Remote Automation Solutions Bristol TeleRTU RTU 3530-15B Owner's Manual

PDF

Dokument

Reklama

Instruction Manual

CI-3530-15B

May, 2006

TeleRTU Model 3530-15B

TeleRTU

™

Remote Terminal Unit

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.

These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance.

Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Bristol for further information.

EQUIPMENT APPLICATION WARNING

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

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol are clean to safe levels, as such levels are defined and/or determined by applicable federal, state and/or local law regulations or codes. Such party agrees to indemnify Bristol and save Bristol harmless from any liability or damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to "Design Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically-operated devices such as lights, switches, relays, alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read supplemental document S14006 at the back of this manual for proper care and handling of ESD-sensitive components.

Bristol Inc.

1100 Buckingham Street, Watertown, CT 06795

Telephone (860) 945-2200

WARRANTY

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 Water-town office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstalllation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can arrange to have a Bristol service person come to the site. The Service person's transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.

Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation, from use of the information herein or from the purchase or use by Buyer, its employees or other parties of goods sold under said agreement.

How to return material for Repair or Exchange

Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return

Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Repair Dept. to effectively and efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX

Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair

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

B. E-MAIL

Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com) and sending it via E-Mail to [email protected]

. A Bristol Repair Dept. representative will return E-Mail (or other requested method) with a RA number.

C. Mail

Mail the form (GBU 13.01) to

Bristol Inc.

Repair

1100 Buckingham Street

Watertown, CT 06795

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

D. Phone

Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Department representative will record a RA number on the form and complete Part I, then send the form to the Customer via fax (or other requested method) for Customer completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and return your product to you.

Bristol Inc. Repair Authorization Form

(off-line completion)

(Providing this information will permit Bristol Inc. 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_

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

Line No.____________

Please be aware of the Non warranty standard charge:

•

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

√

in “returned”

B,C, or D of part III below)

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

Address No.

Bill to :

Purchase Order:

Phone:

(office use only) Address No.

Ship to:

Fax:

(office use only)

Contact Name: ____________________________________

E-Mail:

Model No./Part No. Description

Range/Calibration S/N

Reason for return : Failure Upgrade Verify Operation Other

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: ______________

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

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

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

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

If product is deemed not repairable would you like your product: repaired returned replaced scrapped? returned replaced scrapped?

If Bristol is unable to verify the discrepancy, would you like the product: 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 Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: 860-945-2442 Fax: 860-945-3875 Form GBU 13.01 Rev. B 04/11/06

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

INSTRUMENT OR SYSTEM

• Avoid Delays and problems in getting your system on-line

• Minimize installation, start-up and maintenance costs.

• Make the most effective use of our hardware and software.

• Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol products and realize the full potential of your system.

For information or to enroll in any class, contact our training department in Watertown at

(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

A Few Words About Bristol Inc.

For over 100 years, Bristol has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey

SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water company, there are Bristol Inc. instruments, controllers, and systems running year-in and year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:

Help Files / Release Notes

Many Bristol Inc. software products incorporate help screens. In addition, the software typically includes a ‘read me’ release notes file detailing new features in the product, as well as other information which was available too late for inclusion in the manual.

Contacting Bristol Inc. Directly

Bristol Inc.'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 Inc.'s Application Support Group can provide telephone support for your technical questions.

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

For technical questions about Control Wave call (860) 945-2394 or (860) 945-2286.

For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865 or e-mail: [email protected]

For technical questions regarding ACCOL products, OpenBSI Utilities , UOI and all other software except for Control Wave and OpenEnterprise products, call (860) 945-2286.

For technical questions about Network 3000 hardware, call (860) 945-2502.

You can e-mail the Application Support Group at: [email protected]

The Application Support Group maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication

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

You can e-mail the Communication Technology Group at: [email protected]

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery information, etc.) should be directed to the nearest sales office (listed on the rear cover of this manual) or to your Bristol-authorized sales representative.

Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Inc. and its products, please visit our site on the

World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol’s Training Department offers a wide variety of courses in Bristol hardware and software at our Watertown, Connecticut headquarters, and at selected Bristol regional offices, throughout the year. Contact our Training Department at (860) 945-2343 for course information, enrollment, pricing, and scheduling.

Contents

Section 1 - INTRODUCTION

Page

1.2.2 TeleRTU CPU Board ................................................................................................ 1-3

1.2.3 Internal Mounting Brackets ....................................................................................... 1-5

1.2.4 Display/Switch Panel Assembly ................................................................................ 1-5

1.2.5 Serial Communications Ports ................................................................................... 1-5

1.2.5.1 BSAP Message Support ........................................................................................... 1-6

1.3 .................................................................................................................. 1-6

1.3.1 Solar Panel Option .................................................................................................... 1-7

1.3.3

1.3.4

1.3.5

Expansion Transmitter Interface Board (ETIB) Option .............................................. 1-7

Expansion Communications Port RS-232 Board Option ........................................... 1-8

Expansion RS-485 and/or Analog Output Board Option ........................................... 1-8

1.5 MODEL NUMBER ANALYSIS ................................................................................ 1-10

Section 1A - APPLICATION SOFTWARE

1A.1 CATEGORIES OF APPLICATION SOFTWARE ....................................................1A-1

1A.2 ACCOL TOOLS SOFTWARE .................................................................................1A-2

1A.4 OPEN BSI UTILITIES SOFTWARE .......................................................................1A-4

1A.5.2 Local Area network (LAN) .......................................................................................1A-7

1A.5.3 Wide Area Network (WAN) .....................................................................................1A-9

Section 2 - INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS ............................................................... 2-1

2.2 TeleRTU INSTALLATION SITE CONSIDERATIONS .............................................. 2-1

2.2.3 Opening The Instrument Front Cover ....................................................................... 2-1

2.2.4 CPU Board Configuration ......................................................................................... 2-2

2.2.4.1 JP3 Battery Backup Enable ...................................................................................... 2-2

2.2.4.2 JP4

2.2.4.3 JP5 Manual Reset .................................................................................................... 2-3

2.3.1

2.3.2

Overview of TeleRTU Configuration .......................................................................... 2-3

Mounting the Model 3530-15B TeleRTU Unit............................................................ 2-5

2.3.2.1 Notes .............................................................................................................. 2-5

2.3.2.4 Signal Shielding and Grounding ............................................................................... 2-6

CI-3530-15B Contents / 0-1

Contents

Page

Section 2 - INSTALLATION & OPERATION (Continued)

2.3.2.5 ................................................................................................... 2-7

2.3.3.1 RS-232 Network and Local Communications Ports................................................... 2-8

2.3.3.4 Modem or Radio On Network Port........................................................................... 2-10

2.3.4 Wiring Input/Output Signals .................................................................................... 2-11

2.3.5 Mounting the Optional Solar Panel ........................................................................ 2-15

2.3.5.1 Swivel (Directional Facing) ..................................................................................... 2-15

2.4.1 Changing the Local Address for a New TeleRTU.................................................... 2-16

2.4.2 Downloading the Application Load .......................................................................... 2-20

2.4.3 Upgrading TeleRTU Firmware................................................................................. 2-22

2.5 APPLICATION SOFTWARE REFERENCE DOCUMENTS .................................... 2-25

2.6 INSTALLATION & CONFIGURATION OF OPTIONS ............................................. 2-26

Section 3 - SERVICE

3.2 ACCESSING PARTS FOR TESTING OR REPLACEMENT .................................... 3-1

3.3 COMPONENT REMOVAL & REPLACEMENT PROCEDURES .............................. 3-2

3.3.1 Lead Acid Battery Removal/Replacement Procedure .............................................. 3-2

3.3.2 CPU Circuit Board Removal/Replacement ............................................................... 3-3

3.3.3 Removal/Replacement of the On Board Fuse F1 ..................................................... 3-5

3.3.4 Removal/Replacement of the On Board Battery ....................................................... 3-5

3.3.5 Removal/Replacement of the Display/Switch Panel Assembly ................................ 3-6

3.3.6 Removal/Replacement of Modem or Radio Options ................................................ 3-8

3.3.7 Removal/Replacement of the Expansion TIB Option ............................................... 3-8

3.3.8 Removal/Replacement of the Expansion RS-232 Intf. Bd. Option ............................ 3-8

3.3.9 Removal/Replacement of the EXP. RS-485 and/or AO Bd. Option .......................... 3-8

3.4 TROUBLESHOOTING TIPS ..................................................................................... 3-8

3.4.1 Battery & Fuse F1 Checks (Processor not running or no power) ............................ 3-8

3.4.3 LCD Display Checks ................................................................................................. 3-9

3.4.4 Field Wiring/Signal Checks ..................................................................................... 3-10

Section 4 - SPECIFICATIONS

4.2 CPU, MEMORY & PROGRAM INTERFACE ........................................................... 4-1

0-2 / Contents CI-3530-15B

Contents

Section 4 - SPECIFICATIONS (Continued )

Page

4.10 ................................................................................................. 4-4

Supplements

Special Instructions for Class I, Division 2 Hazardous Locations ......................... Appendix A

Reserved .............................................................................................................. Appendix B

Reserved ...............................................................................................................Appendix C

Reserved ...............................................................................................................Appendix D

Reserved ...............................................................................................................Appendix E

Reserved ............................................................................................................... Appendix F

Reserved .............................................................................................................. Appendix G

Radio Installation Guide for MDSModel 4710A/B, 9710A/B & 9810 Radios ..........Appendix H

FreeWave Radio Option For Instruction Manual CI-3530-15B................................ Appendix I

Expansion Comm. Port RS-232 Board for Models 3530-XXX .........................PIP-EXP232TF

Expansion RS-485 and/or Analog Output Board for 3530-XXX ......................PIP-EXP485AO

Expansion Transmitter Interface Board for Models 3530-XXX......................... PIP-EXPTIBTF

TeleFlow Site Considerations For Equipment Installation, Grounding & Wiring ......... S1400A

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

TeleFlow Material Safety Data Sheets .................................................................. Appendix Z

REFERENCED or ASSOCIATED BRISTOL DOCUMENTS

Bristol 9600 bps -PSTN Modem Instruction Manual ................................................... CI-9600

Bristol 9600 bps -PSTN Modem P/N 400000-01-6 Instruction Manual .................. CI-9600TF

Isolated RS-485 Interface Board ...................................................................... PIP-ISORS485

CI-3530-15B Contents / 0-3

Contents

Page

REFERENCED OEM MANUALS

MDS 4710A – Remote Data Transceiver (Radio)

MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver Installation and Operation Guide –

MDS Doc. 05-3305A01, Rev. B, Sept. 2000 (PDF = 3305B-710AC.pdf) for model MDS 4710A

MDS 4710B – Data Transceiver (Radio)

MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev. E,

Sept. 2000 (PDF = 3316E-x710B.pdf) for model MDS 4710B

MDS 9810 – Spread Spectrum Data Transceiver (Radio)

MDS 9810/24810 900 MHz/2.4GHz Spread Spectrum Transceivers Installation and Operation Guide –

MDS Doc. 05-3301A01, Rev. B, April 2000 (PDF = 3301B-x810.pdf) for model MDS 9810

MDS 9710A Remote Data Transceiver (Radio)

MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver – MDS Doc. 05-3305A01,

Rev. B, Sept. 2000 (Installation & Operation) (PDF = 3305B-710AC.pdf) for model MDS 9710A

MDS 9710B Data Transceiver (Radio)

MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev. E,

Sept. 2000 (PDF = 3316E-x710B.pdf) for model MDS 9710B

FreeWave Radio Spread Spectrum Data Transceiver Model FGRM-501X005

Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the latest copy of the user manual.

0-4 / Contents CI-3530-15B

Section 1 INTRODUCTION

1.1 GENERAL DESCRIPTION

TeleRTU Ô Model 3530-15B provides a high performance and economical choice for control and measurement in the following applications:

$ SCADA RTU

$ Lift Stations

$ Metering Stations

$ Well Monitoring

$ Reservoir and Tank Monitoring

$ Pump Controller

$ Custody Transfer

$ Pressure Monitor

In addition to operation in an unprotected outdoor environment, the TeleRTU has been designed to provide the following key features:

$ Very low power consumption

$ Two independent serial ports

$ Two line alphanumeric display

$ Two discrete outputs with control capability & Two discrete inputs

$ Four analog inputs

$ Two high speed counter or two pulse inputs

$ Two pulse inputs

$ UL approved for Class I, Division 2 Groups C & D Hazardous Locations

1.2 PHYSICAL DESCRIPTION

TeleRTUs are comprised of the following major components:

$ Enclosure

$ Circuit (CPU) Board

$ Internal mounting brackets

$ Display/Switch Panel Assembly

$ Serial communications ports

$ 12V, 7 Amp. Hour Battery

Additionally the TeleRTU has been designed to support the following options:

$ Solar Panel option (see Section 1.3.1)

$ Comm. option (see Section 1.3.2) (see appropriate modem manual or Appendix H for

MDS Radios or Appendix I for FreeWave Radio)

$ Expansion Transmitter Interface option (see Section 1.3.3 & PIP-EXPTIBTF)

$ Expansion Comm. Port RS-232 Board option (see Section 1.3.4 & PIP-EXP232TF)

$ Expansion RS-485 and/or Analog Output Board option (see Section 1.3.5 & PIP-

EXP485/AO)

$ Field wiring options

TeleRTU™ Introduction / 1-1

1.2.1 Enclosure

The enclosure is custom molded in Lexan 503 plastic. Its external dimensions are 10.14” high by 10.375” wide by 7.4175” deep. An installed TeleCounter Assembly adds 4.36” to the height. The enclosure consists of two pieces, the body and the Instrument Front Cover. A continuous gasket seals the unit when the Instrument Front Cover is closed. A hinge on the right side (facing the front of the unit) is formed by molded channels on the Instrument

Front Cover and body that capture a stainless steel pin. When closed, the Instrument

Front Cover is secured by three captive quarter turn fasteners along the left side. A hole is provided on the left side to allow the use of a padlock to secure the Instrument Front

Cover.

1-2 / Introduction

Figure 1-1 - TeleRTU J

TeleRTU™

Figure 1-2 - TeleRTU™ CPU Board

1.2.2 TeleRTU CPU Board

The TeleRTU CPU circuit board is mounts on the right side of the enclosure, attached to standoffs on the Mounting Bracket by three screws and two posts. The board is approximately 7.3” tall, 4.6” wide, and 0.7” deep. Both surface mount and through-hole components are located on the component side of the board, and small surface mount components are located on the solder side.

TeleRTU™ Introduction / 1-3

Pluggable screw terminal connectors line the front edge of the board, along with two LED indicators and a potentiometer for display contrast adjustment.

Figure 1-3 - Opened TeleRTU with 12V Battery Option

Radio/Modem Mounting Bracket Removed

1-4 / Introduction TeleRTU™

1.2.3 Internal Mounting Brackets

Aluminum brackets attach to the interior of the enclosure body to support the CPU circuit board, battery, and communications options. Another bracket attaches to the inside of the

Instrument Front Cover to support the LCD Display and Switch Panel.

1.2.4 Display/Switch Panel Assembly

The Display/Switch Panel Assembly mounts to the inside of the Instrument Front Cover where it is visible through a window. This Assembly consists of the LCD Display

Subassembly and the Membrane Switch Assembly. A Gasket (on the inside of the cover) provides a seal between the LCD Display Subassembly and the Instrument Front Cover.

Both the LCD Display Subassembly and the Membrane Switch Panel connect to the CPU

Board through dedicated ribbon cables. The Membrane Switch is used to activate the 2 X

16 Character LCD Display.

In normal operation, the display stays off after the unit has been configured and placed into service. The operator may activate the display at any time by pressing the front panel button. When activated, the display scrolls through a list of current values. The list defaults to an appropriate set of values.

When the button is pressed (or a properly configured cable is plugged into the Local Port), the TeleRTU J wakes up from sleep mode and enters calculation mode, where all circuits except the RS-232 transceiver are active. While cycling through the display list, the calculation interval switches to 1 second. After cycling through the list twice, the calculation interval is restored to the programmed interval and the unit returns to normal operation. Although the RS-232 transceiver is disabled while in calculation mode or sleep mode, the receiver channel dedicated to buffering Receive Data Carrier Detect (RDCD) is always active.

1.2.5 Serial Communications Ports

The TeleRTU J provides two serial ports for serial communications, designated the network port (9600 bps - Default) and the local port (19200 bps - default). Both ports operate independently at rates up to 19.2 Kbps. Prior to receiving the ACCOL load, the network port is a standard BSAP slave port and the local port is a BSAP pseudo-slave port for direct connect communication with various BBI programs running on a laptop PC. Note that on the local port with a direct connect, the TeleRTU J will answer to any local BSAP node address.

In a BSAP network, the TeleRTU J may be used as a slave node. As such it is not capable of initiating a BSAP message intended for another node. The TeleRTU J is always an immediate response node.

A circular plastic connector on the bottom of the enclosure body provides connection for a local communications device, typically an IBM compatible PC (personal computer). A custom cable connects the PC serial port to the TeleRTU J . Internally, the circular connector is wired to field wiring terminals on the CPU circuit board.

TeleRTU™ Introduction / 1-5

1.2.5.1 BSAP Message Support

The TeleRTU J supports a subset of BSAP messages. Specifically, the following messages are supported:

Poll message

TS/NRT message

Alarm Acknowledge

Alarm Initialization

Peer to Peer

RDB Functions

Normal response to poll messages including alarm reporting in short, long, and extended format. If a poll is received on the network port, and the TeleRTU has no NRT, it will respond with a request for a Node Routing Table.

Normal handling.

Supports send and poll mode.

Supports read signal by name and address, read packed logical, read by list, read selected signal data (name match only), read array sizes, read by data array number (short form

& general form), by name and address, write by list, and write by data array number (short form & general form).

Supports Audit Trial functions, security code functions,

EBSAP Group functions, archive data functions, read array elements, and read special information: read version, features,

PROM link. All subfunctions of these are supported.

Special RDB Functions Supports date and time requests, local BSAP address requests, and the system reset request.

1.2.6 12V Battery

The 12V Sealed Lead-Acid battery is rated for 7 Amp Hours and mounts to the left of the

CPU board and is secured by a Battery Mounting Bracket and the Radio/Modem Option

Mounting Bracket. The battery connects to J2 on the CPU board.

1.2.7 Field Wiring

The TeleRTU supports connection to external devices through its field wiring terminals on the CPU board.

$ Digital inputs

$ Digital outputs

$ Pulse inputs

$ Analog inputs

$ External communications

1.3 OPTIONS

The following options are covered in sections 1.3.1 through 1.3.5 respectively; Solar Panel option, Communications option, Expansion TIB option, Expansion Communications Port

RS-232 Board option and Expansion RS-485 and/or Analog Output Board option..

1-6 / Introduction TeleRTU™

1.3.1 Solar Panel Option

A 12V, 5 watt solar panel can be used with the rechargeable battery. This solar panel can be mounted to a 2" to 2.375” pipe. The solar panel mounts on a bracket that offers adjustable swivel and fixed tilt angles. The solar panel wires enter the TeleFlow through a liquid tight conduit fitting on the bottom of the enclosure. Internally the solar panel wires connect to the rechargeable battery via the CPU board connector J1’s PWR (red wire) and

GND (black wire) terminals.

1.3.2 Communications Option

Either a 9600 PSTN modem or a radio (with integral modem) can be mounted inside the

TeleFlow Plus enclosure. The modem option will typically connect to the rechargeable battery via the CPU Board connector J2’s PWR 1 and GND terminals. The radio is supplied power from the CPU Board connector J4’s AUX PWR and GND terminals. The modem’s communication lines are interfaced via a wiring harness connected to CPU Board

Connector J8 and the modem’s 9-pin D-type connector. The MDS Radio’s communication lines are interfaced between the radio’s 25-pin D-type connector and CPU Board connectors

J7, J8 and J10. The FreeWave Radio’s communication lines are interfaced between the radio’s 10-pin connector and CPU Board connector J8.

1.3.3 Expansion Transmitter Interface Board (ETIB) Option

Expansion Transmitter Interface Boards (ETIBs) allow up to two (2) Bristol Babcock,

Series 3508C Transmitters to communicate with an ACCOL loaded host TeleFlow or

TeleFlow Plus Electronic Gas Measurement Computer (EGMC) (3530-10B/20B), or a

TeleRTU, TeleRTU Plus or TeleRTU Module (3530-15B/25B/35B). The EGMC/RTU polls and stores data from each transmitter and communicates with the network.

TeleRTU™

Figure 1-3 - Expansion Transmitter Interface Board

Introduction / 1-7

The ETIB Board is interfaced to a TeleFlow/TeleRTU CPU Board via the CPU Board’s

Expansion Connector. Power from and communication with the host CPU Board is supplied through the Expansion Connector. ETIB Boards contain one jumper (JP1) for configuration purposes.

1.3.4 Expansion Communications Port RS-232 Board Option

The Expansion Communications Port RS-232 Board (EXPCOM232) provides a single RS-

232 asynchronous serial communications port to ACCOL-based 3530-XXX models. In addition to assignments of the resident (host) CPU’s “local” and “network” RS-232 ports, any model 3530-XXX unit equipped with an EXPCOM232 Board can establish RS-232 communications with an external device. An EXPCOM232 Board plugs into the Expansion

Connector of the TeleFlow or TeleRTU CPU Board and is stood-off by three 15/32” long hex standoffs and is secured via three screws. The CPU Board Expansion Connector supplies power and 3530-XXX communication to the EXPCOM232 Board.

Programmable baud rates up to 19.2Kbps are supported by the EXPCOM232 Board. TXD,

RXD, RTS, CTS, DTR, CD and GND (RS-232) signals are available at TB1 of the

EXPCOM232 Board. CD (Carrier Detect) (supplied by a DCE attempting to communicate with a model 3530-XXX), will awaken the 3530-XXX CPU Board. If no activity is required, the EXPCOM232 Board‘s serial communications controller (SCC) chip and RS-232 drivers can be put to sleep (low power mode) along with the host/parent 3530-XXX.

Figure 1-4 - Expansion Communications Port RS-232 Board

1.3.5 Expansion RS-485 and/or Analog Output Board Option

The Expansion RS-485 Comm. Port with Analog Output Board (EXP485/AO) provides a single RS-485 communications port to ACCOL-based 3530-XXX models. In addition to assignments of the resident (host) CPU’s “local” and “network” RS-232 ports, any model

1-8 / Introduction TeleRTU™

3530-XXX unit equipped with a fully populated EXP485/AO Board can establish RS-485 communications with other 3530-XXX devices and/or interface to an Analog Output circuit.

The EXP485/AO Board plugs into the Expansion Connector of the TeleFlow or TeleRTU

CPU Board, is stood-off by three 15/32” long hex standoffs and is secured via three screws.

The CPU Board Expansion Connector supplies power and 3530-XXX communication to the

EXP485/AO Board.

Programmable baud rates up to 19.2Kbps are supported by the EXP485/AO Board.

Interface signals are available at TB1 of the EXP485/AO. The SLEEP+ and SLEEP- signals

(supplied by the Master 3530-XXX) will awaken the remote 3530-XXXCPU Boards. If no activity is required, the EXP485/AO Board’s serial communications controller (SCC) chip and RS-485 drivers can be put to sleep (low power mode) along with the host/parent 3530-

XXX.

Figure 1-5 - Expansion RS-485 and/or Analog Output Board

1.4 ENVIRONMENT

The TeleRTU J operates in an unprotected outdoor environment. See Table 1-1 below for environmental specifications.

Table 1-1 - ENVIRONMENTAL SPECIFICATIONS

TOPIC

Operating Temp. Range

Operating Humidity Range

Transient Susceptibility

Vibration Effect

ESD Susceptibility

SPECIFICATION

-40 E to +60 E C (-40 E to +140 E F)

15% to 90% RH Noncondensing

Field connected circuits meet the requirements of ANSI/IEEE

C37.90-1980 (formerly IEEE 472) for surge withstand capability.

Less than " 0.1% FS for (15 to 150)Hz at 2g and (150-2K)Hz at 1g on any axis per SAMA PMC.31.1.

Meets ESD withstand capability up to 10KV (No Damage).

TeleRTU™ Introduction / 1-9

Table 1-1 - ENVIRONMENTAL SPECIFICATIONS (Continued)

TOPIC

EMI Susceptibility

Hazardous Locations

SPECIFICATION

Meets SAMA PMC 33.1-1978 from 20MHz to 500 MHz. Effect on pressure and temperature reading is less than " 0.25% FS.

Nonincendive for use in Class I, Division 2, Groups C & D hazardous locations (in certain configurations - see Section 5.1 for model numbers)(see Appendix A).

1.5 MODEL NUMBER ANALYSIS

The model number is stamped on a plate affixed to the inside of the Instrument Front

Cover. The RTU’s general features can be identified by comparing the data plate number to

Table 1-2.

Table 1-2 - MODEL NUMBER BREAKDOWN

Sample Model Number -

3530-15B-AB-CD-EFG-H ß Table Reference

3530-15B-01-02-010-1 ß Model Number

A B = PACKAGING

0 1 BASIC PARTS

0 2 SPECIAL

C D = APPLICATION PROGRAM*

0 2 ACCOL

0 9 CUSTOM PROGRAM

E F = POWER SYSTEM

(* = ANY SELECTION)

(# = 1 OR 2)

0 0 EXTERNAL WITH RS-232

0 # EXTERNAL WITH RADIO

OR MODEM

6 * 12V, 7AH LEAD ACID BATTERY

5W, 12V SOLAR PANEL SYSTEM

F = COMMUNICATION

0 RS-232

1 RADIO

2 MODEM

G = CERTIFICATION

(* = ANY SELECTION)

0 NONE

2 CLASS 1, DIV 2 (NON-INCENDIVE)

H = EXPANSION BOARDS

0 NONE

1 EXPANSION TIB

2 EXPANSION RS232

3 EXPANSION RS485

Note: Table 1-2 is only provided for product identity and not for sales ordering purposes.

Note: Field changeable items may not match the unit’s Model Number as shipped from the factory.

1-10 / Introduction TeleRTU™

Section 1A

APPLICATION SOFTWARE

3530-15B

3530-20B

3530-25B

3530-35B

3530-45B

3530-50B

3530-55B

1A.1 CATEGORIES OF APPLICATION SOFTWARE

All TeleFlow GFC (Gas Flow Computer), TeleFlow Corrector, TeleRTU and TeleRecorder units have the option of running a user generated ACCOL load. In addition, Fixed ‘ C ’ application loads are available for the TeleFlow GFC and the TeleFlow Corrector, a standard

BBI ACCOL load (or a variation) is available for the TeleFlow GFC, the TeleCorrector and

TeleRecorders. Additionally, ACCOL based TeleFlow GFC, TeleFlow Corrector, TeleRTU and TeleRecorder users have the option of using UOI or TMS to view menus, and UOI configuration tools to modify menus. Units that have a Low Power I/O Expansion Board installed have the option of utilizing the 2-Run ACCOL load.

With respect to the program load, TeleRTU units that don’t contain a Low Power I/O

Expansion Board (3530-15B/25B/35B) do not have a standard BBI ACCOL load installed; the user must create and download their own ACCOL load.

Table 1A-1 provides a list of the TeleFlow GFC, TeleFlow Corrector, TeleRTU and

TeleRecorder program loads.

Table 1A-1

TeleFlow (3530-10B/20B), TeleFlow Corrector (3530-50B),

TeleRTU (3530-15B/25B/35B) & TeleRecorder (3530-45B/55B) Program Loads

Model #

3530-10B

Program Load

Fixed ‘ C ’ Program

Standard BBI ACCOL Load

User-created ACCOL load

Fixed ‘ C ’ Program

User-created ACCOL load

Standard BBI ACCOL Load or 2-Run ACCOL Load

User-created ACCOL load

Standard BBI ACCOL Load or 2-Run ACCOL Load

User-created ACCOL load

Standard BBI ACCOL Load or 2-Run ACCOL Load

TeleRecorder ACCOL load

User-created ACCOL load

Fixed ‘ C ’ Program

TeleCorrector ACCOL load

User-created ACCOL load

TeleRecorder ACCOL load

User-created ACCOL load

Operator Interface/Configuration

TeleFlow Menu System (TMS)

TMS or UOI Menu System Interface.

- ACCOL Workbench is used to create the load.

- Open BSI Utilities is used to download and communicate.

- User created/modified menus via UOI.

See 3530-10B with user-created ACCOL load.

TeleFlow Menu System (TMS)

See 3530-10B with user-created ACCOL load.

TMS or UOI Menu System Interface.

See 3530-10B with user-created ACCOL load.

TMS or UOI Menu System Interface.

See 3530-10B with user-created ACCOL load.

TMS or UOI Menu System Interface.

UOI Menu System Interface.

See 3530-10B with user-created ACCOL load.

TeleFlow Menu System (TMS)

TMS or UOI Menu System Interface.

See 3530-10B with user-created ACCOL load.

UOI Menu System Interface.

See 3530-10B with user-created ACCOL load.

TeleFlow 3530-XXX Application Software / 1A-1

There are basically three categories of application software used with the TeleFlow GFC,

TeleFlow Corrector, TeleRTU and TeleRecorder series:

1) ACCOL Tools and related software which are used to program your TeleFlow GFC,

TeleFlow Corrector, TeleRTU (Remote Terminal Unit) or TeleRecorder for its intended application (pump control, pipeline monitoring, etc.). In general, the System Engineer or ACCOL programmer uses this type of software.

2) Supervisory Software which is used to allow operator interaction with the controller via graphical displays, trending, and printed reports. In general, this type of software is used by the Process Operator, or Technician.

3) Open BSI Utilities Software which facilitates communication between the TeleFlow

GFC, TeleFlow Corrector, TeleRTU and/or TeleRecorder and certain types of Supervisory software. In general, the System Engineer configures this software.

Each of these application software categories will be discussed briefly in this section. Additional information on these subjects is found in documents referenced within the text.

1A.2 ACCOL TOOLS SOFTWARE

ACCOL stands for A dvanced C ommunications and C ontrolO riented L anguage, and is

Bristol Babcock's proprietary language for programming Network 3000-series controllers, such as the TeleFlow GFC, TeleFlow Corrector, the TeleRTU and the TeleRecorder. The

ACCOL compilers and related software are collectively referred to as the ACCOL Tools.

Each of these tools will be discussed later in this section.

The ACCOL language includes a large set of pre-programmed software modules and control statements which can perform various mathematical, logical, process control, or communication functions.

For example, the PID3TERM module allows proportional, integral, and derivative control over a process input value; the AGA3ITER module computes natural gas volume flow rates, and the DIFFERENTIATOR module calculates the rate of change of an input. There are over 100 different modules and control statements to choose from. For more detailed information on particular modules or statements, see the ACCOL II Reference Manual

(document # D4044).

These modules and control statements are organized by the ACCOL programmer into individual tasks . Each task is specified to execute at a specific rate, and with a specific priority, relative to other tasks. One or more tasks are then combined by the ACCOL programmer into an ACCOL program. This program must be tailored for the particular use of this controller, for example, measuring and controlling natural gas flows, monitoring pressure of a pump, etc.

Depending upon which ACCOL Tools you are using, your ACCOL program is initially created either as ASCII text in an ACCOL source file (.ACC file) or as binary data in an

ACCOL object file (.ACO file). Facilities exist for quickly translating between these two formats.

1A2 / Application Software TeleFlow 3530-XXX

When editing of the ACCOL program has been completed, it must be compiled and linked to generate an ACCOL load file . The ACCOL load file contains the original programming instructions in a machine-readable format that can be executed by the TeleFlow GFC,

TeleFlow Corrector, TeleRTU and TeleRecorder. In order to get the load file into the controller, the file is downloaded into the TeleFlow GFC, TeleFlow Corrector, TeleRTU or

TeleRecorder, which then executes the programming instructions in the load file.

The Windows Ô -based ACCOL Workbench software allows you to create, modify, compile, link, and document an ACCOL source file, all using a single integrated tool. Workbench allows direct editing of an ACCOL source file, without the need for a separate ASCII text editor, and allows the user to call up a pre-defined template of any ACCOL module or statement. The user can then edit the template to conform to the requirements of the intended application. See the ACCOL Workbench User Manual (document # D4051) for more information.

(NOTE: All workbench on-line communication and downloading is facilitated via Open

BSI Utilities software, discussed later in this chapter).

Figure 1A-1 - Files Created by Windows-based ACCOL Workbench

1A.3 SUPERVISORY SOFTWARE

Supervisory software allows operator interaction with the Bristol Babcock controllers via graphical displays, trends, and reports of historical data. Generally, the supervisory

TeleFlow 3530-XXX Application Software / 1A-3

software requires a customized communication driver in order to communicate with the

Bristol devices. In some cases this is provided via Open BSI Utilities.

Among the types of supervisory software currently supported are:

1) OpenEnterprise software is Bristol Babcock's own supervisory system. OpenEnterprise utilizes a Windows Ô NT server and one or more PC client workstations. Communication with the controller network is supported via Open BSI. OpenEnterprise provides large real time and historical data bases, which may be displayed, logged, or exported.

2) UOI or TMS are DOS-based programs, which allow an operator to view text-based menus. Operators can view process data, modify TeleFlow parameters, and collect log information, see the UOI Configuration Manual (document # D5074) and the UOI

Operators Manual (document # D5075). For information on using TMS and TeleFlow menus, see Appendix F of documents CI-3530-10B, CI-3530-20B, or CI-3530-50B.

3) Iconics Inc. Genesis software is a popular PC-based supervisory package that is suitable for systems with smaller numbers of ACCOL signals. Genesis, and the Bristol driver may be purchased from Bristol Babcock (see "Local Area Network" on page 7).

4) Intellution ® FIX ® software is a powerful PC-based graphical user interface package, suitable for high-end systems. Open BSI Utilities software is required for communications.

1A.4 OPEN BSI UTILITIES SOFTWARE

The Open Bristol System Interface (Open BSI) is a layer of communications software which provides access to a network of Bristol Babcock remote process controllers. Above this communications layer are a group of applications (programs) which are collectively known as the Open BSI Utilities . These utilities interact with the communications layer to:

$ Download ACCOL load files to 33xx controllers and/or TeleFlow GFC, TeleFlow

Corrector, TeleRTU and TeleRecorder units in the network

$ Collect and display data from the 3xxx controllers and/or TeleFlow GFC, TeleFlow

Corrector, TeleRTU and TeleRecorder units

$ Monitor and control Open BSI communications

Third-party supervisory software, such as Intellution ® FIX ® , can also use Open BSI communications, and data files generated by Open BSI utilities, to access the Bristol network in order to display and report information from field instrumentation about a running process. An operator then uses this information to monitor and/or interact with the process.

The standard set of Open BSI utilities is accessed from within a Windows program group on the PC; the major utilities are described, briefly, below. Full details on each utility are included in the Open BSI Utilities Manual (D5081).

1A4 / Application Software TeleFlow 3530-XXX

Figure 1A-2 - Open BSI Interface Diagram

NetView allows the user to define communication network characteristics, define details about individual Controllers, Correctors, RTUs and Recorders, and to change these characteristics on-line. It also allows monitoring of communication statistics from the workstation end of the communication line.

Downloader transfers a linked ACCOL load file (*.ACL) to a remote 3xxx unit.

DataView collects and displays several types of process data from a 3xxx-series controller, including signal values, data array values, signal lists, archive data, and audit trail information. In addition, it allows the user to search for signals based on various criteria.

Remote Communication Statistics Tool allows additional monitoring of Open BSI communication information. Details on buffers, communication ports, and custom protocols are accessible via this tool. Some of the information collected via this tool is primarily of interest to Bristol Babcock support personnel.

SigWrite reads ASCII files containing ACCOL signal values, and writes those values to corresponding signals or signal lists in a 3xxx controller. SigWrite scans for such files at a user-definable interval.

In addition to the standard set of Open BSI Utilities, just described, there are other utilities, available from Bristol Babcock as add-ons to the standard utilities, which provide

TeleFlow 3530-XXX Application Software / 1A-5

capabilities for scheduled data collection, and file export. These utilities include the Open

BSI Scheduler, the Open BSI DDE Server, and the Open BSI Data Collector. See the Open

BSI Scheduler Manual (document # D5082) and the Open BSI Collection & Export Utilities

Manual (document # D5083) for details.

For more information on these packages, consult the manuals accompanying them, or contact Bristol Babcock's application support group for assistance.

1A.5 SYSTEM APPLICATIONS

A TeleFlow GFC, TeleFlow Corrector, TeleRTU or TeleRecorder can operate as an independent, stand-alone unit, or as a node in a local or wide area network. These applications are described in sections 1A.5.1 through 1A.5.3.

Note: The TeleFlow GFC, TeleFlow Corrector, TeleRTU or TeleRecorder cannot serve as a serial Communications Front End (CFE) or Data Concentrator (DC).

1A.5.1 Stand-Alone Unit

Figure 1A-3 shows a TeleFlow GFC, TeleFlow Corrector, TeleRTU or TeleRecorder used as a stand-alone unit in a non-network application. This arrangement is ideal for small local systems requiring a limited number of monitoring and control points. The PC for this application runs Bristol Babcock's ACCOL Workbench Software and Open BSI Utilities.

Data stored in the TeleFlow GFC, TeleFlow Corrector, TeleRTU or TeleRecorder can be observed or edited via the PC.

Once on line, the TeleFlow GFC, TeleFlow Corrector, TeleRTU or TeleRecorder executes the

ACCOL load and performs its configured tasks. Although the PC is attached to the Model

3530-XXX in Figure 1A-3, it can be disconnected and removed once the 3530-XX-X unit has been loaded and made operational.

Figure 1A-3 - Basic Stand-Alone Application

1A6 / Application Software TeleFlow 3530-XXX

1A.5.2 Local Area Network (LAN)

LANs typically support the communications requirements of computers and equipment in one or more buildings at a site or plant complex. A local area network requires a PC with extended graphics capability. This PC will typically run a supervisory software package to display process parameters, real time or historical process data, and graphic displays, etc.

An example of a local area network is shown in Figure 1A-4. This network can communicate directly through RS-485 cable connections for short distances (1000 feet max. from master to most distant slave) or over longer distances when interconnected on RS-232 ports. For much greater distances (miles) network communications require the use of phone line modems, fiber modems or broadband/carrier band modems (on coaxial cable).

Figure 1A-4 shows a network that contains a PC as the network master and a DPC 3330 at the first level of the network hierarchy. The data concentrator, which functions as a communications traffic director, communicates upward with the PC through a slave (S) port and downward with the second level through a master (M) port. This pattern repeats through each descending level. The second level contains two controllers; one communicates with three other controllers at the third level, while the other communicates with two at the third level. Each master (configured) port has the capability of supporting up to 127 slaves.

The network communication port of each TeleFlow GFC, TeleFlow Corrector, TeleRTU or

TeleRecorder requires either TMS or ACCOL configuration to change the 9600 bps default rate. The network port operates at rates up to 19.2 Kbps. Additionally, in a BSAP network, the network communication port must be defined in the ACCOL load using Workbench

Software. The network port is a standard BSAP slave port with alarm support intended for remote communication via a BSAP network.

All TeleFlow GFCs, TeleFlow Correctors, TeleRTUs and TeleRecorders act as terminal slave nodes in the BSAP network. As such, they are not capable of initiating a BSAP message intended for another node. These units are always immediate response nodes.

The PC, which runs the supervisory software, oversees the activities of the local area network. It displays process parameters, real-time data, and historical process information in both tabular and graphic formats. Journaling and system configuration utilities can also be employed as required.

The Bristol Babcock NETWORK 3000 system supports a maximum of six levels starting with the master device at level 1. Slave nodes at each descending level communicate upward through its preceding master node. Each master node stores data from its slaves until polled.

A local area network can also include printers and/or display terminals. Figure 1A-4 shows a printer connected directly to a PC port; however, a controller port could have been configured as a logger and used in the same manner.

TeleFlow 3530-XXX Application Software / 1A-7

1A8 / Application Software

Figure 1A-4 - Local Area Network

TeleFlow 3530-XXX

1A.5.3 Wide Area Network (WAN)

WANs typically support the communications requirements of computers and equipment at numerous geographical locations and may encompass many local and remote sites. A

Network 3000 system can also be constructed as a wide area network encompassing many local area networks. This application places a dedicated “Area Operator” computer at the top of the hierarchy as shown in Figure 1A-5. The central system includes the interface, monitoring and data recording equipment necessary to operate all the subservient networks. The central system employs Open BSI software to provide the on-line network interface.

Figure 1A-5 - An Example of a Wide Area Network

The Area Operator computer running Open BSI software provides the operator with realtime communications with remotes. Depending on the associated Man Machine Interface

(MMI) software package (such as OpenEnterprise, Genesis, Winterm, moXi, FIX, etc.), various features such as real-time management, historical data, alarm logging, event journaling, color graphics, CRT trending, report logging, process modeling, supervisory control, and high-level language support may be employed. The Area Operator PC of Figure

1A-5 communicates with the local area networks and discrete remote BBI RTUs, Flow

Computers and a Smart Transmitter through a DPC 3330. Depending on the configuration

TeleFlow 3530-XXX Application Software / 1A-9

of the DPC 3330, four or more asynchronous channels for use with phone line or modem applications, as well as a single, redundant channel for data highway applications may be utilized.

1A10 / Application Software TeleFlow 3530-XXX

Section 2 INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS

TeleRTUs J are furnished in a housing designed to meet the NEMA Type 4X specifications and to operate in a Class I, Division 2, Groups C & D environment with a nonincendive rating (see Appendix A).

Figure 2-1 - Top View of TeleRTU Mounted to a 2 Inch Pipe

2.2 TeleRTU INSTALLATION SITE CONSIDERATIONS

Check all clearances when choosing an installation site. Make sure that the TeleRTU will be accessible for wiring and service. To install a TeleRTU unit, see Section 2.3.

2.2.1 Temperature Limits

The TeleRTU has been designed to operate over a -40 to 140 o F (-40 to +60 o C) temperature range. Operation beyond this temperature range could cause output errors and erratic performance. Prolonged operation under extreme conditions could also result in failure of the unit.

2.2.2 Vibration Limits

Check the mounting pipe for mechanical vibration. Make sure that the TeleRTU is not exposed to a level of vibration that exceeds those given in the specifications. The TeleRTU limits are 2g for 15-150 Hz & 1g for 150-2000 Hz.

2.2.3 Opening The Instrument Front Cover

The Instrument Front Cover must be opened to access the electrical wiring terminals on the

TeleRTU J CPU Board and on the various options. The Instrument Front Cover is hinged

TeleRTU J Installation /Operation/ 2-1

on the right side and is secured on the left side by three captive quarter turn fasteners.

Additionally, aligned holes in the Instrument front Cover and body have been provided to accommodate a padlock or other securing device.

Figure 2-2 - TeleRTU J CPU Board

2.2.4 CPU Board Configuration (see Figure 2-2)

The TeleRTU J CPU Board contains three (3) sets of User Configurable Jumpers that provide configuration selection as follows:

2.2.4.1 JP3 Battery Backup Enable

When JP3 is open, the battery is disabled. When JP3 is installed, the battery maintains the contents of the RAM and the Real Time Clock while power is less than 3.6 VDC. When main

2-2 / Installation/Operation TeleRTU J

power is connected and is greater than 3.6VDC, no current will be drawn from the backup battery regardless of the state of JP3.

2.2.4.2 JP4 Security (Manufacturing Tests Only)

Jumper JP4 is used to prevent the occurrence of ACCOL downloads or Firmware FLASH loads.

2.2.4.3 JP5 Manual Reset

For normal operation, JP5 is left open. When the Shunt Jumper associated with JP5 is installed, the TeleRTU J is held in a reset condition, with all processing halted. When JP5 is removed, normal operation will resume.

2.3 TeleRTU INSTALLATION/CONFIGURATION

2.3.1 Overview of TeleRTU Configuration

An overview of the steps required to configure a Model 3530-15B TeleRTU Remote Terminal

Unit is provided below.

Step 1. Hardware Configuration

This involves unpacking the Model 3530-15B TeleRTU hardware, mounting the unit, wiring

I/O terminations, making proper ground connections and connecting a communication cable to the PC workstation. To install and configure the Model 3530-15B TeleRTU follow hardware configuration steps 1 through 4 below. For network configuration see Section

2.3.3.

1. Remove the unit from its carton. Install appropriate I/O wiring to the CPU Board’s removable terminal blocks (see Sections 2.3.4 through 2.3.4.4). Install field wiring associated with any optional I/O board to the appropriate terminal blocks (see the appropriate PIP - Product Information Package).

2. Install a ground wire between the Chassis Ground Lug and a known good Earth

Ground (see Section 2.3.2.4).

3. Connect DC Power to the TeleRTU CPU Board. 12 Vdc Battery Terminals PWR 1

(P1) and GND (G2) should be plugged into connector J2 on the CPU Board.

4. Configure/Connect appropriate communication port(s) (see Section 2.3.3). Connect the Local Port of the TeleRTU to the PC workstation, and apply power.

Step 2. Software Installation on the PC Workstation

ACCOL software must be installed on the PC workstation. This is accomplished by installing the ACCOL Workbench Kit from the Open BSI CD ROM.

If you will be including the TeleRTU in an Open BSI network, you should also install the

Open BSI Essentials Kit which includes the NetView software.

For information on minimum system requirements and more details of the installation, and registration process see Chapter 2 of the Open BSI Utilities Manual (document # D5081).

TeleRTU J Installation /Operation/ 2-3

Step 3. Create an ACCOL Load Using ACCOL Workbench

ACCOL stands for A dvanced C ommunications and C ontrolO riented L anguage, and is

Bristol Babcock's proprietary language for programming all Network 3000 controllers, including the TeleRTU. The ACCOL language includes a large set of pre-programmed software modules and control statements that can perform various mathematical, logical, process control, or communication functions. For introductory information on

ACCOL concepts, please see An Introduction to ACCOL (document# D4056). For detailed information on particular modules or statements, see the ACCOL II Reference Manual

(document # D4044).

All programming is performed using ACCOL Workbench software. ACCOL Workbench allows you to create, modify, compile, link, debug, and document an ACCOL program, all using a single integrated tool.

In ACCOL Workbench, you select pre-defined templates of various modules and control statements, and then edit them to suit your needs. Variables called signals are used to connect the modules together, and you combine the modules and statements into a logical sequence, referred to as an ACCOL task , which can execute at a specific rate. You design the task to meet the requirements of your intended application, such as measuring and controlling natural gas flow in a pipeline, controlling a pump, etc. You save the tasks and signals making up the ACCOL program as ASCII text in an ACCOL source file which has the file extension of (*.ACC). See the ACCOL Workbench User Manual (document # D4051) for more information on creating an ACCOL source file.

Note: When creating your ACCOL source file, be sure to include at least one

CALCULATOR Module, or IF-ELSE statement, as these are necessary for your

ACCOL file to be considered complete.

When you have finished editing your ACCOL source file, you compile and link it to generate a binary ACCOL Object (*.ACO) file, and an ACCOL Load (*.ACL) file. The ACCOL load file contains the original programming instructions in a machine-readable format, which can be executed by the TeleRTU. This load file will be downloaded into the TeleRTU (see

Step 6).

Step 4. Create an Open BSI Network Containing the TeleRTU unit, or ADD the

TeleRTU unit to an Existing Open BSI Network

In order for the TeleRTU unit to function as part of a Bristol Babcock network, it is necessary to include it in the Bristol Babcock BSAP network.

If no Bristol Babcock BSAP network exists:

You will need to start Open BSI’s NetView software on the PC workstation in order to define a Bristol Babcock BSAP network. A series of software wizards are used to define a

Network Host PC, a network, and the RTUs (controllers) belonging to the network.

Finally, communication lines must be specified which handle the address assigned to the

TeleRTU controller. Chapter 3 of the Open BSI Utilities Manual (document # D5081) includes ‘quick start’ examples for performing these steps. More detailed information is included in the NetView chapter (Chapter 6) of the same manual.

2-4 / Installation/Operation TeleRTU J

If a Bristol Babcock BSAP network already exists:

You will need to add the TeleRTU unit to the existing network using NetView’s RTU

Wizard. Chapter 6 of the Open BSI Utilities Manual (document # D5081) for details.

In either case, you will specify in software, a BSAP local address , which is a number from

1 to 127 that identifies the location of the TeleRTU in its particular level in the network.

Step 5. Establish Communications with the TeleRTU and set the BSAP Local

Address of the TeleRTU

The TeleRTU ships from the factory with its BSAP local address set to 127. You must change this number to whichever address you assigned in NetView software, in Step 4. The easiest way to do this is via the “Change Local Address” option in LocalView or NetView.

(See Section 2.4.1 for details).

Step 6. Download the ACCOL Load File into the TeleRTU

In order to get the ACCOL load file into the TeleRTU, the *.ACL file must be downloaded into it. The Open BSI Downloader can be accessed from within LocalView (see Section

2.4.2). After receiving the download, the TeleRTU will execute the programming instructions in the ACCOL load file, and will be ready for on-line operations.

2.3.2 Mounting the Model 3530-15B TeleRTU J Unit

Check all clearances when choosing an installation site. Make sure that the TeleRTUs J

Instrument Front Cover (hinged on right side) can be opened for wiring and service. Make certain that the LCD display and sensor switch is visible and accessible to the on-site operator. There should also be clearance for the optional Solar Panel (if required). The basic unit measures 10.375" in height by 10.14" in width by 7.4375" in depth. An optional

TeleCounter Assembly adds 4.36" to the height of the unit.

The TeleFlow is to be positioned vertically (base at bottom) and is to be mounted to a 2-inch pipe (clamped to the rear of the unit via two clamps and four bolts). The pipe is to be cemented into the ground deep enough to conform to local building codes associated with frost considerations (see Figure 2-1).

2.3.2.1 Wiring Notes

The field wiring terminals on the TeleRTU J CPU Board are accessed by opening the Instrument Front Cover. The CPU Board is mounted vertically (on edge) near the instrument’s right side such that the wiring connectors on the board's card edge are facing the front of the unit. Note: Exercise care when installing a conduit fitting or field wiring to prevent damage to the CPU Board and/or other system components.

2.3.2.2 Wire Routing

Wiring will enter the TeleRTU J through holes in the bottom of the case. Up to seven holes may be provided in the bottom of the case (in addition to the center hole that is plugged).

The purpose of each of these holes (see Figure 2-3) is provided as follows:

TeleRTU J Installation /Operation/ 2-5

$ (1) - A .437" hole accommodates the local port jack.

$ (2) - A .5" hole is plugged.

$ (3) - A .75” hole is provided to accommodate all DI/Os, Analog Inputs and Pulse Input

Wiring. This hole accommodates a .75” Liquid Tight Nonmetallic Conduit Fitting and is plugged when the unit is factory shipped.

$ (4) - A .406" hole accommodates the Battery Ventilation Assembly.

$ (5) - This hole accommodates input wiring from the optional solar panel. If the optional solar panel is not present, this hole is plugged.

$ (6) - This hole accommodates an antenna cable or Polyphaser or phone cord. If one of these items isn’t present, this hole is plugged.

$ (7) - Solderless Ground Lug

Figure 2-3 - TeleRTU (Bottom) Wiring Holes

2.3.2.3 Terminal Connections

This device uses compression-type terminals that accommodate up to #14 AWG wire. A connection is made by inserting the bared end (1/4 inch max.) into the clamp beneath the screw and securing the screw. The wire should be inserted fully to prevent short circuits.

Allow some slack in the wires when making terminal connections. The slack makes the connections more manageable and minimizes mechanical strain on the CPU Board and harnesses.

2.3.2.4 Signal Shielding and Grounding

TeleRTU units are provided with a Ground Lug that is situated on the bottom of the enclosure. Only units equipped with a modem MUST have the Ground Lug connected to a known good earth ground using wire no larger than #4 AWG in size. A cabinet ground cable situated inside the enclosure provides the interconnection between the modem’s protective surge circuitry and the unit’s Ground Lug. The use of twisted-pair, shielded and insulated

2-6 / Installation/Operation TeleRTU J

cable for I/O signal wiring will minimize signal errors caused by electromagnetic interference (EMI), radio frequency interference (RFI) and transients (see Supplement S1400A).

2.3.2.5 Power Connections

The unit is provided with four power connections, i.e., J1 (Solar Panel Power - PWR), J2

(Primary - PWR1), J3 (Secondary - PWR2) & J4 (Auxiliary Power - AUX PWR). Right angle

2-position harness connectors P1, P2, P3 and P4 are removable from the CPU board’s card edge to accommodate wiring when the unit is installed. Connectors J1, J2, J3 and J4 function as follows:

$ J1 - Solar Panel Power Jack

Solar power is interfaced via card edge connector J1, which utilizes a 2-connector right angle plug (P1) which can be unplugged from the edge of the PCB. This connector accommodates the input from a solar panel as follows:

Table 2-1 - Solar Panel Power Jack J1

J1 Pin

Name

PWR

GND

Connection

SP Red Wire

SP Black Wire

$ J2 - Primary Power Jack

Primary power utilizes a 2-connector right angle plug (P2) that can be unplugged from the edge of the PCB. This connector accommodates the input from the battery and power to the optional Modem as follows:

Table 2-2 - Primary Power Plug J2

J2 Pin

Name

Connection

PWR1 Red Wire Battery (+), Modem (TB4+)

GND Blk. Wire Battery (-), Modem (TB4-)

$ J3 - Secondary Power Jack

Secondary power utilizes a 2-connector right angle plug (P3) that can be unplugged from the card edge. This connector is used to install a temporary battery while the original battery is being replaced.

Table 2-3 - Secondary Power Jack J3

J3 Pin

Name

Connection

PWR2 Battery (+)

GND Battery (-)

$ J4 - Auxiliary Power Output Jack

The auxiliary power output connector can be used to supply power to a communications device such as a Radio or Modem Option. This jack acts as an output supply that originates at the Primary Power Source. This output is not fused, so a fuse should be

TeleRTU J Installation /Operation/ 2-7

installed elsewhere in the circuitry. This fuse should not exceed a 2.5 Amp rating.

Connection to a load is accommodated as follows:

Table 2-4 - Auxiliary Power Output Jack J4

J4 Pin

Name

Connection

AUX PWR Red Wire 12 VDC (+), Radio (J6+)

GND Blk. Wire Ground/return (-), Radio (J6-)

Modems are powered by the Auxiliary Power Output (Connector J4). Units shipped from the factory, with a modem installed, have the Auxiliary Power Output set ON in the standard load shipped with the product.

If you want the modem powered continuously, and

· you have since re-downloaded your standard load, or-

· you are running an ACCOL load other than the standard load shipped from the factory, or-

· you are installing a modem for a unit which originally shipped without a modem, then you MUST set the Auxiliary Power Output to ON. This can be accomplished, for standard loads, using the TeleFlow Menu System (TMS), by setting the Auxiliary Power

Output Default to ON via the Radio Communications Setup Menu (See Section F.8.5). If you are NOT using one of the standard loads, you must use the SYS_3530 Module in your

ACCOL Load to set the Auxiliary Power Default ON/OFF signal to ON. (This signal is Entry

1 in Parameter List 4 of the SYS_3530 Module, see ‘SYS_3530’ section in the ACCOL II

Reference Manual , document # D4044).

2.3.3 Communication Ports

2.3.3.1 RS-232 Network and Local Communications Ports

The TeleRTU provides a network (or remote) port and a customer port. Both ports provide for serial asynchronous communications compatible with RS-232 levels. These ports operate independently at baud rates up to 19.2Kbps.

2.3.3.2 Local Port

Table 2-5 - Local Port/PC Interconnect Cable Wiring

D Conn. Pin #

& Wire Color

5 (Black)

2 (White)

3 (Red)

N/A

VII

Plug Pin #

J7 Pin #

& Wire Color

1 (Black)

2 (Red)

3 (White)

4 (Green)

1 (Brown)

RTU Signal

Name

GND

LTXD

LRXD

Wake Up

GND

2-8 / Installation/Operation TeleRTU J

* T he green and brown wires are shorted together in the VII Plug/D Conn.

Wiring Harness and do not connect to the D-Type Connector. Pins 7 & 8 of the

D-Type Connector are shorted together.

Figure 2-4 - PC Connected to TeleRTU J Local Port

2.3.3.3 Network Port

The network port functions as a DTE (Data Terminal Equipment) device. The network port employs the standard RS-232 Interface signals for data transfer and handshaking.

Whenever the Carrier Detect Signal (RDCD) is active (RS-232 Mark or High Level), the

TeleRTU J exits sleep mode and stays in communication mode as long as the signal is active. The standard RS-232 signals are provided on the Network Port as follows:

Table 2-6 - Network Port Connections to the CPU Board

CPU Pin

J7-4

Name

Modem D-Conn.

# & Wire Color

WAKEUP N/A

Radio Conn. # &

Wire Color

(MDS/FreeWave)

6/N/A (Yellow)

TeleRTU Plus

Function

Wake Up

J8-1

J8-2

J8-3

J8-4

J8-5

J8-6

J8-7

J10-1

GND

RDCD

RDTR

RCTS

RRTS

RRXD

RTXD

AIN1

5 (Green)

1 (Gray)

4 (Yellow)

7 (Violet)*

7 (Orange)

2 (Blue)

3 (Brown)

N/A

7/6 (Black)

8/8 (Green)

N/A

5/10 (Brown)

4/9 (Blue)

3/7 (White)

2/5 (Red)

21 (Orange)

Ground

Data Carrier Detect Input

Data Term. Ready Output

Clear To Send Input

Request To Send Output

Receive Data Input

Transmit Data Output

Analog Input 1

* In the case of the TeleRTU’s modem harness, a violet wire connected to CPU board connector J8-4 (RCTS) is tied to the orange wire which is connected to

CPU board connector J8-5 (RRTS).

TeleRTU J Installation /Operation/ 2-9

Figure 2-5 - TeleRTU with Modem P/N 400000-01-6 Installed

2.3.3.4 Modem or Radio On Network Port

The RS-232 signals utilized by the optional radio or BBI PSTN modem are provided in

Table 2-6 above. Table 2-7 provides the power interconnects required for optional modem or radio usage. Table 2-7 also provides the 2-wire phone connections associated with the BBI

PSTN modem.

TeleRTU

Conn. & Sig. Name

J2-1 (PWR1)

J2-2 (GND)

J4-1 (AUX PWR)

J4-2 (GND)

Radio

Conn. & Name

13.8V (+Pwr.)

13.8V (-Pwr.)

Modem

Conn. & Sig. Name

TB4-1 (EXTVDC)

TB4-2 (GND)

TB1-1 (T/R)

TB1-2 (T/R)

Port

Usage

Power (+)

Pwr. Gnd. (-)

Modem Power (+)

Modem Pwr. Gnd. (-)

Phone Line

Table 2-7 - Wire Listing for Modem & Radio Power Connections

2-10 / Installation/Operation TeleRTU J

Figure 2-6 - TeleRTU with MDS Radio Installed

Illustrations of modem and radio equipped TeleRTUs J are provided in Figures 2-5 and 2-6 respectively. The option in question is secured to the Radio/Modem Mounting Bracket that accommodates its installation or removal. The option is easily installed onto or removed from the Battery Mounting Bracket.

For additional information about the MDS Radio option, refer to Appendix H.

For additional information about the FreeWave Radio option, refer to Appendix I.

For additional information on the BBI PSTN Modem, see the appropriate modem instruction manual.

2.3.4 Wiring Input/Output Signals

The TeleRTU J provides I/O termination for two (2) Discrete Inputs, two (2) Discrete

Outputs, four (4) Analog Inputs and two (2) 0-16V Pulse Input. The connections for each type are described as follows:

TeleRTU J Installation /Operation/ 2-11

2.3.4.1 Discrete Inputs (See Figure 2-7)

Two independent discrete input channels are available. Discrete Inputs are accepted from transistor, mechanical relays, TTL, CMOS and other devices that provide from 0 to 16 VDC.

These inputs are not isolated; therefore, field input devices which are not isolated must be referenced to the TeleRTU J Ground.

Figure 2-7 - Discrete Input Wired to TeleRTU J

Table 2-8 - Discrete Input Connections to J5

J5 Pin Signal

DIN0

GND

Function

Discrete Input 0

Ground

Table 2-9 - Discrete Input Connections to J6

J6 Pin Signal

1 DIN1

2 GND

Function

Discrete Input 1

Ground

2.3.4.2 Discrete Outputs (See Figure 2-8)

Two independent firmware controlled open drain discrete outputs are provided for control or signaling functions. Each output is wired to the source terminal of an N Channel MOSFET capable of switching up to 16 volts at up to 100mA. When closed, the FET shorts the output to ground with resistance of .5 ohms or less. These outputs are protected by 16V TVS diodes.

Because these outputs are not isolated, caution must be exercised to ensure that the load current does not affect operation of the TeleRTU J or related devices.

Table 2-10 - Discrete Output Connections to J5

J5 Pin

Signal Function

GND Ground

DOUT 0 Discrete Output 0

2-12 / Installation/Operation TeleRTU J

Table 2-11 - Discrete Output Connections to J6

J6 Pin

Signal

GND

Function

Ground

DOUT 1 Discrete Output 1

Figure 2-8 - Discrete Output Wired to TeleRTU J

2.3.4.3 Pulse Inputs (See Figure 2-9)

The TeleRTU J can accept pulse inputs from TTL or CMOS outputs, transistors, mechanical relays or other signaling devices. The maximum pulse frequency input is 5KHz with low impedance sources and 200Hz with high impedance sources such as Open Collector Drive

(see Figure 2-9).

TeleRTU J

J9 Pin

Figure 2-9 - Pulse Input Wired to TeleRTU

Table 2-12 - Pulse Input Connections to J9

Signal

GND

Function

Ground

PULSE 1 Pulse Input 1

J9 Pin

Signal

GND

Function

Ground

PULSE 2 Pulse Input 2

Installation /Operation/ 2-13

2.3.4.4 Analog Inputs (See Figure 2-10)

The 1 to 5 V Auxiliary Analog Inputs AI1 through AI4 can be supplied source power

(nominally +9.5V) to J10 Pin 2, J11 Pin 2, J12 Pin 2 or J13 Pin 2 (Excitation), respectively, through the CPU Board’s Transmitter Excitation Regulator which has a 20mA current limit. The resolution of the analog input is nominally 186 V.

Figure 2-10 - Analog Input Wired to TeleRTU

Table 2-13 - Analog Input Connections to J10

J10 Pin

Signal

AIN1

EXC

GND

Function

Analog Input 1

Excitation

Ground

Table 2-14 - Analog Input Connections to J11

J11 Pin

Signal

AIN2

EXC

GND

Function

Analog Input 2

Excitation

Ground

2-14 / Installation/Operation TeleRTU J

Table 2-15 - Analog Input Connections to J12

J12 Pin

Signal

AIN3

EXC

GND

Function

Analog Input 3

Excitation

Ground

Table 2-16 - Analog Input Connections to J13

J13 Pin

Signal

AIN4

EXC

GND

Function

Analog Input 4

Excitation

Ground

2.3.5 Mounting the Optional Solar Panel

The 5 Watt, 12 Volt Solar Panel System is to be mounted to a 2” to 2 & 3/8” pipe as illustrated in Figure 2-11. The Muffler (Pipe) Clamps are secured via four 1/4-20 bolts and lock washers.

2.3.5.1 Swivel (Directional Facing)

Solar panels used in the northern hemisphere should face due south (not magnetic south) while those used in the southern hemisphere should face due north (not magnetic north).

2.3.5.2 Tilt Angle

The Solar Panel Mounting Bracket provided by Bristol Babcock is designed to mount the

Solar panel at a fixed 45° ( ± 2 ° ) tilt angle.

TeleRTU

Figure 2-11 - Solar Panel & Mounting Hardware 2 & 3/8" Pipe Mount

J Installation /Operation/ 2-15

2.4 OPERATIONAL DETAILS

2.4.1 Changing the Local Address for a New TeleRTU

When the TeleRTU ships from the factory, it has a default local address of 127, which must be changed to match the actual address defined for the TeleRTU within NetView software.

If your particular TeleRTU has already had its local address set to some other number, and you need to change it, substitute that address when establishing a connection through

LocalView.

1. Start Open BSI ( OpenBSI Tools ). Select LocalView (see Figure 2-12).

Fig 2-12 - Starting OpenBSI and Entering Local Mode

From the Local View Startup Menu, highlight Local under the Mode: field. Enter the desired name in the Name: field, e.g., TeleRTU, and then click on the Create… button

(see Figure 2-13). The Communication Setup: Step 1 Menu (Figure 2-14) should appear.

Figure 2- 13 - Local View Startup Menu (Untitled)

2-16 / Installation/Operation TeleRTU J

From the Communication Setup: Step 1 Menu (Figure 2-14), change the Baud Rate to

19200 and then click on Next . The RTU Setup Menu (Figure 2-15) should appear.

Figure 2-14 - Communications Setup: Step 1 Menu

On the RTU Setup: Step 2 of 3 Menu (Figure 2-15) click on No, thank you for the question, Would you like auto local address detection?

Figure 2-15 - RTU Setup: Step 2 of 3 Menu

5. Enter 127 for the question, What is the local address of the RTU that you want to connect to?

Set the RTU type to 3530 . Under Control Strategy File Name: , enter the

TeleRTU J Installation /Operation/ 2-17

name of your ACCOL Load file (not necessary if you are only changing the address). Use the Browse Button if necessary. Click on Finish . The menu of Figure 2-16 should appear.

Figure 2-16 - Titled Local View (Figure 1) Menu

Click on plus sign ( + ). When the menu of Figure 2-17 appears, Click on RTU .

Figure 2-17 - Titled Local View (Figure 2) Menu

Make sure that the Primary Status: indicates 0x0000 . If not, check the Comm. link configuration and make sure that the CPU’s green status LED is blinking.

8. From the menu of Figure 2-17, right click on the RTU icon. On the menu of Figure 2-18, select RTU and then Change Local Address . The Change Local Address Menu

(Figure 2-19) should appear.

2-18 / Installation/Operation TeleRTU J

Figure 2-18 - Invoking the Change Local Address Menu

9. On the Change Local Address Menu (Figure 2-19) set the desired local address via the

Select New Local Address: selector, e.g., 32 . Click on the Change button. Status should read, Status: Local address changed (see Figure 2-20).

Figure 2-19 - Change Local Address Menu - No Status:

10.

Click on the Exit button. Processing Command will appear (communications will momentarily be lost as the command is processed) followed by the titled Local View

Menu showing the new Local Address: , e.g. 32 .

The local address is now changed. In subsequent LocalView sessions, you must use the new local address when establishing communications.

TeleRTU J Installation /Operation/ 2-19

Figure 2-20 - Change Local Address Menu - Status: Local address changed

2.4.2 Downloading the Application Load

Continue from step 10 of Section 2.4.1 or follow steps 1 through 7 of Section 2.4.1 (to start

LocalView if necessary) and then follow steps 1 through 3 below to download the ACCOL

Load. You must have specified the proper ACCOL load file name in LocalView (see Figure 2-

15).

From the menu of Figure 2-21, right click on the RTU icon. On the menu of Figure 2-22, select RTU and then Download . The ACCOL Download Menu (Figure 2-23) should appear.

Figure 2-21 - Titled Local View Menu with New Local Address

2-20 / Installation/Operation TeleRTU J

Figure 2-22 Invoking the ACCOL Downloader Menu

Figure 2-23 - ACCOL Download Menu

Enter the Password: and then press the Begin button. Download will begin (see Figure

2-24).

TeleRTU J Installation /Operation/ 2-21

Figure 2-24 - ACCOL Download - Downloading Menu

3. Once application download has completed, the titled Local View Menu appears. Exit

Local View.

The unit is now ready for field installation.

2.4.3 Upgrading TeleRTU Firmware

If Bristol Babcock releases a new version of firmware for the TeleRTU, for example, with new features you want to use, a firmware upgrade must be performed in order to use the new version.

Start Open BSI ( OpenBSI Tools ). Select LocalView (see Figure 2-12).

From the Local View Startup Menu, highlight Flash under the Mode: field. Enter the desired name in the Name: field, e.g., TeleRTU, and then click on the Creat… button

(see Figure 2-25). The Communications Setup Menu (Figure 2-13) should appear.

From the Communications Setup: Step 1 Menu (Figure 2-14), change the Baud Rate to 19200 and then click on Next. The Flash RTU Setup: Step 2 of 3 Menu (Figure 2-

26) should appear.

On the Flash RTU Setup: Step 2 of 3 Menu (Figure 2-26), set the type of RTU to 3530 .

Enter the desired number (in this example 127 ) for the question, What is the local address of the RTU that you want to connect to? Click on the Next> button; The

Flash Data Setup: Step 3 of 3 Menu (Figure 2-27) should appear.

2-22 / Installation/Operation TeleRTU J

Figure 2-25 - Local View Startup Menu (Untitled with Flash Mode Selected)

Figure 2-26 - Flash RTU Setup: Step 2 of 3 Menu

(Untitled with Flash Mode Selected)

5. Use the Browse… button to find the Location of the Flash Master File: and then enter the name of the firmware file to be Flashed under Please, enter the name of the binary file to flash: if you know it or click on the Open… button to search for it.

Once the appropriate information has been entered into the Flash Data Setup: Step 3 of 3 Menu, click on the Finish button. The menu of Figure 2-28 should appear with download ensuing and the % of download posted as a progressing bar.

TeleRTU J Installation /Operation/ 2-23

Figure 2-27 - Flash Data Setup: Step 3 of 3 Menu

Once the download has completed the menu’s download bar will show 100% and the message Sending End of File Message… will be posted instead of Downloading (see

Figure 2-29). The following Local View error message will be posted: Error on sending

End of File Record. Flash load failure.

Click on the OK button. Figure 2-30 will appear.

The Local View - TeleRTUflash.LVG

Menu’s download bar will show 100 % to indicate the download has completed (see Figure 2-30).

Click on the X in the upper right corner to exit Local View.

Figure 2-28 - Local View - TeleRTUflash.LVG Menu (Download in Process)

2-24 / Installation/Operation TeleRTU J

Figure 2-29 - Local View - TeleRTUflash.LVG Menu (Sending End of File Message)

Figure 2-30 - Local View - TeleRTUflash.LVG Menu (100% - (Download Completed)

2.5 APPLICATION SOFTWARE REFERENCE DOCUMENTS

Categories of application software are discussed in Chapter 1A.

The following BBI software manuals provide the information necessary to configure and operate your system:

TeleRTU J Installation /Operation/ 2-25

D4044 ACCOL II Reference Manual - for information on ACCOL modules and statements

D4051 ACCOL Workbench User Manual - for information on creating an ACCOL source file

D5081 Open BSI Utilities Manual - for information on setting up communications between the PC and the BBI controller network

D5074 UOI Configuration Manual - for information on creating and modifying menus and logs

D5075 UOI Operator Manual - for information on how to view menus and logs

D5120 - Open BSI Harvester - for information on collecting data at regular intervals (for file export).

2.6 INSTALLATION & CONFIGURATION OF OPTIONS

For information on removal/replacement and service of the various options see Table 2-17.

Table 2-17 - Options Installation/Configuration Reference

Option

Expansion Transmitter Intf. Bd.

Section

PIP-EXPTIBTF -

Expansion Comm. Port RS-232 Bd. PIP-EXP232TF -

Expansion RS-485 and/or AO Bd.

PIP-EXP485/AO -

MDS Radio

FreeWave Radio

Appendix H

Appendix I

9600 bps PSTN Modem &

Modem Grounding Kit

9600 bps PSTN Modem (Current)

Isolated RS-485 Intf. Bd.

Notes see CI-9600 see PIP-3530MGKI (for units without a Ground Lug)

See CI-9600TF

See PIP-ISORS485 -

(Ext. Mounted on DIN Rail)

2-26 / Installation/Operation TeleRTU J

Section 3 SERVICE

3.1 INTRODUCTION

This section provides Removal and Replacement Procedures, and Troubleshooting/Fault

Isolation information for the TeleRTU J model 3530-15B.

Setup utilizes a PC running the ACCOL Workbench program or the Universal Operator

Interface (UOI) program. External test equipment such as a digital multimeter and oscilloscope will also be required to aid in isolating and troubleshooting certain problems.

Figure 3-1 - Local Port Communications Setup

3.2 ACCESSING PARTS FOR TESTING OR REPLACEMENT

In order to test or replace any major system component, it will be necessary to open the Instrument Front Cover. These operations should only be performed by technically qualified persons having advanced mechanical and electronic skills, and possessing the proper service equipment. Any damage to the TeleRTU J resulting from improper handling or incorrect service procedures will not be covered under the product warranty agreement. If these procedures cannot be performed properly, the unit should be returned to Bristol

Babcock for factory evaluation and repairs.

TeleRTU™ Service / 3-1

Warning

Opening the door of a powered TeleRTU that is operating in a hazardous area exposes the electrical circuitry to the atmosphere and could result in accidental fire or explosion.

Caution

PC board components can be damaged by electrostatic discharges (ESD) during disassembly, reassembly, and test procedures. Use grounded wrist straps and surface pads when working near or handling the Main Circuit Board. See attached instruction supplement

S14006 for proper grounding and handling techniques.

3.3 COMPONENT REMOVAL & REPLACEMENT PROCEDURES

The following major items are covered in this section or in an appendix:

$ Lead Acid Battery

$ CPU Board

$ On Board Fuse

$ On Board Battery

$ LCD Display/Switch Panel Assembly

$ Optional Radio (Appendix H for MDS or Appendix I for FreeWave))

$ Optional PSTN Modem (CI-9600 for 396039-02-2 or CI-9600TF for 400000-01-6)

3.3.1 Lead Acid Battery Removal/Replacement Procedure (see Figure 3-2)

1. Push the Activate Display Button on the TeleFlow's Instrument Front Cover.

2. Open the Instrument Front Cover.

3. Remove the connector P2 (Battery & Power) from J2 on the TeleRTU CPU Board. Note:

In the event the TeleRTU requires continuous operation, a small auxiliary 9V battery can be plugged into the Secondary Connector (J3).

4. If a Radio or Modem Option is installed it will have to be removed (see Section 3.3.6 for

Radio or Modem removal).

5. Remove the Radio/Modem Mounting Bracket if it was not removed in step 4. The

Radio/Modem Mounting Bracket is secured to the Battery Mounting Bracket by four screws (see Figure 3-2 - Holes Labeled B).

6. Disconnect the Red and Black wires from the battery and remove the battery.

7. To replace the battery:

Follow steps 3 through 6 in reverse order, replacing rather than removing the item in question. Close and secure the Instrument Front Cover.

3-2 / Service TeleRTU™

Figure 3-2 - TeleRTU with 12V Lead Acid Battery System

Radio/Modem Mounting Bracket Removed

3.3.2 CPU Circuit Board Removal/Replacement (see Figure 3-3)

Note:

The CPU Board is not to be removed under any circumstances unless the TeleRTU has been moved to an ESD safe area (see ESDS Manual S14006). The CPU Board should typically be removed to replace the on board Lithium Battery or Fuse F1 or to install/replace a Display/Switch Panel Assembly.

1. Open the Instrument Front Cover.

2. Disconnect power by removing harness connector plug P2 from CPU Board edge connector J2.

3. Remove all other harness from the CPU Board’s front edge connectors, i.e., P1 & P3 through P13.

4. Remove the battery (see Section 3.3.1).

5. While holding the Main Mounting Bracket, carefully remove the four (4) screws that secure the Battery Mounting Bracket and the Main Mounting Bracket to the rear wall.

Remove the battery Mounting Bracket and temporally secure the Main Mounting

Bracket to the rear wall with at least two of the screws removed in this step.

6. Remove the two screws that secure the CPU Board Shield to the CPU Board. Remove the two screws that secure the CPU Board Shield to the Main Mounting Bracket and remove the CPU Board Shield.

TeleRTU™ Service / 3-3

7. Remove the two (2) #4-40 x 5/8” Hex Standoff Posts that secure the CPU Board to the

Main Mounting Bracket. This will require the use of a 3/16” Wrench or Hex Driver.

8. Remove the remaining three (3) #4-40 x ¼” screws that secure the CPU Board to the

Main Mounting Bracket.

9. Carefully slide the CPU Board toward the front of the unit and remove harness connections from J14 (Front Panel Switch), J17 (Display Module) and J16 (Wakeup

Switch).

Note:

Exercise extreme care to avoid damage to surface mounted components.

3-4 / Service

Figure 3-3 - TeleFlow CPU Board - Front Edge View

TeleRTU™

10. Remove the Ground wire by loosening the CPU Board’s CPU Ground Screw.

11. Carefully remove the CPU Board from the TeleRTU Enclosure. Be careful not to damage the surface mounted components. Avoid contact with the Mounting Brackets,

Wiring Harnesses, etc. Note: This operation should only be performed in an ESD safe work area

12. To Replace the CPU Board:

Follow steps 2 through 11 in reverse order, replacing rather than removing the item in question.

13. Close and secure the Instrument Front Cover.

3.3.3 Removal/Replacement of the On Board Fuse F1

F1 is a 350mA (Schurter 3402.0043) fast acting fuse that is located on the CPU Board.

1. Open the Instrument Front Cover.

2. Disconnect power from the CPU Board by unplugging P1, P2 and P3 as required.

3. Remove F1 with a pair of Needle-nose Pliers or a pair of tweezers.

4. Carefully press the replacement fuse (using Tweezers or Needle-nose Pliers) into its receptacle.

5. Reconnect power to the CPU Board.

6. Close and secure the Instrument Front Cover.

3.3.4 Removal/Replacement of the On Board Battery

Note:

The On Board Battery should be changed in an ESD safe area.

The On Board Lithium Thionyl Chloride Battery provides 1AH of 3.6VDC backup power for

RAM, Real Time Clock and analog switches which are powered from the V+5B Supply.

1. Open the Instrument Front Cover.

2. To save the contents of RAM when removing the Lithium Battery leave power at J2/P2.

3. Follow step 3 through 6 of Section 3.3.2 leaving the battery connected to J2/P2.

4. Cut the holddown Tie Wrap that secures the Lithium Battery and carefully pull the three-pronged battery off the CPU Board.

5. Carefully install the replacement Lithium Battery onto the CPU Board making sure to install a new holddown Tie Wrap.

6. Disconnect the Main Battery Power Supply from J8.

TeleRTU™ Service / 3-5

7. Follow steps 3 through 6 of Section 3.3.2 in reverse order, replacing rather than removing the item in question.

8. Close and secure the Instrument Front Cover.

3.3.5 Removal/Replacement of the Display/Switch Panel Assembly

1. Open the Instrument Front Cover.

2. Disconnect power by removing harness plug P2 from CPU Board edge connector J2.

3. Remove all other harness from the CPU Board’s front edge connectors.

4. Follow steps 4 through 8 of Section 3.3.2.

5. Carefully slide the CPU Board toward the front of the unit and remove harness connections from J17 (Display Module) and J16 (Wakeup) at the rear of the board.

Note: The following connectors do not require removal from the CPU Board, J15

(TeleCounter) and J14 (Front Panel).

Note:

Exercise extreme care to avoid damage to surface mounted components.

6. Carefully remove the cable assemblies associated with the LCD Display/Switch Panel

Assembly’s switch. This will require opening the Flat Cable Mount clamp on the inside of the Instrument front Cover (door).

7. Remove the multi-color ribbon cable connector from the rear of the LCD Display Board on the inside of the Instrument Front Cover.

8. Hold (or secure with tape) the LCD Display/Switch Panel Bezel on the outside of the

Instrument Front Cover and remove the eight (8) ¼” nuts that secure the LCD

Display/Switch Panel Assembly to the Bezel and cover. Remove the LCD

Display/Switch Panel Assembly with attached Panel Switch Cable. Replace at least one of the locking nuts to temporarily secure the Bezel to the door.

9. The LCD Display/Switch Panel Assembly can be disassembled if it is desired to replace either the Membrane Switch Panel or LCD Display Sub-assembly. The LCD Display

Sub-assembly is secured to the Membrane Switch Panel via four screws (with washers).

10.

To replace the LCD Display/Switch Panel assembly:

While securing the Bezel on the outside of the Instrument Front Cover (door), install the LCD Display/Switch Panel Assembly on the inside of the door via eight (8) self locking ¼” nuts.

Plug the multi-color ribbon cable connector into its mating Display Module connector on the top of the LCD Display Board (on the inside of the door). Note: The yellow wire should be on the right side when installed.

Additionally the cable’s connector must be centered on its mating board connector. Position the multi-colored Display Module

Cable so that it is aligned with the Flat Cable Mount (clamp) on the inside of the door.

3-6 / Service TeleRTU™

Figure 3-4 - Inside View of TeleRTU J

- Carefully position and route the Switch Panel Cable so that it runs above the Display

Module Cable and along with the Display Module cable is aligned with the Flat

Cable Mount on the inside of the door.

- Close the Flat Cable Mount on the inside of the door.

- Install the Display Module cable connector into connector J17 on the CPU Board.

Note: The cable’s yellow conductor should be adjacent to J17 pin 1.

TeleRTU™ Service / 3-7

- Install the Wakeup cable connector to J16. Note: This cable can be plugged in either way, i.e., it is not polarity sensitive.

11. To Replace the CPU Board:

Follow steps 2 through 5 in reverse order, replacing rather than removing the item in question.

12. Close and secure the Instrument Front Cover.

3.3.6

Removal/Replacement of Modem or Radio Options

Removal/Replacement of the 9600 bps Modem Option is covered in BBI Customer

Instruction Manuals as follows: Modem P/N 396039-02-2 (see CI-9600)

Modem P/N 400000-01-6 (see CI-9600TF)

Removal/Replacement of the MDS Radio Option is covered in Appendix H. Removal/-

Replacement of the FreeWave Radio Option is covered in Appendix I.

3.3.7

Removal/Replacement of the Expansion TIB Option

Removal/Replacement of the Expansion Transmitter Interface Board Option is covered in

BBI Product Information Package PIP-EXPTIBTF.

3.3.8

Removal/Replacement of the Expansion RS-232 Intf. Bd. Option

Removal/Replacement of the Expansion RS-232 Interface Board Option is covered in BBI

Product Information Package PIP-EXP232TF.

3.3.9

Removal/Replacement of the Exp. RS-485 and/or AO Bd. Option

Removal/Replacement of the Expansion RS-485 and/or Analog Output Board Option is covered in BBI Product Information Package PIP-EXP485/AO.

3.4 TROUBLESHOOTING TIPS

3.4.1 Battery & Fuse F1 Checks (Processor not running or no power

)

Check the output of the PWR1, PWR2 , AUX PWR (and Solar Power - PWR if present) circuits at the card edge connector.

The CPU Board requires a Supply Voltage of 10.8 to 16 (VDC) for normal operation. PWR1

(J2-1 & J2-2) and PWR2 (J3-1 & J3-2) share a single 350mA Fuse. Auxiliary Power (J4-1

& J4-2) and Solar Power (J1-1 & J1-2) are not fused.

$ If Power is below 12 VDC at PWR1 or PWR2 (or SPWR) check the battery (and solar panel if present).

$ If no voltage is present at the PWR1 or PWR2 terminals check Fuse F1 on the CPU

Board.

3-8 / Service TeleRTU™

PIN #

J4-1

J4-2

J3-1

J3-2

J2-1

J2-2

J1-1

J1-2

Table 3-3 - Power Plugs J1, J2, J3 & J4

PIN

NAME

CONNECTION PURPOSE

AUX PWR +5 to +16 (VDC) Auxiliary Power Output

GND Ground/Return Auxiliary Power Output

PWR 2

GND

PWR 1

GND

PWR

GND

Battery +

Battery -

Battery +_

Battery -

Solar Panel +

Solar Panel -

Secondary Power Input

Primary Power Input

Solar Power Input

3.4.2 LED Checks:

The CPU Board contains two LEDs (D27 is green & D26 is red). These LEDs are situated between the LCD Contrast Adjuster (R18) and the AUX POWER connector (J4) on the card edge. These LEDs function as follows:

D27 - Green: This LED indicates the TeleRTU J operating mode.

Flash 5/Sec. = Communications or Calculation Mode.

Short Flash 1/Sec. = Sleep Mode.

D26 - Red:When flashing, this LED indicates a FLASH PROM download is in progress.

$ If these LEDs are inoperable, check the voltage at PWR1. Check Fuse F1.

3.4.3 LCD Display Checks

On initial system startup, the LCD will indicate that a warm or cold start is in progress.

In the case of a cold start (for new units received from the factory), the LCD Display will prompt the user as follows:

AWAITING ACCOL DOWNLOAD

The user must download an ACCOL load to continue.

The display will then scroll through its list twice. Verify that the LCD displays the following messages:

1. Date & Time

2. Local I.D. & Group I.D.

3. Network Comm. Active (Note: This message will appear intermittently when the

Carrier Detect RS-232 signal on the Network Serial Port is active.)

TeleFlow Version X.X

$ If the LCD Display is difficult to read, check its Contrast Adjustment on the CPU

Board. This Adjusting Pot. (R18) is situated between the Secondary Power Connector

(J3) and the Green LED (D27).

TeleRTU™ Service / 3-9

$ If the LCD Display is inoperative or erratic check the cable connection at the CPU

Board and the Display Board.

$ If after checking the cable connections, the LCD Display is still inoperative replace the

LCD Display Module and cables with known good hardware. If the LCD Display is still inoperative, the most likely cause is a defective CPU Board.

3.4.4 Field Wiring/Signal Checks

Check Input or Output Field Wires at the Card Edge Connector and at the field device.

Check wiring for continuity, shorts & opens. Check the I/O signals at the Card Edge

Connectors (see Table 3-4).

Table 3-4 - Standard Field I/O Wiring List

PIN# Signal

J5-1 DIN 0

J5-2 GND

J5-3 DOUT 0

J6-1 DIN 1

Function

Discrete Input 0

Ground

Discrete Output 0

Discrete Input 1

Notes

See Section 2.4.1

See Section 2.4.1 & 2.4.2

See Section 2.4.2

See Section 2.4.1

J6-2 GND

J6-3 DOUT 1

J7-1 GND

J7-2 LTXD

Ground

Discrete Output 1

Ground

Transmit Data Output

See Section 2.4.1 & 2.4.2

See Section 2.4.2

See Section 2.4.5.2

J7-3 LRXD Receive Data Input

J7-4 WAKEUP Wakeup Signal

J8-1 GND

J8-2 RDCD

Ground

See Section 2.4.5.2

See Section 2.4.5.2 & 2.4.5.3

See Section 2.4.5.3

Data Carrier Detect Input See Section 2.4.5.3

J8-3 RDTR

J8-4 RCTS

J8-5 RRTS

J8-6 RRXD

J8-7 RTXD

Data Term Ready Output See Section 2.4.5.3

Clear To Send Input See Section 2.4.5.3

Request To Send Output

Receive Data Input

Transmit Data Output

See Section 2.4.5.3

J9-1 GND

J9-2 PULSE 1

J9-3 GND-

J9-4 PULSE 2

J10-1 AIN1

J10-2 EXC

J10-3 GND

J11-1 AIN2

J11-2 EXC

J11-3 GND

J12-1 AIN3

J12-2 EXC

J12-3 GND

J13-1 AIN4

J13-2 EXC

J13-3 GND

Ground

Pulse Input 1

Ground

Pulse Input 2

Analog Input 1

Excitation

Ground

Analog Input 2

Excitation

Ground

Analog Input 3

Excitation

Ground

Analog Input 4

Excitation

Ground

See Section 2.4.3

See Section 2.4.4

3-10 / Service TeleRTU™

Section 4 SPECIFICATIONS

4.1 ENVIRONMENTAL CONDITIONS

Temperature:

Relative Humidity:

Vibration Effect:

Transient Susceptibility:

ESD Susceptibility:

EMI Susceptibility:

EMI Radiation:

Operating Range: -40 to +60°C (-40 to 140°F)

5% to 90% (noncondensing)

< ±0.1% FS for 10-500 Hz at 1 g on any axis per

SAMA PMC 33.1-1978.

Meets the requirements of ANSI/IEEE C37.90.1-

1989 (formerly IEEE 472) for surge withstand capability.

Meets the requirements of IEC 801-2 for ESD withstand capability up to 10KV (No Damage).

Meets the requirements of IEC 801-3 level 3

(10V/M) from 500kHz to 500MHz. Effect on pressure and temperature readings is < "0.25% FS.

Computational, archival, communications, and control functions are not impaired.

Meets FCC Rules Part J, Subpart 15, Class A for radiated emissions.

Hazardous Locations: Nonincendive for use in Class I, Division 2, Groups

C & D hazardous locations (see Appendix A).

4.2 CPU, MEMORY & PROGRAM INTERFACE

Processor:

Memory:

RAM Battery Backup:

80C188EB, 16-bit microprocessor operating at

8MHz.

- 256K bytes Flash PROM.

- 512K bytes of Battery Backed Static RAM.

Lithium battery (3.6 V) with 5000 hours cumulative backup.

4.3 COMMUNICATIONS

Communication Ports:

Signal:

Two asynchronous ports standard

RS-232 Levels

TeleRTU™ Specifications / 4-1

Local Port:

Network Port:

Communication Rates:

Protocol:

For configuration, data collection, etc.

For Radio or Modem or RS-485 network

Selectable from 1200 bps to 19.2 Kbps

Bristol Standard Asynchronous Protocol (BSAP) compatible with International Standard, ISO 1745,

2111 & 2629. Interface compatible for use with

Radio Modems or Phone-line Modems (Private Line or Switched Network types).

4.4 DISCRETE INPUTS

No. of Inputs:

Input Voltage Range:

Input Threshold:

2 DIs

0 to 16 Vdc

High = 3.6V (Min)

Low = 0.98V (Max)

Pullup Voltage:

Input Leakage:

4.8V (Nominal) at terminal (with input open)

15uA (Max)

Sink Current (to pull input low): 100uA (Min)

Allowable Source Leakage: 7uA (Max)

4.5 DISCRETE OUTPUTS

No. of Outputs:

Switched Voltage Range:

Load:

Off-state Leakage:

2 DOs

0 to 16 Vdc (Transorb Clamped)

100 mA Max.

8uA (Typical), 100uA (Max)

On-state Resistance (to ground): 0.29 Ohms (Typical), 0.50 Ohms (Max)

4.6 PULSE INPUTS

No of Inputs:

Voltage Range:

Minimum Frequency:

2 PIs

0 to 16V

4-2 / Specifications TeleRTU™

Maximum Frequency:

(0-5V Square Wave)

Minimum Pulse Width:

Input Threshold (Low)

Input Threshold (High)

Accumulator Capacity:

4.7 ANALOG INPUTS

No of Inputs:

Input Range

Resolution

Accuracy (Calibrated):

4.8 POWER

Operating Voltage

Ripple Voltage Tolerance

(# 60Hz)

Operating Current

Noise Voltage Tolerance

Connector Type

(J2 & J3)

Wire Size

Fuse Type & Rating

9kHz (Max.) (Low Impedance Source)

200 Hz (Open Collector or Dry Contact)

100uS

1.95V (Typical), 1.50V (Minimum)

2.95V (Typical), 3.50V (Maximum)

65535 pulses

4 AIs

1 to 5 Vdc

±15 bits, 186 m V nominally

±0.03%

Min. = +10.8Vdc (Max. = +16Vdc)

Max. = 100mVpp

Typ. = 81mA Communication Mode

(Max. = 100mA)

Typ. = 63mA Calculation Mode

(Max. = 75mA)

Typ. = 0.9mA Sleep Mode

(Max. = 1.6mA)

Max. = 100mVpp

Pluggable Weidmuller

Max. = 14AWG

350mA (Schurter 3402.0043)

TeleRTU™ Specifications / 4-3

4.9 AUXILIARY POWER

Output Voltage

Max. Load Current

On Resistance

Leakage:

4.10 BACKUP BATTERY

Type

Capacity

Voltage

Discharge Current (Backup)

Equals [Vin - (Iload) x Ron)] where:

Vin = Power at the PWR1 Connector

Iload = Load Current

Ron = On Resistance

1.8A Continuous (2.5A Momentary)

Typ. = 0.37 Ohms (Max. = 0.5 Ohms)

Typ. = 22 m A (Max. = 100 m A)

Tadiran TL-5134 (Lithium Thionyl Chloride)

1 Ah

3.6Vdc (Nominal)

Max. = 60uA

4-4 / Specifications TeleRTU™

TeleRTU

Special Instructions for Class I, Division 2 Hazardous Locations

1. A version of the TeleRTU is available which is listed by Underwriters Laboratories (UL) as nonincendive for use in Class I, Division 2, Group C and D hazardous and non-hazardous locations.

Read this document carefully before installing a nonincendive TeleRTU. Refer to the TeleRTU User's

Manual for general information. In the event of a conflict between the TeleRTU User's Manual and this document, always follow the instructions in this document.

2. The TeleRTU includes both nonincendive and unrated field circuits. Unless a circuit is specifically identified in this document as nonincendive, the circuit is unrated. Unrated circuits must be wired using Division 2 wiring methods as specified in article 501-4(b) of the National Electrical Code (NEC),

NFPA 70 for installations within the United States, or as specified in Section 18-152 of the Canadian

Electrical Code for installation in Canada.

3. The local communications port terminates in a circular connector on the bottom of the TeleRTU enclosure. The wiring on this connector is unrated. No connections may be made to this port unless the user ensures that the area is known to be nonhazardous. Connections to this port are temporary, and must be short in duration to ensure that flammable concentrations do not accumulate while it is in use.

4. An optional power system (solar panel and battery pack) is approved for use with the nonincendive

TeleRTU as described in the Model Specification. The connection to this solar panel is approved as a nonincendive circuit, so that Division 2 wiring methods is not required. The nominal panel voltage must match the nominal battery voltage (12V).

WARNING: EXPLOSION HAZARD - Do Not disconnect the Solar PWR, PWR1, PWR2 or AUXPWR terminals unless the area is known to be nonhazardous.

WARNING: EXPLOSION HAZARD Substitution of components may impair suitability for use in

Class I, Division 2 environments.

WARNING: EXPLOSION HAZARD - The area must be known to be nonhazardous before servicing/replacing the unit and before installing or removing I/O wiring.

WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless power has been disconnected and the area is known to be nonhazardous.

9. The signals available for customer wiring are available in Table A1.

10. The UL listed nonincendive TeleRTU includes radio communications (MDS Model 2310, 4310, 4710,

9710 or 9810) or (FreeWave Spread Spectrum Radio) which is used in conjunction with a 5W, 12V

Solar Panel System. Installation of a BBI modem in the TeleRTU housing is approved. Connection to the radio or modem is approved as a nonincendive circuit, so that Division 2 wiring methods are not required.

Table A1 - CPU Board Customer Wiring Signal Names

Signal Name

SOLAR

PWR

PWR 1 & 2

AUX

POWER

DIN 0 & 1

DOUT 0 & 1

Signal Description

Solar Panel inputs; 5W, 12V. Refer to ¶ 4 of this document.

Power supply inputs; maximum 16VDC. Refer to ¶ 5 of this document.

Power output to Radio or Modem; maximum 16VDC. Refer to ¶ 5 of this document.

Discrete inputs; maximum 16VDC. Use Division 2 wiring methods.

Discrete outputs; maximum 16VDC, 100mA. Use Division 2 wiring methods.

11/21/2000 Appendix A, Document CI3530-15B Page 1 of 2

TeleRTU

Special Instructions for Class I, Division 2 Hazardous Locations

LRXD, LTXD,

& WAKEUP

RDCD, RDTR,

RCTS, RRTS,

RRXD, RTXD

Pulse 1 & 2

AI EXC &

AIN1 - 4

Local communications port; factory wired, maximum input or output is ±16VDC.

Refer to ¶ 3 of this document. Note: When WAKEUP is used with an optional radio refer to ¶ 10 of this document.

Remote communications port (for radio or modem). Refer to 3530-15B Model

Spec. and ¶ 10 of this document.

Pulse inputs; maximum 16VDC. Use Division 2 wiring methods.

Analog inputs and excitations; maximum 16VDC. Use Division 2 wiring methods.

Note: When AIN1//2/3 or 4 is used with an optional radio refer to ¶ 10 of this document.

11/21/2000 Appendix A, Document CI3530-15B Page 2 of 2

Instruction Manual

CI-3530-15B

May, 2006

TeleRTU Model 3530-15B

RADIO INSTALLATION GUIDE for MDS

Model 4710A/B, 9710A/B & 9810 Radios

Appendix H

www.EmersonProcess.com/Bristol

BLANK PAGE

Appendix H

RADIO INSTALLATION GUIDE

For MDS Model 4710A/B, 9710A/B & 9810 Radios

SECTION TITLE

Section 1 - INTRODUCTION

1.2 LEDs ................................................................................................................................... 1

Section 2 - INSTALLATION & SERVICE

2.2 WIRING LISTS.................................................................................................................... 4

Section 3- SPECIFICATIONS

3.1

GENERAL SPECIFICATIONS............................................................................................ 5

3.1.1

3.1.2

3.1.3

Model 4710 General Specs ................................................................................................ 5

Model 9710 General Specs. ............................................................................................... 5

Model 9810 General Specs. ............................................................................................... 5

3.2 TRANSMITTER

3.2.1

Model 4710 Transmitter Specs. .......................................................................................... 6

3.2.2

Model 9710 Transmitter Specs. .......................................................................................... 6

3.2.3

3.3

3.3.1

3.3.2

3.3.3

3.4

3.5

Model 9810 Transmitter Specs. .......................................................................................... 7

RECEIVER SPECIFICATIONS........................................................................................... 7

Model 4710 Receiver Specs. .............................................................................................. 7

Model 9710 Receiver Specs. .............................................................................................. 7

Model 9810 Receiver Specs. .............................................................................................. 8

ENVIRONMENTAL SPECIFICATIONS .............................................................................. 8

MDS Models 4710, 9710 & 9810 ........................................................................................ 8

REFERENCED OEM MANUALS

MDS 4710A – Remote Data Transceiver (Radio)

MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver Installation and Operation Guide –

MDS Doc. 05-3305A01, Rev. B, Sept. 2000 (PDF = 3305B-710AC.pdf) for model MDS 4710A

MDS 4710B – Data Transceiver (Radio)

MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev. E,

Sept. 2000 (PDF = 3316E-x710B.pdf) for model MDS 4710B

MDS 9810 – Spread Spectrum Data Transceiver (Radio)

MDS 9810/24810 900 MHz/2.4GHz Spread Spectrum Transceivers Installation and Operation Guide –

MDS Doc. 05-3301A01, Rev. B, April 2000 (PDF = 3301B-x810.pdf) for model MDS 9810

MDS 9710A Remote Data Transceiver (Radio)

MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver – MDS Doc. 05-3305A01,

Rev. B, Sept. 2000 (Installation & Operation) (PDF = 3305B-710AC.pdf) for model MDS 9710A

CI-3530-15B Appendix H Page 0-1 Table Of Contents

Appendix H

RADIO INSTALLATION GUIDE

For MDS Model 4710A/B, 9710A/B & 9810 Radios

REFERENCED OEM MANUALS (Continued)

MDS 9710B Data Transceiver (Radio)

MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev. E,

Sept. 2000 (PDF = 3316E-x710B.pdf) for model MDS 9710B

CI-3530-15B Appendix H Page 0-2 Table Of Contents

Appendix H

RADIO INSTALLATION GUIDE for MDS Model 4710A/B, 9710A/B & 9810 Radios

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION

Each TeleRTU may be ordered with an MDS Radio Installed, i.e., "Radio Equipped," or as a "Radio

Ready" unit. Radio Ready units contain all hardware required to field install a Bristol provided MDS Radio except the radio, antenna and external antenna cable. Radio Ready units can be ordered with or without an optional Polyphaser (Lightning/Impulse Suppresser) (see Figures 1, 2 & 3).

Each Bristol supplied MDS Data Transceiver (Radio) Option mounts inside the TeleRTU Enclosure and is secured to the Radio/Modem Mounting Bracket via four screws. The Radio/Modem Mounting Bracket is secured to the Battery Mounting Bracket via four screws.

TeleRTUs equipped with the MDS Radio Option utilize the following additional hardware:

MDS Radio Transceiver (Choice of five models):

Model 4710A/B (9600 Baud/330-512 MHz)

Model 9710A/B (9600 Baud/800-960 MHz)

Model 9810 (900MHz - Spread Spectrum)

Radio/Modem Mounting Bracket (secured to rear of MDS radio via four (4) screws - ‘C’)

Radio/Modem Mounting Bracket (secured to Battery Mounting Bracket via four (4) screws ‘B’)

(see Figure 1)

Radio/TeleRTU Interface Cable (392733-01-3) - 25-Pin D-Type Plug P1 connects to Radio and 7 open-ended wires connect to CPU Bd. Connectors P8 & P10 (see Table 2)

2-Wire Radio Power Cable (395445-02-7) - Connects to the Radio Power Connector and P4 of

TeleRTU) (see Table 1).

Internal Coaxial Antenna Cable or Polyphaser and Polyphaser Cable

12V Battery Mounting Bracket (for Radio Option) with 12V Battery

1.2 LEDs

MDS Radio model 9810 is supplied with six (6) LEDs that function as follows:

TR - Terminal Ready RTS (Request To Send) has been received by the internal modem from the TeleRTU.

MR - Modem Ready CTS (Clear To Send) time has elapsed and the radio is ready to transmit data from the TeleRTU.

CD - Carrier Detect The radio senses a RF signal from the master station.

TD - Transmit Data Reflects the current state of the Transmit Data (TXD) line from the

TeleRTU. LED ON = 0 Bit, LED OFF = 1 Bit.

IN - Radio Inhibited/Disabled A ground on Pin 12 of the INTERFACE connector disables all radio functions. This LED is dimly lit when Pin 12 of the INTERFACE connector is grounded and power is applied to the radio.

RD - Receive Data Reflects the current state of the Receive Data line from the transceiver's internal modem. LED ON = 0 Bit, LED OFF = 1 Bit.

MDS Radios models 4710 & 9710 are supplied with four (4) LEDs that function as follows:

CI-3530-15B Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide Page 1

Rapid Flash - (Five times/second) = Fault Indication.

Off = No power applied to radio or radio is in sleep mode.

Continuous = Radio is receiving a data signal from a continuously keyed radio.

TXD - Transmit Data A mark signal is being received at the Data Interface.

RXD - Receive Data A mark signal is being sent out from the Data Interface.

Page 2

Figure 1 - TeleRTU with Radio Option

Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide CI-3530-15B

Section 2 - INSTALLATION & SERVICE

2.1 RADIO REMOVAL/REPLACEMENT & INSTALLATION

DANGER

The MDS Radio models 4710A/B, 9710A/B & 9810 provided by Bristol Inc. are approved for use in Class I, Groups C & D, Division 2, Hazardous Locations. The installer must be familiar with hazardous location installation guidelines before installation or maintenance is undertaken. Do not begin radio installation or service to the TeleRTU unless the area is known to be non-hazardous. Refer to the appropriate appendix of the

MDS Installation, Operation & Field Maintenance Manual applicable to the radio in question, for approved conditions under which the MDS radio can be installed in hazardous locations.

AVOID OPERATING EQUIPMENT DURING AN ELECTRICAL STORM. THE IMPULSE SUP-

PRESSOR MAY SAVE EQUIPMENT FROM DANGER, BUT SHOULD NOT BE CONSIDERED

AS BEING SAFE FOR PERSONNEL.

Figure 2 - Bottom View of MDS Radio Option

2.1.1 Radio Removal/Replacement Procedure

To remove the Radio Transceiver follow steps 1 through 6 below. To replace the Radio Transceiver follow steps 2 through 6 below in reverse order, installing rather than removing the item in question and then perform step 6.

1. Loosen the three (3) captive quarter-turn fasteners (and remove the lock if present) which secure the

Instrument Front Cover. Open the Instrument Front Cover.

Disconnect power from the radio by removing the two-wire power plug from the bottom of the radio.

CI-3530-15B Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide Page 3

Disconnect the Radio/TeleFlow Interface Cable (392733-01-3) from the bottom of the Radio.

Unscrew the Antenna Lead from the bottom of the radio.

Unscrew the four (4) screws that secure the radio (via the Radio/Modem Mounting Bracket) to the

Battery Mounting Bracket (Location B Figure 1).

6. Remove the MDS radio

7. Close and secure the Door.

2.2 WIRING LISTS

Radio Power Cable (395445-02-7)

RADIO

Pwr. Conn.

COLOR

TeleFlow CPU

SIGNAL

+ RED 1

- BLK 2

16.5 V Max

13.8 V Typ.

GND

Table 1 - Radio Power Cable (395445-02-7) Wire List

Radio/TeleFlow Interface Cable (392733-01-3)

CPU Pin # CPU Board

Sig. Name

Radio D-Conn. #

& Wire Color

Radio D-Conn.

Signal Name

J8-1 GND 7 GND

J8-2 RDCD 8 (Green) DCD (Out)

J8-4

J8-5

J8-6

J8-7

RCTS

RRTS

RRXD

RTXD

5 (Brown)

4 (Blue)

3 (White)

2 (Red)

CTS (Out)

RTS (In)

RXD (Out)

TXD (In)

J10-1 AIN1 21

Function

Ground

Data Carrier Detect Input

Clear To Send Input

Request To Send Output

Receive Data Input

Transmit Data Output

Receive Signal Strength

Indicator/Analog Input

Table 2 - TeleFlow/Radio Interface Cable (392733-01-3) Wire List

Page 4

Figure 3 - Radio/TeleFlow Interface Cable 392733-01-3

Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide CI-3530-15B

Note:

The red RSSI conductor (Receive Strength Signal Indicator) can be used to monitor the receiver's signal strength when a volt meter is placed across

RRSI (Orange) and Ground (CPU Connector J8-1).

Section 3 - SPECIFICATIONS

3.1 GENERAL SPECIFICATIONS

3.1.1 Model 4710 General Specs.

Frequency Band:

Frequency Increments:

Frequency Stability:

380-512 MHz

6.25 kHz or 5 kHz (factory configurable)

1.5 PPM, -30

C to +60

(-22

F to +140

Primary Power:

Voltage: 13.8 Vdc nominal

(10.5 - 16 Vdc Operating Range)

1.8 A nominal, 2.5 A maximum TX Supply Current:

RX Supply Current:

Reverse Polarity Protection:

3.1.2 Model 9710 General Specs.

Frequency Band:

Frequency Increments:

Frequency Stability:

150 mA (< 16 mA in Sleep Mode)

Diode across primary input

800-960 MHz

6.25 kHz or 5 kHz (factory configurable)

1.5 PPM, -30

C to +60

(-22

F to +140

Primary Power:

Voltage:

TX Supply Current:

RX Supply Current:

Reverse Polarity Protection:

3.1.3 Model 9810 General Specs.

Frequency Band:

Frequency Hopping Range:

13.8 Vdc nominal

(10.5- 16 Vdc Operating Range)

1.8 A nominal, 2.5 A maximum

150 mA (< 16 mA in Sleep Mode)

Diode across primary input

902-928 MHz part 15 Spread Spectrum Band

8 selectable zones each containing 128 frequencies for a total of 1019 frequencies

Frequency Stability:

0.00015% (1.5 PPM), -30

C to +60

(-22

F to +140

F) For all Models

CI-3530-15B Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide Page 5

Primary Power:

Voltage:

TX Supply Current:

RX Supply Current:

Standby Current (Sleep Mode):

Reverse Polarity Protection:

3.2 TRANSMITTER SPECIFICATIONS

3.2.1 Model 4710 Transmitter Specs.

Frequency Range:

13.8 Vdc nominal

(10.5- 26.0 Vdc Operating Range)

<400 mA

<125 mA

<30 mA

Diode across primary input

Power Output:

Duty Cycle:

Output Impedance:

Frequency Stability:

RF Channel Bandwidth:

Spurious & Harmonic Emissions:

Response Time:

Time-out Timer:

3.2.2 Model 9710 Transmitter Specs.

Frequency Range:

Power Output:

Duty Cycle:

Output Impedance:

Frequency Stability:

RF Channel Bandwidth:

380-512 MHz, Programmable in 6.25 kHz or 5 kHz increments (factory configurable) to any channel pair in radio operating sub-band.

5 Watts/+37 dBm (maximum) at the Antenna

Connector

Continuous

50 Ohms

1.5 PPM, -30

C to +60

(-22

F to +140

12.5 kHz

-65 dBc

5 ms

Internal; programmable from 1-255 seconds in

1-second increments

800-960 MHz, Programmable in 6.25 kHz or 5 kHz increments (factory configurable) to any channel pair in radio operating sub-band.

5 Watts/+37 dBm (maximum) at the Antenna

Connector

Continuous

50 Ohms

1.5 PPM, -30

C to +60

(-22

F to +140

12.5 kHz

Page 6 Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide CI-3530-15B

Spurious & Harmonic Emissions:

Response Time:

Time-out Timer:

3.2.3 Model 9810 Transmitter Specs.

Frequency Band:

Power Output:

Duty Cycle:

Output Impedance:

Frequency Stability:

Spurious Emissions:

Harmonic Emissions:

Transmitter Keying:

3.3 RECEIVER SPECIFICATIONS

3.3.1 Model 4710 Receiver Specs.

Frequency Range:

Frequency Stability:

Intermodulation:

IF Selectivity:

Desensitization:

Spurious and Image Rejection:

RF Channel Bandwidth:

Sensitivity:

Squelch Opening Time:

CI-3530-15B

-65 dBc

5 ms

Internal; programmable from 1-255 seconds in

1-second increments

902-928 MHz Part 15 Spread Spectrum Band

.1 to 1 Watt (20-30 dBm ± 1dB)

Continuous

50 Ohms

0.00015% (1.5 PPM), -30

C to +60

(-22

F to +140

F) For all Models

-60 dBc

-80 dBc

Data activated

380-512 MHz Programmable in 6.25 kHz increments to any channel pair in radio operating sub-band.

1.5 PPM, -30

C to +60

(-22

F to +140

75 dB minimum (EIA)

65 dB minimum at adjacent Channel

65 dB minimum on 12.5 kHz Channel

85 dB minimum

12.5 kHz

12 dB SINAD at -110 dBm

2 ms

Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide Page 7

3.3.2 Model 9710 Receiver Specs.

Frequency Range: 800-960 MHz Programmable in 6.25 kHz increments to any channel pair in radio operating sub-band.

Frequency Stability:

Conversion Superheterodyne

1.5 PPM, -30

C to +60

(-22

F to +140

Intermodulation: 75 dB minimum (EIA)

IF Selectivity:

Desensitization:

Spurious and Image Rejection:

RF Channel Bandwidth:

Sensitivity:

Squelch Opening Time:

65 dB minimum at adjacent Channel

65 dB minimum on 12.5 kHz Channel

85 dB minimum

12.5 kHz

12 dB SINAD at -110 dBm

2 ms

3.3.3 Model 9810 Receiver Specs.

Frequency Band: 902-928 MHz Part 15 Spread Spectrum Band.

Frequency Stability:

Intermodulation:

Desensitization:

Spurious and Image Rejection:

Bit Error Rate:

3.4 ENVIRONMENTAL SPECIFICATIONS

3.4.1 MDS Models 4710, 9710 & 9810

Temperature Range:

Humidity:

±0.00015% (1.5 PPM), -30

C to +60

(-22

F to +140

F) For all Models

75 dB minimum (EIA)

65 dB minimum (EIA) on 12.5 kHz Channels

70 dB minimum

Less than 10

-6

at -110 dBm

Full Performance -30

C to +60

(-22

F to +140

95% at +40

C (104

Page 8 Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide CI-3530-15B

Appendix I

FreeWave RADIO OPTION

For Instruction Manuals

CI-3530-15B

Issue: 04/2002

FREE

W AVE

Model Number: DGRO9RFS

RS232

Serial Number: XXX-XXXX

FCC ID: KNY-205-108213

Canada: 2329 102 336A

FreeWavw Technologies, Inc.

Boulder, CO 80301. This device complies with

Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) this device must accept any interference received, including interferences that may cause undesired operation.

Bristol Babcock

Appendix I

FreeWave RADIO OPTION

SECTION TITLE

1.1

1.2

2.1

2.1.1

2.1.2

2.2

2.3

PAGE #

Section 1 - INTRODUCTION

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

LEDs................................................................................................................................... 1

Section 2 - INSTALLATION & SERVICE

RADIO REMOVAL/REPLACEMENT & INSTALLATION ............................................ 4

Radio Removal/Replacement Procedure .......................................................................... 4

Radio Installation Procedure ............................................................................................ 5

WIRING LISTS.................................................................................................................. 9

ADDITIONAL FreeWave INFORMATION ..................................................................... 9

Section 3- SPECIFICATIONS

3.1

3.2

3.3

3.4

GENERAL SPECIFICATIONS ...................................................................................... 10

TRANSMITTER SPECIFICATIONS ............................................................................. 10

RECEIVER SPECIFICATIONS ..................................................................................... 10

ENVIRONMENTAL SPECIFICATIONS....................................................................... 11

Reference Document

FreeWave Spread Spectrum Wireless Data Transceiver User Manual

FreeWave Technologies, Inc.

1880 South Flatiron Court

Boulder, CO 80301

CI-3530-15B Appendix I Page 0-1 Table Of Contents

Section 1 INTRODUCTION

1.1 GENERAL INTRODUCTION

The TeleRTU J may be ordered with a FreeWave Radio installed, i.e., "Radio Equipped," or the FreeWave Radio may be “ field installed." TeleFlow units contain all hardware required to field install a BBI provided FreeWave Radio except the radio (with Radio/Mounting

Plate), signal cable, four (4) 4-40 x 1/4 pan head screws, the antenna and the external antenna cable. The FreeWave Radio option can be used with or without an optional

Polyphaser (Lightning/Impulse Suppresser) (see Figures 1 through 6).

The BBI supplied FreeWave Radio is mounted to the Radio Mounting Plate via four (4) 4-

40 UNC-2A x 1/4 Pan Head Screws. The Radio Mounting Plate (with Radio Option) mounts inside the TeleFlow J Enclosure and is secured to the Radio/Modem Mounting Plate

(Battery Cover) via (4) 4-40 x 1/4 pan head screws. The Radio/Modem Mounting Plate is secured to the Battery Mounting Bracket by four screws.

TeleRTUs equipped with the FreeWave Radio Option utilize the following additional hardware:

1. FreeWave Wireless Data Transceiver

2. Radio Mounting Plate (secured to rear of the radio via four (4) screws) - Secures Radio to Radio/Modem Mounting Plate (Battery Cover) via four (4) screws (see Figures 2 & 3).

Mounting holes for Radio to Radio Mounting Plate are indicated by four (4) ‘ Cs.

’

Mounting holes for Radio Mounting Plate to Radio/Modem Mounting Plate (Battery

Cover) are indicated by four (4) ‘ Bs.

’

3. Radio/TeleRTU Interface Cable (396369-01-4) - 10-Pin Jack Connector (MTA-100) connects to the radio while the and eight (8) open-ended wires (see Table 4) are connected to CPU Board Connectors J4/P4 (Power) and J8/P8 (Network).

Internal Coaxial Antenna Cable or Polyphaser and Polyphaser Cable.

Four (4) 4-40 x 1/4 pan head screws - secures radio to Radio Mounting Plate.

Four (4) No. 4 washers (Internal Tooth Lock) - used with item 5 above.

Four (4) 4-40 x 1/4 pan head screws - secures Radio Mounting Plate to Radio/Modem

Mounting Plate (Battery Cover) (Location B - Figures 2 & 3)

1.2 LEDs

The FreeWave Radio is supplied with three (3) visible LEDs that provide important information on the operation of the transceiver. Compare the status of radio’s LEDs with

Tables 1 and 2 to aid you in the troubleshooting process.

CD - Carrier Detect LED

TX Transmit LED

CTS - Clear To Send LED

CI-3530-15B Appendix I Page 1 FreeWave Radio Option

Table 1 - LED Status in Point to Point Communications

Condition

Power Disconnected

Connected, no repeater, sending sparse data

Master calling slave through repeater

Master connected to

Repeater, not to slave

Repeater connected to slave

Mode 6, disconnected

Setup Mode

Master Slave Repeater

CD TX CTS CD TX CTS CD TX CTS

SR SR SR SR O BR SR O BR

SG IF IF SG IF IF

SR SD

FO SD

SG SG

Table 1 & Table 2 Legend:

Blinking Red

Flashing Orange

Intermittent Flash Red

Off

Solid Red, Dim

Solid Green

Solid Red, Bright

Table 2 - LED Status in Multipoint Communications

Condition

Power Disconnected

Repeater & slave connected to master, no data

Repeater & slave connected to master, master sending data to slave

Repeater & slave connected to master, slave sending data to master

Master Slave Repeater

CD TX CTS CD TX CTS CD TX CTS

SR SD O SR O BR SR O BR

SG-

SR*

* = CTS will be Solid Red with a solid link, as the link weakens the CTS LED on the repeater and slave radios will begin to flash.

FreeWave Radio Option Page 2 CI-3530-15B Appendix I

Figure 1 - FreeWave Radio

Figure 2 - Radio Mounting Plate installation Diagram

CI-3530-15B Appendix I Page 3 FreeWave Radio Option

Section 2 INSTALLATION & SERVICE

2.1 RADIO REMOVAL/REPLACEMENT & INSTALLATION

DANGER

The FreeWave Wireless Data Transceiver (Radio) model DGRO-115 provided by Bristol Babcock is approved for use in Class I, Division 2,

Groups A, B, C & D or non-hazardous locations. The installer must be familiar with hazardous location installation guidelines before installation or maintenance is undertaken. Do not begin radio installation or service to the TeleFlow J unless the area is known to be non-hazardous.

AVOID OPERATING EQUIPMENT DURING AN ELECTRICAL STORM. THE

IMPULSE SUPPRESSOR MAY SAVE EQUIPMENT FROM DANGER, BUT

SHOULD NOT BE CONSIDERED AS BEING SAFE FOR PERSONNEL.

2.1.1 Radio Removal/Replacement Procedure

To remove the Radio follow steps 1 through 6 below. To replace the Radio perform step 6 of section 2.1.2 and then follow steps 2 through 6 below in reverse order, installing rather than removing the item in question and then perform step 7.

1. Loosen the three (3) quarter-turn fasteners (and remove the lock if present) which secure the Instrument Front Cover. Open the Instrument Front Cover.

2. Disconnect power from the radio by removing the two-wire auxiliary power jack from the TeleRTU CPU Board connector P4.

3. Disconnect the Radio/TeleFlow Interface Cable (396369-01-4) from the lower edge of the radio.

4. Unscrew the Antenna Lead from the bottom of the radio.

5. Unscrew the four (4) screws that secure the radio (via the Radio Mounting Plate) to the

Radio/Modem Mounting Plate (Battery Cover) (Location B Figure 2).

6. Remove the FreeWave radio (installed on the Radio Mounting Plate).

7. Close and secure the Door.

FreeWave Radio Option Page 4 CI-3530-15B Appendix I

Figure 3 - FreeWave Radio Option Installed in TeleFlow

(without Polyphaser Option)

2.1.2 Radio Installation Procedure

To install the FreeWave Radio Option into a TeleFlow (for the first time) follow steps 1 through 9 below.

Loosen the three (3) quarter-turn fasteners (and remove the lock if present) which secure the Instrument Front Cover. Open the Instrument Front Cover.

Loosen the four screws that secure the Radio/Modem Mounting Plate (Battery Cover) to the Battery Mounting Bracket (Location A - Figure 3) and remove the Radio/Modem

Mounting Plate.

CI-3530-15B Appendix I Page 5 FreeWave Radio Option

3. Install the FreeWave radio (mounted on the Radio Mounting Plate) onto the

Radio/Modem Mounting Plate using four (4) 4-40 x 1/4 pan head screws (see Figures 4

& 2).

Figure 4 - FreeWave Radio Mounted on Radio Mounting Plate

4. Install the Radio/Modem Mounting Plate (with radio installed) onto the TeleRTU’s

Batery Mounting Bracket. Secure the screws loosened in step 2 (Location A - Figure 3).

5. Install the Radio Cable (396306-01-2) between the radio’s RF connector and the bottom of the TeleRTU enclosure (see Figure 3 & 5) (also see Section 2.3.1 of CI-3530-15B).

Note: If an optional Polyphaser is used install Radio Cable (396306-02-0) between the radio’s RF connector and the top of the Polyphaser (within the enclosure) (see Figure 6). TeleRTU enclosures that support a Polyphaser have is

.625” diameter mounting hole while those that support a radio (without Polyphaser

Option) have a .580” diameter mounting hole.

FreeWave Radio Option Page 6 CI-3530-15B Appendix I

Figure 5 - Top View - TeleFlow with FreeFlow Radio (without Polyphaser)

Figure 6 - Partial View - TeleFlow with Polyphaser Installed

CI-3530-15B Appendix I Page 7 FreeWave Radio Option

6. Follow the “Tuning Transceiver Performance” section of the FreeWave Technologies,

Inc. FreeWave Spread Spectrum Wireless Data Transceiver User Manual to configure the radio.

Note: The setup program is invoked by connecting the radio to any PC equipped with a terminal program (such as Hyperterminal), setting the parameters for that terminal to those of Table 3, and putting the radio into setup mode.

Connection to the PC requires a special RS-232 cable with a 9-pin Female D-

Type connector on the PC side and a 10-pin Female MTA-100 Connector assembly on the radio side. A cable can be constructed as illustrated in Figure

7. The terminal program must be running before invoking the setup program.

The setup program is invoked by shorting MTA-100 Connector pins 4 (GND) and 2 (MENU) together.

Table 3 - Setup Menu Terminal Settings

PARAMETER

Baud Rate

Data Rate

Parity

Stop Bits

Parity Check

Carrier Detect

SETTING

19,200

None

None/Off

Figure 7 - Cable Diagram for Radio to PC Interface

7. Install the TeleRTU Radio Interface Cable (396369-01-4) between Radio Connector J1 and TeleRTU CPU Board Connectors J4 & J8 (see Table 4). Make sure that the cable connector’s red wire aligns with FreeWave Radio connector Pin 1 (see Figures 1 & 3).

8. Connect the Antenna Cable between the remote Antenna and the Radio Cable (or

Polyphaser on the bottom of the TeleRTU.

9. Close and secure the Door.

FreeWave Radio Option Page 8 CI-3530-15B Appendix I

2.2 WIRING LISTS

Radio/TeleRTU Interface Cable (396369-01-4)

CPU Pin #

J4-1

J4-2

J8-1

J8-2

J8-4

J8-5

J8-6

J8-7

CPU Board

Sig. Name

AUX PWR

GND

RDCD

RCTS

RRTS

RRXD

RTXD

Wire Pin. #

& Color

01 (Red)

04 (Black)

06 (Black)

08 (Green)

10 (Brown)

09 (Blue)

05 (Red)

07 (White)

Note: Pins 2 & 3 are not used.

Radio

Signal Name

B+

GND

DCD (Out)

CTS (Out)

RTS (In)

TXD (Out)

RXD (In)

Function

DC Power (+)

DC Power (-) Ground

Ground

Data Carrier Detect Output

Clear To Send Output

Request To Send Input

Transmit Data Output

Receive Data Input

Table 4 - Radio/TeleRTU Interface Cable (396369-01-4) Wire List

2.3 ADDITIONAL FreeWave INFORMATION

The FreeWave Spread Spectrum Wireless Data Transceiver User Manual contains indepth details on modem parameters, operation, installation, tuning transceiver performance, and more. Copies of the FreeWave Spread Spectrum Wireless Data

Transceiver User Manual can be obtained from FreeWave Technologies, Inc.

(electronically) by contacting their Technical Support Group.

FreeWave Tech. Support can be reached at 303-444-3862 or 303-786-9948.

Online information about Spread Spectrum Modem (Model DRG09RFS) can be obtained at www.freewave.com or www.freewave.com/ProductInformation/products.htm.

CI-3530-15B Appendix I Page 9 FreeWave Radio Option

Section 3 SPECIFICATIONS

3.1 GENERAL SPECIFICATIONS

Frequency:

Power Requirements:

Transmit Current:

Receive Cuurrent:

Idle Current:

Operating Modes:

3.3 RECEIVER SPECIFICATIONS

Sensitivity:

902 - 928 MHz

650 mA at 12V for 1W

600 mA at 8.5V for 400mW

100 mA at 12V

65 mA at 12V

Point-to-Point

Point-to-Multipoint

Peer-to-Peer

Store and Forward Repeater

Data Transmission:

Error Detection:

Data Encryption:

Link Throughput:

Interface:

32 Bit CRC, resend on error

Substitution, dynamic key

115 Kbaud

RS-232, 1200 Baud to 115.2 Kbaud,

Async., full duplex

3.2 TRANSMITTER SPECIFICATIONS

Output Power:

Range:

Modulation:

Occupied Bandwidth:

1W (+30 dBm) at 9.5V to 18.0V

400mW (+25 dBm) at 7.5V to 9.5V

20 Miles - Line of sight distance with unity gain antenna at 900 MHz.

GFSK, 120 kBs - 170 kBs

230 kHz

-108 dB at 10 -6 raw BER

FreeWave Radio Option Page 10 CI-3530-15B Appendix I

Selectivity: 40 dB at fc ±230kHz

60 dB at fc ±460 kHz

3.4 ENVIRONMENTAL SPECIFICATIONS

Temperature Range:

Humidity:

Full Performance -40 ° C to +60 ° C,

(-40 ° F to +140 ° F)

5% to 90% (noncondensing)

CI-3530-15B Appendix I Page 11 FreeWave Radio Option

BLANK PAGE

EXPANSION COMMUNICATIONS

PORT RS-232 BOARD

Part No. 392970-01-5

(For Models 3530-XXX)

For The Following BBI Instruction Manuals:

CI-3530-10B, CI-3530-15B, CI-3530-20B, CI-3530-25B,

CI-3530-35B, CI-3530-40B, CI-3530-45B & CI-3530-50B

Product Information Package

Bristol Babcock

PIP-EXP232TF – December, 2003

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.

TeleFlow TM , TeleRTU TM and TeleRecorder TM are trademarks 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.

Bristol Babcock.

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

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

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 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.

&VMWXSP&EFGSGO-RG6ITEMV%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 (

√

in “returned” B,C, or D of part III below)

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

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.

Description

Range/Calibration

Reason for return : Failure Upgrade

S/N

Verify Operation Other

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

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?

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

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

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

returned replaced scrapped?

returned replaced *see below?

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 three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol 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.

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)

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) 945-3865 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 maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol Babcock hardware to radios, contact Bristol Babcock’s

Communication Technology Group 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 on the rear cover) or to your Bristol-authorized sales representative.

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

Training Courses

Bristol Babcock’s Training Department offers a wide variety of courses in Bristol hardware and software at our Watertown, Connecticut headquarters, and at selected Bristol regional offices, throughout the year. Contact our Training Department at (860) 945-2269 for course information, enrollment, pricing, and scheduling.

PIP-EXP232TF

EXPANSION COMMUNICATIONS PORT

RS-232 BOARD

PT. Number 392970-01-5

Product Information Package

TABLE OF CONTENTS

1.1

1.1.1

1.1.2

1.2

1.3

1.3.1

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

DESCRIPTION................................................................................................................... 1

Function .............................................................................................................................. 1

Features............................................................................................................................... 2

COMPONENT IDENTIFICATION................................................................................... 2

INSTALLATION COMPATIBILITY................................................................................ 2

Restrictions ......................................................................................................................... 2

2.1

2.1.1

2.1.1.1

2.1.1.2

2.1.1.3

2.2

Section 2 - INSTALLATION & SERVICE

EXPCOM232 REMOVAL/REPLACEMENT & INSTALLATION................................. 3

Installation/Removal of the EXPCOM232 Board .............................................................. 3

Installation/Removal for Models 3530-10B, -15B, -40B, -45B & -50B ............................ 3

Installation/Removal for Models 3530-20B & -25B ........................................................ 10

Installation/Removal for Models 3530-35B ..................................................................... 11

RS-232 WIRING............................................................................................................... 12

Section 3 - SPECIFICATIONS

3.1

3.2

PERFORMANCE SPECIFICATIONS ............................................................................ 15

ENVIRONMENTAL SPECIFICATIONS ....................................................................... 15

SUPPLEMENTS

Special Instructions for Class I, Division 2 Hazardous Locations ..............................................Appendix A

Special Instructions for Class I, Division 1 Hazardous Locations ..............................................Appendix B

PIP-EXP232TF Page 0-1 Table Of Contents

Section 1 INTRODUCTION

1.1 DESCRIPTION

1.1.1 Function

The Expansion Communications Port RS-232 Board (EXPCOM232) provides a single RS-

EXPCOM232 Boards measure 4.0” by 3.75” and utilizes a 7-position Industrial 3.5mm pitch plugable connector to interface with an external RS-232 device. 16V bi-directional

Transient Absorption Zener Diodes are placed across all RS-232 outputs.

Programmable baud rates up to 19.2Kbps are supported by the EXPCOM232 Board. TXD,

RXD, RTS, CTS, DTR, CD and GND (RS-232) signals are available at TB1 of the

PIP-EXP232TF

Figure 1 - Expansion Communications Port RS-232 Board

Page 1 EXPCOM232 Option

1.1.2 Features

· Low Power

+5V @ 20mA (Max) regulated power is supplied by the host/parent 3530-XXX via the

40-pin Expansion Interface Connector P1.

· ESD & Transient Susceptibility

The RS-232 I/O circuitry has been designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV and the requirements of ANSI/IEEE

C37.90.1-1989 (formerly IEE 472) for surge withstand capability.

· EMI Compatibility

EXPCOM232 Boards have been designed to coexist inside a shielded enclosure with the TeleFlow ä electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

· Mounting

The EXPCOM232 Board measures 3.75” (9.525cm) in width x 4.0” (10.160cm) in height and mounts piggy-back on a TeleFlow or TeleRTU CPU Board.

· RS-232 Serial Port

EXPCOM232 Boards provide an additional RS-232 serial port that is programmable for rates up to 19.2Kbps. 3530-XXX units equipped with the EXPCOM232 Board can communicate with a local RS-232 device even though a radio or modem may be installed on the CPU Board’s network port.

1.2 COMPONENT IDENTIFICATION

EXPCOM232 Boards do not contain LEDs, switches or configuration jumpers. Two connectors are provided; 40-pin connector P1 mates with the host 3530-XX-X (connector J4 -

TeleFlow CPU or J18 - TeleRTU CPU) and accommodates the TTL interface between the two entities, while 7-pin connector TB1 mates with the RS-232 device that is being interfaced to the 3530-XXX. Additionally, the 3.5mm pitch plugable connector TB1 is removable from its mating EXPCOM232 Board socket.

1.3 INSTALLATION COMPATIBILITY

An EXPCOM232 Board can be installed into any of the following 3530-XXX models:

3530-10B - TeleFlow

3530-15B - TeleRTU

3530-35B - TeleRTU Module

3530-40B - TeleFlow ECR

3530-20B - TeleFlow Plus 3530-45B - TeleRecorder

3530-25B - TeleRTU Plus 3530-50B - TeleFlow Corrector

1.3.1 Restrictions

The 3530-XXX in question must be equipped with ACCOL application software. 3530-XXX units support installation of only one optional piggyback mounted Expansion Board (I/O,

Comm. or TIB).

EXPCOM232 Option Page 2 PIP-EXP232TF

Section 2 INSTALLATION & SERVICE

2.1 EXPCOM232 REMOVAL/REPLACEMENT & INSTALLATION

2.1.1 Installation/Removal of the EXPCOM232 Board

In addition to hardware normally contained within the 3530-XXX in question, units with an installed EXPCOM232 Option will contain the following major parts.

Expanded Communications Port RS-232 Board (EXPCOM232)

Three #4-40 x 15/32” Standoffs (Note: Models 3530-10B, - 15B, -40B, -45B & -50B will also contain Three (3) #4-40 x .188” Standoffs & Two (2) #4-40 x 1/8” SEM Screws)

Modified PC Shield Assembly (for models 3530-10B, -15B, -40B, -45B & -50B)

WARNING

Never attempt to service a TeleFlow, TeleRTU,

TeleRecorder or TeleFlow Corrector while it is powered and operating in a hazardous environment. Either the area must be made safe or the unit must be powered down, unwired, unmounted, and taken to a safe, nonhazardous area.

WARNING

Never attempt to install or remove any components

(PCBs, Field Wiring, Transducers, etc.) while the unit is powered and running. Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module or component in question, as well as other associated circuit boards. Always turn off the external/internal power source, including any additional supply sources used for externally-powered

I/O circuits, before changing or adding any components.

CAUTION

Place any related critical processes under manual or auxiliary control prior to shutting down or performing any of the steps discussed herein.

2.1.1.1 Installation/Removal for Models 3530-10B, -15B, -40B, -45B & -50B

To install the optional EXPCOM232 Board into a model 3530-10B, -15B, -40B, -45B or -

50B, follow steps 1 through 14 below. To remove the optional EXPCOM232 Board, see step

15. Note: The Instrument Front Cover must be open.

To open the Instrument Front Cover, remove the lock if present and turn each of the three captive screws a quarter (1/4) turn counterclockwise.

PIP-EXP232TF Page 3 EXPCOM232 Option

Note:

The CPU Board is not to be removed under any circumstances unless the unit has been moved to an ESD safe area (see ESDS Manual - S14006).

Remove the Power Plug(s), Solar Panel Power Plug, and the Auxiliary Power Plug as required, from the CPU Board in question.

Remove the optional radio or modem if installed.

To remove an optional modem :

Disconnect the phone wires. Loosen the four (4) screws that secure the Modem/Radio

Mounting Plate (with modem) to the Battery Mounting Bracket. Slide the modem to the left and remove it and then disconnect the D-Type connector from the modem.

To remove an optional radio :

Disconnect the Radio/TeleFlow Interface Cable from the bottom of the Radio. Unplug the 2-wire power connector associated with the 2-wire Radio Power Interface Cable from the bottom of the Radio. Loosen the four (4) screws that secure the Modem/Radio

Mounting Plate (with radio) to the Battery Mounting Bracket. Slide the radio to the left and remove it.

Remove the Battery(s) (if present).

To remove the battery(s) from units without an optional modem or radio :

Hold the battery securely and remove the Left Battery Mounting Bracket (secured with 2 screws. Loosen the screws which secure the Right Battery Mounting Bracket

(Carefully remove the battery (with wiring harness). Remove the Right Battery

Mounting Bracket.

To remove the battery(s) from units with an optional modem or radio :

Carefully remove the battery (with wiring harness). Note: You may have to loosen the two left 1/4-20 x 3/8” screws that secure the left side of the Battery Mounting Bracket and the Main Mounting Bracket to the rear of the unit.

While holding the Main

Mounting Bracket, remove the four (4) 1/4-20 x 3/8” screws and lock washers that secure the Battery Mounting Bracket and Main Mounting Bracket to the rear of the unit. Remove the Battery Mounting Bracket and temporarily reinstall the four screws to secure the Main Mounting Bracket to the 3530-10B, 15B, -45B or -50B.

Disconnect the Local Port, Network Port, RTD, and Field I/O wires from the CPU Bd.

connectors by unplugging their associated Term. Plugs on the front edge of the CPU.

6. Carefully remove the PC Shield which is secured to the Main Mounting Bracket by 2

(#4-40 x 1/4”) screws and to the CPU Board by 2 (#4-40 x 1/4”) screws.

7. Remove the screw (location ‘A’ in Figures 2 & 3) and the two (2) #4-40 x 5/8” Standoffs

(location ‘B’ in Figures 2 & 3) which secure the CPU Board to the Main Mounting

Bracket. Replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

Align the EXPCOM232 Board Connector P1 with CPU Board Connector J4 (for 3530-

10B, 40B or -50B) or J18 (for 3530-15B & -45B). Push the EXPCOM232 Board toward the CPU Board until Connector P1 is fully seated.

EXPCOM232 Option Page 4 PIP-EXP232TF

Figure 2 - TeleFlow CPU Board – Installation Drawing #1

Secure the EXPCOM232 Board to the CPU Board by installing three (3) #4-40 x .188”

Standoffs at locations ‘A’ and ‘B’ (see Figures 2 & 3).

10. Carefully install the Modified PC Shield, securing it to the Main Mounting Bracket (at locations ‘C’) with two #4-40 x 1/4” screws and to the CPU Board (at locations ‘B’) with two (2) #4-40 x 1/8” SEM screws (see Figures 4, 5, 6 & 7).

11. Follow steps 2 through 6 in reverse order, replacing rather than removing the item in question.

PIP-EXP232TF Page 5 EXPCOM232 Option

12.

Connect wiring between the EXPCOM232 Board and the DTE/DCE device to which it is to be interfaced (see Section 2.2).

13.

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.

Figure 3 - TeleRTU CPU Board – Installation Drawing #1

14.

Close and secure the Instrument Front Cover.

15. To remove an optional EXPCOM232 Board, follow steps 1 through 6 (unplug the RS-

232 cable during step 5). Remove the PC Shield along with the three Standoffs that

EXPCOM232 Option Page 6 PIP-EXP232TF

secure the EXPCOM232 Board to the CPU Board. Then unplug the EXPCOM232

Board from the CPU Board in question.

Figure 4 - TeleFlow CPU Board (with EXPCOM232 Installed)

Installation Drawing #2

PIP-EXP232TF Page 7 EXPCOM232 Option

Figure 5 - TeleRTU CPU Board (with EXPCOM232 Installed)

Installation Drawing #2

EXPCOM232 Option Page 8 PIP-EXP232TF

Figure 6 - 3530-10B, 3530-40B & 3530-50B (with EXPCOM232 Installed)

Figure 7 - 3530-15B & 3530-45B (with EXPCOM232 Installed)

PIP-EXP232TF Page 9 EXPCOM232 Option

2.1.1.2 Installation/Removal for Models 3530-20B & -25B

To install the optional EXPCOM232 Board into a model 3530-20B or 3530-25B, follow steps

1 through 11 below. To remove the optional EXPCOM232 Board, perform steps 1 and 2 and then follow steps 4 through 9 in reverse order, removing rather than installing the item in question after the system has been shut down. Note: The Instrument Front Cover must be open.

Open the Instrument Front Cover

Disconnect power by removing harness connector plug (P8 for TeleFlow - P2 for

TeleRTU) from the CPU Board edge connector (J8 for TeleFlow – J2 for TeleRTU).

Figure 8 - 3530-20B CPU (with EXPCOM232 Installed)

Unplug the remaining removable Terminal Blocks (with wiring harnesses installed) from the CPU Board’s front edge connectors.

Remove the two screws that secure the CPU Board’s Sliding Mounting Bracket to the

Fixed Bracket on the bottom of the Battery Bracket. Carefully slide the CPU Board

(and optional EXPCOM232 Board) toward the front of the unit. Remove harness connections from the Front Panel Switch (J12 on the TeleFlow CPU - J14 on TeleRTU

CPU), the Display Module (J2 on TeleFlow CPU - J16 on TeleRTU CPU), the Wakeup

Switch (J3 on TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards connector J1 (associated with the Multivariable Transducer).

Remove the three screws (of five) that secure the CPU Board to the Sliding Mounting

Bracket (locations ‘A’ & ‘B’ in Figures 2 & 3) and replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

Align the EXPCOM232 Board Connector P1 with CPU Board Connector J4 (for 3530-

20B) or J18 (for 3530-25B). Push the EXPCOM232 Board toward the CPU Board until

Connector P1 is fully seated.

Secure the EXPCOM232 Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figures 8 & 9.

EXPCOM232 Option Page 10 PIP-EXP232TF

Figure 9 - 3530-25B CPU (with EXPCOM232 Installed)

Route the RS-232 cable through a ¾” conduit fitting (user installed) on the bottom of the enclosure.

Connect wiring between the EXPCOM232 Board and the DTE/DCE device to which it is to be interfaced (see Section 2.2).

10.

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.

11. Close and secure the Instrument Front Cover.

2.1.1.3 Installation/Removal for Models 3530-35B

To install the optional EXPCOM232 Board into a model 3530-35B, follow steps 1 through 8 below. To remove the optional EXPCOM232 Board, perform step 1 and then follow steps 5 through 7 in reverse order, removing rather than installing the item in question after the system has been shut down.

Disconnect power by removing harness connector plug P2 from the CPU Board edge connector J2.

2. Unplug the remaining removable Terminal Blocks (with wiring harnesses installed) from the CPU Board’s front edge connectors.

3. Remove harness connections from the Front Panel Switch (J14), the Display Module

(J16) and the Wakeup Switch (J16).

Remove the three screws (of five) that secure the CPU Board to the RTU Mounting

Bracket (locations ‘A’ & ‘B’ in Figures 2 & 3) and replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

Align the EXPCOM232 Board Connector P1 with CPU Board Connector J18. Push the

EXPCOM232 Board toward the CPU Board until Connector P1 is fully seated.

PIP-EXP232TF Page 11 EXPCOM232 Option

Secure the EXPCOM232 Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figure 10.

Connect wiring between the EXPCOM232 Board and the DTE/DCE device to which it is to be interfaced (see Section 2.2).

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.

Figure 10 - 3530-35B (with EXPCOM232 Installed)

2.2 RS-232 WIRING

Table 2-1 and Figure 11 must be referenced to configure the RS-232 cable. Pin 2 of TB1 =

DCD (Data Carrier Detect - DCD). DCD can be used to awaken the 3530-XXX in question from power conservation (sleep) mode. This signal is not supplied by DTE equipment.

EXPCOM232 Option Page 12 PIP-EXP232TF

PIP-EXP232TF

Figure 11 - EXPCOM232 Wiring Diagrams

Page 13 EXPCOM232 Option

Either an RS-232 level control signal (high) can be supplied to TB1-2, or TB1-2 may be connected to the EXC signal on the CPU Board. It must be noted that as long as TB1-2

(DCD) remains HIGH, the 3530-XXX in question will remain awake. Therefore, if TB1-2 is connected to an EXC signal on the resident CPU Board, power conservation will be defeated, thus reducing the battery back-up time.

RS-232 cables are typically short (20’ or less in length). When significant distances are a factor (i.e., between an EXPCOM232 Board and the remote Data Terminal Device (DTE) to which it is desired to communicate), the RS-232 Port (TB1) cable can be connected to the

RS-232 Port of a modem or that of a BBI Isolated RS-485 Board (see Table 2-1).

Table 2-1

EXPCOM232 Board (DTE) & DCE/DTE - RS-232 Port Pin Assignments

EXPCOM232

RS-232 – TB1

DTE

2 - DCD (In)

6 - RXD (In)

7 - TXD (Out)

3 - DTR (Out)

1 - GND

5 - RTS (Out)

4 - CTS (In)

EXPCOM232

RS-232 TB1 or

3530 Network

Port J13/J8

DTE

7 - TXD (Out)

6 - RXD (In)

1 - GND

4 - CTS (In)

5 - RTS (Out)

Modem

9-Pin – J4

DCE

1 - DCD (Out)

2 - RXD (Out)

3 - TXD (In)

4 - DTR (In)

5 - GND

6 - DSR (Out)

7 - RTS (In)

8 - CTS (Out)

9 - N/A

(RS-232)

3310/30/35

3305

3332

Notes 1 & 2

BBI

Isolated RS-485

Board Option

DTE

3 - TXD (Out) 2 - TXD (Out) 7 - TXD (Out)

2 - RXD (In)

4 - RXD (In)

6 - RXD (In)

5 - GND

8 - CTS (In)

7 - RTS (Out)

9 - GND

6 - CTS (In)

5 - RTS (Out)

1 - GND

4 - CTS (In)

5 - RTS (Out)

Note 1: Ports BIP1 & BIP2

BIP1 and BIP2 are RS-562 Ports (RS-232 compatible.

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

A & C are RS-423 Ports (RS-232 compatible).

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).

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

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)

The device uses compression-type terminals that accommodate up to #14 AWG wire. A connection is made by inserting the bared end (1/4 inch Max.) into the clamp beneath the screw and then securing the screw. Insert the bared end fully to prevent short circuits.

Allow some slack in the wires when making terminal connections. The slack makes the connections more manageable and minimizes mechanical strain on the printed circuit boards and harnesses.

EXPCOM232 Option Page 14 PIP-EXP232TF

Section 3 SPECIFICATIONS

3.1 PERFORMANCE SPECIFICATIONS

Baud Rate (Max.):

Power Requirements:

Transient Protection:

RS-232 Outputs:

RS-232 Inputs:

RS-232 Ground:

RS-232 Interface Connector:

19.2K Asynchronous

+5Vdc @ 20mA Max. (Regulated)

16V Bi-directional Transient Absorption Zeners across all

RS-232 outputs

TXD (TB1-7)

DTR (TB1-3)

RTS (TB1-5)

DCD (TB1-2)

RXD (TB1-6)

CTS (TB1-4)

GND (TB1-1)

7-Pin Industrial 3.5mm Pitch Plugable Connector

3.2 ENVIRONMENTAL SPECIFICATIONS

Operating Temperature:

Storage Temperature:

Humidity:

ESD Susceptibility:

EMI Compatibility:

Transient Susceptibility:

-40 ° to +60 ° (C) [-40 ° to 140 ° (F)]

-40 ° to +85 ° (C) [-40 ° to 185 ° (F)]

15% to 90% RH (Non-Condensing)

Meets the requirement of IEC 801-2 for ESD withstand

Capability up to 10KV.

Designed to coexist inside a shielded enclosure with the

TeleFlow electronics. EMI radiation is insignificant and

Susceptibility is comparable or superior to associated

Electronics.

Designed to meet the requirements of ANSI/IEEE

C37.90.1-1989 (Formerly IEEE 472) for surge withstand

Capability.

PIP-EXP232TF Page 15 EXPCOM232 Option

Expansion Communications Port RS-232 Board

Special Instructions for Class I, Division 2 Hazardous Locations

1. The BBI Expansion Communications Port RS-232 Board is listed by Underwriters

Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups

A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive BBI Expansion Communications Port RS-232

Board. In the event of a conflict between the Expansion Communications Port RS-232

Board User Manual (PIP-EXP232TF) and this document, always follow the instructions in this document.

2. Wiring must be performed in accordance with Class I, Division 2 wiring methods as defined in Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations within the United States, or as specified in Section 18-152 of the Canadian Electrical

Code for installation in Canada.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location, turn off power before servicing/replacing the unit and before installing or removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the power has been switched off or the area is known to be nonhazardous.

07/17/2000 Appendix A of PIP-EXP232TF - EXPCOM232 Board Page 1 of 1

Expansion Communications Port RS-232 Board for 3530-XXX

Special Instructions for Class I, Division 1 Hazardous Locations

A version of the Expansion Communications Port RS-232 Board is available that is listed by Underwriters Laboratories (UL) as intrinsically safe for use in Class I, Division

1, Groups C and D hazardous locations. Read this document carefully before installing an intrinsically safe Expansion Communications Port RS-232 Board. Refer to the

Expansion Communications Port RS-232 Board User’s Manual (PIP-EXP232TF) for general information. In the event of a conflict between the Expansion Communications

Port RS-232 Board User’s Manual and this document, always follow the instructions in this document.

Unless the Expansion Communications Port RS-232 Board is used in conjunction with an IStran Communications Interface Assembly (see CI-3530-Istran) it may not be used in a Class I, Division 1 hazardous location.

When a TeleFlow equipped with an Expansion Communications Port RS-232 Board is used in a Class I, Division 1 location, it must be used in conjunction with a BBI IStran

Communications Interface and installed per instruction manual CI-3530-IStran and

PIP-EXP232TF.

The IStran and Expansion Communications Port RS-232 Board can be located in a nonhazardous or Division 2 rated area, while the TeleFlow can reside in a Division 1, 2 or nonhazardous area.

A suitable enclosure must be provided for the IStran. When the IStran is mounted in a

Division 2 area, the nonhazardous interface connections shall be made in accordance with Article 501-4(b) of the National Electrical Code NFPA 70.

CAUTION

When connecting the IStran and Expansion Communications

Port RS-232 Board to a TeleFlow that is mounted in a Division

1 area, wire all circuits using wiring methods specified in article 504 of the National Electrical Code NFPA 70. Contact your IStran supplier for assistance.

When installing an Expansion Communications Port RS-232

Board in a TeleFlow that is mounted in a Division 2 area, ensure that the area is nonhazardous before connecting or disconnecting the nonhazardous interface.

Figures B1 through B4 show variations of approved connections to the Expansion

Communications Port RS-232 Board via a BBI IStran Communications Interface

Assembly.

12/12/03 Appendix B - Document PIP-EXP232TF Page 1 of 3

Expansion Communications Port RS-232 Board for 3530-XXX

Special Instructions for Class I, Division 1 Hazardous Locations

Figure B1 - Intrinsically Safe System with Radio and EXPCOM232 Board

(with Single Power Source)

Figure B2 - Intrinsically Safe System with Modem and EXPCOM232 Board

(with Single Power Source)

12/12/03 Appendix B - Document PIP-EXP232TF Page 2 of 3

Expansion Communications Port RS-232 Board for 3530-XXX

Special Instructions for Class I, Division 1 Hazardous Locations

Figure B3 - Intrinsically Safe System with Modem and EXPCOM232 Board

(with Independent Power Sources)

Figure B4 - Intrinsically Safe System with Radio and EXPCOM232 Board

(with Independent Power Sources)

12/12/03 Appendix B - Document PIP-EXP232TF Page 3 of 3

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READER RESPONSE FORM

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DOCUMENT NUMBER: PIP-EXP232TF

TITLE: EXPANSION COMMUNICATIONS PORT RS-232 BOARD (for Models 3530-XXX)

Product Information Package

ISSUE DATE: DEC., 2003

COMMENT/COMPLAINT:

______________________________________________________________________________

Mail this page to:

Bristol Babcock Inc.

1100 Buckingham Street

Watertown, CT 06795

Attn: Technical Publications Group, Dept. 315

Bristol Babcock

1100 Buckingham Street

Watertown, CT 06795

Phone: +1 (860) 945-2200

Fax: +1 (860) 945-2213

Website: www.bristolbabcock.com

U.S.A. Locations:

Northern Region

Bristol Babcock Inc.

1100 Buckingham Street

Watertown, CT 06795

Phone: +1 (860) 945-2381

Fax: +1 (860) 945-2525

[email protected]

Gulf Coast Region

Bristol Babcock Inc.

2000 Governor's Circle

Suite F

Houston, TX 77092-8731

Phone: +1 (713) 685-6200

Fax: +1 (713) 681-7331

[email protected]

Western Region

Bristol Babcock Inc.

1609 South Grove Avenue

Suites 106 & 107

Ontario, CA 91761

Phone: +1 (909) 923-8488

Fax: +1 (909) 923-8988

[email protected]

Southeast Region

Bristol Babcock Inc.

317 S. North Lake Blvd.

Suite 1016

Altamonte Springs, FL 32701

Phone: +1 (407) 740-7084

Fax: +1 (407) 629-2106

[email protected]

Helicoid Instruments

1100 Buckingham Street

Watertown, CT 06795

Phone: +1 (860) 945-2218

Fax: +1 (860) 945-2213 [email protected]

Central Region

Bristol Babcock Inc.

777 South Central

Expressway

Suite 1-C

Richardson, TX 75080

Phone: +1 (972) 238-8197

Fax: +1 (972) 238-8198 [email protected]

International Affiliates:

Canada

Bristol Babcock, Canada

234 Attwell Drive

Toronto, Ont. M9W 5B3

Canada

PH: 416-675-3820

FAX: 416-674-5129 [email protected]

Mexico

BBI, S.A. de C.V.

Homero No. 1343, 3er Piso

Col. Morales Polanco

11540 Mexico, D.F.

Mexico

PH: (52-55)-52-81-81-12

FAX: (52-55)-52-81-81-09

[email protected]

Rocky Mountain Region

Bristol Babcock Inc.

906 San Juan Blvd., Suite A

Farmington, NM 87401

Phone: +1 (505) 320-5046

Fax: +1 (505) 327-3273

[email protected]

Communications

Technology Group

Bristol Babcock Inc.

317 S. North Lake Blvd.

Suite 1016

Altamonte Springs, FL 32701

Phone: +1 (407) 629-9464

Fax: +1 (407) 629-2106 [email protected]

United Kingdom

Bristol Babcock Ltd.

Blackpole Road

Worcester, WR3 8YB

United Kingdom

PH: +44 (0) 1905 856950

FAX: +44 (0) 1905 856969 [email protected]

Asia Pacific

Bristol Babcock, Inc.

PO Box 1987

Bunbury, Western Australia

6231

PH: +61 (0) 8 9791 3654

FAX: +61 (0) 8 9791 3173 [email protected]

Victoria, Australia

PH: +61 (0) 3 9384 2171

FAX: +61 (0) 3 8660 2501

Calgary Office

Bristol Babcock, Canada

3812 Edmonton Trail N.E.

Calgary, Alberta T2E 5T6

Canada

PH: 403-265-4808

FAX: 403-233-2914 [email protected]

Villahermosa Office

BBI, S.A. de C.V.

Av. Plomo No.2

Bodega No. 1 - Ciudad

Industrial

Villahermosa, Tabasco 86010

Mexico

PH: 52-993-353-3142

FAX: 52-993-353-3145 [email protected]

Middle East

Bristol Babcock Ltd.

Blackpole Road

Worcester, WR3 8YB

United Kingdom

PH: +44 (0) 1905 856950

FAX: +44 (0) 1905 856969 [email protected]

RC Rev: 13-Jun-03

EXPANSION RS-485 and/or

ANALOG OUTPUT BOARD

Series No. 392971-XX-X

(For Models 3530-XXX)

For The Following BBI Instruction Manuals:

CI-3530-10B, CI-3530-15B, CI-3530-20B, CI-3530-25B,

CI-3530-35B, CI-3530-40B & CI-3530-50B

Product Information Package

Bristol Babcock

PIP-EXP485/AO - January 2003

NOTICE

Copyright Notice

Request for Additional Instructions

TeleFlow TM and TeleRTU TM are trademarks of Bristol Babcock. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.

Bristol Babcock.

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

EQUIPMENT APPLICATION WARNING

If additional in-formation is required, the purchaser is advised to contact Bristol

Babcock.

RETURNED EQUIPMENT WARNING

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 document S14006 for proper care and handling of ESDsensitive components.

Bristol Babcock 1100 Buckingham Street, Watertown, CT 06795

Telephone (860) 945-2200

WARRANTY

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.

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

Bristol Babcock Inc. Repair Authorization Form

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 ( or D of part III below)

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

Ö in “returned” B,C,

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.

Description

Range/Calibration

Reason for return : Failure Upgrade

S/N

Verify Operation Other

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: ______________

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

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

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?

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

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

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

returned replaced scrapped?

returned replaced *see below?

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.

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.

A Few Words About Bristol Babcock

SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.

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)

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 maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol Babcock hardware to radios, contact Bristol Babcock’s

Communication Technology Group 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 on the rear cover) or to your Bristol-authorized sales representative. A list of

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

Training Courses

PIP-EXP485/AO

EXPANSION RS-485 COMMUNICATIONS and/or ANALOG OUTPUT BOARD

PT. Number 392971-XX-X

Product Information Package

1.1

1.1.1

1.1.2

1.2

1.3

1.3.1

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

DESCRIPTION................................................................................................................... 1

Function .............................................................................................................................. 1

Features............................................................................................................................... 2

COMPONENT IDENTIFICATION................................................................................... 3

INSTALLATION COMPATIBILITY................................................................................ 3

Restrictions ......................................................................................................................... 3

2.1

2.1.1

2.1.1.1

2.1.1.2

2.1.1.3

2.2

Section 2 – INSTALLATION & SERVICE

EXP485/AO REMOVAL/REPLACEMENT & INSTALLATION ................................... 4

Installation/Removal of the EXP485/AO Board ................................................................ 4

Installation/Removal for Models 3530-10B, -15B, -40B & -50B ...................................... 4

Installation/Removal for Models 3530-20B & -25B ........................................................ 11

Installation/Removal for Models 3530-35B ..................................................................... 13

RS-485 and AO WIRING ................................................................................................. 14

3.1

3.2

3.3

Section 3 - SPECIFICATIONS

PERFORMANCE SPECIFICATIONS ............................................................................ 16

ENVIRONMENTAL SPECIFICATIONS ....................................................................... 16

ENTITY PARAMETERS (INTRINSICALLY SAFE EXPAO Bd.) ............................... 17

SUPPLEMENTS

Special Instructions for Class I, Division 2 Hazardous Locations ..............................................Appendix A

Special Instructions for Class I, Division 1 Hazardous Locations ..............................................Appendix B

PIP-EXP485/AO Page 0-1 Table Of Contents

Section 1 INTRODUCTION

1.1 DESCRIPTION

1.1.1 Function

3530-XXX unit equipped with a fully populated EXP485/AO Board can establish RS-485 asynchronous communications with other 3530-XXX devices and/or can interface to an

Analog Output circuit. The EXP485/AO Board plugs into the Expansion Connector of the

TeleFlow or TeleRTU CPU Board, is stood-off by three 15/32” long hex standoffs and is secured via three screws or standoffs depending on the model. The CPU Board Expansion

Connector supplies power and 3530-XXX communication to the EXP485/AO Board.

EXP485/AO Boards measure 4.25” by 3.75” and utilizes a 9-position Industrial 3.5mm pitch plugable connector to interface (RS-485) to a series of remote 3530-XXX devices and or a single 1-5Vdc or 4-20mA AO device.

Programmable baud rates up to 19.2Kbps are supported by the EXP485/AO Board.

Interface signals are available at TB1 of the EXP485/AO. When the SLEEP+ & SLEEPsignals (supplied by the Master 3530-XXX) are Low and High respectively, the remote

3530-XXX CPU Boards will be awakened. If no activity is required, the EXP485/AO Board‘s serial communications controller (SCC) chip and RS-485 drivers can be put to sleep (low power mode) along with the host/parent 3530-XXX and the SLEEP+ and SLEEP- signals will be set High and Low respectively.

Figure 1 - EXP485/AO Board (with RS-485 & Configurable AO)

PIP-EXP485/AO Page 1 EXP485/AO Option

Figure 2 - EXPAO Board (with 1-5Vdc AO and without RS-485)

1.1.2 Features

· Low Power

+5Vdc @ 20mA (Max) regulated power and 5.8Vdc to 16Vdc @ 50mA (Max) unregulated power are supplied by the host/parent 3530-XXX via the 40-pin

Expansion Interface Connector P1.

· ESD & Transient Susceptibility

The RS-485 I/O circuitry has been designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV and the requirements of ANSI/IEEE

C37.90.1-1989 (formerly IEE 472) for surge withstand capability.

· EMI Compatibility

EXP485/AO Boards have been designed to coexist inside a shielded enclosure with the TeleFlow ä electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

· Mounting

The EXP485/AO Board measures 3.75” (9.525cm) in width x 4.25” (10.795cm) in height and mounts piggy-back on a TeleFlow or TeleRTU CPU Board.

· RS-485 Comm. Port

EXP485/AO Boards provide an RS-485 communications port that is programmable for asynchronous rates up to 19.2Kbps. 3530-XXX units equipped with the

EXP485/AO Board can communicate with a network of 3530-XXX units (equipped

EXP485/AO Option Page 2 PIP-EXP485/AO

with EXP485/AO Boards), even though a radio or modem may be installed on the

CPU Board’s network port.

1.2 COMPONENT IDENTIFICATION

EXP485/AO Boards do not contain LEDs or switches. Fully populated EXP485/AO Boards

(P/N 392971-01-0) are provided with seven (7) configuration jumpers (see Figures 1 & 11).

Depopulated EXPAO Boards (P/N 392971-02-0) are factory set for 1-5Vdc AO operation and don’t have configuration jumpers (see Figure 2). Two connectors are provided; 40-pin connector P1 mates with the host 3530-XX-X (connector J4 - TeleFlow CPU or J18 - TeleRTU

CPU) and accommodates the TTL interface between the two entities, while 9-pin connector

TB1 mates with the RS-485 device that is being interfaced to the 3530-XXX and/or an analog output device. Additionally, the 3.5mm pitch plugable connector TB1 is removable from its mating EXP485/AO Board socket.

1.3 INSTALLATION COMPATIBILITY

An EXP485/AO Board can be installed into any of the following 3530-XXX models:

3530-10B - TeleFlow

3530-15B - TeleRTU

3530-35B - TeleRTU Module

3530-40B - TeleFlow ECR

3530-20B - TeleFlow Plus 3530-50B - TeleFlow Corrector

3530-25B - TeleRTU Plus

1.3.1 Restrictions

The 3530-XXX in question must be equipped with ACCOL application software. The

TeleFlow Plus (3530-20B), TeleRTU Plus (3530-25B) and the TeleRTU Module (3530-35B) support installation of either a Low Power I/O Expansion Board (LPI/OEB), an

EXPCOM232 Board, or the EXP485/AO Board discussed herein, i.e., YOU CAN ONLY

INSTALL ONE (1) OF THESE ITEMS .

EXP485/AO Board (P/N 392971-01-0) is fully populated and supports RS-485 network communications and interface to either a 1-5Vdc or a 4-20mA analog output device.

P/N 392971-02-0 is a depopulated version of the EXP485/AO Board and only supports interface to a 1-5Vdc analog output device. Connector TB1 has two usable pins (08 = AO and 09 = AOGND). This version is designed for use in a Class I, Division 2, Groups C and D nonincendive environment or a Class I, Division 1, Groups C and D intrinsically safe environment.

Intrinsically safe EXPAO Boards can be installed in 3530-XXX units with 6V Lead Acid or

7.2V Lithium battery systems.

PIP-EXP485/AO Page 3 EXP485/AO Option

Section 2 INSTALLATION & SERVICE

2.1 EXP485/AO REMOVAL/REPLACEMENT & INSTALLATION

2.1.1 Installation/Removal of the EXP485/AO Board

In addition to hardware normally contained within the 3530-XXX in question, units with an installed EXP485/AO Option will contain the following major parts.

Expanded Comm. Port RS-485/AO Board (EXP485/AO)

Three (3) #4-40 x 15/32” Standoffs (Note: Models 3530-10B, -15B, -40B & -50B will also contain Three (3) #4-40 x .188” Standoffs & Two (2) #4-40 x 1/8” SEM Screws)

Modified PC Shield Assembly (for models 3530-10B, -15B, -40B & -50B)

WARNING

Never attempt to service a TeleFlow, TeleFlow ECR, TeleRTU or

TeleFlow Corrector while it is powered and operating in a hazardous environment. Either the area must be made safe or the unit must be powered down, unwired, unmounted, and taken to a safe, nonhazardous area.

WARNING

Never attempt to install or remove any components (PCBs, Field

Wiring, Transducers, etc.) while the unit is powered and running.

Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module or component in question, as well as other associated circuit boards. Always turn off the external/internal power source, including any additional supply sources used for externally-powered I/O circuits, before changing or adding any components.

CAUTION

Place any related critical processes under manual or auxiliary control prior to shutting down or performing any of the steps discussed herein.

2.1.1.1 Installation/Removal for Models 3530-10B, -15B, -40B & -50B

To install the optional EXP485/AO Board into a model 3530-10B, -15B, -40B or -50B, follow steps 1 through 14 below. To remove the optional EXP485/AO Board, see step 15. Note: The

Instrument Front Cover must be open.

To open the Instrument Front Cover, remove the lock if present and turn each of the three captive screws a quarter (1/4) turn counterclockwise.

EXP485/AO Option Page 4 PIP-EXP485/AO

Note:

The CPU Board is not to be removed under any circumstances unless the unit has been moved to an ESD safe area (see ESDS Manual - S14006).

Remove the Power Plug(s), Solar Panel Power Plug, and the Auxiliary Power Plug as required, from the CPU Board in question.

Remove the optional radio or modem if installed.

To remove an optional modem :

Disconnect the phone wires. Loosen the four (4) screws that secure the Modem/Radio

Mounting Plate (with modem) to the Battery Mounting Bracket. Slide the modem to the left and remove it and then disconnect the D-Type connector from the modem.

To remove an optional radio :

Mounting Plate (with radio) to the Battery Mounting Bracket. Slide the radio to the left and remove it.

Remove the Battery(s) (if present).

To remove the battery(s) from units without an optional modem or radio :

Hold the battery securely and remove the Left Battery Mounting Bracket (secured with 2 screws. Loosen the screws which secure the Right Battery Mounting Bracket

(Carefully remove the battery (with wiring harness). Remove the Right Battery

Mounting Bracket.

To remove the battery(s) from units with an optional modem or radio :

While holding the Main

Disconnect the Local Port, Network Port, RTD, and Field I/O wires from the CPU

Board connectors by unplugging their associated Terminal Plugs on the front edge of the CPU.

6. Carefully remove the PC Shield which is secured to the Main Mounting Bracket by 2

(#4-40 x 1/4”) screws and to the CPU Board by 2 (#4-40 x 1/4”) screws.

7. Remove the screw (location ‘A’ in Figures 3 & 4) and the two (2) #4-40 x 5/8” Standoffs

(location ‘B’ in Figures 2 & 3) which secure the CPU Board to the Main Mounting

Bracket. Replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

Align the EXP485/AO Board Connector P1 with CPU Board Connector J4 (for 3530-

10B or -50B) or J18 (for 3530-15B). Push the EXP485/AO Board toward the CPU

Board until Connector P1 is fully seated.

PIP-EXP485/AO Page 5 EXP485/AO Option

Figure 3 - TeleFlow CPU Board – Installation Drawing #1

Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x .188”

Standoffs at locations ‘A’ and ‘B’ (see Figures 3 & 4).

10. Carefully install the Modified PC Shield, securing it to the Main Mounting Bracket (at locations ‘C’) with two #4-40 x 1/4” screws and to the CPU Board (at location ‘B’) with two (2) #4-40 x 1/8” SEM screws (see Figures 5, 6, 7 & 8).

11.

Follow steps 2 through 6 in reverse order, replacing rather than removing the item in question.

EXP485/AO Option Page 6 PIP-EXP485/AO

12.

Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to which it is to be interfaced (see Section 2.2).

13.

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.

Figure 4 - TeleRTU CPU Board – Installation Drawing #1

14.

Close and secure the Instrument Front Cover.

15. To remove an optional EXP485/AO Board, follow steps 1 through 6 (unplug the RS-485 cable during step 5). Remove the PC Shield along with the three Standoffs that secure

PIP-EXP485/AO Page 7 EXP485/AO Option

the EXP485/AO Board to the CPU Board. Then unplug the EXP485/AO Board from the CPU Board in question.

Figure 5 - TeleFlow CPU Board (with EXP485/AO Installed)

Installation Drawing #2

EXP485/AO Option Page 8 PIP-EXP485/AO

Figure 6 - TeleRTU CPU Board (with EXP485/AO Installed)

Installation Drawing #2

PIP-EXP485/AO Page 9 EXP485/AO Option

Figure 7 - 3530-10B, 3530-40B & 3530-50B (with EXP485/AO Installed)

EXP485/AO Option

Figure 8 - 3530-15B (with EXP485/AO Installed)

Page 10 PIP-EXP485/AO

2.1.1.2 Installation/Removal for Models 3530-20B & -25B

To install the optional EXP485/AO Board into a model 3530-20B or 3530-25B, follow steps 1 through 11 below. To remove the optional EXP485/AO Board, perform steps 1 and 2 and then follow steps 4 through 9 in reverse order, removing rather than installing the item in question after the system has been shut down. Note: The Instrument Front Cover must be open.

Open the Instrument Front Cover

Disconnect power by removing harness connector plug (P8 for TeleFlow - P2 for

TeleRTU) from the CPU Board edge connector (J8 for TeleFlow - J2 for TeleRTU).

PIP-EXP485/AO

Figure 9 - 3530-20B CPU (with EXP485/AO Installed)

Page 11 EXP485/AO Option

Unplug the remaining removable Terminal Blocks (with wiring harnesses installed) from the CPU Board’s front edge connectors.

Remove the two screws that secure the CPU Board’s Sliding Mounting Bracket to the

Fixed Bracket on the bottom of the Battery Bracket. Carefully slide the CPU Board

(and optional EXP485/AO Board) toward the front of the unit. Remove harness connections from the Front Panel Switch (J12 on the TeleFlow CPU - J14 on TeleRTU

CPU), the Display Module (J2 on TeleFlow CPU - J16 on TeleRTU CPU), the Wakeup

Switch (J3 on TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards connector J1 (associated with the Multivariable Transducer).

Figure 10 - 3530-25B CPU (with EXP485/AO Installed)

Remove the three screws (of five) that secure the CPU Board to the Sliding Mounting

Bracket (locations ‘A’ & ‘B’ in Figures 3 & 4) and replace these items with the three new #4-40 x 15/32” Standoffs.

EXP485/AO Option Page 12 PIP-EXP485/AO

Note:

This operation should only be performed in an ESD safe area.

Align the EXP485/AO Board Connector P1 with CPU Board Connector J4 (for 3530-

20B) or J18 (for 3530-25B). Push the EXP485/AO Board toward the CPU Board until

Connector P1 is fully seated.

Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figures 9 & 10.

Route the RS-485 and AO cables through a ¾” conduit fitting (user installed) on the bottom of the enclosure.

Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to which it is to be interfaced (see Section 2.2).

10.

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.

11. Close and secure the Instrument Front Cover.

2.1.1.3 Installation/Removal for Models 3530-35B

To install the optional EXP485/AO Board into a model 3530-35B, follow steps 1 through 8 below. To remove the optional EXP485/AO Board, perform step 1 and then follow steps 5 through 7 in reverse order, removing rather than installing the item in question after the system has been shut down.

Disconnect power by removing harness connector plug P2 from the CPU Board edge connector J2.

2. Unplug the remaining removable Terminal Blocks (with wiring harnesses installed) from the CPU Board’s front edge connectors.

3. Remove harness connections from the Front Panel Switch (J14), the Display Module

(J16) and the Wakeup Switch (J16).

Remove the three screws (of five) that secure the CPU Board to the RTU Mounting

Bracket (locations ‘A’ & ‘B’ in Figures 2 & 3) and replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

Align the EXP485/AO Board Connector P1 with CPU Board Connector J18. Push the

EXP485/AO Board toward the CPU Board until Connector P1 is fully seated.

Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figure 11.

Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to which it is to be interfaced (see Section 2.2).

PIP-EXP485/AO Page 13 EXP485/AO Option

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.

Figure 11 - 3530-35B (with EXP485/AO Installed)

2.2 RS-485 and AO WIRING

Figure 12 must be referenced to configure the RS-485 cable. It is recommended that a low capacitance 24-gauge communications grade 2-twisted pair cable such as Belden 9842 be used for RS-485 networking.

EXP485/AO Option Page 14 PIP-EXP485/AO

Figure 12 - EXP485/AO Wiring Diagrams

Allow some slack in the wires when making terminal connections. The slack makes the connections more manageable and minimizes mechanical strain on the printed circuit boards and harnesses.

PIP-EXP485/AO Page 15 EXP485/AO Option

Section 3 SPECIFICATIONS

3.1 PERFORMANCE SPECIFICATIONS

Baud Rate (Max.):

Power Requirements:

Transient Protection:

RS-485 Inputs/Outputs:

Analog Output Pins:

Interface Connector:

19.2K Asynchronous

+5Vdc @ 20mA Max. (Regulated)

+5.8Vdc to +16Vdc @ 50mA Max. (Unregulated)

5V Bi-directional Transient Absorption Zeners across all

RS-485 communication points

12V Bi-directional Transient Absorption Zeners across the

AO points (when configured for 1-5Vdc operation)

16V Bi-directional Transient Absorption Zeners across the

AO points (when configured for 4-20mA operation)

TXD/RDX+ (TB1-3)

TXD/RXD- (TB1-4)

SLEEP+ (TB1-5)

SLEEP(TB1-6)

AO (TB1-8) - 1-5Vdc @ 5mA Max. ONLY on

392971-02-0

(TB1-8) - 1-5Vdc @ 5mA Max. or 4-20mA on

392971-01-0

AOGND (TB1-9) - Analog Output Ground/Return

9-Pin Industrial 3.5mm Pitch Plugable Connector

3.2 ENVIRONMENTAL SPECIFICATIONS

Operating Temperature:

Storage Temperature:

Humidity:

Vibration:

RFI Susceptibility:

EMI Compatibility:

-40 ° to +60 ° (C) [-40 ° to 140 ° (F)]

-40 ° to +85 ° (C) [-40 ° to 185 ° (F)]

15% to 90% RH (Non-Condensing)

10 to 500 Hz at 1g on any axis per SAMA PMC-31-1 without damage or impairment.

Meets the requirement of IEC 1000-4-6 level 2 (3V/M) from 150kHz to 80MHz.

Designed to coexist inside a shielded enclosure with the

TeleFlow electronics. EMI radiation is insignificant and

Susceptibility is comparable or superior to associated

Electronics.

EXP485/AO Option Page 16 PIP-EXP485/AO

Surge Susceptibility:

EMI Radiated:

Designed to meet the requirements of ANSI/IEEE

C37.90.1-1989 (Formerly IEEE 472) for surge withstand capability.

Designed to meet the requirements of IEC 1004-4-3 for radiated emissions.

3.3 ENTITY PARAMETERS (INTRISICALLY SAFE EXPAO Bd.)

F1: .125A

R66:

D20/D21:

Voc:

Vmax:

Isc:

Imax:

Ca:

Ci:

La:

Li:

200 Ohms ±5%, .5W

6.2V ±5%

6.51V

15V

34.3mA

150mA

400µF

0µF

80mH

0mH

PIP-EXP485/AO Page 17 EXP485/AO Option

Expansion RS-485 and/or Analog Output Board

Special Instructions for Class I, Division 2 Hazardous Locations

1. The BBI Expansion RS-485 and/or Analog Output (EXP485/AO) Board is listed by

Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I,

Division 2, Groups C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive BBI Expansion RS-485 and/or

Analog Output Board. In the event of a conflict between the Expansion RS-485 and/or

Analog Output Board User Manual (PIP-EXP485/AO) and this document, always follow the instructions in this document.

Code for installation in Canada.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location, turn off power before servicing/replacing the unit and before installing or removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the power has been switched off or the area is known to be nonhazardous.

12/14/2001 Appendix A of PIP-EXP485/AO - EXP485/AO Board Page 1 of 1

Expansion RS-485 and/or Analog Output Board for 3530-XXX

Special Instructions for Class I, Division 1 Hazardous Locations

A version of the Expansion RS-485 and/or Analog Output (EXP485/AO) Board is available that is listed by Underwriters Laboratories (UL) as intrinsically safe for use in

Class I, Division 1, Groups C and D hazardous locations. Read this document carefully before installing an intrinsically safe Expansion RS-485 and/or Analog Output Board.

Refer to the Expansion RS-485 and/or Analog Output Board User’s Manual (PIP-

EXP485/AO) for general information. In the event of a conflict between the Expansion

RS-485 and or Analog Output User’s Manual and this document, always follow the instructions in this document.

Only the depopulated version of the Expansion RS-485 and/or Analog Output Board

(EXP485/AO) (P/N 392971-02-0) may be used in a Class I, Division 1 hazardous location.

TeleFlow models 3530-10B, 3530-40B and 3530-50B approved for use in Class I,

Division 1, Groups C and D hazardous locations and equipped with the EXP485/AO

Board option may reside in a Division 1, 2 or nonhazardous area. 3530-XXX units not approved for use in a Class I, Division 1 environment may contain an EXP485/AO Board but can only reside in a Class I, Division 2 or nonhazardous area.

CAUTION

When connecting the Expansion Analog Output Board to a

TeleFlow that is mounted in a Division 1 area, wire all circuits using wiring methods specified in article 501-4(A) of the

National Electrical Code NFPA 70.

When installing an Expansion RS-485 and/or Analog Output

Board (EXP485/AO) into a TeleFlow that is mounted in a

Division 2 area, ensure that the area is nonhazardous before connecting or disconnecting the nonhazardous interface.

Intrinsically safe TeleFlows equipped with an intrinsically safe EXPAO Board (P/N

392971-02-0) do not include any internal communications options.

01/11/02 Appendix B - Document PIP-EXP485/AO Page 1 of 1

BLANK PAGE

READER RESPONSE FORM

DOCUMENT NUMBER: PIP-EXP485/AO

TITLE: EXPANSION RS-485 and/or ANALOG OUTPUT BOARD (for Models 3530-XXX)

Product Information Package

ISSUE DATE: JAN., 2003

COMMENT/COMPLAINT:

______________________________________________________________________________

Mail this page to:

Bristol Babcock Inc.

1100 Buckingham Street

Watertown, CT 06795

Attn: Technical Publications Group, Dept. 315

Bristol Babcock

1100 Buckingham Street

Watertown, CT 06795

Phone: (860) 945-2200

Fax: (860) 945-2213

Website: www.bristolbabcock.com

U.S.A. Locations:

Northern Region

Bristol Babcock Inc.

1100 Buckingham Street

Watertown, CT 06795

Phone: (860) 945-2381

Fax: (860) 945-2525

[email protected]

Southwest Region

Bristol Babcock Inc.

2000 Governor's Circle

Suite F

Houston, TX 77092-8731

Phone: (713) 685-6200

Fax: (713) 681-7331

[email protected]

Western Region

Bristol Babcock Inc.

1609 South Grove Avenue

Suites 106 & 107

Ontario, CA 91761

Phone: (909) 923-8488

Fax: (909) 923-8988

[email protected]

Southeast Region

Bristol Babcock Inc.

317 S. North Lake Blvd.

Suite 1016

Altamonte Springs, FL 32701

Phone: (407) 740-7084

Fax: (407) 629-2106

[email protected]

Helicoid Instruments

1100 Buckingham Street

Watertown, CT 06795

Phone: (860) 945-2218

Fax: (860) 945-2213 [email protected]

Dallas District Office

Bristol Babcock Inc.

777 South Central

Expressway

Suite 1-C

Richardson, TX 75080

Phone: (972) 238-8197

Fax: (972) 238-8198 [email protected]

International Affiliates :

Canada

Bristol Babcock, Canada

234 Attwell Drive

Toronto, Ont. M9W 5B3

Canada

PH: 416-675-3820

FAX: 416-674-5129 [email protected]

Mexico

BBI, S.A. de C.V.

Ejercito Nacional No. 718, 4

Piso

Colonia Polanco

Mexico, D.F. 11560

Mexico

PH: 52-555-254-5281

FAX: 52-555-254-3408

[email protected]

Sales Office New Mexico

Bristol Babcock Inc.

906 San Juan Blvd., Suite A

Farmington, NM 87401

Phone: (505) 320-5046

Fax: (505) 327-3273

[email protected]

Communications

Technology Group

Bristol Babcock Inc.

317 S. North Lake Blvd.

Suite 1016

Altamonte Springs, FL 32701

Phone: (407) 629-9464

Fax: (407) 629-2106 [email protected]

United Kingdom

Bristol Babcock Ltd.

Vale Industrial Estate

Stourport Road

Kidderminster

Worcestershire DY11 7QU

United Kingdom

PH: +44 (0) 1562 820001

FAX: +44 (0) 1562 746721 [email protected]

Australia

Bristol Babcock, Inc.

22 Hastie St.

PO Box 1987

Banbury, Western Australia

6230

PH: 61 (0)8 9791 3654

FAX: 61 (0)8 9791 3173 [email protected]

Calgary Office

Bristol Babcock, Canada

3812 Edmonton Trail N.E.

Calgary, Alberta T2E 5T6

Canada

PH: 403-265-4808

FAX: 403-233-2914 [email protected]

Villahermosa Office

BBI, S.A. de C.V.

Av. Plomo No.2

Bodega No. 1 - Ciudad

Industrial

Villahermosa, Tabasco 86010

Mexico

PH: 52-993-353-3142

FAX: 52-993-353-3145 [email protected]

Middle East

Bristol Babcock Ltd.

Vale Industrial Estate

Stourport Road

Kidderminster

Worcestershire DY11 7QU

United Kingdom

PH: +44 (0) 1562 820001

FAX: +44 (0) 1562 746721 [email protected]

Product Information Package

PIP-EXPTIBTF

Mar., 2007 TeleFlow Series 3530-10B/15B/20B/25B/35B/50B

Expansion Transmitter Interface

Board Part No. 392960-01-0

For The Following Bristol Instruction Manuals:

CI-3530-10B, CI-3530-15B, CI-3530-20B,

CI-3530-25B, CI-3530-35B & CI-3530-50B

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

EQUIPMENT APPLICATION WARNING

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, failsafe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional in-formation is required, the purchaser is advised to contact Bristol .

RETURNED EQUIPMENT WARNING

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

Bristol 1100 Buckingham Street, Watertown, CT 06795

Telephone (860) 945-2200

WARRANTY

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

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

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or modified without Bristol's consent, (iii) not installed, maintained and operated in strict compliance with instructions furnished by Bristol, or (iv) worn, injured or damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION

WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY

REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY

BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE

NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE

FACE HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.

REMEDIES

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to Bristol's Watertown office, unless Bristol's 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.

B. Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation, from use of the information herein or from the purchase or use by Buyer, its em-ployees or other parties of goods sold under said agreement.

How to return material for Repair or Exchange

Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return

You can easily obtain a RA number by:

A. FAX

Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair

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

B. E-MAIL

Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com) and sending it via E-Mail to [email protected]

. A Bristol Repair Dept. representative will return E-Mail (or other requested method) with a RA number.

C. Mail

Mail the form (GBU 13.01) to

Bristol Inc.

Repair

1100 Buckingham Street

Watertown, CT 06795

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

D. Phone

Bristol

Repair Authorization Form

(off-line completion)

(Providing this information will permit Bristol 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

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

Line No.____________

Please be aware of the Non warranty standard charge:

•

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

√

in “returned”

B,C, or D of part III below)

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

Address No.

Bill to :

Purchase Order:

Phone:

(office use only) Address No.

Ship to:

Fax:

(office use only)

Contact Name: ____________________________________

E-Mail:

Model No./Part No. Description

Range/Calibration S/N

Reason for return : Failure Upgrade Verify Operation Other

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: ______________

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