Remote Automation Solutions Bristol 9600bps PSTN Modem Owner's Manual

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Document

Instruction Manual

CI-9600A

BBI 9600 bps - PSTN MODEM

Series 392958-XX-X

Issue: 05/2002

Modem

PC Modem Version - P/N 392958-03-1

Modem

Panel Mount Modem Version - P/N 392958-04-0

Modem

RTU 3305 Modem Version - P/N 392958-05-8

Modem

DPC 3335 Modem Version - P/N 392958-02-3

Modem

DPC 3330 & RTU 3310 Modem Version - P/N 392958-01-5

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.

ACCOL TM is a trademark of Bristol Babcock. Other trademarks or copy-righted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.

Copyright Ó 2002 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.

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 Babcock for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for whatever reason, may leave an operating process without protection. Depending upon the application, this could result in possible damage to property or injury to persons. It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.

If additional information is required, the purchaser is advised to contact Bristol

Babcock.

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol Babcock for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol Babcock 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 Babcock and save Bristol Babcock harmless from any liability or damage which Bristol Babcock 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 BBI supplemental document S14006 for proper care and handling of ESD-sensitive components.

Bristol Babcock 1100 Buckingham Street, Watertown, CT 06795

Telephone (860) 945-2200

WARRANTY

Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing.

Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

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.

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.

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.

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

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 Watertown 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 reinstallation 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.

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 Babcock 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 Babcock 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 BBI 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 Babcock Web site

(www.bristolbabcock.com) and sending it via E-Mail to [email protected]

A BBI 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 Babcock Inc.

Repair Dept.

1100 Buckingham Street

Watertown, CT 06795

A BBI Repair Dept. representative will return call (or other requested method) with a RA number.

D. Phone

Calling the BBI Repair Department at (860) 945-2442. A BBI 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.

&VMWXSP &EFGSGO -RG 6ITEMV %YXLSVM^EXMSR *SVQ

(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________

Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.

•

Evaluate / Test / Verify Discrepancy

•

Repair / Replace / etc. in accordance with this form

•

Return to Customer

Part I

Please be aware of the Non warranty standard charge:

•

There is a $100 minimum evaluation charge, which is applied to the repair if applicable (

B,C, or D of part III below)

Please complete the following information for single unit or multiple unit returns

√

in “returned”

Address No.

Bill to :

(office use only) Address No.

Ship to:

(office use only)

Purchase Order:

Phone: Fax:

Contact Name:____________________________________

E-Mail:

Part II Please complete Parts II & III for each unit returned

Model No./Part No.

Range/Calibration

Description

S/N

Reason for return : Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________

What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due to BBI’s warranty clause, would you like the product: repaired returned replaced scrapped?

B. If product were found to exceed the warranty period, would you like the product:

C. If product is deemed not repairable would you like your product:

D. If BBI is unable to verify the discrepancy, would you like the product: repaired returned replaced scrapped?

returned replaced scrapped?

returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that has the most knowledge of the problem is: _______________________________ phone

If we are unable to contact this person the backup person is: _________________________ phone

Special Requests:

Ship prepaid to: Bristol Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: 860-945-2442 Fax: 860-945-3875

Form GBU 13.01

Rev. A

Bristol Babcock

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 Babcock offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at four locations: Houston, Birmingham, 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 Babcock 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) 945-2269. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

BLANK PAGE

A Few Words About Bristol Babcock

For over 100 years, Bristol 7 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 Babcock 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:

Contacting Bristol Babcock Directly

Bristol Babcock's world headquarters are 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 Babcock's Application Support Group can provide telephone support for your technical questions.

For technical questions about TeleFlow Ô products call (860) 945-8604.

For technical questions about Control Wave call (860) 945-2244 or (860) 945-2286.

For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-2501 or e-mail: [email protected]

For technical questions regarding ACCOL products, Open BSI Utilities , as well as

Bristol's Enterprise Server 7 / Enterprise Workstation 7 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 also maintains a service area within our main web site.

Technical information, as well as software updates are available in this area. To access our web site, go to: bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol Babcock hardware to radios, contact Communication

Technologies in Orlando, FL at (407) 629-9463 or (407) 629-9464.

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 below) or to your

Bristol-authorized sales representative.

Major U.S. Sales Offices

Watertown, CT (860) 945-2262

Birmingham, AL (205) 980-2010

Ontario, CA (909) 923-8488

Farmington, NM (505) 327-3271

Houston, TX (713) 685-6200

Richardson, TX (972) 238-8935

Major International Sales Offices:

Bristol Babcock Ltd (UK): (441) 562-820-001

Bristol of Canada: (416) 675-3820

Bristol Babcock Asia Pacific 61 8-9455-9955

BBI, S.A. de C.V. (Mexico) (52555) 254-5281

Please call the main Bristol Babcock 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 Babcock and its products, please visit our site on the

World Wide Web at: www.bristolbabcock.com

CI-9600A

BBI 9600 bps - PSTN MODEMS

4.1

4.2

4.2.1

4.2.1.1

4.2.2

4.2.2.1

4.2.3

4.2.3.1

4.2.4

4.3

3.1

3.1.1

3.1.2

3.1.3

3.1.4

3.1.5

3.1.6

3.1.7

3.1.7.1

3.1.7.2

3.1.7.3

3.1.7.4

3.1.7.5

3.1.7.6

3.2

3.2.1

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1

1.2

1.3

GENERAL DESCRIPTION ...........................................................................................1-1

MODEM COMPONENT IDENTIFICATION...............................................................1-9

COMMUNICATION MNEMONICS ...........................................................................1-11

2.1

2.2

Section 2 - PC CONFIGURABLE OPTIONS

PC CONFIGURABLE OPTIONS ..................................................................................2-1

14.4 Kbps OPERATION .................................................................................................2-2

Section 3 - MODEM INSTALLATION & SETUP PROCEDURES

INSTALLATION INSTRUCTIONS ..............................................................................3-1

Installing a 9600 bps Modem into the RTU 3305 ......................................................... 3-1

Installing a 9600 bps Modem into the RTU 3310 ......................................................... 3-6

Installing a 9600 bps Modem into a DPC 3330.............................................................3-9

Installing a 9600 bps Modem into a DPC 3335...........................................................3-13

Connecting a 9600 bps Modem to a RED 3332 ...........................................................3-16

Installing the 9600 bps PC Modem..............................................................................3-16

Installing the 9600 bps Panel Mount Modem.............................................................3-19

General Installation .....................................................................................................3-19

Connection to a RTU 3305 ...........................................................................................3-21

Connection to a RTU 3310 ...........................................................................................3-21

Connection to a DPC 3330 ...........................................................................................3-21

Connection to a RED 3332 (RSP Assembly) ...............................................................3-22

Connection to a DPC 3335 ...........................................................................................3-24

PSTN HOOKUP............................................................................................................3-26

If Telephone Equipment Problems Arise ....................................................................3-28

Section 4 - MODEM DIAGNOSTICS

ESCAPE CODE SEQUENCE ........................................................................................4-1

LOOPBACK & LINE SIGNAL TESTS .........................................................................4-1

Line Signal Level Test....................................................................................................4-1

Line Signal Level Command (%L) .................................................................................4-1

Line Signal Quality Test ................................................................................................4-2

Line Signal Quality Command (%Q) .............................................................................4-2

Connection Failure Cause..............................................................................................4-2

Call Failure Reason Code of S86 ...................................................................................4-2

Test and Diagnostic Command (&Tn)...........................................................................4-4

MODEM LEDs................................................................................................................ 4-6

9600 bps - PSTN Modem Contents / 0-1

CI-9600A

BBI 9600 bps - PSTN MODEMS

SECTION TITLE PAGE #

5.1

5.2

5.3

5.4

5.4.1

5.4.2

5.4.3

5.4.4

5.4.5

5.4.6

5.4.7

5.4.8

Section 5 - MODEM SPECIFICATIONS

OPERATING SPECIFICATIONS .................................................................................5-1

ENVIRONMENTAL SPECIFICATIONS......................................................................5-1

FCC & FM APPROVALS ...............................................................................................5-2

MODEM CONNECTORS...............................................................................................5-2

Connector J1 ...................................................................................................................5-2

Connector J2 ...................................................................................................................5-2

Connector P1...................................................................................................................5-2

Connectors J4, J5 & J6...................................................................................................5-3

Connector TB1 ................................................................................................................5-3

Connector TB2 ................................................................................................................5-4

Connector TB3 ................................................................................................................5-4

Connector TB4 ................................................................................................................5-4

Supplements

Guidelines for System Grounding ......................................................................................................S1400

Care and Handling of PC Boards and ESD-Sensitive Components ...............................................S14006

0-2 / Contents 9600 bps - PSTN Modem

Section 1 INTRODUCTION

1.1 GENERAL DESCRIPTION

The BBI 9600 bps - PSTN Modem transmits and receives digital data at 9600 BPS over

"Public Switched Telephone Networks" (PSTN). The modem transfers data synchronously or asynchronously and supports the modulation schemes listed in Table 1.

Table 1-1 - Configurations, Signaling Rates & Data Rates

Configuration Modulation

V.32 bis 9600

V.32 bis 7200

V.32 bis 4800

V.32 9600

V.32 4800

V.22 bis 2400

V.22 bis 1200

V.22 1200

V.22 600

V.21 300

Bell 212A

Bell 103J

TCM

QAM

DPSK

FSK

DPSK

FSK

Notes:

Carrier

Freq. (Hz)

" 0.01%

1800

1200/2400

1080/1750

1200/2400

2225/1270(M)

2025/1070(S)

Data Rate

(bps)

" 0.01%

9600

7200

4800

9600

4800

2400

1200

600

300

1200

0-300

Baud

Symbols/Sec.

2400

600

300

600

300

Bits Per

Symbol

Data TCM

4 1

Constellation

Points

TCM = Trellis-Coded Modulation QAM = Quadrature Amplitude Modulation

FSK = Frequency Shift Keying DPSK = Differential Phase Shift Keying

A typical example of where these modems are used in a PSTN is shown in Figure 1. This network contains four Bristol Babcock Distributed Process Controllers equipped with BBI

9600 bps - PSTN Modems operating in a master/slave configuration. During operation, the master controller dials up and communicates with each slave (remote) at prescribed intervals to send and receive data. The interval of dialing is a function of the application software that is executed by the master device.

The modem's transmitter output, as measured with 600 ohm termination (typical for telephone lines) is -10 dBm (Fixed). This qualifies the modem for use with any voice grade

PSTN hookup in compliance with FCC "Loop Start" requirements.

The BBI 9600 bps - PSTN Modem has been designed to provide the following features:

$ Operates on 2-Wire (Loop Start) Switched Networks (PSTN) only.

$ CCITT compatibility (see Table 1)

$ Compatible with Bell 212A @ 1200 bps (600 baud) and Bell 103J @ 0-300 bps.

$ AutoDial/AutoAnswer operation.

$ Smart programming based on the Hayes “ AT ” command set.

$ Storage of all parameters in non-volatile memory.

$ MNP Class 2-4, MNP 10 & V.42 Error Correction.

$ MNP 5 & V.42 bis Data Compression.

CI-9600A Section 1 Introduction / 1-1

$ Data Access Arrangement (DAA) with 1000 Vac Isolation.

$ Surge withstand of 100A with 10 x 160 m S waveform.

$ FCC Part 68 Approved.

Figure 1-1 - Typical BBI 9600 BPS - PSTN Modem PSTN Network

There are seven (7) versions of BBI 9600 bps - PSTN Modem which are identified as follows

(see Figures 1-2 through 1-8):

PC Modem (see Figure 1-3)

Panel Mount (see Figure 1-4)

RTU 3305 (see Figure 1-5)

DPC 3335 (see Figure 1-6)

RTU 3310 & DPC 3330 (see Figure 1-7)

1-2 / Introduction Section 1 CI-9600A

CI-9600A

Figure 1-2 - Modem Versions (Side Profile)

Section 1 Introduction / 1-3

Figure 1-3 - 9600 bps PSTN Modem Board (PC Version) P/N 392958-03-1

(May be connected to a PC or RED 3332 - RSP Assembly)

1-4 / Introduction Section 1 CI-9600A

Figure 1-4 - 9600 bps PSTN Modem Board (Panel Mount Version) P/N 392958-04-0

(May be connected to a PC or any 33XX Product)

CI-9600A Section 1 Introduction / 1-5

Figure 1-5 - 9600 bps PSTN Modem Board (RTU 3305 Version) P/N 392958-05-8

1-6 / Introduction Section 1 CI-9600A

Figure 1-6 - 9600 bps PSTN Modem Board (DPC 3335 Version) P/N 392958-02-3

CI-9600A Section 1 Introduction / 1-7

1-8 / Introduction

Figure 1-7 - 9600 bps PSTN Modem Board

(RTU 3310 & DPC 3330 Version) P/N 392958-01-5

Section 1 CI-9600A

1.2 MODEM COMPONENT IDENTIFICATION

Modem components discussed in this manual are previewed below. These components include Connectors, Configuration Jumpers, LEDs, Fuse F1 and Switch SW1.

• Interconnection connectors are listed in Table 1-2. Specific connector pin number and signal name descriptions are provided in Section 5 - Modem Specifications.

Table 1-2 - 9600 bps Modem Connector Identification

BBI Version Purpose

All Telco Interface

Panel Mount

RTU 3305

DPC 3335

Reg. Power

RS232 Intf. &

Configuration

RS232

Configuration

RTU 3310

DPC 3330

RS232

Configuration

RTU 3310

DPC 3330

DPC 3335

TTL Interface

TB1 ALL

TB2 RTU 3305

TB3 RTU 3305

TB4 Panel Mount

# of Pins

9-Pin D-

Type Conn.

9-Pin D-

Type Conn.

9-Pin D-

Type Conn.

12-Pin Header

DAA Iso. Gnds.

2-Pin TB

TTL Intf.

Unreg. Pwr.

3-Pin TB

8-Pin TB

2-Pin TB

Notes

RJ11 Pins 3 & 4 Used

Used with BBI Power Supply

Standard RS-232 Port

Pins 2, 3, & 4 Used

3310 Modem to J7 on MFIB

3330 Modem to J3 on 2PECB

3335 Modem to J3 on Blank

Multipurpose Intf. Bd.

TB1-1 to DTE Chassis Ground

TB1-2 to Local Earth Ground

Pin 10 used on 3305

To P4 on MI/OB Bd.

9-35 Vdc

PSTN RJ11 Modem Connector (J1), provides the interface to the PSTN network via a modular phone cord and the Telephone Co. RJ11 Jack on all versions of the BBI

9600 PSTN modem.

Power Jack (J2) is provided for the PC Mount version of the modem along with either a +12Vdc Regulated Power Supply (P/N 395480-01-9) or DC Power Cord (P/N

396302-01-7).

A 9-pin D-Type connector (J4, J5, or J6) for modem configuration and/or

DTE/Modem interfacing. J6 is provided with the RTU 3310 and the DPC 3330 modem versions. J5 is provided with the RTU 3305 and the DPC 3335 modem versions. J5 & J6 are used for configuring the modem with an ASCII Terminal or a

Terminal “Emulation” program (such as PROCOMM Plus or PCPLUS). J4 is provided with the PC (Desk Top) and Panel Mount versions of the modem. J4 is used for configuring the modem and as the RS-232 Interface Data Port.

DTE/Modem TTL 12-pin Serial Connector #1 (P1) provides the TTL interface between a RTU 3310, DPC 3330, or a DPC 3335.

Terminal Block (TB1) (2-Pin on all versions of 9600 bps Modem). TB1-2 provides connection for the overvoltage and surge device to Earth Ground. TB1-1 provides the connection for suppression devices to Chassis Ground.

Terminal Block (TB2) (2-Pin on the RTU 3305 Modem version). TB2-10 provides the

TTL Interface Ground connection between the RTU 3305 and the modem.

Terminal Block (TB3) provides an 8-Pin TTL interface between the RTU 3305 and the RTU 3305 Modem version.

CI-9600A Section 1 Introduction / 1-9

Power Terminal (TB4) provides screw mount terminals (+12/24Vdc and Ground) for the Panel Mount version of the Modem.

• The BBI 9600 Modem contains up to six (6) factory configured Configuration Jumpers as follows:

JP1 - Power Feed for Panel Mount Modems

- Installed = For all Panel Mount Modems

- Removed = For all versions except Panel Mount Modems

JP2 - Power Save Selection

- Installed = Enable Power Save Mode

- Removed = Disable Power Save Mode

The modem’s power will be removed after no activity for 1 second if JP2 is installed.

The modem’s power will be reconnected if pulses are detected at the Ring indicator pin or if activity is detected at the DTR pin. Note: The modem requires 2-3 seconds after power has been restored before it can receive AT commands.

JP3 & JP4 - Configuration Selection

- JP3 OUT, JP4 IN = DPC/RTU-3330/35/10/05 Mode

- JP3 IN, JP4 OUT = PC/Panel Mount Mode

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 = CTS from Modem (Pump)

- JP5-2 to JP5-3 = CTS Connected to DTE’s RTS (Factory Setting)

The RTS/CTS Loopback Jumper must be installed in position 2-3.

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

• The BBI 9600 bps PSTN Modem contains eight (8) LEDs. When Jumper JP6 has been removed, these LEDs are disabled. LED designation depends on the version of the modem (see Table 1-3). These LEDs function as follows:

TXD (Transmit Data) - DS1/DS2 - When lit, this LED indicates transmitting activity.

Both MARK and SPACE data (TXD) from the host device (DTE) are sent to the modem at P1-6 (DPC/RTU 3310/30/35), TB3-2 (RTU 3305) or J4-3 (PC & Panel Mount

Modems).

RXD (Receive Data) - DS3/DS4 - When lit, this LED indicates receiving activity.

Both MARK and SPACE data (RXD) are being sent to the DTE at P1-9 (DPC/RTU

3310/30/35), TB3-5 (RTU 3305) or J4-2 (PC & Panel Mount Modems).

RTS (Request to Send) - DS5/DS6 - When lit, this LED indicates that the host (DTE) in question is ready to send data to the modem.

CTS (Clear to Send) - DS7/DS8 - When lit, this LED indicates that the DCE (Local

Modem) has signaled the DTE (Local CPU) that it is clear to send data. CTS is issued in response to an RTS.

1-10 / Introduction Section 1 CI-9600A

DTR (Data Terminal Ready) - DS9/DS10 - When lit, this LED indicates that the

DTE has activated the local modem.

DCD (Data Carrier Detect) - DS11/DS12 - When lit, this LED indicates that the modem has detected the presence of a carrier from a remote modem.

DSR (Data Set Ready) - DS13/DS14 - When lit, this LED indicates to the DTE that the local modem is ready to send or receive data to/from the remote modem.

PWR (Power) - DS15/DS16 - When lit, this LED indicates that power has been supplied to the modem. Jumper JP6 must be installed to enable all LEDs.

Table 1-3 - LED Assignments

LED Designation

DS1 - DS15 (Odd)

DS2 - DS16 (Even)

Modem Types

Panel Mount & PC

RTU 3305, RTU 3310,

DPC 3330, RED 3332 (RDPC)

& DPC 3335

• Power ON/OFF Switch SW1 for PC Mount version of the modem.

• Fuse F1 - (.5 Ampere Fast Blow) on PC and Panel Mount Modem versions.

1.3 COMMUNICATION MNEMONICS

The communication mnemonics (Terms) used in this document are listed in the table below.

Terms

CTS

DSR

EXTVDC

RXD

TXD

DCD

Definition

Clear to Send

Modem’s

RS-232 - I/O

Output

Data Set Ready Output

Unreg. Pwr. Input N/A

Receive Data Output

Transmit Data

Data Carrier Detect

Input

Output

Terms

DTR

PSTN

RTS

T/R

DCE

DTE

Definition

Modem’s

RS-232 I/O

Data Terminal

Ready

Public Switched

Telephone Network

Request to Send

Input

N/A

Input

Transmit/Receive N/A

Data Comm.

Equipment

Data Term. Equip.

N/A

CI-9600A Section 1 Introduction / 1-11

BLANK PAGE

Section 2 PC CONFIGURABLE OPTIONS

2.1 PC CONFIGURABLE OPTIONS

All modem configuration parameters and options must be configured via software. Configuration occurs via an ASCII Terminal (or a PC equipped with Terminal Emulator Software) and the modem's RS-232 Configuration/Data Port, i.e., the 9-pin D-type Connector

J4, J5 or J6. This port serve as "Hayes compatible" configuration only port for modems other than PC and Panel Mount versions. Note: Use a standard RS-232 Cable, i.e., Pin 1 to

Pin 1, Pin 2 to Pin 2, etc.

Note: J5 & J6 only use pin numbers 2, 3 and 5. The RS-232

Configuration/Data Port will not respond to configuration messages during an active phone connection

Note: The PC/Terminal Emulator must be set for 9600 bps DTE speed while configuring the modem for use with all BBI products.

The modem is factory set for use in the product in which it will be installed. This is accomplished by invoking one of the two stored profiles contained in non-volatile memory.

Profile '0' should be used if the modem is interfaced with a DPC 3330, DPC 3335, RTU

3305 or RTU 3310, while profile '1' is reserved for use with PC and Panel Mount modems.

If the modem was purchased installed in a product, the correct profile should be recalled on power up, becoming the "active" profile. Modems purchased separately, as a spare or replacement will default to profile '0' on power-up.

If it is desired to switch, modify or simply observe the current stored profiles, a PC equipped with terminal emulation software such as HyperTerminal or Procomm, or an

ASCII terminal must be connected to the modem's RS-232 configuration port. For all products, the terminal's speed must be set for 9600 bps.

The modem will remember the last

DTE speed at which it communicated with the terminal.

To view and verify the active and stored profiles, type AT&V, then press ENTER. The following data should appear:

ACTIVE PROFILE: (Should match one of the stored profiles below. Other "S" registers may be included)

STORED PROFILE 0: (For the RTU 3305, RTU 3310, DPC 3330 & DPC 3335 Modems)

B1 E1 L1 M1 N1 Q0 T V1 W0 X4 Y0 &C1 &D2 &G0 &J0 &K0 &Q5 &R1 &S0 &T5 &X0

S00:001 S02:043 S06:002 S07:050 S08:002 S09:006 S10:014 S11:095 S12:050 S18:010

S36:007 S37:000 S40:232 S41:195 S46:138 S95:000

STORED PROFILE 1: (For PC & Panel Mount Modems)

B1 E1 L1 M1 N1 Q0 T V1 W0 X4 Y0 &C1 &D0 &G0 &J0 &K0 &Q5 &R1 &S0 &T5 &X0

S00:001 S02:043 S06:002 S07:050 S08:002 S09:006 S10:014 S11:095 S12:050 S18:010

S36:007 S37:000 S40:232 S41:195 S46:138 S95:000

CI-9600A Section 2 PC Configurable Options / 2-1

If the NVRAM is not installed or is not operational as detected by the NVRAM test, the following message is displayed: NVRAM FAILED OR NOT INSTALLED.

If different profile data appears, the modem must be re-profiled by issuing the following command string:

AT&F&K0S0=1S18=10&W0&D0&W1 ENTER

If re-profiling was performed the AT&V command should be re-issued to observe and verify the correct profile data.

The modem will normally (by default) force stored profile 0 to become active on power-up, unless commanded to use profile 1. To switch the active profile on power-up, use the following command:

AT&Y0 ENTER (for use with 33XX products)

The modem should now be ready for use in a PSTN network operating at a maximum line speed of 9600 bps. All modem features, including data compression, error detection, speed buffering and auto-bauding are enabled. In this configuration, the modem will automatically adjust its line speed to the highest possible value, based on line quality. The line speed may drop down to 1200 bps, while the 33XX terminal speed is still operating at

9600 bps.

2.2 14.4 Kbps OPERATION

If desired, network performance can be increased somewhat by allowing a maximum modem line speed of 14.4 Kbps without re-profiling. The master and any or all slave nodes may be modified for this feature. This includes all BBI products. Follow steps 1 through 3 below to achieve this capability:

1. Edit each ACCOL load for the master and slave nodes to be modified by increasing the network port speed to at least 19.2 Kbps (38.4 Kbps maximum).

2. Using a PC running terminal emulation software, i.e., HyperTerminal, Procomm, or an ASCII terminal connected to the modem’s configuration port, access each modem at the network speed specified in each load using the AT&V ENTER command.

3. If possible, re-configure the cold start default rate for each slave node, so that colddownloads via the PSTN network are possible.

2-2 / PC Configurable Options Section 2 CI-9600A

Section 3 MODEM INSTALLATION & SETUP PROCEDURES

Caution

PC board components can be damaged by electrostatic discharge (ESD) during handling, i.e., disassembly, reassembly, and test procedures. Use grounded wrist straps and surface pads when working near or handling any BBI Circuit Board. Refer to BBI supplement manual S14006 for proper ESD grounding and handling techniques.

3.1 INSTALLATION INSTRUCTIONS

The BBI 9600 BPS - PSTN Modem is intended for use on the Public Switched Telephone

Network (PSTN) operating in North America as illustrated in Figures 1-1 & 3-26.

Installation of the modem versions is provided as follows:

Section 3.1.1 - RTU 3305 Modem

Section 3.1.2 - RTU 3310 Modem

Section 3.1.3 - DPC 3330 Modem

Section 3.1.4 - DPC 3335 Modem

Section 3.1.5 - RED 3332 (RSP Assembly) (Panel Mount Modem)

Section 3.1.6 - PC Modem

Section 3.1.7 - Panel Mount Modem

3.1.1 Installing a 9600 bps Modem into the RTU 3305

Modems mount to the 3305’s Option Mounting Brackets (see Figures 3-2 & 3-3). To install a modem into a RTU 3305, follow steps 1 through 12 below. Note: The procedure for installing and configuring an RTU 3305 is covered in Instruction Manual CI-3305. An internally mounted BBI 9600 bps Modem can only be connected to Port C of the RTU 3305.

1. Disconnect power from the RTU 3305 (Shut down or place under manual control any critical processes prior to disconnecting power).

2. Remove the four screws (A) that secure the Top Plate (see Figure 3-1) or Local LCD

Display Assembly (see Figure C) to the four Mounting Standoffs. If the Local LCD

Display Assembly is present disconnect it’s Ribbon cable from P3 on the Backplane

Board.

3. Remove the four 2” Mounting Standoffs (if present) from the two Option Mounting

Brackets (see Figure 3-2).

Note: If the RTU 3305 has not already been configured for operation, it will have to be configured, i.e., jumpers and switches set as required, before proceeding with the remaining steps. See Sections 2.3 and 2.4 of Instruction Manual CI-3305. BBI

Modem operation requires that the RTU 3305’s loopback setting, associated with the port in question, must be disabled. Set PMPP Board Switch SW1-1, SW1-2 & SW1-3

(associated with Port C) to their Open (OFF) position.

CI-9600A Section 3 Modem Installation / 3-1

Figure 3-1 - 3305 Without Options (Face Plate Present)

5. Remove the Integrated Circuit U32 (the RS-232 IC associated with Port C) from it’s socket on the Power Supply/CPU Board and install the Jumper Plug Assembly (BBI

Part Number 392511010) in its place (see Figure 3-3).

Place the modem assembly onto the two Option Mounting Brackets aligning the mounting holes. Secure the modem assembly to the two Option Mounting Brackets with the four 2” Mounting Standoffs (see Figure 3-3).

7. Connect the Communication Option Cable D-Type connector to Port C (P4) on the

3305’s MI/OB Board. Install the wires on the other end of this cable onto modem connectors TB3 and TB2 (see Figure 3-3 & Table 3-1).

3-2 / Modem Installation Section 3 CI-9600A

Figure 3-2 - 3305 RTU Without Options (Face Plate Removed)

Table 3-1 - Wiring List for RTU 3305 Modem Cable (Ass’y 396049-02-8)

MI/OB

P4/D-Type

Pin #

3* 1

Wire

Color

Green

Brown

Yellow

Blue

White

Signal

DTR NOT

TXD NOT

+5V

RXD NOT

RTS NOT

ModemTB3

Term. #

ModemTB2

Term. #

Notes

TTL Signal

+5V Power

TTL Signal

8* 2

Black

Red

CTS NOT

DCD NOT

Yellow +5V

Orange PCOM

TTL Signal

+5V Power

+5V Ground

* 1 = On cable used with Rev. 5 and higher versions of RTU 3305 MI/OB Bd.

* 2 = On cable used with Rev. 4 and earlier versions of RTU 3305 MI/OB Bd.

CI-9600A Section 3 Modem Installation / 3-3

Figure 3-3 - 3305 With 9600 bps Modem Installed (Face Plate Present)

8. Configure the modem’s jumpers as follows:

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 =

- JP5-2 to JP5-3 =

CTS from Modem

CTS Connected to RTS (Factory Setting)

Note: The Modem’s RTS/CTS Loopback Jumper must be installed in position

2-3. The RTU 3305’s RTS/CTS Loopback setting for Port C must be disabled

(see step 4).

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

9. Connect the System Grounds to modem connector TB1 (see Supplement Manual

S1400 - Guidelines for System Grounding) as follows:

3-4 / Modem Installation Section 3 CI-9600A

Circuitry associated with the telephone line interface provides overvoltage and surge protection to Earth Ground at modem connector TB1-2. TB1-1 provides connection for EMI/RFI suppression devices to Chassis Ground.

Connect the modem’s Chassis ground (TB1-1) to the associated DTE (RTU 3305)

Chassis Ground. Note: RTU 3305 Chassis Ground is tied to the CHASSIS terminal

(TB3-3) on the Multifunction Input/Output Board (MI/OB). The RTU CHASSIS terminal must be connected to a “Chassis Ground” as supplied with the RTU 3305

Standard Assembled Package, i.e., RTU 3305’s supplied in a NEMA 4X enclosure.

Do NOT connect modem connector TB1-1 to the CHASSIS terminal (TB3-3) on the

Multifunction Input/Output Board (MI/OB). Use a separate #14 AWG wire (green) to connect to the “Chassis Ground.”

Connect the modem’s Earth Ground at TB1-2 to the local Earth Ground. Note: Use a separate #14 AWG wire (green) to connect to the “Power Grid Ground” of the facility.

Note: In the case of the RTU 3305 SAP (see Supplement 1 of CI-3305), Power Ground is connected to the Enclosure’s Backpanel via the non-isolated DIN Rail Mounted

Power Distribution Terminal Block. The customer supplied Earth Ground is typically connected to the Chassis Ground Lug on the bottom of the enclosure.

Note: Ground wiring from modem connectors TB1-1 and TB1-2 may be connected to a known good “Earth Ground” in installations where a “Power Grid Ground” or

“Chassis Ground” is not available.

Figure 3-4 - 3305 Top Plate/Local LCD Display - Modem Installation Diagram

CI-9600A Section 3 Modem Installation / 3-5

10. Connect the modem to the phone line (see Section 3.2). After the telephone company has installed the phone jack (wall), connect the phone line to the modem by inserting the appropriate equipment interface cable (plugs) into the modem jack

(J1) and the wall jack.

11. Install the Top Plate or Local LCD Display Assembly to the four 2” Mounting

Standoffs. Connect the Ribbon Cable associated with the Local LCD Display

Assembly (if present) to P3 on the Backplane Board (see Figure 3-4).

12. Connect a PC equipped with Bristol Babcock ACCOL software to the RTU 3305’s

Port A, i.e., J3 on the PMPP Board. Apply power and configure the RTU 3305 for modem operation on Port C (see ACCOL II Reference Manual D4044 - Auto Dial

Modem Interface.

3.1.2 Installing a 9600 bps Modem into the RTU 3310

Modems mount to the 3310’s Multi-Function Interface Board (MFIB) (see Figure 3-5). To install a modem into a RTU 3310, follow steps 1 through 9 below. Note: The procedure for installing and configuring a RTU 3310 is covered in Instruction Manual CI-3310.

1. Disconnect power from the DPC 3310 (Shut down or place under manual control any critical processes prior to disconnecting power).

2. Remove the RTU 3310’s cover (see CI-3310) to gain access o the MFIB Board.

3. Set MFIB Board Switch SW2-1 through SW2-8 to the OFF position. This assigns a modem to Port B of the RTU 3310. Set the MFIB Jumpers if not already configured.

4. Secure the modem assembly (4 screws) to the MFIB Board by aligning the MFIB

Board’s 4 Mounting Standoffs with the modem’s mounting holes (see Figure 3-6).

Note modem connector P1 mates with MFIB connector J7.

5. Configure the modem’s jumpers as follows:

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 =

- JP5-2 to JP5-3 =

CTS from Modem

CTS Connected to RTS (Factory Setting)

The RTS/CTS Loopback Jumper must be installed in position 2-3.

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

6. Connect the System Grounds to modem connector TB1 (see Supplement Manual

S1400 - -Guidelines for System Grounding) as follows:

3-6 / Modem Installation Section 3 CI-9600A

Connect the modem’s Chassis Ground (TB1-1) to the associated DTE (RTU 3310)

Chassis Ground. Note: The RTU’s Chassis Ground is tied to the CHASSIS terminal of TB1 of the MFIB Board. The RTU CHASSIS terminal must be connected to a

“Power Grid Ground.” Do NOT connect modem connector TB1-1 to the CHASSIS terminal of TB1 on the MFIB Board. Use a separate #14 AWG wire (green) to connect to the “Power Grid Ground.”

CI-9600A

Figure 3-5 - RTU 3310 MFIB Board (Surface Mount Version)

Section 3 Modem Installation / 3-7

Connect the modem’s Earth Ground (TB1-2) to the local Earth Ground or Power

Grid Ground.

Figure 3-6 - Modem Mounted to RTU 3310 MFIB Board

3-8 / Modem Installation Section 3 CI-9600A

7. Connect the modem to the phone line (see Section 3.2). After the telephone company has installed the phone jack (wall), connect the phone line to the modem by inserting the appropriate equipment interface cable (plugs) into the modem jack

(J1) and the wall jack.

8. Install the RTU 3310’s cover.

9. Connect a PC equipped with Bristol Babcock ACCOL software to the Connector J5 of the RTU 3310 CPU Board. Apply power and configure the RTU 3310 for modem operation on Port B (see ACCOL II Reference Manual D4044 - Auto-Dial Modem

Interface.

3.1.3 Installing a 9600 bps Modem into a DPC 3330

Modems mount to the 2-Port Enhanced Communication Board(s) of the DPC (see Figures

3-7 & 3-8). Note: Modems cannot be mounted to a 4-Port Enhanced Communication Board.

To install a modem into a DPC 3330, follow steps 1 through 10 below. Note: The procedure for installing and configuring a DPC 3330 is covered in Instruction Manual CI-3330.

1. Disconnect power from the DPC 3330 (Shut down or place under manual control any critical processes prior to disconnecting power).

2. Remove the DPC 3330’s cover (see CI-3330) and remove if installed the 2-Port

Enhanced Communication Board (from Comm. Slot 1 or 2) to which the modem will be mounted.

3. Secure the modem assembly (4 screws) to the selected 2-Port ECB aligning the

ECB’s 4 Mounting Standoffs with the modem’s mounting holes (see Figure 3-7)

4 Configure the modem’s Jumpers (if not already configured) as follows:

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 =

- JP5-2 to JP5-3 =

CTS from Modem

CTS Connected to RTS (Factory Setting)

The RTS/CTS Loopback Jumper must be installed in position 2-3.

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

5. Set the ECB’s Jumpers and Switches if not already configured. Make sure that

SW3-1 is OFF and SW3-2 is ON.

6. Connect the System Grounds to modem connector TB1 (see Supplement Manual

S1400 - Guidelines for System Grounding) as follows:

CI-9600A Section 3 Modem Installation / 3-9

Connect the modem’s Chassis Ground (TB1-1) to the associated DTE (DPC 3330)

Chassis Ground. Note: DPC Chassis Ground is tied to the CHASSIS terminal on

System Interconnect Board connector TB1. The DPC CHASSIS terminal must be connected to a “Power Grid Ground.” Do NOT connect modem connector TB1-1 to the

CHASSIS terminal of TB1 on the System Interconnect Board. Use a separate #14

AWG wire (green) to connect to the “Power Grid Ground.”

Figure 3-7 - DPC 3330 2-Port ECB with 9600 bps Modem Installed

3-10 / Modem Installation Section 3 CI-9600A

Figure 3-8 - Modem Installed on Comm. Bd. in Slot 1 of DPC 3330

(with Real/Protected Mode CPU)

CI-9600A

Figure 3-9 - Modem Installed on Comm. Bd. in Slot 2 of DPC 3330

(with Real/Protected Mode CPU)

Section 3 Modem Installation / 3-11

Connect the modem’s Earth Ground at TB1-2 to the local Earth Ground or Power

Grid Ground.

Note: See Figure 3-9 for identification of Comm. Port assignment when the modem is installed on a Comm. Board in Slot #2. The Ethernet version of Figure 3-9 is similar to Figure 3-10 with Fig. 3-10’s Ethernet CPU

Board substituted for the Real/Protected Mode CPU shown in Figure 3-9 and Ports E & F as shown in Figure 3-10 substituted for Ports E and F as shown in Figure 3-9.

Figure 3-10 - Modem Installed on Comm. Bd. in Slot 1 of DPC 3330

(with Ethernet CPU)

3-12 / Modem Installation Section 3 CI-9600A

7. Install the modem (on the 2-Port ECB) into the DPC 3330. Push the ECB (with modem) into slot until the ECB’s connector P1 is fully seated in the mating connector of the System Interconnect Board. Secure (with a screw) the 2-Port ECB to the DPC’s frame (Mounting Bracket - see Figures 3-8, 3-9 & 3-10).

8. Connect the modem to the phone line (see Section 3.2). After the telephone company has installed the phone jack (wall), connect the phone line to the modem by inserting the appropriate equipment interface cable (plugs) into the modem jack

(J1) and the wall jack.

9. Install the DPC 3330 cover.

10. Connect a PC equipped with Bristol Babcock ACCOL software to Connector J5 of the DPC’s CPU Board. Apply power and configure the DPC for modem operation on

Port B or D (whichever is applicable) (see Auto-Dial Modem Interface in the ACCOL

II Reference Manual D4044).

3.1.4 Installing a 9600 bps Modem into a DPC 3335

3335 modems are mounted on a blank Multipurpose Interface Board (MIB) (see Figure 3-

11). To install a modem into a DPC 3335, follow steps 1 through 9 below. Note: The procedure for installing and configuring a DPC 3335 is covered in Instruction Manual CI-

3335. Note: An internal modem (3335 Modem on blank MIB) is always assigned to

Port B.

1. Disconnect power from the DPC 3335 (Shut down or place under manual control any critical processes prior to disconnecting power).

2. Remove the DPC 3335’s cover (see CI-3335).

3. Set the DPC 3335’s 2-Port Enhanced Communication Board (in Slot #1) Jumpers and Switches if not already configured. Make sure that SW3-1 is OFF and SW3-2 is

ON. This assigns a modem to Port B of the DPC 3335. Note: the 9-pin D-type connector associated with Port B on the 2-Port ECB that is assigned to DPC

Slot #1 is disabled when a modem is installed.

4 Configure the modem’s jumpers (if not already configured) as follows:

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 =

- JP5-2 to JP5-3 =

CTS from Modem

CTS Connected to RTS (Factory Setting)

The RTS/CTS Loopback Jumper must be installed in position 2-3.

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

5. Connect the System Grounds to modem connector TB1 (see Supplement Manual

S1400 - -Guidelines for System Grounding) as follows:

CI-9600A Section 3 Modem Installation / 3-13

Connect the modem’s Chassis Ground (TB1-1) to the associated DTE (DPC 3335)

Chassis Ground. Note: DPC Chassis Ground is tied to the Bonding Bolt on the rear of the DPC. The DPC CHASSIS terminal must be connected to a “Power Grid

Ground.” Do NOT connect modem connector TB1-1 to the CHASSIS terminal on the rear of the DPC 3335. Use a separate #14 AWG wire (green) to connect to the “Power

Grid Ground.”

Figure 3-11 - DPC 3335 Blank MIB Board with 9600 bps Modem Installed

3-14 / Modem Installation Section 3 CI-9600A

Connect the modem’s Earth Ground (TB1-2) to the local Earth Ground or Power

Grid Ground.

Figure 3-12 - Modem Installed in DPC 3335 on Blank Multipurpose Intf. Board

6. Install the modem (on the blank MIB) into the DPC 3335. Push the modem assembly into MIB slot until the MIB’s Securing Bracket is snug against the DPC frame. Secure the modem assembly to the frame with the Securing Bracket’s Captive Screw (see Figure B).

(J1) and the wall jack.

8. Install the DPC 3335’s cover.

CI-9600A Section 3 Modem Installation / 3-15

9. Connect a PC equipped with Bristol Babcock ACCOL software to the Connector J5 of the DPC 3335 CPU Board. Apply power and configure the DPC for modem operation on Port B (see ACCOL II Reference Manual D4044 - Auto-Dial Modem

Interface.

3.1.5 Connecting a 9600 bps Modem to a RED 3332

A Panel Mount version of the 9600 bps Modem is used in conjunction with RED 3332 units.

The 9600 bps Panel Mount Modem may be connected to Ports J1C, J2C, J3C, J4C or J5C on the RED 3332’s Redundancy Switchover Panel (RSP) (see Section 3.1.7.5).

3.1.6

Installing the 9600 bps PC Modem

The PC Modem assembly P/N 395595-01-0 is housed in a desk-top enclosure [7” (L) x 4.75”

(W) x 1.875” (H)] and may be powered from a regulated +12Vdc or +24Vdc source. BBI can provide either a +12Vdc Regulated Power Supply P/N 395480-01-9 that plugs into a standard 110Vac power receptacle (wall jack) and into modem Jack J2 or DC Power Cord

P/N 396302-01-7 that interfaces power from a user supplied +12/24V power source to modem jack J2. These modems are interfaced to a PC via a standard 9-Pin to 9-Pin Comm.

cable, i.e., Pin 1 to Pin 1, Pin 2 to Pin 2, etc. To install and interface a PC Modem to a PC follow steps 1 through 7 below.

1. Disconnect power from PC (Shut down or place under manual control any critical processes prior to disconnecting power).

2 Configure the modem’s Jumpers (if not already configured). To do this you will have to remove the four cover screws that secure the modem’s cover (see Figure 3-22).

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 =

- JP5-2 to JP5-3 =

CTS from Modem

CTS Connected to RTS (Factory Setting)

The RTS/CTS Loopback Jumper must be installed in position 2-3.

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

3. Connect the modem’s Comm./Config. Port (J4) to one of the PC’s Comm. Ports. Use a 9-Pin to 9-Pin Comm. cable, i.e., Pin 1 to Pin 1, Pin 2 to Pin 2, etc.

4. Connect the System Grounds to modem connector TB1 (see Supplement Manual

S1400 - Guidelines for System Grounding) as follows:

Connect the modem’s Chassis Ground (TB1-1) to the associated DTE (PC) Chassis

Ground. Note: The CHASSIS Ground must be connected to a “Power Grid Ground” or to a known good “Earth Ground.”

Connect the modem’s Earth Ground (TB1-2) to the local Earth Ground or Power

Grid Ground.

3-16 / Modem Installation Section 3 CI-9600A

CI-9600A

Figure 3-13 - PC Modem Component Identification Diagram

Section 3 Modem Installation / 3-17

Figure 3-14 - PC Modem (Front & Rear Views)

Make sure the modem is OFF (SW1 set to the ‘O’ position). If using BBI +12V Power

Supply (P/N 395480-01-9), plug the power supply into the ac wall receptacle

(110Vac). Plug the power supply’s dc power cord into the modem’s power jack (J2). If using BBI Power Cable (P/N 396302-01-7), connect the plain black wire to the user supplied +12/24Vdc power source’s negative (-) terminal and the coded black wire to the power source’s positive (+) terminal (see Figure 3-15). Connect the BBI Power

Cable’s plug into the modem’s power jack (J2).

Figure 3-15 - BBI Power Cable P/N 396302-01-7

6. Connect the modem to the phone line (see Section 3.2). After the telephone company has installed the phone jack (wall), connect the phone line to the modem by inserting the appropriate equipment interface cable (plugs) into the modem jack

(J1) and the wall jack.

7. Apply power to the modem and to the PC. Configure the PC (equipped with Bristol

Babcock ACCOL software) for modem operation on the appropriate Comm. Port (see

Auto-Dial Modem Interface in the ACCOL II Reference Manual D4044).

3-18 / Modem Installation Section 3 CI-9600A

Note:

The PC Modem may be connected to various BBI equipment in a similar manner to the Panel Mount Modem. The basic difference is that the PC Modem is provided in an enclosure and requires a special power plug and an external Power

Supply. Except for connection of the Power

Supply, installation of a PC Modem to BBI equipment is identical to that of the Panel

Mount Modem (see Section 3.1.6).

3.1.7 Installing the 9600 bps Panel Mount Modem

Panel Mount Modems mount to an equipment cabinet mounting plate or panel. These modems may be connected to a RTU 3305, RTU 3310, DPC 3330, RED 3332 (RSP Panel) or a DPC 3335. To install a modem for use with one of these systems refer to sections 3.1.7.1

through 3.1.7.6 below. These sections cover installation as follows:

Section 3.1.7.1 - General Installation

Section 3.1.7.2 - Connection to a RTU 3305

Section 3.1.7.3 - Connection to a RTU 3310

Section 3.1.7.4 - Connection to a DPC 3330

Section 3.1.7.5 - Connection to a RED 3332

Section 3.1.7.6 - Connection to a DPC 3335

3.1.7.1 General Installation

1. Mount the Panel Mount Modem to the mounting plate or panel in question. Use standoffs to electrically isolate the modem from the mounting surface (see Figure 3-

15).

2. Disconnect power from the RTU/DPC in question (Shut down or place under manual control any critical processes prior to disconnecting power).

3. Remove the cover (if present) from the RTU/DPC in question.

4. Configure the modem’s jumpers (if not already configured) as follows:

JP5 - RTS to CTS Loopback Selection

- JP5-1 to JP5-2 =

- JP5-2 to JP5-3 =

CTS from Modem

CTS Connected to RTS (Factory Setting)

The RTS/CTS Loopback Jumper must be installed in position 2-3.

JP6 - LED Enable Selection

- Installed = Enable LEDs

- Removed = Disable LEDs

5. If connecting to a RTU 3305, proceed to Section 3.1.7.2.

If connecting to a RTU 3310, proceed to Section 3.1.7.3.

CI-9600A Section 3 Modem Installation / 3-19

If connecting to a DPC 3330, proceed to Section 3.1.7.4.

If connecting to a RED 3332 (RSP Assembly), proceed to Section 3.1.7.5.

If connecting to a DPC 3335, proceed to Section 3.1.7.6.

Figure 3-16 - 9600 bps PSTN Modem Board (Panel Mount Version

3-20 / Modem Installation Section 3 CI-9600A

3.1.7.2 Connection to a RTU 3305

1. Panel Mount Modems may be connected to Ports B, C and/or D of the RTU 3305. If connecting the modem to RTU 3305 Port D (P3 on MI/OB Board), set MI/OB Board

Switch SW1-2 to the CLOSED (ON) position (RS-232 Enabled) and SW1-6, SW1-7 &

SW1-8 to the OPEN position. If connecting the modem to RTU 3305 Port C (P4 on

MI/OB Board), set PMPP Board Switch SW1-1, SW1-2 & SW1-2 to the OPEN (OFF) position. If connecting the modem to RTU 3305 Port B (P5 on MI/OB Board), set

PMPP Board Switch SW1-4, SW1-5 & SW1-6 to the OPEN (OFF) position. Note: If the RTU 3305 has not already been configured for operation, it will have to be configured, i.e., jumpers and switches set as required, before proceeding with the remaining steps. See Sections 2.3 and 2.4 of Instruction Manual CI-3305.

2. Connect one end of the RS-232 Comm. Cable (see Table 3-3) to the RTU 3305 MI/OB

Board port in question, i.e., Port B = P5, Port C = P4 and Port D = P3. Connect the cable’s remaining D-Type Connector to modem connector J4.

3. Perform step 9 of Section 3.1.1. Connect a 9 to 30 Vdc power supply to modem connector TB4 as follows: TB4-1 = +Vdc Input, TB4-2 = Vdc return.

4. Perform steps 10 and 12 of Section 3.1.1.

3.1.7.3 Connection to a RTU 3310

1. Panel Mount Modems may be connected to Ports A, B and C on the 3310’s MFIB

Board and to Real/Protected Mode CPU’s off-board Ports (BIP1 and/or BIP2). If connecting the modem to RTU 3310 Port B (J9 on MFIB Board), set MFIB Switch

SW2-1 to the OPEN (Off) position (RS-232 Enabled). If connecting the modem to offboard ports BIP1 or BIP2 the CPU Board in question will have to be configured.

SW3 and SW4 on the CPU Board control Ports BIP1 and BIP2 respectively. SW1 on the CPU Board selects various board operating modes. Note: If the RTU 3310 has not already been configured for operation, it will have to be configured, i.e., jumpers and switches set as required, See Instruction Manual CI-3310.

2. Connect one end of the RS-232 Comm. Cable (see Table 3-3) to the RTU 3310 MFIB

Board port in question, i.e., Port A = J8, Port B = J9 and Port C = J10 or to the CPU off-board port in question, i.e., BIP1 or BIP2. Connect the cable’s remaining D-Type

Connector to modem connector J4.

3. Perform step 6 of Section 3.1.2. Connect a 9 to 30 Vdc power supply to modem connector TB4 as follows: TB4-1 = +Vdc Input, TB4-2 = Vdc return.

4. Perform steps 7 through 9 of Section 3.1.2.

3.1.7.4 Connection to a DPC 3330

1. Panel Mount Modems may be connected to Ports A, B, C, D, G, H, I and J on 3330

Enhanced Communication Boards (ECB) and to Ports BIP1 (E) and BIP2 (F) on

Real Mode, Protected Mode or Ethernet CPU Boards. In some cases Ports BIP1 (E) and BIP2 (F) may be situated off-board (i.e., external to the DPC). If connecting the modem to a port on an ECB the ECB’s Switches must be properly configured. Table

CI-9600A Section 3 Modem Installation / 3-21

3-2 provides ECB Switch assignment. The port assigned to the modem must have the associated switch positions 1 and 2 set for RS-232 operation, i.e., SWX-1 set

OFF and SWX-2 set ON. If connecting the modem to off-board ports BIP1 (E) or

BIP2 (F) the DPC’s CPU Board will have to be configured. SW3 and SW4 on the

CPU Board control Ports BIP1 and BIP2 respectively (SW3/4-2 must be set for EIA-

562 operation, i.e., set ON. SW1 on the CPU Board selects various board operating modes. Note: If the DPC has not already been configured for operation, it will have to be configured, i.e., jumpers and switches set as required, See Instruction Manual CI-

3330.

2. Connect one end of the RS-232 Comm. Cable (see Table 3-3) to the DPC 3330 communication port in question (see Figures 3-7 through 3-10 in Section 3.1.3).

Connect the cable’s remaining D-Type Connector to modem connector J4.

3. Perform step 6 of Section 3.1.3. Connect a 9 to 30 Vdc power supply to modem connector TB4 as follows: TB4-1 = +Vdc Input, TB4-2 = Vdc return.

4. Perform steps 8 through 10 of Section 3.1.3.

Table 3-2 - 3330/3332/3335 Comm. Board Switches SW1 - SW4 Port Assignment

Switch # Ports Controlled

SW1 A/C

SW2

SW3

SW4

G/I

B/D

J/J

3.1.7.5 Connection to a RED 3332 (RSP Assembly)

1. Panel Mount Modems may be connected to Ports J1C, J2C, J3C, J4C or J5C on the

3332 RSP. Note: If the RED 3332 has not already been configured for operation, it will have to be configured, i.e., jumpers and switches set as required, See Instruction

Manual CI-3330.

2. Connect one end of the RS-232 Comm. Cable (see Table 3-3) to the RED 3332 communication port in question, i.e., Port A (J1C), Port B (J2C), Port C (J3C), Port

D (J4C) or Port D2 (J5C) (see Figure 3-17). Connect the cable’s remaining D-Type

Connector to modem connector J4.

3. Connect the System Grounds to modem connector TB1 (see Supplement Manual

S1400 - Guidelines for System Grounding) as follows:

Connect the modem’s Chassis Ground (TB1-1) to the associated DTE (RED 3332)

Chassis Ground. Note: The DPC CHASSIS terminal must be connected to a “Power

Grid Ground.” Do NOT connect modem connector TB1-1 to the CHASSIS terminal of the RED 3332. Use a separate #14 AWG wire (green) to connect to the “Power Grid

Ground.”

3-22 / Modem Installation Section 3 CI-9600A

3. Connect the modem to the phone line (see Section 3.2). After the telephone company has installed the phone jack (wall), connect the phone line to the modem by inserting the appropriate equipment interface cable (plugs) into the modem jack

(J1) and the wall jack.

CI-9600A

Figure 3-17 - RED 3332 RSP Assembly with Cover Removed

Section 3 Modem Installation / 3-23

5. Install the RED 3332’s cover (if removed). Connect a 9 to 30 Vdc power supply to modem connector TB4 as follows: TB4-1 = +Vdc Input, TB4-2 = Vdc return.

6. Connect a PC equipped with Bristol Babcock ACCOL software to a RSP Port, i.e.,

J1C through J4C (see Figure 3-17). Apply power and configure the RED 3332 for modem operation on the assigned port (see ACCOL II Reference Manual D4044 -

Auto-Dial Modem Interface.

3.1.7.6 Connection to a DPC 3335

1. Panel Mount Modems may be connected to Ports A, B, C, D, I and J on 3335

Enhanced Communication Boards (ECB) and to Ports BIP1 (E) and BIP2 on Real

Mode, Protected Mode or Ethernet CPU Boards. In some cases BIP1 (E) and BIP2

(F) may be situated off-board (i.e., external to the DPC). If connecting the modem to a port on an ECB the ECB’s Switches must be properly configured. Table 3-2 provides ECB Switch assignment.

Figure 3-18 - DPC 3335 Comm. Port Assignments

3-24 / Modem Installation Section 3 CI-9600A

The port assigned to the modem must have the associated switch positions 1 and 2 set for RS-232 operation, i.e., SWX-1 set OFF and SWX-2 set ON. If connecting the modem to off-board ports BIP1 (E) or BIP2 (F) the DPC’s CPU Board will have to be configured. SW3 and SW4 on the CPU Board control Ports BIP1 and BIP2 respectively (SW3/4-2 must be set for EIA-562 operation, i.e., set ON. SW1 on the

CPU Board selects various board operating modes. Note: If the DPC has not already been configured for operation, it will have to be configured, i.e., jumpers and switches set as required, See Instruction Manual CI-3335.

2. Connect one end of the RS-232 Comm. Cable (see Table 3-3) to the DPC 3335 communication port in question (see Figure 3-18). Connect the cable’s remaining D-Type

Connector to modem connector J4.

3. Perform step 5 of Section 3.1.4. Connect a 9 to 30 Vdc power supply to modem connector TB4 as follows: TB4-1 = +Vdc Input, TB4-2 = Vdc return.

4. Perform steps 7 through 9 of Section 3.1.4.

Table 3-3 - PC/Panel Mount Modem (DCE) & DTE - RS-232 Port Pin Assignments

Modem

9-Pin - J4

(RS-232)

3310/30/35

BIP1 & BIP2

3310/30/35

A, B, C, D,

G, H, I & J

3332 RSP

J1C, J2C, J3C

J4C & J5C

3305

B, C & D

1 - DCD (Out) 1 - DCD (In) 7 - DCD (In)

2 - RXD (Out) 2 - RXD (In) 4 - RXD (In)

3 - TXD (In)

4 - DTR (In)

3 - TXD

4 - DTR

(Out)

2 - TXD

1 - DTR

(Out)

7 - DCD

4 - RXD

2 - TXD

1 - DTR

(In)

(Out)

7 - DCD

4 - RXD

2 - TXD

1 - DTR

(In)

(Out)

7 - DCD

4 - RXD

2 - TXD

1 - DTR

(In)

(Out)

5 - GND 5 - GND

6 - DSR (Out) 6 - DSR (In)

9 - GND 9 - GND 9 - GND

8 - (see Note 1) 8 - (see Note 2) 8 - DSR (In)

9 - GND

8 - (see Note 3)

7 - RTS (In) 7 - RTS (Out) 5 - RTS (Out) 5 - RTS (Out) 5 - RTS (Out) 5 - RTS (Out)

8 - CTS (Out) 8 - CTS (In) 6 - CTS (In) 6 - CTS (In) 6 - CTS (In) 6 - CTS (In)

9 - N/A 9 - N/A 3 - N/A 3 - N/A 3 - N/A 3 - N/A

Note 1: Ports BIP1 & BIP2

BIP1 and BIP2 are RS-562 ports (RS-232 compatible) and have both pins 1 and

8 assigned as DTR (Out). When configuring the RS-232 cable between the

PC\Panel Mount Modem and the CPU Board Comm. Port in question, leave pin 8 (or pin 6 at the modem port) OPEN, unconnected.

Note 2: 3310 Ports A & C (MFIB Board)

A & C are RS-423 ports (RS-232 compatible) with pin 8 assigned as DSR (In).

3330 Ports A, B, C, D, G, H, I & J (Enhanced Comm. Boards)

ECB’s 392587-01-7, 392587-02-5, 392587-03-3 & 392903-01-6

A, B, C, D, G, H, I & J are RS-562 ports (RS-232 compatible) and have both pins

1 and 8 assigned as DTR (Out). When configuring the RS-232 cable between the PC\Panel Mount Modem and the ECB Comm. Port in question, leave pin 8

(or pin 6 at the modem port) OPEN, unconnected.

3335 Ports A, B, C, D, I & J (Enhanced Comm. Boards)

ECB’s 392589-01-0 & 392589-02-8

A, B, C, D, I & J are RS-232 ports and have both pins 1 and 8 assigned as DTR

(Out). When configuring the RS-232 cable between the PC\Panel Mount

Modem and the ECB Comm. Port in question, leave pin 8 (or pin 6 at the modem port) OPEN, unconnected.

CI-9600A Section 3 Modem Installation / 3-25

3335 Ports A, B, C & D (Comm. Engine Boards)

CEB’s 392043-01-7 & 392058-01-4

A, B, C & D are RS-423 ports (RS-232 compatible) and have pin 8 assigned as

DSR (In).

Note 3 3305 Ports B, C & D

P3 (Port D) Pin 8 = DSR (In).

P4 (Port C) Pin 8 = DSR (In) when U32 on the PMPP Board = DS232IC.

P5 (Port B) Pin 8 = DSR (In) when W18 on the MI/OB Board is set in Pos. 1-2.

3.2 PSTN HOOKUP

A PSTN using a master and three (3) remote DPCs (each equipped with a BBI 9600 BPS -

PSTN Modem) is shown in Figure 3-20. A connection to the PSTN is made using a cable having standard telephone connectors at each end. One end of the cable plugs into J1 of the modem while the other end plugs into a telephone wall receptacle. The telephone company provides the necessary subscriber loops at its central system along with the phone numbers for each destination.

Warning

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.

An application consisting of A single master and a single remote requires only one of the remote connections shown in Figure 3-20.

The BBI 9600 bps - 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.

· The equipment compliance information is summarized as follows:

Complies with Part 68 FCC Rules.

Contains device with FCC Registration Number: B46USA-30667-F-A-E

Ringer Equivalence Number (REN): .6B

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 either a USOC:FJ45S or a USOC:RJ11C.

Note: The Jack (J1) that is provided on the Modem is a 6-Pin TLECO RJ-11.

The connections to the modem are

Pin 3 PSTN-Tip, and Pin 4 PSTN-Ring.

· After the telephone company has installed the phone jack, connect the modem to your equipment by inserting the appropriate equipment interface cable (plugs) into the modem jack and the wall jack.

3-26 / Modem Installation Section 3 CI-9600A

Figure 3-19 - Wiring for Phone Connector

Figure 3-20 - Field Connections For RTUs/DPCs (etc.) on Basic PSTN

CI-9600A Section 3 Modem Installation / 3-27

3.2.1 If Telephone Equipment Problems Arise

If any of your telephone equipment is not operating properly, you should immediately remove it from your telephone line, as it may cause harm to the telephone network. If the telephone company notes a problem, they may temporarily disconnect service. When pratical, they will notify you in advance of this disconnection. If advance notice is not feasible, you will be notified as soon as possible. When you are notified, you will be given the opportunity to correct the problem and informed of your right to file a complaint with the FCC. Contact your telephone company if you have any questions about your phone line.

In the event that repairs are ever needed on the BBI 9600 bps PSTN Modem, it should be returned to Bristol Babcock (in Watertown, CT) after a BBI Return Authorization Form

(GBU 13.01) has been completed by the customer and a return authorization (RA) number has been issued by BBI (see pages 5 & 6 at the beginning of this manual). For more information contact the Bristol Babcock Repair Department at (860) 945-2442.

3-28 / Modem Installation Section 3 CI-9600A

Section 4 MODEM DIAGNOSTICS

Caution

4.1 ESCAPE CODE SEQUENCE

When the modem has established a connection and has entered on-line data mode, it is possible to break into the data transmission in order to issue further commands to the modem in an on-line command mode. This is achieved by the DTE sending the modem a sequence of three (3) ASCII characters specified in register S2. The default character is ‘ +.

’

The maximum time allowed between receipt of the last character of the three escape character sequence from the DTE and sending of the OK result code to the DTE is controlled by register S12.

4.2 LOOPBACK & LINE SIGNAL TESTS

AT&Tn commands form part of the CCITT V.54 protocol and can be used for diagnostic testing . Note: &Tn commands can only be used when the modem is configured for &Q0

<CR> (unbufered/direct asynchronous mode). There are 4 loopback configurations that can be used to aid in troubleshooting modem/line problems: Local Analog Loopback (see Figure

4-2), Local Digital Loopback (see Figure 4-3), Remote Digital Loopback with Local Self Test

(see Figure 4-41), and Local Analog Loopback with Self Test (see Figure 4-5). The following tests can be done but communication between the master and slave units has to be stopped. Using a Terminal Emulation Software (such as HyperTerminal or PROCOMM, or an ASCXII terminal at 9600 bps, type ATDT and the number that you want to dial. Wait for a connect at 9600 bps (or less) then type +++ to put the modem into the Command

Mode. Wait for O.K., then type AT%L%Q.

4.2.1 Line Signal Level Test

The AT%L provide a means of determining the received signal level.

4.2.1.1 Line Signal Level Command ( %L )

The %L command causes the modem to return a value that indicates the received signal level at the modem DATA PUMP interface. The value is determined by the loss/gain of the modem Telco interface circuit ( " bB) at the Tip/Ring input to the modem ( not at the telephone line connector). For example, 009 = -9 dBm, 043 = -43 dBm, and so on. Typical values should be -25dBm to -35dBm for most Telco connections.

Results Code: OK

CI-9600A Section 4 Modem Diagnostics / 4-1

4.2.2 Line Signal Quality Test

The AT%Q command causes the modem to report information about the line signal quality.

4.2.2.1 Line Signal Quality Command ( %Q )

The %Q command causes the modem to report the line signal quality (DAA Teleco

Interface dependent) at the modem DATA PUMP interface. The modem returns the higher order byte of the Eye Quality Monitor (EQM) value. Typical value should be below 10. The lower the number, the better the performance of the modem. Based on the EQM value, retrain or fallback/fall forward may be initiated if enabled by %E1 or %E2.

Example:

AT%Q

015

Results Codes:

OK If connected.

ERROR If not connected, or connected in 300 bps, V.23, or fax modes (N/A).

4.2.3 Connection Failure Cause

S-Register S86 can help you to determine the cause of a connection failure. When the modem issues a NO CARRIER result code, a value is written to this register. To read this register, following the connection failure, issue ATS86?<CR>. The modem will report a Call

Failure Reason Code.

4.2.3.1 Call Failure Reason Code of S86

When the modem issues a NO CARRIER result code, a value is written to this S-Register to help determine the reason for the failed connection. Register S86 stores the first event that contributes to a NO CARRIER message.

Range: 0, 4, 5, 9, 12, 13, or 14

The following cause codes are associated with register S86:

S86 = 0 Normal disconnect, no error occurred.

S86 = 4 Loss of carrier.

S86 = 5 V.42 negotiation failed to detect an error-correction modem at the other end.

S86 = 6 Other error-control modem did not respond to feature negotiation message sent by this modem.

S86 = 7 Other modem is synchronous-only; this modem is asynchronous-only.

S86 = 8 Modems could not find a common framing technique.

S86 = 9 The modems could not find a common protocol.

S86 = 10 Feature negotiation message sent by other modem is incorrect.

S86 = 11 Synchronous information (data of flags) not received from other modem.

S86 = 12 Normal disconnect initiated by the remote modem.

4-2 / Modem Diagnostics Section 4 CI-9600A

S86 = 13 Remote modem doesn't respond with 10 re-transmissions of the same message.

S86 = 14 Protocol violation occurred.

S86 = 15 Compression failure.

Figure 4-1 - Typical Modem Configuration

Figure 4-2 - Initiate Local Analog Loopback Diagram

CI-9600A

Figure 4-3 - Perform Local Digital Loopback Diagram

Section 4 Modem Diagnostics / 4-3

Figure 4-4 - Remote Digital Loopback with Local Self Test

Figure 4-5 - Local Analog Loopback with Self Test

4.2.4 Test and Diagnostic Command ( &Tn )

The modem will perform selected test and diagnostic functions according to the parameter supplied. A test can be run only when in an asynchronous operation in non-error correction mode (normal or direct mode). To terminate a test in progress, the escape sequence must be entered first, except for parameters 7 and 8 (see Escape Code Sequence Section 4.1). If

S18 is non-zero, a test will terminate automatically after the time specified by S18 and display the OK message. &Tn commands are formatted and function as follows:

4-4 / Modem Diagnostics Section 4 CI-9600A

AT&T0

AT&T1

AT&T2

AT&T3

AT&T4

AT&T5

Terminate Test In Progress and clear register S16. If a V.54 loopback test is in process (as a result of executing an &Tn command), the &T0 command will cause the test to be terminated provided that the modem is in command state, or a V.54 state that accepts commands from the DTE.

Initiate Local Analog Loopback , V.54 Loop 3. Sets S16 bit 0. If a connection exists when this command is issued, the modem hangs up. The

CONNECT XXXX message is displayed upon the start of the test. When the

AT&T1 command is entered, the modem goes on hook and configures itself for analog loopback. DSR is turned OFF (if &S1 is in effect), the analog loopback state is entered, and the test timer is set to the value in S18 (10 seconds). A connect result code is sent to the DTE, and the test timer then begins its count down. The test is terminated when the test timer expires.

Results Code Description

CONNECT When local analog loopback state is entered.

ERROR

If any other &Tn test is active (except &T0) or if in the on-line command state.

After test is stopped by the test timer, the HO command, or the

&T0 command.

No Function.

Perform Local Digital Loopback , V.54 Loop 2. Sets S16 bit 2. If no connection exists when this command is issued, ERROR is returned. Sets register S16 bit 4 when the test is in progress. The modem must be in the command state (after connection is established) when this command is issued, otherwise an ERROR result code will occur. The AT&T3 command establishes a loopback of received data, after demodulation, and sends it back to the distant end. The modem is configured for local digital loopback,

DSR is turned OFF (if &S1 is in effect), the test timer is started with the value in S18 (10 seconds), and an OK result code is sent to the DTE.

Results Code Description

CONNECT After 2 second delay.

ERROR

If any other self test is active (&T1, &T6, &T7 or &T8) or if in idle state.

When test is terminated.

Grant Remote Digital Loopback (RDL) Requests - Enables digital loopback acknowledgment for remote request, i.e., an RDL request from a remote modem is allowed. Sets register S23 bit 0 (Factory Default). When in the online state, the modem will honor a remote digital loopback request from a distant modem if it occurs. This will result in an ERROR if the command is given while any V.54 test is active (&T1, &T3, &T6, &T7 or &T8). N OTE:

There are data patterns that may cause a Remote Digital Loopback condition.

Care should be given to the type of data being received so that no RDL modes will be initiated.

Deny RDL Request - Clears register S23 bit 0 (Profile Default). the modem will not respond to a remote digital loopback request from a distant modem.

This will result in an error if the command is given while any V.54 test is active (&T1, &T3, &T6, &T7 or &T8).

CI-9600A Section 4 Modem Diagnostics / 4-5

AT&T7 Initiate a Remote Digital Loopback (RDL) With Local Self Test - V.54

loop 2, with self test. (In self test, a test pattern is looped back and checked by the modem.) If no connection exists, ERROR is returned. The test is terminated after the expiration of S18 (10 seconds) and the number of detected errors is reported to the DTE. Register S16 bit 5 will be set when the test is in progress. This is a system test, end to end. The command is valid if the modems are in the command state with a connection established.

Configure the remote modem with an AT&T4 command so that it will honor an RDL request. Enter AT&T7 at the local modem and it will send a digital loopback request to the remote modem. After the RDL acknowledgment signal has been received from the remote modem, DSR is turned OFF (if &S1 is in effect), the on-line state is entered, an OK result code is sent to the

DTE, and the test timer is set to the value in S18 (10 seconds). While the test is active, the local modem sends a test message to the remote modem and counts the errors in the received (looped back) signal. The modems stay in the command state during the test. When the test is terminated (except by a loss of carrier), the local modem sends the release signal to the remote modem, as in &T6, and reports the three-digit error count to the DTE. The information text is followed by an OK result code. The test is terminated by the S18 timer running out.

Results Code Description

ERROR

When command executed is started.

After error count is sent to DTE (&T1, &T3, &T6, &T7 or &T8).

If not in the on-line command state.

If the RDL signal is not acknowledged.

AT&T8 Local Loopback With Self Test - Initiates local analog loopback, V.54 Loop

3, with self test. (In self test, a test pattern is looped back and checked by the modem). If a connection exists, the modem hangs up before the test is initiated. When the test is terminated either via expiration of S18, or via the

&T0 or H command, the number of detected errors is reported to the DTE.

Sets register S16 bit 6 when the test is in progress. This command may not be available in some countries due to PTT restrictions. The modem should be on hook. Enter AT&T8 to configure the modem for analog loopback and self test. The test timer is started at the time indicated by S18 (10 seconds), DSR is turned OFF (if &S1 is in effect). A self test condition is entered, and an OK result code is sent to the DTE. During the test, the modem sends a test message and counts the errors in the looped back signal. The test is terminated when the timer (S18) times out. When the test is terminated, the three digit error count is sent to the DTE. An OK result code follows the error count.

Results Code Description

ERROR

If a test state is entered.

After error count is sent to DTE.

If any other V.54 test is active (&T1, &T3, &T6, &T7) or if online.

4.3 MODEM LEDs

The BBI 9600 bps PSTN Modem contains eight (8) LEDs. When Jumper JP6 has been removed, these LEDs are disabled. LED designation depends on the version of the modem

(see Table 4-1). These LEDs function as follows:

4-6 / Modem Diagnostics Section 4 CI-9600A

TXD (Transmit Data) - DS1/DS2

When lit, this LED indicates transmitting activity. Both MARK and SPACE data (TXD) from the host device (DTE) are sent to the modem at P1-6 (DPC/RTU 3310/30/35), TB3-

2 (RTU 3305) or J4-3 (PC & Panel Mount Modems).

RXD (Receive Data) - DS3/DS4

When lit, this LED indicates receiving activity. Both MARK and SPACE data (RXD) are being sent to the DTE at P1-9 (DPC/RTU 3310/30/35), TB3-5 (RTU 3305) or J4-2

(PC & Panel Mount Modems).

RTS (Request to Send) - DS5/DS6

When lit, this LED indicates that the host (DTE) is ready to send data to the modem.

CTS (Clear to Send) - DS7/DS8

When lit, this LED indicates that the DCE (Local Modem) has signaled the DTE (Local

CPU) that it is clear to send data. CTS is issued in response to an RTS.

DTR (Data Terminal Ready) - DS9/DS10

When lit, this LED indicates that the DTE has activated the local modem.

DCD (Data Carrier Detect) - DS11/DS12

When lit, this LED indicates that the modem has detected the presence of a carrier from a remote modem.

DSR (Data Set Ready) - DS13/DS14

When lit, this LED indicates to the DTE that the local modem is ready to send or receive data to/from the remote modem.

PWR (Power) - DS15/DS16

When lit, this LED indicates that power has been supplied to the modem. Jumper JP6 must be installed to enable all LEDs.

Table 4-1 - LED Assignments

LED Designation

DS1 - DS15 (Odd)

DS2 - DS16 (Even)

Modem Types

Panel Mount & PC

RTU 3305, RTU 3310,

DPC 3330, RED 3332 (RDPC)

& DPC 3335

CI-9600A Section 4 Modem Diagnostics / 4-7

BLANK PAGE

Section 5 MODEM SPECIFICTIONS

5.1 OPERATING SPECIFICATIONS

Function:

Operating Modes:

Line Type:

Provides PSTN (Public Switched Telephone Network) communications.

Sync. or Async. 2-wire switched network - Half or Full Duplex.

Two-wire loop start lines.

Modem Config.

Data Rate:

"AT" based commands.

V.32 bis - 9600 bps, V.32 - 9600 bps, V.22 bis - 2400 bps,

V.22 - 1200 bps or 600 bps, V.21 - 300 bps.

Bell 103J - 300 bps, Bell 212A - 1200 bps.

Telephone Functions: Dialing and answering by AT commands. Automatic answering is also programmable.

Approvals: Telephone - FCC Part 68. (also suitable for approval within

Canada).

Trans. Output Levels: -10 dBm fixed (USA) - (0-15 dBm adjustable - firmware dependent).

PSTN Arrangements: Loop Start arrangement (transmission output does not exceed -

10 dBm). Allows connection to any voice telephone jack.

Isolation : Data Access Arrangement (DAA) with 1000 Vac (Modem to

PSTN).

Surge Capability:

Safety:

Withstand surge of 100A with 10 x 160 m s waveform.

Suitable for use in Class I, Division 2 Hazardous Locations.

5.2 ENVIRONMENTAL SPECIFICATIONS

Temperature:

Relative Humidity:

Vibration:

RFI Susceptibility:

Operating Range: -40 E to +70 E C (-40 E to 158 E F)

Storage Range: -40 E to +85 E C (-40 E to 185 E F)

10% to 95% (Noncondensing)

1g for 10-500 Hz or .5g for 150-2000 Hz per SAMA PMC-31-1 without damage or impairment.

Withstand 20 to 500 MHz (10V/M) without damage or impairment.

CI-9600A Section 5 Modem Specifications / 5-1

5.3 FCC & FM APPROVALS

Telephone Interface:

Environment:

FCC Part 68.

FM listed (pending) for use in Class I, Division 2, Groups C and D hazardous locations.

5.4 MODEM CONNECTORS

5.4.1 Connector J1

PSTN RJ11 Modem Connector (J1), provides the interface to the PSTN network via a modular phone cord and the Telephone Co. RJ11 Jack.

Table 5-1 - Primary Telephone RJ11 Connector - J1

J1 Pin # Signal Name

1 N/A

N/A

T/R_1

T/R_2

N/A

Description

Not Used

Transmit/Receive

Not Used

Input/Output

---

I/O

---

5.4.2 Connector J2

Power Jack (J2) is provided for the PC Mount version of the modem along with either a

+12Vdc Regulated Power Supply (P/N 395480-01-9) or BBI Power Cable (P/N 396302-01-

7).

Table 5-2 - PC Modem Power Connector - J2

J2 Pin # Signal Name

1 +12Vdc

2 & 3 Gnd

Description

+12 Vdc power

Ground

5.4.3 Connector P1

DTE/Modem TTL 10-pin Serial Connector #1 (P1) provides the TTL interface between the modem and a RTU 3310, DPC 3330 or a DPC 3335.

Table 5-3 - DPC 3310/3330/3335 To Modem Intf. (TTL Serial Connector #1 - P1)

P1 Pin #

Signal Name Description

Not Used N/A

GND

VCC

MDM_PWR

Not Used

Ground

Logic Power (+5VDC)

Modem Power

N/A

Input/Output

N/A

---

N/A

5-2 / Modem Specifications Section 5 CI-9600A

Table 5-3 - DPC 3310/3330/3335 To Modem Intf. (TTL Serial Connector #1 - P1)

(Continued)

P1 Pin # Signal Name Description

6 TXD Transmit Data

RTS

DTR

Request To Send

Data Terminal Ready

RXD

CTS

Not Used

DCD

Receive Data

Clear To Send

N/A

Data Carrier Detect

Input/Output

N/A

5.4.4 Connectors J4, J5 & J6

A 9-pin D-Type connector (J4, J5, or J6) for modem configuration and/or DTE/Modem interfacing. J6 is provided with the RTU 3310 and the DPC 3330. J5 is provided with the

RTU 3305 and DPC 3335. J5 & J6 are used for configuring the modem with an ASCII

Terminal or a Terminal “Emulation” program (such as PROCOMM Plus or

SMARTCOM). J4 is provided with the PC Mount and Panel Mount versions of the modem. These connectors are used for configuring the modem and (with the exception of the 3305 modem version) as the RS-232 Data Port.

Table 5-4 - RS-232 Data/Configuration Port D-Type Connector J4

(PC & Panel Mount Modems) (Pin 9 Not used)

(Also used in conjunction with the RED 3332 - RSP Assembly)

J4 Pin # Signal Name

DCD

RXD

TXD

DTR

GND

DSR

RTS

CTS

Description

Data Carrier Detect

Receive Data

Transmit Data

Data Terminal Ready

Ground

Data Set Ready

Request To Send

Clear To Send

Input/Output

---

Table 5-5 - RS-232 Configuration Port D-Type Connectors J5 & J6

(All Version Except PC & Panel Mount Modems)

J5/6 Pin # Signal Name

RXD

TXD

GND

Description Input/Output

Receive Data

Transmit Data

Ground

---

5.4.5 Connector TB1

Terminal Block (TB1) (2-Pin on all versions of 9600 bps Modem) is provided for Data

Access Arrangement (DAA) isolation ground (GND) connections.

CI-9600A Section 5 Modem Specifications / 5-3

Table 5-6 - DAA Isolator Ground Connector TB1 (for All Modem Versions)

TB1 Pin # Signal Name

CGND

EGNDR

Description

Chassis Ground

Earth Ground

Connection

Connect to DTE

Chassis Ground.

Connect to Local Earth Ground.

5.4.6 Connector TB2

TTL Ground Interface Terminal Block (TB2) (2-Pin on the RTU 3305 Modem). Note:

Pins 1 through 8 are not provided and Pin 9 is not used.

Table 5-7 - RS-232/TTL Interface Connector TB2 (for RTU 3305)

TB2 Pin # Signal Name Description Input/Output

10 GND Ground I/O

5.4.7 Connector TB3

Terminal Block (TB3) provides an 8-Pin TTL interface between the RTU 3305 and the

Modem.

Table 5-8 - RTU 3305 TTL Interface Connector TB3 - MI/OB Connector P4

MI/OB Bd.

P4/D-TypePin #

Signal Name

DTR (Not)

TXD

RXD

RTS (Not)

CTS (Not)

DCD (Not)

+5V

PCOM

Wire

Color

Green

Brown

Blue

White

Black

Red

Yellow

Orange

TB3

Pin #

TB4

Pin #

5.4.8 Connector TB4

Power Terminal (TB4) provides screw mount terminals (9-35Vdc and ground) for the

Panel Mount version of the modem.

Table 5-9 - Unregulated Power Connector - TB4

TB4 Pin # Signal Name

1 GND

2 EXTVDC

Description

Ground

Unregulated Power Input

(+5.4 to +16 VDC)

Input/Output

---

5-4 / Modem Specifications Section 5 CI-9600A

Supplement Guide - S1400

Issue: 09/01

SITE CONSIDERATIONS

For

EQUIPMENT INSTALLATION,

GROUNDING

&

WIRING

A Guide for the Protection of

Site Equipment & Personnel

In the Installation of

BBI Series 33XX DPCs & RTUs

Bristol Babcock

NOTICE

Copyright Notice

Request for Additional Instructions

Trademarks or copy-righted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.

Bristol Babcock.

Supplement Guide S1400

SITE CONSIDERATIONS FOR EQUIPMENT

INSTALLATION, GROUNDING & WIRING

4.1

4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.2

3.5

3.5.1

3.5.2

3.5.3

3.6

3.6.1

3.6.2

3.6.3

3.6.4

3.1

3.2

3.3

3.4

3.4.1

3.4.1.1

3.4.1.2

3.4.1.3

SECTION TITLE

1.1

1.2

2.1

2.1.1

2.2

2.2.1

2.2.2

2.3

PAGE #

Section 1 - INTRODUCTION

GENERAL INTRODUCTION .......................................................................................1-1

MAJOR TOPICS.............................................................................................................1-1

Section 2 - PROTECTION

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

POWER & GROUND SYSTEMS...................................................................................3-1

IMPORTANCE OF GOOD GROUNDS.........................................................................3-1 transients and interference............................................................................................3-2

EARTH GROUND CONNECTIONS.............................................................................3-2

Establishing a Good Earth Ground. ..............................................................................3-2

Soil Conditions................................................................................................................3-4

Soil Types ........................................................................................................................3-4

Dry, Sandy or Rocky Soil................................................................................................3-6

GENERAL RECOMMENDATIONS .............................................................................3-7

Noise and Signal Errors .................................................................................................3-7

General Considerations..................................................................................................3-8

Other Grounding Considerations. .................................................................................3-8

GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS ................................3-12

Several DPCs Mounted in Metal Cabinet with Power Supply .................................. 3-12

Multiple DPC Cabinets with Local Power Supply in Each Cabinet..........................3-14

Multiple DPC Cabinets Powered by Single Power Supply ........................................3-14

Multiple Clusters of DPC Cabinets Powered by Local Supplies................................3-16

Section 4 - LIGHTNING ARRESTERS & SURGE PROTECTORS

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

Supplement S1400 Page 0-1 Table Of Contents

Supplement Guide S1400

SITE CONSIDERATIONS FOR EQUIPMENT

INSTALLATION, GROUNDING & WIRING

SECTION TITLE ..................................................................................................... PAGE #

Section 5 - WIRING TECHNIQUES

5.1

5.2

5.2.1

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

OVERVIEW ....................................................................................................................5-1

INSTRUMENT WIRING. ..............................................................................................5-1

Common Returns............................................................................................................5-1

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. IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std

142-1982

2. 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, 1 st Edition

Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam

Street, Shreveport, Louisiana 71151

Supplement S1400 Page 0-2 Table Of Contents

Section 1 - Overview

1.1 INTRODUCTION

This document provides information pertaining to the installation of BBI Series 33XX 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 likelyhood 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 S1400

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

Series 33XX 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 S1400

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 Indoor or outdoor – Dress Appropriately

Guide

2 If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees, spiders, snakes, etc.)

3 If indoor or outdoor – determine if there are any pieces of dangerous equipment or any processes which might be a risk to your safety

4 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.)

5 Hazardous or Non-Hazardous Environment – Wear appropriate safety equipment and perform all necessary safety measures.

6 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.

7 Never assume that adjacent or peripheral equipment has been properly installed and grounded. Determine if this equipment and the 33XX unit in question can be touched simultaneously without hazard to personnel and/or equipment?

8 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!

9 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, 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

# Guide

1 Environment - Class I, Division 2 - Nonincendive

Environment - Class I, Division 1 - Intrinsically Safe

Other - Safe or unrated area

2 Earth Ground - Established by mechanical/electrical or

(both) or not at all.

3 Is the area prone to lightning strikes?

4 Are there surge suppressors installed or to be installed?

5 Are there overhead or underground power or communication cables in the immediate area?

Reference Section

See Appendix A of CI Manual

See Appendix B of CI Manual

See Section 3

See Section 4

See Section 2.3

S1400 Page 2-2 Section 2 - Protection

Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued)

# Guide

6 Is there an antenna in the immediate area?

7 How close is other equipment? Can someone safely touch this equipment and a 33XX unit simultaneously?

8 Determine equipment ground requirements. How will the 33XX unit and its related wiring be grounded? Consider Earth Ground, Circuit

Ground, Conduit Ground, Site Grounds!

9 Are there any obviously faulty or questionable power or ground circuits?

2.3 OTHER SITE SAFETY CONSIDERATIONS

Reference Section

See Section 4.1.2

See Section 2.3

See Section 3

See Section 2.3

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 S1400

Section 3 - Grounding & Isolation

3.1 POWER & GROUND SYSTEMS

Series 33XX DPCs and RTUs (3305, 3310, 3330, 3331, 3332, 3335) utilize DC power systems. With the exception of some 3305 SAPs, AC power supplies are not provided with these units. Series 3305 SAP RTUs and 3335 DPCs are provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing a connection to Earth Ground.

Table 3-1 provides ground connection information for these units.

Model

3305 RTU

3305 SAP None

3310 RTU

3330 DPC

3332 RED

W1A, W1B

See C3A - topic

Grounding Option

W1A, W1B, W1C

See C3A - topic

Grounding Option

CI-3305 - Sup 1

Section 2.2.3

CI-3310 - C3A

CI-3330 - C3A

CI-3330 - C3K

3331 RIO

3335 DPC

Gnd. Jumpers

None

W13A, W13B

See C3A - topic

Grounding Option

Doc. Ref.

CI-3305 - C2

CI-3335 - C3L

CI-3335 - C3A

Location

MI/OB Bd.

Ground Lug

MFIB Bd.

SI Bd.

Jumpers = SI Bd.

Wiring = System

Monitor Module

& Ground Lug

Notes

# 12 AWG Wire

Pin 1 = PCOM (DC Ret.)

Pin 2 = POWER (DC+)

Pin 3 = CHASSIS

#4 AWG - see Figs.

S1-5, -6

#14 AWG Wire - see Figs.

3A-1, -2, -4, -6

#14 AWG Wire - see Figs.

3A-1, -2, -3, 3K-7, 3K-8

# 12 AWG Wire from

SMM - TB1 pin 2 (GND) to Zero Ref. Point - see

Figs 3A-1, -2, -7, -8, -9

#4 AWG Wire from

Chassis Bonding Bolt to

Power Grid Ground

3.2 IMPORTANCE OF GOOD GROUNDS

Series 33XX DPCs and RTUs 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 relationship 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.

Section 3 - Grounding & Isolation Page 3-1 S1400

3.3 TRANSIENTS AND INTERFERENCE

The extensive use of low-power integrated circuitry in modern electronic equipment requires proper grounding techniques to insure reliable system operation. The following checklist will help identify some critical areas:

1. All instrumentation devices at the site should be checked so that no potential greater than the standoff voltage can exist within or between devices.

2. To minimize outside signal interference and provide equipment protection from lightning or transients, the earth ground at the site must be tested to insure that its impedance measures less than 10 ohms at 7 MHz. This qualification is essential since a transient potential or an interference signal at the instrument site can vary over the entire electromagnetic spectrum from DC to several hundred MHz.

Note that transients can be produced through natural phenomena and man-made conditions. Natural transients may result from lightning (7-14 MHz), static (many frequencies), and wind (DC charge and static). Man-made transients can result from defective light bulbs or electrical appliances, sudden electrical load shifts, inductive load surges, arcing contacts and poor AC power connections.

3. If radio frequency (RF) interference is present at the input of an instrument, observe if it has a consistent or irregular pattern. Constant interference can come from commercial radio stations, while irregular interference can come from private stations.

Although shielding and grounding will eliminate or minimize most cases of RF interference, obstinate cases may require attenuation filters.

RF interference can also be caused by power companies that apply modulated RF signals to power lines to communicate data. Other RF noise sources include digital clocks, computers, relay contacts, motors transformers, switches, arc welders, etc.

3.4 EARTH GROUND CONNECTIONS

To properly ground a DPC or RTU 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.

3.4.1 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 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.

S1400 Page 3-2 Section 3 - Grounding & Isolation

Figure 3-1 - Basic Ground Rod Installation

Figure 3-2 - Overhead Map of Ground Bed for Gas Metering Station

Section 3 - Grounding & Isolation Page 3-3 S1400

3.4.1.1 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 (CaCl

3.4.1.2 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 ground has been established, it should be tested on a regular basis to preserve system integrity.

S1400

Figure 3-3 - Basic Ground Bed Soil Test Setup

Page 3-4 Section 3 - Grounding & Isolation

Figure 3-3 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

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 3-4). * 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 - Basic Ground Bed Soil Test Setup with Additional Ground Rods

Figure 3-5 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 3-6 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 3-5 - Ground Electrode Construction for Poor Soil Conditions

Section 3 - Grounding & Isolation Page 3-5 S1400

3.4.1.3 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.

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Figure 3-6 - Poor Soil Ground Bed Construction Diagram

Page 3-6 Section 3 - Grounding & Isolation

3.5 GENERAL RECOMMENDATIONS

When wiring equipment into a system, the electrical conduit must have a diameter that will accommodate the desired number of wires. The cross- sectional area of the conduit should be large enough to allow the wires to be pulled through without excessive tightness or binding. A conduit that is too tight can shred insulation, damage wiring, and result in possible opens, shorts, or intermittent effects. Such conditions are often difficult to trace because the defect is concealed inside the conduit.

3.5.1 Noise and Signal Errors

Noise and signal errors are often the result of poor wiring and grounding practices. Some common problem areas are listed as follows: o Shielding AIs and AOs.

Very often analog DC signal leads must run parallel to wires radiating AC fields, pulse information, or switching transients. Due to inductive and capacitive pickup, some of this information can leak into an analog I/O and cause peculiar effects in the control systems. To minimize or eliminate this problem, the use of insulated and shielded, twisted lead pairs is recommended between the external devices (transmitters, sensors, etc.) and the instrument inputs

(controllers, recorders, etc.).

The shields of each analog signal source should only be grounded at the input of the in-strument. In some equipment, the shield will connect to the instrument chassis.

In other equipment, a "shield" terminal will be provided with several grounding options. The user should refer to the instrument manual and follow grounding recom-mendations.

o Common Returns.

The use of a single "common" return wire for two or more input signals is not recommended. This approach may introduce system ground loops that cause erroneous readings at the instrument. Shielded transmitter or sensor wires should be grounded at the input of the instrument, or connected to a shield terminal

(where provided) to prevent "sneak" ground paths.

o Discrete Outputs.

Instruments provided with bi-state discrete outputs perform functions such as control switching, alarm switching or pulse duration communications. These outputs are furnished as either open collector or relay contact outputs that operate at low power levels. While these levels are sufficient to operate many devices, some will require much higher power levels. The use of external amplifiers or repeating relays to drive end devices will prevent output overload and add to the reliability of the system.

o Placement of Wiring.

The dressing or physical placement of wiring requires close scrutiny. Cables inside cabinets should be neatly secured at regular intervals.

Cables running between cabinets at different locations should be placed in conduits.

The cable length should allow sufficient slack for routine operational checks and maintenance of the equipment. Wiring from input signal circuits and power circuits should be separated as much as possible to minimize noise and transient pickup.

Power and signal leads should be run in separate conduit to minimize inductive pickup.

Section 3 - Grounding & Isolation Page 3-7 S1400

o Terminal Lugs.

The use of crimp-type terminal lugs as connections for screw terminals should be avoided. Terminal lugs, in many industrial climates, can be affected by hidden corrosion. It is preferable to tin the wire end with solder and loop it around the terminal screw. The screw should be tightened sufficiently to hold the lead in place but not excessively so that the lead is sheared or the screw is stripped.

Equipment furnished with compression-type terminals includes an opening for inserting tinned ends.

3.5.2 General Considerations

The following considerations are provided for the installation of 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.

3.5.3 Other Grounding Considerations

Instrument enclosures, measuring devices, metal process vats, metal piping, and other associated mechanical and electrical devices should all be grounded. The method of grounding an instrument rack is shown in Figure 3-6. In this application the ground lead typically attaches to a ground bus that is common to all equipment in the rack.

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 3-7. The ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.

Applications that use transmitters or transducers require grounding and shielding. In

Figure 3-8, the ground conductor feeds through the electrical conduit and connects to the ground screw of the transmitter even though the support pipe is grounded. However, if the transmitter uses shielded wiring for its signal output, the shield should not be grounded at the transmitter. For maximum signal accuracy, the shield should only be grounded at one point in the system, typically at the input of the associated equipment.

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Figure 3-6 - Grounding of Equipment Housing

Figure 3-7 - Grounding of Phone Line

Section 3 - Grounding & Isolation Page 3-9 S1400

Figure 3-8 - Grounding of Transmitter

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Figure 3-9 - Grounding of Thermometer Well in Gas Line

Page 3-10 Section 3 - Grounding & Isolation

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 arrestor as shown in Figure 3-9. A copper braid, brazed to the thermal well, is dressed into a smooth curve and connected to the arrestor as shown. The curve is necessary to minimize arcing caused by lightning strikes or high static surges. The path from the lightning arrestor to the ground bed should also be smooth and free from sharp bends for the same reason.

The ac power required to operate a system typically includes a service transformer located at the street and a main breaker box and rate meter assembly at the building as shown in

Figure 3-10. The service transformer is grounded at the company's pole, while the breaker box is grounded at the building. A lightning arrestor should be included at the breaker box in each phase of the AC line, and each arrestor should be grounded accordingly.

Figure 3-10 - AC Power Grounding System

Section 3 - Grounding & Isolation Page 3-11 S1400

3.6 GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS

When installing a system that includes a number of Bristol Babcock, Series 33XX

Distributed Process Controllers (DPCs), it is essential to follow the procedures set forth by the National Electrical Code (NEC) to minimize risk of equipment damage and electrical shock.

WARNING

Electrically powered equipment must be properly grounded to protect users from electrical shock and injury. All such devices must be installed, wired, and grounded in accordance with the

National Electrical Code (NEC).

Series 33XX DPCs employ a power grid ground terminal (CHASSIS) and an instrument ground terminal (24VRET) that connects to the "zero reference point" of the system.

Improper grounding of these terminals can produce multiple ground paths throughout the system and result in increased noise pickup and signal offset errors. If more information is required on this subject, the reader should refer to the publications cited at the end of this document.

The examples that follow describe the grounding techniques for several types of Bristol

Babcock systems employing DPCs. Refer to the system description that is closest to your application.

3.6.1 Several DPCs Mounted in Metal Cabinet with Power Supply

A small system can consist of one or more DPCs mounted in a single metal cabinet or rack with a power supply. A power wiring diagram for this arrangement is shown in the example of Figure 8. The following installation procedures apply:

1. Instrument Ground. The instrument ground of the DPCs (24VRET terminal of each

DPC) must connect to a terminal block within the cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all instrument grounds and include termination for a multistranded, insulated, #4 gauge wire (or greater). This wire, which will connect to the "zero reference point" of the facility, must be run through metal conduit (pipe). Only the #4 wire will be contained in this conduit. The conduit must also be connected by bonding strap to the cabinet and facility frame as described in the NEC.

2. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and

W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24VRET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.

Series 3308 Gas Flow Computers or Correctors, if used with these systems, provide an isolated instrument ground without setting jumpers.

3. AC Power Source. The 24 Vdc power supply requires a 120 Vac power source. The ac power terminals of this supply are identified in Figure 3-11. The 120 Vac wiring for this supply must be contained in cable trays along with the power grid grounding wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical

S1400 Page 3-12 Section 3 - Grounding & Isolation

facility. The cabinet frame and the DPC chassis must be connected with bonding strap at points specified in the NEC.

Figure 3-11 - Grounding for DPCs and Power Supplies in Single Metal Cabinet

4. Grounding of Peripheral Equipment. Some peripheral devices such as printers, CRTs, personal computers, etc., have their internal logic ground connected to the chassis.

This configuration will cause loss of isolation between the DPC's instrument ground and chassis. These devices may still be used providing that opto-isolated circuits,

Section 3 - Grounding & Isolation Page 3-13 S1400

galvanic isolation, or other types of circuitry between the device and the DPC are added to maintain the integrity of the DPC's instrument ground-to-chassis isolation.

3.6.2 Multiple DPC Cabinets with Local Power Supply in Each Cabinet

This application consists of two or more DPC cabinets either separated or clustered together in a room. Each cabinet has its own 24 Vdc power supply. The following procedures apply:

Multi-Cabinet Instrument Grounding using Multiple Supplies. The instrument ground (24VRET terminal) of each DPC in a cabinet must connect to a terminal block within that cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all DPC instrument grounds within that cabinet and include termination for a #4 gauge (or greater), multistranded, insulated wire that will connect to the zero reference point of the facility. This #4 wire will be run through metal conduit (pipe) to the same termination point in the other cabinets. Only the #4 wire will be containe in this conduit. This conduit must also be connected by bonding strap to the cabinet and facility frame as described in the NEC.

2. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and

W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.

Series 3308 Gas Flow Computers, if used with these systems, provide an isolated instrument ground without setting jumpers.

4. Grounding of Peripheral Equipment. Some peripheral devices such as printers, CRTs, personal computers, etc., have their internal logic ground connected to the chassis.

This configuration will cause loss of isolation between the DPC's instrument ground and chassis. These devices may still be used providing that opto-isolated circuits, galvanic isolation, or other types of circuitry between the device and the DPC are added to maintain the integrity of the DPC's "instrument ground to chassis" isolation.

3.6.3 Multiple DPC Cabinets Powered by Single Power Supply

All of the DPC cabinets in this installation operate from a single power supply which may be installed in one of the cabinets or in a separate cabinet. The following procedures apply:

1. Multi-Cabinet Instrument Grounding using Single Supply. The instrument ground

(24VRET terminal) of each DPC in a cabinet must connect to a terminal block within that cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all instrument grounds within that cabinet and include termination for a multistranded, insulated, #4 gauge wire (or greater).

S1400 Page 3-14 Section 3 - Grounding & Isolation

From: Grounding for the Control of EMI by Hugh W. Denny (see ref. 1)

- Courtesy of Interference Control Technologies -

Figure 3-12 - Elements of a Facility Ground System

2. Routing of Instrument Ground and 24 V Power Wires. The #4 wire, along with +24V and 24VRET wires, are run through conduit trays to the power supply. The #4 wire

Section 3 - Grounding & Isolation Page 3-15 S1400

connects to the 24VRET terminal of the supply and to the zero reference point of the facility. The +24V and 24RET wires connect to corresponding terminals on the power supply.

Cable Trays. Figure 3-12 illustrates the cable tray layout and grounding points of a typical facility. The cabinet frame and the DPC chassis must be connected with bonding strap at points specified in the NEC. The NEC also applies to the connection of the 120 Vac power supply terminals to the line.

4. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and

W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.

Series 3308 Gas Flow Computers, if used with these systems, provide an isolated instrument ground without setting jumpers.

3.6.4 Multiple Clusters of DPC Cabinets Powered by Local Supplies

A cluster consists of two or more DPC cabinets that may be grouped together as shown in

Figure 9. Several such clusters performing related functions in the same facility make up a multiple cluster system. The following procedures apply:

1. Grounding for DPC Cabinet Cluster using Local Supply. The instrument ground

24VRET terminal of the local power supply.

2. Routing of Cluster Grounds. The instrument grounds (isolated terminal) from each cabinet cluster must connect to each other and then to a single wire that connects to the zero reference point of the facility. This wire should be #4 gauge minimum

(multistranded and insulated) and be contained in a metal conduit (pipe). A heavier stranded #4/0 gauge could be used to connect each cluster to the zero reference point while the #4 wire instrument grounds could be locally terminated to the #4/0 wire.

The conduit containing this wire must also be connected by bonding strap to the cabinet and facility frame as described in the NEC.

3. AC Power Source. The 24 Vdc power supply of each cluster requires a 120 Vac power source. The ac power terminals of this supply are identified in Figure 3-11. The 120

Vac wiring for this supply must be contained in cable trays along with the power grid grounding wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical facility. The frame of each cabinet and each DPC chassis a cluster must be connected with bonding strap at points specified in the NEC.

4. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and

W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.

Series 3308 Gas Flow Computers and Correctors, if used with these systems, provide an isolated instrument ground without setting jumpers.

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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 (I 2 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 various 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 S1400

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:

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.

Refer to Figure 4-1 to find the latitude. Then using Chart 2, find “ B ” for your latitude

(Lat.°).

Multiply “ A ” x “ B ” to get “ C ” .

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 H 2 ) ÷ (.57 x 10 6 )

Chart 1

I “ A ”

100

169

275

402

548

712

893

1069

1306

Chart 2

LAT.° “ 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 BBI Series 33XX 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 modem has been interfaced to a 33XX unit, the possibility of damage due to a lightning strike on

S1400 Page 4-2 Section 4 - Lightning & Surge

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:

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.

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.

Mount antenna discharge unit as close as possible to where the lead-in wire enters the structure.

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.

Push the cable through the hole and form a rain drip loop close to where the wire enters the exterior of the structure.

Caulk around the lead-in wire (where it enters the structure) to keep out drafts.

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).

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 S1400

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. Additional communication equipment lightning arresters and surge suppressors should be tied to the same system ground. System ground consists of the tower leg grounds

S1400 Page 4-4 Section 4 - Lightning & Surge

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

33XX 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 33XX units would then have a single ground point from its Chassis

Ground Terminal/Ground Lug to this panel. In lieu of this, the 33XX 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 Use more than one ground rod.

i Place multi-ground stakes more than their length apart.

i Tie Power, Telco, Tower, Bulkhead and equipment ground together.

i 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.

i Watch out for dissimilar metals connections and coat accordingly.

Section 4 - Lightning & Surge Page 4-5 S1400

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

Southwaset 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.

S1400 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 S1400

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.

S1400 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

33XX units should only have one connection to earth ground. 33XX units (with the exception of 3305 SAPs and DPC 3335s) require the installation of a ground lug, ground bus or ground plate/panel. Since 33XX 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

33XX unit. 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.

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.

Section 5 - Wiring Techniques Page 5-3 S1400

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

Series 33XX units utilize compression-type terminals that accommodate up to #12 or #14

AWG gauge wire (see Table 3-1). 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

33XX unit.

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:

= V

- (V

22 = 24 - 2

+ V

)

where

C where 2V

+ V

= (R

+ R

= (20 Ω

) I

) 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

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 recom-

S1400 Page 5-4 Section 5 - Wiring Techniques

mended 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 that 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 S1400

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Please help us make our documentation more useful to you! If you have a complaint, a suggestion, or a correction regarding this manual, please tell us by mailing this page with your comments. It's the only way we know we're doing our job by giving you correct, complete, and useful documentation.

DOCUMENT NUMBER: S1400

TITLE: SITE CONSIDERATIONS For EQUIPMENT INSTALLATION, GROUNDING &

WIRING

ISSUE DATE: SEPT., 2001

COMMENT/COMPLAINT:

______________________________________________________________________________

Mail this page to:

Bristol Babcock Inc.

1100 Buckingham Street

Watertown, CT 06795

Attn: Technical Publications Group, Dept. 315

Bristol Babcock Inc.

an FKI company

1100 Buckingham Street

Watertown, CT 06795

Telephone: (860) 945-2200

ESDS Manual

S14006

4/15/92

CARE AND HANDLING

OF

PC BOARDS

AND

E SD-SENSITIVE

COMPONENTS

BRISTOL BABCOCK

BLANK PAGE

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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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Materials

Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent)

Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent)

Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent)

ESD-SENSITIVE COMPONENT HANDLING PROCEDURE

Introduction

Microelectronic devices such as PC boards, chips and other components are 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

10-20 Percent

Relative Humidity

65-90 Percent

Relative Humidity

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

35,000

12,000

6,000

7,000

20,000

18,000

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

(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) 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.

Static-safe Field Procedure

(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.

✰

E F

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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(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) 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.

Following the ESD-sensitive component handling procedures, remove the connectors from the boards and remove the PC boards from their holders.

Use cleaner to remove excessive dust build-up from comb connectors and other connectors. This cleaner is especially useful for removing dust.

Liberally spray all PC board contacts with Inhibitor. The inhibitor:

Provides a long lasting lubricant and leaves a protective film to guard against corrosion e.

Improves performance and reliability

Extends the life of the contacts

Is nonconductive, and is safe for use on most plastics

Clean the comb contacts using a lint-free wiping cloth.

Lightly mist all comb contacts again with Inhibitor.

NOTE: Do not use so much Inhibitor that it drips.

Repeat the above procedure for the other PC boards from the device.

(3) Cleaning PC edge connectors a.

Use cleaner to remove excessive dust build-up from connectors. This cleaner is especially useful for removing dust.

Liberally spray the outboard connector with Inhibitor.

Lightly brush the outboard connector with a soft, non-metallic, bristle brush such as a toothbrush.

ESDS Manual

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Spray the connector liberally to flush out any contaminants.

Remove any excess spray by shaking the connector or wiping with either a toothbrush, or a lint-free wiping cloth.

Completion

(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.

READER RESPONSE FORM

DOCUMENT NUMBER: CI-9600A

TITLE: BBI 9600 bps - PSTN MODEM Instruction Manual

ISSUE DATE: MAY, 2002

COMMENT/COMPLAINT:

______________________________________________________________________________

Mail this page to:

Bristol Babcock Inc.

1100 Buckingham Street

Watertown, CT 06795

Attn: Technical Publications Group, Dept. 315

Bristol Babcock Inc.

an FKI company

1100 Buckingham Street

Watertown, CT 06795

Telephone: (860) 945-2200

Instruction Manual

BBI 9600 bps - PSTN MODEM

Series 392958-XX-X

Bristol Babcock

NOTICE

Request for Additional Instructions

WARRANTY

REMEDIES

How to return material for Repair or Exchange

&VMWXSP &EFGSGO -RG 6ITEMV %YXLSVM^EXMSR *SVQ

Bristol Babcock

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

A Few Words About Bristol Babcock

Getting Additional Information

TABLE OF CONTENTS

TABLE OF CONTENTS

Section 1

INTRODUCTION

1.1 GENERAL DESCRIPTION

1.2 MODEM COMPONENT IDENTIFICATION

1.3 COMMUNICATION MNEMONICS

Section 2

PC CONFIGURABLE OPTIONS

2.1 PC CONFIGURABLE OPTIONS

2.2 14.4 Kbps OPERATION

Section 3

MODEM INSTALLATION & SETUP PROCEDURES

Section 4

MODEM DIAGNOSTICS

4.1 ESCAPE CODE SEQUENCE

4.2 LOOPBACK & LINE SIGNAL TESTS

4.3 MODEM LEDs

Section 5

MODEM SPECIFICTIONS

5.1 OPERATING SPECIFICATIONS

5.2 ENVIRONMENTAL SPECIFICATIONS

5.3 FCC & FM APPROVALS

5.4 MODEM CONNECTORS

Supplement Guide - S1400

SITE CONSIDERATIONS

For

EQUIPMENT INSTALLATION,

GROUNDING

&

WIRING

Bristol Babcock

NOTICE

Request for Additional Instructions

Supplement Guide S1400

SITE CONSIDERATIONS FOR EQUIPMENT

INSTALLATION, GROUNDING & WIRING

TABLE OF CONTENTS

Supplement Guide S1400

SITE CONSIDERATIONS FOR EQUIPMENT

INSTALLATION, GROUNDING & WIRING

TABLE OF CONTENTS

Section 1 - Overview

1.1 INTRODUCTION

1.2

MAJOR TOPICS

Section 2 - Protection

2.1 PROTECTING INSTRUMENT SYSTEMS

2.2

PROTECTING EQUIPMENT & PERSONNEL

2.3

OTHER SITE SAFETY CONSIDERATIONS

Section 3 - Grounding & Isolation

3.1 POWER & GROUND SYSTEMS

3.2 IMPORTANCE OF GOOD GROUNDS

3.3 TRANSIENTS AND INTERFERENCE

3.4 EARTH GROUND CONNECTIONS

3.5 GENERAL RECOMMENDATIONS

3.6 GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS

Section 4 - Lightning Arresters & Surge Protectors

4.1 STROKES & STRIKES

4.2 USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS

Section 5 - Wiring Techniques

5.1 OVERVIEW