9710B
& 9810
RIGHT
SIDE VIEW
(Mounted)
+
BOTTOM VIEW
Figure 1 - Radio Installation/Mounting Diagram - MDS Radios
Models 4710A, 4710B, 9710A, 9710B & 9810
+
FRONT VIEW (Mounted)
LEFT
SIDE VIEW
RIGHT
SIDE VIEW
(Mounted)
MDS Transnet
TOP VIEW
Figure 2 - Radio Installation/Mounting Diagram - MDS Transnet Radio
CI-ControlWave GFC-CL
Appendix G - Radio Ready Installation Guide / G-3
+
FRONT VIEW (Mounted)
LEFT
SIDE VIEW
RIGHT
SIDE VIEW
(Mounted)
MDS entraNET 900
TOP VIEW
Figure 3 - Radio Installation/Mounting Diagram - MDS entraNET 900 Radio
7. Plug the Radio Interface Cable into the radio’s Comm. Port. Plug the other end of this
cable into Comm. Port 2 on the CPU/System Controller Board Assembly. In the case of
the FreeWave Radio, power is also supplied via the Interface Cable.
8. Remove the MDS Radio’s Power Connector from the MDS Radio in question and connect the unterminated ends of the MDS Power Cable to the MDS Power Connector (Red
= Pos. and Black = GND). Plug the end of the MDS Radio Power Cable that you just
dressed into the MDS Radio. Connect the other end of the MDS Radio Power Cable to
connector TB4 of the Battery Charger & I/O Board Assembly (Red = Pin-1, Black = Pin2).
G-4 / Radio Ready Installation Guide
CI-ControlWave GFC-CL
+
MDS entraNET 900
Access Point Radio
FRONT VIEW (Mounted)
LEFT
SIDE VIEW
RIGHT
SIDE VIEW
(Mounted)
MDS iNET 900 Radios
BOTTOM VIEW
FRONT VIEW (Mounted)
Figure 4- Radio Installation/Mounting Diagram - MDS Radios
MDS entraNET900 Access Point Radio & MDS iNET 900 Radios
CI-ControlWave GFC-CL
Appendix G - Radio Ready Installation Guide / G-5
9. After testing the unit, close and secure the Door.
FRONT VIEW (Mounted)
FreeWave
RIGHT
SIDE VIEW
(Mounted)
TOP VIEW
Figure 5 Radio Installation/Mounting Diagram – FreeWave Radio
Internal
Antenna
Cable
Polyphaser
or
Internal Antenna Cable’s
Bulk Head Jack
Figure 6- Partial View - ControlWave GFC-CL with/without Polyphaser
G-6 / Radio Ready Installation Guide
CI-ControlWave GFC-CL
G2.2 ADDITIONAL FreeWave INFORMATION
The FreeWave Spread Spectrum Data Transceiver Model FGRM-501X005 User Manual
contains in-depth details on modem parameters, operation, installation, tuning transceiver
performance, and more. Copies of the FreeWave Spread Spectrum Data Transceiver Model
FGRM-501X005 User Manual can be obtained from FreeWave Technologies, Inc. (electronically) by contacting their Technical Support Group.
FreeWave Tech. Support can be reached at 303-444-3862 or at www.freewave.com.
Follow the “Tuning Transceiver Performance” section of the FreeWave Technologies, Inc.
FreeWave Spread Spectrum Data Transceiver Model FGRM-501X005 User Manual to
configure the radio.
Note:
The setup program is invoked by setting CPU/System Controller Board Jumper
W8 across pins 1 & 2, connecting the ControlWave GFC-CL Local Port to any PC
equipped with a terminal program (such as Hyperterminal), setting the
parameters for that terminal to those of Table 1, and putting the radio into setup
mode. Connection to the PC requires connection to ControlWave GFC-CL Comm.
Port 1 (via J19 on the CPU/System Controller Bd. or the Local Port on the bottom
of the Instrument Front Cover (see Figures 8 & 9). The terminal program must be
running before invoking the setup program. The setup program is invoked by
shorting MTA-100 Connector pins 4 (GND) and 2 (MENU) together.
Table 1 - Setup Menu Terminal Settings
PARAMETER
Baud Rate
Data Rate
Parity
Stop Bits
Parity Check
Carrier Detect
SETTING
19,200
8
None
1
None/Off
None/Off
Cable Side of
8-Pin
Terminal
Block
1 = DCD
2 = RXD
3 = TXD
4 = DTR
5 = GND
6 = DSR
7 = RTS
8 = CTS
Cable Side of
Female
MTA 100
Connector
1
To
TB4 *
1 = +12Vdc
4 = PWR Gnd
5 = TXD
6 = GND
7 = RXD
2 = RXD to TXD = 5
3 = TXD to RXD = 7
5 = GND to GND = 6
* TB4 is on the Battery Charger & I/O Board
Figure 7 - Cable Diagram for Radio to COM2 (TB2) Interface & Radio Power
CI-ControlWave GFC-CL
Appendix G - Radio Ready Installation Guide / G-7
Figure 8 - PC Connected to ControlWave GFC-CL (COM1) via Local Port
Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable
ControlWave GFC
5 = GND
4 = DTR
8 = CTS
3 = TXD
7 = RTS
2 = RXD
6 = DSR
1 = DCD
To P2 Pin-5
To P2 Pin-6
To P2 Pin-2
To P2 Pin-1
To P2 Pin-3
To P2 Pin-4
To P2 Pin-7
9-Pin Female
“D” Connector
(Looking into
Wire Terminal Side
of
Cable Connectors)
or
vice
versa
1 = DCD
6 = DSR
2 = RXD
7 = RTS
3 = TXD
8 = CTS
4 = DTR
5 = GND
9-Pin Female
“D” Connector
Figure 9 - PC Connected to ControlWave GFC-CL (COM1) via J19 on CPU/System
Controller Bd. (Use Null Modem Cable - Bristol Part Number 392843-01-3)
G-8 / Radio Ready Installation Guide
CI-ControlWave GFC-CL
ControlWave GFC Classic
Material Safety Data Sheets
A Material Safety Data Sheet is provided herein to comply with OSHA’s Hazard Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific
requirements.
Material Safety Data Sheets are provided below.
MSDS for ControlWave GFC Classic Instruction Manual (CI-ControlWave GFC-CL)
Manufacture
r
DURACELL
General Description
3V Lithium Manganese
Dioxide Battery
Part Number
DL 2450
Bristol Battery Part Number = 395620-01-5
Manufacturer
General Description
Part Number
Two - 7.2 Vdc Lithium
Battery Packs
Individual Battery Part No. =
Tadiran
(Each Pack Composed of TL-5137
two 3.6V, 35AH
Batteries)
Bristol Battery Pack Part Number = 39413-01-0
Manufacturer
General Description
Part Number
7.2 Vdc Lithium
Individual Part No. =
Battery Pack
Tadiran
TL-5137
(Composed of two
3.6V, 35AH Batteries)
Bristol Battery Pack Part Number = 395413-01-0
Manufacturer
General Description
Part Number
6V, 7AH Lead Acid
Battery -Used with
Power Sonic
PS-670
1W, 6V Solar Panel or
5W, 6V Solar Panel
Bristol Battery Part Number = 395407-01-0
Manufacturer
General Description
Part Number
12V, 7AH Lead Acid
Power Sonic
PS-1270
Battery -Used with
5W, 12V Solar Panel
Bristol Battery Part Number = 395407-02-8
Manufacturer
Dow Corning
04/28/06
General Description
Silicone 200(R) Fluid,
100 CST
Media Notes
Pressure Transducer Media Fill
Appendix Z - CI-ControlWave GFC-CL
MSDS
BLANK PAGE
Gillette
Environment
Health and Safety
37 A Street
Needham, MA 02492
Tel 781.292.8151
Page 1 of 4
MATERIAL SAFETY DATA SHEET
NAME:
DURACELL LITHIUM MANGANESE DIOXIDE COIN BATTERIES
Effective Date: 8/8/03
Not applicable
CAS NO:
Rev:
3
A. — IDENTIFICATION
%
65-75
Manganese Dioxide (1313-13-9)
Propylene Carbonate (108-32-7)
Lithium (7439-93-2)
Graphite, synthetic (7440-44-0)
1,2-Dimethoxyethane (110-71-4)
Lithium Perchlorate (7791-03-9)
Formula: Mixture
Mixture
Molecular Weight:
NA
10-15
5-10
Synonyms:
Lithium Manganese Dioxide Coin Cells:
3V-DL2016; DL2025; DL2430; DL2450;
DL2032; DL1616; DL1620
5-10
1-10
<1.5
B. — PHYSICAL DATA
NA
Boiling Point
°F
NA
°C
Melting Point
°F
NA
NA
°C
Specific Gravity (H2O=1)
Vapor Density (air=1)
NA
NA
Evaporation
(
=1)
Ether
NA
Freezing Point
°F
NA
NA
Vapor Pressure @
°F
NA
Saturation in Air
(by volume@
°C
mm Hg
Autoignition Temperature
°F
°F)
NA
NA
% Volatiles
Solubility in Water
NA
NA
NA
pH
Appearance/Color
Coin cells. Contents dark in color.
Flash Point and
Test Method(s)
1,2-Dimethoxyethane (Approximately 3-7% of contents): 42.8 °F, 6°C (Closed Cup)
Flammable Limits in Air
(% by volume)
Lower
NA
°C
%
%
NA
Upper
C. — REACTIVITY
Stability
X
stable
unstable
Polymerization
Conditions to Avoid
Do not heat, crush, disassemble, short circuit or
recharge.
Incompatible Materials
Contents incompatible with strong oxidizing agents.
may occur
X
will not occur
Conditions to Avoid
Not applicable
Hazardous Decomposition Products
Thermal degradation may produce hazardous fumes
of manganese and lithium; oxides of carbon and other
toxic by-products.
* IF MULTIPLE INGREDIENTS, INCLUDE CAS NUMBERS FOR EACH
NA=NOT AVAILABLE
Footnotes
Not applicable
GMEL#
2033.3
Page 2 of 4
D. — HEALTH HAZARD DATA
Occupational Exposure Limits PEL’s, TLV’s, etc.)
8-Hour TWAs: Manganese Dioxide (as Mn) - 5 mg/m3 (Ceiling) (OSHA); 0.2 mg/m3 (ACGIH/Gillette)
1,2-Dimethoxyethane - 0.15 ppm (Gillette)
Graphite (all kinds except fibrous) - 2 mg/m3 (synthetic, ACGIH); 15 mg/m3 (total, OSHA);
5 mg/m3 (respirable, OSHA)
These levels are not anticipated under normal consumer use conditions.
Warning Signals
Not applicable
Routes/Effects of Exposure
These chemicals and metals are contained in a sealed can. For consumer use, adequate hazard warnings are
included on both the package and on the battery. Potential for exposure should not exist unless the battery
leaks, is exposed to high temperature, is accidentally swallowed or is mechanically, physically, or electrically
abused.
1. Inhalation
Not anticipated. Respiratory (and eye) irritation may occur if fumes are released due to heat or
an abundance of leaking batteries.
2. Ingestion
An initial x-ray should be obtained promptly to determine battery location. Batteries lodged in
the esophagus should be removed immediately since leakage, burns and perforation can occur
as soon as 4-6 hours after ingestion. Irritation to the internal/external mouth areas may occur
following exposure to a leaking battery.
3. Skin
a. Contact
Irritation may occur following exposure to a leaking battery.
b. Absorption
Not anticipated.
4. Eye Contact
Irritation may occur following exposure to a leaking battery.
5. Other
Not applicable
E. — ENVIRONMENTAL IMPACT
1. Applicable Regulations All ingredients listed in TSCA inventory.
2. DOT Hazard Class 3. DOT Shipping Name -
Not applicable
Not applicable
While lithium batteries are regulated by IATA and ICAO, the type of lithium batteries offered for sale by DURACELL are
considered non-hazardous per provision A45 of the IATA Dangerous Goods Regulations and provision A45 of the ICAO
Technical Instructions For The Safe Transport Of Dangerous Goods By Air. Per section A45 of the IATA and ICAO
regulations, properly marked, labeled and packaged DURACELL consumer lithium batteries, which are of the solid cathode
type, with less than 1g lithium per cell and less than 2g lithium per battery, are exempt from further regulation. When these
batteries are separated to prevent short circuits and properly packaged in strong packaging (except when installed in electronic
devices), they are acceptable for air transport as airfreight without any other restrictions. In addition, when installed in
equipment or when no more than 24 cells or 12 batteries meeting the A45 provision are shipped, they are not subject to
special packaging, marking, labeling or shipping documentation requirements. Thus, these batteries are not considered
hazardous under the current regulations and are acceptable for air transport.
Environmental Effects
These batteries pass the U. S. EPA's Toxicity Characteristic Leaching Procedure and therefore, maybe
disposed of with normal waste.
GMEL#
2033.3
Page 3 of 4
F. — EXPOSURE CONTROL METHODS
Engineering Controls
General ventilation under normal use conditions.
Eye Protection
None under normal use conditions. Wear safety glasses when handling leaking batteries.
Skin Protection
None under normal use conditions. Use butyl gloves when handling leaking batteries.
Respiratory Protection
None under normal use conditions.
Other
Keep batteries away from small children.
G. — WORK PRACTICES
Handling and Storage
Store at room temperature. Avoid mechanical or electrical abuse. DO NOT short or install incorrectly.
Batteries may explode, pyrolize or vent if disassembled, crushed, recharged or exposed to high temperatures.
Install batteries in accordance with equipment instructions. Replace all batteries in equipment at the same
time. Do not carry batteries loose in pocket or bag.
Normal Clean Up
Not applicable
Waste Disposal Methods
No special precautions are required for small quantities. Large quantities of open batteries should be treated
as hazardous waste. Dispose of in accordance with federal, state and local regulations. Do not incinerate,
since batteries may explode at excessive temperatures.
GMEL#
2033.3
Page 4 of 4
H. — EMERGENCY PROCEDURES
Steps to be taken if material is released to the environment or spilled in the work area
Evacuate the area and allow vapors to dissipate. Increase ventilation. Avoid eye or skin contact. DO NOT
inhale vapors. Clean-up personnel should wear appropriate protective gear. Remove spilled liquid with
absorbent and contain for disposal.
Fire and Explosion Hazard
Extinguishing Media
Batteries may burst and release hazardous decomposition products when As for surrounding area. Dry
exposed to a fire situation. See Sec. C.
chemical, alcohol foam, water or
carbon dioxide. For incipient
fires, carbon dioxide extinguishers
are more effective than water.
Firefighting Procedures
Cool fire-exposed batteries and adjacent structures with water spray from a distance. Use self-contained
breathing apparatus and full protective gear.
I. — FIRST AID AND MEDICAL EMERGENCY PROCEDURES
Eyes
Not anticipated. If battery is leaking and material contacts eyes, flush with copious amounts of clear, tepid
water for 30 minutes. Contact physician at once.
Skin
Not anticipated. If battery is leaking, irrigate exposed skin with copious amounts of clear, tepid water for a
least 15 minutes. If irritation, injury or pain persists, consult a physician.
Inhalation
Not anticipated. Respiratory (and eye) irritation may occur if fumes are released due to heat or an abundance
of leaking batteries. Remove to fresh air. Contact physician if irritation persists.
Ingestion
Consult a physician. Published reports recommend removal from the esophagus be done endoscopically
(under direct visualization). Batteries beyond the esophagus need not be retrieved unless there are signs of
injury to the GI tract or a large diameter battery fails to pass the pylorus. If asymptomatic, follow-up x-rays
are necessary only to confirm passage of larger batteries. Confirmation by stool inspection is preferable
under most circumstances. If mouth area irritation/burning has occurred, rinse the mouth and surrounding
area with clear, tepid water for at least 15 minutes.
Notes to Physician
1) For information on treatment, telephone (202)-625-3333 collect.
2) Potential leakage of less than 50 milligrams of propylene carbonate (CAS #108-32-1) and
dimethoxyethane (CAS #110-71-4).
3) Dimethoxyethane readily evaporates.
4) Under certain misuse conditions and by abusively opening the battery, exposed lithium can react with
water or moisture in the air causing potential thermal burns or fire hazard.
Replaces # 1461
The information contained in the Material Safety Data Sheet is based on data considered to be accurate, however, no warranty is
expressed or implied regarding the accuracy of the data or the results to be obtained from the use thereof.
MSDS-4 (8/95)
GMEL#
2033.3
B
TQM
Quality
First
MSDS No.- T-36-01 (Revision. -G)
MATERIAL SAFETY DATA SHEET
SECTION 1- CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Manufacturer Name- Tadiran Batteries Ltd., P. O. Box 1, Kiryat Ekron, Israel 70500.
US office address- 2 Seaview Blvd. Port Washington NY 11050
Emergency Telephone No. – CHEMTREC: 1-800-424-9300
Tel. for information: 1-516-621-4980
Tel. for information 972-8-944-4503
Products Name: Primary Lithium Thionyl Chloride (Li/SOCl2) cells and batteries, Nonrechargeable. Cells include the models of TL, TLH, and TLL, 3.6V series.
SECTION 2- COMPOSITION, INFORMATION ON INGREDIENTS
Ingredient Name
CAS #
%
ACGIH (TLV)
Lithium Metal (Li)
7439-93-2
<5%
Not Established
Thionyl Chloride (SOCl2)
7719-09-7
<47
%
1 ppm
(5 mg/M3)
5 mg/m3
Carbon (C)
Aluminum Chloride (AlCl3)
1333-86-4
7446-70-0
<6%
<5%
3.5 mg/m3
2 mg/m3 (Al
salt, soluble)
3.5 mg/m3
Lithium Chloride (LiCl)
Glass
PVC
PTFE
7447-41-8
<2%
<1%
<1%
<1%
Not Established
Not Established
Not Established
Not Established
9002-86-2
9002-84-0
OHSA
(PEL)
None
CHIP
Classification
F: R14/15
C: R34
R: 14/15, 34
S:(1/2), 8,43,45
R: 14,20/22,29,
35.
S: (1/2),26,36/
37/39, 45
None known
R: 34
S: (1/2),7/8,28,
45
SECTION 3 - HAZARD IDENTIFICATION
The lithium Thionyl chloride batteries described in this MSDS are hermetically sealed
units, which are not hazardous when used according to the recommendations of the
manufacturer.
Under normal condition of use of the batteries, the electrode materials and the liquid
electrolyte they contained are non-reactive provided the battery integrity is
maintained. Risk of exposure exists only in case of mechanical, electrical or thermal
abuse. Thus the batteries should not short circuit, recharge, puncture, incinerate,
crush, immerse in water, force discharge, or expose to temperatures above the
temperature range of the cell or battery. In these cases there is risk of fire or explosion
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SECTION 4- FIRST AID MEASURES
In case of battery rupture, explosion, or major leakage, evacuate personnel from
contaminated area and provide good ventilation to clear out corrosive fumes, gases or
the pungent odor. Seek immediate medical attention.
Eyes - First rinse with plenty of water for 15 minutes (remove contact lenses if easily
possible), and then seek medical attention.
Skin - Remove contaminated clothes and rinse skin with plenty of water or shower for
15 min. Refer to medical attention.
Inhalation - Remove to fresh air, rest, and half-upright position, use artificial
respiration if needed, and refer to medical attention.
Ingestion - rinse mouth, DO NOT induce vomiting, give plenty of water to drink, and
refer to medical attention.
SECTION 5- FIRE FIGHTING MEASURES
FLASH POINT:
NA
LOWER (LEL):
NA
FLAMMABLE LIMIT IN AIR:
NA
UPPER (LEL):
NA
EXTINGUISHING MEDIA:
1. Lith- X (Class D extinguishing media) is the only effective on fires involving a few
lithium batteries. If the cells are directly involved in a fire DO NOT USE: WATER,
SAND, CO2, HALON, and DRY POWDER OR SODA ASH EXTINGUISHERS.
2. If the fire is in adjacent area and the cells that are either packed in their original
containers or unpacked, the fire can be fought based on fueling material, e.g., paper
and plastic products. In these cases the use of copious amounts of cold water is
effective extinguishing media. Storage area may employ sprinkler system with cold
water.
AUTO-IGNITION:
NA
SPECIAL FIRE FIGHTING PROCEDURES: Wear self-contained breathing
apparatus to avoid breathing of irritant fumes (NIOSH approved SCBA & full
protective equipment). Wear protective clothing and equipment to prevent body
contact with electrolyte solution.
Fire may be fought, but only from safe fire-fighting distance. Evacuate all persons
from immediate area of fire.
UNUSUAL EXPLOSION AND FIRE EXPLOSION: Battery may explode when
subject to: excessive heat (above 150ºC), recharged, over-discharged (discharge
below 0V), punctured and crushed. During thermal decomposition generation of
chlorine (Cl2), hydrogen chloride (HCl), and sulfur dioxide (SO2) can be formed.
SECTION 6- SPILL OR LEAKAGE PROCEDURES
PROCEDURES TO CONTAIN AND CLEAN UP LEAKS OR SPILLS: The material
contained within the battery would only be released under abusive conditions.
In the event of battery rapture and leakage: contain the spill while wearing proper
protective clothing and ventilate the area. Than, cover with sodium carbonate
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(Na2CO3) or 1:1 mixture of soda ash and slaked slime. Keep away from water, rain,
and snow. Placed in approved container (after cooling if necessary) and disposed
according to the local regulations.
NEUTRALIZING AGENT: Sodium carbonate (Na2CO3) or 1:1 mixture of soda ash
and slaked slime.
WASTE DISPOSAL METHOD: Product decomposed by water must be neutralized.
May be added to waste water in sufficiently diluted form.
PRECAUTIONS IN HANDLING AND STORING; Avoid short-circuiting, overcharging and heating to high temperatures. Store the batteries in dry and cool area and
keep container dry and tightly closed in well-ventilated area. Store away from food
and drink.
OTHER PRECAUTIONS; Never attempt to disassemble, machine, or otherwise
modify batteries or injury may result.
SECTION 7- HANDLING AND STORAGE
The batteries should not be opened, destroyed or incinerate, since they may leak or
rupture and release to the environment the ingredients that they normally contained in
the hermetically sealed container.
HANDLING- Do not short circuit terminals, or expose to temperatures above the
temperature rating of the battery, over charge the battery, forced over-discharge
(voltage below 0.0V), throw to fire.
Do not crush or puncture the battery, or immerse in liquids.
STORAGE- Storage preferably in cool (below 30ºC), dry and ventilated area, which
is subject to little temperature change.
Do not place the battery near heating equipment, nor expose to direct sunlight for long
periods. Elevated temperatures can result in shortened battery life and degrade
performance.
Keep batteries in original packaging until use and do not jumble them.
Do not store batteries in high humidity environment for long periods.
OTHER- the cells and the batteries are not rechargeable batteries and should not be
charged.
Applying pressure and deforming the battery may lead to disassembly followed by
eye skin and throat irritation.
Follow manufacturers recommendations regarding maximum recommended current
and operating temperature range.
SECTION 8 - EXPOSURE CONTROLS & PERSONAL PROTECTION
RESPIRATORY PROTECTION: None necessary under normal use. In case of abuse
and leak of liquid or fumes, use NIOSH approved Acid Gas Filter Mask or SelfContained Breathing Apparatus.
VENTILATION: Not necessary under normal use. In case of abuse, use adequate
mechanical ventilation (local exhaust) for battery that vent gas or fumes.
PROTECTIVE GLOVES: None under normal use. In case of spill use PVC or Nitrile
gloves of 15 mils (0.015 inch) or thicker.
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EYE PROTECTION: Use ANSI approved chemical worker safety goggles or face
shield.
OTHER PROTECTIVE EQUIPMENT: Chemical resistance clothing is recommended
along with eye wash station and safety shower should be available meeting ANSI
design criteria.
WORK HYGIENIC PRACTICES: Use good chemical hygiene practice. Wash hands
after use and before drinking, eating or smoking. Launder contaminated cloth before
reuse.
SUPPLEMENTARY SAFETY AND HEALTH DATA: If the battery is broken or
leaked the main hazard is the electrolyte. The electrolyte is mainly solution of Lithium
chloride (LiCl), and aluminum chloride (AlCl3) in Thionyl chloride (SOCl2).
Fires may be fought but only from safe fire fighting distance, evacuate all persons
from immediate area of fire.
Prevent heating of the battery, charging the battery, discharge to predetermined limit,
do not crush, disassemble, incinerate or short circuit.
SECTION 9- PHYSICAL DATA
BOILING POINT (760 mm Hg)
VAPOR PRESSURE (mm Hg, 25ºC)
VAPOR DENSITY (air=1)
DENSITY (gr/cc)
VOLATILE BY VOLUME (%)
EVAPORATION RATE (butyl acetate=1)
PHYSICAL STATE
SOLUBILITY IN WATER (% by weight)
PH
APPEARANCE
ODOR
NA, unless individual components exposed
NA, unless individual components exposed
NA, unless individual components exposed
> 1 gr/cc
NA
NA, unless individual components exposed
Solid
NA, unless individual components exposed
NA, unless individual components exposed
Geometric Solid Object
If leaking, gives off pungent corrosive odor
SECTION 10- STABILITY AND REACTIVITY
STABLE OR NOT STABLE
Stable
INCOMPATIBILITY (MATERIAL TO AVOID)
Strong mineral acids, water and
alkali solutions.
1. Reaction of lithium with water: Hydrogen (H2), Lithium
hydroxide (LiOH).
2. Thermal decomposition over 150ºC: Sulfur oxides, (SO2,
SO3), Sulfur chorides (SCl2, S2Cl2), Chlorine (Cl2), Lithium
oxide (Li2O).
3. Electrolyte with water: Hydrogen Chloride (HCl) and SO2
NA
DECOMPOSITION TEMPERATURE (ºF)
HAZARDOUS
DECOMPOSITION
PRODUCTS
HAZARDOUS POLYMERIZATION:
CONDITIONS TO AVOID
MSDS SOCl2 G rev GB.doc
May Occur____
Will Not Occur __X__
Avoid mechanical abuse, and electrical abuse such
as short-circuiting, overcharge, over-discharge,
(voltage reversal) and heating.
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SECTION 11- TOXICOLOGICAL INFORMATION
THRESHOLD LIMIT VALUE (TLV) AND SOURCE: NA
HEALTH HAZARD ACUTE AND CHRONIC: Inhalation, skin contact, eye contact
and ingestion are not likely by exposure to sealed battery.
Inhalation, skin contact and eye contact are possible when the battery is opened.
Exposure to internal contents, the corrosive fumes will be very irritating to skin, eyes
and mucous membranes. Overexposure can cause symptoms of non-fibrotic lung
injury and membrane irritation.
Carcinogenicity- NTP: No
Carcinogenicity- IARC: No
Carcinogenicity- OSHA: No
Explanation of Carcinogenicity- No ingredient of a concentration of 0.1% or greater is
listed as a carcinogen or suspected carcinogen.
SIGNS AND SYMPTOMS OF OVEREXPOSURE: Exposure to leaking electrolyte
from ruptured or leaking battery can cause:
Inhalation- Burns and irritation of the respiratory system, coughing, wheezing, and
shortness of breath.
Eyes- Redness, tearing, burns. The electrolyte is corrosive to all ocular tissues.
Skin- The electrolyte is corrosive and causes skin irritation and burns.
Ingestion- The electrolyte solution causes tissue damage to throat and gastro/
respiratory track.
MEDICAL CONDITION AGGRAVATED BY EXPOSURE: Preexisting skin,
asthma and respiratory diseases are generally aggravated by exposure to liquid
electrolyte vapors or liquid. For further information refer to section 4.
SECTION 12- ECOLOGICAL INFORMATION
1. When properly used and disposed the battery does not present environmental
hazard.
2. The battery does not contain mercury, cadmium, or lead.
3. Do not let internal components enter marine environment. Avoid release to
waterways, wastewater or ground water.
SECTION 13- DISPOSAL CONSIDERATIONS
1. Disposal must be in accordance with the applicable regulations in every country
and state.
2. Disposal of the Lithium batteries should be performed by permitted, professional
disposal firms knowledgeable in Federal, State or Local requirements of hazardous
waste treatment and hazardous waste transportation.
3. Incineration should never be performed by battery users, but eventually by trained
professional in authorized facility with proper gas and fume treatment.
4. Recycling of battery can be done in authorized facility, through licensed waste
carrier.
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SECTION 14- TRANSPORTATION /SHIPPING
Lithium batteries UN number 3090, class 9 (miscellaneous)
Lithium batteries contained in equipment, UN number 3091, class 9 (miscellaneous).
Packing instructions for 3090- ICAO 903 for air transport
IMDG 903 for sea transport
ADR/RID 903 and 903a for road /rail transport
Packing instructions for 3091- ICAO 912/918 for air transport
IMDG 903 for sea transport
ADR/RID 903 and 903a for road /rail transport
In the USA transportation is according to Code of Federal Regulations (CFR 49
Chapter 1, paragraph 173.185)
A list of Tadiran batteries and cells that are subject to transport regulations and those
that are exempted can be obtained from Tadiran Batteries Ltd.
Identification and labeling in compliance with the product drawing should include the
battery title, nominal voltage, lot number and warning.
SECTION 15- REGULATORY INFORMATION
1. The transport of the lithium batteries is regulated by the United Nations, “Model
Regulations on Transport of Dangerous Goods”, 13 revised edition-2003 (special
provisions 188, 230, and 310).
2. Within the US the lithium batteries and cells are subject to shipping requirements
under 49 CFRCh. 1, paragraph 173.185, “lithium batteries”.
3. Shipping of lithium batteries in aircrafts are regulated by the International Civil
Aviation Organization (ICAO) and the International Air Transport Association
(IATA) 2003 requirements in Special Provisions A45, A88 and A99.
4. Shipping of lithium batteries on sea are regulated the International Maritime
Dangerous Goods (IMDG) 2002 requirements in special provisions 188, 230 and 310.
5. Shipping of lithium batteries on Road and Rail, 2002 requirements in special
provisions 188, 230 and 310.
6. The internal component (thionyl chloride) is hazardous under the criteria of the
Federal OHSA Hazard Communication Standard 29 CFR 1920.1200.
SECTION 16- OTHER INFORMATION/DISCLAIMER
The information and the recommendations set forth are made in good faith and
believed to be accurate at the date of preparation. The present file refers to normal
use of the product in question. Tadiran Batteries makes no warranty expressed or
implied.
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MATERIAL SAFETY DATA SHEET
Product Name: Sealed Maintenance Free Lead-Acid Batteries
DATE:
10/1/2003
ISSUED BY
ENGINEERING
TELEPHONE NO.
(619) 661-2030
HAZARDOUS COMPONENTS
LD50
LC50
LC50
INHALATION
CONTACT
WEIGHT %
TLV
about 70%
N/A
(500) mg/kg
N/A
N/A
Sulfuric Acid
about 20%
1mg/m3
(2,140) mg/kg
N/A
N/A
Fiberglass Separator
about 5%
N/A
N/A
N/A
N/A
ABS Plastic
about 5%
N/A
N/A
N/A
N/A
COMPONENTS
Lead (Pb, Pb02, PBSO4)
ORAL
PHYSICAL DATA
COMPONENTS
Lead
DENSITY
MELTING POINTS
SOLLUBILITY
(H2O)
ODOR
APPEARANCE
11.34
327.4º C (Boiling)
None
None
Silver-Gray Metal
0
Lead Sulfate
6.2
1070º C (Boiling)
40 mg/l(15 C)
None
White Powder
Lead Dioxide
9.4
290º C (Boiling)
None
None
Brown Powder
Clear Colorless Liquid
about 1.3
about 114º C (Boiling)
100%
Acidic
Fiberglass Separator
N/A
N/A
Slight
Toxic
White Fibrous Glass
ABS Plastic
N/A
N/A
None
No Odor
Solid
Sulfuric Acid
FLAMMABILITY DATA
FLASHPOINT
EXPLOSIVE LIMIT
Lead
None
None
Sulfuric Acid
None
None
COMPONENTS
Hydrogen
COMMENTS
4% - 72.4%
Sealed batteries can emit hydrogen if over charged
(float voltage > 2.40 VPC).
Fiberglass Separator
N/A
N/A
Toxic vapors may be released. In case of fire, wear
self-contained breathing apparatus.
ABS Plastic
None
N/A
Temp. over 300º C (572º F) may release combustible gases. In case
of fire: wear positive pressure self-contained breathing apparatus.
FIRST AID
SULFURIC ACID PRECAUTIONS
Skin Contact:
Flush with water, see physician if contact area is large or if blisters form.
Eye Contact:
Call physician immediately and flush with water until physician arrives.
Ingestion:
Call physician. If patient is conscious, flush mouth with water, have patient drink milk or sodium
bicarbonate solution.
Continued on Page 2
MATERIAL SAFETY DATA SHEET
(PAGE 2 OF 2)
R EACTI VI TY DATA
C O M PO N E N T
Sulfuric Acid
i
STABI LI TY
Stable at all temperatures
COLYM ER I ZATI ON
Will not polymerize
I NCOM PATI BI LI TY
Reactive metals, strong bases, most organic compounds
DECOM POSI TI ON PR ODUCTS
Sulfuric dioxide, trioxide, hydrogen sulfide, hydrogen
CONDI TI ONS TO AVOI D
Prohibit smoking, sparks, etc. from battery charging area. Avoid mixing acid with other chemicals
SPI LL OR LEAK PR OCEDUR ES
St e ps t o t a k e in ca s e of le a k or s pill:
If sulfuric acid is spilled from a battery, neutrilize acid with bicarbonate (baking soda), sodium
carbon (soda ash), or calcium oxide (lime). Flush area with water and discard to the sewage
system. Do not allow unneutralized acid into sewage system.
Wa s t e dis pos a l me t hod:
Neutrilized acid may be flushed down the sewer. Spent batteries must be treated as hazardous
waste and disposed of according to local, state, and federal guidelines. A copy of this MSDS must
be supplied to any scrap dealer or secondary lead smelter with battery.
PR O T E C T I O N
EXPOSUR E SI TE
PR OTECTI ON
SK I N
Rubber gloves, Apron
R ESPI R ATORY
Respirator (for lead)
EYES
Safety goggles, Face Shield
COM M ENTS
Protective equipment must be worn if the battery is cracked or
otherwise damaged. A respirator should be worn during reclaim
operations if the TLV is exceeded.
ELECTR I CAL SAFETY
Due to the battery's low internal resistance and high power density, high levels of short circuit current can be developed across the battery
terminals. Do not rest tools or cables on the battery. Use insulated tools only. Follow all installation instructions and diagrams when installing or
maintaining battery systems.
HEALTH HAZAR D DATA
LEAD: The toxic effects of lead are accumulative and slow to appear. It affects the kidneys, reproductive, and central nervous systems. The
symptoms of lead overexposure are anemia, vomiting, headache, stomach pain (lead colic), dizziness, loss of appetite, and muscle and joint
pain. Exposure to lead from a battery most oftern occurs during lead reclaim operations through the breathing or ingestion of lead dust or fumes.
SULFUR I C ACI D: Sulfuric acid is a strong corrosive. Contact with acid can casue severe burns on the skin and in eyes. Ingestion of sulfuric
acid will cause GI tract burns. Acid can be released if the battery case is damaged or if vents are tampered with.
FI BER GLASS SEPAR ATOR : Fibrour glass is an irritant of the upper repiratory tract, skin and eyes. For exposure up to 10F/CC use MSA
Comfoll with type H filter. Above 10F/CC up to 50F/CC use Ultra- Twin with type H filter. This product is not considered carcinogenic by
NTP or OSHA.
ALL DATA M UST BE PASSED TO ANY SCR AP DEALER OR SM ELTER WHEN BATTERY I S R ESOLD.
Power-Sonic Corporation
9163 Siempre Viva Road, San Diego, CA 92154 Tel (619) 661-2020 Fax (619) 661-3650
Website: www.power-sonic.com E-Mail: [email protected]
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 1 of 7
DOW CORNING 200(R) FLUID, 100 CST.
1. IDENTIFICATION OF THE SUBSTANCE AND OF THE COMPANY
24 Hour Emergency Telephone:
Customer Service:
Product Disposal Information:
CHEMTREC:
Dow Corning Corporation
South Saginaw Road
Midland, Michigan 48686
MSDS No.: 01013190
(989) 496-5900
(989) 496-6000
(989) 496-6315
(800) 424-9300
Revision Date: 2002/12/09
Generic Description:
Physical Form:
Color:
Odor:
Silicone
Liquid
Colorless
Characteristic odor
NFPA Profile: Health
0 Flammability
1 Instability/Reactivity
0
Note: NFPA = National Fire Protection Association
2. OSHA HAZARDOUS COMPONENTS
None present. This is not a hazardous material as defined in the OSHA Hazard Communication Standard.
3. EFFECTS OF OVEREXPOSURE
Acute Effects
Eye:
Direct contact may cause temporary redness and discomfort.
Skin:
No significant irritation expected from a single short-term exposure.
Inhalation:
No significant effects expected from a single short-term exposure.
Oral:
Low ingestion hazard in normal use.
Prolonged/Repeated Exposure Effects
Skin:
No known applicable information.
Inhalation:
No known applicable information.
Oral:
No known applicable information.
Signs and Symptoms of Overexposure
No known applicable information.
Medical Conditions Aggravated by Exposure
No known applicable information.
The above listed potential effects of overexposure are based on actual data, results of studies performed upon similar
compositions, component data and/or expert review of the product. Please refer to Section 11 for the detailed toxicology
information.
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 2 of 7
DOW CORNING 200(R) FLUID, 100 CST.
4. FIRST AID MEASURES
Eye:
Immediately flush with water.
Skin:
No first aid should be needed.
Inhalation:
No first aid should be needed.
Oral:
No first aid should be needed.
Comments:
Treat symptomatically.
5. FIRE FIGHTING MEASURES
Flash Point:
> 214 °F / > 101.1 °C (Closed Cup)
Autoignition
Temperature:
Not determined.
Flammability Limits in Air: Not determined.
Extinguishing Media:
On large fires use dry chemical, foam or water spray. On small fires use carbon dioxide
(CO2), dry chemical or water spray. Water can be used to cool fire exposed containers.
Fire Fighting Measures:
Self-contained breathing apparatus and protective clothing should be worn in fighting
large fires involving chemicals. Use water spray to keep fire exposed containers cool.
Determine the need to evacuate or isolate the area according to your local emergency
plan.
Unusual Fire Hazards:
None.
Hazardous Decomposition Products
Thermal breakdown of this product during fire or very high heat conditions may evolve the following hazardous
decomposition products: Carbon oxides and traces of incompletely burned carbon compounds. Silicon dioxide.
Formaldehyde.
6. ACCIDENTAL RELEASE MEASURES
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 3 of 7
DOW CORNING 200(R) FLUID, 100 CST.
Containment/Clean up:
Determine whether to evacuate or isolate the area according to your local emergency
plan. Observe all personal protection equipment recommendations described in Sections
5 and 8. For large spills, provide diking or other appropriate containment to keep material
from spreading. If diked material can be pumped, store recovered material in appropriate
container. Clean up remaining materials from spill with suitable absorbant. Clean area
as appropriate since some silicone materials, even in small quantities, may present a slip
hazard. Final cleaning may require use of steam, solvents or detergents. Dispose of
saturated absorbant or cleaning materials appropriately, since spontaneous heating may
occur. Local, state and federal laws and regulations may apply to releases and disposal
of this material, as well as those materials and items employed in the cleanup of releases.
You will need to determine which federal, state and local laws and regulations are
applicable. Sections 13 and 15 of this MSDS provide information regarding certain
federal and state requirements.
Note: See section 8 for Personal Protective Equipment for Spills. Call Dow Corning Corporation, (989) 496-5900, if
additional information is required.
7. HANDLING AND STORAGE
Use with adequate ventilation. Avoid eye contact.
Use reasonable care and store away from oxidizing materials.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Component Exposure Limits
There are no components with workplace exposure limits.
Engineering Controls
Local Ventilation:
General Ventilation:
None should be needed.
Recommended.
Personal Protective Equipment for Routine Handling
Eyes:
Use proper protection - safety glasses as a minimum.
Skin:
Washing at mealtime and end of shift is adequate.
Suitable Gloves:
No special protection needed.
Inhalation:
No respiratory protection should be needed.
Suitable Respirator:
None should be needed.
Personal Protective Equipment for Spills
Eyes:
Use proper protection - safety glasses as a minimum.
Skin:
Washing at mealtime and end of shift is adequate.
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 4 of 7
DOW CORNING 200(R) FLUID, 100 CST.
Inhalation/Suitable
Respirator:
No respiratory protection should be needed.
Precautionary Measures: Avoid eye contact. Use reasonable care.
Comments:
When heated to temperatures above 150 degrees C in the presence of air, product can
form formaldehyde vapors. Formaldehyde is a potential cancer hazard, a known skin and
respiratory sensitizer, and an irritant to the eyes, nose, throat, skin, and digestive system.
Safe handling conditions may be maintained by keeping vapor concentrations within the
OSHA Permissible Exposure Limit for formaldehyde.
Note: These precautions are for room temperature handling. Use at elevated temperature or aerosol/spray applications may
require added precautions. For further information regarding aerosol inhalation toxicity, please refer to the guidance document
regarding the use of silicone-based materials in aerosol applications that has been developed by the silicone industry
(www.SEHSC.com) or contact the Dow Corning customer service group.
9. PHYSICAL AND CHEMICAL PROPERTIES
Physical Form:
Color:
Odor:
Specific Gravity @ 25°C:
Viscosity:
Liquid
Colorless
Characteristic odor
0.965
100 cSt
Freezing/Melting Point:
Boiling Point:
Vapor Pressure @ 25°C:
Vapor Density:
Solubility in Water:
pH:
Volatile Content:
Not determined.
> 65 °C
Not determined.
Not determined.
Not determined.
Not determined.
Not determined.
Note: The above information is not intended for use in preparing product specifications. Contact Dow Corning before writing
specifications.
10. STABILITY AND REACTIVITY
Chemical Stability:
Stable.
Hazardous
Polymerization:
Conditions to Avoid:
Hazardous polymerization will not occur.
Materials to Avoid:
Oxidizing material can cause a reaction.
None.
11. TOXICOLOGICAL INFORMATION
Special Hazard Information on Components
No known applicable information.
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 5 of 7
DOW CORNING 200(R) FLUID, 100 CST.
12. ECOLOGICAL INFORMATION
Environmental Fate and Distribution
Air:
This product is a high molecular weight liquid polymer which has a very low vapour
pressure (<1 mm Hg). As a result it is unlikely to become an atmospheric contaminant
unless generated as an aerosol.
Water:
This product has a very low water solubility (< 100 ppb). As it has a specific gravity of < 1,
if discharged to water, it will initially form a surface film. As the product is non volatile and
has a high binding affinity for particulate matter, it will adsorb to particulates and sediment
out.
Soil:
If discharged to surface water, this product will bind to sediment. If discharged in effluent
to a waste water treatment plant, the product is removed from the aqueous phase by
binding to sewage sludge. If the sewage sludge is subsequently spread on soil, the
silicone product is expected to degrade.
Degradation:
This product, polydimethylsiloxane, degrades in soil abiotically to form smaller molecules.
These in turn are either biodegraded in soil or volatilized into the air where they are
broken down in the presence of sunlight. Under appropriate conditions, the ultimate
degradation products are inorganic silica, carbon dioxide and water vapour. Due to the
very low water solubility of this product, standard OECD protocols for ready and inherent
biodegradability are not suitable for measuring the biodegradability of this product. The
product is removed >80% during the sewage treatment process.
Environmental Effects
Toxicity to Water
Organisms:
Based on analogy to similar materials this product is expected to exhibit low toxicity to
aquatic organisms.
Toxicity to Soil Organisms: Experiments show that when sewage sludge containing polydimethylsiloxane is added to
soil, it has no effect on soil micro-organisms, earthworms or subsequent crops grown in
the soil.
Bioaccumulation:
This product is a liquid and is a high molecular weight polymer. Due to its physical size it
is unable to pass through, or be absorbed by biological membranes. This has been
confirmed by testing or analogy with similar products.
Fate and Effects in Waste Water Treatment Plants
This product or similar products has been shown to be non-toxic to sewage sludge bacteria.
Hazard Parameters (LC50 or EC50)
Acute Aquatic Toxicity (mg/L)
Acute Terrestrial Toxicity
Ecotoxicity Classification Criteria
High
Medium
<=1
>1 and <=100
<=100
>100 and <= 2000
Low
>100
>2000
This table is adapted from "Environmental Toxicology and Risk Assessment", ASTM STP 1179, p.34, 1993.
This table can be used to classify the ecotoxicity of this product when ecotoxicity data is listed above. Please read the other information presented
in the section concerning the overall ecological safety of this material.
13. DISPOSAL CONSIDERATIONS
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 6 of 7
DOW CORNING 200(R) FLUID, 100 CST.
RCRA Hazard Class (40 CFR 261)
When a decision is made to discard this material, as received, is it classified as a hazardous waste? No
State or local laws may impose additional regulatory requirements regarding disposal.
Call Dow Corning Corporate Environmental Management, (989) 496-6315, if additional information is required.
14. TRANSPORT INFORMATION
DOT Road Shipment Information (49 CFR 172.101)
Not subject to DOT.
Ocean Shipment (IMDG)
Not subject to IMDG code.
Air Shipment (IATA)
Not subject to IATA regulations.
Call Dow Corning Transportation, (989) 496-8577, if additional information is required.
15. REGULATORY INFORMATION
Contents of this MSDS comply with the OSHA Hazard Communication Standard 29 CFR 1910.1200.
TSCA Status:
All chemical substances in this material are included on or exempted from listing on the TSCA
Inventory of Chemical Substances.
EPA SARA Title III Chemical Listings
Section 302 Extremely Hazardous Substances:
None.
Section 304 CERCLA Hazardous Substances:
None.
Section 312 Hazard Class:
Acute: No
Chronic: No
Fire: No
Pressure: No
Reactive: No
Section 313 Toxic Chemicals:
None present or none present in regulated quantities.
DOW CORNING CORPORATION
Material Safety Data Sheet
Page: 7 of 7
DOW CORNING 200(R) FLUID, 100 CST.
Supplemental State Compliance Information
California
Warning: This product contains the following chemical(s) listed by the State of California under the Safe Drinking
Water and Toxic Enforcement Act of 1986 (Proposition 65) as being known to cause cancer, birth defects or other
reproductive harm.
None known.
Massachusetts
No ingredient regulated by MA Right-to-Know Law present.
New Jersey
CAS Number
63148-62-9
Wt %
Component Name
> 60.0
Polydimethylsiloxane
Wt %
Component Name
> 60.0
Polydimethylsiloxane
Pennsylvania
CAS Number
63148-62-9
16. OTHER INFORMATION
Prepared by: Dow Corning Corporation
These data are offered in good faith as typical values and not as product specifications. No warranty, either
expressed or implied, is hereby made. The recommended industrial hygiene and safe handling procedures are
believed to be generally applicable. However, each user should review these recommendations in the specific
context of the intended use and determine whether they are appropriate.
(R) indicates Registered Trademark
BLANK PAGE
Supplement Guide - S1400CW
Issue: 04/05
TM
SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING
A Guide for the Protection of
Site Equipment & Personnel
In the Installation of
ControlWave
Process Automation Controllers
Bristol Babcock
NOTICE
Copyright Notice
The information in this document is subject to change without notice. Every effort has been
made to supply complete and accurate information. However, Bristol Babcock assumes no
responsibility for any errors that may appear in this document.
Request for Additional Instructions
Additional copies of instruction manuals may be ordered from the address below per
attention of the Sales Order Processing Department. List the instruction book numbers or
give complete model number, serial or software version number. Furnish a return address
that includes the name of the person who will receive the material. Billing for extra copies
will be according to current pricing schedules.
ControlWave® is a re registered trademark of Bristol Babcock. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their
respective companies, or trademark holders.
Copyright (c) 2005 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of
this manual may be reproduced in any form without the express written permission of
Bristol Babcock.
Supplement Guide S1400CW
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 1 - INTRODUCTION
1.1
1.2
GENERAL INTRODUCTION ....................................................................................... 1-1
MAJOR TOPICS ............................................................................................................. 1-1
Section 2 - PROTECTION
2.1
2.1.1
2.2
2.2.1
2.2.2
2.3
PROTECTING INSTRUMENT SYSTEMS................................................................... 2-1
Quality Is Conformance To Requirements.................................................................... 2-1
PROTECTING EQUIPMENT & PERSONNEL ........................................................... 2-1
Considerations For The Protection of Personnel .......................................................... 2-2
Considerations For The Protection of Equipment ........................................................ 2-2
OTHER SITE SAFETY CONSIDERATIONS............................................................... 2-3
Section 3 - GROUNDING & ISOLATION
3.1
3.2
3.3
3.3.1
3.3.1.1
3.3.1.2
3.3.1.3
3.3.2
3.3.3
3.4
3.4.1
3.4.2
POWER & GROUND SYSTEMS................................................................................... 3-1
IMPORTANCE OF GOOD GROUNDS......................................................................... 3-1
EARTH GROUND CONNECTIONS............................................................................. 3-1
Establishing a Good Earth Ground. .............................................................................. 3-1
Soil Conditions ................................................................................................................ 3-2
Soil Types ........................................................................................................................ 3-2
Dry, Sandy or Rocky Soil................................................................................................ 3-4
Ground Wire Considerations. ........................................................................................ 3-5
Other Grounding Considerations. ................................................................................. 3-6
ISOLATING EQUIPMENT FROM THE PIPELINE ................................................... 3-7
Meter Runs Without Cathodic Protection..................................................................... 3-7
Meter Runs With Cathodic Protection .......................................................................... 3-7
Section 4 - LIGHTNING ARRESTERS & SURGE PROTECTORS
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.2
STROKES & STRIKES .................................................................................................. 4-1
Chance of Being Struck by Lightning. .......................................................................... 4-1
Antenna Caution ............................................................................................................ 4-3
Ground Propagation ....................................................................................................... 4-5
Tying it all Together....................................................................................................... 4-5
Impulse Protection Summary ........................................................................................ 4-5
USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS................................ 4-6
Section 5 - WIRING TECHNIQUES
5.1
5.2
5.2.1
OVERVIEW ....................................................................................................................5-1
INSTRUMENT WIRING. .............................................................................................. 5-1
Common Returns ............................................................................................................5-1
Supplement S1400CW
Page 0-1
Table Of Contents
Supplement Guide S1400CW
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 5 - WIRING TECHNIQUES (Continued)
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
Use of Twisted Shielded Pair Wiring (with Overall Insulation).................................. 5-2
Grounding of Cable Shields. .......................................................................................... 5-3
Use of Known Good Earth Grounds .............................................................................. 5-3
Earth Ground Wires ....................................................................................................... 5-3
Working Neatly & Professionally .................................................................................. 5-3
High Power Conductors and Signal Wiring .................................................................. 5-4
Use of Proper Wire Size ................................................................................................. 5-4
Lightning Arresters & Surge Protectors ....................................................................... 5-4
Secure Wiring Connections ............................................................................................ 5-5
REFERENCE DOCUMENTS
1.
2.
3.
4.
5.
6.
7.
IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std
142-1982
IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise inputs to Controllers
from External Sources - IEE Std 518-1982
Lightning Strike Protect; Roy B. Carpenter, Jr. & Mark N. Drabkin, Ph.D.; Lightning Eliminators &
Consultant, Inc., 6687 Arapahoe Road, Boulder Colorado
Lightning Protection Manual for Rural Electric Systems, NRECA Research Project 82-5, Washington DC,
1983
Grounding for the Control of EMI; Hugh W. Denny; Don White Consultants, Inc., 1983, 1st Edition
Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam
Street, Shreveport, Louisiana 71151
TeleFlow Modem Grounding Kit 621495-01-8 Installation Instructions - PIP-3530MGKI; Bristol Babcock,
Watertown, CT 06795
Supplement S1400CW
Page 0-2
Table Of Contents
Section 1 - Overview
1.1 INTRODUCTION
This document provides information pertaining to the installation of ControlWave
systems; more specifically, information covering reasons, theory and techniques for
protecting your personnel and equipment from electrical damage. Your instrument system
affects the quality of service provided by your company and many aspects of its operational
safety. Loss of instruments means lost production and profits as well as increased expenses.
Information contained in this document is for educational purposes. Bristol Babcock makes
no warranties or guarantees on the effectiveness or the safety of techniques described herein.
Where the safety of installations and personnel is concerned, refer to the National Electrical
Code Rules and rules of local regulatory agencies.
1.2 MAJOR TOPICS
Topics are covered in seven sections designed to pinpoint major areas of concern for the
protection of site equipment and personnel. The following overview is provided for each of
the major sections.
·
Section 2 - Protection
This section provides the reasons for protecting instrument systems. An overview of the
definition of quality and what we are trying to accomplish in the protection of site
installations and how to satisfy the defined requirements is presented. Additionally,
this section provides considerations for the protection of personnel and equipment.
·
Section 3 - Grounding & Isolation
Information pertaining to what constitutes a good earth ground, how to test and
establish such grounds, as well as when and how to connect equipment to earth grounds
is provided
·
Section 4 - Lightning Arresters & Surge Protectors
Some interesting information dealing with Lightning strikes and strokes is presented in
technical and statistical form along with a discussion of how to determine the likelihood
of a lightning strike. Protecting equipment and personnel during the installation of
radios and antenna is discussed in a review of the dangers to equipment and personnel
when working with antennas. Reasons for the use of lightning arresters and surge
protectors are presented along with overviews of how each device protects site
equipment.
·
Section 5 - Wiring Techniques
Installation of Power and “Measurement & Control” wiring is discussed. Information on
obscure problems, circulating ground and power loops, bad relays, etc. is presented.
Good wire preparation and connection techniques along with problems to avoid are
discussed. This sections list the ten rules of instrument wiring.
Section 1 - Overview
Page 1-1
S1400CW
Section 2 - Protection
2.1 PROTECTING INSTRUMENT SYSTEMS
Electrical instrumentation is susceptible to damage from a variety of natural and man
made phenomena. In addition to wind, rain and fire, the most common types of system and
equipment damaging phenomena are lightning, power faults, communication surges &
noise and other electrical interference’s caused by devices such as radios, welders,
switching gear, automobiles, etc. Additionally there are problems induced by geophysical
electrical potential & noise plus things that are often beyond our wildest imagination.
2.1.1 Quality Is Conformance To Requirements
A quality instrumentation system is one that works reliably, safely and as purported by the
equipment manufacturer (and in some cases by the system integrator) as a result of good
equipment design and well defined and followed installation practices. If we except the
general definition of quality to be, “quality is conformance to requirements,” we must also
except the premise that a condition of “quality” can’t exist where requirements for such an
end have not been evolved. In other words, you can’t have quality unless you have
requirements that have been followed. By understanding the requirements for a safe, sound
and reliable instrumentation system, and by following good installation practices (as
associated with the personnel and equipment in question), the operational integrity of the
equipment and system will be enhanced.
Understanding what is required to properly install BBI equipment in various environments, safely, and in accordance with good grounding, isolating and equipment
protection practices goes a long way toward maintaining a system which is healthy to the
owner and customer alike. Properly installed equipment is easier to maintain and operate,
and is more efficient and as such more profitable to our customers. Following good installation practices will minimize injury, equipment failure and the customer frustrations
that accompany failing and poorly operating equipment (of even the finest design). Additionally, personnel involved in the installation of a piece of equipment add to or subtract
from the reliability of a system by a degree which is commensurate with their technical
prowess, i.e., their understanding of the equipment, site conditions and the requirements
for a quality installation.
2.2 PROTECTING EQUIPMENT & PERSONNEL
ControlWave installations must be performed in accordance with National Electrical Code
Rules, electrical rules set by local regulatory agencies, and depending on the customer
environment (gas, water, etc), other national, state and local agencies such as the American
Water Works Association (AWWA). Additionally, installation at various customer sites may
be performed in conjunction with a “safety manager” or utility personnel with HAZMAT
(hazardous material) training on materials present (or potentially present) as required by
OSHA, the customer, etc.
Section 2 - Protection
Page 2-1
S1400CW
2.2.1 Considerations For The Protection of Personnel
Always evaluate the site environment as if your life depended on it. Make sure that you
understand the physical nature of the location where you will be working. Table 2-1
provides a general guideline for evaluating an installation site.
Table 2-1 - Installation Site Safety Evaluation Guide
#
1
2
3
4
5
6
7
8
9
Guide
Indoor or outdoor – Dress Appropriately
If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees,
spiders, snakes, etc.)
If indoor or outdoor – determine if there are any pieces of dangerous equipment or any
processes which might be a risk to your safety
If in a tunnel, bunker, etc. watch out for a build up of toxic or flammable gases. Make
sure the air is good. Watch out for local varmint (bees, spiders, snakes, etc.)
Hazardous or Non-Hazardous Environment – Wear appropriate safety equipment and
perform all necessary safety measures.
Before installing any equipment or power or ground wiring, make sure that there are no
lethal (life threatening) voltages between the site where the instrument will be installed
and other equipment, pipes, cabinets, etc. or to earth itself.
Never assume that adjacent or peripheral equipment has been properly installed and
grounded. Determine if this equipment and the ControlWave unit in question can be
touched simultaneously without hazard to personnel and/or equipment?
Before embarking to remote locations where there are few or no human inhabitants ask a
few simple questions like, should I bring water, food, hygienic materials, first aid kit, etc?
Be Prepared!
Observe the work habits of those around you – for your own safety!
Some of the items that a service person should consider before ever going on site can be
ascertained by simply asking questions of the appropriate individual. Obviously other
safety considerations can only be established at the installation site.
2.2.2 Considerations For The Protection of Equipment
Always evaluate the site installation/service environment and equipment. Understand the
various physical interfaces you will be dealing with such as equipment mounting and
supporting, ControlWave analog and digital circuits, power circuits, communication
circuits and various electrical grounds. Table 2-2 provides a general guideline for
evaluating the equipment protection requirements of an installation site.
Table 2-2 - Equipment Protection Site Safety Evaluation Guide
#
1
2
3
4
5
Guide
Environment - Class I, Division 2 - Nonincendive
Environment - Class I, Division 1 - Intrinsically Safe
Other - Safe or unrated area
Earth Ground - Established by mechanical/electrical or
(both) or not at all.
Is the area prone to lightning strikes?
Are there surge suppressors installed or to be installed?
Are there overhead or underground power or communication cables in the immediate area?
S1400CW
Page 2-2
Reference Section
See Appendix A of CI Manual
See Appendix B of CI Manual
See Section 3
See Section 4
See Section 4
See Section 2.3
Section 2 - Protection
Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued)
#
6
7
8
9
2.3
Guide
Is there an antenna in the immediate area?
How close is other equipment? Can someone safely touch this
equipment and a ControlWave simultaneously?
Determine equipment ground requirements. How will the
ControlWave and its related wiring be grounded? Consider Earth
Ground, Circuit Ground, Conduit Ground, Site Grounds!
Are there any obviously faulty or questionable power or ground
circuits?
Reference Section
See Section 4.1.2
See Section 2.3
See Section 3
See Section 2.3
OTHER SITE SAFETY CONSIDERATIONS
Overhead or underground power or communication cables must be identified prior to
installing a new unit. Accidentally cutting, shorting or simply just contacting power,
ground, communication or process control I/O wiring can have potentially devastating
effects on site equipment, the process system and or personnel.
Don’t assume that it is safe to touch adjacent equipment, machinery, pipes, cabinets or even
the earth itself. Adjacent equipment may not have been properly wired or grounded, may be
defective or may have one or more loose system grounds. Measure between the case of a
questionable piece of equipment and its earth ground for voltage. If a voltage is present,
something is wrong.
AC powered equipment with a conductive case should have the case grounded. If you don’t
see a chassis ground wire, don’t assume that it is safe to touch this equipment. If you notice
that equipment has been grounded to pipes, conduit, structural steel, etc., you should be
leery. Note: AWWA’s policy on grounding of electric circuits on water pipes states,
“The American Water Works Association (AWWA) opposes the grounding of
electrical systems to pipe systems conveying water to the customer’s premises….”
Be sure that the voltage between any two points in the instrument system is less than the
stand-off voltage. Exceeding the stand-off voltage will cause damage to the instrument and
will cause the instrument to fail.
Section 2 - Protection
Page 2-3
S1400CW
Section 3 - Grounding & Isolation
3.1 POWER & GROUND SYSTEMS
ControlWaves utilize DC power systems. AC power supplies are not provided with ControlWave units. ControlWave, ControlWave MICRO, ControlWave EFM/GFC/EFC,
ControlWaveRED, ControlWaveREDIO and ControlWave I/O Expansion Racks are
provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing
a connection to Earth Ground. In the case of the ControlWaveLP, a Chassis Ground
termination terminal (TB2, Pin-3), that accepts up to a #14 AWG size wire, is provided on
the unit’s Power Supply/Sequencer Board.
3.2 IMPORTANCE OF GOOD GROUNDS
ControlWave units (see above) are utilized in instrument and control systems that must
operate continually and within their stated accuracy over long periods of time with
minimum attention. Failures resulting from an improperly grounded system can become
costly in terms of lost time and disrupted processes. A properly grounded system will help
prevent electrical shock hazards resulting from contact with live metal surfaces, provide
additional protection of equipment from lightning strikes and power surges, minimize the
effects of electrical noise and power transients, and reduce signal errors caused by ground
wiring loops. Conversely, an improperly grounded system may exhibit a host of problems
that appear to have no relation-ship to grounding. It is essential that the reader (service
technician) have a good under-standing of this subject to prevent needless troubleshooting
procedures.
WARNING
This device must be installed in accordance with the National
Electrical Code (NEC) ANSI/NEPA-70. Installation in hazardous
locations must also comply with Article 500 of the code. For
information on the usage of ControlWave units in Class I, Division 2,
Groups C & D Hazardous and Nonhazardous locations, see appendix A
of the applicable Customer Instruction (CI) manual. For information
on the usage of ControlWave units in Class I, Division 1, Groups C &
D Hazardous locations, see appendix B of the applicable Customer
Instruction (CI) manual.
3.3 EARTH GROUND CONNECTIONS
To properly ground a ControlWave unit, the units Chassis Ground (post or terminal) must
ultimately be connected to a known good Earth Ground. Observe recommendations
provided in topics Establishing a Good Earth Ground and Ground Wire Considerations.
3.3.1 Establishing a Good Earth Ground
A common misconception of a ground is that it consists of nothing more than a metal pipe
driven into the soil. While such a ground may function for some applications, it will often
Section 3 - Grounding & Isolation
Page 3-1
S1400CW
not be suitable for a complex system of sophisticated electronic equipment. Conditions such
as soil type, composition and moisture will all have a bearing on ground reliability.
A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into
conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG
solid copper wire should be used for the ground wire. The end of the wire should be clean,
free of any coating and fastened to the rod with a clamp. This ground connection should be
covered or coated to protect it from the weather and the environment.
Figure 3-1 - Basic Ground Rod Installation
3.3.1.1 Soil Conditions
Before installing a ground rod, the soil type and moisture content should be analyzed.
Ideally, the soil should be moist and moderately packed throughout to the depth of the
ground rod. However, some soils will exhibit less than ideal conditions and will require
extra attention.
Soil types can be placed into two general categories with respect to establishing and
maintaining a good earth ground, i.e., ‘Good Soil’ and ‘Poor Soil.’
To be a good conductor, soil must contain some moisture and free ions (from salts in the
soil). In very rainy areas, the salts may be washed out of the soil. In very sandy or arid area
the soil may be to dry and/or salt free to a good conductor. If salt is lacking add rock salt
(NaCl); if the soil is dry add calcium chloride (CaCl2).
3.3.1.2 Soil Types:
Good
Damp Loam
Salty Soil or Sand
Farm Land
Poor
Back Fill
Dry Soil
Sand Washed by a Lot of Rain
Dry Sand (Desert)
Rocky Soil
Ground Beds must always be tested for conductivity prior to being placed into service. A
brief description of ground bed testing in ‘Good Soil’ and ‘Poor Soil’ is provided herein.
Details on this test are described in the National Electrical Code Handbook. Once a reliable
S1400CW
Page 3-2
Section 3 - Grounding & Isolation
ground has been established, it should be tested on a regular basis to preserve system
integrity.
Figure 3-2 - Basic Ground Bed Soil Test Setup
Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods
Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5
ohms, the ground is good. The lower the resistance, the better the earth ground. If the
Section 3 - Grounding & Isolation
Page 3-3
S1400CW
Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is
indicated, one or more additional ground rods connected 10 feet from the main ground rod
should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x
¼-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the
Biddle Instrument Co. (now owned by AVO International). Other devices that
may be used to test ground resistance are “Viboground”; Associated Research,
Inc., “Groundmeter”; Industrial Instruments, Inc., and “Ground-ohmer”; Herman
H. Sticht Co., Inc.
If the Megger still reads more than 10 ohms, mix a generous amount of cooking salt, ice
cream salt or rock salt with water and then pour about 2.5 to 5 gallons of this solution
around each rod (including the test rods). Wait 15 minutes and re-test the soil. If the test
fails, the soil is poor and a ‘Poor Soil Ground Bed’ will have to be constructed.
Figure 3-4 shows a typical Poor Soil Ground Bed Electrode. A Poor Soil Ground Bed will
typically consists of four or more 10-foot long electrodes stacked vertically and separated by
earth. Figure 3-5 shows the construction of a Poor Soil Ground Bed. For some poor soil
sites, the ground bed will be constructed of many layers of ‘Capacitive Couplings’ as
illustrated. In extremely poor soil sites one or more 3’ by 3’ copper plates (12 gauge or 1/16”
thick) will have to be buried in place of the electrodes.
Figure 3-4 - Ground Electrode Construction for Poor Soil Conditions
3.3.1.3 Dry, Sandy or Rocky Soil
Very dry soil will not provide enough free ions for good conductance and a single ground rod
will not be effective. A buried counterpoise or copper screen is recommended for these
situations. It will be necessary to keep the soil moist through regular applications of water.
Sandy soil, either wet or dry, may have had its soluble salts leached out by rain water,
thereby reducing conductivity of the ground. High currents from lightning strikes could also
melt sand and cause glass to form around the ground rod, rendering it ineffective. A buried
counterpoise or copper screen is preferred for these installations along with regular
applications of salt water.
Rocky soil can pose many grounding problems. A counterpoise or copper plate will probably
be required. Constructing a trench at the grounding site and mixing the fill with a
hygroscopic salt such as calcium chloride may help for a time. Soaking the trench with
water on a regular basis will maintain conductivity.
Units with phone modems require the use of a lightning arrester. The lightning arrester
must be situated at the point where the communication line enters the building.
S1400CW
Page 3-4
Section 3 - Grounding & Isolation
Figure 3-5 - Poor Soil Ground Bed Construction Diagram
3.3.2 Ground Wire Considerations
ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveRED, ControlWave REDIO & ControlWave I/O Expansion Rack
ControlWave Chassis are provided with a Ground Lug that accommodates up to a #4 AWG
wire size. A ground wire must be run between the Chassis Ground Lug and a known good
Earth Ground. The cases of the various ControlWave Modules are connected to Chassis
Ground when they have been installed and secured via their two Captured Panel
Fasteners. As an extra added precaution, it is recommended that a #14 AWG wire be run
from PSSM Power Connector TB2-5 (Chassis Ground) (PSSM Connector TB1-3 for
ControlWave MICRO unit) (SCM Connector TB1-3 for ControlWave EFM) to the same
known good Earth Ground.
ControlWaveLP Process Automation Controller
A #14 AWG ground wire must be run from the ControlWaveLP’s PSSB Terminal TB2-3
(Chassis Ground) to a known good Earth Ground. In lieu of a direct connection to Earth
Section 3 - Grounding & Isolation
Page 3-5
S1400CW
Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a
conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground
Bus. The panel, lug or bus in turn must be connected to a known good Earth Ground via a
#4 AWG wire.
General Considerations
The following considerations are provided for the installation of ControlWave system
grounds:
i Size of ground wire (running to Earth Ground should be #4 AWG. It is recommended
that stranded copper wire is used for this application and that the length should be as
short as possible.
i This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
i The wire ends should be tinned with solder prior to installation.
i The ground wire should be run such that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above ground.
The units Earth Ground Cable should be clamped to an exposed Ground Rod or to an AWG
0000 stranded copper Ground Cable that in turn should be connected to either an Earth
Ground Rod or Earth Ground Bed. Both ends of the units Earth Ground Cable must be free
of any coating such as paint or insulated covering as well as any oxidation. The connecting
point of the Ground Rod or AWG 0000 Ground Cable must also be free of any coating and
free of oxidation. Once the ground connection has been established (at either the Ground
Rod or Ground Cable) it should be covered or coated to protect it from the environment.
3.3.3 Other Grounding Considerations
Figure 3-6 - Grounding of Phone Line
S1400CW
Page 3-6
Section 3 - Grounding & Isolation
For applications employing equipment that communicates over telephone lines, a lightning
arrester Must Be provided. For indoor equipment the lightning arrester must be installed
at the point where the communication line enters the building as shown in Figure 3-6. The
ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.
Gas lines also require special grounding considerations. If a gas meter run includes a
thermocouple or RTD sensor installed in a thermowell, the well (not the sensor) must be
connected to a gas discharge-type lightning arrester as shown in Figure 3-7. A copper braid,
brazed to the thermal well, is dressed into a smooth curve and connected to the arrester as
shown. The curve is necessary to minimize arcing caused by lightning strikes or high static
surges. The path from the lightning arrester to the ground bed should also be smooth and
free from sharp bends for the same reason.
Figure 3-7 - Grounding of Thermometer Well in Gas Line
3.4 ISOLATING EQUIPMENT FROM THE PIPELINE
3.4.1 Meter Runs Without Cathodic Protection
ControlWave EFM/GFC/XFC’s may be mounted directly on the pipeline or remotely on a
vertical stand-alone two-inch pipe (see Figure 3-8). The Earth Ground Cable is to run
between the ControlWave EFM/GFC/XFC’s Ground Lug and Earth Ground (Rod or Bed)
even though the ControlWave EFM/GFC/XFC’s Multivariable Transducer may be
Section 3 - Grounding & Isolation
Page 3-7
S1400CW
grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely
mounted, connect their chassis grounds to the pipeline or earth ground.
Figure 3-8 - ControlWave EFM (Installation is similar to GFC/XFC)
Remote Installation without Cathodic Protection
3.4.2 Meter Runs With Cathodic Protection
Dielectric isolators are available from Bristol Babcock and are always recommended as an
added measure in isolating the ControlWave EFM/GFC/XFC from the pipeline even
though the ControlWave EFM/GFC/XFC does provide 500V galvanic isolation from the
pipeline and should not be affected by cathodic protection or other EMF on the pipeline.
ControlWave EFM/GFC/XFC may be mounted directly on the pipeline (see Figure 3-9) or
remotely on a vertical stand-alone two-inch stand-pipe (see Figure 3-10). It is recommended
that isolation fitting always be used in remotely mounted meter systems. An isolation
fittings or gasket should be installed between the following connections:
S1400CW
Page 3-8
Section 3 - Grounding & Isolation
•
•
•
all conductive tubing that runs between the pipeline and mounting valve manifold
and/or the units multivariable pressure transducer
all conductive connections or tubing runs between the ControlWave EFM/GFC and
turbine meter, pulse transducer, or any input other device that is mounted on the
pipeline
any Temperature Transducer, Pressure Transmitter, etc. and their mount/interface to
the pipeline
Figure 3-9 - ControlWave EFM (Installation is similar to EFM/GFC/XFC)
Direct Mount Installation (with Cathodic Protection)
The ground conductor connects between the ControlWave EFM/GFC/XFC’s Ground Lug
and a known good earth ground. Connect the cases of Temperature Transducers, Pressure
Transmitters, etc., to the known good earth ground. If the mounting 2-inch pipe is in
continuity with the pipeline it will have to be electrically isolated from the ControlWave
EFM/GFC/XFC. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU
3140. This black tubing will easily slip over the 2-inch pipe and then after uniform heating
(e.g., with a rose-bud torch) it electrically insulates and increases the strength of the pipe
stand.
Section 3 - Grounding & Isolation
Page 3-9
S1400CW
See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems
and Manifolds.
Figure 3-10 – ControlWave EFM (Installation is similar to GFC/XFC)
Remote Installation (with Cathodic Protection)
S1400CW
Page 3-10
Section 3 - Grounding & Isolation
Section 4 - Lightning Arresters & Surge Protectors
4.1 STROKES & STRIKES
Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay
to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will
average 18 KA for the first impulse and about half of that for the second and third
impulses. Three strokes (impulses) is the average per lightning strike. The number of
visible flashes that may be seen is not necessarily the number of electrical strokes.
A lightning strike acts like a constant current source. Once ionization occurs, the air
becomes a luminous conductive plasma reaching up to 60,000° F. The resistance of a struck
object is of little consequence except for the power dissipation on the object (I2 x R). Fifty
percent of all lightning strikes will have a first impulse of at least 18 KA, ten percent will
exceed the 60 KA level, and only about one percent will exceed 120 KA.
4.1.1 Chance of Being Struck by Lightning
The map of Figure 4-1 shows the average annual number of thunderstorm days
(Isokeraunic level) for the various regions within the continental U.S.A. This map is not
representative of the severity of the storm or the number of lightning strikes since it does
not take into account more than one lightning strike in a thunderstorm day. The
Isokeraunic or Isoceraunic number provides a meteorological indication of the frequency of
thunderstorm activity; the higher the Isokeraunic number the greater the lightning strike
activity for a given area. These levels vary across the world from a low of 1 to a high of 300.
Within the United States the Isokeraunic level varies from a low of 1 to a high of 100.
Figure 4-1 - Average Thunderstorm Days of the Year (for Continental USA)
Section 4 - Lightning & Surge
Page 4-1
S1400CW
Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the
United States there is an average of 30 thunderstorm days per year. Any given storm may
produce from one to several strokes. Data on the subject indicates that for an average area
within the United States there can be eight to eleven strokes to each square mile per year.
The risk of stroke activity is increased for various areas such central Florida where up to 38
strokes to each square mile per year are likely to occur.
To determine the probability of a given structure (tower, building, etc.) (within your
location) being struck, perform the following computation:
1. Using the map of Figure 4-1 (or a comparable meteorological map for your local), find
the Isokeraunic level (I) for your area. Then using Chart 1, find “A” for your area.
2. Refer to Figure 4-1 to find the latitude. Then using Chart 2, find “B” for your latitude
(Lat.°).
3. Multiply “A” x “B” to get “C”.
4. To calculate the number of lightning strikes per year that are likely to strike a given
object (tower, mast, etc.), use the equation that follows (where “C” was calculated in
step 3 and “H” is equal to the height of the object.
Strikes Per Year = (“C” x H2) ÷ (.57 x 106 )
Chart 1
I
5
10
20
30
40
50
60
70
80
90
100
“A”
8
26
85
169
275
402
548
712
893
1069
1306
Chart 2
LAT.°
25
30
35
40
45
“B”
.170
.200
.236
.280
.325
Note for these charts:
I = Thunderstorm Days Per Year (Isokeraunic Number)
A = Stroke activity for associated Isokeraunic Area
B = Height/Stroke coefficient for associated latitude
For Example: On Long Island, New York (Isokeraunic number 20), Chart 1 gives “A” to
equal 85. The latitude is approximately 40°. Referring to Chart 2, “B” is found to be equal to
.28. “C” for this example is equal to 23.80. Using the equation for strikes per year, it is
determined that a 100-foot tower has .4 chances per year of being struck by lightning.
Assuming that no other structures are nearby, the tower will more than likely be struck by
lightning at least once in three years.
Note: The Isokeraunic activity numbers connoted as I, “A” and “B” in Charts 1 and 2 above
are provided for the continental United States. Isokeraunic data for various countries
is available from various federal or state Civil Engineering or Meterorelogical
organizations. This information is typically available from manufacturers of lightning
strike protection equipment (such as Lightning Arresters).
Since ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP and ControlWaveEXP units are dc operated systems that are isolated from AC
grids, they are typically immune to lightning strikes to power lines or power equipment
(except for inductive flashover due to close installation proximity). However, once a radio or
S1400CW
Page 4-2
Section 4 - Lightning & Surge
modem has been interfaced to a ControlWave, ControlWave MICRO, ControlWave
EFM/GFC/XFC, ControlWaveLP, or ControlWaveEXP the possibility of damage due to a
lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower
must be considered. It is recommended that the additional lightning protection
considerations listed below be followed for units installed in areas with a high possibility or
history of stroke activity.
Units interfaced to a modem: In series with the phone line (as far away as possible
from the equipment) - for indoor installations the lightning arrester should typically be
located at the point where the line enters the structure.
Units interfaced to a radio: Mount antenna discharge unit (lightning arrester) as
close as possible to where the lead in wire enters the structure. See Antenna Caution
below.
4.1.2 Antenna Caution
Each year hundreds of people are killed, mutilated, or receive severe permanent injuries
when attempting to install or remove an antenna or antenna lead. In many cases, the
victim was aware of the danger of electrocution but failed to take adequate steps to avoid
the hazard. For your safety, and for proper installation maintenance, please read and
follow the safety precautions that follow - they may save your life.
i When installing or servicing an antenna:
DO NOT use a metal ladder. DO NOT step onto or touch an antenna mast while power
is applied to an associated radio unless the radio is a low power (low current) type.
DO NOT work on a wet or windy day, especially during a thunderstorm or when there is
lightning or thunder in your area. Dress properly; shoes with rubber soles and heels,
rubber gloves, long sleeve shirt or jacket.
i The safe distance from power lines should be at least twice the height of the antenna
and mast combination.
i Antenna Grounding per National Electrical Code Instructions:
A. Use AWG 10 or 8 aluminum or AWG 1 copper-clad steel or bronze wire, or larger as
ground wires for both the mast and lead-in. Securely clamp the wire to the bottom of
the mast.
B. Secure lead-in wire from antenna to antenna discharge (lightning arrester) unit and
the mast ground wire to the structure (building, shed, etc.) with stand-off insulators
spaced from 4 feet (1.22 meters) to 6 feet (1.83 meters) apart.
C. Mount antenna discharge unit as close as possible to where the lead-in wire enters
the structure.
D. The hole drilled through the wall for the lead-in wire should be just large enough to
accommodate the cable. Before drilling this hole, make sure there are no wires or
pipes, etc. in the wall.
E. Push the cable through the hole and form a rain drip loop close to where the wire
enters the exterior of the structure.
F. Caulk around the lead-in wire (where it enters the structure) to keep out drafts.
G. Install lightning arresters (antenna discharge units). The grounding conductor
should be run in as straight a line as practicable from the antenna mast and/or the
antenna discharge units to grounding electrode(s).
H. Only connect the antenna cable to the radio after the mast has been properly
grounded and the lead-in cable has been properly connected to lightning arresters
which in turn have each been properly connected to a known good earth ground.
Section 4 - Lightning & Surge
Page 4-3
S1400CW
Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram
For all systems it is best to have all communication equipment input/output grounds tied
together. In the case of ControlWave units, this is accomplished via the unit’s Chassis
Ground (Typically at a ground lug, ground bus or ground plate). However additional
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Page 4-4
Section 4 - Lightning & Surge
communication equipment lightning arresters and surge suppressors should be tied to the
same system ground. System ground consists of the tower leg grounds utility ground and
bulkhead-equipment ground-stakes that are tied together via bare copper wire.
4.1.3 Ground Propagation
As in any medium, a dynamic pulse, like R.F., will take time to propagate. This propagation
time will cause a differential step voltage to exist in time between any two ground rods that
are of different radial distances from the strike. With a ground rod tied to a struck tower,
the impulse will propagate its step voltage outwardly from this rod in ever-expanding
circles, like a pebble thrown into a pond. If the equipment house has a separate ground rod
and the power company and/or telephone company grounds are also separate, the dynamic
step voltage will cause currents to flow to equalize these separate ground voltages. Then if
the coax cable (associated with a radio) is the only path linking the equipment chassis with
the tower ground, the surge can destroy circuitry.
4.1.4 Tying it all Together
To prevent this disaster from occurring, a grounding system must be formed which
interconnects all grounds together. This will equalize and distribute the surge charge to all
grounds, and at the same time, it will make for a lower surge impedance ground system.
This interconnection can be done as a grid, where each ground has a separate line to each
other ground, or by using a “rat Race” ring which forms a closed loop (not necessarily a
perfect circle) which surrounds the equipment house completely.
By making this interconnection, it will be necessary to use proper I/O protectors for the
equipment. Of course, these should be a requirement regardless of whether this grounding
technique is used. I/O protectors are used for power lines (even those these don’t feed into a
ControlWave unit), telephone lines, and also to minimize EMI pick-up from a strike.
Ideally it is best to place all I/O protectors on a common panel that has a low inductance
path to the ground system. The ControlWave units would then have a single ground point
from its Chassis Ground Terminal/Ground Lug to this panel. In lieu of this, the
ControlWave unit in question should be tied to a ground rod that in turn is connected to
the Earth/System Ground created for the site.
Your protected equipment connected to a common single ground system, will now be just
like a bird sitting on a high tension wire. When lightning strikes, even with a 50 ohm surge
impedance ground system, the entire system consisting of equipment, ground system,
building, etc., will all rise together to the one million volt peak level (for example) and will
all decay back down together. So long as there is no voltage differential (taken care of by
protectors and ground interconnections, there will be no current flow through the
equipment and therefore no resulting equipment damage.
4.1.5 Impulse Protection Summary
i
i
i
i
Use more than one ground rod.
Place multi-ground stakes more than their length apart.
Tie Power, Telco, Tower, Bulkhead and equipment ground together.
Make all ground interconnect runs that are above ground with minimum radius
bends of eight inches and run them away from other conductors and use large solid
wire or a solid strap.
Section 4 - Lightning & Surge
Page 4-5
S1400CW
i Watch out for dissimilar metals connections and coat accordingly.
i Use bare wire radials together where possible with ground stakes to reduce ground
system impedance.
i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground
system.
i Ground the Coaxial Cable Shield (or use an impulse suppressor) at the bottom of the
tower just above the tower leg ground connection.
4.2 USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS
Units equipped with radios or modems use lightning arresters and surge protectors to
protect equipment from lightning strikes, power surges and from damaging currents that
have been induced onto communication lines.
The first line of defense is the Lightning Arrester. These devices typically use gas discharge
bulbs that can shunt high currents and voltages to earth ground when they fire. The high
current, high voltage gas discharge bulb has a relatively slow response time and only fire
when their gas has been ionized by high voltage.
The second line of defense is the Surge Protector, which is made of solid state devices, fires
very quickly and conducts low voltages and currents to ground. Surge protectors are built
into BBI 9600 bps modems.
Lightning Arresters are applied to circuits as follows:
i Equipment or circuits that can be exposed to lightning strikes, falling power lines,
high ground currents caused by power system faults, by operational problems on
electric railways, etc.
i Equipment installed in dry, windy areas, such as the Great Plains and the
Southwest Desert in the United States. Wind and wind blown dust can cause high
voltages (static) to appear on overhead wires, fences, and metal buildings.
Note: Lightning Arresters may explode if lightning strike is very close. Mount
lightning arresters where flying parts won't cause injury to equipment or
personnel.
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Page 4-6
Section 4 - Lightning & Surge
Section 5 - Wiring Techniques
5.1 OVERVIEW
This section provides information pertaining to good wiring practices. Installation of Power
and “Measurement & Control” wiring is discussed. Information on obscure problems,
circulating ground and power loops, bad relays, etc. is presented. Good wire preparation
and connection techniques along with problems to avoid are discussed.
5.2 INSTRUMENT WIRING
Each of the rules listed below is briefly discussed; the emphasis herein is placed on the
avoidance of problems as well as equipment safety.
Rule 1 - Never utilize common returns.
Rule 2 - Use twisted shielded pairs (with overall insulation) on all Signal/Control circuits.
Rule 3 - Ground cable shields at one end only.
Rule 4 - Use known good earth grounds (Rod, Bed, System) and test them periodically,
Rule 5 - Earth connections must utilize smoothly dressed large wire.
Rule 6 - Perform all work neatly and professionally.
Rule 7 - Route high power conductors away from signal wiring according to NEC Rules.
Rule 8 - Use appropriately sized wires as required by the load.
Rule 9 - Use lightning arresters and surge protectors.
Rule 10 - Make sure all wiring connections are secure.
5.2.1 Common Returns
Use of common returns on I/O wiring is one of the most common causes of obscure and
difficult to troubleshoot control signal problems. Since all wires and connections have
distributed resistance, inductance and capacitance, the chances of a achieving a balanced
system when common returns are present is very remote. Balanced systems (or circuits) are
only achieved when all currents and voltages developed in association with each of the
common returns are equal. In a balanced system (or circuit) there are no noise or
measurment errors introduced due to by “sneak circuits.”
The illustration of Figure 5-1 shows the difference between testing an I/O circuit that is
discrete and has no sneak circuits and one that utilizes common returns. Common sense
tells us that it is tough to mix up connections to a twisted shielded pair (with overall vinyl
covering) to every end device. Do yourself a favor; to make start up easier, DON’T USE
COMMON RETURNS!
Section 5 - Wiring Techniques
Page 5-1
S1400CW
Figure 5-1 - Field Wired Circuits With & Without A Common Return
5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation)
For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly
recommended. This type of cable provides discrete insulation for each of the wires and an
additional overall insulated covering that provides greater E.M.I. immunity and protection
to the shield as well.
S1400CW
Page 5-2
Section 5 - Wiring Techniques
5.2.3 Grounding of Cable Shields
DO NOT connect the cable shield to more than one ground point; it should only be grounded
at one end. Cable shields that are grounded at more than one point or at both ends may
have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O
signals. This will occur when the ground systems associated with multipoint connections to
a cable shield have a high resistance or impedance between them and a ground induced
voltage is developed (for what ever reason, i.e., man made error or nature produced
phenomena).
5.2.4 Use of Known Good Earth Grounds
ControlWave units should only have one connection to earth ground. For ControlWave
and ControlWave MICRO Process Automation Controllers, ControlWave MICRO,
ControlWave EFM Electronic Flow Meters, ControlWave GFC/XFC Gas Flow Computers
and ControlWave I/O Expansion Racks, this connection is provided via the Ground Lug
that is situated on the bottom of the unit. ControlWaveLPs require the installation of a
ground lug, ground bus or ground plate/panel. Since ControlWave units are DC-based
systems, grounding does not take into account AC power grounding considerations. Earth
grounding the unit is absolutely necessary when the unit is equipped with a radio or
modem. Additionally these units should be connected to earth ground when they are
installed in areas that have frequent lightning strikes or are located near or used in
conjunction with equipment that is likely to be struck by lightning or if struck by lightning
may cause equipment or associated system failure. Earth Grounds must be tested and must
be known to be good before connecting the ControlWave. Earth grounds must be
periodically tested and maintained (see Section 4).
5.2.5 Earth Ground Wires
Earth connections must utilize smoothly dressed large wire. Use AWG 3 or 4 stranded
copper wire with as short a length as possible. Exercise care when trimming the insulation
from the wire ends. Twists the strands tightly, trim off any frizzes and tin the ends with
solder. The earth ground wire should be clamped or brazed to the Ground Bed Conductor
(that is typically a standard AWG 0000 copper cable. The earth ground wire should be run
such that any routing bend in the cable is a minimum 8-inch radius above ground or a
minimum 12-inch radius below ground.
5.2.6 Working Neatly & Professionally
Take pride in your work and observe all site and maintenance safety precautions. After
properly trimming the stranded pair wire ends, twist them in the same direction as their
manufacturer did and then tin them with solder. Install the tinned wire end into it’s
connector and then secure the associated connector’s clamping screw. Remember to check
these connections for tightness from time to time. If solid copper wire is used (in
conjunction with the DC Power System or for Earth Ground) make sure that the conductor
is not nicked when trimming off the insulation. Nicked conductors are potential disasters
waiting to happen. Neatly trim shields and whenever possible, coat them to protect them
and prevent shorts and water entry.
Section 5 - Wiring Techniques
Page 5-3
S1400CW
Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to
being costly.
5.2.7 High Power Conductors and Signal Wiring
When routing wires, keep high power conductors away from signal conductors. Space wires
appropriately to vent high voltage inductance. Refer to the National Electrical Code
Handbook for regulatory and technical requirements.
5.2.8 Use of Proper Wire Size
ControlWaves utilize compression-type terminals that accommodate up to #14 AWG gauge
wire. A connection is made by inserting the bared end (1/4 inch max.) into the clamp
beneath the screw and securing the screw.
Allow some slack in the wires when making terminal connections. Slack makes the
connections more manageable and minimizes mechanical strain on the PCB connectors.
Provide external strain relief (utilizing Tie Wrap, etc.) to prevent the loose of slack at the
ControlWave.
Be careful to use wire that is appropriately sized for the load. Refer to equipment
manufacturer’s Specs. and the National Electrical Code Handbook for information on wire
size and wire resistance. After installing the field wiring, test each load to determine if the
correct voltage or current is present at the load. If you know the resistance of the field wires
(Circular Mills x Length) you should be able to calculate the load voltage. Conversely, if you
know the minimum load voltage and current, you should be able to derive the maximum
voltage loss that is allowable due to line resistance and then the correct wire size.
Referring to Figure 5-2, a relay that is picked by 100 mA, with a loop supply voltage of 24V
and a total line resistance of 20 ohms, the load voltage (voltage across the relay) should be:
VL = VS - (VC + VC) where VC + VC = (RC + RC) I
22 = 24 - 2
where 2V
= (20 Ω) x 0.1 A
Figure 5-2 - Calculating Load Voltage due to Line Resistance
5.2.9 Lightning Arresters & Surge Protectors
Use lightning arresters in association with any radio or modem equipped unit. BBI 9600
bps modems are equipped with surge protection circuitry. Lightning arresters or Antenna
S1400CW
Page 5-4
Section 5 - Wiring Techniques
Discharge Units should be placed on the base of the antenna and at the point where the
antenna lead (typically coax) enters the site equipment building. When a modem is used, a
lightning arrester should be placed at the point where the phone line enters the site
equipment building. If you use a modem (manufactured by other than BBI) it is
recommended that you also install a surge suppressors or lightning arrester on the phone
line as close to the modem as possible. Any unit interfaced to a radio or modem must be
connected to a known good earth ground.
5.2.10 Secure Wiring Connections
Make sure that all wiring connections are secure. In time wires that were once round will
become flattened due to the pressure applied by screw compression type terminals and site
vibrations. After a while these compression screws have a tendency to become loose. Part of
a good maintenance routine should be to check and tighten all screws associated with
wiring terminal connections. Avoid nicking the wire(s) when stripping insulation.
Remember, nicked conductors will lead to future problems. Also remember to provide some
cabling slack and strain relief.
If installing stranded or braided wiring that has not been tinned, be sure to tightly twist
the end (in the same direction as manufactured) and then trim off any frizzed wires.
Section 5 - Wiring Techniques
Page 5-5
S1400CW
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DOCUMENT NUMBER: S1400CW
TITLE: ControlWaveTM SITE CONSIDERATIONS For EQUIPMENT INSTALLATION,
GROUNDING & WIRING
ISSUE DATE: APR., 2005
COMMENT/COMPLAINT:
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Attn: Technical Publications Group, Dept. 315
Bristol Babcock
1100 Buckingham Street
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Phone: +1 (860) 945-2200
Fax: +1 (860) 945-2213
Website: www.bristolbabcock.com
U.S.A. Locations:
Northern Region
Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2381
Fax: +1 (860) 945-2525
[email protected]
Helicoid Instruments
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2218
Fax: +1 (860) 945-2213
[email protected]
Gulf Coast Region
Bristol Babcock Inc.
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Houston, TX 77092-8731
Phone: +1 (713) 685-6200
Fax: +1 (713) 681-7331
Western Region
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Suites 106 & 107
Ontario, CA 91761
Phone: +1 (909) 923-8488
Fax: +1 (909) 923-8988
Southeast Region
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317 S. North Lake Blvd.
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Phone: +1 (407) 740-7084
Fax: +1 (407) 629-2106
[email protected]
[email protected]
[email protected]
Central Region
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Suite 1300
Richardson, TX 75080
Phone: +1 (972) 238-8935
Fax: +1 (972) 238-8198
[email protected]
Rocky Mountain Region
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906 San Juan Blvd., Suite A
Farmington, NM 87401
Phone: +1 (505) 320-5046
Fax: +1 (505) 327-3273
Communications
Technology Group
Bristol Babcock Inc.
317 S. North Lake Blvd.
Suite 1016
Altamonte Springs, FL 32701
Phone: +1 (407) 629-9464
Fax: +1 (407) 629-2106
[email protected]
[email protected]
International Affiliates:
Canada
Bristol Babcock, Canada
234 Attwell Drive
Toronto, Ont. M9W 5B3
Canada
PH: 416-675-3820
FAX: 416-674-5129
[email protected]
Mexico
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
PH: (52-55)-52-81-81-12
FAX: (52-55)-52-81-81-09
[email protected]
United Kingdom
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
[email protected]
Asia Pacific
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PO Box 1987
Bunbury, Western Australia
6231
PH: +61 (0) 8 9791 3654
FAX: +61 (0) 8 9791 3173
[email protected]
Victoria, Australia
PH: +61 (0) 3 9384 2171
FAX: +61 (0) 3 8660 2501
Calgary Office
Bristol Babcock, Canada
3812 Edmonton Trail N.E.
Calgary, Alberta T2E 5T6
Canada
PH: 403-265-4808
FAX: 403-233-2914
[email protected]
RC Rev: 05-Feb-04
Villahermosa Office
BBI, S.A. de C.V.
Av. Plomo No.2
Bodega No. 1 - Ciudad
Industrial
Villahermosa, Tabasco 86010
Mexico
PH: 52-993-353-3142
FAX: 52-993-353-3145
[email protected]
Middle East
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
[email protected]
ESDS Manual
S14006
4/15/92
CARE AND HANDLING
OF
PC BOARDS
AND
ESD-SENSITIVE
COMPONENTS
BRISTOL BABCOCK
BLANK PAGE
ESDS Manual
S14006
4/15/92
TABLE OF CONTENTS
PAGE
TOOLS AND MATERIALS REQUIRED
1
ESD-SENSITIVE COMPONENT HANDLING PROCEDURE
2
1.
Introduction
2
2.
General Rules
3
3.
Protecting ESD-Sensitive Components
5
4.
Static-Safe Field Procedure
6
5.
Cleaning and Lubricating
8
6.
Completion
10
TOOLS AND MATERIALS REQUIRED
1.
Tools
Anti-Static Field kit. It is recommended that an anti-static field kit be kept on any
site where solid-state printed circuit boards and other ESD-sensitive components are handled. These kits are designed to remove any existing static charge
and to prevent the build-up of a static charge that could damage a PC board or
ESD-sensitive components. The typical anti-static field kit consists of the
following components:
1.
A work surface (10mm conductive plastic sheet with a female snap
fastener in one corner for ground cord attachment).
2.
A 15-foot long ground cord for grounding the work surface.
3.
Wrist strap (available in two sizes, large and small, for proper fit and
comfort) with a female snap fastener for ground cord attachment.
4.
A coiled ground cord with a practical extension length of 10 feet for
attachment to the wrist strap.
Toothbrush (any standard one will do)
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2.
Materials
●
Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent)
●
Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent)
●
Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent)
ESD-SENSITIVE COMPONENT HANDLING PROCEDURE
1.
Introduction
Microelectronic devices such as PC boards, chips and other components are electrostatic-sensitive. Electrostatic discharge (ESD) of as few as 110 volts can damage or
disrupt the functioning of such devices. Imagine the damage possible from the 35,000
volts (or more) that you can generate on a dry winter day by simply walking across a
carpet. In fact, you can generate as much as 6,000 volts just working at a bench.
There are two kinds of damage that can be caused by the static charge. The more
severe kind results in complete failure of the PC board or component. This kind of
damage is relatively simple, although often expensive, to remedy by replacing the
affected item(s). The second kind of damage results in a degradation or weakening
which does not result in an outright failure of the component. This kind of damage is
difficult to detect and often results in faulty performance, intermittent failures, and
service calls.
Minimize the risk of ESD-sensitive component damage by preventing static build-up and
by promptly removing any existing charge. Grounding is effective, if the carrier of the
static charge is conductive such as a human body. To protect components from
nonconductive carriers of static charges such as plastic boxes, place the component
in static-shielding bags.
This manual contains general rules to be followed while handling ESD-sensitive
components. Use of the anti-static field kit to properly ground the human body as well
as the work surface is also discussed.
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Table 1
Typical Electrostatic Voltages
Electrostatic Voltages
Means of Static
Generation
Walking across carpet
Walking over vinyl floor
Worker at bench
Vinyl envelopes for work instructions
Poly bag picked up from bench
Work chair padded with poly foam
2.
10-20 Percent
Relative Humidity
35,000
12,000
6,000
7,000
20,000
18,000
65-90 Percent
Relative Humidity
1,500
250
100
600
1,200
1,500
General Rules
(1)
ESD-sensitive components shall only be removed from their static-shielding
bags by a person who is properly grounded.
(2)
When taken out of their static-shielding bags, ESD-sensitive components shall
never be placed over, or on, a surface which has not been properly grounded.
(3)
ESD-sensitive components shall be handled in such a way that the body does
not come in contact with the conductor paths and board components. Handle
ESD-sensitive components in such a way that they will not suffer damage from
physical abuse or from electric shock.
(4)
EPROMS/PROMS shall be kept in anti-static tubes until they are ready to use
and shall be removed only by a person who is properly grounded.
(5)
When inserting and removing EPROMS/PROMS from PC boards, use a chip
removal tool similar to the one shown in the figure following. Remember, all work
should be performed on a properly grounded surface by a properly-grounded
person.
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Typical Chip Removal Tool
4
(6)
It is important to note when inserting EPROMS/PROMS, that the index notch on
the PROM must be matched with the index notch on the socket. Before pushing
the chip into the socket, make sure all the pins are aligned with the respective
socket-holes. Take special care not to crush any of the pins as this could destroy
the chip.
(7)
Power the system down before removing or inserting comb connectors/plugs or
removing and reinstalling PC boards or ESD-sensitive components from card
files or mounting hardware. Follow the power-down procedure applicable to the
system being serviced.
(8)
Handle all defective boards or components with the same care as new components. This helps eliminate damage caused by mishandling. Do not strip used PC
boards for parts. Ship defective boards promptly to Bristol Babcock in a staticshielding bag placed inside static-shielding foam and a box to avoid damage
during shipment.
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CAUTION
Don't place ESD-sensitive components and paperwork in the same bag.
The static caused by sliding the paper into the bag could develop a charge and
damage the component(s).
(9)
3.
Include a note, which describes the malfunction, in a separate bag along with each
component being shipped. The repair facility will service the component and
promptly return it to the field.
Protecting ESD-Sensitive Components
(1)
As stated previously, it is recommended that an electrically-conductive anti-static
field kit be kept on any site where ESD-sensitive components are handled. A
recommended ESD-protective workplace arrangement is shown on page 7. The
anti-static safety kit serves to protect the equipment as well as the worker. As a safety
feature, a resistor (usually of the one-megohm, 1/2-watt, current-limiting type) has
been installed in the molded caps of the wrist strap cord and the ground cord. This
resistor limits current should a worker accidently come in contact with a power
source. Do not remove the molded caps from grounded cords. If a cord is damaged,
replace it immediately.
(2)
Be sure to position the work surface so that it does not touch grounded conductive
objects. The protective resistor is there to limit the current which can flow through
the strap. When the work surface touches a grounded conductive object, a short is
created which draws the current flow and defeats the purpose of the current-limiting
resistor.
(3)
Check resistivity of wrist strap periodically using a commercially-available system
tester similar to the one shown in the figure below:
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Note: If a system checker is not available, use an ohmmeter connected to the cable
ends to measure its resistance. The ohmmeter reading should be 1 megohm +/15%. Be sure that the calibration date of the ohmmeter has not expired. If the
ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a
new one.
4.
Static-safe Field Procedure
6
(1)
On reaching the work location, unfold and lay out the work surface on a convenient
surface (table or floor). Omit this step if the table or floor has a built-in ESD-safe work
surface.
(2)
Attach the ground cord to the work surface via the snap fasteners and attach the
other end of the ground cord to a reliable ground using an alligator clip.
(3)
Note which boards or components are to be inserted or replaced.
(4)
Power-down the system following the recommended power-down procedure.
(5)
Slip on a known-good wristband, which should fit snugly; an extremely loose fit is not
desirable.
(6)
Snap the ground cord to the wristband. Attach the other end of the ground cord to
a reliable ground using the alligator clip.
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(7)
The components can now be handled following the general rules as described
in the instruction manual for the component.
(8)
Place the component in a static-shielding bag before the ground cord is
disconnected. This assures protection from electrostatic charge in case the work
surface is located beyond the reach of the extended ground cord.
C
D
✰R
E
A
F
R
G
B
R
R
EARTH GROUND
FLOOR
OF
BUILDING
LEGEND
A
- Chair with ground (optional)
B
- ESD protective floor mat (optional)
C
- Wrist strap
D
- ESD protective trays, etc.
E
- Ionizer
F
- Other electrical equipment
G
- Workbench with ESD protective table top
✰ NOTE: ALL RESISTORS 1M Ω +/-10% 1/2W
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5.
(9)
If a component is to undergo on-site testing, it may be safely placed on the
grounded work surface for that purpose.
(10)
After all component work is accomplished, remove the wrist straps and ground
wire and place in the pouch of the work surface for future use.
Cleaning And Lubricating
The following procedure should be performed periodically for all PC boards and
when a PC board is being replaced.
CAUTION
Many PC board connectors are covered with a very fine gold-plate.
Do not use any abrasive cleaning substance or object such as a pencil eraser to
clean connectors.
Use only the approved cleaner/lubricants specified in the procedure following.
WARNING
Aerosol cans and products are extremely combustible.
Contact with a live circuit, or extreme heat can cause an
explosion.
Turn OFF all power and find an isolated, and ventilated
area to use any aerosol products specified in this procedure.
(1)
8
Turn the main line power OFF. Blow or vacuum out the component. This should
remove potential sources of dust or dirt contamination during the remainder of
this procedure.
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(2)
Clean PC board connectors as follows:
a.
Review the static-safe field procedure detailed earlier.
b.
Following the ESD-sensitive component handling procedures, remove
the connectors from the boards and remove the PC boards from their
holders.
c.
Use cleaner to remove excessive dust build-up from comb connectors
and other connectors. This cleaner is especially useful for removing dust.
d.
Liberally spray all PC board contacts with Inhibitor. The inhibitor:
●
Provides a long lasting lubricant and leaves a protective film to
guard against corrosion
●
Improves performance and reliability
●
Extends the life of the contacts
●
Is nonconductive, and is safe for use on most plastics
e.
Clean the comb contacts using a lint-free wiping cloth.
f.
Lightly mist all comb contacts again with Inhibitor.
NOTE: Do not use so much Inhibitor that it drips.
g.
(3)
Repeat the above procedure for the other PC boards from the device.
Cleaning PC edge connectors
a.
Use cleaner to remove excessive dust build-up from connectors. This
cleaner is especially useful for removing dust.
b.
Liberally spray the outboard connector with Inhibitor.
c.
Lightly brush the outboard connector with a soft, non-metallic, bristle
brush such as a toothbrush.
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6.
10
d.
Spray the connector liberally to flush out any contaminants.
e.
Remove any excess spray by shaking the connector or wiping with either
a toothbrush, or a lint-free wiping cloth.
Completion
(1)
Replace any parts that were removed.
(2)
Make sure that the component cover is secure.
(3)
Return the system to normal operation.
(4)
Check that the component operates normally.
BLANK PAGE
ControlWave GFC-CL (Gas Flow Computer)
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09
www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969
www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955
www.EmersonProcess.com/Bristol
Customer Instruction Manual
CI-ControlWave GFC-CL
Oct., 2006
The information in this document is subject to change without notice. Every effort has
been made to supply complete and accurate information. However, Bristol, Inc.
assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your
local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software
delivered herewith. The Customer shall inspect and test such software and other
materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and
fitness for a particular purpose, concerning the software and other materials delivered
herewith.
TeleFlow™ is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service
mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in
this document are for information only, and belong to their respective companies, or
trademark holders.
Copyright (c) 2006, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part
of this manual may be reproduced in any form without the express written permission of
Bristol Inc.
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