REMOTE TERMINAL UNITS
RTU 3305
Instruction Manual
Bristol Babcock
CI-3305 - December, 2005
NOTICE
Copyright Notice
The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol Babcock assumes no responsibility for any errors that may appear in this document.
Request for Additional Instructions
Additional copies of instruction manuals may be ordered from the address below per attention of the Sales Order Processing Department. List the instruction book numbers or give complete model number, serial or software version number. Furnish a return address that includes the name of the person who will receive the material. Billing for extra copies will be according to current pricing schedules.
ACCOL TM is a trademark of Bristol Babcock. Other trademarks or copy-righted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2005 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol Babcock.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Bristol Babcock for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may leave an operating process without protection. Depending upon the application, this could result in possible damage to property or injury to persons. It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional information is required, the purchaser is advised to contact Bristol
Babcock.
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol Babcock for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol Babcock are clean to safe levels, as such levels are defined and/or determined by applicable federal, state and/or local law regulations or codes. Such party agrees to indemnify Bristol Babcock and save Bristol Babcock harmless from any liability or damage which Bristol Babcock may incur or suffer due to such party’s failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically-operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read supplemental document S14006 at the back of this manual for proper care and handling of ESD-sensitive components.
Bristol Babcock 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
A.
B.
C.
D.
E.
F.
A.
B.
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 WAR-
RANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION WAR-
RANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY REP-
RESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY BRIS-
TOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE FACE
HEREOF.
No agent of Bristol is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.
REMEDIES
Buyer’s sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to Bristol’s Watertown office, unless Bristol’s Watertown office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can arrange to have a Bristol service person come to the site. The Service person’s transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.
Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation from use of the information herein or from the purchase or use by Buyer, its employees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Bristol Babcock for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA
(Return Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Babcock Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A BBI Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Babcock Web site
(www.bristolbabcock.com) and sending it via E-Mail to [email protected]
.
A BBI Repair Dept. representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Babcock Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795
A BBI Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the BBI Repair Department at (860) 945-2442. A BBI Repair Department representative will record a RA number on the form and complete Part I, then send the form to the Customer via fax (or other requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and return your product to you.
&VMWXSP &EFGSGO -RG 6ITEMV %YXLSVM^EXMSR *SVQ
(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
•
Evaluate / Test / Verify Discrepancy
•
Repair / Replace / etc. in accordance with this form
•
Return to Customer
Part I
Please be aware of the Non warranty standard charge:
•
There is a $100 minimum evaluation charge, which is applied to the repair if applicable (
B,C, or D of part III below)
Please complete the following information for single unit or multiple unit returns
√
in “returned”
Address No.
Bill to :
(office use only) Address No.
Ship to:
(office use only)
Purchase Order:
Phone: Fax:
Contact Name:____________________________________
E-Mail:
Part II Please complete Parts II & III for each unit returned
Model No./Part No.
Range/Calibration
Description
S/N
Reason for return : Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3.
What is the Firmware revision? _____________________ What is the Software &version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due to BBI’s warranty clause, would you like the product: repaired returned replaced scrapped?
B. If product were found to exceed the warranty period, would you like the product:
C. If product is deemed not repairable would you like your product:
D. If BBI is unable to verify the discrepancy, would you like the product: repaired returned replaced scrapped?
returned replaced scrapped?
returned replaced *see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that has the most knowledge of the problem is: _______________________________ phone
If we are unable to contact this person the backup person is: _________________________ phone
Special Requests:
Ship prepaid to: Bristol Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-3875
Form GBU 13.01
Rev. A
Bristol Babcock
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
• Avoid Delays and problems in getting your system on-line
• Minimize installation, start-up and maintenance costs.
• Make the most effective use of our hardware and software.
• Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Babcock offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at 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) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 685-
6200.
BLANK PAGE
A Few Words About Bristol Babcock
For over 100 years, Bristol 7 has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water company, there are Bristol Babcock instruments, controllers, and systems running year-in and year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Help Files / Release Notes
Many Bristol Babcock 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 Babcock Directly
Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol Babcock's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow 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 Babcock hardware to radios, contact Bristol Babcock’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 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) 945-2343 for course information, enrollment, pricing, and scheduling.
CI-3305
MODEL 3305 REMOTE TERMINAL UNIT
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 1 -INTRODUCTION
1.1
1.2 DESCRIPTION........................................................................................... 1-2
1.2.1 Backplane
1.2.2 Processor Memory Peripheral Power Supply Board (PMPP)....................................... 1-3
Configuration
1.2.2.2 Processor Memory Peripheral Power Supply Board Configuration Switch................ 1-5
1.2.2.3 Processor Memory Peripheral Power Supply Board LED Indicators.......................... 1-6
1.2.2.4
1.2.2.5 Subsystem .......................................................................................... 1-7
1.2.2.6 Processor Memory Peripheral Power Supply Board Connectors................................. 1-8
1.2.3 Multifunction
1.2.3.1
1.2.3.2
1.2.3.3
1.2.3.4 Output
1.2.3.5 High Speed Counter Circuitry ..................................................................................... 1-11
Watchdog
1.2.3.7 Ports .................................................................................................1-12
1.2.3.8 Multifunction I/O Board Terminal Blocks and Connectors........................................ 1-12
1.2.3.9 Multifunction I/O Board Jumpers & Switch SW1 ...................................................... 1-17
1.2.3.10 MI/OB LEDs ........................................................................................................................ 1-17
1.2.3.11 MI/OB On-Board Fuse F1................................................................................................... 1-18
OPTIONS ...................................................................................................................... 1-18
1.3.1 LCD
1.3.2 Network
1.3.2.1
Communication
Modems ........................................................................................................................ 1-21
1.3.2.2 BBI Transmitter Interface Board ............................................................................... 1-23
RS-485
1.3.2.4 Delay
1.3.2.5 BBI Network Interface Box (NIB) ............................................................................... 1-25
1.3.2.6 HART Device Interface Option .................................................................................... 1-25
Supplies.............................................................................................................. 1-25
Section 1A -APPLICATION SOFTWARE
1A.1 CATEGORIES
1A.2 ACCOL
OF
SOFTWARE........................................................................................ 1A-1
1A.3 SUPERVISORY SOFTWARE..................................................................................... 1A-3
BSI
1A.5 SYSTEM
1A.5.1 Unit ......................................................................................................... 1A-5
1A.5.2 Local Area Network (LAN).......................................................................................... 1A-5
1A.5.3 Wide Area Network (WAN)......................................................................................... 1A-7
3305 RTU Contents / 0 - 1
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.4
3.5
3.5.1
3.1
3.1.1
3.1.2
3.2
3.2.1
3.3
3.3.1
3.3.2
3.5.2
3.6
3.6.1
2.4.8.1
2.4.8.2
2.4.8.3
2.5
2.5.1
2.5.1.1
2.5.1.2
2.5.2
2.5.2.1
2.5.2.2
2.6
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.4
SECTION
TABLE OF CONTENTS
TITLE PAGE #
Section 2 - INSTALLATION
INSTALLATION IN HAZARDOUS AREAS.................................................................2-1
MOUNTING THE MODEL 3305 RTU..........................................................................2-2
Temperature & Humidity Limits ..................................................................................2-2
Vibration Limits..............................................................................................................2-3
3305 RTU INSTALLATION/CONFIGURATION......................................................... 2-3
PMPP Board Jumper Configurable Options.................................................................2-4
Soft switch Configuration ..............................................................................................2-4
WIRING NOTES ............................................................................................................2-7
Discrete Inputs ...............................................................................................................2-9
Discrete Outputs...........................................................................................................2-10
Analog Inputs................................................................................................................2-12
Analog Outputs.............................................................................................................2-13
High Speed Counter Circuitry .....................................................................................2-14
Watchdog Relay Circuitry ...........................................................................................2-15
DC Power Configuration & Wiring .............................................................................2-15
Communication Ports ..................................................................................................2-16
RS-485 Interface (Port D)............................................................................................. 2-16
RS-232 Interface (Ports B, C & D)............................................................................... 2-18
Port A RS-232 Interface ............................................................................................... 2-19
INSTALLING LCD OPTIONS.....................................................................................2-19
Installing the 2 X 20 Local LCD Display Module .......................................................2-19
Installation of Local LCD Display (No Network Option Present) .............................2-19
Installation of Local LCD Display (Network Option Present)...................................2-20
Installing the Remote LCD Display Module...............................................................2-26
Installing the Remote 2 X 16 LCD Display Assembly................................................2-27
Installing the Remote 4 X 20 LCD Display/Keyboard Assembly...............................2-28
INSTALLING A COMMUNICATION OPTION.........................................................2-29
Section 3 - LIQUID CRYSTAL DISPLAYS
INTRODUCTION TO LCDs .........................................................................................3-1
2 X 16 LCD Display & Sensor Buttons.......................................................................... 3-1
4 X 20 LCD Display/Keyboard ....................................................................................... 3-2
PREPARING THE ACCOL LOAD ................................................................................3-2
ACCOL Module Terminals.............................................................................................3-7
USING THE 4 X 20 DISPLAY/KEYBOARD ..............................................................3-11
Display/Keyboard Scrolling .........................................................................................3-13
Signing-On With the Display/Keyboard......................................................................3-13
Clock Functions Via the Display/Keyboard ................................................................3-14
Choosing a Signal List from the List Menu via the Display/Keyboard.....................3-15
Moving Through a Signal List via the Display/Keyboard..........................................3-16
Changing Signal Parameters via the Display/Keyboard ...........................................3-16
Signing-Off via the Display/Keyboard.........................................................................3-20
INTERPRETING ERROR MESSAGES......................................................................3-20
2 X 16 LCD DISPLAY SCROLLING DETAILS.........................................................3-22
Main 2 X 16 LCD Display ............................................................................................3-22
Other Lists Associated with the 2 X 16 LCD Display ................................................3-23
RESET & DIAGNOSTIC..............................................................................................3-26
Reset/Self-Test Diagnostics.......................................................................................... 3-26
0 - 2 / Contents 3305 RTU
4.1
4.2
4.3
4.3.1
4.3.2
4.4
4.5
4.5.1
4.5.2
4.5.3
4.5.4
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.4
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.2
5.2.1
5.2.2
5.4.1
5.4.2
5.4.3
5.5
5.5.1
5.5.2
5.5.3
SECTION
3.6.2
6.1
6.2
6.2.1
6.2.2
6.2.3
TABLE OF CONTENTS
TITLE
Section 3 - LIQUID CRYSTAL DISPLAYS (Continued)
PAGE #
OFF-Line/ACCOL Diagnostics.....................................................................................3-26
Section 4 - OPERATION
GEBERAL .......................................................................................................................4-1
PRELIMINARY CHECKS .............................................................................................4-1
STARTING THE RTU....................................................................................................4-2
Equipment Required ......................................................................................................4-2
General Setup Procedures .............................................................................................4-2
SHUTDOWN PROCEDURE..........................................................................................4-5
USING THE BBI SYSTEM CONFIG/FLASH DOWNLOADER PROGRAM.............4-6
Downloading Standard System or Custom System Firmware .................................... 4-9
Download An ACCOL Load into FLASH Memory ..................................................... 4-10
Download An ACCOL Load into RAM ........................................................................4-10
Using BBI System/Flash Downloader Program Diagnostics.....................................4-11
Section 5 - SERVICE
SERVICE INTRODUCTION .........................................................................................5-1
Accessing PC Boards For Testing..................................................................................5-1
Removal/Replacement of the PMPP Board...................................................................5-2
Removal/Replacement of the MI/OB Board ..................................................................5-4
Removal/Replacement of the Backplane Board............................................................5-6
DIAGNOSTIC TEST PROCEDURES ...........................................................................5-6
Self-Test Diagnostics (PMPP Board Status LEDs).......................................................5-6
Startup Diagnostics Using a Terminal Emulator.......................................................5-10
DIAGNOSTIC PROGRAM (DIAG05.ACL) .................................................................5-11
Testing the 3305 RTU CPU Peripherals and Comm Ports........................................5-12
Analog Input Circuitry Offset Calibration..................................................................5-13
Analog Output Circuitry Calibration ..........................................................................5-14
Discrete Output & Discrete Input Tests .....................................................................5-14
High Speed Counter Tests ...........................................................................................5-14
LCD Display & Display/Keyboard Tests..................................................................... 5-16
POWER SUPPLY TESTS & TRIP POINT ADJUSTMENTS ....................................5-16
Setting the Power Fail Trip Point ...............................................................................5-16
Setting the Low Battery Voltage Detection Trip Points ............................................ 5-17
Power Checks................................................................................................................5-17
GENERAL NOTES.......................................................................................................5-18
Extent of Field Repairs ................................................................................................5-18
Disconnecting RAM Battery ........................................................................................5-18
Maintaining Backup Files............................................................................................5-18
Section 6 - SPECIFICATIONS
CPU, MEMORY & PROGRAM INTERFACE ..............................................................6-1
COMMUNICATION PORTS ........................................................................................6-1
Communication Ports.....................................................................................................6-1
Network Ports (B, C & D) ..............................................................................................6-1
Customer Port (A)...........................................................................................................6-2
3305 RTU Contents / 0 - 3
TABLE OF CONTENTS
6.2.4
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.4
6.5
6.5.1
6.5.2
6.5.3
6.6
SECTION TITLE PAGE #
Section 6 - SPECIFICATIONS (Continued)
Communication Protocols (Network Ports)................................................................... 6-2
INPUT/OUTPUT SPECIFICATIONS ..........................................................................6-2
Analog Inputs .................................................................................................................6-2
Analog Outputs...............................................................................................................6-3
Discrete Inputs ..............................................................................................................6-3
Discrete Outputs ............................................................................................................6-3
Watchdog Contacts ........................................................................................................6-4
High Speed Counter ......................................................................................................6-4
ENVIRONMENTAL SPECIFICATIONS......................................................................6-4
POWER SPECIFICATIONS ..........................................................................................6-5
Input Power Specs. .........................................................................................................6-5
DC To DC Converter Specs............................................................................................6-5
Power Requirements ......................................................................................................6-6
RTU 3305 MODEL VARIATIONS.................................................................................6-6
APPENDICES
Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A
TRANSMITTER INTERFRACE BOARDS (Appendix 1).........................PIP-TIBS33XX
RADIO DELAY BOARD................................................................................... Appendix 2
RS-485 INTERFACE BOARD.......................................................................... Appendix 3
NETWORK INTERFACE BOX ....................................................................... Appendix 4
HIGHWAY ADDRESSABLE REMOTE TRANSDUCER (HART)
DEVICE INTERFACE (Appendix 5)....................................................... PIP-HART33XX
RTU 3305 POWER SUPPLY/BATTERY CHARGER..................................... Appendix 6
ISOLATED RS-485 INTERFACE BOARD (Appendix 7)......................... PIP-ISORS485
MATERIAL SAFETY DATA SHEETS ...........................................................Appendix Z
SUPPLEMENTAL INSTRUCTIONS
RTU 3305 STANDARD ENCLOSURE .......................................................Supplement 1
GUIDELINES FOR SYSTEM GROUNDING .........................................................S1400
CARE AND HANDLING OF PC BOARDS AND
ESD-SENSITIVE COMPONENTS.........................................................................S14006
REFERENCED BBI CUSTOMER INSTRUCTION MANUALS
BBI 1200 bps - PL & PSTN MODEMS..................................................................CI-1200
BBI 9600 bps - PSTN MODEM (396039-10-3).....................................................CI-9600
BBI 9600 bps - PSTN MODEM (392958-05-8).................................................. CI-9600A
33XX DIAGNOSTICS............................................................................................... D4041
WINDIAG – Windows Diagnostics for BBI Controllers.......................................D4041A
0 - 4 / Contents 3305 RTU
Section 1
INTRODUCTION
1.1 GENERAL DESCRIPTION
Model 3305 Remote Terminal Units are low priced ACCOL based controllers designed to act as master or slave nodes in a Bristol Babcock 33XX communications network. An RTU
3305, loaded with a custom ACCOL program, will provide intelligent measurement and control for a wide variety of process applications and will communicate with other Bristol
Babcock 33XX products within a local area network (LAN) or a wide are network (WAN).
3305 RTU
Figure 1-1 - 3305 RTU (With 1200 bps Modem)
Introduction / 1-1
The 3305 RTU has been designed to provide the following key features:
• Low cost
• Low power consumption
• Small size
• Four independent asynchronous serial ports
• Optional 16 character by 2 line LCD Display (local or remote) with 2 mechanical buttons or 20 character by 4 line remote LCD Display/Keyboard
• Eight discrete inputs (DIs) with interrupt capability
• Two discrete outputs (DOs)
• Six selectable bi-directional DI/DO points
• Four analog inputs (AIs) - optional
• Two analog outputs (AOs) - optional
• One high-speed counter input (HSC)
• Flash EPROM for system/custom firmware, as-well-as storage of the ACCOL load.
• Soft (menu driven) configuration of the node address, baud rate and other selections formerly configured by DIP switches and jumpers.
1.2 PHYSICAL DESCRIPTION
Model 3305 RTUs are comprised of the following major components:
• Backplane Board
• Processor Memory Peripheral Power Supply Board (PMPP)
• Multifunction Input/Output Board (MI/OB)
• Mounting Plate, Brackets & Hardware
1.2.1 Backplane Board
1-2 / Introduction
Figure 1-2 - The Backplane PCB
3305 RTU
The Backplane Board is a multilayer board that measures 6.25” wide by 3.8” long and is used to interconnect the Processor Memory Peripheral Power Supply Board, Multifunction
Input/Output Board and one of three display assemblies, i.e., a local 16 character by 2 line
Display Module with two pushbuttons, a remote 16 character by 2 line Display Module with two pushbuttons, or a remote 20 character by 4 line Display/Keyboard Module. The
Backplane Board contains up to four connectors which function as follows:
• Two 60-pin connectors P1 & P2 - connect the Multifunction I/O Board and the
Processor Memory Peripheral Power Supply Board together.
• One 26-pin connector P3 - for the local 2 X16 character LCD Module.
• One 50-pin connector P4 - for the remote 4 X20 character Display/Keyboard Module or the remote 2X16 character LCD Module.
There are two versions of the Backplane Board; one supports only the local 2 X 16 LCD
Display (P4 not present), the other supports both the Local 2 X 16 LCD Display and the
Remote 2 X 16 Display or the 4 X 20 Display/Keyboard Module (P3 & P4 present).
1.2.2 Processor Memory Peripheral Power Supply Board (PMPP)
The PMPP Board is a double sided Surface-Mount PCB that measures 6” wide by 6.5” long and provides the CPU/Memory function, communications subsystem, DC-to-DC power regulation, Real Time Clock (RTC), the System I/O BUS, and Status LEDs.
The PMPP Board utilizes a 12MHz 80C186XL CMOS, high-integration, 16-bit microprocessor chip that provides the CPU, three 16-bit Programmable Timers, a Programmable Interrupt Controller, Chip-Select/Ready Generation Logic, and Watchdog functions for the 3305
RTU.
The Processor/Memory Subsystem includes the Real Time Clock, Watchdog Timer, status
LEDs (6 firmware controlled plus Idle and Watchdog) and, in addition to the Microprocessor, contains the following memory devices:
• 512K bytes of System FLASH
• 504K bytes of RAM with battery backup
• 224K bytes of ACCOL Load Storage in FLASH
• 32K bytes of Boot & Configuration Firmware in FLASH
On board communication subsystems include the electronics for three RS-232 Ports (A, B &
C) and one TTL Port (D) (Port D becomes either an RS-232 or RS-485 Port on the MI/OB
Board). The D-type connectors associated with ports B, C and D are located on the MI/OB
Board. All 3305 RTU Communication Ports support asynchronous communications. Port A is the “Customer/Local/Diagnostic/FLASH Port” and uses a 3-Pin Molex connector.
The Real-time Clock Module is a complete CMOS timekeeper which incorporates a crystal oscillator, an integral real-time clock, and a lithium battery/power detect circuit. The RTC
Module combines three unique features: a complete time-of-day clock with alarm and onehundred year calendar, a programmable periodic interrupt and square-wave generator, and 64 bytes of low-power static RAM. The integral crystal oscillator has an accuracy of 1 sec/day (from 0 ° to +50 ° C). Table 1-1 provides the accuracy for temperatures between -30 ° C to +80 ° C.
3305 RTU Introduction / 1-3
RTC Memory consists of 50 general purpose RAM bytes, ten RAM bytes containing time, calendar and alarm data, and four bytes of RAM for control and status. Node Address and
Configuration data are stored in the RTC memory. Configuration data include the
Standard/Expanded Node Address selection, ACCOL load to RAM or FLASH, Updump
Switch, ACCOL FLASH lock, enable/disable Diagnostic messages on Port A, and the Cold
Download baud rate for Ports B, C and D.
Figure 1-3 - Processor Memory Peripheral Power Supply (PMPP) Board
1-4 / Introduction 3305 RTU
Table 1-1 - RTC Crystal Oscillator Accuracy Data
Temp. (Deg. C)
-30
-20
0
10
20
Temp. (Deg. F)
-22
-4
32
50
68
Sec./Day Max
8.0
5.0
1.0
0.8
0.4
30
40
50
60
86
104
122
140
0.4
0.6
1.0
2.8
70
80
158
176
5.0
7.4
Note: These numbers assume a standard 24 hour exposure to a particular temperature, which can be considered worst case.
Most of the inaccuracy occurs at the extremes of the Temp.
range.
1.2.2.1 Configuration Jumpers
The following Processor Memory Peripheral Power Supply Board (PMPP Board) Jumpers support configurable options:
• Jumper W2 Board Status LEDs Enable/Disable
IN = Board Status LEDs enabled
OUT = Board Status LEDs disabled
• Jumper W4 IN or OUT N/A to 3305
• Jumper W6 Communications Status LEDs Enable/Disable
IN = Comm. Status LEDs enabled
OUT = Comm. Status LEDs disabled
• Jumper W7 RAM Battery Back-up Enable/Disable
1 to 2 = RAM Battery back-up enabled
2 to 3 = RAM Battery back-up disabled
• Jumper W8 Boot/Configuration FLASH Boot Sector Write Protect
1 to 2 = Boot Sector write protect
2 to 3 = Boot Sector write enabled (For Factory Use Only)
• Jumper W10 - Power Fail trip Point Select (Used in conjunction with R11)
1 to 2 = Selects the trip point for the 9-20V input voltage range
2 to 3 = Selects the trip point for the 20-30V input voltage range
• Jumper W11 - Low battery detect (Used in conjunction with R12)
1 to 2 = Selects the low battery detect trip point for the 9-20V range
2 to 3 = Selects the low battery detect trip point for 20-30V range
• Jumper W12 - Master Clear (MC) and Power Fail (PF) LEDs Enable/Disable
IN = MC and PF LEDs enabled
OUT = MC and PF LEDs disabled
1.2.2.2 Processor Memory Peripheral Power Supply Board Configuration Switch
Switch SW1 on the PMPP Board sets loopback (testing) for Ports A, B & C (see Table 1-2).
3305 RTU Introduction / 1-5
Table 1-2 - Function of PMPP Board Switch SW1
Port ID Switch #
Port C 1
Port C
Port C
2
3
Port B
Port B
Port B
4
5
6
Port A
Port A
7
8
ON Definition
TXD to RXD Loopback
RTS to CTS Loopback
DTR to DCD loopback
TXD to RXD Loopback
RTS to CTS Loopback
DTR to DCD Loopback
TXD to RXD Loopback
RTS to CTS Loopback
1.2.2.3 Processor Memory Peripheral Power Supply Board LED Indicators
The PMPP Power Supply Board contains 18 LEDs (LEDs DS10 through DS15 are discussed in Section 5). These 18 LEDs are designated as follows:
DS1 - Port A (Transmit Status)
DS2 - Port A (Receive Status)
DS3 - Port B (Transmit Status)
DS4 - Port B (Receive Status)
DS5 - Port C (Transmit Status)
DS6 - Port C (Receive Status)
DS7 - Port D (Transmit Status)
DS8 - Port D (Receive Status)
DS9 - (System Halted/Running)
DS10 - STATUS 1
DS11 - STATUS 2
DS12 - STATUS 3
DS13 - STATUS 4
DS14 - STATUS 5
DS15 - STATUS 6
DS16 - State of MC* (ON = MC* inactive)
DS17 - State of PFIN* (ON = PFIN* inactive)
DS18 - WDOG (Watchdog Occurred)
1.2.2.4 Lithium Battery
A Lithium battery provides back-up power to the RAM when the +5V supply fails. This battery provides a cumulative back-up period of four months. Battery status can be determined by using the ACCOL TOOLS DIAG software Lithium Battery test (see 33XX
Diagnostics Manual - D4041) (see Section 4 - SERVICE of this manual). When the battery is functioning properly, the RTU can lose power but still retain its ACCOL load and continue running from the point of power loss once power is restored. The battery is checked at 8:00 A.M. daily as a function of ACCOL.
1-6 / Introduction 3305 RTU
1.2.2.5 Communications Subsystem (also see Section 1.2.3.7)
The Communications Subsystem of the PMPP Board handles all 3305 RTU serial communications via two Z85C30 Serial Communications Controllers. These ports are assigned as follows:
Port A - Local Configuration/Communications Port (3-Pin Molex Connector J3)
Port B - RS-232 Network Port (P2 cable to MI/OB - 9-Pin D-Type Connector P5 on MI/OB)
Port C - RS-232 Network Port (J1 to MI/OB - 9-Pin D-Type Connector P4 on MI/OB)
Port D - TTL Port on Power Supply/CPU Board (J1 to MI/OB) (MI/OB RS-232/485 9-Pin D-
Type Connector P3)
Port A Local Configuration/Diagnostic/Communications Port
Port A is used to download FLASH configuration and FLASHWARE via a 3-Pin Molex type connector (J3). This Local Port can be connected to a Process Engineer’s Interface (PEI) computer RS-232 Comm. Port for BSAP Slave/Pseudo-Slave applications. Additionally, a
Terminal Emulator or a computer with a Terminal Emulation Software package (such as
PROCOMM) can be used to monitor the start-up sequence. Port A is not a network port and therefore does not support interface to a modem.
Port B Local/Network RS232 Port
Port B can be used for local or network communications and supports external options such as a modem. Port B supplies standard RS-232 signals: RX, TX, RTS, DTR, DSR, CTS, and
DCD with loopback switches for TX to RX, RTS to CTS and DTR to DCD. +5V can be obtained from pin 3 of connector P5 for modems or other RS-232 devices that require 5V power. When Jumper W18 is installed in position 2-3, +5V power can be obtained from pin
8 of connector P5. The 9-Pin D-Type Connector (P5) associated with Port B is situated on the MI/OB Board.
Port C Local/Network RS232 or TTL Port
Port C can be used for local or network communications and it can be configured for TTL or
RS-232 operation. As a standard RS-232 port, Port C supplies the following signals: RX,
TX, RTS, DTR, DSR, CTS, and DCD with loopback switches for TX to RX, RTS to CTS and
DTR to DCD. When used in conjunction with TTL devices such as Bristol Babcock’s Transmitter Interface (TI) Board, Radio Delay Interface (RDI) Board, RS-485 Interface Board
(Non-isolated), or a modem, the RS-232 Driver IC (U32) is replaced with a Jumper Block
(P/N 392511-01-0) allowing Port C to provide a TTL interface. For modems or other devices that require 5V power and RS-232 logic, DO NOT replace IC U32 with the Jumper Block.
+5V can be obtained from pin 3 of connector P4. The 9-Pin D-Type Connector (P4) associated with Port C is situated on the MI/OB Board.
Port D Local/Network RS-232/RS-485 Port
Port D provides a TTL Interface to connector J2 of the Power Supply/CPU Board and J1 of the MI/OB Board. These signals are converted on the MI/OB Board to either RS-232 or RS-
485 levels. The 9-Pin D-Type Connector (P3) associated with Port D is situated on the
MI/OB Board.
3305 RTU Introduction / 1-7
1.2.2.6 Processor Memory Peripheral Power Supply Board Connectors
The PMPP Board contains four connectors; J1, J2, J3 and J4. Off-board Connector J1 interfaces the RS-232 signals associated with port B between the Board and the MI/OB Board
Connector P2 (see Section 1.2.3.8 - Table 1-5).
Connector J2 mates with P1 of the Backplane Board and handles all I/O between the
MI/OB and the PMPP Board (see Table 1-3).
Table 1-3 - PMPP PCB Bus Interface Connector J2 Pin Assignments
PIN
#
1
2
5
6
3
4
MNEMONIC
WDOGB*
-
IODATA7*
IODATA0*
7
8
IODATA5*
IODATA2*
IODATA3*
IODATA4*
9 IODATA1*
10 IODATA6*
11 IOMADEN1*
12 IOMADEN2*
25 DCDD*
26 HSC
27 RXDD
28 IOMCLK
29 IOMADEN1
30 -
* = NOT
DESCRIPTION
Reset
-
Data
Data
Data
Data
Data
Data
Data
Data
Board Select
Board Select
PIN
#
MNEMONIC
31 IOMADEN2
32 DCDC
33 IOMADEN3
34 IOMINT1*
35 +18V
36 IOMINT2*
37 RTSC
38 CTSD*
39 TXDC*
40 DTRD*
41 DTRC
42 CTSC
13 IOMADEN3*
14 TXDD
15 IOMADR1
16 IOMADR0
17 IOMADR3
18 IOMADR2
19 IOMWR*
20 IOMRD*
Board Select
Comm Line (TTL)
Subfunction Address 45 IOINT3*
Subfunction Address 46 PB1OUT
Subfunction Address 47 -
Subfunction Address 48 PB2OUT
I/O Mem. Write
I/O Mem. Read
21 IOMSEL*
22 IOMRDYB*
I/O System Select
Access Ackng.
23 IOMRST+MC* Board Reset
24 RXDC* RS232 Comm Line
43 -18V
44 DSRC
49
50
51
RTSD*
52 MC*
53 DSRD*
54 +21V
-
-
TTL Comm Line
High Speed Counter
TTL Comm Line
6MHz System Clock
Board Select
-
55 VCC (+5V)
56 GND
57 VCC (+5V)
58 GND
59 VCC (+5V)
60 GND
DESCRIPTION
Board Select
RS232 Comm Line
Board Select
Slot 1 Interrupt (DI)
Analog Power
Interrupt 2 (Keybd)
RS232 Comm Line
RS232 Comm Line
RS232 Comm Line
TTL Comm Line
RS232 Comm Line
RS232 Comm Line
Analog Power
RS232 Comm Line
I/O Slot 5 Interrupt 3
Push-button 1 Intrpt
-
Push-button 2 Intrpt
TTL Comm Line
-
-
Power Supply Reset
Sequencer Signal
Analog Power
Digital Logic Power
Digital Logic Ground
Digital Logic Power
Digital Logic Ground
Digital Logic Power
Digital Logic Ground
J3 is the 3-Pin Molex Connector associated with Port A. RS-232 level signals TXD, RXD, and GND appear on pins 1, 2, and 3 respectively.
Off-board Connector J4 mates with Connector P1 on the MI/OB Board. Bulk (9-30Vdc)
Power is supplied on Pin 1 and power return is on Pin 2.
1-8 / Introduction 3305 RTU
1.2.3 Multifunction Input/Output Board (MI/OB)
The MI/OB Board is a multilayer board that measures 6” wide by 10.1” long and contains the circuitry used for Discrete Inputs, Discrete Outputs, Analog Inputs, Analog Outputs, a
High Speed Counter, communications and watchdog functions. The MI/OB is the bottom board of the RTU 3305 and is stoodoff from the 3305 Mounting Plate at six points via mounting posts. The MI/OB Board is secured to four of the mounting posts via the PMPP
Board’s standoff/mounting posts and is secured to the remaining two mounting posts via screws. Interface to the PMPP Board is accomplished via the Backplane Board. Terminal blocks, cable connectors, and con-figuration jumpers are accessible without disassembly.
The MI/OB contains 3 terminal blocks (TB1, TB2 & TB3), three 9-pin D-type connectors
(P3, P4 & P5), a two-pin cable connector (P1), a 12-pin cable connector (P2) and a 60-pin mass termination connector (J1).
1.2.3.1 Discrete Input Circuitry
Discrete Input Circuitry features optical isolation, surge suppression, and 1msec filtering for DI7 through DI14 and 30msec filtering for DI1 through DI6. Input Range is (0-24 or 0-
12) Vdc ±10%. Field connections for DI1-DI14 are located at TB1. The DI is activated by closing the connection between +DI and -DI with a dry contact (see Section 2.4.1).
The MI/OB Board DI interrupt circuitry can be used to generate an interrupt on a change of state condition associated with DIs 7 though 14. This circuitry compares the previous state of a DI with the present state and the interrupt mask for the DI in question. Each DI is tested sequentially. Detection of a change of state causes the circuitry to halt until an interrupt service routine has been completed. During the interrupt service routine, the address of the DI that changed state (and generated the interrupt) is read. Upon completion of the interrupt service routine, the change of state detection circuitry is started and the next DI is examined.
A status register indicates which DI/O points are available as DIs. DI/O1 through DI/O6
(which can also be configured for DO operation) do not generate interrupts on change of state. Therefore, DI1 through DI6 should not be used for counting applications.
Each DI is supported with a status LED, i.e., one each for DI7 through DI14 and one each for DI/O1 through DI/O6. Jumper W7 is used to enable or disable these LEDs. W7 in position 1-2 enables the LEDs; W7 in position 2-3 disables the LEDs.
1.2.3.2 Discrete Output Circuitry
The MI/OB Board supports up to eight open drain type DOs capable of handling 100mA @
35Vdc. Surge suppression is included. Field connections for DO1 through DO8 are located at TB1 (see Section 2.4.2).
An 8-bit DO Load Register controls the ON/OFF state of each discrete output. Writing a 1 bit turns the corresponding DO to an “ON” state and writing a 0 turns the corresponding
DO to an “OFF” state. Writing to a bit which corresponds to an DI/O point configured as an input has no effect on the input point. Upon power up or after a watchdog reset, the DO register is cleared and all outputs are set “OFF.”
3305 RTU Introduction / 1-9
An 8-bit DO Status Register provides the status of each DO. A bit set to “0” means that DO is “OFF” and a bit set to “1” indicates the DO is “ON.” The DO Status Register will post a
“0“ for any DI/O point which has been configured for DI operation. The 6-bit DO
Configuration Status Register indicates which DI/O points have been configured as DOs.
Each DO is supported with a status LED, i.e., one each for DO7 and DO8 and one each for
DI/O1 through DI/O6. Jumper W7 is used to enable or disable these LEDs. W7 in positions
1-2 enables these LEDs; W7 in position 2-3 disabled these LEDs.
1-10 / Introduction
Figure 1-4 - The Multifunction Input/Output Board
3305 RTU
1.2.3.3 Analog Input Circuitry
The MI/OB Board’s analog input circuitry supports up to four 1-5V isolated inputs, 4-20mA isolated inputs, or 4-20mA internally powered loops that are referenced to the PCOM of the board. Analog inputs feature 180V Common Mode. The 180V Common Mode input circuitry utilizes an input stage composed of 40:1 resistive dividers and a 1 m F capacitor which functions as a low pass filter.
An analog multiplexor is used to select one of four channels as the input to an instrument
Amplifier. An Analog-To-Digital Converter takes approximately 130 microseconds to convert the selected input voltage to a 12-bit digitized value. Potentiometers R143 and R144 are provided for calibration of the analog input circuitry. ACCOL Diagnostics is used to test the gain and offset of the analog input circuit. The gain is set by adjusting R144 (with
+5Vdc placed across TB2-2 and TB2-1). The offset is set by adjusting R143 (with +1Vdc placed across TB2-2 & TB2-1). Four sets of jumper pairs (W8A/8B through W11A/11B) are used to configure analog inputs AI1 through AI4 respectively (see Section 2.4.3).
1.2.3.4 Analog Output Circuitry
The MI/OB Board’s analog output circuitry supports two analog outputs and is comprised of a bus interface, a two channel Digital-To-Analog Converter and a signal conditioning circuit to generate a 4-20mA output (see Section 2.4.4). Two potentiometers per channel are used to adjust the 4mA point and the 20mA point. ACCOL Diagnostics are required to calibrate the analog outputs. A Current meter (or a 250 Ohm 0.01% tolerance resistor and
DVM) is required to measure the output current during the calibration adjustments.
1.2.3.5 High Speed Counter Circuitry
High Speed Counter circuitry is comprised of two opto-isolated circuits which are powered from the 12V or 24V RTU 3305 power source, and a one shot IC used to limit the input frequency to 15KHz. A debounce circuit (enabled with Jumper W15 installed) supports relay contact type field signals.
High Speed Counter inputs are configured as dry contacts. Field connections are HSCSET,
HSCRESET, and PCOM. The frequency range of the High Speed Counter circuit is DC to
10KHz and inputs are surge protected. HSCSET, HSCRESET, and PCOM connections are
TB3-6, TB3-4 and TB3-5 respectively. Field devices can be either Open Collector Transistor
(Using Set Input) (Jumper W15, 2-3 installed) or SPDT Dry Contact (Using Set/Reset Inputs) (Jumper W15, 1-2 installed) (see Section 2.4.5).
1.2.3.6 Watchdog Relay Circuitry
The MI/OB Board contains the Watchdog Relay which de-energizes when MC* or WDOGB* are active. A SPDT contact is routed to three terminal blocks: TB3-7, TB3-8 and TB3-9 where TB3-7 to TB3-9 is the NC contact and TB3-8 to TB3-9 is the NO contact. The
Watchdog Relay output can be used to drive an alarm or annunciation device (see Section
2.4.6).
3305 RTU Introduction / 1-11
1.2.3.7 Communication Ports (also see Section 1.2.2.5)
The MI/OB Board contains three communications ports. All three ports support modems and function as follows:
Port B - Port B provides RS-232 signals for a local communication device such as a PC or an optional external Modem. Signals are routed through connector P2 of the PMPP
Board to the 9-Pin D-Type connector P5 on the MI/OB Board. MI/OB Jumper W18 is used in conjunction with Port B to select +5V or DSR on P5 pin 8 as follows: standard
RS-232 operation - W18 in position 1-2 (DSR), modem requiring 5V power and RS-232 signal levels - W18 in position 2-3 (+5V).
Port C - Port C provides an interface for local communication (RS-232) or an optional communications device such as a TIB, Modem, RS-485, or RDI Board. RS-232 signals are routed through connector J1 of the PMPP Board to the 9-Pin D-Type connector P4.
Port C supplies standard RS-232 signals: RX, TX, RTS, DTR, DSR, CTS, and DCD with loopback switches for TX to RX, RTS to CTS, and DTR to DCD. When used with a local option, the RS-232 Driver (U32) is replaced with a Jumper Block (P/N 392511-01-0) providing a TTL interface. The 9-Pin D-Type Connector (P4) associated with port C is situated on the MI/OB Board. For modems requiring +5V power and RS-232 logic, DO
NOT replace U32 with the Jumper Block.
Port D - Port D provides either an RS-232 or RS-485 interface for local network communication. TTL signals are routed through connector J1 from the PMPP Board to the
LTC-1322 Converter on the MI/OB Board and on to the 9-Pin D-Type connector P3.
When transmitting data, the LTC1322 Converter changes TTL level inputs (RX, TX,
RTS, CTS, CD, DCD and DSR) to RS-232/RS-485 levels. When receiving data, the
LTC1322 Converter changes RS-232/RS-485 signals to TTL levels. An eight position
DIP Switch (SW1) selects the mode of operation for Port D. SW1 also selects loopback for RS-232 signals and transmitter/receiver line terminations for RS-485 mode.
1.2.3.8 Multifunction I/O Board Terminal Blocks and Connectors
Functionality of the MI/OB’s Terminal Blocks and Connectors are discussed below:
J1 - Bus Interface Connector:
The 60-pin Bus Interface Connector (J1) supports the I/O Bus between the PMPP Board and the MI/OB Board (via Backplane Board Connector P1). The I/O Bus consists of 8 data lines, 4 address lines, 4 control lines, a 6MHz clock line, board enable lines (which are selected from 6 board enable signals), and 14 communications lines. The typical board cycle time is 1 m Sec. All signals are CMOS compatible except the data lines, which are TTL compatible (see Table 1-4).
P1 - MI/OB Power Connector:
The 2-pin Power Connector (P1) supplies +12V or +24V power on pin 1 and Power Return on pin 2.
P2 - Port B RS-232 Interface Connector:
P2 is a 12-pin connector that interfaces the port B RS-232 signals between the MI/OB and the PMPP Board. P2 mates with PMPP Board Off-board Connector J1 (see Table 1-5).
1-12 / Introduction 3305 RTU
Table 1-4 - PMPP PCB Bus Interface Connector P2 Pin Assignments
PIN
#
1
2
3
4
5
MNEMONIC
WDOGB*
VIN
IODATA7*
IODATA0*
IODATA5*
8
9
6
7
IODATA2*
IODATA3*
IODATA4*
IODATA1*
10 IODATA6*
11 IOMADEN1*
12 IOMADEN2*
13 IOMADEN3*
14 TXDD
15 IOMADR1
16 IOMADR0
17 IOMADR3
18 IOMADR2
19 IOMWR*
20 IOMRD*
21 IOMSEL*
22 IOMRDYB*
23 IOMRST+MC*
24 RXDC*
25 DCDD*
26 HSC
27 RXDD
28 IOMCLK
29 IOMADEN1
30 -
* = NOT
DESCRIPTION
Reset
-
Data
Data
Data
Data
Data
Data
Data
Data
Board Select
Board Select
Board Select
Comm Line (TTL)
Subfunction Address
Subfunction Address
Subfunction Address
Subfunction Address
I/O Mem. Write
I/O Mem. Read
I/O System Select
Access Ackng.
Board Reset
RS232 Comm Line
TTL Comm Line
High Speed Counter
TTL Comm Line
6MHz System Clock
Board Select
-
PIN
#
MNEMONIC
31 IOMADEN2
32 DCDC
33 IOMADEN3
34 IOMINT1*
35 +18V
36
37 RTSC
38 CTSD*
39 TXDC*
-
40 DTRD*
41 DTRC
42 CTSC
43 -18V
44 DSRC
45
46
47
-
-
-
48
49 RTSD*
-
50
51 -
-
52 MC*
53 DSRD*
54 +21V
55 VCC (+5V)
56 GND
57 VCC (+5V)
58 GND
59 VCC (+5V)
60 GND
DESCRIPTION
Board Select
RS232 Comm Line
Board Select
Slot 1 Interrupt (DI)
Analog Power
-
RS232 Comm Line
RS232 Comm Line
RS232 Comm Line
TTL Comm Line
RS232 Comm Line
RS232 Comm Line
Analog Power
-
-
-
-
-
TTL Comm Line
-
-
Power Supply Reset
Sequencer Signal
Analog Power
Digital Logic Power
Digital Logic Ground
Digital Logic Power
Digital Logic Ground
Digital Logic Power
Digital Logic Ground
Table 1-5 - Port B Interface Connector P2 (MI/OB) J1 (PMPP) Pin Assignments
Pin # MNEMONIC
1 TXDB*
2
3
RTSB
RXDB*
4
9
10
11
12
CTSB
DCDB
PCOM
DTRB
DSRB
DESCRIPTION
Transmit Data NOT
Request To Send
Receive Data NOT
COLOR CODE
White (1)
Blue (2)
Gray (3)
Clear To Send
Data Carrier Detect
Violet (4)
Yellow (5)
Power Common Green (6)
Data Terminal Ready Tan (7)
Data Set Ready Pink (8)
Note:
Column labeled Pin # applies to MI/OB Connector P2 and PMPP
Board Off-board Connector J1. Numbers in parenthesis in Column labeled COLOR CODE, apply to PMPP Board On-board Connector J1.
3305 RTU Introduction / 1-13
1-14 / Introduction
Figure 1-5 - MI/OB’s Field Wiring Terminals
3305 RTU
TB1 - Discrete I/O Interface Termination Connector:
Removable Terminal Blocks TB1-1 through TB1-32 are used for Discrete I/O field wiring
(see Table 1-6 and Figure 1-5).
Table 1-6 - Discrete I/O Wiring Connector (TB1) Pin Assignments
23
24
25
26
19
20
21
22
27
28
29
30
31
32
11
12
13
14
7
8
9
10
15
16
17
18
Pin # MNEMONIC
1 -DI1/DO1
2
3
+DI1/DO1
-DI2/DO2
4
5
6
+DI2/DO2
-DI3/DO3
+DI3/DO3
-DI4/DO4
+DI4/DO4
-DI5/DO5
+DI5/DO5
-DI6/DO6
+DI6/DO6
-DI7
+DI7
-DI8
+DI8
-DI9
+DI9
-DI10
+DI10
-DI11
+DI11
-DI12
+DI12
-DI13
+DI13
-DI14
+DI14
-DO7
+DO7
-DO8
+DO8
DESCRIPTION
PCOM
Discrete I/O Source
PCOM
Discrete I/O Source
PCOM
Discrete I/O Source
PCOM
Discrete I/O Source
PCOM
Discrete I/O Source
PCOM
Discrete I/O Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Input Source
PCOM
Discrete Output Source
PCOM
Discrete Output Source
TB2 - Analog I/O Interface Termination Connectors:
Removable Terminal Blocks TB2-1 through TB2-12 are used for Analog I/O field wiring
(see Table 1-7 and Figure 1-5).
TB3 - Power, High Speed Counter & Watchdog I/O Interface Connector:
TB3-1 through TB3-9 provide High Speed Counter inputs and Watchdog outputs in addition to +12V or +24V (Bulk 9 to 30 Vdc) power and ground (see Table 1-8 & Figure 1-5).
3305 RTU Introduction / 1-15
Table 1-7 - Analog I/O Field Wiring Connector (TB2) Pin Assignments
10
11
12
8
9
6
7
Pin # MNEMONIC
1 -AI1
2
3
+AI1
-AI2
4
5
+AI2
-AI3
+AI3
-AI4
+AI4
-AO1
+AO1
-AO2
+AO2
DESCRIPTION
Analog Input Channel 1
Analog Input Channel 1
Analog Input Channel 2
Analog Input Channel 2
Analog Input Channel 3
Analog Input Channel 3
Analog Input Channel 4
Analog Input Channel 4
Analog Common
Analog Output 1 Source
Analog Common
Analog Output 2 Source
Table 1-8 - PWR, HSC & WD Circuits I/O Wiring Connector (TB3) Pin Assignments
7
8
5
6
9
Pin # MNEMONIC
1 PCOM
2
3
4
POWER
CHASSIS
+HSCRESET
PCOM
+HSCSET
NCWDOG
NOWDOG
COMMON
DESCRIPTION
System Ground
System Power (12/24V)
Chassis Ground
HSC Reset Input
System Ground
HSC Set Input
NC Watchdog Contact
NO Watchdog Contact
COMMON Watchdog Contact
Ports B, C & D - RS-232 Connectors:
The 9-Pin D-Type communication port connectors are wired for RS-232 operation as detailed in Table 1-9 below. P3 is assigned as Port D, P4 is assigned as Port C, and P5 is assigned as Port B. Note: Pin #3 is unassigned on Port D (P3) for RS-232 operation.
Table 1-9 - RS-232 Ports B, C & D Wiring
Pin #
1
2
DTR
TXD
P3/5-3 PWR
4
5
RXD
RTS
MNEMONIC
6
7
CTS
DCD
P3-8 DSR
P4-8
5V (U32 = 392511-01-0 Intf. Adapter
DSR (U32 = DS232 IC)
P5-8
9
5V (W18 in Position 2-3)
DSR (W18 in Position 1-2)
PCOM
DESCRIPTION
Data Terminal Ready (Output)
Transmit (Output)
+5Vdc
Receive (Input)
Request To Send (Output)
Clear To Send (Input)
Data Carrier Detect (Input)
Data Set Ready (Input)
+5Vdc
Data Set Ready
+5Vdc
Data Set Ready
Port Ground
1-16 / Introduction 3305 RTU
Port D - 9-Pin D-Type Connector P3 Configured For RS-485 Operation:
The 9-Pin D-Type communication port connector associated with Port D can be configured for RS-232 or RS-485 operation. When configured for RS-485 operation, Port D appears as detailed in Table 1-10 below.
Table 1-10 - Port D (Configured for RS-485 Operation) Wiring
Pin # MNEMONIC DESCRIPTION
1 +TX Transmit (Pos.)
2
3
-TX
+RX
Transmit (Neg.)
Receive (Pos.)
4
9
-RX
PCOM
Receive (Neg.)
Port Ground
1.2.3.9 Multifunction I/O Board Jumpers & Switch SW1
The MI/OB Board contains 18 Jumpers (4 factory installed) and 1 Switch that function as follows:
• Jumpers W1 through W6 - Set individual DI/O points 1 through 6 (respectively) for discrete input or discrete output operation. When set in position A, the associated point will be configured for DI operation. When set in the B position, the associated point will be configured for DO operation.
• Jumper W7 - Enables/Disables eight (8) DI LEDs, six (6) DI/O LEDs, two (2) DO
LEDs, and one (1) HSC LED on the MI/OB Board. When set in position 1-2, the
LEDs are enabled. When set in position 2-3 these LEDs are disabled.
• Jumpers W8A/W8B, W9A/W9B, W10A/W10B & W11A/W11B - Set individual Analog
Inputs 1 through 4 (respectively) for Isolated Voltage Input, Isolated Current Input or Internally Sourced Current Input operation (see Section 1.2.3.3).
• Jumper W15 - Enables/Disables the High Speed Counter debounce circuitry. W15 must be installed in position 2-3 to disable the debounce circuit for HSC Open
Collector operation and installed in position 1-2 to enable the debounce for SPDT
Dry Contact operation.
• Jumper W17 - Enables/Disables the Watchdog Relay circuitry. W17 must be installed in position 2-3 to disable the Watchdog Relay and installed in position 1-2 to enable the Watchdog Relay.
• Jumper W18 - Selects +5V or DSR on P5 pin 8.
• Standard RS-232 Operation - W18 in position 1-2 (DSR).
• Modem requiring 5V power and RS-232 signal levels - W18 in position 2-3 (+5V).
• Switch SW1 - SW1 is an 8-position DIP switch used for configuring Port D for RS-
232 or RS-485 operation (see Table 1-11).
1.2.3.10 MI/OB LEDs
The MI/OB Board contains 17 LEDs which are enabled when Jumper W7 is set in position
1-2 and disabled when W7 is set in position 2-3. These LEDs follow the state of the input or output field circuit to which they are assigned. LEDs are situated behind the I/O Card
Edge Connectors. Table 1-12 provides assignments for the MI/OB LEDs.
3305 RTU Introduction / 1-17
Table 1-11 - MI/OB -Port D Configuration Switch SW1 Assignments
SW1
#
1
2
Function
-
RS-232/485 Selection
RS-232
Operation
-
ON = 232
Enabled
RS-485
Master station
-
OFF = 485
Enabled
ON =
Enabled
RS-485 Most
Distant
Slave
-
OFF = 485
Enabled
ON =
Enabled
RS-485
Other
Slaves
-
OFF = 485
Enabled
OFF =
Disabled
3
4
5
6
7
8
RS-484 XMTR 120 S
Term. Resistor
RS485 RCVR 120 S
Term. (+ Bias) Resistor
RS485 RCVR 120 S
Term. (- Bias) Resistor
RS-232 TXD/RXD
Loopback
RS-232 RTS/CTS
Loopback
RS-232 DTR/DCD
Loopback
N/A
N/A
N/A
ON enables
Local Loopback
ON enables
Local Loopback
ON enables
Local Loopback
ON =
Enabled
ON =
Enabled
N/A
N/A
N/A
ON =
Enabled
ON =
Enabled
N/A
N/A
N/A
OFF =
Disabled
OFF =
Disabled
N/A
N/A
N/A
Note: SW1-4 & SW1-5 must be set together, i.e., both must be set ON to enable (install) the
RS-485 120 S Receiver (Bias) Resistor.
Note: SW1 switches -6, -7 & -8 are provided for RS-232 configuration. These switches are typically set ON for test purposes and with the exception of SW1-7 are otherwise set
OFF. When Port D is connected to a PC, SW1-7 should be set ON (see Figure 2-19).
Table 1-12 - MI/OB LED Assignments
LED Name I/O Assignment LED Name I/O Assignment
CR29 DI/O1 CR75 DI10
CR30
CR31
DI/O2
DI/O3
CR76
CR77
DI11
DI12
CR32
CR70
CR71
CR72
CR73
CR74
DI/O4
DI/O5
DI/O6
DI7
DI8
DI9
CR78
CR79
CR80
CR81
CR82
-
DI13
DI14
DO7
DO8
HSC
-
1.2.3.11 MI/OB On-Board Fuse F1
A replaceable Fuse (F1) in the bulk dc supply circuit provides short circuit or excessive current protection for the 3305 RTU. This fuse is located near the MI/OB’s Card Edge
Terminal Blocks and is rated at .5 Amps for the bulk 20-30 Vdc supply or 1 Amp when a bulk 9-20 Vdc supply is used.
1.3 OPTIONS
Options fall into three categories; LCD Displays, Communication Assemblies and Power
Supplies. Note: An optional Power Supply is only available with the RTU 3305
Standard Enclosure Assembly.
1-18 / Introduction 3305 RTU
1.3.1 LCD Displays
Each 3305 RTU can be interfaced to one LCD Display. LCD Displays available for the RTU
3305 are listed as follows:
• 2 X 16 Character LCD Display (locally mounted)
• 2 X 16 LCD Display (remotely mounted)
• 4 X 20 Display/Keyboard (remotely mounted)
Figure 1-6 - Front & Side Views of 4 X 20 Display/Keyboard Assembly
3305 RTU Introduction / 1-19
Figure 1-7 - Front View of 2 X 16 LCD Display Assembly
These LCD Display Assemblies are powered by the 3305 RTU via the Interface Ribbon
Cable. The 2 X 16 LCD Displays are physically and functionally identical except for the Interface Ribbon Cable. The Remote 2 X 16 LCD Display and the 4 X 20 Display/Keyboard assemblies interface with the RTU via Backplane Assembly Connector P4 (a 50-pin
Header), while the Local 2 X 16 LCD Display interfaces via Backplane Assembly Connector
P3 (a 26-pin Header) and is mounted on standoffs which in turn are mounted on brackets at the top of the unit (see Figure 2-23). When connecting a Ribbon Cable to Backplane Connector P3 or P4, make sure that the arrows adjacent to Pin 1 (Ribbon Cable Connector and appropriate Backplane PCB Connector) are aligned.
Figure 1-8 - Bottom View of 2 X 16 LCD Display Assembly
DC power for the Local 2 X 16 LCD Display is available on pins 2 & 17 of Backplane
Connector P3 with PCOM on pins 1, 16, and 20 through 26. In the case of the remotely mounted Display assemblies, DC power is available on pins 46 through 50 of Backplane
Connector P4 with PCOM on pins 1, 29, 30, 44 & 45.
1-20 / Introduction 3305 RTU
Operation of the 2 X 16 LCD Display Assemblies and the 4 X 20 Display/Keyboard Assembly are discussed in Section 3.
1.3.2 Network Communication Options
The 3305 RTU can be interfaced to one of the following communication options via Port C on the MI/OB Board:
• BBI 9600 bps PSTN Modem (see CI-9600 or CI-9600A Manual)
• BBI 1200 bps PL/PSTN Modem (see CI-1200 Manual)
• BBI Transmitter Interface Board (see Appendix 1 - PIP-TIBS33XX)
• BBI Radio Delay Board (see Appendix 2)
• BBI RS-485 Intf. Board (see Appendix 3) or (see Appendix 7 - PIP-ISORS485 for
Isolated version)
• BBI Highway Addressable Remote Transducer (HART®) Device Interface (see
Appendix 5 – PIP-HART33XX)
The 3305 RTU can be interfaced to one of the following communication options via Port D on the MI/OB Board:
• BBI Network Interface Board for surge protection of 3305 on an RS-485 configured multidrop HART Network (see Appendix 4 & Appendix 5), or for surge protection and bias termination of industry standard (non-BBI) RS-485 Interface boards (see
Appendix 4).
Figure 1-9 - BBI 9600 bps PSTN Modem Layout (P/N 396039-10-3)
1.3.2.1 Modems (see Figures 1-9, 1-10, & 1-11)
Either a BBI 1200 bps Private Line (PL)/Public Switched Telephone Network (PSTN)
Modem or a Hayes Compatible BBI 9600 bps Public Switched Telephone Network (PSTN)
3305 RTU Introduction / 1-21
Modem can be directly mounted to the 3305 RTU. When installed, the modem will be mounted to the top of the 3305’s Option Mounting Brackets. The modem interface is between TB3 (with TB4 providing Ground, i.e., PCOM) on the modem in question and Port
C (P4) on the MI/OB Board. Figures 1-9 through 1-11 provide partial surface views of these modems.
Figure 1-10 - BBI 9600 bps PSTN Modem Layout (P/N 392958-05-8)
1-22 / Introduction
Figure 1-11 - BBI 1200 bps PL/PSTN Modem Layout
3305 RTU
1.3.2.2 BBI Transmitter Interface Board (see Figure 1-12)
The Transmitter Interface Board (TI Board) allows up to five Bristol Babcock, Series 3508
Transmitters to communicate with a series 3305 RTU. The 3305 RTU polls and stores data from each transmitter and communicates with the network. The TI Board will be stood off from the top of the 3305’s Option Mounting Brackets with 1” standoffs. Interface occurs via connector P1A of the TI Board and Port C (P4) on the MI/OB Board. Power for the TI
Board (TB1) will be derived from the MI/OB Board as follows: TB3-2 = Power & TB3-1 =
PCOM. Figure 1-12 provides a surface view of the BBI Transmitter Interface Board. See
Appendix 1 for details on the BBI TI Board.
Figure 1-12 - +24V TI Board Layout
1.3.2.3 RS-485 Interface Board (see Figure 1-13)
The RS-485 Interface Board allows an RTU 3305 to be multidropped with up to 31 other
BBI 33XX Controllers. The RS-485 Interface Board will be mounted to the top of the 3305’s
Option Mounting Brackets. Interface occurs via connector J1A of the RS-485 Interface
Board and Port C (P4) on the MI/OB Board. The RS-485 Interface Board requires a +9V
External Power Source. Power for the RS-485 Interface Board will be derived from the
MI/OB Board as follows: TB3-2 = Power & TB3-1 = PCOM. Quick Disconnects are used to connect field wiring to the RS-485 Board. Appendix 3 in the rear of this manual provides details on the BBI RS-485 Interface Board.
An Isolated RS-485 Interface Board is also available. The Isolated RS-485 Interface Board allows any BBI Network 3000 product to communicate over an isolated master/slave network. Each node on the network that incorporates an Isolated RS-485 Interface Board is optically isolated from the rest of the network, thereby eliminating ground loop and potential difference effects that may degrade network communication performance. The result is a reliable communication medium for in-plant or building to building LANs. PIP-
3305 RTU Introduction / 1-23
ISORS485 in the rear of this manual provides details on the BBI Isolated RS-485 Interface
Board.
Figure 1-13 - RS-485 Interface Board Layout
1-24 / Introduction
Figure 1-14 - Radio Delay Board Layout
3305 RTU
1.3.2.4 Radio Delay Board (see Figure 1-14)
The Radio Delay Board acts as an interface between the RTU 3305 and an external radio frequency (rf) transceiver or modem. This board will be mounted to the top of the 3305’s option Mounting Brackets. Interface occurs via Port C on the MI/OB Board and connectors
TB3 and TB1 on the Radio Delay Board (TB1 is used for Ground - PCOM). Appendix 2 in the rear of this manual provides details on the BBI Radio Delay Board.
1.3.2.5 BBI Network Interface Box (NIB) (see Appendix 4)
The BBI Network Interface Box (NIB) is required on RS-485 communication networks in order to maintain the correct line status during periods of inactivity. While a NIB is recommended for each node, only the master and the most distant slave require bias termination. If these nodes are not biased, communication errors can result and the system may go into a “watchdog” condition. All NIBs include surge protection circuitry designed to protect the communication port of a node.
When used in conjunction with the 3305 RTU, the NIB’s jumpers W2 and W3 should be set in the A position to provide surge protection (without bias termination). The 3305 RTU handles bias and termination via Switch SW1 on the MI/OB Board (see Table 1-11).
1.3.2.6 HART Device Interface Option (see Appendix 5)
Highway Addressable Remote Transducer (HART) Device Interfaces (HDI) allows HART slave devices or BBI 3508 transmitters to communicate with a BBI Series 33XX DPC/RTU, i.e., 3305s, 3310s, 3330s, and 3335s. The HDI supports RS-232 and RS-485 interfaces. The interface to the field devices is composed of a jumper selectable 249 ohm resistor in parallel with an AC coupled transformer. An HART/TIB ACCOL Custom Module and the configuration of a host (33XX) communications port as a custom port in ‘HART mode’ are required to support the protocol (Data Link Layer) for HART devices. The ACCOL Master
Module is used to support RS-232 configured HDIs for communication with BBI 3508 transmitters. Each HDI can interface with up to 15 HART slave devices.
1.3.3 Power Supplies (see Appendix 6)
The RTU 3305 Standard Enclosure is available with a 40 Watt Power Supply Module
(+12Vdc or +24Vdc) or a compact Power Supply/Battery Charger. The 12V version of the 40
Watt Power Supply Module provides a maximum of 13.8Vdc while the 24V version provides a maximum of 28Vdc. A 40 Watt Power Supply Module is mounted to a Power Supply
Mounting Bracket via two (2) screws. The Power Supply Mounting Bracket is secured to the RTU 3305 Standard Enclosure’s “Back Fabrication Panel” via three (3) screws (See
Figures 1-15 and 1-16).
The RTU 3305 Power Supply/Battery Charger is a compact assembly that mounts externally to the RTU 3305. This linear power supply is actually a battery charger that contains temperature compensation circuitry. Peak output of the supply is +17.6V for a 24V system and +13.8V for a 12V system with a 10mA or greater load applied. Appendix 6 in the rear of this manual provides details on the RTU 3305 Power Supply/Battery Charger.
3305 RTU Introduction / 1-25
Figure 1-15 - 40 Watt Power Supply Module
Figure 1-16 - 40 Watt Power Supply Module Mounted on Mounting Bracket
1-26 / Introduction 3305 RTU
Section 1A
APPLICATION SOFTWARE
1A.1 CATEGORIES OF APPLICATION SOFTWARE
There are basically three categories of application software used with the RTU 3305:
1) ACCOL Tools and related software which are used to program your RTU 3305
Remote Terminal Unit for its intended application (pump control, pipeline monitoring, etc.). In general, this type of software is used by the System Engineer or
ACCOL programmer.
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 RTU
3305 and certain types of Supervisory software. In general, this software is configured by the System Engineer.
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 RTU 3305. 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.
3305 RTU Application Software / 1A- 1
Depending upon which ACCOL Tools you are using, your ACCOL program is initially created as ASCII text in an ACCOL source file (.ACC file).
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 which can be executed by the RTU 3305 controller. In order to get the load file into the controller, the file is downloaded into the
RTU 3305, which then executes the programming instructions in the load file.
The Windows™-based ACCOL Tools set consists of ACCOL Workbench 7.0 (or newer), together with the WINDIAG diagnostic program. Note: Windows diagnostics are detailed in the WINDIAG Diagnostics Manual - Document # D4041A.
ACCOL Workbench 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.
Figure 1A-1 - Files Created by Windows ™ -based ACCOL Workbench
(NOTE: All workbench on-line communication and downloading is facilitated via Open
BSI Utilities software, discussed later in this chapter).
1A-
2
/ Application Software 3305 RTU
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 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™ 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) Iconics Inc. Genesis software is a popular PC-based supervisory package which 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).
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 in the network
Collect and display data from the 3xxx controllers
Monitor and control Open BSI communications
Third-party supervisory software 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; some of the major utilities are described, briefly, below. Full details on each utility are included in Open BSI Utilities Manual [document # D5076 (Ver. 2.x users) or D5081
(Ver. 3.x users)].
Downloader transfers a linked ACCOL load file (*.ACL) to a remote 3xxx DPC/RTU.
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.
3305 RTU Application Software / 1A- 3
Figure 1A-3 - Open BSI Interface Diagram
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.
NetView allows the user to define communication network characteristics, define details about individual RTUs, and to change these characteristics on-line NetView supports existing BSAP networks.
LocalView is used for local communication only. It is used for performing field upgrades of system firmware.
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 capabilities for scheduled data collection, and file export. These utilities include the Open
BSI Harvester and the Data File Conversion utility (see the Ooen BSI Harvester manual
(document # D5120) for details.
For more information on these packages, consult the manuals accompanying them, or contact Bristol Babcock's application support group for assistance.
1A-
4
/ Application Software 3305 RTU
1A.5 SYSTEM APPLICATIONS
An RTU 3305 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 RTU 3305 cannot serve as a serial Communications Front End (CFE).
1A.5.1 Stand-Alone Unit
Figure 1A-4 shows an RTU 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 RTU can be observed or edited via the
PC.
Figure 1A-4 - Basic Stand-Alone Application
Once on line, the RTU executes the ACCOL load and performs its configured tasks.
Although the PC is attached to the RTU 3305 in Figure 1A-4, it can be disconnected and removed once the 3305 has been loaded and made operational.
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 the Iconics GENESIS 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-5. 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).
3305 RTU Application Software / 1A- 5
Figure 1A-5 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.
1A-
6
/ Application Software
Figure 1A-5 - Local Area Network
3305 RTU
The communication ports of each controller require hardware and soft switch configuration in addition to ACCOL configuration. In the case of the RTU 3305, the hardware configuration for Ports A through D are performed using the following hardware: PMPP
Board's Jumper (W1) for Port B, PMPP Board’s Switch SW3 for Ports A, B and C and the
MI/OB Board's Switch SW1 for Port D. Soft switch configuration is performed via a PEI equipped with (in addition to other programs) the BBI SYSTEM CONFIG/FLASH
DOWNLOADER Software (see Section 2.3.2). Additionally, communication ports must be defined in the ACCOL load using ACCOL Workbench Software. Note: SW3 on the PMPP
Board controls Ports A, B & C normal/testing, i.e., loopback, functions. When SW3 switch is set in the ON position, the associated loopback function is set. SW1 on the MI/OB Board sets RS-232 or RS-485 operation for Port D. SW1 also provides loopback testing and RS-485 network end node termination resistor installation. Note: NetView is used to configure the hierarchy of the network.
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.
A Bristol Babcock BSAP network 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-5 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.
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-6. The central system includes all 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.
The Area Operator computer running Open BSI software provides the operator with realtime communications with remotes. Depending on the associated Human Machine
Interface (HMI) software package (such as Open Enterprise, Genesis, 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 highlevel language support may be employed. The Area Operator PC of Figure 1A-6 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 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.
3305 RTU Application Software / 1A- 7
Figure 1A-6 - An Example of a Wide Area Network
1A-
8
/ Application Software 3305 RTU
Section 2
INSTALLATION
2.1 INSTALLATION IN HAZARDOUS AREAS
The Model 3305 RTU is not furnished in a housing. The three PCBs which comprise the system are mounted to a metal plate, which in turn, is ready for user supplied backplate mounting. The 3305 RTU is approved for operation in Class I, Division 2, groups A, B, C &
D hazardous areas. Use in hazardous areas will require the selection of an appropriate enclosure that meets the NEMA Type 4X specification.
3305 RTU
Figure 2-1 - 3305 RTU Dimensions - Top View
Installation / 2-1
Figure 2-2 - 3305 RTU Dimensions - Lower Edge View
2.2
MOUNTING THE MODEL 3305 RTU
Check all clearances when choosing an installation site. Make sure that the 3305 RTU is accessible for wiring and service. Make sure that the LCD Display Panel (and keyboard if present) are accessible to the on-site operator.
The RTU’s Mounting Plate measures 7.375” in width by 11.5” in length by 4.30” or 5.32” in height (see Figures 2-1 & 2-2). The 3305 RTU may be vertically mounted (Backplane PCB at top) with the following restrictions;
The bottom of the 3305’s Mounting Plate must mount to the selected enclosure’s backplate.
The unit must be positioned so that the top plate or the Local LCD Display Option is completely visible for service; reading the LEDs on the Processor Memory Peripheral
Power Supply (PMPP) Board and MI/OB Board, installation or removal of an option, i.e., Modem, Radio Delay, Transmitter Interface Board, RS-485 Interface Board, and replacement of the RAM Battery, Fuse or a PCB.
2.2.1 Temperature & Humidity Limits
The Model 3305 RTU is designed to operate over a -40 to 158 ° F (-40 to +70 ° C) temperature range and a 15% to 95% Relative Humidity range. Make sure that the ambient temperature and humidity at the measuring site remains within these limits.
Operation beyond these ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in failure of the unit.
2-2 / Installation 3305 RTU
2.2.2 Vibration Limits
Check the mounted enclosure for mechanical vibrations. Make sure that the 3305 RTU is not exposed to a level of vibration that exceeds those given in the specifications. The 3305’s vibration limits are 1g for 10-150 Hz & .5g for 150-2000 Hz.
2.3 3305 RTU INSTALLATION/CONIGURATION
Figure 2-3 - Processor Memory Peripheral Power Supply (PMPP) Board
3305 RTU Installation / 2-3
To configure the 3305 RTU follow the steps listed below:
1. Install appropriate I/O wiring to the MI/OB Board’s removable Terminal Blocks (see
Section 2.4.1 through 2.4.6).
2. Configure the Jumpers on the PMPP Board (see Section 2.3.1).
3. Configure/Connect appropriate communication port(s) (see Sections 2.4.8 & 1.2.2.2).
4. Connect DC Power to 3305 RTU (see Section 2.4.7).
5. Connect Port A of the RTU to a Process Engineer’s Interface (PEI), apply power and configure the 3305’s “Soft Switches” for an ACCOL Load (see Section 2.3.2).
6. After receiving the ACCOL Load, the RTU 3305 is ready for on line operation (see
Chapter 4).
2.3.1 PMPP Board Jumper Configurable Options
The 3305 RTUs Processor Memory Peripheral Power Supply (PMPP) Board contains 7
Jumpers which must be set for the desired performance options.
Jumper W2 - PMPP Board Status LEDs Enable
IN - Board Status LEDs Enabled
OUT - Board Status LEDs Disabled
Jumper W6 - Communications Status LEDs Enable
IN - Comm. Status LEDs Enabled
OUT - Comm. Status LEDs Disabled
Jumper W7 - RAM Battery back-Up Enable/Disable
1 to 2 - RAM Battery Back-Up Enabled
2 to 3 - RAM Battery Back-Up Disabled
Jumper W8 - Boot/Configuration FLASH Boot Sector Write Protect
1 to 2 - Boot Sector Write Protected
2 to 3 - Boot Sector Write Enabled ( FOR ATE ONLY )
Jumper W10 - Power Fail Trip Point Select
1 to 2 - Selects the Power Fail Trip Point for the 9-20V input voltage range
2 to 3 - Selects the Power Fail Trip Point for the 20-30V input voltage range
Jumper W11 - Low Battery Detect
1 to 2 - Selects the Low Battery Detect Trip Point for the 9-20V input voltage range
2 to 3 - Selects the Low battery Detect Trip Point for the 20-30V input voltage range
Jumper W12 - Master Clear and Power Fail LEDs Enable/Disable
IN - MC and PF LEDs Enabled
OUT - MC and PF LEDs Disabled
2.3.2 Soft Switch Configuration
Prior to installing of the ACCOL load, it is necessary to configure the 3305’s Unit
Configuration Parameters (Soft Switches) using a (Process Engineer’s Interface) PEI equipped with the BBI SYSTEM CONFIG/FLASH DOWNLOADER Software, the ACCOL
2-4 / Installation 3305 RTU
Load and a Terminal Emulation program (such as PROCOMM Plus or SMARTCOM). For a complete description of the operation of the BBI SYSTEM CONFIG/FLASH DOWN-
LOADER Software Program, see Chapter 4 - Section 4.5.
1. Connect the PEI to Port A on the PMPP Board using the special BBI Download cable (Part Number 395414-02-4) and apply power to the PEI and the 3305 RTU.
Note: Port A defaults to a rate of 38.4K baud, but will automatically fall back to
19.2K baud if required by handshake routine (transparent to user). The cold download baud rates for Ports B, C and D are configurable via the Soft Switches.
2. Select the CONFIG. SYSTEM PARAMETER Poke Point on the SYSTEM FLASH
DOWNLOAD/PARAMETER CONFIGURATION ENTRY Menu (see Figure 2-4) and press the INSERT key
Figure 2-4
System FLASH Download/Parameter Configuration Entry Menu of
BBI SYSTEM CONFIG/FLASH DOWNLOADER Program
3. Within 30 seconds, press the Reset Button (SW2) on the 3305’s Power Supply/CPU
Board. This action will evoke the SYSTEM PARAMETER CONFIGURATION Menu on the PEI (see Figure 2-5).
3305 RTU
Figure 2-5
System Parameter Configuration menu of
BBI SYSTEM CONFIG/FLASH DOWNLOADER Program
Installation / 2-5
•
Node Address (Default = 127)
The Node Address is a value from 1 to 127 (with 127 being the default).
•
Group Number (Default = 0)
The Group Number (0 to 127) selects the relative group of the 3305. Normal BSAP messages occupy group zero. When expanded BSAP is selected, the Group Number identifies the group in which the unit resides. If standard BSAP is selected, the
Group Number will default to zero (0).
•
RAM/FLASH ACCOL Load (Default = RAM)
The RAM/LASH ACCOL Load field selects where ACCOL will be stored upon download, i.e., in FLASH where it will reside until it is changed by another download, or in RAM where it resides as long as power is applied (from system power or battery backup). An ACCOL load stored in FLASH is copied into and executed out of RAM.
•
ACCOL Flash Lock (Default = Locked)
The ACCOL Flash Lock feature gives the user the ability to prevent a FLASH-based
ACCOL load from being overwritten accidentally. With this feature enabled (locked)
(the default state), all ACCOL downloads will be rejected; however, if the unit detects that there is no ACCOL load currently in FLASH, it will allow the ACCOL load to be downloaded to the 3305 RTU.
•
Std/Exp BSAP (Default = Standard)
The Standard or Expanded BSAP Slave option allows the user to select the mode for the BSAP slave port, i.e., either standard or expanded). If the standard mode is selected, Group Number will have no meaning and the unit is assumed to reside in
Group 0. When the expanded option is selected, the Group Number defines the group in which the unit resides. In A BSAP Master/Slave network, the first 127 nodes connected to a single master reside in Group 0.
•
Cold Download Rate (Default = 9600)
The Cold Download Rate option defines the parameters associated with Ports B, C and D for the Cold Download baud rate (Port A defaults to 9600). The available baud rates are: 1200, 2400, 4800, 9600, 19200 and 38400 baud. The list of values will be provided to the BBI SYSTEM CONFIG/FLASH DOWNLOADER
Program Software after a connection has been established. The chosen baud rate takes effect during a reset of the unit. Once downloaded, the ACCOL load controls the rate and function of each port.
•
Updump (Default = Disabled) The Updump option is reserved for factory use only.
•
Diagnostic Msgs (Default = Enabled)
Diagnostic Messages (available through a separate “terminal emulation” program such as PROCOMM) (see Chapter 5) can be enabled or disabled via this poke point.
•
Put RTU in Updump State and exit FLASH (Poke Point).
This poke point is only available (viewed) on 3305s that are equipped with boot firmware level LB501 and higher. Selection of this poke point should only be performed for debugging purposes under direction from BBI.
2-6 / Installation 3305 RTU
•
Make Changes (Poke Point).
When the Make Changes poke point is selected the pending changes are automatically loaded into 3305 system firmware. Pending changes can also be loaded into the RTU 3305 at any time by pressing the F4 key. When the F4 Key has been pressed the following message will appear on the bottom of the menu:
Changes are pending. Change the target before exiting? ---
At this point the user can press Y for yes, N for no, or the Insert key (for yes).
Changes will be downloaded and the previous menu, i.e., the SYSTEM FLASH
DOWNLOAD/PARAMETER CONFIGURATION ENTRY Menu (Figure 2-4) will appear.
Note: When the F4 key is pressed, the Exit Mode (see EXIT CONFIG/Flash download Poke Point below) controls the next step performed by the BBI SYSTEM
CONFIG/FLASH DOWNLOADER Program Software.
•
EXIT CONFIG/Flash download (Poke Point)
The EXIT CONFIG/Flash download poke point sets the exit mode from this menu.
Uppercase indicates the mode selected. Use the Insert or Enter key to switch between selections. A System FLASH download is required when new 3305 firmware has been issued by BBI for field upgrade installation. Use the Insert Key to change this prompt to exit config/FLASH DOWNLOAD if a system download is desired. If EXIT/CONFIG mode is selected (and the F4 key is pressed), the System
Parameter Configuration Menu is exited and the System FLASH Download/-
Parameter Configuration Entry Menu is displayed. If FLASH DOWNLOAD mode is selected (and the F4 key is pressed), the program enters the download mode and the selected firmware file is downloaded into the RTU 3305. If a file has not been selected, the system will prompt the user for the file to be Flashed.
4. Configure the soft switches as required. To download Standard or Custom System
Firmware, see Section 4.5.1. Select the Make Changes poke point to send these changes to the RTU 3305 (see
•
Make Changes above). If firmware is not to be downloaded, make sure that the exit mode is set to EXIT CONFIG and press the F4 key. If either system or custom firmware is to be downloaded, set the exit mode to
FLASH DOWNLOAD and press the F4 key. See Section 4.5.1 for the firmware download procedure.
5. To download an ACCOL load into FLASH Memory, see Section 4.5.2. To download an ACCOL load into RAM see Section 4.5.3.
2.4
WIRING NOTES
54 Field Wiring Terminals (53 used) are located on the Multifunction I/O Board (see Figure
2-6).
Terminal Connections
The 3305 uses compression-type terminals that accommodate up to #12 AWG wire. A connection is made by inserting the wire’s bared end into the clamp beneath the screw and securing the screw. The wire should be inserted fully so that no bared wires are exposed to
3305 RTU Installation / 2-7
cause shorts. If using standard wire, tin the bare end with solder to prevent flattening and improve conductivity.
Figure 2-6
Multifunction Input/Output Board’s Field Wiring Edge Connectors
2-8 / Installation 3305 RTU
Allow some slack in the wires when making terminal connections. The slack makes the connections more manageable and minimizes mechanical strain on the terminal blocks.
Wiring may be placed in trays or panduit to improve appearance and increase ease of maintenance.
Signal Shielding and Grounding
The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize signal errors caused by electromagnetic interference (EMI), radio frequency interference
(RFI) and transients. When using shielded cable, all shields should only be grounded at one point in the system. This is necessary to prevent circulating ground current loops that can cause signal errors. Connect all shields to a common terminal block tied to the system ground. The terminal Block should be placed at the RTU 3305 location.
2.4.1 Discrete Inputs
(see Figures 2-7 & 2-8)
A total of 14 Discrete Inputs are available. DI7-14 are dry contact inputs with 1msec filtering and DI/O1-6 (when configured for DI operation) are dry contact inputs with
30msec filtering. Inputs are internally sourced from the system power (12 or 24 V). DIs feature surge suppression. Their input range is dependent on the RTU 3305 system input power, i.e., 0-24 or 0-12 Vdc ± 10%. In addition to Dry Contact inputs from relays, switches etc., DI7 through DI14 can accept inputs from Low Speed Turbine Meters.
Field connections for DI1 through DI14 are located at TB1. A Discrete Input is activated by closing the connection between the +DI and -DI terminal in question with a dry contact
(see Table 2-1).
To configure DI/O1 through DI/O6 for DI operation the MI/OB Board Jumper associated with the DI/O in question must be set in the “A” position (see Figure 2-7).
3305 RTU
Figure 2-7 - DI/O Jumper Block For DI Operation
Installation / 2-9
Figure 2-8 - Discrete Input Wired to 3305 RTU
Table 2-1 - Discrete Input Connections to TB1
DI
Designation
DI1
D12
DI3
DI4
DI5
DI6
DI7
DI8
DI9
DI10
DI11
DI12
DI13
DI14
TB1 (-DI) Assignment
(Bottom Row of Connectors)
TB1-1
TB1-3
TB1-5
TB1-7
TB1-9
TB1-11
TB1-13
TB1-15
TB1-17
TB1-19
TB1-21
TB1-23
TB1-25
TB1-27
TB1 (+DI) Assignment
(Top Row of Connectors)
TB1-2
TB1-4
TB1-6
TB1-8
TB1-10
TB1-12
TB1-14
TB1-16
TB1-18
TB1-20
TB1-22
TB1-24
TB1-26
TB1-28
2.4.2 Discrete Outputs
(see Figures 2-9 & 2-10)
A total of 8 (Open Drain) Discrete Outputs (DOs) with surge protection are provided for control or signaling functions. Each DO is wired to the source terminal of an N Channel
MOSFET capable of switching up to 35 volts at up to 100mA. When closed, the FET shorts the output to ground with a voltage drop of .8 volts. 38V MOVs are provided to protect each
DO.
Field connections for DO1 through DO8 are located at TB1 (see Table 2-2).
To configure DI/O1 through DI/O6 for DO operation the jumper associated with the DI/O in question must be set in the “B” position (see Figure 2-8). Jumpers are assigned to DI/Os as follows:
2-10 / Installation 3305 RTU
Figure 2-9 - DI/O Jumper Block Set for DO Operation
Table 2-2 - Discrete Output Connections to TB1
DI
Designation
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
TB1 (-DO) Assignment
(Bottom Row of Connectors)
TB1-1
TB1-3
TB1-5
TB1-7
TB1-9
TB1-11
TB1-29
TB1-31
TB1 (+DO) Assignment
(Top Row of Connectors)
TB1-2
TB1-4
TB1-6
TB1-8
TB1-10
TB1-12
TB1-30
TB1-32
3305 RTU
Figure 2-10 - Discrete Output Wired to 3305 RTU
Installation / 2-11
2.4.3 Analog Inputs
(see Figures 2-11, 2-12 & 2-13)
A total of 4 Analog Inputs are available. The Multifunction I/O Board can support four 1-
5V isolated inputs, four 4-20mA isolated inputs, or four 4-20mA internally powered loops that are referenced to the PCOM of the board. Analog inputs feature 180V Common Mode for noise suppression. The use of twisted pair cable enhances this feature. Refer to Figures
2-11, 2-12 and 2-13 for setting the range of each input
Figure 2-11 - Analog Input (Isolated Voltage Source) Field Wiring (AI1 Shown)
Figure 2-12 - Analog Input (Isolated Current Source) Field Wiring (AI1 Shown)
Potentiometers R143 and R144 are provided on the MI/OB Board for calibration of the analog input circuitry. ACCOL Diagnostics is used to change the gain and offset of the analog input circuit. The gain is set by adjusting R144 (with +5Vdc placed across TB2-2 and TB2-1. The offset is set by adjusting R143 (with +1Vdc placed across TB2-2 and TB2-
1). Four sets of jumpers (W8A/8B through W11A/11B) are used to configure analog inputs
AI1 through AI4 respectively.
Field connections for AI1 through AI4 are located at TB2 (see Table 2-3).
2-12 / Installation 3305 RTU
A I
Designation
AI1
AI2
AI3
AI4
Table 2-3 - Analog Input Connections to TB2
TB2 (-AI) Assignment
(Bottom Row of Connectors)
TB2-1
TB2-3
TB2-5
TB2-7
TB2 (+AI) Assignment
(Top Row of Connectors)
TB2-2
TB2-4
TB2-6
TB2-8
Figure 2-13 - Analog Input (Internal Current Source) Field Wiring
(AI1 Shown)
2.4.4 Analog Outputs
(see Figure 2-14)
Figure 2-14 - Analog Output Field Wiring
A total of 2 Analog Outputs are available. The MI/OB Board’s analog output circuitry is comprised of a bus interface, a two channel Digital-To-Analog Converter (DAC) and a signal conditioning circuit which generates 4-20mA outputs. Two potentiometers per channel are used to adjust the 4mA and 20mA points; [(AO1 - R93 for 20mA, & R94 for
3305 RTU Installation / 2-13
4mA) (AO2 - R98 for 20mA & R101 for 4mA)]. Utilizing ACCOL Diagnostics, a Current
Meter (or a 250 ohm 0.01% tolerance resistor) is required to measure the output current during the calibration adjustments. Field connections for AO1 and AO2 are located at TB2
(see table 2-4).
Table 2-4 - Analog Output Connections to TB2
AO
Designation
AO1
AO2
TB1 (+AO) Assignment
(Bottom Row of Connectors)
TB2-10
TB2-12
TB1 (-AO) Assignment
(Top Row of Connectors)
TB2-9
TB2-11
2.4.5 High Speed Counter Circuitry
(see Figures 2-15 & 2-16
The High Speed Counter circuitry is comprised of two opto-isolated circuits which are powered from either the 12V or 24V RTU 3305 power source and a one shot IC which is used to limit the input frequency. A debounce circuit which is enabled when Jumper W15 is installed in position 1-2 supports SPDT Dry Contact (Using Set/reset Inputs) type field signals.
The frequency range of the High Speed Counter circuit is DC to 10KHz and the inputs are surge protected. Field connections are HSCSET (TB3-6), HSCRESET (TB3-4), and PCOM
(TB3-5). Field devices can be either Open Collector (Using Set Input) (Jumper W15 installed in position 2-3) or SPDT Dry Contact (Using Set/Reset Inputs) (W15 installed in position 1-2).
Figure 2-15 - High Speed Counter (SPDT Dry Contacts Using Set/Reset Inputs)
Field Wiring
2-14 / Installation 3305 RTU
Figure 2-16 - High Speed Counter (Open Collector Using Set Input) Field Wiring
2.4.6 Watchdog Relay Circuitry
(see Figure 2-17)
The Watchdog Relay Output circuit can be used to drive an alarm or annunciation device.
The Watchdog Relay is inactive when the signals Master Clear NOT (MC*) or Watchdog B
NOT (WDOGB*) are active. The Watchdog Relay Output circuit drives a Single Pole
Double Throw (SPDT) relay from terminal blocks TB3-7 (WDNC), TB3-8 (WDNO) and
TB3-9 (WDCOM). The Watchdog Relay is enabled when Jumper W17 is installed in position 1-2 and is disabled when W17 is installed in position 2-3.
Figure 2-17 - Watchdog Relay Field Wiring
2.4.7 DC Power Configuration & Wiring
The 3305 RTU requires a DC power source within the range of +9 to +30 V. A DC to DC
Converter on the Processor Memory Peripheral Power Supply (PMPP) Board (which operates from 9 to 30 VDC) has been designed to shut down at 20V for 24V units (Jumpers
W10 & W11 in position 2-3), i.e., systems with inputs of 20 to 30V) or to shut down at 9V for 12V units (Jumpers W10 & W11 in position 1-2, i.e., systems with inputs of 9-20V).
3305 RTU Installation / 2-15
Jumper W10 selects the Power Fail Trip Point and Jumper W11 selects the Low Battery
Detect Trip point. These Jumpers are situated on the PMPP Board (see Figure 2-3).
DC Power is connected to TB3 pins 1 and 2 of the MI/OB Board, where pin 2 = PWR+
(12/24V), and pin 1 = PCOM (see Figure 2-6). The input power source is coupled to the
PMPP Board via connector P1 of the MI/OB and J4 of the PMPP Board. The PMPP Board contains the DC To DC Converter that produces the +5V, +18V, -18V and +21V sources required for 3305 RTU operation. Regulated power for the MI/OB is provided through the
Backplane Board.
2.4.8 Communication Ports
The 3305 RTU contains 4 Comm. Ports, i.e., Ports A through D. Port A is physically located on the PMPP Board; the remaining ports are physically located on the MI/OB Board. 8position DIP Switch SW1 on the PMPP Board selects RS-232 loopback for Ports A, B and C while 8-position DIP Switch SW1 on the MI/OB Board supports Port D by providing for selection of RS-232 loopback signals or transmitter/receiver line terminations for RS-485 mode. All Ports support asynchronous operation (not synchronous) and RS-232 operation.
These ports originate on the PMPP Board and are assigned as follows:
Port A = RS-232 Local Configuration FLASH Download and Diagnostic Port (3-Pin Molex
Connector J3 on PMPP Board. Note: Port A can also be used by ACCOL the same as Ports B, C and D except for Comm. Options.
Port B = RS-232 Local/Network Port (J1 of PMPP Board connected to P2 of MI/OB Board).
Network connection is provided via 9-Pin D-Type Connector P5 on MI/OB.
Port C = RS-232 Local/Network Port (routed to/from MI/OB via the Backplane Board).
Network connection is provided via 9-pin D-Type Connector P4 on MI/OB.
Port D = RS-232/RS-485 Local/Network Port (TTL Port on PMPP Board and routed to/from
MI/OB via the Backplane Board). Network connection via 9-Pin D-Type
Connector P3 on MI/OB.
Any of the four communication ports can be configured for local communications, i.e., connected to a PEI (portable engineers interface). A PEI is any terminal or computer running ACCOL Tools. Port A is dedicated to this function since the other ports may be used for networking via modems, radios, or in the case of Port D, direct LAN connections.
2.4.8.1 RS-485 Interface (Port D)
Figure 2-18 - RS-485 Connector
3305 RTUs require an RS-485 configured port for local network communications to multiple nodes up to 4000 feet away. The connections for the 9-pin, RS-485 interface are shown in
Figure 2-18, while the corresponding pin labels are given in Table 2-5. Since this interface is
2-16 / Installation 3305 RTU
intended for network communications, Table 2-6 provides the appropriate connections for wiring the master, 1st slave, and nth slave. Essentially, the master and the first slave transmit and receive data on opposite lines, while all slaves (from the first to the "nth") are paralleled
(daisy chained) across the same lines. The master node should be wired to one end of the RS-
485 cable run.
Table 2-5 - RS-485 Pin Identifiers
Pin No.
Pin Code
1 TXD+
2
3
TXD-
RXD+
4
9
RXD-
GND
Signal Name
Transmit Data +
Transmit Data -
Receive Data +
Receive Data-
Ground
Table 2-6 - RS-485 Network Connections (see Note below)
From
Master
To 1st
Slave
To nth
Slave
1 TXD+ 3 RXD+ 3 RXD+
2 TXD 4 RXD 4 RXD-
3 RXD+ 1 TXD+ 1 TXD+
4 RXD 2 TXD 2 TXD-
Note
Pins 5 to 8 of each connector are unused.
Table 2-7 - MI/OB -Port D Configuration Switch SW1 Assignments
SW1
#
1
2
Function
-
RS-232/485 Selection
RS-232
Operation
-
ON = 232
Enabled
RS-485
Master station
-
OFF = 485
Enabled
RS-485 Most
Distant
Slave
-
OFF = 485
Enabled
RS-485
Other
Slaves
-
OFF = 485
Enabled
3
4
5
6
7
8
RS-484 XMTR 120 S
Term. Resistor
RS485 RCVR 120 S
Term. (+ Bias) Resistor
RS485 RCVR 120 S
Term. (- Bias) Resistor
RS-232 TXD/RXD
Loopback
RS-232 RTS/CTS
Loopback
RS-232 DTR/DCD
Loopback
N/A
N/A
N/A
ON enables
Local Loopback
ON enables
Local Loopback
ON enables
Local Loopback
ON =
Enabled
ON =
Enabled
ON =
Enabled
N/A
N/A
N/A
ON =
Enabled
ON =
Enabled
ON =
Enabled
N/A
N/A
N/A
OFF =
Disabled
OFF =
Disabled
OFF =
Disabled
N/A
N/A
N/A
Note: SW1-4 & SW1-5 must be set together, i.e., both must be ON to enable (install) the RS-
485 120 S Receiver (Bias) Resistor.
Note: SW1 switches -6, -7 & -8 are provided for RS-232 configuration. These switches are typically ON for test purposes and with the exception of SW1-7 are otherwise left
OFF. When Port D is connected to a PC, SW1-7 should be ON (see Figure 2-19).
3305 RTU Installation / 2-17
To ensure that the “Receive Data” lines are in a proper state during inactive transmission periods, certain bias voltage levels must be maintained at the master and most distant slave units. This is accomplished by configuring MI/OB Board Switch SW1 (at these locations) so that the 100-Ohm termination resistors are installed (see Table 2-7). Note:
Pin # 3 is unassigned on Port D for RS-232 operation.
2.4.8.2 RS-232 Interface (Ports B, C & D)
An RS-232 port can be used to provide a communication interface to devices such as printers, VDTs, PCs, and options such as an external modem (see supplemental manuals and appendixes in rear of manual). For RS-232 applications the device must be located within 25 feet of the distributed controller (this interface scheme is not intended for network communications). Pin connections for RS-232 are shown in Figure 2-19 and are defined in Table 2-8. PMPP Board Switch SW1 provides for selection of RS-232 loopback signals associated with Ports B and C (see Table 1-2 in Section 1.2.2.3) while MI/OB Board
Switch SW1 provides for selection of the RS-232 loopback signals associated with Port D
(see Table 2-7).
Figure 2-19 - RS-232 Interface (Ports B, C & D) for IBM PC AT or Compatible
Port C can be used for local or network communications and it can be configured for TTL or
RS-232 operation. When used in conjunction with TTL devices such as Bristol Babcock’s
Transmitter Interface (TI) Board, Radio Delay Interface (RDI) Board, RS-485 Interface
Board (Non-isolated), or a modem, the RS-232 Driver IC (U32) is replaced with a Jumper
Block (P/N 392511-01-0) allowing Port C to provide a TTL interface. For modems or other devices that require 5V power and RS-232 logic, DO NOT replace IC U32 with the Jumper
Block. +5V can be obtained from pin 3 of connector P4.
Table 2-8 - RS-232 Pin Identifiers
Pin # MNEMONIC
1 DTR
2
3
TXD
PWR
6
7
4
5
8
9
RXD
RTS
CTS
DCD
DSR
PCOM
DESCRIPTION
Data Terminal Ready
Transmit
+5V
Receive
Request To Send
Clear To Send
Data Carrier Detect
Data Set Ready
Port Ground
2-18 / Installation 3305 RTU
2.4.8.3 Port A RS-232 Interface
Port A is a standard BSAP Port dedicated to support the 3305 RTU in a local or remote port capacity. As a local port, it can serve as an interface to a Process Engineer’s Interface
(PEI) for diagnostics, ACCOL configuration, or FLASH downloading. Port A utilizes a three-pin Molex connector and is wired to a PEI as illustrated in Figure 2-20.
Figure 2-20 - RS-232 Interface (Port A) To PEI
2.5 INSTALLING LCD OPTIONS
The are three versions of LCD Displays that can be installed into an RTU 3305.
• 2 X 16 Character LCD Display (locally mounted) (see Section 2.5.1)
• 2 X 16 LCD Display (remotely mounted) (see Section 2.5.2)
• 4 X 20 Display/Keyboard (remotely mounted) (see Section 2.5.2)
2.5.1 Installing the 2 X 20 Local LCD Display Module
There are two possible scenarios for installation of the Local LCD Display option. Section
2.5.1.1 covers installation of the Local LCD Display option when the unit is not equipped with a network option. Section 2.5.1.2 covers installation of the Local LCD Display option when a network option (such as a modem) is present.
2.5.1.1 Installation of Local LCD Display (No Network Option Present)
Follow steps 1 through 6 to install the Local 2 X 16 LCD Display into an RTU 3305.
1. Disconnect power from the RTU 3305 (Shut down or place under manual control any critical processes prior to disconnecting power).
2. Remove the four screws (A) that secure the blank Name Plate to the Options
Mounting Brackets (C) (see Figure 2-21).
3. Remove the blank Name Plate, install the Standoffs (B) and install the Local LCD
Display Assembly (see Figure 2-22).
4. Install the four screws (A) to secure the LCD Display Assembly to the 4 mounting post (B) (see Figure 2-23).
3305 RTU Installation / 2-19
5. Plug the LCD Display Ribbon Cable Connector into Connector P3 on the Backplane
Board.
6. Apply Power and test the LCD Display (see Section 3 for details on operation of the
LCD Display).
Figure 2-21 - 3305 RTU Without Options (Face Plate Present)
2.5.1.2
Installation of Local LCD Display (Network Option Present)
Follow steps 1 through 6 to install the Local 2 X 16 LCD Display into an RTU 3305.
2-20 / Installation 3305 RTU
1. Disconnect power from the RTU 3305 (Shut down or place under manual control any critical processes prior to disconnecting power).
2. Remove the four screws (A) that secure the blank Name Plate to the four Mounting
Standoffs (B) which secure the local Network Option to the Options Mounting
Brackets (C) (see Figure 2-23).
3. Remove the blank Name Plate and replace it with the Local LCD Display Assembly
(see Figures 2-24 & 2-25).
4. Install the four screws (A) to secure the LCD Display Assembly to the 4 mounting post B).
5. Plug the LCD Display Ribbon Cable Connector into Connector P3 on the Backplane
Board.
6. Apply Power and test the LCD Display (see Section 3 for details on operation of the
LCD Display).
3305 RTU
Figure 2-22 - 3305 RTU Without Options (Name Plate Removed)
Installation / 2-21
Figure 2-23 - 3305 RTU Local LCD Display Installation Diagram
2-22 / Installation 3305 RTU
Figure 2-24 - 3305 With Network Comm. Option (Modem) (Name Plate Removed)
3305 RTU Installation / 2-23
Figure 2-25 - 3305 RTU With LCD Display & Network Comm. (Modem) Option
2-24 / Installation 3305 RTU
3305 RTU
Figure 2-26 - 3305 RTU With Network Comm. Option (Modem)
Installation / 2-25
2.5.2 Installing the Remote LCD Display Module
There are two versions of remote LCD Display options; the Remote 2 X 16 LCD Display
Assembly and the 4 X 20 LCD Display/Keyboard Assembly. The Remote 2 X 16 LCD Display Assembly is similar to the Local 2 X 16 LCD Display Assembly with the exception of the Ribbon Cable assembly. Both versions of remote LCD Display assemblies use 50-pin
Headers while the Local LCD Display utilizes a 26-pin Headers. Remote LCD Displays can be situated up to 50 feet (standard cable lengths of 3 feet or 10 feet are offered) from the
Backplane Connector (P4). The Remote 2 X 16 LCD Display Assembly is provided with a
Bezel Cover Plate to accommodate panel mounting (see Figure 2-27). The 4 X 20 LCD Display/Keyboard Assembly is provided with a self-adhesive tape and 6 Mounting Studs that accommodates panel mounting (see Figures 2-28 & 2-29).
Figure 2-27 - Remote LCD Display Installation Diagram
2-26 / Installation 3305 RTU
The Panel or Cover onto which the Remote 2 X 16 LCD Display Assembly will be mounted will require eight .140” diameter holes and a cutout area of 1.140” x 5.532” (see Figure 2-
27). The Panel or Cover onto which the Remote 4 X 20 Display/Keyboard Assembly is to be mounted will require six .166” diameter holes and a cutout area of 1.4” x 3.4” for the Display and a cutout area of .25” x 1.875” for the Keyboard’s flat cable (see Figure 2-28). After machining the area where the unit is to be mounted, follow steps 1 through 4 of Section
2.5.2.1 to install the Remote 2 X 16 LCD Display Assembly or follow steps 1 through 9 of
Section 2.5.2.2 to install the Remote 4 X 20 Display/Keyboard Assembly.
Figure 2-28 - 4 X 20 Display/Keyboard Assembly Installation Diagram
2.5.2.1 Installing the Remote 2 X 16 LCD Display Assembly
1. Disconnect power from the RTU 3305 (Shut down or place under manual control any critical processes prior to disconnecting power).
3305 RTU Installation / 2-27
2. Place the Bezel or Mounting Plate in question into the machined panel or cover aligning the eight mounting posts with the eight mounting holes. In the case of the
2 X 16 LCD Display Assembly, install the assembly onto the inside (rear side) of the machined panel or cover, aligning the assembly’s eight mounting holes with the
Bezel’s eight mounting studs.
3. Install the securing nuts to the eight mounting studs to secure the LCD Display
Assembly to the panel/cover.
4. Plug the LCD Display Ribbon Cable Connector into Connector P4 on the Backplane
Board. Apply Power and test the LCD Display (see Section 3 for details on operation of the LCD Display).
2.5.2.2 Installing the Remote 4 X 20 Display/Keyboard Assembly (see Figure 2-28)
1. Disconnect power from the RTU 3305 (Shut down or place under manual control any critical processes prior to disconnecting power).
2. Unplug the 4 X 20 Display/Keyboard’s Keyboard Cable from its connector P1 on the
Backplane Board (the larger Printed Circuit Board). Remove the six screws that secure the assembled boards to the Mounting Spacers and place the assembled boards on an ESD safe area
3. Remove the six Mounting Spacers from the rear of the units Face/Mounting Plate.
4. Carefully remove the paper from the self-adhesive mounting tape.
5. Carefully align the Face/Mounting Plate with the machined mounting area (on the panel or enclosure in question) and feed the Keyboard Cable and the flat Ground
Lead through the area that was cutout to accommodate them.
6. With Mounting Studs aligned with their machined mounting holes, firmly press the
Face/Mounting Plate onto the panel or enclosure in question.
7. Install the flat Ground Lead over its designated Mounting Stud. Install the six
Washers and the six Mounting Spacers onto the Mounting Studs that protrude through the inside of the panel or enclosure in question. Note: The flat Ground
Lead is to be attached to the associated equipment’s Chassis Ground in the event that the mounting panel or enclosure is plastic.
8. With the units Display aligned with its cutout area, place the assembled boards onto the six Mounting Spacers and replace the six screws.
9. Plug the Keyboard Cable Connector into Connector P1 of the Backplane Board (the larger Printed Circuit Board). Plug the 50 conductor LCD Display Ribbon Cable
Connector into Connector P4 on the Backplane Board. Apply Power and test the 4 X
20 LCD Display/Keyboard (see Section 3 for details on operation of the LCD
Display).
2-28 / Installation 3305 RTU
Figure 2-29 - RTU 3305 Remote 4 X 20 Display/Keyboard Assembly
2.6 INSTALLING A COMMUNICATION OPTION
3305 RTUs support one of the following communications options via port C on the MI/OB
Board.
• BBI 9600 bps PSTN Modem (see Manual CI-9600 for 396039-10-3 or CI-9600A for
392958-05-8)
• BBI 1200 bps PL/PSTN Modem (see Manual CI-1200)
• BBI Transmitter Interface Board (see Appendix 1 - PIP-TIBS33XX)
• BBI Radio Delay Board (see Appendix 2)
• BBI RS-485 Interface Board (see Appendix 3) (Also see Appendix 4 - Network Interface Box)
3305 RTU Installation / 2-29
• BBI Highway Addressable Remote Transducer (HART®) Device Interface (see
Appendix 5 - PIP-HART33XX)
• BBI Isolated RS-485 Interface Board (see Appendix 7 - PIP-ISORS485) (Also see
Appendix 4 - Network Interface Box)
With the exceptions of the HART® Device Interface, the Isolated RS-485 Interface Board, and the Network Interface Box, the option in question mounts to the 3305’s Option
Mounting Brackets (see Figures 2-21 through 2-26).
To install a communication option (other than a Network Interface Box, HART® Device
Interface or an Isolated RS-485 Interface option) into a RTU 3305, follow steps 1 through 9 below. See Appendices 4, 5 & PIP-ISORS485 (respectively) for information on the installation of a Network Interface Box, HART® Device Interface, or Isolated RS-485
Interface option.
1. Disconnect power from the RTU 3305 (Shut down or place under manual control any critical processes prior to disconnecting power).
2. Remove the four screws that secure the Top Plate or Local LCD Display Assembly to the four Mounting Standoffs. If the Local LCD Display Assembly is present discon-nect it’s Ribbon cable from P3 on the Backplane Board.
3. Remove the four 2” Mounting Standoffs (if present) from the two Option Mounting
Brackets.
4. Remove the Integrated Circuit U32 (the RS-232 IC associated with Port C) from it’s socket on the Power Supply/CPU Board and install the Jumper Plug Assembly (BBI
Part Number 392511010) in its place.
5. In the case of the TIB option, install four 1” Mounting Standoffs onto the option
Mounting Brackets and place the TIB assembly onto the standoffs aligning the mounting holes. Secure the TIB assembly to the four 1” Mounting Standoffs with the four 2” Mounting Standoffs. For all other Communication assemblies, place the option in question onto the two Option Mounting Brackets aligning the mounting holes. Secure the Communication option assembly to the two Option Mounting
Brackets with the four 2” Mounting Standoffs.
6. Connect the Communication Option Cable D-Type connector to Port C (P4) on the
MI/OB Board. In the case of a modem install the wires on the other end of this cable onto the modem in question (see Table 2-9). In the case of Radio, RS-485 or TIB options, install the other end of the Comm. Option Cable onto the appropriate board as follows: For the RS-485 option the other end of the Comm. Option cable plugs into the RS-485 Board’s connector J1A. Power and Ground must be wired to the
MIOB Board connectors TB3-2 and TB3-1 respectively. It should be noted that the
RS-485 Board will require a +9V to +30V power source to operate (see Table 2-10) and the TIB Board will require an external +24V power source to operate. For the
Radio Delay Board install the other end of the Comm. Option cable into the Radio
Delay Board’s TB3 and TB1 connectors (see Table 2-13). In the case of the
Transmitter In-terface Board (TIB) option, install the other end of the Comm.
Option cable into TIB connector P1 (see Table 2-14) and install power between the
MIOB Board and Transmitter Interface Board Connector TB1 (see Table 2-11).
2-30 / Installation 3305 RTU
7. Complete the required field I/O wiring connections (see Table 2-12 for RS-485
Board) (see appropriate Manual or Appendix).
8. Install the Top Plate or Local LCD Display Assembly to the four 2” Mounting
Standoffs. If the Local LCD Display Assembly is present connect it’s Ribbon cable to
P3 on the Backplane Board.
9. Apply Power and test the unit (see appropriate manual or Appendix).
Table 2-9 - Wiring List for BBI Modems (Cable Ass’y 396049-02-8)
MI/OB
Port C
P4/D-Type
Pin #
1
2
5
6
3
4
7
Wire
Color
Green
Brown
Yellow
Blue
White
Black
Red
Signal
DTR NOT
TXD NOT
+5V
RXD NOT
RTS NOT
CTS NOT
DCD NOT
TB3 TB2 TB4
3
6
7
1
5
4
2
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Notes
TTL Signal
TTL Signal
+5V Power (Rev 5 & Higher MI/OB)
TTL Signal
TTL Signal
TTL Signal
TTL Signal
8
9
-
Yellow +5V
Orange PCOM
+12/24V
1
-
8
-
10
-
-
1
-
+5V Power (Rev 4 & Earlier MI/OB)
+5V Ground
Loose Wire to MIOB TB3-2 (Power) for 1200 bps PL/PSTN Modem
Note: TB2, TB3 & TB4 are located on the Modem Assembly. Use TB2 for 1200 bps
PL/PSTN Modem. Use TB4 for 9600 bps PSTN Modem.
Table 2-10 - Wiring List for BBI RS-485 Board (Cable Ass’y 396049-01-0)
P4/D-Type
Pin #
1
2
5
6
3
4
7
8
9
-
-
Wire
Color
Blue
-
Brown
-
White
Black
Signal
DTR NOT
TXD NOT
-
RXD NOT
RTS NOT
CTS NOT
Red
Yellow
DCD NOT
+5V
Orange PCOM
Tan
Gray -
-
P1A
9
10
14
13
12
-
8
-
7
1
2
Notes
-
TTL Signal
-
TTL Signal
TTL Signal
TTL Signal
TTL Signal
+5V Power
+5V Ground
Loose Wire to MIOB TB3-2 (Power)
Loose Wire to MIOB TB3-1 (GND)
3305 RTU
Table 2-11 - Power Wiring List for Transmitter Interface Board
TIB Connector TB1 MIOB Connector TB3
+24V TB3-2
+24VRET TB3-1
Installation / 2-31
Table 2-12 - Wiring List for BBI RS-485 Board Field Wiring
(Cable Ass’y 396049-03-6)
J2 Pin # Wire Color RS-485 Signal
1 Black TX+
2
3
Brown
Red
TX-
RX+
4
5
Orange
Yellow
RX-
ISOGND
6 Green SURGE
Table 2-13 - Wiring List for BBI Radio Delay Board (Cable Ass’y 396049-02-8)
P4/D-Type
Pin #
1
2
5
6
3
4
7
8
9
Wire
Color
Green
Brown
Yellow
Blue
White
Black
Signal
DTR NOT
TXD NOT
+5V
RXD NOT
RTS NOT
CTS NOT
Red
-
DCD NOT
-
Orange PCOM
TB3 TB1
7
-
3
6
-
1
5
4
2
-
-
-
-
6
-
-
-
-
Notes
TTL Signal
TTL Signal
+5V Power
TTL Signal
TTL Signal
TTL Signal
-
TTL Signal
+5V Ground
Table 2-14 - Comm. Wiring List for Transmitter Interface Board
(Cable Ass’y 396049-04-4)
P4/D-Type
Pin #
1
8
9
6
7
4
5
2
3
Wire
Color
Green
Signal
DTR NOT
Brown
-
Blue
White
TXD NOT
-
RXD NOT
RTS NOT
Black
Red
CTS NOT
DCD NOT
Yellow +5V
Orange PCOM
J1 Notes
-
6 TTL Signal
-
9 TTL Signal
7 TTL Signal
10 TTL Signal
-
3 +5V Power
2 +5V Ground
2-32 / Installation 3305 RTU
Section 3
LIQUID CRYSTAL DISPLAYS
3.1
INTRODUCTION TO LCDs
The 3305 RTU can be equipped with one of three Liquid Crystal Displays:
• Local 2 X 16 LCD with 2 Pushbuttons
• Remote 2 X 16 LCD with 2 Pushbuttons
• Remote 4 X 20 LCD Display/Keyboard Assembly
The Local LCD mounts on the top of the 3305 RTU and interfaces to the system via
Backplane Connector P3. Remote versions of the LCD interface to the system via
Backplane Connector P4. Except for the Ribbon Cable/Interface Connector, both versions of the 2 X 16 LCD Display are functionally identical.
These Displays allow an operator or engineer to view (and in the case of the Keypad/Display, modify) ACCOL signal values and associated status bit information. ACCOL signals include inputs, process variables, calculated variables, constants, setpoints, tuning parameters and outputs used in a measurement or control application. Status bits include alarm state, alarm acknowledge, control inhibit state, manual inhibit state, and questionable data.
Setting up the display is a simple matter of creating a Keyboard Module in the ACCOL load.
3.1.1 2 X 16 LCD Display & Sensor Buttons
The 2 by 16 character LCD Display with 2 push-buttons provides a set of lists which are organized from left to right with each list organized top to bottom. The Main Display
(Identifier Display) contains user defined data (using the SELECT-n and LIST terminals of the ACCOL KEYBOARD Module). The Scroll List is activated using the Down ( ↓ ) arrow and is unique because it contains system data and user defined data such as Data, Time,
Node I.D. and System Firmware I.D. All other lists are user-defined using the INPUT-n terminals of the ACCOL Keyboard Module. The information displayed on the screen is controlled by two push-buttons located just to the right of the LCD screen.
When the left push-button ( ↓ ) has been pressed, automatic scrolling from top to bottom
(circular) will start and continue through the selected list at a user defined rate. The right push-button ( → ), when pressed, steps from left to right (circular) through the set of lists.
Once scrolling is active, the left push-button ( ↓ ) causes the LCD Module to toggle between
“Hold” and “Resume” modes to allow the user to halt the screen at a particular signal and then resume scrolling when it is so desired. Scrolling stops when the right push-button ( → ) has been pressed and the identifier of the next list is displayed.
3305 RTU Liquid Crystal Displays / 3-1
3.1.2 4 X 20 LCD Display/Keyboard
The Display/Keyboard is comprised of a four line by twenty character liquid crystal display, with adjustable viewing angle, and a five-by-five membrane key matrix. Each key has a microswitch for positive tactile feedback. This means that as you firmly press the keys, you will feel it click as it engages. The Display/Keyboard assembly is always mounted
“remotely.”
3.2 PREPARING THE ACCOL LOAD
In order for the LCD Display in question to operate, the ACCOL load must include a properly configured “Keyboard Module.” Use the ACCOL Interactive Compiler (AIC), or
ACCOL Batch Compiler (ABC), or version 5.13 (or higher 5.X revision) of ACCOL
Workbench to create this module in Task 0 and assign the “Module Terminals” according to the five following steps.
Figure 3-1 - ACCOL Keyboard Module Symbol
Step 1: Creating the Identifier Display (see Figures 3-1, 3-2 & 3-3)
The Identifier Display is the first display to appear when the ACCOL load begins to execute. This display will look similar to Figure 3-2C or 3-3C. Each line of the display contains the text value of a string signal (in the case of the Display/Keyboard this is true for each of the first three lines). These string signals are named on the SELECT terminals of the Keyboard Module (See Figure 3-1). Since this is the first display that the user will see, you may want the display to contain general information such as the node name of the controller or the process that the controller is monitoring.
In the case of the Display/Keyboard assembly, the bottom line on the Identifier Display is called the legend line. It shows which function keys are currently active and their purpose.
Function keys are those keys on the Keypad that are marked ([F1] through [F4]). Function key assignments are preconfigured and cannot be changed. Using function keys is described in Section 3, Using the Keypad.
3-2 / Liquid Crystal Display 3305 RTU
The legend line in Figure 3-2C shows that the user has two choices: to sign-on (using [F1]) or scroll (using [F3]).
Figure 3-2 - Creating the Identifier Message for Display/Keyboard Units
Step 2: Defining a Scroll List (see Figure 3-4
Once the Keyboard Module has been configured and the LCD Display in question is operating properly, you can automatically scroll through a list of signals. Scrolling can be done without entering a password (discussed in the next step.) The signals in the list are displayed one at a time and in the same order in which they were entered in the signal list.
This list might contain summary information about the process the RTU 3305 is controlling.
3305 RTU Liquid Crystal Displays / 3-3
(Later, we'll discuss other signal lists that can be accessed via an LCD Display. To distinguish this list from others, this signal list is called the Scroll List.)
On the LIST terminal, enter the number of a signal list to be scrolled. (You may also enter a signal name whose value equals the number of the signal list.) This signal list becomes the Scroll List. The Scroll List can contain different types of signals (that is, logical, analog and string). You can create a specific scroll signal list or use any list in the ACCOL load.
Figure 3-3 - Creating the Identifier Message for 2 X 16 LCD Display Units
3-4 / Liquid Crystal Display 3305 RTU
Each signal in the Scroll List will be displayed for the number of seconds defined at the
TIME terminal. If you don't specify a time on this terminal, the hold time will be two seconds. If you signed-on and then started scrolling you will be signed-off in 20 minutes if no keys are pressed. If this is unacceptable, sign-off (INIT key) before starting scrolling.
Figure 3-4 - Defining a Scroll List Diagram
Step 3: Assigning Passwords (see Figure 3-5)
Once the Display/Keyboard is operating, a password will be needed to go beyond the initial displays. These passwords are defined on the PASSWORD_RD and PASSWORD_WT terminals.
Someone using the password named on the PASSWORD_RD terminal will only be allowed to read signal information. When the password named on the PASSWORD_WT terminal is used, that person can also change signal values and other parameters.
These terminals can accept a value or signal name.
Passwords can be any combination of numbers up to 6 digits in length, from 000001 to
999999. If none are specified on the Keypad Module, the default values are 333333 for read only access and 666666 for read/write access.
Step 4: Assigning Monitoring Signals (see Figure 3-6)
Enter signal names on the STATE, FAIL_STATE, and STATUS terminals.
Enter a logical alarm signal name on the STATE terminal. This signal will turn ON when a valid password has been entered. It will be set OFF when the user has signed off. In each case, an alarm will be reported to notify the network of this activity.
3305 RTU Liquid Crystal Displays / 3-5
Enter a logical alarm signal name on the FAIL_STATE terminal. The module will turn the signal ON after three invalid passwords have been entered. It will be turned off when the user signs off. In each case an alarm will be reported.
Enter an analog signal name on the STATUS terminal. When the load is executing, the value of this signal, when read by the PEI, will indicate the present module state. The signal will assume one of the following codes:
Figure 3-5 - Assigning Passwords Diagram
Figure 3-6 - Assigning Monitoring Signals Diagram
3-6 / Liquid Crystal Display 3305 RTU
Table 3-1 - Status Codes Associated with LCD Displays
STATUS Code:
-1.0
2.0
3.0
4.0
5.0
6.0
Meaning
No Display Device or Both Local & Remote types detected
Waiting for push-button/key press
Waiting for push-button/key press or timeout
Writing to display
Writing to display
Clearing LCD display
Step 5: Defining the List Menu (see Figure 3-7)
The INPUT terminals are used to define the menu and signal lists to be accessed from the
List Menu. Once the Keypad is operating, a user who has signed on with a password can scroll through the names of signal lists and choose a list to read or change.
Figure 3-7 - Defining the List Menu Diagram
Up to 255 INPUT terminals are available. Each terminal can contain a signal list number or signal name. These terminals should be used consecutively, that is, unwired INPUT terminals should only appear after the last used INPUT terminal and will generate an
'unwired input' message on the display. Unwired terminals between wired terminals will use ACCOL load memory space. Unwired terminals after the last used terminal do not use memory.
If the terminal is assigned a number, this number will be presented on the List Menu.
When the terminal is assigned a signal name, both the signal name and its value are shown on the List Menu. If you have properly configured the ACCOL Keyboard Module, you will see the Identifier Display when the ACCOL load begins to execute.
3.2.1 ACCOL Module Terminals
ACCOL Module Terminals supported by the 3305 RTU with 2 X 16 LCD Displays are described in Table 3-2. ACCOL Module Terminals supported by 3305s with a Keyboard/Display are described in Table 3-3.
3305 RTU Liquid Crystal Displays / 3-7
Table 3-2 - Definitions of Module Terminals for 3305s with a 2 X 16 LCD Display
Name
SELECT 1
&
SELECT 2
LIST
TIME
STATE
STATUS
INPUT_n
Default
None
None
2 Seconds
None
Analog
Signal or
Constant
Logical
Alarm
Signal
None
None
Format
String
Signal
Analog
Signal or
Constant
Analog
Signal
Analog
Signal or
Constant
I/O
Input
Input
Input
Description
SELECT 1 and SELECT 2 are String Signals which provide the text for the initial or Main
Display. Each string can be up to 16 characters in length. This information is displayed on load startup and is typically used to identify the location and/or function of the unit, e.g.,
BARTLESVILLE, OK
WELL-PATCH 27
LIST specifies the number of the signal list for the
Main Display. The elements in this list are part of the Main Display and will appear in order following the display of internal data when scrolling is active. Scrolling is activated from the
Main Display using the Down Arrow (left pushbutton).
TIME sets the time in seconds that each display item will appear on the screen for when scrolling has become active. The value assigned to TIME should not be less than 1 second.
Output STATE provides an indicator to the ACCOL load, or to the network, of activity at the display device.
This signal (along with a 20-second timer) is set
ON whenever an operator presses one of the two push-buttons associated with the LCD Display.
The STATE Signal will be set OFF after 20minutes without any push-button activity. The signal can also be turned OFF via ACCOL logic or from an external source such as Toolkit. Note: No action is taken at the device when the 20 minute timer expires. If the last action was to activate scrolling a list, that scrolling will continue.
Output STATUS is set to one of the following status codes:
1.0 No Display Device or Both Display types detected.
2.0 Waiting for push-button press.
3.0 Waiting for push button press or timeout.
4.0 Writing to display.
5.0 Writing to display.
6.0 Clearing display.
When scrolling has been activated, the module will alternate between 1 and 4, or between 2 and
4.
Input INPUT is set of up to 255 terminals which may be used to define the List menu. The List menu is activated and scanned using the Right Arrow
(Right push-button). When viewing the Main
Display, pressing the Right Arrow causes the first element in the List Menu to be displayed.
3-8 / Liquid Crystal Display 3305 RTU
Table 3-2 - Definitions of Module Terminals for 3305s with a 2 X 16 LCD Display
(Continued)
Name
INPUT_n
Default
None
Format
Analog
Signal or
Constant
I/O
Input
Description n Continued from previous page -
Each subsequent press of the Right Arrow prompts a move to the next element in the List menu. When at the last element in the menu, pressing the Right
Arrow Button will cause a return to the main
Display. Pressing the Down Arrow Button at any time activates scrolling from top-to-bottom in the current list. The Down Arrow Button then toggles between “Hold” and “Resume” modes until the Right
Arrow Button has been pressed to select a different list.
Each INPUT terminal can contain a signal list number (Constant) or a signal name where the name provides a title for the list and the value of the signal is the list number, e.g., signal name = CONFIG.LIST
and the signal value = 10.
INPUT terminals should be used consecutively, that is , unwired terminals should appear only after the last used INPUT terminal. Unwired terminals between wired terminals will use memory space in the ACCOL load and the message ‘unwired input’ will appear when the menu position is displayed.
The individual signal lists defined in the List Menu can be of variable lengths and can contain any mixture of signal types.
Table 3-3 - Definitions of Module Terminals for 3305s with a Display/Keyboard
Name
SELECT 1
SELECT 2
&
SELECT 3
Default
None entry required
Format
String
Signal
I/O Description
Input SELECT 1, SELECT 2 & SELECT 3 are String
Signals which provide the text for the initial or
Identifier Display. Each string can be up to 20 characters in length. The value of each signal will appear on the display. The signal named on
SELECT 1 will appear on the top line. SELECT 2 will be on the middle line and SELECT 3 will be on the third line. This information is displayed on load startup and is typically used to identify the location and name and/or function of the unit, e.g.,
BARTLESVILLE, OK
WELL-PATCH 27
PUMP 14
SIGN-ON SCROLL
3305 RTU Liquid Crystal Displays / 3-9
Table 3-3 - Definitions of Module Terminals for 3305s with a Display/Keyboard
(Continued)
Name
LIST
TIME
PASSWORD_RD
PASSWORD_WT
STATE
FAIL_STATE
STATUS
Default
None entry required
2
Seconds
None entry required
None entry required
None
None
None
Format
Analog
Signal or
Constant
Analog
Signal or
Constant
I/O
Input
Input
Description
LIST specifies the number of the signal list which is called the Scroll List. The elements in this list are part of the Main Display and will appear in order following the display of internal data when scrolling is active.
Scrolling is activated from the Main Display using the Scroll (F3) key.
TIME sets the time in seconds that each signal in the Scroll List/Scroll Display will appear on the screen for when scrolling has become active. The value assigned to TIME should not be less than 1 second.
PASSWORD_RD is the password for ‘readonly’ access. The password cannot exceed 6 digits.
Analog
Signal or
Constant
Analog
Signal or
Constant
Input
Logical
Alarm
Signal
Analog
Signal
Analog
Signal
Input PASSWORD_WT is the password for read-
/write access. The password cannot exceed 6 digits. Note: The user will be logged off if the keyboard is inactive for a period of 20 consecutive minutes.
Output STATE provides an indicator to the ACCOL load, or to the network, of activity at the display device. This signal (along with a 20minute timer) is set ON whenever a valid password is entered and set OFF when the operator has signed off. It is also set OFF if
20-minute elapse without any keyboard activity, while an operator is signed on. The signal can also be turned OFF via ACCOL logic or from an external source such as
Toolkit. Note: No action is taken at the device when the 20 minute timer expires. If the last action was to activate scrolling a list, that scrolling will continue.
Output FAIL_STATE is set ON after three invalid passwords have been entered consecutively and is turned OFF when the user signs off. In each case an alarm will be reported.
Output STATUS is set to one of the following status codes:
1.0 Display/Keyboard hardware
(or both) not detected.
2.0 Waiting for key press
3.0 Waiting for key press or timeout.
4.0 Writing to display.
5.0 Writing to display.
6.0 Clearing LCD display.
3-10 / Liquid Crystal Display 3305 RTU
Table 3-3 - Definitions of Module Terminals for 3305s with a Display/Keyboard
(Continued)
Name
INPUT_n
Default
None
Format
Analog
Signal or
Constant
I/O Description
Input INPUT is set of up to 255 terminals which may be used to define the List Menu. The List menu is activated at the display using the MENU option. The user can scroll through the names/numbers of signal lists and choose individual lists to be displayed.
Each INPUT terminal may contain a signal list number (Constant), or a signal name where the name provides a title for the list and the value of the signal is the list number, e.g., signal name =
CONFIG.LIST and the signal value = 10.
INPUT terminals should be used consecutively, that is , unwired terminals should appear only after the last used INPUT terminal. Unwired terminals between wired terminals will use memory space in the ACCOL load and the message ‘unwired input’ will appear when the menu position is displayed.
The individual signal lists defined in the List Menu can be of variable lengths and can contain any mixture of signal types.
3.3 USING THE 4 X 20 DISPLAY/KEYBOARD
The Identifier Display is the starting point from which you can go to other displays. It shows an identification message and the words SIGN-ON and SCROLL at the bottom of the screen (see Note 1). The identification message may contain the name of the controller the plant equipment it is monitoring, or the signals you can expect to see when you use this display.
Note 1: If your display shows something else, press the [F4] key until you see the words
SIGN-ON and SCROLL on the bottom line.
If your screen is blank, adjust the Display Intensity (see Figure 1-6). If no letters appear, either a hardware failure has occurred or the controller has not been programmed properly to operate the keypad.
The words SIGN-ON and SCROLL at the bottom of the screen are on the legend line. It tells you which function keys (that is, keys [F1] through [F4]) are active and their purpose at that time.
Up to four legends can appear on the legend line. The legend on the far left corresponds to the function of the [F1] key. The assignment for the [F4] key is on the far right. Keys [F2] and [F3] are described to the left and right of center. When no legend appears, that function key is not active at that time. For example, in Figure 3-8 only [F1] and [F3] are active.
3305 RTU Liquid Crystal Displays / 3-11
Figure 3-8 - The Identifier Display
Figure 3-9 - Identifier Display Legends and Corresponding Keypad Alignment
Figure 3-10 - Display/Keyboard Scrolling
3-12 / Liquid Crystal Display 3305 RTU
From the Identifier Display, you have two choices. Pressing [F1] will allow you to sign-on if you have a password. By pressing [F3] you can activate automatic scrolling through a list of signals.
3.3.1 Display/Keyboard Scrolling
To begin automatic scrolling, press [F3] from the Identifier Display (Figure 3-4). After pressing F3, the three sequential screens followed by a screen which contains the first item from the Scroll List which in turn is followed by 2nd, 3rd, etc. items from the Scroll List.
After the last item from the scroll List has been displayed, the sequence returns to the 1st
Screen and repeats the pattern until disabled. Each screen is displayed for 2 to 10 seconds.
In the case of the 4th through last screens the signal name appears on the first line. Signal value and units appear on the second line and status appears on the third line. An example is shown in Figure 3-10.
When all signals in the list have been displayed, they will be shown again in the same order.
Press HOLD ([F1]) to halt scrolling and freeze the display. Press GO ([F2]) to resume scrolling.
Press EXIT ([F4]) to return to the Identifier Display (Figure 3-8).
3.3.2 Signing-On With the Display/Keyboard
To access the List Menu, you must first sign-on with a proper password. From the
Identifier Display (Figure 3-8), press [F1]. The screen will look like Figure 3-11A or 3-11B.
If the display looks like Figure 3-11B:
Someone else has already signed on. Go to the paragraph below that starts "Once the correct password has been entered...".
If the display looks like Figure 3-11A:
Enter a password using the 0 to 9 keys. For security, asterisks will appear as you enter the digits. If you make a mistake, press [F1] and try again. Press [ENT] to enter your password into the system.
If your password is not recognized, the asterisks will be erased after you press [ENT].
Check your password and try again. After three unsuccessful attempts to sign-on, an alarm signal is turned ON. The alarm signal can be reported to the external network
(via message).
Once the correct password has been entered, the display will look like Figure 3-11B.
When the second line shows READ/WRITE, you can read and write signal parameters.
When it shows READ ONLY you cannot change signal parameters. You are only permitted to read signal information. If your display shows READ ONLY and you want to change signal values, sign-off (press the [INIT] key), press [F1] from the Identifier Display, and enter the password for READ/WRITE access.
3305 RTU Liquid Crystal Displays / 3-13
Once you have successfully signed on, the legend line will show that you have three options. You can view and change the time and date of the local clock, access more signal lists, or return to the Identifier Display. Let's start by setting the local clock.
Figure 3-11 - Signing On
3.3.3 Clock Functions Via the Display/Keyboard
From the Sign-On Display (Figure 3-11B), press [F1]. The screen will show the present date and time and will look like Figure 3-12. Follow the instructions below to change the time or date. When you're finished, press [F4] to exit.
Today’s date is shown in the first line in the format month/day/year.
The current time is shown in the format hours:minutes:seconds.
Figure 3-12 - Clock Display
Changing the Time
From the display shown in Figure 3-12, press [F1]. Colons (:) will appear on the third line
(see Figure 3-13). Enter the new time there and press [ENT]. Valid times range from
00:00:00 to 23:59:59. Invalid entries will be ignored. The display will be updated to show the new time.
3-14 / Liquid Crystal Display 3305 RTU
Figure 3-13 - Time Set Display
If you make a mistake while entering the new time, press [CLR] and start again or use
[DEL] to backspace and delete one character at a time.
Press [F2] to return to the clock display (Figure 3-12).
Changing the Date
From the clock display (Figure 3-12), press [F2]. Slash marks (/) will appear on the third line (see Figure 3-14). Enter the new date there and press [ENT].
Figure 3-14 - Date Set Display
If you make a mistake while entering the new date, press [CLR] and start again or use
[DEL] to back space and delete one character at a time.
Press [F4] to return to the Sign-On Display (Figure 3-11B).
3.3.4 Choosing a Signal List from the List Menu via the Display/Keyboard
The List Menu is another area where signal information can be seen. As explained earlier in this section, your first opportunity to read signal information is by choosing the
SCROLL function from the Initial Display. Signal name, value and units text are presented from the Scroll List. This function is available to all users even without signing-on.
The List Menu will show other groups of signals which you can choose to read. This information will be more detailed than the Scroll List.
To get to the List Menu, choose MENU (press [F2]) from the Sign-On Display (Figure 3-
11B).
The first signal list number in the menu will appear on the first line. If a signal name was used to name the list in the ACCOL load, the signal name appears on the second line; otherwise, the display indicates NO NAME.
Press NEXT and BACK to see the other signal lists that are available in the List Menu.
The List Menu can contain up to 255 signal list numbers.
3305 RTU Liquid Crystal Displays / 3-15
Figure 3-15 - Using the List Menu Display
To advance or backup in large increments, enter a one to three digit number on line 3 and press NEXT or BACK. For example, if the fifth signal is being displayed and you enter the number 22 and press NEXT, the twenty-seventh signal will appear.
Wraparound will occur for increments exceeding the list length. For example, suppose the second signal in a 10-signal list is displayed. If the number 11 is entered and NEXT is pressed, the third signal in the list will be displayed.
To move directly to a list, enter the list number, then press pick.
3.3.5 Moving Through a Signal List via the Display/Keyboard
After READ or CONF has been pressed, the display will show the first signal in the list. An example is shown in Figure 3-16. Each time NEXT is pressed, the display will show the next signal in the list. BACK will show the previous signal.
To move in large increments, enter a one to three digit skip count and press NEXT. The display will skip over that number of signals. The maximum skip count is 255; larger values default to 255.
Automatic wraparound occurs in either direction. When you reach the end of the list, [F1] will display the first signal again. At the top of the list, [F2] will display the last signal.
You can skip through long lists by entering a one to three digit number and pressing NEXT or BACK. For example, to move 50 signals down the list, press 5, then 0, then [F1].
3.3.6 Changing Signal Parameters via the Display/Keyboard
From Figure 3-15, you can change signal parameters by pressing CONF [F2]. Then follow the directions summarized below (see Note 2).
Note 2: If your display does not contain the legend CONF in the legend line, your password will only allow you to read signals. If you want to change signal values at this time, you must first sign-off and then sign-on using the correct password. See your
Systems Engineer for the correct password.
3-16 / Liquid Crystal Display 3305 RTU
Before making any changes, first check the signal inhibit status field (See Figure 3-16).
When the display shows ME (manual enable) you can change signal parameters. When it shows MI (manual inhibit), you cannot alter the parameters of this signal. If the field indicates MI, press the OPER IE key to change it to ME.
To change an analog value:
Press CLR to clear the third line. Use the number keys 0 through 9 to enter the new value. The minus sign and period are also permitted. Press [ENT].
If you make a mistake, press CLR and enter the number again or use the [DEL] key to erase a character.
Another way to enter new values is by using the arrow up and arrow down keys
(located below the [F4] and [INIT] keys). These keys will raise and lower the value by
1% of the displayed amount.
To change the status of a logical signal:
Press CLR, then use either the down and up arrow keys or the [0/OFF] and [1/ON] keys to change the state of a logical signal. If the [0/OFF] and [1/ON] keys are used, you must also press [ENT].
While editing an analog value or digital status, you may see the following messages:
PRESS CLR TO CHANGE
NOT IN MANUAL MODE
The first message is a reminder that the first thing you must do to change an analog value or digital status is to press CLR.
The second message will appear when the signal cannot be changed because it is not in manual enable (ME) mode.
To acknowledge an alarm: Press [ALM ACK].
To change the alarm enable/inhibit status for alarm signals:
Press [ALM I/E] key. (Note, this will only inhibit alarm reporting, and not alarm level detection.)
3305 RTU Liquid Crystal Displays / 3-17
Figure 3-16 - Interpreting Signal Information
Notes for Figure 3-16
1. Signal Name - base name (8 characters max.), extension (6 characters max.), and attribute
(4 characters max.)
2.
Value - analog value, string value, or logical value. Values which cannot fit in this field will be shown as asterisks.
Analog values are displayed in floating point format, for example, 0.0125, 99.627, and
1287.66. When the value cannot be shown in floating point format, scientific format is used
(1.287668E+10 or 1.25E-02 for example).
3.
Questionable Data Status - for analog signals, column 1 will be clear if the status is valid. It will display a question mark if the status is questionable (requires Firmware Level AL.00
or RMS02 or later).
4.
Skip - how far to move in the list when NEXT or BACK is pressed (Default = 1, Max = 255).
5.
Signal Inhibit Status
CE (Control Enable) means this signal can be updated by the ACCOL program.
CI (Control Inhibit) means the signal cannot be updated by the ACCOL program.
ME (Manual Enable) means the signal can be changed manually.
MI (Manual Inhibit) means the signal cannot be changed manually.
6.
Alarm Enable (for alarm signals only)
AE - signal is alarm enabled (changes will be reported).
AI - signal is alarm inhibited (changes will not be reported).
3-18 / Liquid Crystal Display 3305 RTU
Notes for Figure 3-16 (Continued)
7.
Units - units text (for analog signals only), if any units have been defined.
8.
Alarm Type
For Analog Signals:
HH
HI
LO
LL
NA
- high-high alarm TA
- high alarm
- low alarm
For Logical Signals:
- low-low alarm NA
- no alarm
FA
CA
- true alarm
- false alarm
- change-of-state alarm
- no alarm
! - alarm is unacknowledged
9.
Multiple Signal Display
In Read Mode, pressing MULT will display the signal name extension, value, and units for three signals at one time. These signals include the signal displayed when NEXT was pressed and the next two signals in the list. Press SNGL [F3] to return to viewing one signal at a time (see Figure 3-17).
Figure 3-17 - Example of MULT Display in READ mode
Signals are shown below as they would appear in SNGL mode.
1) String
SITE.NAME
WEST SUNBURY PUMP STATION
CE ME
2) Analog
TOTAL.FLOW.RATE
1260.578
CE MI
GALS.
3) Logical
FLOW.ALARM
OFF
CE MI AE NA
3305 RTU Liquid Crystal Displays / 3-19
3.3.7 Signing-Off via the Display/Keyboard
Once you have signed-on, use the [INIT] key at any time to sign-off. When this key has been pressed, the screen will look like Figure 3-18. Press YES to sign-off. You are signedoff when the Identifier Display (Figure 3-2C) appears.
Figure 3-18 - Sign Off Display
If you do not want to sign-off, press EXIT to leave the Sign-Off Display.
Once you are signed-on an automatic sign-off will occur if 20 minutes has elapsed since the last key was pressed.
3.4
INTERPRETING ERROR MESSAGES
NO INPUT LISTS
Meaning: This may occur when the MENU function is selected. No input lists were entered during configuration.
Remedy: Values or signal names must be entered on the INPUT terminals of the
Keyboard Module using the ACCOL Interactive Compiler (AIC) or ACCOL
Batch Compiler (ABC) (See Step 5, page 5).
UNWIRED INPUT
Meaning: No value has been entered at this INPUT terminal in the ACCOL load.
Remedy: Using the AIC or ABC, enter a valid value.
NON-EXISTENT LIST
Meaning: The list was not found in the load. An invalid signal list number was entered on the LIST or INPUT terminals.
Remedy: Using the AIC or ABC, enter a valid signal list number on the LIST or
INPUT terminals (See Steps 2 and 5, pages 3 and 7).
3-20 / Liquid Crystal Display 3305 RTU
NO SCROLL LIST
Meaning: The Scroll Terminal has been left unwired.
Remedy: Use the AIC or ABC to enter a value or signal name on the LIST terminal
(See Step 2, page 3).
EMPTY LIST
Meaning: A valid signal list number has been requested but the signal list is empty.
Remedy: Use the AIC or ABC to create a signal list and/or place the appropriate signal names into the empty list.
NOT IN MANUAL MODE
Meaning: The signal is manual inhibited (MI) mode.
Remedy: Use the OPER I/E key to change mode to ME.
STRING SIGNAL:
Meaning: User is trying to change a string signal
Remedy: None - String signals cannot be changed with the keypad.
3305 RTU
Figure 3-19 – Keypad
Liquid Crystal Displays / 3-21
0 to 9, -, .
∆
∇
ALM I/E
ALM ACK
A/M
OPER I/E
DEL
ENT
KEY
F1, F2, F3, F4
INIT
Table 3-5 - The Keypad Keys
FUNCTION
Function keys will take on a variety of different functions depending on the situation. The function of these keys is listed on the legend line (bottom line) of the display.
The INIT key is used to terminate the keyboard session and sign-off.
These keys are used to change the value of analog signals in the CON-
FIGURATION mode. The 0/OFF and 1/ON keys are used to change the state of logical signals.
Each press of this key will raise an analog signal value by 1% of the displayed value or turn a logical signal ON.
Each press of this key will lower an analog signal value by 1% of the displayed value or turn a logical signal OFF.
Use this key to enable or inhibit alarm signals.
Use this key to acknowledge alarms.
Toggle between AUTO (CE) and MANUAL (CI) with this key.
Toggle between manual inhibit (MI) and enable (ME) with this key.
Use this backspace key to erase digits that have been entered on the keypad.
This key is used to enter new data from the display into the RTU 3305, e.g., password or signal values.
3.5 2 X 16 LCD DISPLAY SCROLLING DETAILS
3.5.1 Main 2 X 16 LCD Display
The Main Display is comprised of both user-defined and internal system data. The screens associated with the Main Display are defined as follows:
1st Screen: User defined text (contents of SELECT-1 & SELECT-2)
Figure 3-20 - Identifier Display Screen
The following screens occur when scrolling has started:
2nd Screen:
3rd Screen:
Data
Time
System Firmware Version String
Custom Firmware Version String
3-22 / Liquid Crystal Display 3305 RTU
4th Screen: Local ID (Node Address)
Group ID (Group Number)
First element from LIST terminal signal list 5th Screen:
Nth Screen: Last element from LIST terminal signal list
(Continues from 2nd Screen)
Note 3: If your screen is blank, adjust the Display Intensity (see Figure 1-8). If no letters appear, either a hardware failure has occurred or he controller has not been programmed properly to operate the keypad.
3.5.2 Other Lists Associated with the 2 X 16 LCD Display
All other lists are defined in a List Menu using the INPUT_n terminals of the Display/Keyboard Module. The signal name provides a title for the list and the signal value provides the list number. Note: If only the signal value is entered, NO NAME is displayed.
The screens associated with the Other Lists are defined as follows:
1st Screen: List No: nnn
List Title (Name of signal from INPUT terminal)
The following screens occur when scrolling has started:
2nd Screen: First element from list
Nth Screen: Last element from list
(Continues from 2nd Screen)
3.5.3
Display Of Signal Data Associated with the 2 X 16 LCD Display
The first line of the Signal Data Display will contain the signal name. The first 16 characters of the full name will be displayed. It is the users’ responsibility to create signal names which can be fully displayed without truncation, i.e., if the full field width for
BASE.EXTENSION.ATTRIBUTE (8.6.4) was used, the Attribute text will not be displayed.
The second line of the display contains signal value, units or OFF/ON text, or state information as described in Table 3-6 (see Figures 3-21 through 3-26).
Note 4: The floating point value displayed in 10 character positions is similar to but more accurate than the Display/Keypad MULT Mode (associated with the Keypad-
/Display) where 8 character positions are available.
3305 RTU Liquid Crystal Displays / 3-23
Figure 3-21 - Analog Signals on the 2 X 16 LCD Display
Figure 3-22 - Analog Alarms on the 2 X 16 LCD Display
Figure 3-23 - Logical Signals on the 2 X 16 LCD Display
3-24 / Liquid Crystal Display 3305 RTU
Figure 3-24 - Logical Alarms on the 2 X 16 LCD Display
Figure 3-25 - String Signals on the 2 X 16 LCD Display
Notes for Figures 3-21 Through 3-25
1. Signal Name - base name (8 characters max.), extension (6 characters max.), and attribute (4 characters max.) (Not to exceed 16-character limit).
2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be shown as asterisks. The Sign will be blank for (positive) and - for (negative).
Analog values are displayed in floating point format, for example, 0.0125, 99.627, and 1287.66.
When the value cannot be shown in floating point format, scientific format is used
(1.287668E+10 or 1.25E-02 for example).
3. Questionable Data Status - for analog signals, column 1 will be clear if the status is valid. It will display a question mark if the status is questionable.
4. Units - units text (for analog signals only), if any units have been defined.
3305 RTU Liquid Crystal Displays / 3-25
Notes for Figures 3-21 Through 3-25 (Continued)
5. Alarm Type
For Analog Signals: For Logical Signals:
HH - high-high alarm
HI
LO
LL
NA
- high alarm
- low alarm
TA
FA
CA
- low-low alarm NA
- no alarm
- true alarm
- false alarm
- change-of-state alarm
- no alarm
! - alarm is unacknowledged
6. User defined ON/OFF Text for Logical signals or Logical Alarms (not to exceed 6-character limit).
7. String Signals
Up to 16 character user defined string.
3.6 RESET & DIAGNOSTIC
3.6.1 Reset/Self-Test Diagnostics
On a reset (Rest Button pressed or power up of a unit without an ACCOL load) the following sequence will occur at the display (for both the 2 X 16 LCD Display and the 4 X
20 Display/Keyboard):
All pixels OFF (clear screen)
All pixels ON (for 3 seconds)
All pixels OFF (for at least 3 seconds)
Local ID: nnn
Group ID: nnn
Line 1 (Node Address)
Line 2 (Group Number)
The Node Address and Group Number (No.) will remain on the LCD screen until an
ACCOL load containing a DISPLAY/KEYBOARD module is activated; at which time the text for the Main Display (or Identifier Display) will appear on the LCD screen. If there is no DISPLAY/KEYBOARD Module in the load, the Node Address and Group No. will remain on the screen.
3.6.2 OFF-Line/ACCOL Diagnostics
Off-Line Diagnostics require a Process Engineer’s Interface (PEI) equipped with BBI
ACCOL Diagnostic Control Program (DIAG05.ACL) Software. The WINDIAG Manual
D4041A describes the communication interface between the PEI and the 3305 RTU and the procedures for loading DIAG5, downloading the ACCOL diagnostic load file (DIAG05.ACL) to the 3305 RTU, and for testing the Display/Keypad. The 33XX Diagnostic Manual test for the 4 X 20 Display/Keyboard Module also apply to the 2 X 16 LCD Display.
Also see Chapter 5 SERVICE of this manual.
3-26 / Liquid Crystal Display 3305 RTU
Section 4
OPERATION
4.1 GENERAL
This section provides Guidelines for starting and operating an RTU 3305. Since a variety of options and peripheral equipment can be present in any given installation, specific information cannot be provided to cover every situation. The user must be familiar with the equipment contained in his system and be alert to any trouble or danger that could result from improper startups.
4.2 PRELIMINARY CHECKS
Before applying power, the following items should be checked: a) Be sure that all PC boards and I/O circuits have been properly configured. Set all board jumpers and switches for the desired application. Refer to "Section 2 INSTAL-
LATION to identify the appropriate boards and assemblies.
b) All RTUs should have jumper W7 on the Processor Memory Peripheral Power
Supply (PMPP) Board set so that the battery is in the circuit, i.e., in position 1 to 2.
If this is not done, all ACCOL load data will be lost during a power interruption or failure. FLASH memory will maintain the programmable portion of the load, but the RAM portion (running states of program) will be lost without battery backup. As such, the RTU will "cold start" when power reappears and all related process signals will be set to initial values specified in the load.
3305 RTUs require battery backup to initiate a "warm start" after a power interruption. A good battery ensures that the RTU will provide power-fail recovery whereby all variables maintain the same values and statuses they held prior to the failure.
c) Make sure that all PC boards are plugged into their proper sockets and are properly secured.
d) Check that all I/O terminal block connectors are secure.
e) Check that the dc supply voltage matches the supply voltage specified for the RTU
(12V battery or +9V to +20V Bulk) or (24V Battery or +20V to +30V Bulk).
f) Check for proper size fuse on the MI/OB Board, i.e., .5 Amp.
g) Clear the RTU of any stray tools, test clips, test probes, wire leads, etc. that could cause shorts or intermittent operating problems.
h) Check that all external process functions associated with the RTU are closed down or under some form of guarded control.
3305 RTU Operation / 4-1
Warning
Some processes are hazardous by nature and can become extremely dangerous during power-ups, power-downs, or power failures. If such processes are allowed to run out of control, property damage and injury to persons may result. The use of manual or automatic backup control equipment and alarm warning devices are recommended to ensure safety.
4.3 STARTING THE RTU
The startup procedure described herein is general for most applications. Installations that utilize optional or specialized equipment may require additional steps not listed here.
When such equipment is encountered, the user should refer to the manufacturer's manuals before applying power to the system.
4.3.1 Equipment Required
Digital Multimeter (DMM)
Personal Computer (PC)
System Config/FLASH
Downloader Software*
- 5-1/2 digit resolution
- Required to communicate with RTU
AIC Software*
To set system soft switches (see Section 2.3.2)
AIC Software Manual, D4042 - Contains on-line operating instructions
User's ACCOL load
- Required to install ACCOL load
- Contains RTU configuration data
• = ACCOL Tools for DOS Version 5.13 or Workbench 5.13 or later.
4.3.2 General Startup Procedure
After performing the steps listed under PRELIMINARY CHECKS on page 4-1, proceed as follows:
1. Turn on the external supply source (24V or 12V) that powers the RTU. Using a
DMM (Digital Multimeter), check the external supply for the correct output voltage.
If the supply is adjustable, set the DC output to its proper output level.
2. When power is applied, the Power Fail Indicator (PFIN*) LED (DS17) on the PMPP
Board should light to indicate the presence of the +24V (or +12V), +18V, -18V, +5V and 32V (for 24V systems & DI/O) or +21V (for 12V systems) dc supply outputs. If
DS17 does not light, it may indicate a blown fuse. Check fuse F1 on the MI/OB and replace it if necessary. If Fuse F1 continues to blow, recheck wiring at the signal ter-minals for a possible short. Further details are covered in "Section 5 Service."
3. When the RTU is operating, the MASTER CLEAR indicator (MC*) LED (DS16) on the PMPP Board should be continuously lit to indicate that the supply is performing properly.
4-2 / Operation 3305 RTU
4. If an ACCOL load has not been installed, the RTU will execute an internal diagnostic startup test upon powerup. This type of startup is called a "cold start" and it is identical to the sequence that is executed once the Reset Button (SW2) on the PMPP Board has been pressed.
Warning
An RTU that has not been loaded (or one that has been reset) will provide defaults of 0% for analog outputs, and OFF for all discrete outputs. For some critical processes, these defaults could represent dangerous output levels. Critical processes should in-clude automatic/manual control stations or limiting devices to maintain safe operation during startups or powerdowns.
5. The internal RTU diagnostic test cycle can be observed on the status LEDs of the
PMPP Board. In general, LEDs DS10 through DS15, as well as the WATCHDOG
LED (DS18), will be lit throughout the test sequence. A momentary flash at the beginning of the sequence signifies the initiation of the RAM diagnostic test cycle.
Any failure detected during testing will cause the IDLE/RUN LED (DS9) indicator on the PMPP Board to turn ON. At the same time, the lighting pattern of status
LEDs DS10-DS15 will display the type of failure.
If the battery voltage is low, there will be a momentary flashing LED sequence, after which the diagnostic cycle will resume.
During the next part of the test, LEDs DS10-DS15 will go off for 1 second, on for 1 second, then go off for 1 second. The status of the 3305’s I/Os, if any, is then displayed. Details are contained in Chapter 5 Service.
6. Full completion of the diagnostic test cycle is indicated by a "ripple" pattern whereby each STATUS LED is turned on and off in sequence beginning with LED
DS15 and ending with LED DS10.
At this point a 3305 RTU which has previously received download FLASH memory will execute it’s ACCOL load. The WATCH-DOG LED (DS18) should turn OFF and the IDLE/RUN LED (DS9) should be blinking.
A unit which does not have the ACCOL load installed, will wait to be downloaded.
It’s WATCHDOG LED will remain on until a download is performed. See Chapter 5 for a list of failures that can be displayed on STATUS LEDs DS10-DS15 when a
3305 RTU unit is waiting for a download.
7. In order to download locally or globally to a 3305 RTU, there must be a communications path from the external device (PC or supervisory computer) to any of the 3305’s four
Comm. Ports. Port A will default to 9600 baud for a "cold start" download. The download baud rate for ports B, C and D is selectable via soft switch settings in the
BBI SYSTEM CONFIG/FLASH DOWNLOADER program. A RAM or FLASH download can be initiated using AIC, TOOLKIT, Open BSI Downloader or the DIAGNOSTIC software program utilities
3305 RTU Operation / 4-3
A local download is typically initiated from a PC connected directly to a local RS-232 port. A global download is typically initiated from a supervisory computer or PC positioned at a higher echelon of the network and directed downward to a target node (The required network files must be present at the originating device in order to perform a global download). Refer to User Manual D4042, ACCOL II Interactive
Compiler for download procedures.
8. When the download is complete, the RTU will begin executing the ACCOL load. At this stage the WATCHDOG LED will turn OFF and the IDLE/RUN LED will blink.
Note: The IDLE/RUN LED will be OFF when the processor is executing and ON when the processor is idle.
Once a download is complete, all RTU communication ports will take on the usage and characteristics specified by the user in the ACCOL load. For example, if "port
A" was used for a download but it turned out that no functions were specified for
"port A" in the load, the communications between the RTU and the external loading device will be lost when the download is complete. Similarly, if the baud rate used for the download is different from the baud rate specified for that port in the
ACCOL load, or if the port is not a slave/pseudo slave BSAP port it will be necessary to modify the local link baud rate to communicate properly when the download concludes.
Note
Should communications become lost or erratic after a download, transfer the PC connection over to the appropriately assigned port. Remember, the ACCOL load determines the port's function!
9. Once it has received the appropriate ACCOL load file, the RTU will execute its control program. Any manually-controlled process valves and operating devices that were previously set to a guarded condition may now be set to their operating positions. If automatic-manual control panels are included in the installation, their operating mode should now be switched from manual to automatic control.
10. The startup procedure is now complete. The RTU should be performing the user functions programmed into the ACCOL load.
The on-line activities can be monitored in various ways depending on the user's configuration. For example, a PC can be connected to a Slave or Pseudo-Slave port and the AIC or TOOLKIT software utilities can be used to communicate with the unit.
11. Cold Starts: If the Manual Reset button is pressed, the RTU will perform a "cold start" (i.e. the RTU will execute its diagnostic startup sequence and, if it has lost its
ACCOL load (as it would in a RAM-based unit), it will wait for a new download).
Caution
Prior to initiating a “Reset,” make sure that any critical process functions associated with the RTU have been turned off or placed under guarded manual control.
4-4 / Operation 3305 RTU
12. Warm Downloads: A running RTU can be reloaded at any time without doing a manual reset. This procedure is called a "warm download." When the download procedure is initiated from a supervisory computer or a PC, the target RTU will
Watchdog momentarily and then begin accepting the new load. The RTU diagnostic startup cycle, in this situation, does not execute.
Note:
The baud rate for a “warm download” is determined by the on-line ACCOL load currently executed by the RTU.
13. Warm Start: A running RTU will resume execution of the active load after a powerfail providing that RAM data has been preserved via the battery backup. This is called a "warm start." The active environment is saved when the power fails, and is resumed when the power is restored. The diagnostic startup cycle is not executed for this type of startup. Note that RAM backup batteries are required for both RAM and FLASH based units in order to successfully Warm Start.
4.4 SHUTDOWN PROCEDURE
The procedure for shutting down an RTU will vary with the user’s application. The following steps provide a general check list.
1. If critical processes are involved, close down all related process elements, valves, switches, etc. as required. If the installation includes user-supplied, manual control panels, switch them over to manual control and bring the processes to a safe standby level; then close each process down as required.
2. Turn off the associated power source.
3. Turn off all associated signal power sources.
Warning
High voltages may still be present at the field wiring terminals even though the RTU is OFF. This voltage can emanate from sources that are used to power external devices such as Discrete Inputs. Make sure that all external power sources are turned off or disconnected before working in these areas.
4. When the RTU is shut down, the contents of RAM will be retained because of the
RAM battery backup system. This battery provides RAM retention for a period of approximately 4000 hours (167 days). If the RTU is not powered up within that time frame, the battery will become completely discharged and the RAM data will be lost.
If it is planned to shut the equipment down for an extended period of time, the backup battery should be disconnected (Jumper W7 on the Power Supply/CPU
Board installed in position 2 to 3) to prevent unnecessary current drain. Conversely, the battery must be reconnected just before the equipment is restored to service.
Before disconnection the battery, it is recommended that the user ensures that a backup copy of the ACCOL load is available (not required for FLASH-based RTUs).
3305 RTU Operation / 4-5
A RAM-based RTU that has been turned off and left dormant under these conditions will require a reload upon startup. A FLASH-based RTU will automatically restart its ACCOL load upon completion of the startup diagnostics.
5. The shutdown procedure is now complete.
4.5 USING THE BBI SYSTEM CONFIG/FLASH DOWNLOADER PROGRAM
The BBI System Config/FLASH Downloader Program is required for configuring the RTU
3305’s Soft Switches, i.e., the switches associated with ACCOL communications parameters. This program allows the user to change configurations options (node address, cold download baud rates, FLASH RAM ACCOL selection, etc.) as-well-as enabling the download of system and/or custom firmware to FLASH, and/or forcing units equipped with level LB501 (or higher) boot firmware into UPDUMP mode. The ACCOL parameters to configure include the following:
•
Node Address
•
Cold Download Parameters
•
Updump ability
•
FLASH or RAM based ACCOL loads
•
ACCOL FLASH Lock
•
Standard or Expanded BSAP Slave
•
Group Number
•
Normal or Debug Operation
NOTE: This configuration may also be performed using the LocalView Utility in
OpenBSI (see chapter 5 of the OpenBSI Utilities Manual - D5081).
As part of the installation of a 3305 RTU, it is necessary to configure the 3305’s Unit Configuration Parameters (Soft Switches). To begin configuration, start the BBI SYSTEM
CONFIG/FLASH DOWNLOADER Program. The initial menu will be displayed.
Figure 4-1
System FLASH Download/Parameter Configuration Entry Menu of
•
The Select a File To Download Poke Point
When the Select a File To Download poke point is selected (highlight poke point and press the Insert key), a new display appears that provides a lists of available binary files (files with .BIN extensions). The user must select the files he wants to load and
4-6 / Operation 3305 RTU
then press the Insert Key. The program will return to the menu of Figure 4-1 and will provide the user the .BIN file(s) selected. If the user has no idea of the .BIN file name(s) required for a new system firmware download, then the Select a File To
Download poke point should be selected prior to using the Configure System
Parameters poke point.
•
Download System Flash Poke Point
The Download System Flash poke point is only applicable when the System
Parameter Configuration Menu has been entered and the exit config/FLASH
DOWNLOAD poke point has been selected.
•
The Configure System Parameter Poke Point
The Configure System Parameter poke point is chosen to set the 3305’s Soft Configuration Switches displayed in Figure 4-2. Selection of this poke point is also required to initiate a System Firmware download to 3305 FLASH Memory.
•
The Reconfigure Communications Set-up Poke Point
The Reconfigure Communications Set-up poke point is used to set the current communications parameters for the connection with the PEI
•
The EXIT Poke Point
The EXIT Poke is used to exit out of the BBI SYSTEM CONFIG/FLASH DOWN-
LOADER Program.
Figure 4-2
System Parameter Configuration Menu
•
Node Address (Default = 127)
The Node Address is a value from 1 to 127 (with 127 being the default).
•
Group Number (Default = 0)
The Group Number (0 to 127) selects the relative group of the 3305. Normal BSAP messages occupy group zero. When expanded BSAP is selected, the Group Number identifies the group in which the unit resides. If standard BSAP is selected, the
Group Number will default to zero (0).
3305 RTU Operation / 4-7
•
RAM/FLASH ACCOL Load (Default = RAM)
The RAM/FLASH ACCOL Load field selects where the ACCOL load will be stored when downloaded, i.e., in FLASH where it will reside until it is changed by another download, or in RAM where it resides as long as power is applied (from system power or battery backup). An ACCOL load stored in FLASH is copied into and executed out of RAM.
•
ACCOL Flash Lock (Default = Locked)
The ACCOL Flash Lock feature gives the user the ability to prevent a FLASH-based
ACCOL load from being overwritten accidentally. With this feature enabled (locked)
(the default state), all ACCOL downloads will be rejected; however, if the unit detects that there is no ACCOL load currently in FLASH, it will allow the ACCOL load to be downloaded to the 3305 RTU.
•
Std/Exp BSAP (Default = Standard)
The Standard or Expanded BSAP Slave option allows the user to select the mode for the BSAP slave port, i.e., either standard or expanded). If the standard mode is selected, Group Number will have no meaning and the unit is assumed to reside in
Group 0. When the expanded option is selected, the Group Number defines the group in which the unit resides. In a BSAP Master/Slave network, the first 127 nodes connected to a single master reside in Group 0.
•
Cold Download Rate (Default = 9600)
The Cold Download Rate option defines the parameters associated with Ports B, C and D for the Cold Download baud rate (Port A defaults to 9600). The available baud rates are: 1200, 2400, 4800, 9600, 19200 and 38400 baud. The list of values will be provided to the BBI SYSTEM CONFIG/FLASH DOWNLOADER
Program Software after a connection has been established. The chosen baud rate takes effect during a reset of the unit. Once downloaded, the ACCOL load controls the rate and function of each port.
•
Updump (Default = Disabled)
The Updump option is reserved for factory use only. Note: The Updump Option must be OFF. Do NOT enter updump mode following reset unless so directed by a representative of BBI.
•
Diagnostic Msgs (Default = Enabled)
Diagnostic Messages (available through a separate “Terminal Emulation” program such as PROCOMM or equivalent) (see Chapter 5 SERVICE) can be enabled or disabled. via the Diagnostic Msgs poke point.
•
Put RTU in Updump State and exit FLASH (Poke Point)
This poke point is only available (viewed) on 3305s that are equipped with boot firmware level LB501 and higher. Selection of this poke point should only be performed for debugging purposes under direction from BBI. When this poke point has been selected, the menu will post the following message:
4-8 / Operation 3305 RTU
“Put RTU in Updump and exit? _”
Type Y for yes if BBI has instructed you to perform this procedure, otherwise type N for no.
•
Make Changes (Poke Point).
When the Make Changers poke point is selected the changes made so far are automatically loaded into 3305 system firmware. Pending changes can also be loaded into the RTU 3305 at any time by pressing the F4 key. When the F4 key has been pressed the following message will appear on the bottom of the menu:
Changes are pending. Change the target before exiting?
At this point the user can press in Y for yes, N for no, or the Insert key (for yes). If
Changes will be downloaded and the program will display the previous menu, i.e., the SYSTEM FLASH DOWNLOAD/PARAMETER CONFIGURATION ENTRY
Menu (Figure 4-1). However; if the N key is pressed, the current pending changes will not be made and the menu of Figure 4-1 will be displayed.
•
EXIT CONFIG/Flash download (Poke Point)
The EXIT CONFIG/Flash download poke point sets the exit mode from this menu.
Uppercase indicates the mode selected. Use the Insert or Enter key to switch between selections. A System Firmware FLASH download is required when new
3305 system firmware has been issued by BBI for field upgrade installation. Use the
Insert key to change this prompt to exit config/FLASH DOWNLOAD if a system download is desired. If EXIT/CONFIG mode is selected (and the F4 key is pressed), the System Parameter Configuration Menu is exited and the System FLASH
Download/Parameter Configuration Menu is displayed. If FLASH DOWNLOAD mode is selected (and the F4 key is pressed), the program enters the download mode and the selected firmware file is downloaded into the RTU 3305. If a file has not been selected, the system will prompt the user for the file to be Flashed.
4.5.1 Downloading Standard System or Custom System Firmware
A system Firmware FLASH download is required when new 3305 system firmware been issued by BBI for field upgrade installation or if the pre-installed firmware has been lost for some reason.
1. Connect the PEI to Port A on the Power Supply/CPU Board and apply power to the
PEI and the 3305 RTU. Note: Ports A and D default to a rate of 38.4K baud, but will automatically fall back to 19.2K baud if required by handshake routine (transparent to user). Only Ports B, C and D are configurable via the Soft Switches.
Evoke the
BBI SYSTEM CONFIG/FLASH DOWNLOADER software.
2. Select the CONFIG. SYSTEM PARAMETER Poke Point on the SYSTEM FLASH
DOWNLOAD/PARAMETER CONFIGURATION ENTRY Menu (see Figure 4-1) and press the INSERT key
3. Within 30 seconds, press the Reset Button (SW2) on the 3305’s Power Supply/CPU
Board or turn OFF and then ON the system power. This action will evoke the
SYSTEM PARAMETER CONFIGURATION Menu (see Figure 4-2) on the PEI.
3305 RTU Operation / 4-9
4. Make the changes that are required to configure the soft switches. Change the EXIT
CONFIG/Flash download poke point to exit config/FLASH DOWNLOAD and press the PF4 key. The BBI SYSTEM CONFIG/FLASH DOWNLOADER PRO-GRAM and the 3305 now enter the download firmware mode and the menu of Figure 4-1 will be displayed.
5. If a .BIN file was already selected, download will begin. Otherwise, select the desired .BIN file at the prompt, e.g., LS500.BIN, STP08.BIN and press the INSERT key. If the file names are not known use the Select A File To Download poke point and choose the file(s) to be downloaded. Download of the firmware should begin.
Wait for the download to complete.
4.5.2 Download An ACCOL Load into FLASH Memory
1. Perform steps 1 through 3 of section 4.5.1.
2. Set the Ram/Flash Accol Load poke point to FLASH. This will cause the 3305 to store the next ACCOL load into FLASH memory.
3. In order for the load to successfully download, the ACCOL Flash Lock poke point must be set to UNLOCK. If this poke point is set in the LOCK state, the 3305’s system firmware will reject the download request and post an error message.
4. If required, change the exit config/FLASH DOWNLOAD poke point to read EXIT
CONFIG/Flash download. Press the F4 key. Exit from the tool. If a load already exist in FLASH memory from a previous download, the 3305 will perform a Cold
Start and then start running that load.
5. Select the desired ACCOL load download tool and activate it.
6. Select the desired ACCOL load file and select download option. Acknowledge the confirmation prompt, if presented. Download of the ACCOL load should begin. Wait for the download to complete. The ACCOL load will be placed into FLASH memory.
Note:
All subsequent ACCOL loads downloaded while this configuration is active will be placed into FLASH memory, over writing the previous load in the FLASH memory. To prevent over writing the load in
FLASH memory, change the ACCOL Flash lock poke point to the
LOCK state.
4.5.3 Download An ACCOL Load into RAM
1. Perform steps 1 through 3 of section 4.5.1.
2. Set the Ram/Flash Accol Load poke point to Ram. This will cause the 3305 to store the next ACCOL load into RAM memory, over-writing any previous ACCOL load in the RAM. The state of the ACCOL Flash Lock poke point has no effect on a RAM download.
4-10 / Operation 3305 RTU
3. If required, change the exit config/FLASH DOWNLOAD poke point to read EXIT
CONFIG/Flash download. Press the F4 key. Exit from the tool. If a load already exist in FLASH memory from a previous download, the 3305 will start that load.
4. Select the desired ACCOL load download tool and activate it.
5. Select the desired ACCOL load file and select download option. Acknowledge the confirmation prompt, if presented. Download of the ACCOL load should begin. Wait for the download to complete. The ACCOL load will be placed into RAM memory.
The ACCOL load in FLASH (if any) is not disturbed.
Note:
All subsequent ACCOL loads downloaded while this configuration is active will be placed into RAM, over writing the previous load.
4.5.4 Using BBI System/Flash Downloader Program Diagnostics
To use the BBI System/Flash Downloader program’s diagnostic capabilities, the PEI will have to be equipped with a Terminal Emulation program such as SMARTCOM or PROCOMM.
1. Connect the 3305’s Port A to the PEI. Evoke the BBI System Config/Flash Downloader Program and set the Diagnostic Msgs poke point to ON. If required, change the exit config/FLASH DOWNLOAD poke point to read EXIT CONFIG/Flash download. Press the F4 key. Exit the BBI System Config/Flash Downloader program. The
3305 will now send diagnostic messages to the PEI whenever a Master Reset or
Power Up occurs.
2. At the PEI, enter terminal emulation mode and configure the program (PROCOMM,
SMARTCOM, etc.) for 9600 Baud, 8 data bits, 1 stop bit, no parity for the appropriate communications port of the PC, i.e., either COM1 or COM2. Set the program to receive ASCXII data. Since the messages will scroll by quickly, you may want to store the data to an ASCII file for comparison against expected results, e.g.,
SELFTEST.LOG.
3. Power on the 3305 (if off) or reset it. The general sequence of messages is notification of start of a test followed by successful completion or failed status. For example, the selftest RAM diagnostic, displays the segment as-well-as the starting and ending offsets as each block is successfully tested. For both Make RAM (upper
512 bytes of BASE RAM) and SELFRAM, failure is identified to the component level
(socket designation) where:
Byte Addr Range Chip
Odd
Even
Odd
Even
20000h - 5FFFFh U33
20000h - 5FFFFh U34
60000h - 9EFFFh U36
60000h - 9EFFFh U38
3305 RTU Operation / 4-11
The message sequence ends if a failure occurs, or ends with notification of start of
MI/OB board testing if no hard failures have occurred. Section 5.2.2 provides the message sequence when the unit self-test is successful.
Diagnostic messages and associated source files for each diagnostic area are provided below.
MAKE RAM DIAGNOSTICS
DGSELF.ASM
mk_ram_pass:
DGGOX.ASM
u33_fail-str: u34_fail_str:
“Make RAM Diag Success”
“Make RAM Diag - RAM chip U33 failed”
“Make RAM Diag - RAM chip U34 failed”
NOTE: There is no make RAM diag start message.
SELFTEST RAM DIAGNOSTICS
SELFRAM.ASM
ib1:
DGBAT.ASM
ib_start_str: ib_fail_str: ib_succ_str: rb_start_str: rb_fail_str: rb_succ_str:
“Self Test RAM Diag” sarm-pass: u33_fail_str: u34_fail_str: u36_fail_str: u38_fail_str: ib1:
“passed”
“RAM chip U33 failed”
“RAM chip U34 failed”
“RAM chip U36 failed”
“RAM chip U38 failed”
“Self test Ram Diag”
SYSTEM BATTERY/RTC INTERNAL BATTERY DIAGNOSTICS
“System Battery diag start”
“WARNING - Sys,Btry. Low or Dead (or not enabled)”
“System Battery diag success”
“RTC Internal Battery diag start”
“WARNING - RTC Internal battery Dead”
“RTC Internal Batery diag success”
RTC/PIC DIAGNOSTICS
DGRTC.ASM
start_str: succ0_str: succ1_str: fail0_str: fail1_str:
“RTC/PIC Diag start”
“RTC Diag success”
“PIC Diag success”
“RTC Diag failed”
“PIC Diag failed”
4-12 / Operation 3305 RTU
PROM DIAGNOSTICS (SYSTEM/CUSTOM/ACCOL)
DGSELF.ASM
rm_diag_strt: prm_diag_ok: prm_diag_fail: aclflash_fail:
“PROM Diagnostics Strt”
“System PROM Diag Success”
“System PROM Diag failed”
“ACCOL PROM diag failed”
DGPROM.ASM
aclflash_pass: aclflash_inv: cstprom_pass: cstprom_warning:
“ACCOL PROM Diag Success”
“ACCOL PROM Diag bypassed - no valid load”
“Custom PROM diag Success”
“Custom PROM Warning - Checksum Failed”
TIMER 2 DIAGNOSTICS
DGSELF.ASM
tmr2_diag_strt: tmr2_diag_ok: tmr2_diag_fail:
“Timer 2 Diag Strt”
“Timer 2 Diag Success”
“Timer 2 Diag Failed”
CPU CLOCK SPPED DIAGNOSTICS
DGSELF.ASM
cpuspd_start-str: cpu-succ-srt: cpu-fail-str:
DGDMA.ASM
dma-start-str: dma-success: dma-fail:
DGSELF.ASM
io_diag_strt:
“CPU Speed Diag start”
“CPU running at 12 MHz”
“CPU Speed Diag Failed - Clock speed unknown”
DMA DIAGNOSTICS
“DMA Diag start”
“DMA Diag success”
“DMA Diag Failed”
I/O BOARD DIAGNOSTICS
“I/O Board Diag Start - See LED pattern for status”
3305 RTU Operation / 4-13
BLANK PAGE
Section 5
SERVICE
5.1 SERVICE INTRODUCTION
This section provides general, diagnostic and calibration test information for the Model
3305 RTU.
The service procedures described herein will require the following test equipment:
1.
PC with BBI’s WINDIAG Software
2.
BBI Cable P/N 395414-02-4 (Port A)
3.
BBI Cable P/N 390486-03-5 (Ports B, C & D)
4. DMM (Digital Multimeter): 5-1/2 digit resolution
5. Oscilloscope: 10mV to 10V per division sensitivity; 100 to 200 MHz vertical frequency response; 1 mSec to 1 Sec/division time base.
6. Variable DC Supply: Variable to 30Vdc ± .001Vdc.
7. Two 250-Ohm ± .01% Resistors (AO Calibration)
Accurate measurements will require properly shielded test leads. All test equipment measurements described in the text are referenced to power ground (PCOMM) unless specified otherwise.
When RTUs are serviced on site, it is recommended that any associated processes be closed down or placed under manual control. This precaution will prevent any processes from accidentally losing control when test are conducted.
Warning
Harmful electrical potentials may still be present at the field wiring terminals even though the RTU’s power source may be turned off or discon-nected. Do not attempt to unplug termination connectors or perform any wiring operations until all the associated supply sources are turned off and/or disconnected.
Warning
Never attempt to install or remove any modules (plug-in boards) from an
RTU while it is powered and running. Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module itself, as-well-as other associated circuit boards. Always turn off the Main power, including any additional supply sources used for externally-powered I/O circuits, before changing any modules.
5.1.1 Accessing PC Boards For Testing
Testing and replacement of PC boards should only be performed by technically-qualified persons having advanced mechanical and electrical skills and possess the service equipment described in the text. It is important that the reader study the disassembly and test
3305 RTU Service / 5-1
procedures described in this manual before starting. Any damage to the RTU 3305 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 (with prior authorization from Bristol Babcock) for factory evaluation and repairs.
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 circuit boards. See attached instruction supplement S14006 for proper grounding and handling techniques.
5.1.2 Removal/Replacement of the PMPP Board
1. Place any critical control processes under manual control and shut down the RTU
3305.
2. Disconnect power wires from TB3 pins 1 & 2 or pull off Terminal Plugs A1 and B1.
3. If a Network Communications Option Board is installed disconnect its power from
TB3 pins 1 and 2 and disconnect its connection to PORT C, i.e., P4 on the MI/OB
Board. If the Local LCD Display option is installed disconnect its ribbon cable connector from P3 on the Backplane Board.
4. Remove the four screws (A) that secure the Name Plate/LCD Module to the four mounting standoffs (see Figures 5-1 & 5-2) and remove the Name Plate/LCD
Module.
5. If a Network Comm. Option Board is present, remove the Name Plate/LCD Module standoffs (B) (see Figures 5-1 & 5-2) and remove the Network Comm. Option Board.
6. Remove the four screws that secure the Option Mounting Brackets (C) (2 each) to the Baseplate (see Figures 5-1 & 5-2) and remove these two brackets.
7. Disconnect the PMPP Board Port B TTL Connector (J1) from the MI/OB Connector
P2. Disconnect PMPP Board Connector J4 from MI/OB Board Connector P1.
8. Remove the four screws (D) that secure the PMPP Board to the PMPP Board
Mounting Standoffs (E).
9. Slide the PMPP Board away from the Backplane Board and carefully remove the
PMPP Board.
10. To replace the PMPP Board follow steps 1 through 9 in reverse order.
5-2 / Service 3305 RTU
3305 RTU
Figure 5-1 - 3305 Board Removal/Replacement Diagram
Service / 5-3
Figure 5-2 - 3305 with Top Plate/Options Removed
5.1.3 Removal/Replacement of the MI/OB Board
1. Perform steps 1 through 9 of section 5.1.2 (see Figures 5-1 & 5-2).
2. Remove the unpluggable I/O Terminal Blocks from the MI/OB’s card edge connectors.
3. Remove the two short screws (G) that secure the MI/OB Board to the lower two
MI/OB Mounting Standoffs (F) (see Figures 5-1 & 5-3).
5-4 / Service 3305 RTU
4. Remove the Medium Length Standoffs (E) that secure the MI/OB Board to the middle two and upper two MI/OB Mounting Standoffs (F) (see Figure 5-1).
3305 RTU
Figure 5-3 - 3305 with Top Plate/Options & PMPP Board Removed
Service / 5-5
5. Slide the MI/OB Board away from the Backplane Board and carefully remove the
MI/OB Board.
6. To replace the MI/OB Board follow steps 1 through 5 in reverse order.
5.1.4 Removal/Replacement of the Backplane Board
1. Perform steps 1 through 9 of section 5.1.2 to remove the PMPP Board.
2. Perform steps 1 through 5 of section 5.1.3 to remove the MI/OB Board.
3. Remove the Backplane Board by sliding it out of its Card Guides/Holders.
4. To replace the Backplane Board perform steps 1 through 3 in reverse order.
5.2 DIAGNOSTIC TEST PROCEDURES
Testing and calibration are performed using Self-Test and Off-Line methods. Self-tests are described in sections 5.2.1 and 5.2.2. Off-Line tests are described in section 5.3.
5.2.1 Self-Test Diagnostics (
PMPP Board Status LEDs)
LEDs on the PMPP Board (see Figure 5-4) provide an indication of the RTU's operating condition. The WATCHDOG and IDLE/RUN LEDs display the status of the CPU, while
LEDs DS10-DS15 display diagnostic faults.
Some general observations should be noted. The WATCHDOG LED (DS18) will turn ON at power-up (or when the RTU is reset) and turn off as soon as the RTU starts executing an
ACCOL load; this LED will remain off as long as the system is functioning normally.
Should this LED turn on during operation, it indicates that a CPU failure has occurred or that the system has been reset. The IDLE/RUN LED (DS9)will also turn on to indicate that system activity has halted.
The IDLE LED provides an indication of the activity level of the system. When this LED is on, it indicates that the CPU is in a "halted" or "idle" state. When it is off, it indicates that the CPU is busy.
LEDs DS1 through DS8 provide port status (see Figure 5-4).
LEDs DS10 through DS15 are used during a "cold start" to convey information on failure detection and I/O Module configuration. The failure patterns for these LEDs are given in
Table 5-1.
LED DS16 (MC*) will indicates that Master Clear (NOT) is inactive when it is in the ON state while LED DS17 (PFIN*) in the ON state indicates that a power fail has not occurred. These LEDs should remain ON during normal operation and will go OFF if the
+5V, +12V or input voltage go out of specification. LEDs DS16 and DS17 will remain OFF until the +5V, +12V and input voltage are all within specification.
5-6 / Service 3305 RTU
When using Table 5-1, note that it is organized into five categories: CPU/Internal Peripherals, External Peripherals, I/O Modules, Download Communication Initialization, and
Configuration. Tests in all categories (except Download Comm. Initialization) can be initiated by pressing the Reset Button for a "cold start." Tests in the Download Comm.
Initialization category are automatically initiated when a DPC with RAM-based memory is preparing for a download (either a cold or warm download).
Figure 5-4 - Processor Memory Peripheral Power Supply (PMPP) Board
3305 RTU Service / 5-7
The diagnostic test sequence for RTU 3305s runs as follows:
1. The system is initially powered up or manually reset (cold start) by the user. The
WATCHDOG LED will turn ON and all six (6) status LEDs (DS10 - DS15) will be
ON.
2. The CPU Registers, identified in Table 5-1, are the first items to be tested. If a failure is detected, the test will halt and the IDLE/RUN LED will turn ON. The
STATUS LEDs will simultaneously display the failure pattern shown for this condition in the table: 0-0-0-0-0-1, where 0 is OFF and 1 is ON.
3. Assuming there was no failure in step 2, the Make-RAM test is executed next (tests are not in the same sequence shown in the table). This test checks a portion of the
RAM to be used as a working stack during subsequent tests. The PIC (Programmable Interrupt Controller) is tested to verify that interruptions required for RAM testing are available. The full RAM test is then executed. If there are any failures, the IDLE LED will turn ON and the STATUS LEDs will display one of the patterns given in Table 5-1.
4. The remaining diagnostic tests are then executed in the following order:
RAM Backup Battery
RTC (Real Time Clock) Battery
RTC - includes External PIC test.
PROM (FLASH)
Internal Timer
DMA (Direct Memory Access H/W)
5. Any failures are displayed as described in the previous steps with the exception of the battery tests and the Custom PROM test. If the RAM battery is weak or defective, a different pattern will be displayed: 0-1-0-0-X-X. In this pattern, LED DS14 will be ON, LEDs DS15, DS13 and DS12 will be OFF, and LEDs DS10 and DS11 will blink for a short period of time. Note that a defective battery will not halt this test. The diagnostics will proceed to the next test.
In the next test, the I/O Module slots are interrogated and tested as required. All
I/O circuitry is contained on the MI/OB Board and with respect to System Firmware is organized as follows: Slot 1 = DIs, Slot 2 = DOs, Slot 3 = AIs, & Slot 4 = AOs.
At the conclusion of the I/O tests, LEDs DS10-DS15 will turn OFF for 1 second, then turn ON for 1 second, and then OFF again for 1 second. The status of the I/O
Module interrogation is then displayed on LEDs DS10-DS15. The status for slots 1 through 6 is displayed as follows: LED DS15 indicates the status for slot #1, LED
DS14 for slot #2 ... and LED DS10 for slot #6. A LED will turn ON for each slot having a module installed, providing that the module's self test was successful. The
LEDs for all unoccupied or failed slots will be OFF.
After displaying the status for slots #1-6, all six LEDs will go OFF for 1 second. The status for slots #7-12 will then be displayed using LED DS15 to indicate the status for slot #7, LED DS14 for slot #8 ... and LED DS10 for slot #12.
5-8 / Service 3305 RTU
If no I/O Modules are installed, LEDs DS10-DS15 will remain OFF for several seconds between the completion of the diagnostic test cycle and the final "ripple" pattern described in step 6.
Table 5-1 - Power Supply/CPU Board Diagnostic LED Failure Indications
TEST
CPU/INTERNAL PERIPHERALS FAILURES:
CPU Registers
Internal Timer (IT) 2
Internal PIC
DMA
Internal Timer 0 & 1/Incorrect CPU
Speed
NPX present with Software Library link* or NPX not present with
Hardware link.
Error Programming ACCOL FLASH
EXTERNAL PERIPHERALS FAILURES:
System RAM
System Low Battery Warning*
Redundancy Registers
Redundancy RAM
System/ACCOL PROM
Custom PROM Warning*
Make RAM (System RAM upper 512)
Real Time Clock (RTC)
RTC Internal Battery Warning*
I/O MODULE STATUS:
DS15 DS14 DS13 DS12 DS11 DS10
0 0 0 0 0 1
0 0 0 0 1 0
0 0 0 0 1 1
0 0 0 1 0 0
0 0 0 1 0 1
0 0 0 1 1 0
0 0 0 1 1 1
0 1 0 0 0 1
0 1 0 0 X X
0 1 0 1 0 0
0 1 0 1 0 1
0 1 1 0 0 0
0 1 1 0 X X
0 1 1 0 0 1
0 1 1 0 1 1
0 1 1 1 X X
Slot Nos. - >
First Display
Slot Nos - >
Second Display
(see Note 2 below)
DOWNLOAD COMM. INITIALIZATION
FAILURES: (RAM based units only)
Port A/B Failed
Port C/D Failed
Example: Ports A & B Failed
CONFIGURATION ERRORS:
#1 #2 #3 #4 #5 #6
T T T T T T
#7 #8 #9 #10 #11 #12
T T T T T T
1 0 0 0 0 1
1 0 0 0 1 0
1 0 0 0 0 1
Load Version Fail
Memory Configuration Error
-ACCOL load too large for Flash
1 1 0 0 0 1
1 1 0 0 1 0
PROM.
Note 1: * = This is only a warning the unit doesn't stop.
Note 2: If there is an I/O Module in the indicated slot and the module has passed the self test (if applicable), the corresponding LED will be
ON. If the I/O Module didn’t respond (slot is unoccupied/unassigned
3305 RTU Service / 5-9
or the module has failed its self test), the LED will be OFF. With respect to system firmware and the ACCOL load, the 3305’s I/O Slots are assigned as follows: Slot 1 = DIs, Slot 2 = DOs, Slot 3 = AIs and
Slot 4 = AOs.
6. The conclusion of the above test cycle is indicated by a "ripple" pattern on the
STATUS LEDs that sequences from LED DS15 through LED DS10. All six LEDs will then be turned OFF. At this time, an EPROM-based DPC will begin executing its ACCOL load, while a RAM-based DPC will check and initialize its ports to prepare for a download. LEDs DS14 to DS10 will identify the port status as shown in Table 5-1; active or vacant ports will be indicated by an OFF LED, while a defective port will be indicated by an ON LED. If there is one or more defective ports, LED DS15 will be ON for this test. The IDLE/RUN LED will also be OFF for this test since the CPU will remain busy monitoring all of the ports for a download sequence.
7. Configuration errors are indicated prior to the completion of the download if LEDs
DS14 and DS15 are ON. LED DS10 in an ON state indicates a load version failure.
If LED DS11 is ON, the probable cause is that the ACCOL load is too large for
FLASH.
8. At the completion of the download, the LEDs DS10-DS15 and the WATCHDOG
LED will turn OFF. The IDLE/RUN LED will start blinking to indicate the activity level of the ACCOL load.
5.2.2 Startup Diagnostics Using a Terminal Emulator
By connecting Port A (Local/Diagnostic Port) to a PEI (Process Engineer’s Interface), i.e., a computer equipped with Terminal Emulation Software such as WINDOWS TERMINAL,
PROCOMM, SMARTCOM, etc. and the BBI SYSTEM CONFIG/FLASH DOWNLOADER
Software (see Figure 5-5 and section 4.5.4) the following startup diagnostic sequence can be observed upon successful completion of the startup sequence:
Make RAM Diag Success
PIC Diag Start
PIC Diag Success
Self Test RAM Diag - 504K RAM Present
Sgmt Strt End
2000 0000 7FFF Passed
2000 8000 FD5F Passed
3000 0000 7FFF Passed
3000 8000 FFFF Passed
4000 0000 FFFF Passed
5000 0000 FFFF Passed
6000 0000 FFFF Passed
7000 0000 FFFF Passed
8000 0000 FFFF Passed
9000 0000 DFFF Passed
5-10 / Service 3305 RTU
CPU Speed Diag Start
CPU Running at 12 MHz
System Battery Diag Start
System Battery Diag Success
RTC Internal Battery Diag Start
RTC Internal Battery Diag Success
RTC Diag Start
RTC Diag Success
Timer 2 Diag Start
Timer 2 Diag Success
DMA Diag Start
DMA Diag Success
LCD Diag Start
4x20 LCD Is Present (see Note 1)
I/O Board Diag Start - See LED pattern for status
Note 1 This line depends on the type of LCD Module or the lack of an LCD Module.
For a 2 x 16 LCD Module, the line should read as follows:
2x16 LCD Is Present
If an LCD Module isn’t present the line should read as follows:
No LCD Device Is Present
Figure 5-5 - 3305 RTU Connected to PEI Via the Local Communications Cable
5.3 DIAGNOSTIC LOAD (DIAG05.ACL)
Detailed off-line diagnostics allow the user to perform a more extensive evaluation of the
RTU by isolating faults to specific areas such as the CPU, RAM, Serial Communications, or
3305 RTU Service / 5-11
I/O. They also provide support for calibrating the I/O. All I/O circuitry is contained on the
MI/OB Board and with respect to ACCOL is organized as follows:
Slot 1 = DIs, Slot 2 = DOs, Slot 3 = AIs, & Slot 4 = AOs
These tests are initiated through the DIAGNOSTIC Program (DIAG0.5.ACL) (which is run on a personal computer (Global Diagnostics are not supported, i.e., should not be done).
This program is furnished on a disk contained in the AIC software package. For a description of these test procedures, refer to User Manual D4041A, WINDIAG - Windows
Diagnostics for BBI Controllers.
5.3.1 Testing the 3305 RTU CPU Peripherals and Comm Ports
Chapter 2 33XX & 3305 CPU and Peripherals of the WINDIAG Manual (D4041A) provides detailed tests for the CPU internal and external peripherals. Internal Peripherals include the Programmable Interrupt Controller (PIC), Direct Memory Access (DMA) device, and
Inter-nal Timers. External Peripherals include LEDs, the Real Time Clock, the Lithium
Battery, and the External Timers.
Chapter 3 33XX & 3305 Memory of the WINDIAG Manual (D4041A) provides detailed tests for the CPU’s RAM and FLASH memory. It should be noted that with respect to these diagnostic tests, the 3305 RTU’s CPU is tested like a 3330 Real Mode (386-EX). RAM &
FLASH memory is organized as follows:
!
512K bytes of System FLASH
!
504K bytes of RAM with battery backup
!
224K bytes of ACCOL Load Storage in FLASH
!
32K bytes of Boot & Configuration Firmware in FLASH
Chapter 4 33XX & 3305 Communications of the WINDIAG Manual (D4041A) provides detailed tests for checking the 3305’s Communication Ports (A, B C & D). Loopback testing is accommodated via switches SW1 (on the PMPP Board for Ports A, B & C) and SW1 (on the MI/OB Board - for Port D). Loopback switch settings are provided in Tables 5-2 and 5-3 below. The ALL ASYNC Test should be performed for all Comm. Ports except Port A, since
Port A serves as the PEI connection.
Table 5-2 - PMPP Board Switch SW1 Assignments
Port ID
Port C
Port C
Port C
Port B
Port B
Port B
Port A
Port A
Switch #
1
2
5
6
3
4
7
8
ON Definition
TXD to RXD Loopback
RTS to CTS Loopback
DTR to DCD Loopback
TXD to RXD Loopback
RTS to CTS Loopback
DTR to DCD Loopback
TXD to RXD Loopback
RTS to CTS Loopback
The 3305 must be reset to ensure correct acquisition of communication and configuration data. Go to the Communication Menu and set the number of passes to four (4) or higher.
5-12 / Service 3305 RTU
Note: The 3305 RTU Comm. Ports don’t operate in synchronous mode.
Table 5-3 - MI/OB Board Switch SW1 Assignments
SW1
#
1
2
Function
-
RS-232/485 Selection
RS-232
Operation
-
ON = 232
Enabled
RS-485
Master station
-
OFF = 485
Enabled
ON =
Enabled
RS-485 Most
Distant
Slave
-
OFF = 485
Enabled
ON =
Enabled
RS-485
Other
Slaves
-
OFF = 485
Enabled
OFF =
Disabled
3
4
5
6
7
8
RS-484 XMTR 120 S
Term. Resistor
RS485 RCVR 120 S
Term. (+ Bias) Resistor
RS485 RCVR 120 S
Term. (- Bias) Resistor
RS-232 TXD/RXD
Loopback
RS-232 RTS/CTS
Loopback
RS-232 DT/DCD
Loopback
N/A
N/A
N/A
ON enables
Local Loopback
ON enables
Local Loopback
ON enables
Local Loopback
ON =
Enabled
ON =
Enabled
N/A
N/A
N/A
ON =
Enabled
ON =
Enabled
N/A
N/A
N/A
OFF =
Disabled
OFF =
Disabled
N/A
N/A
N/A
Note: SW1-4 & SW1-5 must be set together, i.e., both must be ON to enable (install) the RS-
485 120 S Receiver (Bias) Resistor.
Note: SW1 switches -6, -7 & -8 are provided for RS-232 configuration. These switches are typically ON for test purposes and with the exception of SW1-7, are otherwise left
OFF. When Port D is connected to a PC, SW1-7 should be ON (see Figures 2-19 and
2-20).
5.3.2 Analog Input Circuitry Offset Calibration
Analog Input calibration is performed in conjunction with Section 5.3.1 of the WINDIAG
Manual (D4041A). Access to adjustable resistors on the MI/OB Board is provided by access holes on the PMPP Board (see Figure 5-6). The Analog Input Circuitry Offset is calibrated as follows:
1. Set MI/OB Board Jumpers W8A/B through W11A/B for 1-5V operation (see Section
2.4.3 Figure 2-11).
2. Apply 1.000V DC (0% Span) between TB2-2 (AI+)and TB2-1 (AI-) and adjust potentiometer R143 on the MI/OB Board. From the Analog Input Diagnostic Menu
(Figure 5-4 of D4041A), select the Analog Input poke point. With 1.000V applied to
TB2-2 (AI+) and TB2-1 (AI-) and R143 properly adjusted, the Diagnostics program will display the correct value for AI1 as 0BA hexadecimal.
3. Apply 5.000V DC (100% Span) between TB2-2 (AI+) and TB2-1 (AI-) and adjust potentiometer R144 on the MI/OB Board. With 5.000V applied to TB2-2 (AI+) and
TB2-1 (AI-) and R144 properly adjusted, the Diagnostics program will display the correct value for AI1 as F46 hexadecimal.
3305 RTU Service / 5-13
4. Repeat steps 2 and 3 until the Analog Input Circuitry Offset calibration is within specification.
5. Set MI/OB Board Jumpers W8A/B through W11A/B for the desired input configuration.
5.3.3 Analog Output Circuitry Calibration
Analog Output calibration is performed in conjunction with Section 5.2.1 of the WINDIAG
Manual (D4041A). Access to adjustable resistors on the MI/OB Board is provided by access holes on the PMPP Board (see Figure 5-6). This procedure requires one or two 250-Ohm
± .01% Resistors. The Analog Output Circuitry is calibrated as follows:
1. For AO1, connect a 250 Ohm 0.01% Resistor across Terminals TB2-10 (AO1+) and
TB2-9 (AO1-). For AO2, connect a 250 Ohm 0.01% Resistor across terminals TB2-12
(AO2+) and TB2-11 (AO2-).
2. On the Analog Output Diagnostic Menu (Figure 5-1 of D4041A), select the “Signal
Cond. Zero” poke point and press [ENTER].
3. Use the DVM to measure across the field terminals associated with AO1 or AO2
(depending on which AO is being calibrated), or use a current meter in series with
AO1+ and AO1- or AO2+ and AO2- and adjust the respective potentiometer (R95 for
AO1 & R101 for AO2) for either +1.000V dc ± 0.001V or 4mA ± 0.004mA.
4. On the Analog Output Diagnostic Menu (Figure 5-1 of D4041A), select the “Signal
Cond. Span” poke point and press [ENTER].
5. Use the DVM to measure across the field terminals associated with AO1 or AO2
(depending on which AO is being calibrated), or use a current meter in series with
AO1+ and AO1- or AO2+ and AO2- and adjust the respective potentiometer (R93 for
AO1 & R98 for AO2) for either +5.000V dc ± 0.001V or 20mA ± 0.004mA.
6. Repeat steps 2 through 5 until outputs are within specification.
7. Remove the test resistor.
5.3.4 Discrete Output & Discrete Input Tests
Discrete I/O testing is performed in conjunction with Chapter 5 of the WINDIAG Manual
(D4041A). The 3305 RTU can have a maximum of 14 DIs or 8 DOs. DI/O1-6 can be configured either way, i.e., for DO or DI operation or a combination of each, e.g., DI/O1 may be configured for DI operation and DI/O2 and DI/O3 etc. may be configured for DO operation.
5-14 / Service 3305 RTU
3305 RTU
Figure 5-6 - Adjustable Resistors & DC Measurement Points
Service / 5-15
5.3.5
LCD Display & Display/Keyboard Tests
LCD Display testing is performed in conjunction with Chapter 14 of the WINDIAG Manual
(D4041A). All four off-line diagnostic tests can be performed for the Local/Remote 2 X 16
LCD Display and the Remote 4 X 20 Display/Keyboard.
When the LCD Character ROM Test (associated with the 4 X 20 Display/Keyboard) executes, the 4 X 20 Display should look like Figure 5-8. When the LCD Character ROM
Test (associated with the 2 X 16 LCD Display) executes, the LCD display will proceed through the test providing three (3) sequential displays (see Figure 5-7).
Figure 5-7 - LCD Character Test for 2 X 16 LCD Display
Figure 5-8 - LCD Character Test for 4 X 20 LCD Display
5.4 POWER SUPPLY TESTS & TRIP POINT ADJUSTMENTS
5.4.1 Setting the Power Fail Trip Point
(see Figure 5-6)
Resistor R11 in conjunction with Jumper W10 (both on PMPP Board) provide for setting the Power Fail Trip Point. W10 must be installed for the 9-20V input range and must be removed for 20-30V input range. In the case of a 9-20V (12V Battery) input supply, the DCto-DC Converter will shut down at 9V and will be restarted when the input supply once again exceeds 9.5V. In the case of a 20-30V (24V Battery) input supply, the DC-to-DC Con-
5-16 / Service 3305 RTU
verter will shut down at 20V and will be restarted when the input supply once again exceeds 22V.
During a power fail (Input Power is less than 9V or 20V), the PFINT* signal is generated to the CPU by a Sequencer which monitors a Comparitor circuit. Two milliseconds later,
MC* is generated to the CPU by the Sequencer and power will shut down. When the input sup-ply exceeds 9.5V or 22V, the Power Fail Circuitry will once again indicate good power and the Power Controller will be restarted. 100 milliseconds later, the PFINT* and MC* signals will be released to take the CPU out of the reset state.
To set the Power Fail Trip Point a variable DC Power Supply is required. With power OFF, turn R11 fully counterclockwise. Connect the variable DC Power Supply to TB3-1 (+) and
TB3-2 (-) on the MI/OB Board. In the case of a 9-20V System (12V Battery) apply greater than 9.5V and in the case of a 20-30V System (24V Battery) apply greater than 22V.
Set the variable DC Power Supply to either 9V or 20V (for 12V or 24V 3305 system, respectively). Adjust R11 (clockwise) on the PMPP Board until the unit just turns OFF, i.e.,
LEDs DS16 (MC*) and DS17 (PFIN*) on the PMPP Board turn OFF.
5.4.2 Setting the Low Battery Voltage Detection Trip Points
(see Figure 5-6)
Resistor R12 in conjunction with Jumper W11 (both on PMPP Board) provide for setting the Low Battery Voltage Detection Trip Point. Jumper W11 must be installed for the 9-20V input range (12V Battery) and must be removed for the 20-30V input range (24V Battery).
In the case of a 12V Battery supply, LBIN* will go low when the input voltage drops below
11V and will go high when the input voltage rises above 11.2V. In the case of a 24V Battery supply, LBIN* will go low when the input voltage drops below 23.5V and will go high when the input voltage exceeds 24V.
To set the Low Battery Voltage Detection Trip Point a variable DC Power Supply is required. Additionally, an Encode Module must exist in an executing task within the
ACCOL load. Low power (battery) status is reported using Function 7 of the Encode
Module (see the ACCOL II Reference Manual D4044). Taskspy, On Line AIC or Toolkit must be used to monitor the signal wired to the Input 1 Terminal of the Encode Module.
With power off, turn R12 fully counterclockwise. Connect the variable DC Power Supply to
TB3-2 (+) and TB3-1 (-) on the MI/OB Board. In the case of a 9-20V System (12V Battery) apply 11.2V and in the case of a 20-30V System (24V Battery) apply 24V. Carefully adjust
R12 on the PMPP Board until a value of 1 or ON is reported on the Input 1 Terminal of the
Encode Module.
5.4.3
Power Checks
(see Figure 5-6)
System Power is supplied on TB3 pins 1 & 2 of the MI/OB Board and is supplied to the
PMPP Board on J4 pins 1 & 2. The DC-To-DC Converter (on the PMPP Board) produces
+18V, -18V, +5V and +21V (+32V for 24V Models and DI/O Models. Referring to Figure 5-6 measure the DC output supplies and make sure that they are within the following ranges:
+18VDC ( ± 5%, i.e., ± .9V)
-18VDC ( ± 5%, i.e., ± .9V)
3305 RTU Service / 5-17
+5VDC ( ± .1V)
+21VDC ( ± 5% for a 9-20V input supply, or 12V Battery, i.e., ± 1.05V)
+21VDC (Clamped at approximately 31V ± 5%, i.e., ± 1.55V for 24V Models and
DI/O Models)
The input supply is considered good if the voltage is higher than the Power Fail (OFF) Trip
Point, i.e., 9.5V or 22V for 9-20V or 20-30V systems respectively.
5.5 GENERAL NOTES
Certain questions or situations frequently arise when servicing the BBI Controllers. Some items of interest are provided in Sections 5.5.1 through 5.5.3.
5.5.1 Extent of Field Repairs
Field repairs to Series 3305 units that are used in Class I, Division 2 hazardous areas are strictly limited to the replacement of complete PC boards and assemblies. Any repairs made down to the component replacement level will violate the hazardous area classification of the unit. Defective PC boards or assemblies must be returned to Bristol
Babcock for authorized service.
5.5.2
Disconnecting RAM Battery
If the RAM battery of the FLASH-based RTU 3305 is disconnected when the power is off, the RTU will still execute its ACCOL load but all of the current process data will be lost.
Upon power-up, the FLASH-based RTU will act as though it had just been booted and it will revert back to the initial values specified in its ACCOL load.
5.5.3 Maintaining Backup Files
It is essential to maintain a backup disk of each ACCOL load file to guard against an accidental loss of process configuration data. Without a backup record, it will be necessary to reconfigure the entire ACCOL load which can be a very time consuming procedure. Always play it safe and keep backup copies of your ACCOL loads.
5-18 / Service 3305 RTU
Section 6
SPECIFICATIONS
6.1 CPU, MEMORY & PROGRAM INTERFACE
Processor:
Memory:
80C186XL, 12MHz
512K bytes of system FLASH
256K or 504K bytes battery-backed RAM; 224K bytes ACCOL Load FLASH and 32K Boot/-
Configuration FLASH
DS1287 accurate to one second per day Real Time Clock:
Program Interface: ACCOL programming language tools, which are run on an attached PC, allow the user to configure the
RTU and to obtain access to current data, configurable constants, and a variety of logs.
6.2 COMMUNICATION PORTS
6.2.1 Communication Ports
Local Port:
Network Port:
ESD:
Port A - RS-232
Port B & C - RS-232
Port D - RS-232 or RS-485
Ports A, B & C - 10KV 150 Ω Source Resistance
Port D - 10KV 1.5K
Ω Source resistance
6.2.2 Network Ports (B, C & D)
Interface:
Baud Rate:
Address:
Optional Modem:
Optional Radio Delay:
RS-232 (Ports B, C & D)
RS-485 (Port D)
1.2K, 2.4K, 4.8K, 9.6K, 19.2K & 38.4K (bps)
Software selectable network address from 1 to 126
Ports may be furnished with a private line modem
(PLM) or a switched network modem (SNM) board.
A Port may be furnished with a Radio Delay Board to provide a radio transceiver interface.
3305 RTU Specifications / 6-1
Optional TIB
Optional RS-485 Interface
A Port may be furnished with a Transmitter Interface Board to allow up to 5 BBI Series 3508 to communicate with an RTU 3305.
A Port may be furnished with an RS-485 Interface
Board which allows the 3305 to be included in a 4-
Wire multi-dropped LAN along with other BBI 33XX
Controllers and Transmitters as-well-as RS-485 capable devices.
6.2.3 Customer Port (A)
Interface:
Baud Rate:
Address:
RS-232 (3-Wire)
1.2K, 2.4K, 4.8K, 9.6K, 19.2K & 38.4K (bps)
Software selectable network address from 1 to 126
6.2.4 Communication Protocols (Network Ports
)
BSAP (Bristol Standard Asynchronous Protocol):
Compatibility: Compatible with all Bristol Network 3000 Products
Local Addressing: 127 Nodes
Global Addressing
ISO Standard:
32767 Nodes
1745/2111/2629
6.3 INPUT/OUTPUT SPECIFICATIONS
6.3.1 Analog Inputs
Number of Inputs:
Input Type:
4 Analog Differential Inputs (Selectable for Current or Voltage type inputs)
Voltage Input 1-5 Vdc
Current Input 4-20 mA
Internally Sourced 4-20mA Curent Loop
Input Impedance:
High Common Mode Version: 1-5V Input = 2M Ohms
4-20mA Input = 250 Ohms
Common Mode Range:
High Common Mode version: 180Vdc
6-2 / Specifications 3305 RTU
Accuracy:
At Ambient Temp. (23
°
C)
At -20
°
C to +70
°
C
At -40
°
C to +70
°
C
Input Filtering:
Voltage/Current Input 0.1% of Span
Voltage/Current Input 0.2% of Span
Voltage/Current Input 0.3% of Span
Single Pole (50 msec time constant)
300 msec to within .1% of input value
Settling Time of any AI is 18
µ sec to .01%
Common Mode Rejection Ratio 47 to 63 Hz - 100dB
Normal Mode Rejection Ratio at 60Hz - 26dB
6.3.2 Analog Outputs
Number of Outputs:
Range:
Accuracy:
2
4-20 mA into a 650 Ohm Load
+23
°
C 0.1% os Span
-20
°
C to 70
°
C 0.2% of Span
-40
°
C to 70
°
C 0.3% of Span
100msec to .1%
16V Transorb across output
(Meets ANSI/IEEE C37.90-1978)
Setting Time:
Surge Suppression:
6.3.3 Discrete Inputs
Number of Inputs:
Input Type:
Input Current:
Input Filtering:
Input Impedance:
Surge Suppression:
6.3.4 Discrete Outputs
Number of Outputs:
8 non-isolated inputs
6 non-isolated selectable inputs
Dry Contact
5mA
±
10% (Contact Closure)
30msec time constant for DI/O1-DI/O6
1msec time constant for DI7-DI14
2.2K
Ω ±
10% for 12V Input Range
4.7K
Ω ±
10% for 24V input Range
38V MOV Across Input
(Meets ANSI/IEEE C37.90-1978)
2 (standard) 6 (selectable)
3305 RTU Specifications / 6-3
Output Type:
Surge Suppression:
Open Drain
38V MOV Across Output
Reverse Voltage Diode Clamp
(Meets ANSI/IEEE C37.90-1978)
100mAdc @ 35Vdc Maximum Load:
6.3.5 Watchdog Contacts
Rating:
6.3.6 High Speed Counter
Number of Inputs:
Input Type:
Input Current:
Input Voltage:
Input Filtering:
Input Frequency:
Input Impedance:
Surge Suppression:
2 Amps Resistive @ 30Vdc
1
SPDT Dry Contact/Open Collector
5mA ± 10% (Open Collector/Contact Closure)
+12V ± 10% @ 5mA
+24V ± 10% @ 5mA
20 µ sec Time Constant
DC to 10KHz
2.2K
Ω ± 10% for 12V Input Range
4.7K
Ω ± 10% for 24V Input Range
38V MOV Across Input
(Meets ANSI/IEEE C37.90-1978)
6.4 ENVIRONMENTAL SPECIFICATIONS
Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Approvals:
Operating: -40 to +158 ° F (-40 to +70 ° C)
W/LCD Option: -4 to +158 ° F (-20 to +70 ° C)
Storage: -40 to +185 ° F (-40 to +85 ° C)
W/LCD Option: -22 to +185 ° F (-30 to +85 ° C)
15-95% Non-condensing
1g for 10-150 Hz
.5g for 150-2000 Hz
10V/Meter from 20MHz to 500MHz
FM rated for Class I, Division 2, Groups A, B, C, and D Hazardous Areas.
6-4 / Specifications 3305 RTU
6.5 POWER SPECIFICATIONS
6.5.1 Input Power Specs.
Operating Range:
Inrush Current:
Fusing:
Efficiency:
Reverse Voltage Protection:
Overvoltage Protection:
6.5.2 DC To DC Converter Specs.
9V - 30V (DC)
4 Amps peak (during 2ms)
.5 Amp Slow-Blow (for 20-30 Vdc source)
1 Amp Slow Blow (for 9-20 Vdc source)
75% Min @ 9V Input
Diode Clamp
Transorb Clamp
Outputs - Currents & Voltages: 5V @ 600mA Non-Isolated
21V @ 200mA Non-Isolated
-18V @ 100mA Non-Isolated
+18V @ 100mA Non-Isolated
Regulation:
Ripple:
Line: 5V - .2% for 9-30 V
Load: 5V - 0.1% for 100% Load Change
RMS: 0.1% or 10mV RMS Max.
Peak to Peak: 1% or 50mV pk-to-pk, (whichever is greater)
Transient Response:
Short Circuit Protection:
Overvoltage Protection:
Power Fail Trip Points:
Output voltage returns to within 1% in less than
500
µ sec in response to a 25% load step. Maximum excursion less than 200mV from nominal.
Current Limit to 150% of rated load.
Transorb on 5V Non-isolated Output
9-20V Range (Jumper WX Installed)
ON (Active Low)- Vin <9.0 V
OFF
Hysteresis:
- Vin >9.5 V
- 0.2 V
22-30V Range (Jumper WX Removed)
ON (Active Low)- Vin <20 V
OFF
Hysteresis:
- Vin >21.5V
- 1.5 V
Output Configuration: Open Collector
3305 RTU Specifications / 6-5
Low Battery Trip Points: 9-20V Operation
ON (Active Low) - Vin <11 V
OFF
Hysteresis:
- Vin >11.2 V
- 0.2 V
22-30V Operation
ON (Active Low) - Vin <23.5 V
OFF
Hysteresis:
- Vin >24 V
- 0.5 V
Output Configuration: Open Collector
6.5.3 Power Requirements
3305 RTU Power Requirements: 434 mAmps Max. at +24VDC (+20V - +30V)
829 mAmps Max. at +12VDC (+9V - +20V)
100
µ
Amps Max. at +3.6VB (256K RAM battery back-up)
200
µ
Amps Max. at +3.6VB (512K RAM battery back-up)
Optional Communication
Boards Power Requirement: TIB: .73W @ 24Vdc
RDI: .10W @ 24Vdc
RS-485: <250mW @ 30Vdc
PLM:
SNM:
85Ma @ (9.5 to 18)Vdc
125Ma @ (9.5 to 18)Vdc
6.6 RTU 3305 MODEL VARIATIONS
Table 6-1 RTU 3305 Models
I/O System
DISCRETE I/O
8 DIs
2 DOs
6 DI/Os
ANALOG IN
8 DI
2 DO
6 DI/DO
4 AI
ANALOG OUT
8 DI
2 DO
6 DI/DO
4 AI
2 AO
Input Voltage Display Type
12 VDC or
24 VDC
None
Local 2x16
Remote 2x16
Remote 4x20
12 VDC or
24 VDC
12 VDC or
24 VDC
None
Local 2x16
Remote 2x16
Remote 4x20
None
Local 2x16
Remote 2x16
Remote 4x20
6-6 / Specifications 3305 RTU
Model 3305 Remote Terminal Unit
Special Instructions for Class I, Division 2 Hazardous Locations
1. The BBI Model 3305 Remote Terminal Unit (RTU) 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 and nonhazardous locations only. Read this document carefully before installing a nonincendive BBI Model 3305 RTU. In the event of a conflict between the Model 3305 RTU Customer Instruction Manual (CI-3305) and this document, always follow the instructions in this document.
2. All power and I/O wiring must be performed in accordance with Class I, Division 2 wiring methods as defined in Article 501-4 (b) of the National Electrical Code, NFPA
70, for installations within the United States, or as specified in Section 18-152 of the
Canadian Electrical Code for installation in Canada.
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.
07/12/00 Appendix A, Document CI-3305 Page 1 of 1
BLANK PAGE
Product Information Package
PIP-TIBS33XX
Mar., 2007 Series 3305, 3310& 3330
Transmitter Interface Boards
Part No. 392912-XX-X & 392523-XX-X
For The Following Bristol Instruction Manuals:
CI-3305, CI-3310 & CI-3330 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, 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
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 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
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
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
1.
Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3. What is the Firmware revision? _____________________ What is the Software & version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A.
If product is within the warranty time period but is excluded due to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B.
If product were found to exceed the warranty period, would you like the product:
C.
If product is deemed not repairable would you like your product: repaired returned replaced scrapped? returned replaced scrapped?
D.
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: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
• Avoid Delays and problems in getting your system on-line
• Minimize installation, start-up and maintenance costs.
• Make the most effective use of our hardware and software.
• Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol products and realize the full potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 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 software products incorporate help screens. In addition, the software typically includes a ‘read me’ release notes file detailing new features in the product, as well as other information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about 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.
PIP-TIBS33XX
TRANSMITTER INTERFACE BOARDS
PT. NO. 392912-XX-X & 392523-XX-X
TABLE OF CONTENTS
TITLE PAGE #
DESCRIPTION............................................................................................................................................. 1
RTU-3305 Boards......................................................................................................................................... 1
DPC-3330 Boards ......................................................................................................................................... 1
RTU-3310 Boards......................................................................................................................................... 1
Model 3508 Transmitter Operation .............................................................................................................. 1
Model 3808 Transmitter operation ............................................................................................................... 3
CONFIGURATION & WIRING .................................................................................................................. 4
Wiring Connections ...................................................................................................................................... 4
12V Transmitter Interface Board Jumper Configuration.............................................................................. 5
LED INDICATORS...................................................................................................................................... 5
SPECIFICATIONS....................................................................................................................................... 5
12V TIB ........................................................................................................................................................ 5
24V TIB ........................................................................................................................................................ 6
Supplements
Special Instructions for Class I, Division 2 Hazardous Locations......................... Appendix A
PIP-TIBS33XX Page 0-1 Table Of Contents
BLANK PAGE
TRANSMITTER INTERFACE BOARDS
For Models
RTU-3305, RTU-3310 & DPC-3330
DESCRIPTION
Two versions of the Transmitter Interface Board (+12VDC and +24VDC) are available for models RTU-3305 and two versions are available for models, RTU-3310 and DPC-3330. The
Transmitter Interface Board (TI Board) allows up to five Bristol, Series 3508 or Series 3808
Transmitters to communicate with a host DPC/RTU. The DPC/RTU polls and stores data from each transmitter and communicates with the network. Three LEDS on the TI Board
(TXD, CTS and RXD) indicate the communication status.
The +24V TIB can provide loop power for its associated transmitters directly from the +24V supply used to power the DPC 3330, RTU 3310 or RTU 3305. The +12V TIB includes an onboard DC-DC converter to provide +24V loop power for transmitters not designed to operate from a +12V source.
The +24V version of the TI Board does not contain any switches or jumpers that require con-figuration; however, the +12V version of the TI Board does contain three configuration jumpers which must be set to support LED operation and either of two field wiring configurations.
RTU-3305 Boards
Either of the TI Board shown in Figure 1 (24 Vdc) or Figure 2 (12 Vdc), can be mounted to an RTU-3305’s Option Mounting Brackets and interfaced to the 3305’s Port C via TI Board connector P1 (see Section 2.6 of the CI-3305 Instruction manual).
DPC-3330 Boards
The TI Board shown in Figure 3 (24Vdc) or Figure 4 (12Vdc) plugs into the modem utility connector (J3) on the DPC-3330’s 2-Port CE Board and is assembled to the CE Board using screws and spacers. A TI Board cannot be mounted on the 4-Port Enhanced Comm. Board.
RTU-3310 Boards
The TI Board shown in Figure 3 (24Vdc) or Figure 4 (12Vdc) plugs into the modem utility connector (J7) on the RTU-3310’s Multi-Function Interface Board (MFIB) and is assembled to the MFI Board using screws and spacers.
Model 3508 Transmitter Operation
Each Model 3508 Transmitter must be assigned a unique address via the SMARTKIT program as described in Section 4.2 PROGRAM LOADING AND STARTUP of the appropriate 3508 Transmitter manual. Additionally, all Model 3508 Transmitters wired to the TI Board must be operated in the minimum current mode (3.8 mA). This mode is
PIP-TIBS33XX Page
selected via the SMARTKIT program as described in Section 4.7 TRANSMITTER
OPERATING MODES of the appropriate 3508 Transmitter manual, i.e., CI-3508-10C, CI-
3508-30C or CI-3508-99C.
Figure 1 - 24V Transmitter Interface Board P/N 392523-02-7 for RTU 3305
Figure 2 - 12V Transmitter Interface Board P/N 392912-02-3 for RTU 3305
PIP-TIBS33XX Page
Model 3808 MVT Transmitter Operation
Each Model 3808 MVT Transmitter must be assigned a unique address via the WebBSI
Sign On/Off Menu (see Section 3 of Customer Instruction Manual CI-3808). Additionally, only analog versions of the 3808 MVT can be interfaced to a Transmitter Interface Board.
Figure 3 - 24V Transmitter Intf. Board P/N 392523-01-9 (RTU 3310 or DPC 3330)
Figure 4 - 12V Transmitter Intf. Board P/N 392912-01-5 (RTU 3310 or DPC 3330)
PIP-TIBS33XX Page
CONFIGURATION & WIRING
Wiring Connections
TI Boards are equipped with six dual-terminal blocks for field wiring connections. Terminal block TB1 connects to the transmitter power source, while TB2 through TB6 connect to the signal/power inputs of the transmitters. Two field wiring conventions are supported by the
TI Boards; Internally Powered (see Figure 5) and Externally Powered (see Figure 6).
Figure 5 - Internally Powered Transmitter Field Wiring
Figure 6 - Externally Powered Transmitter Field Wiring
PIP-TIBS33XX Page
In the case of an Internally Powered Transmitter (powered from TIB’s on-board +24V
Supply/Regulator) an external +24 Vdc or +12 Vdc power supply is wired to the TI Board connector TB1 as shown in Figure 5. The supply is wired across the +24V EXT and +24V
RETEXT (+12V EXT and +12V RETEXT) terminals. The input voltage range for a 24V TIB is +22Vdc to +28Vdc. The input voltage range for a 12V TIB is +9Vdc to +15Vdc.
In the case of an Externally Powered Transmitter the -24Vdc side of the Transmitter Power
Source is connected to the TIB’s +12V/24VRET Terminal (TB1-2) as shown in Figure 6
The 12V TI Board contains jumpers that must be configured to support the field wiring option. The 24V TI Board; however, doesn’t contain jumpers. Both versions of the TI Board
(12V and 24V) contain an internal loop resistor and therefore external ones are not required.
12V Transmitter Interface Board Jumper Configuration
Two-position Jumper W1 enables or disables the Internal 24V Power Supply/Regulator.
Jumper W1 is installed, to disable power supply “shutdown” for “Internally Powered Transmitters”. For “Externally Powered Transmitters,” Jumper W1 must be stored in position 1 or 2.
Three-position Jumper W2 enables LED operation when installed in position 1 to 2. To disable LED operation, install Jumper W2 in position 2 to 3.
Jumper W3 must be installed in position 1 to 2 to connect the 249-Ohm Loop Resistor used for Internally Powered Transmitters. When wiring to Externally Powered Transmitters,
Jumper W3 must be installed in position 2 to 3 to remove the 249-Ohm Loop Resistor.
LED INDICATORS
The board contains three LEDs which have the following functions: Transmit Data (TXD),
Receive Data (RXD), and Clear to Send (CTS). When the board is sending data, TXD and
CTS are on and RXD is off. Conversely, when the board is receiving data, TXD and CTS are off and RXD is on. 12V versions of the TI Board contain a two-position Jumper (W2) which is used to enable or disable the LEDs.
SPECIFICATIONS
12V TIB
Communication Interface:
3508/3808 Interface:
24V Output:
Power Consumption Internal +5V:
Power Consumption Internal -5V:
TTL
FSK Modem - Bell 202 Compatible
(1200 Hz/2200 Hz modulation)
24.4Vdc ±6.5%
180mV pk/pk ripple
8.5mA
2mA
PIP-TIBS33XX Page
Power Consumption External +9V:
Power Consumption External +15V:
Operating Temperature:
Storage Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Part Numbers:
24V TIB
Communication Interface:
3508/3808 Interface:
24V Output:
Power Consumption Internal +5V:
Power Consumption External +24V:
Operating Temperature:
Storage Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Part Numbers:
14mA Per Transmitter
8mA Per Transmitter
-40ºC to +70ºC (-40ºF to +152ºC)
-40ºC to +85ºC (-40ºF to +185ºC)
15% - 95% Non-condensing
1G for 10Hz to 150Hz
0.5G for 150Hz to 2000Hz
10V/meter - 20MHz to 500MHz
392912-02-3 (for RTU-3305)
392912-01-5 (for DPC-3330 & RTU-3310)
TTL
FSK Modem - Bell 202 Compatible
(1200 Hz/2200 Hz modulation)
Baud rate is 1200
External 24V Supply
22 - 28Vdc
4mA
4mA Per Transmitter
-40ºC to +70ºC (-40ºF to +152ºC)
-40ºC to +85ºC (-40ºF to +185ºC)
15% - 95% Non-condensing
1G for 10Hz to 150Hz
0.5G for 150Hz to 2000Hz
10V/meter - 20MHz to 500MHz
392523-02-7 (for RTU-3305)
392523-01-9 (for DPC-3330 & RTU-3310)
PIP-TIBS33XX Page
Transmitter Interface Boards
Special Instructions for Class I, Division 2 Hazardous Locations
1. The Bristol Transmitter Interface Boards (TIBs) part numbers 392912-01-5, 392912-02-
3, 292523-01-9 & 392523-02-7 are listed by Factory Mutual (FM) as nonincendive and are 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 Bristol TIB Board. In the event of a conflict between the TIB Board User
Manual (PIP-TIBS33XX) 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.
03/14/2007 Appendix A of PIP-TIBS33XX - TIB Boards Page 1 of 1
Product Information Package
Transmitter Intf. Bd. Part Nos. 392912-XX-X & 392523-XX-X
PIP-TIBS33XX
Mar., 2007
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882 www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955 www.EmersonProcess.com/Bristol
The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol, Inc. assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software delivered herewith. The Customer shall inspect and test such software and other materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and fitness for a particular purpose, concerning the software and other materials delivered herewith.
TeleFlow
™
is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2007, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol, Inc.
Appendix 2
RADIO DELAY INTERFACE BOARD
For Instruction Manual CI-3305
Issue: 04/99
1
RX
ST
MULTIPLIER
UNIT
1S
100mS
DCD
CTS
RXD
DTR
RTS
TXD
+5V
17 MIN.
4 MIN.
1 MIN.
16 SEC.
8 SEC.
GND
RRTS
RDTR
RTXD
RRXD
RDCD
Bristol Babcock
Appendix 2
RADIO DELAY INTERFACE (RDI) BOARD
TABLE OF CONTENTS
TITLE PAGE #
DESCRIPTION..........................................................................................................................1
JUMPER CONFIGURATION...................................................................................................2
Leading Edge Delay .......................................................................................................2
Trailing Edge Delay .......................................................................................................2
Carrier Time Out ...........................................................................................................3
WIRING CONNECTIONS ........................................................................................................4
RDI Board to Transceiver ..............................................................................................4
Carrier Keyed Output ....................................................................................................4
DISPLAY LEDS.............................................................................................................5
ENVIRONMENTAL SPECIFICATIONS......................................................................5
CI-3305 Appendix 2 Page 01 T able Of Contents
RADIO DELAY INTERFACE BOARD
DESCRIPTION
The Radio Delay Interface Board (RDI Board) functions as an interface between a Series
33XX Distributed Process Controller and an external radio frequency (rf) transceiver or modem. The board includes an open collector output that can be used to key the carrier
"ON" or "OFF."
In a 3305 the RDI Board interfaces to Port C on the MI/OB Board and contains a 6-pin connector (TB1) that provides an RS-232 interface to an external modem or transceiver.
Terminal block (TB4) provides an open collector output that can be used to key a radio carrier. The following timing options can be used for communications:
Leading Edge Delay (RTS-to-CTS Delay). This feature delays the start of data transmissions after a "Request To Send" (RTS) signal has been initiated. It allows the rf carrier to reach full power before initiating a "Clear To Send" (CTS) signal. The leading edge delay also allows sufficient time for the remote rf receiver to recover from a squelched condition, thereby preventing a loss of the initial data.
Tailing Edge Delay. This delay keeps the transmitter "on" for a short period at the conclusion of a transmission even though RTS has just been set "off." This action ensures that the radio carrier remains on the air so that the last data are not corrupted by premature squelching or carrier "turn off" transients at the receiver.
CI-3305 Appendix 2
Figure 1. RDI Board No. 392504-02-2
Page 1 Radio Delay Interface Board
Carrier Time Out. This feature prevents a transceiver from tying up network communications should it fail with the rf carrier set "on." This is especially true in an application where a master station polls a field of remotes that operate on the same frequency; a remote that fails with the "carrier on" will halt network polling. By using this feature, the carrier of the failed remote will be forced of the air after the
"time out" has lapsed. In this application RTS must be inactive in order to reset the carrier time out.
JUMPER CONFIGURATION
Board jumpers provide configuration of leading and trailing edge delays and carrier time out.
Leading Edge Delay
The leading edge delay is the time from the start of a Request To Send (RTS) signal to the start of a Clear To Send (CTS) signal. The delay times are determined by plugging in a combination of two jumper headers, W1 and W2. Header W1 provides four time periods from 1.25 ms to 1 sec, while header W2 provides seven multiplier positions from X1 to X8.
Table A is a matrix that shows the time periods for all combinations of W1 and W2. For example, if W1 is placed in the "C" position and W2 in the "A" position, the delay will be 100 milliseconds, but if W2 is moved to the "B" position the delay will be 200 milliseconds.
TABLE A - LEADING EDGE DELAY SELECTIONS
Jumper
W2
Position
E
F
G
A
B
C
D
W2
Set To:
Multiplier
X1
X2
X3
X4
X5
X6
X8
Jumper W1 Set To:
A B C D
(ms) (ms) (ms) (s)
1.25 10 100 1
2.50 20 200 2
3.75 30 300 3
5.00 40 400 4
6.25 50 500 5
7.50 60 600 6
10.0 80 800 8
Example: Above Jumpers set for 100ms leading edge delay.
Trailing Edge Delay
The trailing edge delay occurs from the time RTS is made inactive by the initiating station
(with CTS still enabled) until the time that the RD Board removes RTS from the radio. This delay will not apply if the initiating station inhibits RTS before it receives CTS. Since there
CI-3305 Appendix 2 Page 2 Radio Delay Interface Board
is no data to be protected, RTS will be removed instantly from the radio.
The delay times are determined by plugging in a combination of two jumper headers, W3 and
W4 as noted in Table B. Header W1 provides four time periods from 1.25 ms to 1 sec, while header W2 provides seven multiplier positions from X1 to X8. This table is used in the same manner as previously described for Table A.
TABLE B - TRAILING EDGE DELAY SELECTIONS
Jumper
W4
Position
E
F
G
A
B
C
D
W4
Set To:
Multiplier
X1
X2
X3
X4
X5
X6
X8
Jumper W3 Set To:
A B C D
(ms) (ms) (ms) (s)
1.25 10 100 1
2.50 20 200 2
3.75 30 300 3
5.00 40 400 4
6.25 50 500 5
7.50 60 600 6
10.0 80 800 8
Example: Above Jumpers set for 6 second trailing edge delay.
Carrier Time Out
The carrier time out period starts when an RTS is received by the RD Board. If RTS is not inhibited within the selected time out period, the rf carrier or the modem will be turned off.
The timer is reset only when RTS is inhibited by the initiating station.
The time out period is determined by jumper header W5. This jumper provides seven selectable periods from 4 seconds to infinity as shown in Table C. The infinite selection prevents a time out when the delay is not needed.
TABLE C - CARRIER TIME OUT SELECTIONS
W5
Set To:
E
F
G
A
B
C
D
Time Out
Period
8 Sec.
16 Sec.
1 Min.
4 Min.
17 Min.
Infinite
CI-3305 Appendix 2 Page 3 Radio Delay Interface Board
Example: Above Jumper (W5) set for 1 Minute Carrier Time Out
WIRING CONNECTIONS
RDI Board to Transceiver
The basic wiring concept is shown in Figure 2. The RDI Board interfaces to the 3305’s
MI/OB Board (Port C) and requires an RS-232 cable connection to the transceiver or external modem. Pin connections for RDI/Transceiver Comm. cable are shown in Figure 3.
The RDI Board is wired to the rf transceiver as described in the manufacturer's instruction manual.
Carrier Keyed Output
A carrier keyed output is present across terminal block TB4. These terminals provide an open collector output (50 mA max.) that may be applied to rf transmitters requiring a separately keyed input. Essentially the open collector conducts when the RTU sends an RTS to the RDI Board. This action switches on the transmitter and places the carrier on the air.
The carrier stays on the air as long as RTS is on.
CI-3305 Appendix 2
Figure 2 - Block Diagram of Application
Page 4 Radio Delay Interface Board
Figure 3 - Pin Connections for RDI Board RS-232 Connector TB1
TABLE D - WIRING LIST FOR BBI RADIO DELAY INTERFACE BOARD
P4/D-Type Pin #
MIOB Bd.
1
2
3
6
7
4
5
8
9
Wire Color
MIOB/RDI
Green
Brown
Yellow
Blue
White
Black
Red
-
Orange
Signal
MIOB/RDI
DTR NOT
TXD NOT
+5V
RXD NOT
RTS NOT
CTS NOT
DCD NOT
PCOM
-
6
7
5
3
4
2
1
TB3
RDI
-
-
-
-
-
-
-
6
TB1
RDI
-
-
-
DISPLAY LEDS
The Radio Delay Board contains two LEDs, labeled DS3 and DS4 (see Figure1). LED DS3
(RTS) lights when the board receives a “Request To Send.” LED DS4, Data Carrier
Detected (DCD) lights when the board receives data from the transceiver; this also denotes the presence of a radio carrier.
ENVIRONMENTAL SPECIFICATIONS
Operating Temperature:
Storage Temperature:
Humidity:
Vibration:
RFI:
-20°C to +70°C (-4°F to +158°F)
-40°C to +85°C (-40°F to +185°F)
0-95% Non-condensing
20-150 Hz at 1.0G
150-200 Hz at 0.5G
10 V/M at 20-500 MHz with no operational degradation
CI-3305 Appendix 2 Page 5 Radio Delay Interface Board
BLANK PAGE
Appendix 3
RS-485 INTERFACE BOARD
For Instruction Manual CI-3305
Issue: 04/99
J2
J3
Bristol Babcock
Appendix 3
RS-485 INTERFACE BOARD
PT. NO. 392566-00-1
TABLE OF CONTENTS
TITLE PAGE #
DESCRIPTION .............................................................................................................................................1
Function ................................................................................................................................................1
Features .................................................................................................................................................1
Assembly Description ...........................................................................................................................2
HEADERS & JUMPERS..............................................................................................................................2
J1/W1 ....................................................................................................................................................2
J2/W2 ....................................................................................................................................................3
J3/W3 ....................................................................................................................................................3
J4/W4 ....................................................................................................................................................3
NEWTWORK WIRING ...............................................................................................................................3
Field Terminations For RS485..............................................................................................................3
End Node Configuration .......................................................................................................................3
RS-485 INTERFACE BOARD SPECIFICATIONS ....................................................................................3
Performance Specifications ..................................................................................................................3
Environmental Specifications ...............................................................................................................4
Input/Output Specifications ..................................................................................................................4
CI-3305 Appendix 3 Page 0-1 Table Of Contents
RS-485 INTERFACE BOARD
DESCRIPTION
Function
The RS-485 Interface Board for the 3305 RTU provides a communications interface on Port
C. The RS-485 Interface Board allows the 3305 RTU to be included in a 4-wire, multidropped (up to 32 nodes) LAN along with other Bristol Babcock 33XX Controllers,
Transmitters and RS-485 capable devices. Multiple 3508B Smart Transmitters equipped with an RS-485 interface can be networked to the 3305 RTU.
Features
On-Board isolated Output Power Supply
A galvanically isolated power supply, operating from a bulk 8 to 30 Volt source, powers the RS-485 circuitry, generating 5V (VCCISO) and Isolated Ground
(GNDISO). The 8 to 30 volt source for this on-board power supply is provided to Pin 1 on connectors P1A or J1A, that is, the customer is able to connect the power source to
Pin 1 and ground to PCOMM, Pin 2, on J1A; or to the same pins on P1A.
Reverse Voltage & Over-Voltage Protection
Input power to pins on both connectors can be reversed without damaging the components, because the RS-485 Interface Board has reverse voltage and over-voltage protection. Fuse F1 (1/4 Amp) protects circuitry at the input source, Pin 1, for P1A and J1A. Input power is less than 250 milliwatts on the average.
Optical & Electrical Isolation
Transmit, Receive, and Request-To-Send functions are optically isolated on the RS-
485 Interface Board. These channels pertain to logic level inputs and outputs.
Additionally, the RS-485 compatible transmitter and receiver are electrically isolated.
100-Ohm Line Terminators For Transmitter & Receiver Biasing
For the transmitter, this interface board has a selectable (via W1) 100-Ohm line terminator. The receiver has two (2) selectable 800-Ohm biasing resistors (via W2 &
W3) and a selectable (via W4) 100-Ohm line terminator.
Transmitter & Receiver Circuit Surge Protection
The circuits for the transmitter and receiver each have identical surge protectors.
Surge protection meets IEEE C37.90-1978 to isolated ground. A surge path terminal is available for local connection from isolated ground to earth ground through a 180V
Metal Oxide Varistor (MOV).
CI-3305 Appendix 3 Page 1 RS-485 Interface Board
Figure 1 - RS-485 Interface Board Component Identification Diagram
Assembly Description
The 6” x 3.9” RS-485 Interface Board has the same locations for the mounting holes as the switched network modem and the RDI Board. The board has three connectors: J1A, P1A, and P2. Connector J1A of the RS-485 Interface Board connects to the 3305 RTU’s D-Type
Port C, i.e., Connector P4 on the MI/OB Board. The two floating (open ended) wires connected to J1A pins 1 and 2 are connected to the 3305 terminal Block TB3 with J1A pin-1 connected to TB3-2 (power) and J1A pin-2 connected to TB3-1 (Ground). Connector P1A is typically used to power the RS-485 Interface Board, but is not used for this function when connecting to a 3305 RTU.
Note: Connector P1A is not used with the RTU 3305.
HEADERS AND JUMPERS
Mounted on the assembly board are four 3--pin Jumpers; W1, W2, W3, and W4. Each Header has a jumper wire permanently attached across Pins 2 and 3, i.e., their position ² B.
³ Each
Header has a Suitcase Jumper which when stored across position ² B ³ removes the 100-Ohm
Biasing or 800-Ohm Terminating Resistor from the circuit in question. A Suitcase Jumper will provide the desired biasing/termination when moved from B ³ to ² A.
³
J1/W1
With the Suitcase Jumper associated with Header W1 is set in the ² A position, ² a 100-Ohm carbon Termination Resistor is placed across the RS-485 Network transmitter lines, i.e., P2
(Pins 1 and 2). The Suitcase Jumpers associated with W1 at the two most distant nodes should be placed into the
²
A Position.
³
CI-3305 Appendix 3 Page 2 RS-485 Interface Board
J2/W2
With Suitcase Jumper J2 at Header W2’s ² A Position, ³ an 800-Ohm, metal film, Biasing
Resistor (R39) connects isolated ground (GNDISO) to the RS-485 Receiver’s negative input
(P2 Pin-4). This Jumper should be set in the ² B Position ³ for all nodes except the two most distant nodes, i.e., the
²
End Nodes.
³
Note: At any given node, W2 & W3 should be set together, i.e., both should be in either the ² A Position ³ (for End Nodes) or the ² B
Position
³
(for all other nodes).
J3/W3
With Suitcase Jumper J3 at Header W23s
²
A Position,
³
an 800-Ohm, metal film, Biasing
Resistor (R37) connects the isolated +5V supply (VCCISO) to the RS-485 Receiver’s positive input (P2 Pin-3). This Jumper should be set in the
²
B Position
³
for all nodes except the two most distant nodes, i.e., the
²
End Nodes.
³
J4/W4
A 100-Ohm, carbon Resistor (R38) is connected between the two Biasing Resistors at the receiver termination lines when Suitcase Jumper J4 has been set in Header W4’s ² A
Position.
³
Note: Jumper W4 at W4’s
²
A Position
³
has no effect on line termination unless J3/W3 and/or J2/W2 are also in their
²
A Positions.
³
Jumper J4 should be placed in the ² A Position ³ (for End Nodes), or the ² B Position ³ (for all other Nodes).
NETWORK WIRING
Field Terminations for RS-485
The maximum number of nodes that can be connected to an RS-485 network is 32 including the master. One node should be tied to a common ground for the system. For all other nodes, the SURGE termination should be tied to the common ground at a local point near the 3305.
Two twisted pairs of wire are required. Shielding is not required (but may be utilized). The maximum length of the network is 4000 feet for the available asynchronous baud rates.
End Node Configuration
Excessive noise on the RXD (Receive) Terminals can be interpreted as signal error by a
Model 3305 RTU. A Jumper Selectable Noise Bias Circuit has been built into the RXD+ and
RXD- circuitry. This circuit provides a 100-Ohm termination for the input and a DC Bias
Voltage for the Transmitter output when the receive signal is in the OFF or IDLE state.
RS-485 INTERFACE BOARD SPECIFICATIONS
Performance Specification
Baud Rate (Max.):
Multidrop (Max.):
Network Termination:
38.4K Asynchronous
32 Nodes
100 Ohm Resistors for TX and RX Circuits
CI-3305 Appendix 3 Page 3 RS-485 Interface Board
Network Biasing:
Topology:
Isolation:
Common Mode Range:
Surge Protection:
Isolated Ground
Surge Path:
Input Voltage:
Input Power:
Selectable on Receivers:
800-Ohms (Between Positive (+) Input & Isolated Ground)
800-Ohms (Between Negative (-) Input & Isolated ground)
Master/Slave: (TX+ to RX+) & (TX- to RX-)
Galvanically Isolated Power Source
Optically Isolated Control & Data Signals
-7 Volts to +12 Volts (DC)
Meets IEEE C37.90-1978 (To Isolated Ground)
Terminal Provided for Local Connection to Earth Ground
Terminal Provided for Local Connection from Isolated Ground to Earth Ground through an 180V MOV
+8 to +30 Volts
< 250 mW (Average)
Environmental Specifications
Operating Temperature: -40 to +70 (C) [-40 to +158 (F)]
Storage Temperature: -40
to +85
(C) [-40
to +185
(F)]
Humidity: 5% to 95% (Non-condensing)
RFI Susceptibility: Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)
Vibration: 10-150 Hz, 2g
150-2000 Hz, 1g
Input/Output Specifications
Tables 1 and 2 provide the Pin assignments of the various on-board connectors.
Table 1 - Connector J1A Pin Assignment (Use cable Ass’y. 396049-01-0)
Pin #
1
2
3
6
7
4
5
FUNCTION
PWR
PCOM
AI+
AI-
HSC+
HSC-
TXD
SIGNAL DESCRIPTION
+8V to +30V DC Source (TB3-2)
Power (Logic) Ground (TB3-1)
21 Volt Source (NOT USED)
250-Ohm Input (NOT USED)
HSC Positive Input (NOT USED)
HSC Negative Input (NOT USED)
N/A
CI-3305 Appendix 3 Page 4 RS-485 Interface Board
Table 1 (Continued)
Connector J1A Pin Assignment (Use cable Ass’y. 396049-01-0)
Pin #
7
8
9
FUNCTION
TXD NOT
RXD NOT
RTS NOT
10 CTS NOT
11 NC
12 PCOM
13 VCC
14 DCD NOT
SIGNAL DESCRIPTION
TX Data (Logic Level Input)
RX Data (Logic level Output)
Request To Send (Logic Level Input)
Clear To Send (Logic Level Output)
No Connection
RTU 3305 Logic Ground
RTU 3305 (5Vdc) Source
Data Carrier Detect (Logic Level Input)
Table 2 - Connector P2 Pin Assignment (Use Cable Ass’y. 396049-03-6)
Pin # FUNCTION
1 TXD+
2
3
TXD-
RXD+
4
5
6
RXD-
ISOGND
SURGE
SIGNAL DESCRIPTION
Transmit Data +
Transmit Data -
Receive Data +
Receive Data -
RS-485 Circuit Isolated Ground
MOV Connection to External Ground for RS-485 Circuit
Figure 2 - RTU 3305 Connected on RS-485 Network
CI-3305 Appendix 3 Page 5 RS-485 Interface Board
BLANK PAGE
Appendix 4
NETWORK INTERFACE BOX (NIB)
For Instruction Manual CI-3305
Issue: 04/99
Bristol Babcock
Appendix 4
NETWORK INTERFACE BOX
(NIB)
TABLE OF CONTENTS
SECTION TITLE
1.1
1.2
PAGE #
Section 1 - INTRODUCTION
GENERAL INTRODUCTION.......................................................................................1
PHYSICAL DESCRIPTION..........................................................................................2
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
3.5
Section 2 - CONFIGURATION & CONNECTIONS
MASTER-TO-SLAVE DISTANCES ..............................................................................3
INSTALLING THE NIBs ..............................................................................................4
LIMITS OF SURGE PROTECTION .............................................................................4
USING NIBs IN HART
§
NETWORKS .........................................................................5
Section 3 - SPECIFICATIONS
OPERATIONAL REQUIREMENTS .............................................................................7
ENVIRONMENTAL SPECIFICATION........................................................................7
SURGE PROTECTION LIMITS ...................................................................................7
POWER REQUIREMENTS ..........................................................................................7
DIMENSIONS...............................................................................................................8
CI-3305 Appendix 4 Page 01 T able Of Contents
Section
1
INTRODUCTION
1.1 GENERAL INTRODUCTION
The Network Interface Box (NIB) is a compact assembly that mounts externally to a distributed controller. It contains a dc/dc converter assembly that converts the +24 V power source to separate +15 V and -15 V regulated outputs. These outputs are used to bias the communication line through a resistive circuit.
The NIB can also be furnished on a mounting plate capable of holding four units. The plate has a 5-1/4 x 19 inch surface that is suitable for mounting in a standard 19-inch width rack.
A NIB is required for all RS-485 communication networks in order to maintain the correct line status during periods of inactive transmissions. While a NIB is recommended for each node, only the master and the most distant slave require bias termination. If they are not biased, communication errors can result and the system may go into a "watchdog" condition.
This can lead to excessive delays as the system is checked for non-existent faults. Installing
NIBs from the start will avert this problem.
Electrical surges or spikes on the communication line are another source of trouble that can damage the input circuitry of one or more nodes. All NIBs include surge suppression circuitry designed to protect the communication ports of a node.
Figure 1-1 - Network Interface Box with Cover Removed
CI-3305 Appendix 4 Page 1 NIB
The NIB contains two jumpers that are used to Enable or Disable the bias termination discussed above. Since bias termination is only used with the master and most distant slave units, it should be turned off for all units in between.
1.2 PHYSICAL DESCRIPTION
(see Figures 1-1 and 3-1)
The NIB Board measures 3.5” by 3.5” and is mounted in a box. It has four holes located near its corners which accommodate mounting to its enclosure box which in turn measures 4.25” by 4.625” by 1.125”. It contains 3 terminal blocks and two configuration jumpers.
Table 1 - Terminal Block TB1 - Power
TB1 PIN
1
2
3
+24V
SIGNAL SIGNAL DESCRIPTION
(+) Side of the 24V Supply
24V RET Return to (-) side of the 24V Supply
EARTH GROUND Return to Earth of Surge Currents
Table 2 - Terminal Block TB2 - Connections to Terminal Equipment Comm. Port
TB2 PIN SIGNAL
1 SDT+
2
3
4
SDT-
RDT+
RDT-
SIGNAL DESCRIPTION
SD+ or TXD+ of Term. Equipment Comm. Port
SD- or TXD- of Term. Equipment Comm. Port
RD+ or RXD+ of Term. Equipment Comm. Port
SD- or RXD- of Term. Equipment Comm. Port
Table 3 - Terminal Block TB3 - Connections to Communication Lines
TB3PIN SIGNAL
1 SDL+
2
3
4
SDL-
RDL+
RDL-
SIGNAL DESCRIPTION
(+) Side of the Transmit Line Twisted Pair
(-) Side of the Transmit Line Twisted Pair
(+) Side of the Receive Line Twisted Pair
(-) Side of the Receive Line Twisted Pair
W2
POSITION
A
B
A
B
Table 4 - Jumper Settings
W3
POSITION
A
B
B
A
+24V DC
POWER
FEATURES
Not Required Surge Protection without Termination
Mandatory Surge Protection and Termination
Not Allowed Combination
Not Allowed Combination
CI-3305 Appendix 4 Page 2 NIB
Section 2
CONFIGURATION & CONNECTIONS
2.1 MASTER-TO-SLAVE DISTANCES
The maximum distance of an RS-485 network line should not exceed 4000 feet. Shown graphically in Figure 2-1, this distance extends from the master unit to the last or most distant slave. Although this illustration shows three slaves, this distance is applicable to any number of slaves (each master port can support a maximum of 32 slaves).
The distance from a network line drop to a slave should be kept as small as possible. The
NIBs, which are required in the wiring scheme of Figure 2-1, should be located as close as possible to the node they are serving.
Figure 2-1 - Application Using NIB Connected to RTU Comm. Port
CI-3305 Appendix 4 Page 3 NIB
2.2 INSTALLING THE NIBs
Once a communication network plan has been established, use the following steps as a wiring and setup guide:
1. Start at the location of the MASTER node.
2. Mount the NIB as close as possible to the DPC.
3. Remove the NIB's cover. The cover is secured by two captive screws.
4. With the power for the RTU turned off, wire the 24 V dc supply source to the +24V and -24V terminals of TB1 as shown in Figure 2. Connect a reliable earth ground to the grounding terminal.
5. Wire up the SDL, RDL, SDT and RDT terminals of the NIB as shown in Figure 2-1.
This arrangement effectively connects the NIB in the TXD (transmit) and RXD
(receive) lines of the DPC. Keep these connections as short as possible.
6. Referring to the left of Figure 2-1, insert jumpers W2 and W3 of the NIB into their
"B" positions. This configuration implements bias termination required at this location.
7. Replace and secure the cover of the NIB. The NIB installation at this site is now complete. Note: No other NIBs are required for HART applications.
8. Move to the location of the farthest slave on the line. Repeat steps 2 through 7 but this time apply the same wiring techniques and jumper configurations to the LAST
SLAVE shown in Figure 2-1.
9. Wire up all MIDDLE SLAVES as shown in Figure 2-1 but do not make any power connections to the +24V and -24V terminals. However, be certain that the grounding terminal of each slave node is connected to a reliable earth ground.
10. For all MIDDLE SLAVES, plug in jumpers W2 and W3 as shown at the left. This configuration disables bias termination while retaining the surge protection feature required for all nodes.
11. Apply 24 Vdc power to all nodes and check the network for proper operation.
2.3 LIMITS OF SURGE PROTECTION
For RS-485 networks the NIB provides full protection from surges in accordance with ANSI-
IEEE STANDARD C37.90-1978 (published earlier as IEEE STANDARD 472-1974).
However, the limits of this protection are not automatically extended to other types of communication equipment requiring different drivers. These exceptions are noted in the following warning:
CI-3305 Appendix 4 Page 4 NIB
Warning
The NIB does not provide surge protection for RS-423 drivers (Type 26LS29) wired in parallel to RS-485 or RS-422 IC drivers of other equipment. For these situations, the RS-423 driver should be disengaged by using strapping options where provided, or by removing the Type 26LS29 plug-in IC from its socket at the appropriate communication port. A damaged RS-423 driver that is paralleled across an RS-485 driver will inhibit network communications.
2.4 USING NIBs IN HART NETWORKS
Note: HART is a registered trademark of the HART Communication
Foundation of Austin, Texas, USA. Any time the term HART is used hereafter in this document, the term implies the registered trademark.
NIBs are required on a HART Network when the HART Device Interface (HDI) is configured for RS-485 Operation and multiple HDI assemblies are connected to a single 33XX
DPC/RTU. Figure 3 shows a single 33XX DPC/RTU interfaced to multiple HDI assemblies which in turn are each connected to a groups of HART slaves.
@?G5B
CE@@<I
##HH
BC$(% gYdX
>92
849
9> BC$(%
81BD C<1F5
! !%
! !& 7B?E@C ?6
C<1F5 45F935C
81BD C<1F5
! !%
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9> BC$(%
Figure 2-2 - Multiple HDI Assemblies Connected to Multiple groups of HART Slaves
Refer to Appendix 5 for information on installing and configuring the HDI Board.
CI-3305 Appendix 4 Page 5 NIB
CI-3305 Appendix 4 Page 6 NIB
Section 3
SPECIFICATIONS
3.1 OPERATIONAL REQUIREMENTS
The NIB requires 24VDC power when used for line termination.
3.2 ENVIRONMENTAL SPECIFICATIONS
Temperature:
Relative Humidity:
Operating = -30
C to +70
C
-22
F to +158
F
Storage = -40
C to +100
C
-40
F to +212
F
0 - 95% Non-condensing
Vibration:
RFI Susceptibility:
3.3 SURGE PROTECTION LIMITS
10 - 150 Hz @ .5g
10V/Meter from 10MHz to 550MHz
RS-485 Networks:
RS-422 Networks:
Full protection from surges in accordance with ANSI-IEEE Standard C37.90-1978, published earlier as IEEE Standard 472-
1974. (See Page 5 - Warning prior to implementation).
Partial protection from surges. Typically at 60% of the surge voltages of the
ANSI/IEEE Standard C37.90-1978. If full protection is desired, it may be accomplished by replacing the RS-422 IC drivers with RS-485 IC drivers in the appropriate communications ports in all the BBI equipment throughout the network. (See Page 5 - Warning prior to implementation).
3.4 POWER REQUIREMENTS
Power must be provided if the NIB is used with the termination engaged.
Input Voltage: Nominal =
Range =
24V DC
21V to 28V DC
Input Current: 45mA Max.
CI-3305 Appendix 4 Page 7 NIB
Isolation:
Fusing:
Grounding:
3.5 DIMENSIONS
(See Figure 3-1)
500V DC between the input power terminals and the termination network.
1/8A subminiature fuse for protection from reverse DC connection.
Earth ground must be connected to TB1-3 at all times using proper grounding practices.
CAUTION:
In the absence of a good earth ground, the surge protection by the NIB is compromised or nullified.
CI-3305 Appendix 4
Figure 3-1 - NIB Assembly Dimensions
Page 8 NIB
HIGHWAY ADDRESSABLE
REMOTE TRANSDUCER
(HART Ò )
DEVICE INTERFACE
Part No. 392930-01-3
(For Models 33XX)
For The Following BBI Instruction Manuals:
CI-3305, CI-3310, CI-3330 & CI3335
Product Information Package
Bristol Babcock
PIP-HART33XX
- January 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.
HART ® is a registered trademark of the HART Communication Foundation, Austin, Texas
USA. ACCOL™ is a trademark of Bristol Babcock. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2003, Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol Babcock.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Bristol Babcock for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may leave an operating process without protection. Depending upon the application, this could result in possible damage to property or injury to persons. It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional information is required, the purchaser is advised to contact Bristol
Babcock.
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol Babcock for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol Babcock are clean to safe levels, as such levels are defined and/or determined by applicable federal, state and/or local law regulations or codes. Such party agrees to indemnify Bristol Babcock and save
Bristol Babcock harmless from any liability or damage which Bristol Babcock may incur or suffer due to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically-operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read BBI supplemental document S14006 for proper care and handling of ESD-sensitive components.
Bristol Babcock 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
A.
B.
C.
D.
E.
F.
A.
B.
WARRANTY
Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing.
Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer.
Warranties on goods sold by, but not manufactured by Bristol are expressly limited to the terms of the warranties given by the manufacturer of such goods.
All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or modified without Bristol's consent, (iii) not installed, maintained and operated in strict compliance with instructions furnished by Bristol, or (iv) worn, injured or damaged from abnormal or abusive use in service time.
THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
No agent of Bristol is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.
REMEDIES
Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Watertown office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can arrange to have a Bristol service person come to the site. The Service person's transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.
Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation from use of the information herein or from the purchase or use by Buyer, its employees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Bristol Babcock for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA
(Return Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Babcock Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A BBI Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Babcock Web site
(www.bristolbabcock.com) and sending it via E-Mail to [email protected]
.
A BBI Repair Dept. representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Babcock Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795
A BBI Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the BBI Repair Department at (860) 945-2442. A BBI Repair Department representative will record a RA number on the form and complete Part I, then send the form to the Customer via fax (or other requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and return your product to you.
&VMWXSP &EFGSGO -RG 6ITEMV %YXLSVM^EXMSR *SVQ
(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
•
Evaluate / Test / Verify Discrepancy
•
Repair / Replace / etc. in accordance with this form
•
Return to Customer
Part I
Please be aware of the Non warranty standard charge:
•
There is a $100 minimum evaluation charge, which is applied to the repair if applicable (
B,C, or D of part III below)
Please complete the following information for single unit or multiple unit returns
√
in “returned”
Address No.
Bill to :
(office use only) Address No.
Ship to:
(office use only)
Purchase Order:
Phone: Fax:
Contact Name:____________________________________
E-Mail:
Part II Please complete Parts II & III for each unit returned
Model No./Part No.
Range/Calibration
Description
S/N
Reason for return : Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3.
What is the Firmware revision? _____________________ What is the Software &version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due to BBI’s warranty clause, would you like the product: repaired returned replaced scrapped?
B. If product were found to exceed the warranty period, would you like the product:
C. If product is deemed not repairable would you like your product:
D. If BBI is unable to verify the discrepancy, would you like the product: repaired returned replaced scrapped?
returned replaced scrapped?
returned replaced *see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that has the most knowledge of the problem is: _______________________________ phone
If we are unable to contact this person the backup person is: _________________________ phone
Special Requests:
Ship prepaid to: Bristol Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-3875
Form GBU 13.01
Rev. A
Bristol Babcock
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
● Avoid Delays and problems in getting your system on-line
● Minimize installation, start-up and maintenance costs.
● Make the most effective use of our hardware and software.
● Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Babcock offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at four locations: Houston, Birmingham, Orlando and our Watertown,
CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol Babcock products and realize the full potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2269. For Houston classes, you can also contact our Houston office, at (713) 685-
6200.
BLANK PAGE
A Few Words About Bristol Babcock
For over 100 years, Bristol 7 has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water company, there are Bristol Babcock instruments, controllers, and systems running year-in and year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Contacting Bristol Babcock Directly
Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol Babcock's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow Ô products call (860) 945-8604.
For technical questions about Control Wave call (860) 945-2244 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-2501 or e-mail: [email protected]
For technical questions regarding ACCOL products, Open BSI Utilities , as well as
Bristol's Enterprise Server 7 / Enterprise Workstation 7 products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: [email protected]
The Application Support Group 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
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-HART33XX
HIGHWAY ADDRESSABLE REMOTE TRANSDUCER
(HART
®)
DEVICE INTERFACE
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
3.1
3.2
3.3
3.4
3.5
3.6
2.1
2.1.1
2.1.2
2.2
2.2.1
2.2.2
2.2.3
2.2.3.1
2.2.3.2
SECTION
TABLE OF CONTENTS
TITLE PAGE #
Section 1 - INTRODUCTION
GENERAL INTRODUCTION......................................................................................................... 1
FEATURES...................................................................................................................................... 1
THEORY .......................................................................................................................................... 1
HDI DESCRIPTION ....................................................................................................................... 2
HDI Board Connectors .................................................................................................................... 2
HDI Board Status LEDs ................................................................................................................. 3
HDI Board Circuitry........................................................................................................................ 4
Section 2 - CONFIGURATION & CONNECTIONS
RESTRICTIONS & ASSUMPTIONS ............................................................................................. 7
HART Slave Devices........................................................................................................................ 7
3508 Smart Transmitters ............................................................................................................... 7
CONFIGURAING A SINGLE HDI BOARD .................................................................................. 8
RS-485 Interface - To a Single HDI Board..................................................................................... 8
RS-232 Interface - To a Single HDI Board................................................................................... 10
Configuring Multiple HDI Assemblies into a Single 33XX Master ............................................ 11
Multiple HDI Boards Configured for RS-485 Operation ............................................................. 11
Multiple HDI Boards Configured for RS-232 Operation ............................................................. 13
Section 3 - SPECIFICATIONS
HART COMMUNICATION PROTOCOL PARAMETERS
FOR PHYSICAL LINK ................................................................................................................. 15
HART DEVICE IMPEDANCE SPECIFICATION....................................................................... 15
HART DEVICE POWER SUPPLY REQUIREMENTS ............................................................... 15
PHASE SHIFT SPECIFICATION................................................................................................ 15
PERFORMANCE SPECIFICATION............................................................................................ 15
ENVIRONMENTAL SPECIFICATION ....................................................................................... 16
SUPPLEMENTS
Special Instructions for Class I, Division 2 Hazardous Locations............................... Appendix A
REFERENCE DOCUMENTS
(Note: These documents are not provided in this manual)
BBI HART MASTER PROTOCOL MANUAL........................................................................D4068
BBI ACCOL II REFERENCE MANUAL ...............................................................................D4044
HART ® FSK PHYSICAL LAYER SPECIFICATION -
HART ® Communication Foundation Document Number .......................................HCF_SPEC-54
PIP-HART33XX Page 0-1 Table Of Contents
BLANK PAGE
Section 1
INTRODUCTION
1.1 GENERAL INTRODUCTION
Note: HART ® is a registered trademark of the HART ® Communication
Foundation of Austin, Texas, USA. Any time the term ‘HART’ is used hereafter in this document, the term implies the registered trademark.
Highway Addressable Remote Transducer (HART) Device Interfaces (HDI) allows HART slave devices or BBI 3508 transmitters to communicate with a BBI Series 33XX DPC/RTU, i.e., 3305s, 3310s, 3330s, and 3335s. The HDI supports RS-232 and RS-485 interfaces. The interface to the field devices is composed of a jumper selectable 249 ohm resistor in parallel with an AC coupled transformer. An HART/TIB ACCOL Custom Module and the configuration of a host (33XX) communications port as a custom port in ‘HART mode’ are required to support the protocol (Data Link Layer) for HART devices. The ACCOL Master
Module is used to support RS-232 configured HDIs for communication with BBI 3508 transmitters. Each HDI can interface with up to 15 HART slave devices.
1.2 FEATURES
· Selectable RS-232 or RS-485 Interface to DPC/RTU
· Transformer Coupled Comm. Interface to HART devices
· Operates from external 9 to 30 VDC power source
· Usable with both HART slave devices and BBI 3508 transmitters. RS-232/RS-485 mode of communications is valid for HART slave devices. RS-232 mode is valid for BBI 3508s.
· Conforms to HART ® FSK Physical Layer Specification.
1.3 THEORY
The BBI HART Device Interface (HDI) provides for master/slave communications, with the master originating each transaction, and slaves only generating replies when prompted by the master. HART allows for 2 ‘masters’ on a single link. The “Primary Master” is the normal control-system master, and when required, a hand-held communicator can be used as the “Secondary Master,” for maintenance purposes. Primary and secondary masters must be configured to use separate addresses.
The BBI HDI board provides an RS-485/232 interface to a BBI 33XX DPC/RTU Communications Port and a two-wire (voltage sourced or current sourced) connection to a ‘HART device’ or to a BBI 3508. Twisted-pair copper cable is used as the medium.
The HART Device Interface operates from 9 to 30 VDC bulk supply. The assembly supports
RS-232 or RS-485 interfaces to the host BBI 33XX DPC/RTU. The signals are TXD, RXD,
CTS, RTS and CD for RS-232 operations and +TXD, -TXD, +RXD and -RXD for RS-485 operation. Interface to the field device is composed of a jumper selectable 249 ohm resistor in parallel with an AC coupled transformer. FSK signal amplitude during transmission is between 400 to 600 mV with the average value of the FSK signal at 0 V. The HDI board
PIP-HART33XX Page - 1 HART Device Interface
receiver input requires a signal that must be in the range of 120 mV to 1.5 V (Peak-to-Peak).
FSK signals from the field devices below 80 mV (Peak-to-Peak) will be ignored by the interface board.
1.4 HDI DESCRIPTION
The HART Adapter Interface Board is assembled in a DIN Rail Mounting Assembly. This assembly measures 5.56” long by 4.37” in high by 1.06” deep. In addition to 8 selectable jumpers and 4 status LEDs, the HDI Board contains three connectors (see Figures 1 & 10).
1.4.1 HDI Board Connectors
J1 - a 9-Pin D-Type Connector for the RS-232 Interface (see Table 1)
TB1- a 6-Point Term. Block for the RS-485 Interface and the Input Power (see Table 2)
TB2- a 2-Point Terminal Block for Slave Device Field Connections (see Table 3)
PIP-HART33XX
Figure 1 - HART Device Interface Assembly
Page - 2 HART Device Interface
Table 1 - RS-232 Interface Connector J1 Signal Identification
PIN # RS-232 SIGNAL SIGNAL DESCRIPTION
1 DCD Data Carrier Detect
2
3
5
6
7
/TXD
/RXD
GND
CTS
RTS
Transmit Data NOT
Receive Data NOT
Ground
Clear to Send
Request to Send
DCE I/O
Output
Input
-
Output
Output
Input
Table 2 - Power & RS-485 Interface Connector TB1 Signal Identification
PIN #
1
2
3
4
5
6
NAME DESCRIPTION
VIN +9 - +28 VDC Input Power (+)
GND
-RXD
+RXD
-TXD
+TXD
Power Ground (-)
- TX Data from 33XX
+ TX Data from 33XX
- RX Data to 33XX
+ RX Data to 33XX
Table 3 - Slave Device Field Connector TB2 Signal Identification
PIN #
1
2
FIELD CONNECT
Field Loop (no polarity)
Field Loop (no polarity)
Table 4 - HDI Board Jumper Identification and Assignment
JUMPER #
W1
W2
W3
DESCRIPTION
RS-232 Mode
3508 Mode (10 mS ON Delay)
*RS-485 Rcvr. 120 ohm Terminator
POS. 1-2
Disabled
Disabled
Enabled
POS. 2-3
N/A**
Enabled
Disabled
W4
W5
W6
W7
*RS-485 Rcvr. Positive Bias
*RS-485 Rcvr. Negative Bias
*RS-485 Xmtr. 120 ohm Terminator
Status LED Enable
Enabled
Enabled
Enabled
Enabled
Disabled
Disabled
Disabled
Disabled
W8 249 Ohm Loop Resistor
* = Install on RS-485 End Node
Connected Open
** = W1 is a 2 position Jumper, Installed = RS-232 Disabled/RS-485 Enabled,
Removed = RS-232 Enabled/RS-485 Disabled
1.4.2 HDI Board Status LEDs
There are four status LEDs on the HDI Board. LEDs CR14 through CR17 reflect the status of the active states of Transmit Data NOT (/TXD), Receive Data NOT (/RXD), Data Carrier
Detect NOT (/DCD) and Request to Send NOT (/RTS). A logic “0” state of TXD or RXD will
PIP-HART33XX Page - 3 HART Device Interface
light CR14 or CR15 respectively. The four LEDs can be disabled by placing jumper W7 in position 2-3.
CR14 = /TXD (Transmit Data NOT)
CR15 = /RXD (Receive Data NOT)
CR16 = /DCD (Data Carrier Detect NOT)
CR17 = /RTS (Request to Send NOT)
1.4.3 HDI Board Circuitry
The HDI board has a built-in ± 5V DC Switching Power Supply that is fused and operates from a bulk 9V to 30V DC. A blocking diode protects the power supply circuitry from reversed input power conditions.
Except for the Power Supply, the major components of the HART Device Interface board are shown in the block diagram (Figure 2).
There are independent RS-232 and RS-485 transceivers which are jumper selectable. A 120 ohm biasing resistor is jumper selectable for the RS-485 transmit lines. A 120 ohm terminator and biasing resistors are jumper selectable for the RS-485 receive lines.
20C12
TXD
RXD
DCD
RTS485/232
RTS
GEN.
TXD
RXD
DCD
RS485
XMTR
RCVR
+TERM
+TX
-TX
+RX
-RX
BANDPASS
FILTER/
SWITCH
RTS
CONTROL
RS232
RS485/
RS232
SELECT
XMTR
DRIVE/
SWITCH
3508
RTS/CTS
10 MSEC
DELAY
RTS232
CTS
RXD
DCD
3508/HART
RS232
XCEIVER
TXD
RXD
RTS
CTS
DCD
XFORMER
249 OHM/
JUMPER
PIP-HART33XX
Figure 2 - Block Diagram of BBI HDI Board
Page - 4 HART Device Interface
When the HDI is configured to communicate with slave devices which support the HART protocol, and the communication mode between the HDI and the 33XX device is RS-232.
CTS NOT is asserted 100 microseconds after RTS NOT becomes valid. In the RS-485 mode,
RTS NOT is generated by a 1 to 0 transition of TXD. For BBI 3508 applications in RS-232 mode, a 10 millisecond RTS NOT to CTS NOT delay is selected to emulate the existing TIB design. The added combination of RTS232 NOT and RTS485 NOT enables the 20C12 FSK modem’s transmit circuitry, enables the CMOS switch to the transformer and disconnects the receive signal to the FSK modem’s receiver.
The 20C12 FSK modem operates at Bell 202 standards with a 460.8 KHz clock. The modulated CMOS digital signal from the 20C12 is scaled to a constant ±0.6V level via a transformer drive circuit that provides a constant output signal with varying loads. The transformer drive circuit is isolated from the output transformer with a CMOS switch. This switch is only closed during transmission cycles. The received FSK signal is routed through a doubler and bandpass filter to the FSK modem. A CMOS switch disconnects the filtered signal from the input of the FSK receiver during transmit cycles.
The field side of the transformer is AC coupled with a 2.2 µF capacitor to the field devices and to a jumper selectable 249 ohm load resistor.
RS-232 and RS-485 signals are transorb protected from surge transients and electo-static discharge (ESD).
PIP-HART33XX Page - 5 HART Device Interface
Section 2
CONFIGURATION & CONNECTIONS
2.1 RESTRICTIONS & ASSUMPTIONS
For multidrop configurations, the field devices are placed in a “digital mode” of operation with the loop current for the device set at 4mA or less. The input impedance of the master in receive mode is 249 ohms. The maximum number of field devices that can be placed in parallel with a 24V supply is determined by the following equation: Max. # of Field devices
= {(24V - V(Field device) - [4mA x 249 x #(Field Devices)] - [4mA x #(Field devices) x Wire
Resistance] - 2Vloop} >0V. This calculation implies that the maximum number of transmitters, which require a minimum of 12V to operate in a loop, is 10 when the wire resistance is not included. The power supply voltage must exceed 24V if more than 10 transmitters are to be connected in parallel. Note: The maximum number of transmitters that can be connected in parallel is not to exceed 15.
Field devices with a maximum ID number of 15 cannot be mixed with field devices with a maximum ID number of 2 24 .
2.1.1 HART Slave Devices
The Carrier On Delay and Carrier Off Delay as specified in the HART Foundation Data
Link Layer specification, states that the delay from an idle line to/from an acceptable signal level is 5 bit times maximum. For HDIs configured for RS-232 communications mode, the carrier On delay will be met, but, the off delay may exceed the 5 bit time requirement (but the delay will be less than 12 bit times). HART slave devices are required to send a minimum of 5 preambles. The 20C12 FSK Modem located on the HDI board will output receive data within 9 to 15 milliseconds after the transmit cycle is completed. At 1200 baud, one character time is 11 x 0.833 milliseconds or 10 milliseconds. The slave device will start to transmit the preamble one character time after the end of the last character sent from the master device. The total delay from the end of the last character sent from the master to valid receive data is 25 milliseconds. Since there is a 1 character delay from the HART module, the receive communications driver will synchronize on the third preamble at the latest. The receive communications driver for the HART ACCOL module requires one preamble before the start of data.
For the RS-485 mode, the off delay will be between 12 to 18 milliseconds. This is equivalent to 2 characters. The 20C12 FSK Modem takes 9 to 15 milliseconds to assert Carrier Detect
(CD) and valid data. The total delay is 33 milliseconds. The slave device will delay 1 character time, which is 9 milliseconds. The difference is 33 - 9.2 = 23.8 milliseconds. This is about 2.6 characters. Two valid preambles will be seen by the receive communications driver for the HART ACCOL module, which is sufficient before the start of data.
2.1.2 3508 Smart Transmitters
In the RS-232 communications mode, the HDI can operate properly with 3508 transmitters.
The 10 millisecond RTS/CTS delay must be selected.
PIP-HART33XX Page - 6 HART Device Interface
With existing 33XX firmware, the HDI will not communicate with 3508 TELETRANS when configured in the RS-485 communications mode. A programmable length preamble is required.
2.2 CONFIGURING A SINGLE HDI BOARD
2.2.1 RS-485 Interface - To a Single HDI Board (see Figures 3, 4 & 5)
Note: The maximum length of an RS-485 cable should not exceed 4000 feet.
Follow steps 1 through 4 below to configure a single HDI assembly for RS-485/HART interface operation.
1. Install the HDI Assembly in a suitable location (DIN Rail mounted). Connect the power supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.
2. Connect the HDI board to the HART slaves as shown in Figure 4 (for 4-20mA current sourced transmitters) or to a single HART slave device as shown in Figure 5 (for a +12 to
+45 VDC voltage sourced transmitter).
3. Configure the 33XX Port in question for RS-485 operation (see the HART Master
Protocol Manual, Document # D4068) and connect the port in question to TB1 of the HDI board (see Table 2 for HDI - TB1 designations) (see Figure 3 for 33XX D-Type RS-485 designations). Note: With existing 33XX firmware, the HDI board will not communicate with a 3508 TELETRANS when configured for RS-485 operation.
Figure 3 - 33XX RS-485 D-Type Port Assignment
4. Set the HDI board Jumpers as follows:
Jumper W1 - RS-232 Mode - in position 1-2 (Disabled).
Jumper W2 - In position 1-2 (Disabled) - for all except 3508 Mode.
Jumper W3 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the RS-485 receive lines.
Jumper W4 - RS-485 Receiver Positive Bias - position 1-2 = Enabled.
Jumper W5 - RS-485 Receiver Negative Bias - position 1-2 = Enabled.
Jumper W6 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the RS-485 transmit lines.
Jumper W7 - In position 1-2 to Enable the Status LEDs, or position 2-3 to disable them.
PIP-HART33XX Page - 7 HART Device Interface
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the
Power Supply loop (for 4-20 mA Current Loop Transmitters). In position
2-3 for a voltage output slave device.
Figure 4 - Hart Slaves (Transmitters)(with 4-20 mA Current Source)
Connected to 33XX via HDI Board in RS-485 Mode
Figure 5 - Hart Slave (Transmitter)(with +12 to +45 VDC Voltage Source)
Connected to 33XX via HDI Board in RS-485 Mode
PIP-HART33XX Page - 8 HART Device Interface
2.2.2 RS-232 Interface - To a Single HDI Board (see Figures 6, 7 & 8)
Follow steps 1 through 4 below to configure a single HDI assembly for RS-232 interface operation.
Note: The maximum length of an RS-232 cable should not exceed 25 feet.
1. Install the HDI Assembly in a suitable location (DIN Rail mounted). Connect the power supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.
2. Connect the HDI board to the HART slaves as shown in Figure 7 (for 4-20mA current sourced transmitters) or to a single HART voltage output slave device as shown in
Figure 8.
3. Configure the 33XX Port in question for RS-232 operation (see the HART Master
Protocol Manual, Document # D4068 if HART operation is required or the ACCOL II
Reference Manual, Document # D4044 when interfacing to a 3508 transmitter). Connect the port in question to J1 of the HDI board (see Table 1 for HDI - J1 designations) (see
Figure 6 for 33XX RS-232 cable designations.
Figure 6 - 33XX RS-232 Cable
Figure 7 - Hart Slaves (Transmitters)(with 4-20 mA Current Source)
Connected to 33XX via HDI Board in RS-232 Mode
PIP-HART33XX Page - 9 HART Device Interface
4. Set the HDI board Jumpers as follows:
Jumper W1 - RS-232 Mode - stored in position 1 or 2 (Enabled).
Jumper W2 - In position 2-3 (Enabled) for 3508 Mode - 10 millisecond delay. In position
1-2 (Disabled) - for all except 3508 Mode.
Jumper W3 - In position 2-3 = Disabled.
Jumper W4 - In position 2-3 = Disabled.
Jumper W5 - In position 2-3 = Disabled.
Jumper W6 - In position 2-3 = Disabled.
Jumper W7 - In position 1-2 to Enable the Status LEDs, or position 2-3 to disable them.
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the Power
Supply loop (for 4-20 mA Current Loop Transmitters). In position 2-3 for a
HART voltage output slave device.
Figure 8 - Hart Slaves (Transmitters) (with +12 to +45 VDC Voltage Source)
Connected to 33XX via HDI Board in RS-232 Mode
2.2.3 Configuring Multiple HDI Assemblies into a Single 33XX Master
2.2.3.1 Multiple HDI Boards Configured for RS-485 Operation
When configured for RS-485 operation, more than one HDI board may be used in conjunction with a single 33XX Port to support multiple groups (1 to 15 slave devices interfaced to a single HDI board) of HART slave devices. When so configured, the 33XX port as well as the HDI boards must be configured for RS-485 communications. Figure 9 shows an example of such a network (configured for RS-485 operation). Depending on the type of transmitter, the HDI board will be configured for Current Source or Voltage Source as described earlier.
This configuration requires the use of a BBI Network Interface Box at the 33XX.
Note: The maximum length of an RS-485 cable should not exceed 4000 feet.
Follow steps 1 through 5 below to configure multiple HDI assemblies for RS-485/HART inter-face operation.
1. Install each HDI Assembly in a suitable location (DIN Rail mounted). Connect the power supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.
PIP-HART33XX Page - 10 HART Device Interface
2. Connect each HDI board to the HART slaves as shown in Figure 4 (for 4-20mA current sourced transmitters) or to a single HART slave device as shown in Figure 5 (for a +12 to
+45 VDC voltage output transmitter).
3. Install a BBI NIB assembly at the 33XX in question. Refer to the appropriate 33XX product manual for information on installing the NIB assembly.
4. Configure the 33XX Port in question for RS-485 operation (see the HART Master
Protocol Manual, Document # D4068) and connect the port in question to TB1 of the HDI board (see Table 2 for HDI - TB1 designations) (see Figure 3 for 33XX D-Type RS-485 desig-nations).
Figure 9 - Multiple HDI Assemblies Connected to Multiple Groups of HART Slaves
5. Set the HDI board Jumpers as follows:
Jumper W1 - Installed = RS-485 Mode Enabled.
Jumper W2 - In position 1-2.
Jumper W3 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 receive lines. Jumper W3 should be placed in position 1-2 for the most distant HDI board (End Node) and placed in position 2-3 (Disabled) for all other nodes.
Jumper W4 - RS-485 Receiver Positive Bias - position 1-2 = Enabled, position 2-3 =
Disabled. Jumper W4 should be placed in position 1-2 for the most distant
HDI board (End Node) and placed in position 2-3 (Disabled) for all other nodes.
Jumper W5 - RS-485 Receiver Negative Bias - position 1-2 = Enabled, position 2-3 =
Disabled. Jumper W5 should be placed in position 1-2 for the most distant
HDI board (End Node) and placed in position 2-3 (Disabled) for all other nodes.
PIP-HART33XX Page - 11 HART Device Interface
Jumper W6 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 transmit lines. Jumper W6 should be placed in position 1-2 for the most distant HDI board (End Node) otherwise in position 2-3 (Disabled).
Jumper W7 - In position 1-2 to Enable the Status LEDs, or in position 2-3 to disable them.
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the Power
Supply loop (for 4-20 mA Current Loop Transmitters). In position 2-3 for a
HART voltage output slave device.
2.2.3.2 Multiple HDI Boards Configured for RS-232 Operation
When configured for RS-232 operation, no more than one HDI board may be used in conjunction with a single 33XX Port. Each 33XX Port can support a group of up to fifteen
(15) HART or five (5) 3508 slave devices. If a single 33XX device must communicate with multiple groups, the HDI board associated with each group must be wired to a discrete
33XX Port, i.e., a Port dedicated to the HDI board (and group) in question. Depending on the type of transmitters, each HDI board will be configured for Current Source or Voltage
Source as described earlier.
PIP-HART33XX
5.70“
Figure 10 - HART Device Interface Assembly Dimensions
1.06“
Page - 12 HART Device Interface
Section 3
SPECIFICATIONS
3.1 HART COMM. PROTOCOL PARAMETERS FOR PHYSICAL LINK
DESCRIPTION
Master Transmitted Signal
Slave Transmitted Signal
Minimum Slave Signal, Converted by a 230 ohm load
Maximum Slave Signal, Converted by a 1100 ohm load
Receiver Sensitivity (must receive correctly)
Receiver Sensitivity (must ignore)
VALUE
Min 400 mV p-p
Max 600 mV p-p
Min 0.8 mA p-p
Max 1.2 mA p-p
184 mV p-p
1320 mV p-p
120 mV to 2.0 V p-p
80 mV p-p
3.2 HART DEVICE IMPEDANCE SPECIFICATION
DEVICE
Primary Master (Including
Load Resistor)
Secondary Master
Slave Device
Miscellaneous Devices (Total)
DESIGNATION
Shunt Impedance (Rx)
Max. Source Impedance (Tx)
Min. Shunt Impedance (Rx)
Max. Source Impedance (Tx)
Min. Shunt Resistance
Maximum Shunt Capacitance
Min. Shunt Impedance
Max. Series Impedance
VALUE
230 - 1100 ohms
700 ohms
5 Kohms
100 ohms
100 Kohms
5000 pF
10 Kohms
100 ohms
3.3 HART DEVICE POWER SUPPLY REQUIREMENTS
DESCRIPTION
Maximum Ripple (47 to 125 Hz)
VALUE
0.2V p-p
Maximum Noise (500 Hz to 10 KHz) 1.2mV rms
Maximum Series Impedance (500 Hz to 10 KHz) 10 ohms
3.4 PHASE SHIFT SPECIFICATION
The maximum phase shift for the master or slave at 1200 and 2200 Hz input frequencies is
45 degrees [3dB (0.707) attenuation]. Each device in the loop and the loop wire must be considered for capacitance and resistance.
3.5 PERFORMANCE SPECIFICATION
HDI Communications Interface:
HART Device Interface:
RS-232/485 Interface - switch selectable
Current Input Device
PIP-HART33XX Page - 13 HART Device Interface
3.5 PERFORMANCE SPECIFICATION (Continued)
FSK Modem:
Power Consumption:
Bell 202 Compatibility (1200 Hz/2200 Hz Modulation)
RS-232 @ 9V - 35.57mA
@ 28V - 17.9mA
RS-485 @ 9V - 42.66mA when receiving
@ 28V - 20.09mA when receiving
3.6 ENVIRONMENTAL SPECIFICATIONS
Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Operating - (-40 to 70)ºC (-40 to 152)ºF
Storage - (-40 to 85)ºC (-40 to 185)ºF
15 - 95% non-condensing
1G for 10 - 150 Hz
0.5G for 150 - 2000 Hz
10V/Meter - 20MHz to 500MHz
PIP-HART33XX Page - 14 HART Device Interface
HART ® Device Interface
Special Instructions for Class I, Division 2 Hazardous Locations
1. The BBI Highway Addressable Remote Transducer (HART) Device Interface (HDI) 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 nonhazardous locations only. Read this document carefully before installing a nonincendive BBI
HART Device Interface. In the event of a conflict between the HART Device Interface
User Manual (PIP-HART33XX) 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.
07/21/2000 Appendix A of PIP-HART33XX - HDI Page 1 of 1
BLANK PAGE
READER RESPONSE FORM
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DOCUMENT NUMBER: PIP-HART33XX
TITLE:
Highway Addressable Remote Transducer Device Interface for Instruction Manuals
CI-3305, CI-3310, CI-3330 & CI-3335 Product Information Package
ISSUE DATE: JAN., 2003
COMMENT/COMPLAINT:
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Appendix 6
Issue: 04/02
RTU 3305 POWER SUPPLY/BATTERY CHARGER
For Instruction Manual CI-3305
6
5
4
3
2
1
+
_
Bristol Babcock
RTU 3305 POWER SUPPLY/BATTERY CHARGER
TABLE OF CONTENTS
SECTION TITLE
1.1
1.2
2.1
2.2
2.2.1
2.2.2
PAGE #
Section 1 - INTRODUCTION
GENERAL INTRODUCTION .......................................................................................... 1
PHYSICAL DESCRIPTION.............................................................................................. 2
Section 2 - CONFIGURATION & CONNECTIONS
MOUNTING LOCATION/RESTRICTIONS .................................................................... 3
WIRING THE POWER SUPPLY...................................................................................... 4
Connection to an RTU 3305 & External 12V Battery System........................................ 4
Connection to an RTU 3305 & External 24V Battery System........................................ 5
Section 3 - SPECIFICATIONS
3.1
3.1.1
3.1.2
3.2
3.3
OPERATIONAL REQUIREMENTS..................................................................6
Power Supply/Battery Charger Specifications ................................................................ 6
Battery Specifications ....................................................................................................... 6
ENVIRONMENTAL SPECIFICATIONS......................................................................... 7
BBI PART NUMBERS ...................................................................................................... 7
Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheets on Battery P/N 395407-02-8.
CI-3305 Appendix 6 Page 0-1 Table Of Contents
Section
1
INTRODUCTION
1.1 GENERAL INTRODUCTION
The RTU 3305 Power Supply/Battery Charger is a compact assembly that mounts externally to the RTU 3305. This linear power supply is actually a battery charger that contains temperature compensation circuitry. Peak output of the supply is 27.6V for a 24V system and 13.8V for a 12V system with a 10mA or greater load applied.
The RTU 3305 Power Supply/Battery Charger can operate from 109V to 129V AC at 60 Hz.
Battery charger circuitry will support two 7AH batteries in series for 24V systems and two
7AH batteries in parallel for 12V systems.
Figure 1-1 - RTU 3305 Power Supply/Battery Charger
CI-3305 Appendix 6 Page 1 Power Supply/Battery Charger
The BBI supplied battery system (12V or 24V) will supply power to the RTU 3305 for up to 8 hours.
1.2 PHYSICAL DESCRIPTION
(see Figure 1-1)
The open frame RTU 3305 Power Supply/Battery Charger measures 5.5” x 2.75” x 3.5”. It has eight holes located near its corners which accommodate mounting to an enclosure box or mounting plate. The unit provides two terminals (1 & 6) for connection to a 117V AC source, two turret-shaped terminals for DC output power, and a lug on the transformer core for chassis connection.
CI-3305 Appendix 6 Page 2 Power Supply/Battery Charger
Section 2
CONFIGURATION & CONNECTIONS
2.1 MOUNTING LOCATION/RESTRICTIONS
The RTU 3305 Power Supply/Battery Charger assembly is to be mounted to a backplate. To maintain correct charging voltage, batteries should be located adjacent to the supply (as closely as possible) so that their ambient temperature is as close as possible to that of the battery charger circuit board. To minimize temperature variations between the battery charger circuit board and the batteries, the battery charger bracket (that has the regulator attached) should be mounted to a painted aluminum backplate. Heat sink compound should be placed between the RTU 3305 Power Supply/Battery Charger surface (to which the
Regulator is attached) and the backplate.
BACKPLATE
Heatsink Compound
Between Backplate
&
Power Supply Mounting Surface
BACKPLATE
_
+
4
3
5
2
1
6
Figure 2-1 RTU 3305 Power Supply/Battery Charger Mounting Diagram
CI-3305 Appendix 6 Page 3 Power Supply/Battery Charger
CAUTION
For a power supply that is not heatsunk, the full load ambient operating temperature range is -40°C to +40°C (-40°F to +104°F). Full load condition only occurs when the batteries are being charged after a loss of AC power in normal operation; a condition which occurs infrequently. For full load operation with an ambient temperature range of -40°C to +60°C
(-40°F to +140°F), the power supply should be mounted vertically to a painted aluminum backplate. Heat sink compound should be placed between the RTU 3305 Power
Supply/Battery Charger surface (to which the Regulator is attached) and the backplate.
2.2 WIRING THE POWER SUPPLY
The following two basic wiring configurations are possible:
1. Connecting the supply to +12V battery system and the RTU 3305 (see Figure 2.2).
2. Connecting the supply to a +24V battery system and the RTU 3305 (see Figure 2-3).
2.2.1 Connection to an RTU 3305 & External 12V Battery System
(see Figure 2-2)
Figure 2-2 RTU 3305 Power Supply/Battery Charger Ass’y. Connected to RTU 3305
(With External +12V Battery System)
1. Connect the (+) terminal of the Power Supply to TB3-2 of the MI/OB board and to a 3.0
Amp fuse. Connect the other end of the fuse to the (+) terminal of the 12V battery system.
CI-3305 Appendix 6 Page 4 Power Supply/Battery Charger
2. Connect the (-) terminal of the Power Supply to TB3-1 of the MI/OB board and the (-) terminal of the 12V battery system.
3. Connect the AC terminals of the Power Supply to a 60 Hz (109VAC to 129VAC) power source. A 1 Amp fuse in series with the #1 lead of the transformer is required.
4. Connect the lug on the transformer core to chassis (earth) ground.
5. Connect a 10mA load to the output of the power supply, i.e., a 1K to 1.2K Ohm resistor and measure the voltage at the power supply output terminals. Adjust the single turn potentiometer on the battery charger circuit board for a reading of 13.8VDC ±.2%.
2.2.2 Connection to an RTU 3305 & External 24V Battery System
(see Figure 2-3)
Figure 2-3 RTU 3305 Power Supply/Battery Charger Ass’y. Connected to RTU 3305
(With External +24V Battery System)
1. Connect the (+) terminal of the Power Supply to TB3-2 of the MI/OB board and to a 1.5
Amp fuse. Connect the other end of the fuse to the (+) terminal of 12V battery 1.
2. Connect the (-) terminal of battery 1 to the (+) terminal of battery 2.
3. Connect the (-)terminal of the Power Supply to TB3-1 of the MI/OB board and to the (-) terminal of 12V battery 2.
4. Connect the lug on the transformer core to chassis (earth) ground.
5. Connect the AC terminals of the Power Supply to a 60 Hz (109VAC to 129VAC) power source. A 1 Amp fuse in series with the #1 lead of the transformer is required.
6. Connect a 10mA load to the output of the power supply, i.e., a 2K to 2.4K Ohm resistor and measure the voltage at the power supply output terminals. Adjust the single turn potentiometer on the battery charger circuit board for a reading of 27.6VDC ±0.2%.
CI-3305 Appendix 6 Page 5 Power Supply/Battery Charger
Section 3
SPECIFICATIONS
3.1 OPERATIONAL REQUIREMENTS
3.1.1 Power Supply/Battery Charger Specifications
AC Input Voltage:
DC Output Voltage
Output Ripple Voltage:
Initial DC Voltage:
Long Term Stability:
Output Voltage TC:
Line Regulation:
Load Regulation Current Limit:
Recovery Time:
Short Circuit Protection:
Reverse Battery:
Battery Charger TC:
117VAC ±10% at 60Hz
.01A to 1.7A @ 13.8V
.01A to .9A @ 27.6V
10mV RMS for loads of 10mA to 75% of full load
13.8V or 27.6V ±0.2%
±1% for 30 days (with constant ambient temperature, input voltage and load)
±.03%/Degree C
±1% for 10mA to 75% of rated load for
117VAC ±10%
±20%
200msec for 25% to 75% load step change, voltage change ±1%
Self resetting thermal shutdown
Requires external fuse in battery circuit
-4mV/Degree C/Cell
(12V system -24mV, 24V system -48mV)
3.1.2 Battery Specifications
Open Circuit output Voltage:
Nominal Output Voltage:
Amp Hour Rating:
Operating Temperature Range:
12.8VDC
12VDC
7.0 AH
-40°C to +60°C (-40°F to +140°F) (With Heatsink)
-40°C to +40°C (-40°F to +104°F) (w/o Heatsink)
CI-3305 Appendix 6 Page 6 Power Supply/Battery Charger
Charging Temperature Range: -20°C to +50°C (-4°F to +122°F)
3.2 ENVIRONMENTAL SPECIFICATIONS
Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
3.3 BBI PART NUMBERS
Operating = -40°C to +60°C (-40°F to +140°F)
Storage =-40°C to +70°C (-40°F to +158°F)
15 - 95% Non-condensing
10 - 150 Hz @ 1g
150 - 2000 Hz @ .5g
10V/Meter from 20MHz to .5 GHz
12V RTU 3305 Power Supply/
Battery Charger Assembly
24V RTU 3305 Power Supply/
Battery Charger Ass’y.
BBI Supplied +12 Lead Acid Battery
BBI P/N 396174-01-9
BBI P/N 396174-02-7
BBI P/N 395407-02-8
Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheet on Battery P/N 395407-02-8.
CI-3305 Appendix 6 Page 7 Power Supply/Battery Charger
BLANK PAGE
Product Information Package
PIP-ISORS485
Mar., 2007 Series 33XX, 3508-XX-X, 3530-XX-X & 3808-XX-X
Isolated RS-485 Interface Board
For The Following Bristol Instruction Manuals:
CI-3305, CI-3310, CI-3330, CI-3335
CI-3508-XXX, CI-3530-XXX & CI-3808 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, 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
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 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
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
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
1.
Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3. What is the Firmware revision? _____________________ What is the Software & version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A.
If product is within the warranty time period but is excluded due to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B.
If product were found to exceed the warranty period, would you like the product:
C.
If product is deemed not repairable would you like your product: repaired returned replaced scrapped? returned replaced scrapped?
D.
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: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
• Avoid Delays and problems in getting your system on-line
• Minimize installation, start-up and maintenance costs.
• Make the most effective use of our hardware and software.
• Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol products and realize the full potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 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 software products incorporate help screens. In addition, the software typically includes a ‘read me’ release notes file detailing new features in the product, as well as other information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about 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.
PIP-ISORS485
ISOLATED RS-485 INTERFACE BOARD
PT. NO. 392909-XX-X
TABLE OF CONTENTS
TITLE PAGE #
DESCRIPTION
Function .................................................................................................................................... 1
Features .................................................................................................................................... 1
COMPONENT IDENTIFICATION
Two-Wire End Node Jumpers W1, W3 & W4 .......................................................................... 3
Four-Wire End Node Jumpers W2, W5 & W6 ......................................................................... 3
Connectors ................................................................................................................................ 4
Switches .................................................................................................................................... 5
Indicators .................................................................................................................................. 5
WIRING
RS-232 Interface Between Isolated RS-485 Intf. Board and the Host Node .......................... 5
RS-485 Interface Between Isolated RS-485 Intf. Board and the Host Node .......................... 6
Isolated RS-485 Port Interface to LAN .................................................................................... 6
Field Terminations for RS-485................................................................................................. 6
ISOLATED RS-485 INTERFACE BOARD SPECIFICATIONS
Performance Specifications ...................................................................................................... 9
Environmental Specifications .................................................................................................. 9
Part Numbers ........................................................................................................................... 9
SUPPLEMENTS
Special Instructions for Class I, Division 2 Hazardous Locations ............................................... Appendix A
PIP-ISORS485 Page 0-1 Table Of Contents
BLANK PAGE
ISOLATED RS-485 INTERFACE BOARD
DESCRIPTION
Function
An Isolated RS-485 Interface Board allows any Bristol Network 3000 product to communicate over an isolated master/salve network. Each node on the network that incurporates an Isolated RS-485 Interface Board is optically isolated from the rest of the network, thereby eliminating ground loop and potential difference effects that may degrade network communication performance. The result is a reliable communication medium for in-plant or building to building LANs. The Isolated RS-485 Board effectively replaces the
Network Interface Box (NIB).
Features
• On-Board Power Supply
A power supply, operating from a bulk +9 to +35 VDC source, powers the RS-485 circuitry, generating a regulated 5VDC. A 30V transient Voltage Suppresser provides over-voltage protection on the input terminals. A separate IC provides the -5VDC required by the RS-232 transceiver. Bulk DC power is interfaced to the board on
Connector TB1. The + DC Bulk is connected to TB1 Pin 1 and the VDC Return or
Ground is supplied to TB1 Pin 2. TB1 Pin 3 is not used.
• Optical Isolation
Optically Isolated 2-Wire or 4-Wire RS-485 circuits with 300VDC isolation eliminates ground loops and potential difference effects.
• 100 Ω Isolated RS-485 Termination For 2\4-Wire Boards & Receiver Biasing
Installation of Jumper W1 is required at each Isolated RS-485 Board associated with an end node of a Two-wire or Four-wire RS-485 network. In the case of a Four-wire RS-
485 network, the Isolated RS-485 Board’s Jumper W2 must also be installed at each end node. Units installed at the master node of a 2-wire RS-485 network must also have Jumper W3 (Receiver Bias to Isolated Ground) & Jumper W4 (Receiver Bias to
Isolated VCC) installed, while units installed at the master node of a 4-wire RS-485 network must also have Jumper W5 (Receiver Bias to Isolated Ground) & Jumper W6
(Receiver Bias to Isolated VCC) installed (See Section - End Node Jumpers W1 through
W6).
• RS-232 or RS-485 Node Interfaces
Networks nodes may connect to the Isolated RS-485 Interface Board via an RS-232 or
RS-485 interface. For installations where each node will include its own Isolated RS-
485 Interface Board and asynchronous operation is required (38.4 KBaud max) an RS-
232 interface may be used. In situations where several nodes will be mounted in close proximity, as in an equipment cabinet containing two or more DPCs, a single Isolated
RS-485 Interface Board may be employed by multidropping to each slave using the RS-
485 Interface Connector TB3. For LANs that will operate synchronously (187.5 KBaud to 1 MBaud), all nodes are required to have an RS-485 interface. As with the isolated
LAN itself, up to 32 nodes can be included in a multidrop arrangement. The maximum distance between communicating nodes on a 2-wire 187.5 KBaud LAN is approximately
PIP-ISORS485 Page 1 Isolated RS-485 Interface Board
1000 feet (300 meters). The maximum distance between communicating nodes on a 4wire 1 MBaud LAN is approximately 200 feet (60 meters).
• Surge Protection
Surge suppression on input ports and on the isolated output port meets IEC-801 to isolated ground.
• Isolated RS-485 Common-Mode Voltage Range
The Isolated RS-485 Port features -7V to +12V common-Mode Input Voltage range with respect to Isolated ground. The port also includes current limiting and thermal shutdown circuitry for driver overload protection.
• Switch Selectable Termination, Operating Mode, and 2/4-Wire Configuration
8 position DIP switches S1 and S2 are used to configure the Isolated RS-485 Board’s various operating parameters associated with port usage and LAN configuration.
• Mounting
The Isolated RS-485 Interface Board measures 4.302” (10.917cm) in width x 4.230”
(10.744cm) in height and may be mounted externally or to the top of an RTU 3305 via a
DIN Rail and DIN Rail Mounting Base. When mounted in a DIN Rail Mounting Base the unit measures 4.375” (12.112cm) in width x 4.375” (12.112cm) in height.
• PC LAN Functionality
The RS-232 Interface port allows PCs (which only have an RS-232 port) to be networked over an Isolated RS-485 LAN at asynchronous communication rates.
Figure 1 - Isolated RS-485 Board Component Identification Diagram
PIP-ISORS485 Page 2 Isolated RS-485 Interface Board
COMPONENT IDENTIFICATION
The Isolated RS-485 Interface Board has four wiring connectors; J1, TB1, TB2 and TB3, two configuration switches; S1 and S2, six 2-pin end node configuration jumpers; W1 through W6. Jumpers W1, W3 and W4 are used in on 2-wire networks and Jumpers W1,
W2, W5 & W6 are used on 4-wire networks. The board is protected by an on-board fuse F1 that is rated at .25A.
Figure 2 - Isolated RS-485 Board in a DIN Rail Mounting Base
Two-Wire End Node Jumpers W1, W3 & W4
Jumpers should be placed in an open position, i.e., installed on pin 1 or pin 2 for all nodes except the end nodes. Jumper W1 provides a 100-Ohm termination across TXD/RXD- and
TXD/RXD+ at the most distant (end) nodes. Two-wire RS-485 LANs also require the use of jumper W3 to provide Tx\Rx bias to isolated ground and jumper W4 to provide Tx\Rx bias to isolated VCC. Jumpers W3 and W4 are only required at the Master Node (see Table 1 and Figure 3).
Four-Wire End Node Jumpers W2, W5 & W6
Jumpers should be placed in an open position, i.e., installed on pin 1 or pin 2 for all nodes except the end nodes. Jumper W2 provides a 100-Ohm termination across RXD- and RXD+ at the most distant (end) nodes. On these networks, W5 provides receiver bias to isolated
PIP-ISORS485 Page 3 Isolated RS-485 Interface Board
ground and W6 provides receiver bias to Isolated VCC. Four-wire networks use W2, W5 and
W6 at the master node and W2 at the other end node, unless the network is to operate at other than 1Mbaud (synchronous), in which case jumpers W5 & W6 must also be installed at both end nodes (see Table 1 and Figure 4).
Table 1 - End Node Jumper Assignment
Network
Type
RS-485 - 2-Wire
RS-485 - 4-Wire - 1Mbaud
Master Node
Jumpers Installed
W1, W3, W4
W2, W5, W6
RS-485 - 4-Wire - Not 1Mbaud W2, W5, W6
Last Node (Slave
Jumpers Installed
W1
W2
W2, W5, W6
Connectors
When Connector J1 (9-Pin D-Type) of the Isolated RS-485 Interface Board is connected to a
DPC/RTU, transmitter or computer communications D-Type Connector, an RS-232 interface is established. Connector TB3 of the Isolated RS-485 Interface Board is a 6-Pin
Terminal Block that accommodates interface to an RS-485 port. RS-485 Input Connector
TB3 can be multidropped with up to 32 other RS-485 ports. Connector TB2 provides an interface to a 2-wire or 4-wire isolated RS-485 network. Input power is provided on
Terminal Block TB1. Tables 2 through 5, which follow, provide a description of each connector’s functionality:
Table 2 - Power Connector TB1 Wiring List
Pin #
1
Signal Name
+VDC Input
Description
+9V to +35V DC Bulk
2 VDC Return Bulk Return/Ground
N/A
Table 3 - Isolated RS-485 Port Interface Connector TB2 Wiring List
Pin # Signal Name
(2-Wire)
TXD+ (4-Wire)
2 TXD/RXD-(2-Wire)
TXD- (4-Wire)
3
4
RXD+ (4-Wire)
RXD- (4-Wire)
5
6
Isolated GND
Chassis GND
TXD/RXD+ Signal on 2-wire circuits
TXD+ Signal on 4-wire circuits
TXD/RXD- Signal on 2-wire circuits
TXD- Signal on 4-wire circuits
RXD+ Signal on 4-wire circuits
RXD- Signal on 4-wire circuits
Isolated Ground
Chassis Ground
Description
Table 4 - RS-232 Input Port Interface Connector J1 Wiring List
Pin #
2
4
5
TXD
RXD
RTS
Signal Name Description
RS-232 Transmit Data
RS-232 Receive Data
RS-232 Request To Send
9 GND
Note: Connector Pins 1, 3, 6, 7 & 8 are not used on Connector J1
PIP-ISORS485 Page 4 Isolated RS-485 Interface Board
Table 5 - TB3 RS-485 Input Port Interface Connector TB3 Wiring List
Pin #
1
2
3
4
Signal Name
TXD+
TXD-
RXD+
RXD-
Description
RS-485 Input Interface Signal Transmit Data Plus (+)
RS-485 Input Interface Signal Transmit Data Minus (-)
RS-485 Input Interface Signal Receive Data Plus (+)
RS-485 Input Interface Signal Receive Data Minus (-)
5
6
RTS+
RTS-
RS-485 Input Interface Signal Request To Send Plus (+)
RS-485 Input Interface Signal Request To Send Minus (-)
Switches
Two eight position DIP Switches are provided for board and network configuration. The functionality of these switches are provided in Tables 6 and 7 below:
Table 6 - Switch S1 Configuration Settings
Position Setting Function
1
1
3 & 4
3 & 4
5 & 6
5 & 6
7 & 8
7 & 8
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Select RS-232 Input Port
Select RS-485 Input Port
Enable RS-485 Terminator for TXD+/-
Disable RS-485 Terminator for TXD+/-
Enable RS-485 Terminator for RTS+/-
Disable RS-485 Terminator for RTS+/-
Enable RS-485 Terminator for RXD+/-
Disable RS-485 Terminator for RXD+/-
Table 7- Switch S2 Configuration Settings
Position
1, 3 & 5
1, 3 & 5
Setting
ON
OFF
Function
Select RS-232 Input Port
Select RS-485 Input Port
2, 4 & 6
2, 4 & 6
ON
OFF
Select RS-485 Input Port
Select RS-232 Input Port
Indicators
There are Two LEDs on the Isolated RS-485 Interface Board. LED DS1 will be illuminated when data is being transmitted and LED DS2 will be illuminated when data is being received.
WIRING
RS-232 Interface Between Isolated RS-485 Intf. Board and the Host Node
When it is desired to establish an RS-232 Interface between the Isolated RS-485 Interface
Board and the Host DPC/RTU, transmitter or computer a 24-gauge conductor cable, such as
PIP-ISORS485 Page 5 Isolated RS-485 Interface Board
Belden 9535 should be used. It should be noted that the Isolated RS-485 Interface Board provides 15KV surge protection per IEC-801 on all signals associated with this interface.
RS-485 Interface Between Isolated RS-485 Intf. Board and the Host Node
When it is desired to establish an RS-485 Interface between the Isolated RS-485 Interface
Board and the Host DPC/RTU or transmitter a low capacitance 24-gauge 3-twisted pair communications grade cable, such as Belden 9843 should be used. It should be noted that the Isolated RS-485 Interface Board provides 15KV surge protection per IEC-801 on all signals associated with this interface.
Isolated RS-485 Port Interface to LAN
Two-wire or four-wire RS-485 networks are supported. For two-wire applications, a low capacitance 24-gauge communications grade 2-twisted pair cable, such as Belden 9842, should be used. The cable shield should be connected to the Chassis Ground terminal, i.e.,
TB2 Pin 6 (at one end only). For four-wire applications a similar 3-twisted pair cable, such as Belden 9843, should be used. Again, the cable shield should be connected to the Chassis
Ground terminal (at one end only). It should be noted that the Isolated RS-485 Interface
Board provides 15KV surge protection on all signals associated with this interface.
Figure 3 - 2-Wire RS-485 LAN using Isolated RS-485 Interface Boards
Note: Jumpers W5 & W6 aren’t required at the most distant Slave Node unless the LAN is operating at other than 1Mbaud; however, they aren’t detrimental if they are installed.
Figure 4 - 4-Wire RS-485 LAN using Isolated RS-485 Interface Boards
Field Terminations for RS-485
The maximum number of nodes that can be connected to a RS-485 network is 32 including the master. For maximum protection against unwanted interference, noise and spurious
PIP-ISORS485 Page 6 Isolated RS-485 Interface Board
emission, the shield of each LAN segment should be terminated to the Chassis Ground at one end only. This practice will eliminate the formation of ground loops, thereby minimizing ground induced noise currents in the LAN. A Chassis Ground connection is provided on each Isolated RS-485 Interface Board at TB2 - Pin 6. In addition, the chassis of each Isolated RS-485 Interface Board should be connected to the nearest earth ground via a short length of 12-gauge stranded copper wire in order to take advantage of the built-in surge protection capability. The Isolated Ground terminal (TB2-5) of all nodes on the twowire RS-485 LAN must be connected via a third wire (within the second twisted pair).
For four-wire LANs 3-twisted pairs of wires are required. Shielding is not required (but is recommended). The maximum network length for the available asynchronous speeds (up to
38.4 KBaud) is 4000 feet (point to point) 1000 feet (for multiple nodes). For LANs utilizing synchronous speeds up to 187.5 KBaud (for two-wire LANs) or up to 1 MBaud (for four-wire
LANs) the maximum network length is 1000 feet (300 meters) or 200 feet (60 meters) respectively. The Isolated Ground terminal (TB2-5) of all nodes on the four-wire RS-485
LAN must be connected via a fifth wire (within the third twisted pair).
Figure 5 - Typical 2-Wire Asynchronous RS-485 LAN
Figure 6 - Typical 2-Wire Synchronous 187.5KBaud RS-485 LAN
Figure 7 - Typical 4-Wire Synchronous 1MBaud RS-485 LAN
PIP-ISORS485 Page 7 Isolated RS-485 Interface Board
PIP-ISORS485
Figure 8 - Isolated RS-485 LAN - Typical Installation
Page 8 Isolated RS-485 Interface Board
ISOLATED RS-485 INTERFACE BOARD SPECIFICATIONS
Performance Specifications
Baud Rate (Max.): 38.4K Asynchronous (2-wire or 4-wire)
187.5K
Multidrop (Max.):
Network Termination:
32 Nodes
100 Ohm Resistors for TX and RX Circuits on End Nodes
Topology:
Isolation:
Common Mode Range:
Master/Slave: (TXD+ to RXD+) & (TXD- to RXD-)
Optically Isolated Data Signals
-7 Volts to +12 Volts (DC) (With respect to Isolated Ground)
Surge Protection:
Isolated Ground
Meets IEC-801 (To Isolated Ground)
Surge Path:
Terminal Provided for Local Connection to Cable Shield
(one end of shield only)
Terminal Provided for Local Connection from Isolated Chassis
Ground to Earth Ground through a 280V Sealed Surge
Absorber
Input Voltage:
Input Power:
+9 to +35 VDC
(4-Wire) 65 mA @ 24 VDC (1.56 watt)
(2-Wire) 40 mA @ 24 VDC (1 watt)
Environmental Specifications
Operating Temperature: -40 ° to +70 ° (C) [-40 ° to +158 ° (F)]
Storage Temperature: -40 ° to +85 ° (C) [-40 ° to +185 ° (F)]
Humidity:
RFI Susceptibility:
5% to 95% (Non-condensing)
Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)
Vibration: 10-150 Hz, 1g
150-2000 Hz, 0.5g
Part Numbers
Two-wire Isolated RS-485 Interface Board: With DIN Base:
DIN
Four-wire Isolated RS-485 Interface Board: With DIN Base:
Without
392909-01-4
Base:
392909-03-0
PIP-ISORS485 Page 9 Isolated RS-485 Interface Board
Isolated RS-485 Interface Board
Special Instructions for Class I, Division 2 Hazardous Locations
1. The Bristol, Inc. Isolated RS-485 Interface 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 and non-hazardous locations only. Read this document carefully before installing a nonincendive Bristol Isolated RS-485 Interface Board. In the event of a conflict between the Isolated RS-485 Interface Board User Manual (PIP-ISORS485) and this document, always follow the instructions in this document.
2. All power and I/O wiring must be performed in accordance with Class I, Division 2 wiring methods as defined in Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations within the United States, or as specified in Section 18-152 of the
Canadian Electrical Code for installation in Canada.
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, turnoff 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.
03/14/2007 Appendix A, Document PIP-ISORS485 Page 1 of 1
BLANK PAGE
Product Information Package
Isolated RS-485 Interface Board - 33XX, 3508, 3530 & 3808
PIP-ISORS485
Mar., 2007
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882 www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955 www.EmersonProcess.com/Bristol
The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol, Inc. assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software delivered herewith. The Customer shall inspect and test such software and other materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and fitness for a particular purpose, concerning the software and other materials delivered herewith.
TeleFlow
™
is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2007, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol, Inc.
RTU 3305
Material Safety Data Sheets
Material Safety Data Sheets are provided herein to comply with OSHA’s Hazard
Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific requirements.
Material Safety Data Sheets are provided in the order listed in Table Z-1 below.
TABLE Z-1 MSDS for Model RTU 3305 Instruction Manual CI-3305
Manufacturer
Eagle Pitcher
General Description
3.6V Lithium
Thionyl Chloride Battery
Power Sonic
Corp.
Bristol Babcock Part Number
390147-01-0
12V Sealed Lead-Acid Battery 395407-02-8
Eagle Pitcher 12V Sealed Lead-Acid Battery 395407-02-8
7/23/97 Appendix Z - CI-3305 MSDS
BLANK PAGE
MATERIAL SAFETY DATA SHEET
Product Name: Sealed Maintenance Free Lead-Acid Batteries
DATE:
COMPONENTS
Lead (Pb, Pb0
2
, PBSO
4
)
Sulfuric Acid
Fiberglass Separator
ABS Plastic
COMPONENTS
Lead
Lead Sulfate
Lead Dioxide
Sulfuric Acid
Fiberglass Separator
ABS Plastic
COMPONENTS
Lead
Sulfuric Acid
Hydrogen
Fiberglass Separator
ABS Plastic
Skin Contact:
Eye Contact:
Ingestion:
10/1/2003
WEIGHT %
6.2
9.4
about 1.3
N/A
ISSUED BY ENGINEERING
HAZARDOUS COMPONENTS
LD50
TLV
N/A
1mg/m 3
ORAL
(500) mg/kg
(2,140) mg/kg about 70% about 20% about 5% about 5%
DENSITY
11.34
N/A
N/A
N/A
N/A
PHYSICAL DATA
MELTING POINTS
SOLLUBILITY
(H
2
O)
327.4º C (Boiling)
1070º C (Boiling)
None
40 mg/l(15 0 C)
290º C (Boiling) about 114º C (Boiling)
N/A
None
100%
Slight
N/A N/A None
FLAMMABILITY DATA
FLASHPOINT EXPLOSIVE LIMIT
None
None
None
None
N/A
None
4% - 72.4%
N/A
N/A
TELEPHONE NO.
LC50
INHALATION
N/A
N/A
N/A
N/A
ODOR
None
None
None
Acidic
Toxic
No Odor
COMMENTS
(619) 661-2030
LC50
CONTACT
N/A
N/A
N/A
N/A
APPEARANCE
Silver-Gray Metal
White Powder
Brown Powder
Clear Colorless Liquid
White Fibrous Glass
Solid
Sealed batteries can emit hydrogen if over charged
(float voltage > 2.40 VPC).
Toxic vapors may be released. In case of fire, wear self-contained breathing apparatus.
Temp. over 300º C (572º F) may release combustible gases. In case of fire: wear positive pressure self-contained breathing apparatus.
FIRST AID
SULFURIC ACID PRECAUTIONS
Flush with water, see physician if contact area is large or if blisters form.
Call physician immediately and flush with water until physician arrives.
Call physician. If patient is conscious, flush mouth with water, have patient drink milk or sodium bicarbonate solution.
Continued on Page 2
MATERIAL SAFETY DATA SHEET
(PAGE 2 OF 2)
C O M P O N E N T
S T A B I L I T Y
C O L Y M E R I Z A T I O N
I N C O M P A T I B I L I T Y
D E C O M P O S I T I O N P R O D U C T S
C O N D I T I O N S T O A V O I D
R E A C T I V I T Y D A T A
S u l f u r i c A cid
S t a b l e a t a l l t e m p e r a t u r es
W i l l n o t p o l y m e r i ze
R e a c t i v e m e t a l s , s t r o n g b a s e s , m o s t o r g a n i c c o m p o u n d s
S u l f u r i c d i o x i d e , t r i o x i d e , h y d r o g e n s u l f i d e , h y d r o g e n
P r o h i b i t s m o k i n g , s p a r k s , e t c .
f r o m b a t t e r y c h a r g i n g a r e a .
A v o i d m i x i n g a c i d w i t h o t h e r c h e m i c a l s
S t
W e a p s t s e t o t d i s a k e p o s a i l n c a m e t s e h o o f d : l e a k o r s p i l l :
S P I L L O R L E A K P R O C E D U R E S
I f s u l f u r i c a c i d i s s p i l l e d f r o m a b a t t e r y , n e u t c a r b o n s y s t e m .
( s o
D o d a n o a s h ) , t o a l l o w r c a l c i u m u n n e u t r a l o x i d e i z e d
( l i m e ) .
a c i d i n t o r i l i z e a c i d
F l u s h a r e a s e w a g e s w i t h b i c a r b o n a t e w y s i t h t e m .
w a t e r a n d d
( b a k i n g i s c a r d t s o o d a t h e
) , s o d i u m s e w a g e
N e u w a s t t r i l e i z e d a n d a c i d d i s p o m a y s e d b o f e f l u s h a c c o r e d d i d o n g t w o n t h e l o c a ,l s e w e r .
s t a t e ,
S p a n d e f n t e d b a t t e r i e s e r a l g u i d e m l i u s t n e s .
b e
A t r e a t e d c o p y o f a s h t h i s a z a r
M S d o u s
D S m u s t b e s u p p l i e d t o a n y s c r a p d e a l e r o r s e c o n d a r y l e a d s m e l t e r w i t h b a t t e r y .
P R O T E C T I O N
S
R
E
K
E
Y
I
S P
E
N
S
I R
E
A T
X P
O R
O S
Y
U R E S I T E P R O T E C T I ON C O M M E N TS
R u b b e r g l o v e s , A p r on
R e s p i r a t o r ( f o r l e a d)
P r o t e c t i v e e q u i p m e n t o t h e r w i s e d a m a g e d .
A m u r e s t b s p i r e a t w o o r r n i f t h s h o u l d e b b a t t e r y i s e c r a c k e d o r w o r n d u r i n g r e c l a i m o p e r a t i o n s i f t h e T L V i s e x c e e d e d .
S a f e t y g o g g l e s , F a c e S h i e ld
E L E C T R I C A L S A F E T Y
D u e t o t h e b a t t e r y ' s l o w i n t e r n a l r e s i s t a n c e a n d h i g h p o w e r d e n s i t y , h i g h l e v e l s o f s h o r t c i r c u i t c u r r e n t c a n b e d e v e l o p e d a c r o s s t h e b a t t e r y t e r m i n a l s .
D o n o t r e s t t o o l s m a i n t a i n i n g b a t t e r y s y s t e m s .
o r c a b l e s o n t h e b a t t e r y .
U s e i n s u l a t e d t o o l s o n l y .
F o l l o w a l l i n s t a l l a t i o n i n s t r u c t i o n s a n d d i a g r a m s w h e n i n s t a l l i n g o r
H E A L T H H A Z A R D D A T A
L E A D : T h e t o x i c e f f e c t s o f l e a d a r e a c c u m u l a t i v e a n d s l o w t o a p p e a r .
I t a f f e c t s t h e k i d n e y s , r e p r o d u c t i v e , a n d c e n t r a l n e r v o u s s y s t e m s .
T h e s y m p p a i n .
t o m s
E x p o o f s u r l e e a d t o o v e r l e a d e x p o f r o m s u a r e a b a t r e t e r a n e m i a , y m o s t v o m o f t e r n i t i n g o c
, c h u r e a s d a c h e d u r i n g
, l s t o m a c h e a d r e c l a i p a i n ( l e a d m o p e r a t i c o l o n s i c ) , t h r o d i z z i n e s s , u g h t h e l o s s b r e a t h o f i n g a p p o r e t i t e , a n d m u s c l e a n d i n g e s t i o n o f l e a d d u s t j o i n t o r f u m e s .
S U L a c i d
F U w i l l
R c
I C a u s
A e
C I D : S u l f u r i c
G I t r a c t b u r n s .
a c i d
A c i d i s a c a n s t r o n g b e r e l c o e a r r o s s e d i v i f e t
.
h
C o n t a c t w i t h a c i d e b a t t e r y c a s e i s d c a n a m a c g a s e d u e s e v e r e o r i f v e n t s b u r n s a r e o n t h e s t a m p e r e d k i n w i t a n d h .
i n e y e s .
I n g e s t i o n o f s u l f u r i c
F I B E R G L A S S S E P A R A T O R :
C o m f o l l w i t h t y p e H f i l t e r .
A b o v e
N T P o r O S H A .
F i b r o u r g l a s s
1 0 F / C C u p t o i s a n i r r i t a
5 0 F / C C n t u s o f t h e e U l t r u a p p e r
T w i n r e p i r a t o r y w i t h t y p e t r a c t ,
H f i l s t e r .
k i n
T h a n d i s p e r o y e s .
d u c t
F o r e x p o s u r e i s n o t c o n s i d u p e r e d t o 1 0 F / C C u c a r c i n o g e n i c s e M b y
S A
A L L D A T A M U S T B E P A S S E D T O A N Y S C R A P D E A L E R O R S M E L T E R W H E N B A T T E R Y I S R E S O L D .
Power-Sonic Corporation
9163 Siempre Viva Road, San Diego, CA 92154 Tel (619) 661-2020 Fax (619) 661-3650
Website: www.power-sonic.com E-Mail: [email protected]
Material Safety Data Sheet
May be used to comply with
OSHA's Hazard Communication Standard.
29 CFR 1910.1200 Standard must be consulted for specific requirements.
Identity (As Used on Label and List)
KEEPER II/Lithium/Thionyl Chloride Battery
Section I
Manufacturer's Name
Eagle-Picher Technologies, LLC
Address (Number, Street, City State, and Zip Code)
P.O. Box 130
14212 Bethel Road
Seneca, MO 64865
U.S. Department of Labor
Occupational Safety and Health Administration
(Non-Mandatory Form)
Form Approved
OMB No. 1218-0072
Note: Blank spaces are not permitted. If any item is not applicable, or no information is available, the space must be marked to indicate that
Emergency Telephone Number
417-776-2256 800-424-9300 (CHEMTREC)
Telephone Number for Information
417-776-2256
Date Prepared
1-Jul-98
Signature of Preparer (optional)
Section II - Hazardous Ingredients/Identity Information
Hazardous Components (Specific Chemical Identity, Common Name(s))
Lithium metal Cas #7439-93-2
Thionyl chloride (SOC1
2
) Cas #007719-09-7
OSHA PEL ACGIH TLV
N/A-reactive alkali metal
1/0 ppm 5/0 ppm
Other Limits Recommended % (optional)
Section III - Physical/Chemical Characteristics
Boiling Point
N/A
Vapor Pressure (mm Hg.)
N/A
Vapor Density (Air=1)
N/A
Specific Gravity (H
2
O=1)
Melting Point
N/A
N/A
Evaporation Rate (Butyl Acetate=1)
N/A
Solubility in Water
N/A
Appearance in Odor
N/A
Section IV - Fire and Explosion Hazard Data
Flash Point (Method Used)
N/A
Flammable Limits
Extinguishing Media
Do not use water. Use dry chemical, soda ash, sand.
Special Fire Fighting Procedures
Use self contained breathing apparatus and full protective equipment.
LEL UEL
Unusual Fire and Explosion Hazards
Do not recharge, disassemble, heat above 125°C (257°F), incinerate or expose contents to water.
Vent, rupture or explosion may result and cause severe burns.
(Reproduce Locally) OSHA 174, Sept. 1985
Section V - Reactivity Data
Stability Unstable
Stable XX
Conditions to Avoid:
Vent rupture or explosion will release thionyl chloride
Incompatibility (Materials to Avoid)
SOC1
2
Water, humid air, alkalies, and temperature above 140°C (284°F)
Hazardous Decomposition or Byproducts
SOC1
2
In presence of water or humid air, hydrochloric acid & sulfur oxide.
Hazardous
May Occur
Polymerization Will Not Occur
Section VI - Health Hazard Data
XX
Conditions to Avoid
Routes(s) of Entry
Eyes
Inhalation?
Health Hazards (Acute and Chronic)
Yes
Skin?
Yes
Ingestion?
Yes
SOC1
2
- Will burn and irritate eyes & skin. Upper respiratory irritant. Continuous inhalation of fumes may cause lung damage.
Carcinogenicity
N/A
NTP?
IARC Monographs?
OSHA Regulated?
Signs and Symptoms of Exposure
SOC1
2
- Eye and skin irritation, pungent odor and respiratory irritation.
Medical Conditions Generally Aggravated by Exposure
N/A
Emergency and First Aid Procedures
If free(S0C1
2
) is present, evacuate areas and provide ventilation, wash exposed area with soda ash or sodium bicarbonate solution. Seek medical attention.
Section VII - Precautions for Safe Handling and Use
Steps to Be Taken in Case Material is Released or Spilled
Avoid contact if vent rupture or explosion has occurred. Other wise protect from heat, short circuit of terminals, an accumulation of shorted batteries, which may cause dangerous elevated temperatures
Waste Disposal Method
Dispose of waste according to federal EPA, state and local regulations.
Precautions to be taken in Handling and Storing
Do not short circuit, heat above 125°C (257°F), recharge, disassemble, incinerate or expose to water.
Other Precautions
Section VIII - Control Measures
Self-contained breathing apparatus
Ventilation Local Exhaust
Mechanical (General)
N/A
Protective Gloves
Neoprene
Other Protective Clothing or Equipment
N/A
Work/Hygienic Practices
N/A
Specific
Other
Eye Protection
Recommended
Supplement 1
RTU 3305 STANDARD ENCLOSURE
Issue: 04/02
For Instruction Manual CI-3305
R
L
8
S
E
O
I
Y
C
R
G
K
U
N L
P
N
O
N
O
S
O
D
R
N
T
S
S
G A S
T A T I
S Y
O
S
N
T E M
S C R O L L
F1 F2 F3 F4
7 8
4 5
1
ON
-
2
0
OFF
3
9
6
DEL
ALM
I/E
ALM
ACK
A/M
INIT
ENTER
Bristol Babcock
RTU 3305 STANDARD ENCLOSURE
TABLE OF CONTENTS
SECTION TITLE
2.1
2.2
2.2.1
2.2.2
2.2.3
3.1
3.1.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.5.1
3.2.5.2
1.1
1.2
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.4
1.4.1
1.4.2
1.4.3
1.4.4
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
PAGE #
Section 1 - INTRODUCTION
GENERAL INTRODUCTION ....................................................................Sect. 1 - Pg. 01
FEATURES..................................................................................................Sect. 1 - Pg. 01
PHYSICAL DESCRIPTION........................................................................Sect. 1 - Pg. 04
Power Supply & Rechargeable Battery/Batteries .....................................Sect. 1 - Pg. 05
DIN Rail Mounted Power Distribution Block............................................Sect. 1 - Pg. 05
DIN Rail Mounted Form C Relays for Discrete Outputs ..........................Sect. 1 - Pg. 07
Local Communication Port..........................................................................Sect. 1 - Pg. 08
Wire Routing................................................................................................Sect. 1 - Pg. 09
Phone Line Surge Protectors ......................................................................Sect. 1 - Pg. 10
OPTIONS .....................................................................................................Sect. 1 - Pg. 11
Power Supply Option...................................................................................Sect. 1 - Pg. 11
LCD Display Option ....................................................................................Sect. 1 - Pg. 11
Communications Options............................................................................Sect. 1 - Pg. 11
Relay Option for Discrete Outputs .............................................................Sect. 1 - Pg. 12
Section 2 - INSTALLATION
INSTALLATION IN HAZARDOUS AREAS..............................................Sect. 2 - Pg. 01
MOUNTING THE RTU 3305 STANDARD ENCLOSURE.......................Sect. 2 - Pg. 01
Wire Routing................................................................................................Sect. 2 - Pg. 01
Field Wiring DOs Associated with the Form C Relay Option ..................Sect. 2 - Pg. 04
Signal Shielding and Grounding ................................................................Sect. 2 - Pg. 05
Section 3 - SERVICE
3305 STANDARD ENCLOSURE SERVICE INTRODUCTION ..............Sect. 3 - Pg. 01
Accessing Parts For Testing........................................................................Sect. 3 - Pg. 01
REMOVAL/REOLACEMENT PROCEDURES .........................................Sect. 3 - Pg. 02
Removal/Replacement of Power Distribution Block Fuses.......................Sect. 3 - Pg. 02
Removal/Replacement of Form C Relays ...................................................Sect. 3 - Pg. 03
Removal/Replacement of the Phone Line Surge Protector .......................Sect. 3 - Pg. 04
Removal/replacement of an External Communications Option ...............Sect. 3 - Pg. 04
Removal/Replacement of a Power Supply Option .....................................Sect. 3 - Pg. 06
Removal/Replacement of the Power Supply/Battery Charger Option .....Sect. 3 - Pg. 07
Removal/Replacement of the 40 Watt Power Supply Option....................Sect. 3 - Pg. 08
Section 4 - SPECIFICATIONS
ENVIRONMENTAL RATING & APPROVALS ............................
Sect. 4 - Pg. 01
POWER REQUIREMENTS ........................................................................Sect. 4 - Pg. 01
ACCESSORY SPECIFICATIONS ..............................................................Sect. 4 - Pg. 01
Power Supply/Battery Chargers.................................................................Sect. 4 - Pg. 01
Private Line Modem (External Version) ....................................................Sect. 4 - Pg. 02
Switched Network Modem (External Version) ..........................................Sect. 4 - Pg. 02
Isolated RS-485 Board (External Version).................................................Sect. 4 - Pg. 02
CI-3305 Supplement 1 Page 0-1 Table Of Contents
TABLE OF CONTENTS
SECTION TITLE
4.3.5
4.3.6
PAGE #
Section 4 - SPECIFICATIONS (Continued)
HART Ò Device Interface..............................................................................Sect. 4 - Pg. 03
Internal Communication Options...............................................................Sect. 4 - Pg. 03
Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheets on Battery P/N 395407-02-8.
CI-3305 Supplement 1 Page 0-2 Table Of Contents
BLANK PAGE
Section 1
RTU 3305 STANDARD ENCLOSURE
INTRODUCTION
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed information about the basic RTU 3305 is contained in Instruction Manual CI-3305.
1.1 GENERAL DESCRIPTION
The RTU 3305 Standard Enclosure is a completely assembled unit consisting of an RTU
3305 mounted within a NEMA 4X fiberglass enclosure, along with other, optional components required in many SCADA RTU applications. Package variations support any model 3305, including display type and any internally mounted communication option.
Units are fully wired and tested and simply require installation, FLASH configuration of the RTU, and downloading of the application.
The RTU 3305 Standard Enclosure features a pipe or panel mount NEMA 4X enclosure, steel backplate, and a choice of power supply with optional backup battery, an internal or door mounted display, DIN rail mounted relays, and a variety of communication options, including modems, smart transmitter, radio and local network interfaces. Standard features include DIN rail mounted power distribution system, inlets for power, I/O and communication wiring, external PC interface port, and a grounding lug.
RTU 3305 Standard Enclosures provide a high performance and economical choice for measurement and control in the following applications:
· SCADA RTU
· Lift Stations
· Metering Stations
· Well Monitoring
· Reservoir and Tank Monitoring
· Pump Controller
· Custody Transfer
· Pressure Monitor
1.2 FEATURES
The following items are standard features with all RTU 3305 Standard Enclosures:
· NEMA 4X Fiberglass Enclosure; 16” (40.64cm) H x 14” (35.56cm) W x 8” (20.32cm) D
(NEMA 3X with battery vent open)
· Aluminum Rear Plate
· DIN Rail Mounted Power Distribution Block with fusing and power cutoff
· Dual 1-inch threaded I/O inlets; accommodate up to 50, 14AWG wires
· 3/4 inch threaded power inlet
· Sealed Telephone/Communication Line Port
· External PC/Laptop Interface & Configuration Port
CI-3305 Supplement 1 Section 1 - Page 1 ENC 3305 RTU
· External Grounding Lug
· Panel or 2-inch Pipe Mount
· Choice of RTU 3305 Model (Including display type & internal communication option)
Figure S1-1
RTU 3305 Standard Enclosure with Remote 4x20 Keypad/Display Option
CI-3305 Supplement 1 Section 1 - Page 2 ENC 3305 RTU
Figure S1-2
Inside Cover of RTU 3305 Standard Enclosure with Remote 4x20 Keypad/Display Option & External Modem
All components mount comfortably within the enclosure making installation and maintenance of the unit straight forward. All but two (2) components (the Display Module &
External Modem) are mounted to the aluminum “Back Fabrication Panel” which in turn is mounted to the interior rear wall of the enclosure. The RTU 3305 Power Supply/Battery
Charger, external modem and Surge Suppressor utilize keyed mounting brackets for easy component removal and replacement. A power distribution block, consisting of fused sections for AC line and low voltage DC, is DIN Rail mounted to the aluminum Back
Fabrication Panel. All necessary cabling is neatly contained within half-inch snake ducting
CI-3305 Supplement 1 Section 1 - Page 3 ENC 3305 RTU
routed throughout the Back Fabrication Panel. The Back Fabrication Panel also serves as the instrument’s chassis and is cabled to an external ground lug on the enclosures bottom.
To further simplify installation, all packages include threaded conduit fittings for I/O, power and communications on the bottom of the enclosure. The enclosure is panel or wallmount ready, or can be attached to a vertically mounted 2-inch pipe.
Figure S1-3
RTU 3305 Standard Enclosure Component Identification
1.3 PHYSICAL DESCRIPTION
In addition to the base RTU 3305, RTU 3305 Standard Enclosures are comprised of the following major components:
· NEMA 4X Fiberglass Enclosure; 16” (40.64cm) H x 14” (35.56cm) W x 8” (20.32cm) D
(NEMA 3X with battery vent open)
· Aluminum Rear Plate
· UPS Power Supply (12VD or 24VDC) (see Appendix 6 of CI-3305) (Optional)
· UPS & Backup Battery (ies) (Optional)
· DIN Rail Mounted Power Distribution Block with fusing and power cutoff
CI-3305 Supplement 1 Section 1 - Page 4 ENC 3305 RTU
· Phone Line Surge Protector (Optional)
· Threaded Conduit Fittings
· Ground Lug
· Local Communications Port
· Up to 8 DIN Rail Mounted Form C Relays (for Discrete Outputs) (Optional)
1.3.1 Power Supply & Rechargeable Battery/Batteries
(see Appendix 6)
The power supply option consists of a linear supply/charger that produces a regulated peak output of 27.6V for a 24V system or 13.8V for a 12V system with a 10mA or greater load applied, and a temperature compensated current limiting circuit that will safely charge one or two lead-acid gel cells. Under normal conditions, the charger maintains the battery (ies)’
EMF potential, while the battery (ies) supply RTU system power. During line loss, the battery (ies) act alone for a backup period of 8 hours minimum with one battery (12V only), and 16 hours with two batteries. The supply/charger unit, used independently (without backup battery (ies), will support the RTU 3305 inrush current at 4 Amps for 12V systems or 2 Amps for 24V systems. However; as options are added to the package, the backup battery(s) become necessary to meet the total inrush current requirement. A complete system, i.e., Power Supply & Battery (ies), will support a fully loaded RTU.
1.3.2 DIN Rail Mounted Power Distribution Block
The standard six-section Din Rail mounted Power Distribution Block accommodates the interconnection of power and system grounding between the base RTU 3305 and the optional
Power Supply, battery/batteries, modem and Transmitter Interface Board (TIB). This unit is equipped with fusing and Power Cutoff. The fused power cutoff panel opens to break power or replace the fuse. When both the Power Supply/Charger and battery (ies) option are present, an additional fused power cutoff panel is provided to interconnect the battery
(ies) with the Power Supply/Charger. The fuse associated with the second fused power cutoff panel (F2) is rated at 3 Amps or 1.5 Amps for 12V and 24V systems, respectively while the fuse associated with the primary Fused Power Cutoff Panel (F1) is rated at 1
Amp for either 12V or 24V systems (see Figures S1-4 through S1-7).
CI-3305 Supplement 1
Figure S1-4 - Power Distribution Block
Section 1 - Page 5 ENC 3305 RTU
Figure S1-5 - Power Distribution Wiring Diagram
Base Unit without Battery/Batteries or Power Supply Charger
CI-3305 Supplement 1 Section 1 - Page 6 ENC 3305 RTU
Figure S1-6 - Power Distribution Wiring Diagram
Base Unit with Battery/Batteries & Power Supply Charger
1.3.3 DIN Rail Mounted Form C Relays for Discrete Outputs
Up to 8 DIN Rail mounted Form C Relays can be installed on the same DIN Rail that accommodates the Power Distribution Block. The relay modules are small, enclosed plug-in modules that mount to a pre-wired terminal base, with single-pole, double throw contacts left available for customer wiring. Each relay requires a minimum of 18 V @ 9 mA to
CI-3305 Supplement 1 Section 1 - Page 7 ENC 3305 RTU
energize, therefore 12V systems will not support them. Each relay includes a polarity reversal protection diode and an LED indicator.
Figure S1-7 - DIN Rail Mounted Power Distribution Block & Form C Relays
1.3.4 Local Communication Port
The local communications port is used for configuration and diagnostic communications but is not a network port. Port A of the Processor Memory Peripheral Power Supply Board is used for downloading FLASH configuration and FLASHWARE via the 3-Pin Molex type connector (J3). This port is interconnected to the Laptop VII connector on the bottom of the enclosure (see Section 2.4.8.3 of CI-3305). This Local Port can be connected to a Process
Engineer’s Interface (PEI) computer RS-232 Comm. Port for BSAP Slave/Pseudo-Slave applications. Additionally, a Terminal Emulator or a computer with a Terminal Emulation
Software package (such as PROCOMM) can be used to monitor the start-up sequence.
Note: Port A is not a network port and therefore does not support interface to a modem or other communication devices.
Figure S1-8 - Local Communications Cable Connector VII Plug/Jack
CI-3305 Supplement 1 Section 1 - Page 8 ENC 3305 RTU
Figure S1-9 - RTU 3305 Local Port Communications Link
1.3.5 Wire Routing
Wiring will enter the RTU 3305 Standard Assembled Package through holes in the bottom of the case. Up to seven holes may be provided in the bottom of the case. The purpose of each of these holes is provided in Figure S1-10 below.
Figure S1-10 - RTU 3305 Standard Enclosure Bottom Wiring Holes
CI-3305 Supplement 1 Section 1 - Page 9 ENC 3305 RTU
It should be noted that when a Battery Vent is provided the enclosure rating goes to NEMA 3X.
1.3.6 Phone Line Surge Protectors
Older RTU 3305 Standard Enclosures may be equipped with the SP Model 8792-20A Surge
Protector illustrated in Figure S1-11A. This device will protect against surges up to 300 V for one millisecond or 16 Vdc continuously. The Phoenix Model MT-2FM-RJ12 Surge
Protector currently provided (see Figure S1-11B) has been designed for use in high impedance telecommunications networks. The circuit will protect against surges up to 300
V (Normal Mode) or 450 V (Common Mode) for up to (1.2/50 + 8/20) microseconds.
Each Phone Line Surge Protector provides two surge protection circuits that may be used to protect against surges on one four-wire line or two two-wire lines.
Figure S1-11A - Phone Line Surge Protector SP 8792-20A
Figure S1-11B - Phone Line Surge Protector Phoenix MT-2FM-RJ12
TB2 of either the SP Model 8792-20A or Phoenix MT-2FM-RJ11 Phone Line Surge
Protector is wired to a phone company Jack/Terminal Block in accordance with Table S1-1.
CI-3305 Supplement 1 Section 1 - Page 10 ENC 3305 RTU
Table S1-1 - Phone Line Surge Protector TB2 Wiring Assignments
Configuration
PL 2-Wire
PL 4-Wire
TB2-1
TB2-a1
TB2-2
TB2-b1
TB2-3
TB2-a2
TB2-4
TB2-b2
T/R1 (TX/RX) T/R2 (TX/RX) N/A N/A
T/R1 (TX 4-Wire) T/R2 (TX 4-Wire) R1 (RX 4-Wire) R2 (RX 4-Wire)
PSTN 2-Wire T/R1 (Tip) T/R2 (Ring) N/A N/A
Note: The green wire connected to the Phoenix MT-2FM-RJ11 Surge Protector is connected to the RTU 3305 Standard Enclosure’s Ground Lug.
1.4 OPTIONS
A basic RTU 3305 Standard Enclosure contains a RTU 3305, a DIN Rail Mounted Power
Distribution Block, Local Port Laptop Connector, External Ground Lug, and a NEMA
4X/3X Box equipped with Water Tight Conduit Fitting and other fittings or sealing plugs as specified by customer order.
Configuration options are available for power, LCD Display, communications, and form C
Relays for Discrete Outputs.
1.4.1 Power Supply Option
The following Power Supply Options are available:
· RTU 3305 Standard Enclosure without Power Supply or Battery (ies)
· +12VDC Power Supply (with one +12VDC Lead-acid Battery)
· +12VDC Power Supply with two +12VDC Lead-acid Batteries tied in parallel
· +24VDC Power Supply with two +12VDC Batteries tied in series
· +24VDC Power Supply (40 Watt)
· +12VDC Power Supply (40 Watt)
Note: When a battery option is provided, the enclosure will be equipped with a
Battery vent and the enclosure will have a NEMA 3X rating.
1.4.2 LCD Display Option
The RTU 3305 Standard Enclosure may be packaged with one of the following LCD
Display Options:
· 3305 SAP without LCD Display
· 2 X 16 Character LCD Display (locally mounted), i.e., mounted on top of the base 3305
· 2 X 16 Character LCD Display (remotely mounted), i.e., mounted on the Enclosure Door
· 4 X 20 Keyboard Display (remotely mounted), i.e., mounted on the Enclosure Door
1.4.3 Communications Options
The RTU 3305 Standard Enclosure may be ordered with one or more of the following communication options:
CI-3305 Supplement 1 Section 1 - Page 11 ENC 3305 RTU
· 9600 bps Hayes Compatible PSTN Modem (+12VDC, +24VDC, or AC)
· 1200 bps Hayes Compatible PL Modem (+12VDC, +24VDC, or AC)
· Surge Protector Option (may be used with any BBI supplied modem)
· Radio Delay Interface Board (with or without external MDS Radio) (see Appendix 2 of
CI-3305)
· Transmitter Interface Board (TIB) (For BBI 3508 Transmitters) (see Appendix 1 of CI-
3305)
· RS-485 Interface Board (see Appendix 3 of CI-3305)
· Network Interface Box (External) (see Appendix 4 of CI-3305)
· Highway Addressable Remote Transducer (HART
CI-3305)
Ò ) Device Interface (see Appendix 5 of
1.4.4 Relay Option for Discrete Outputs
Up to 8 Din Rail Mounted Form C Relays (for +24VDC systems only) are available for customer use (see Section 1.3.3 and Section 2 of this supplement).
CI-3305 Supplement 1 Section 1 - Page 12 ENC 3305 RTU
Section 2
RTU 3305 STANDARD ENCLOSURE
INSTALLATION
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed information about the basic RTU 3305 is contained in Instruction Manual CI-3305.
2.1 INSTALLATION IN HAZARDOUS AREAS
An RTU 3305 Standard Enclosure that is installed without any of the available package options (i.e., without Power Supply, Communication, Surge Protection or Relay options) will meet FM approval for Class I, Division 2 hazardous environments. When a battery option is not installed (battery vent closed) the enclosure has a NEMA 4X rating. The enclosure rating for units equipped with a battery option (battery vent open) is NEMA 3X.
Package variations support any model 3305, including display type and any internally mounted communication option. Units are fully wired and tested and simply require installation, FLASH configuration of the RTU, and downloading of the application.
To simplify installation, all packages include threaded conduit fittings for I/O, power and communications on the bottom of the enclosure.
2.2 MOUNTING THE RTU 3305 STANDARD ENCLOSURE
Check all clearances when choosing an installation site. Make sure that the enclosure cover
(door - hinged on left side) can be opened for wiring and service. Make certain that the LCD
Display (if present) is visible and accessible to the on-site operator.
The RTU 3305 Standard Enclosure is to be positioned vertically with the threaded conduit fittings on the bottom of the enclosure. The enclosure is panel or wall-mount ready (see
Figure S2-2), or can be attached to a vertically mounted 2 inch pipe (see Figure S2-1). In the case of an outdoor pipe mounted unit, the pipe is to be cemented into the ground deep enough to conform to the local building code.
2.2.1 Wire Routing
Wiring enters the 3305 Standard Enclosure through holes in the bottom of the case. Two 1inch Water Tight Fittings (each accommodating up to 25 #14 AWG wires) provide for field
I/O wiring along with a 3/4 inch Water Tight Fitting for External Power, and a Sealed
Communications Port Fitting for a phone or external modem cable (see Figure S1-10 in
Section 1.3.5 of this supplement). Basic I/O wiring is covered in CI-3305 Section 2.4. The
3305 Standard Enclosure’s unique wiring is covered in the following sections of this supplement:
· DIN Rail Mounted Power Distribution Block - Section 1.3.2
· DIN Rail Mounted Form C Relays for DOs - Section 1.3.3 and 2.2.2
· Local Communication Port - Section 1.3.4
· Phone Line Surge Protector - Section 1.3.6 and appropriate modem manual.
CI-3305 Supplement 1 Section 2 - Page 1 ENC 3305 RTU
· Communications Options - Section 1.4.3 and appropriate appendix to CI-3305
Figure S2-1 - Side View of 3305 Standard Enclosure
Mounted to a 2” Pipe
CI-3305 Supplement 1 Section 2 - Page 2 ENC 3305 RTU
Figure S2-2 - Side View of 3305 Standard Enclosure
Mounted to a Wall or Panel
CI-3305 Supplement 1 Section 2 - Page 3 ENC 3305 RTU
2.2.2 Field Wiring DOs Associated with the Form C Relay Option
The RTU 3305 Standard Enclosure DIN Rail Mounted Relay Block accommodates up to eight (8) Form C Relays. The Relay Holders utilize compression type terminals that accommodate up to #12 AWG wire. A connection is made by inserting the wire’s bared end into the clamp beneath the screw and then securing the screw. The wire should be inserted fully such that no bared wires are exposed, thus eliminating the possibility of shorts. If using stranded wire, tin the bare end with solder to prevent flattening and to maintain conductivity.
Ordinarily, field connections for DO1 through DO8 are located at TB1 of the MI/OB Board.
When the Relay Option is installed, field connections are provided at the DIN Rail
Mounted Form C Relay Block as illustrated in Figure S2-3. To configure DI/O1 through
DI/O6 for DO operation, the MI/OB Board jumper associated with the DI/O in question must be set in the “B” position (see Figure 2-9 of Instruction Manual CI-3305).
Figure S2-3
Form C Relay DO Connections to TB1 of 3305 Standard Enclosure
It should be noted that the 3305 Standard Enclosure contains two Terminal Blocks that are labeled TB1. One is contained on the MI/OB Board and can accommodate wires up to
14 AWG in size, the other is as illustrated in Figure S2-3 and encompasses power distribution as-well-as Form C Relay wiring.
CI-3305 Supplement 1 Section 2 - Page 4 ENC 3305 RTU
2.2.3 Signal Shielding and Grounding
The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize signal error caused by electromagnetic interference (EMI), radio frequency interference
(RFI) and transients. When using shielded cable, all shields should only be grounded at one point in the system. This is necessary to prevent circulating ground loops that can cause signal error. Connect all shields to a common terminal point that is tied to the system ground. A customer ground lug is provided on the bottom of the enclosure. Also see
Supplement manual S1400 - Guidelines For System Grounding.
CI-3305 Supplement 1 Section 2 - Page 5 ENC 3305 RTU
BLANK PAGE
Section 3
RTU 3305 STANDARD ENCLOSURE
SERVICE
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed
Service information on the basic RTU 3305 is contained in Instruction Manual CI-3305.
3.1 3305 STANDARD ENCLOSURE SERVICE INTRODUCTION
General, diagnostic and calibration test information for the Model 3305 RTU are provided in Section 5 - SERVICE of Instruction Manual CI-3305.
The service procedures described herein supports those elements that are unique to the
RTI 3305 Standard Enclosure.
When RTUs are serviced on site, it is recommended that any associated processes be closed down or placed under manual or redundant/backup control. This precaution will prevent any processes from accidentally losing control when tests or service are conducted.
Warning
Harmful electrical potentials may still be present at the field wiring terminals even though the RTU’s power source may be turned off or disconnected. Do not attempt to unplug termination connectors or perform any wiring operations until all the associated supply sources are turned off and/or disconnected.
Warning
Never attempt to install or remove any modules (plug-in boards or Form C Relays) from an RTU while it is running. Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module itself, as-well-as other associated circuits. Always turn off the Main power, including any additional supply sources used for externally-powered I/O circuits, before changing any modules.
3.1.1 Accessing Parts For Testing
Testing and replacement of RTU hardware should only be performed by technicallyqualified persons having advanced mechanical and electrical skills and proper test equipment (see Section 5.1 of CI-3305). It is important that the reader study the disassembly procedures described herein and the disassembly and test procedures described in the base manual CI-3305 before starting. Any damage to the RTU 3305
Standard Enclosure resulting from improper handling or incorrect service procedures will not be covered under the product warranty agreement. If these procedures cannot be
CI-3305 Supplement 1 Section 3 - Page 1 ENC 3305 RTU
performed properly, the unit should be returned to Bristol Babcock (with prior authorization from Bristol Babcock) for factory evaluation and repairs.
Caution
PC board components can be damaged by electrostatic discharge (ESD) during disassembly/reassembly and test procedures. Use grounded wrist straps and surface pads when working near or handling circuit boards. See attached instruction supplement S14006 for proper grounding and handling techniques.
3.2 REMOVAL/REPLACEMENT PROCEDURES
3.2.1 Removal/Replacement of Power Distribution Block Fuses
System power is supplied to the RTU 3305 from the DIN Rail Mounted Power Distribution
Block of the RTU 3305 Standard Enclosure. Units equipped with the Power Supply Option have two fuses; F1 for AC and F2 for DC while units which are not equipped with the
Power Supply Option have one Fuse (F1) for DC. The Slow Blow AC Fuse is rated for 1
Amp at 120V. The DC Fuse is rated as follows:
· 12VDC System with Power Supply Option - F2 = 3A Slow Blow (see Figure S1-6)
· 24VDC System with Power Supply Option - F2 = 1.5A Slow Blow (see Figure S1-6)
· 12V System without Power Supply Option - F1 = 4A Slow Blow (see Figure S1-5)
· 24VDC System with Power Supply Option - F1 = 2A Slow Blow (see Figure S1-5)
Figure S3-1 - Power Distribution Panel with Fused Power Cutoff Panel Open
(End View)
CI-3305 Supplement 1 Section 3 - Page 2 ENC 3305 RTU
For enclosures equipped with a built-in Power Supply/Battery Charger, measure the DC output (at Terminals 6 & 5 of the Power Distribution Block) and make sure that it is within the following ranges:
+13.8VDC ±0.2% for +12VDC Systems, i.e., +13.77VDC to +13.83VDC
+27.6VDC ±0.2% for +24VDC Systems, i.e., +27.54VDC to +27.66VDC
If Power is present at the input to the system but not at the left side terminals (1 through 6 of the Power Distribution Block check fuse F1 and in the case of units equipped with the
Power Supply Option check fuse F2. Power Supply Distribution Block fuses are easily replaced by opening the appropriate Fused Power Cutoff Panel (see Figure S3-1). For additional power checks see Section 5.4.3 of CI-3305. If DC Power is not present, measure line power (at L1 & L2) for 120VAC. Replace the Line Fuse (F1) if necessary.
3.2.2 Removal/Replacement of Form C Relays
Up to eight (8) Form C Relays can be installed in DIN Rail mounted holders that are ganged on the Power Distribution Block. Relays are easily removed or installed when the
Relay Clamp/Release Lever associated with the Form C Relay in question has been moved to its left position (see Figure 3S-2).
Figure S3-2
DIN Rail Mounted Power Distribution Block & Form C Relays with Relay Associated with DO8 Removed
CI-3305 Supplement 1 Section 3 - Page 3 ENC 3305 RTU
3.2.3 Removal/Replacement of the Phone Line Surge Protector
When a modem is provided, a Phone Line Surge Protector Assembly is mounted in the RTU
3305 Standard Enclosure as illustrated in Figure S1-2. The Surge Protector is assembled to a mounting bracket. The mounting bracket with Surge Protector Board installed is secured to the RTU 3305 Standard Enclosure’s Rear Mounting Panel via two screws.
To remove an installed Phone Line Surge Protector follow steps 1 through 3 below:
1. Loosen the two screws that secure the Phone Line Surge Protector’s mounting bracket to the Rear Mounting Panel.
2. Slide the Surge Protector’s mounting bracket toward the unit’s right side to facilitate removal and carefully raise the unit and then disconnect the wires to the phone circuit and the wires to the modem.
3. The Surge Protector can now be removed from the mounting bracket.
To install a replacement Phone Line Surge Protector, perform the steps above and then follow steps 1 through 3 below:
1. Install the wires associated with the modem. In the case of the standard BBI PL or
PSTN modems, the modem interface harness plugs into connector J1 on the Modem
Interface Board. In the case of an external modem, the modem interface harness plugs into the modem’s RJ-11 Jack.
2. Install wires associated with the phone circuit. The wiring harness associated with the line side of the circuit will typically plug into a phone company supplied RJ-11 type Jack (see Section 1.3.6 of this supplement and the appropriate modem manual).
3. Slide the Phone Line Surge Protector’s mounting bracket over the two screws that secure it to the Rear Mounting Panel and then tighten these screws.
3.2.4 Removal/Replacement of an External Communications Option
An external 9600 bps PSTN Modem or an external 1200 bps private Line Modem may be mounted on the inside of the Instrument Front Cover as illustrated in Figure S1-2. Other communications options (with the exception of the HART Ò Device Interface and the
Network Interface Box) are mounted piggy-back on the RTU 3305 assembly. The HART Ò
Device Interface (see Appendix 5) or the Network Interface Box (NIB) (see Appendix 4) may be mounted on the inside of the Instrument Front Cover via a mounting plate or may be mounted in a location external to the RTU 3305 Standard Enclosure.
External Modems are enclosed units as illustrated in Figures S1-2, S3-3A and S3-3B and are secured to a “Upper Modem Mounting Plate” that accommodates installation to a
“Lower Modem Mounting Plate” on the inside of the Instrument Front Cover. To remove an
External Modem option follow steps 1 through 4 below:
CI-3305 Supplement 1 Section 3 - Page 4 ENC 3305 RTU
1. Disconnect the Power Harness from the Modem in question.
2. Disconnect the phone cord from the 9600 bps PSTN modem’s RJ-11 Telco Port Jack or the 1200 bps PL modem’s Terminal Block TB1. In the case of a 1200 bps PL modem, this cable may be connected on the other end to TB1 of the SP Model 8792-
20A Surge Protector (see Figure S1-11A) or to the OUT Terminals (TB1) of a
Phoenix MT-2FM-RJ12 Surge Protector (see Figure S1-11B). In the case of a 9600 bps PSTN modem, this cable may be connected on the other end to TB1 of the SP
Model 8792-20A Surge Protector (see Figure S1-11A) or to either of the RJ-11 connectors on the Phoenix MT-2FM-RJ12 Surge Protector (see Figure S1-11B).
3. Disconnect the RS-232 D-Type Connector from the modem. The other end of this cable is connected to Port B of the RTU 3305 MI/OB Board.
4. Remove the two (2) screws that secure the Modem Cover to the Modem Mounting
Bracket and remove the modem from the unit.
Figure S3-3A - External 1200 bps PL Modem End View Interface Diagram
CI-3305 Supplement 1 Section 3 - Page 5 ENC 3305 RTU
Figure S3-3B - External 9600 bps PSTN Modem End View Interface Diagram
To install an External Modem Option follow steps 1 through 4 above in reverse installing and securing rather than loosening and/or removing the item in question. If an external modem is being field installed for the first time you will have to install the two “Mounting
Strips” to the inside of the Instrument Front Cover as illustrated in Figure S1-2. Press the
Mounting Strips onto the ends of Modem Mounting Bracket prior to installation. The
Mounting Strips are secured to the inside of the Instrument Front Cover via double sided tape.
3.2.5 Removal/Replacement of a Power Supply Option
There are two types of power supplies available with the RTU 3305 Standard Enclosure, i.e., a 40 Watt Power Supply or a Power Supply/Battery Charger. Both are available in
+12Vdc or +24Vdc versions.
CI-3305 Supplement 1 Section 3 - Page 6 ENC 3305 RTU
3.2.5.1 Removal/Replacement of the Power Supply/Battery Charger Option
The Power Supply/Battery Charger option is mounted above the DIN Rail Mounted Power
Distribution Block on the “Back Fabrication Panel.” It is secured to the “Power Supply
Mounting Plate” via four (4) screws. The Power Supply Mounting Plate is in turn secured to the Back Fabrication Panel via four (4) screws as illustrated in Figure S3-4. To remove a
Power Supply/Battery Charger from the RTU 3305 Standard Enclosure, follow steps 1 through 5 below:
1. Shut off or disconnect AC Power to the unit.
Figure S3-4 -Location of Power Supply/Battery Charger
& Power Distribution Block
2. Disconnect the Power Supply/Battery Charger wires from the RTU 3305 Standard
Assembled Package DIN Rail Mounted Power Distribution Block (see Figure S3-4).
To get the black AC wire assigned to terminal L1 you will have to raise the Fused
Power Cutoff panel on the Power Distribution Block. The wires are assigned to the
Power Distribution Block’s right side as follows:
CI-3305 Supplement 1 Section 3 - Page 7 ENC 3305 RTU
Power Supply
Terminal
+OUT
-OUT
PIN1 (L1)
PIN2 (L1)
GND
Wire
Color
Description
Dist. Block
Terminal
Red +12/24DC Supply 5 - Right
Black -12/24DC Supply 6 - Right
Black 120VAC
White 120VAC
Green Chassis Ground
L1 - Right
L2 - Right
GND - Right
3. Remove the Power Supply/Battery Charger wires from the Wire Duct.
4. Loosen the four (4) screws that secure the Power Supply Mounting Plate to the Back
Fabrication Panel and slide the unit to the left and remove the Power Supply/-
Battery Charger from the RTU 3305 Standard Enclosure.
5. A replacement Power Supply/Battery Charger Assembly will have to be assembled to the Power Supply Mounting Plate and the Power Supply Cover that was removed from the 3305 Standard Enclosure in steps 1 through 4 above. To remove the Power
Supply Mounting Plate remove the four (4) screws from the bottom of the unit that secure the plate to the Power Supply/Battery Charger and Power Supply Cover.
The removal of two (2) more screws is required to separate the supply from the cover.
To install a Power Supply/Battery follow steps 1 through 5 above in reverse order, installing and securing rather than loosening and/or removing the item in question. Be careful not to confuse the two black wires (see Figures S1-6 and S3-4).
3.2.5.2 Removal/Replacement of the 40 Watt Power Supply Option
The 40 Watt Power Supply option is mounted above the DIN Rail Mounted Power
Distribution Block on the “Back Fabrication Panel.” It is secured to a “Power Supply
Mounting Plate” via two (4) screws. The Power Supply Mounting Plate is in turn secured to the Back Fabrication Panel via three (3) screws as illustrated in Figure S3-5. To remove a
40 Watt Power Supply from the RTU 3305 Standard Enclosure, follow steps 1 through 4 below:
1.
Shut off or disconnect AC Power to the unit.
2.
Disconnect the 40 Watt Power Supply wires from the units AC and DC connectors.
3. Loosen the three (3) screws that secure the Power Supply Mounting Plate to the
Back Fabrication Panel and slide the unit to the left and remove the 40 Watt Power
Supply from the RTU 3305 Standard Enclosure.
4. A replacement 40 Watt Power Supply will have to be assembled to the Power
Supply Mounting Plate that was removed from the 3305 Standard Enclosure in steps 1 through 3 above. To remove the Power Supply Mounting Plate remove the two (2) screws from the bottom of the unit that secure the plate to the Power
Supply.
CI-3305 Supplement 1 Section 3 - Page 8 ENC 3305 RTU
Figure S3-5 - 40W Power Supply
Mounted on 40W Power Supply Mounting Bracket
CI-3305 Supplement 1 Section 3 - Page 9 ENC 3305 RTU
BLANK PAGE
Section 4
RTU 3305 STANDARD ENCLOSURE
SPECIFICATIONS
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed specifications on the basic RTU 3305 are contained in Instruction Manual CI-3305.
4.1 ENVIRONMENTAL RATING & APPROVALS
An RTU 3305 Standard Enclosure that is installed without any of the available package options (i.e., without Power Supply, Communication, Surge Protection or Relay options) will meet FM approval for Class I, Division 2 hazardous environments.
4.2 POWER REQUIREMENTS
Unit
Base 3305 RTU
Local 2x16 Display
Remote 2x16 Display
4x20 Display/Keypad
1200 bps PL Modem
9600 bps PSTN Modem
RDI Board
TIB Board
RS-485 Board
Power
(Watt)
3.50
0.02
0.40
0.88
1.15
1.45
0.10
0.73
0.24
Current (mA)
@ 24VDC
145
1
17
37
48
60
4
30
10
4.3 ACCESSORY SPECIFICATIONS
4.3.1 Power Supply/Battery Chargers
Versions: 13.8VDC @ 1.8A Max. (Continuous & Surge)
27.6VDC @ 0.9A Max. (Continuous & Surge)
Size:
Battery Backup:
Operating Temperature:
5.5” x 3.6” x 2.7” (14cm x 9.2cm x 6.9cm)
Rechargeable Lead-acid Gel Cell
12V @ 7.2 A-Hrs. - One Batt. (8 Hrs. Min. Backup)
12V @ 14.4 A-Hrs. - 2 Batts. (16 Hrs. Min. Backup)
24V @ 7.2 A-Hrs. - 2 Batts. (16 Hrs. Min. Backup)
Note: Drained batteries require up to 10 hours recharge time before unit returns on-line.
-40°C to +60°C (-40°F to +140°F)
CI-3305 Supplement 1 Section 4 - Page 1 ENC 3305 RTU
4.3.2 Private Line Modem (External Version)
Speed:
Standards:
Line Type:
Serial Port Connector:
Input Voltage Versions:
1200 bps over 3002 type voice-grade leased lines
Bell 202 or V.23
2 or 4 wire (600 Ohms)
9-Pin D-Type
9 to 36 VDC
48 to 220 VAC
Dimensions: 5.25”W x 4”H x 1.5”D (13.4cm x 10.2cm x 3.8cm)
4.3.3 Switched Network Modem (External Version)
Speed:
Standards:
Line Type:
Serial Port Connector:
Phone Functions:
Input Voltage Versions:
Termination & Biasing:
Multi-dropping:
Input Voltage Version:
Isolation:
Surge Protection:
9600 bps over PSTN lines
Bell 212 or V.32
2 wire loop start lines
9-Pin D-Type
Auto Dial/Answer (Master or Slave Dial)
9 to 36 VDC
48 to 220 VAC
5.25”W x 4”H x 1.5”D (13.4cm x 10.2cm x 3.8cm) Dimensions:
4.3.4 Isolated RS-485 Board (External Version
) (see PIP-ISORS485)
Speed: Up to 38.4 Kbps
Connection Standard: External version connects to any full RS-232 or RS-
485 Port
Internal version connects to 3305 RTU Port C (TTL)
Selectable
Up to 32 nodes
9 to 35 VDC
300VDC
Meets IEEE C37.90-1978 to isolated ground
CI-3305 Supplement 1 Section 4 - Page 2 ENC 3305 RTU
Dimension External Version: 4.375” x 4.135” (11.1cm x 10.5cm)
4.3.5 HART
®
Device Interface
(see PIP-HART33XX)
4.3.6 Internal Communication Options
Internal Communications Options mount on the RTU 3305 as described in the RTU 3305
Manual CI-3305.
Private Line Modem:
Switched Network Modem:
Transmitter Interface Board:
Radio Delay Board:
RS-485 Interface Board;
See Customer Instruction Manual CI-1200-PL
See Customer Instruction Manual CI-9600
See Appendix 1 of CI-3305
See Appendix 2 of CI-3305
See Appendix 3 of CI-3305
CI-3305 Supplement 1 Section 4 - Page 3 ENC 3305 RTU
BLANK PAGE
Supplement Guide - S1400
Issue: 09/01
SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING
A Guide for the Protection of
Site Equipment & Personnel
In the Installation of
BBI Series 33XX DPCs & RTUs
Bristol Babcock
NOTICE
Copyright Notice
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.
Trademarks or copy-righted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2001 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol Babcock.
Supplement Guide S1400
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.2
3.5
3.5.1
3.5.2
3.5.3
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.1
3.2
3.3
3.4
3.4.1
3.4.1.1
3.4.1.2
3.4.1.3
SECTION TITLE
1.1
1.2
2.1
2.1.1
2.2
2.2.1
2.2.2
2.3
PAGE #
Section 1 - INTRODUCTION
GENERAL INTRODUCTION .......................................................................................1-1
MAJOR TOPICS.............................................................................................................1-1
Section 2 - PROTECTION
PROTECTING INSTRUMENT SYSTEMS...................................................................2-1
Quality Is Conformance To Requirements....................................................................2-1
PROTECTING EQUIPMENT & PERSONNEL ...........................................................2-1
Considerations For The Protection of Personnel.......................................................... 2-2
Considerations For The Protection of Equipment........................................................2-2
OTHER SITE SAFETY CONSIDERATIONS...............................................................2-3
Section 3 - GROUNDING & ISOLATION
POWER & GROUND SYSTEMS...................................................................................3-1
IMPORTANCE OF GOOD GROUNDS.........................................................................3-1 transients and interference............................................................................................3-2
EARTH GROUND CONNECTIONS.............................................................................3-2
Establishing a Good Earth Ground. ..............................................................................3-2
Soil Conditions................................................................................................................3-4
Soil Types ........................................................................................................................3-4
Dry, Sandy or Rocky Soil................................................................................................3-6
GENERAL RECOMMENDATIONS .............................................................................3-7
Noise and Signal Errors .................................................................................................3-7
General Considerations..................................................................................................3-8
Other Grounding Considerations. .................................................................................3-8
GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS ................................3-12
Several DPCs Mounted in Metal Cabinet with Power Supply .................................. 3-12
Multiple DPC Cabinets with Local Power Supply in Each Cabinet..........................3-14
Multiple DPC Cabinets Powered by Single Power Supply ........................................3-14
Multiple Clusters of DPC Cabinets Powered by Local Supplies................................3-16
Section 4 - LIGHTNING ARRESTERS & SURGE PROTECTORS
STROKES & STRIKES ..................................................................................................4-1
Chance of Being Struck by Lightning. ..........................................................................4-1
Antenna Caution ............................................................................................................4-3
Ground Propagation .......................................................................................................4-5
Tying it all Together.......................................................................................................4-5
Impulse Protection Summary ........................................................................................4-5
USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS................................4-6
Supplement S1400 Page 0-1 Table Of Contents
Supplement Guide S1400
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION TITLE ..................................................................................................... PAGE #
Section 5 - WIRING TECHNIQUES
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
OVERVIEW ....................................................................................................................5-1
INSTRUMENT WIRING. ..............................................................................................5-1
Common Returns............................................................................................................5-1
Use of Twisted Shielded Pair Wiring (with Overall Insulation)..................................5-2
Grounding of Cable Shields. ..........................................................................................5-3
Use of Known Good Earth Grounds ..............................................................................5-3
Earth Ground Wires .......................................................................................................5-3
Working Neatly & Professionally ..................................................................................5-3
High Power Conductors and Signal Wiring ..................................................................5-4
Use of Proper Wire Size ................................................................................................. 5-4
Lightning Arresters & Surge Protectors .......................................................................5-4
Secure Wiring Connections............................................................................................5-5
REFERENCE DOCUMENTS
1. IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std
142-1982
2. IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise inputs to Controllers from External Sources - IEE Std 518-1982
3.
Lightning Strike Protect; Roy B. Carpenter, Jr. & Mark N. Drabkin, Ph.D.; Lightning Eliminators &
Consultant, Inc., 6687 Arapahoe Road, Boulder Colorado
4.
Lightning Protection Manual for Rural Electric Systems, NRECA Research Project 82-5, Washington DC,
1983
5.
Grounding for the Control of EMI; Hugh W. Denny; Don White Consultants, Inc., 1983, 1 st Edition
6.
Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam
Street, Shreveport, Louisiana 71151
Supplement S1400 Page 0-2 Table Of Contents
Section 1 - Overview
1.1 INTRODUCTION
This document provides information pertaining to the installation of BBI Series 33XX systems; more specifically, information covering reasons, theory and techniques for protecting your personnel and equipment from electrical damage. Your instrument system affects the quality of service provided by your company and many aspects of its operational safety. Loss of instruments means lost production and profits as well as increased expenses.
Information contained in this document is for educational purposes. Bristol Babcock makes no warranties or guarantees on the effectiveness or the safety of techniques described herein.
Where the safety of installations and personnel is concerned, refer to the National Electrical
Code Rules and rules of local regulatory agencies.
1.2
MAJOR TOPICS
Topics are covered in seven sections designed to pinpoint major areas of concern for the protection of site equipment and personnel. The following overview is provided for each of the major sections.
· Section 2 - Protection
This section provides the reasons for protecting instrument systems. An overview of the definition of quality and what we are trying to accomplish in the protection of site installations and how to satisfy the defined requirements is presented. Additionally, this section provides considerations for the protection of personnel and equipment.
· Section 3 - Grounding & Isolation
Information pertaining to what constitutes a good earth ground, how to test and establish such grounds, as well as when and how to connect equipment to earth grounds is provided
· Section 4 - Lightning Arresters & Surge Protectors
Some interesting information dealing with Lightning strikes and strokes is presented in technical and statistical form along with a discussion of how to determine the likelyhood of a lightning strike.
Protecting equipment and personnel during the installation of radios and antenna is discussed in a review of the dangers to equipment and personnel when working with antennas. Reasons for the use of lightning arresters and surge protectors are presented along with overviews of how each device protects site equipment.
· Section 5 - Wiring Techniques
Installation of Power and “Measurement & Control” wiring is discussed. Information on obscure problems, circulating ground and power loops, bad relays, etc. is presented.
Good wire preparation and connection techniques along with problems to avoid are discussed. This sections list the ten rules of instrument wiring.”
Section 1 - Overview Page 1-1 S1400
Section 2 - Protection
2.1 PROTECTING INSTRUMENT SYSTEMS
Electrical instrumentation is susceptible to damage from a variety of natural and man made phenomena. In addition to wind, rain and fire, the most common types of system and equipment damaging phenomena are lightning, power faults, communication surges & noise and other electrical interference’s caused by devices such as radios, welders, switching gear, automobiles, etc. Additionally there are problems induced by geophysical electrical potential & noise plus things that are often beyond our wildest imagination.
2.1.1 Quality Is Conformance To Requirements
A quality instrumentation system is one that works reliably, safely and as purported by the equipment manufacturer (and in some cases by the system integrator) as a result of good equipment design and well defined and followed installation practices. If we except the general definition of quality to be, “quality is conformance to requirements,” we must also except the premise that a condition of “quality” can’t exist where requirements for such an end have not been evolved. In other words, you can’t have quality unless you have requirements that have been followed. By understanding the requirements for a safe, sound and reliable instrumentation system, and by following good installation practices (as associated with the personnel and equipment in question), the operational integrity of the equipment and system will be enhanced.
Understanding what is required to properly install BBI equipment in various environments, safely, and in accordance with good grounding, isolating and equipment protection practices goes a long way toward maintaining a system which is healthy to the owner and customer alike. Properly installed equipment is easier to maintain and operate, and is more efficient and as such more profitable to our customers. Following good installation practices will minimize injury, equipment failure and the customer frustrations that accompany failing and poorly operating equipment (of even the finest design). Additionally, personnel involved in the installation of a piece of equipment add to or subtract from the reliability of a system by a degree which is commensurate with their technical prowess, i.e., their understanding of the equipment, site conditions and the requirements for a quality installation.
2.2
PROTECTING EQUIPMENT & PERSONNEL
Series 33XX installations must be performed in accordance with National Electrical Code
Rules, electrical rules set by local regulatory agencies, and depending on the customer environment (gas, water, etc), other national, state and local agencies such as the American
Water Works Association (AWWA). Additionally, installation at various customer sites may be performed in conjunction with a “safety manager” or utility personnel with HAZMAT
(hazardous material) training on materials present (or potentially present) as required by
OSHA, the customer, etc.
Section 2 - Protection Page 2-1 S1400
2.2.1
Considerations For The Protection of Personnel
Always evaluate the site environment as if your life depended on it. Make sure that you understand the physical nature of the location where you will be working. Table 2-1 provides a general guideline for evaluating an installation site.
Table 2-1 - Installation Site Safety Evaluation Guide
#
1 Indoor or outdoor – Dress Appropriately
Guide
2 If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees, spiders, snakes, etc.)
3 If indoor or outdoor – determine if there are any pieces of dangerous equipment or any processes which might be a risk to your safety
4 If in a tunnel, bunker, etc. watch out for a build up of toxic or flammable gases. Make sure the air is good. Watch out for local varmint (bees, spiders, snakes, etc.)
5 Hazardous or Non-Hazardous Environment – Wear appropriate safety equipment and perform all necessary safety measures.
6 Before installing any equipment or power or ground wiring, make sure that there are no lethal (life threatening) voltages between the site where the instrument will be installed and other equipment, pipes, cabinets, etc. or to earth itself.
7 Never assume that adjacent or peripheral equipment has been properly installed and grounded. Determine if this equipment and the 33XX unit in question can be touched simultaneously without hazard to personnel and/or equipment?
8 Before embarking to remote locations where there are few or no human inhabitants ask a few simple questions like, should I bring water, food, hygienic materials, first aid kit, etc?
Be Prepared!
9 Observe the work habits of those around you – for your own safety!
Some of the items that a service person should consider before ever going on site can be ascertained by simply asking questions of the appropriate individual. Obviously other safety considerations can only be established at the installation site.
2.2.2
Considerations For The Protection of Equipment
Always evaluate the site installation/service environment and equipment. Understand the various physical interfaces you will be dealing with such as equipment mounting and supporting, analog and digital circuits, power circuits, communication circuits and various electrical grounds. Table 2-2 provides a general guideline for evaluating the equipment protection requirements of an installation site.
Table 2-2 - Equipment Protection Site Safety Evaluation Guide
# Guide
1 Environment - Class I, Division 2 - Nonincendive
Environment - Class I, Division 1 - Intrinsically Safe
Other - Safe or unrated area
2 Earth Ground - Established by mechanical/electrical or
(both) or not at all.
3 Is the area prone to lightning strikes?
4 Are there surge suppressors installed or to be installed?
5 Are there overhead or underground power or communication cables in the immediate area?
Reference Section
See Appendix A of CI Manual
See Appendix B of CI Manual
See Section 3
See Section 4
See Section 4
See Section 2.3
S1400 Page 2-2 Section 2 - Protection
Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued)
# Guide
6 Is there an antenna in the immediate area?
7 How close is other equipment? Can someone safely touch this equipment and a 33XX unit simultaneously?
8 Determine equipment ground requirements. How will the 33XX unit and its related wiring be grounded? Consider Earth Ground, Circuit
Ground, Conduit Ground, Site Grounds!
9 Are there any obviously faulty or questionable power or ground circuits?
2.3
OTHER SITE SAFETY CONSIDERATIONS
Reference Section
See Section 4.1.2
See Section 2.3
See Section 3
See Section 2.3
Overhead or underground power or communication cables must be identified prior to installing a new unit. Accidentally cutting, shorting or simply just contacting power, ground, communication or process control I/O wiring can have potentially devastating effects on site equipment, the process system and or personnel.
Don’t assume that it is safe to touch adjacent equipment, machinery, pipes, cabinets or even the earth itself. Adjacent equipment may not have been properly wired or grounded, may be defective or may have one or more loose system grounds. Measure between the case of a questionable piece of equipment and its earth ground for voltage. If a voltage is present, something is wrong.
AC powered equipment with a conductive case should have the case grounded. If you don’t see a chassis ground wire, don’t assume that it is safe to touch this equipment. If you notice that equipment has been grounded to pipes, conduit, structural steel, etc., you should be leery. Note: AWWA’s policy on grounding of electric circuits on water pipes states,
“The American Water Works Association (AWWA) opposes the grounding of electrical systems to pipe systems conveying water to the customer’s premises….”
Be sure that the voltage between any two points in the instrument system is less than the stand-off voltage. Exceeding the stand-off voltage will cause damage to the instrument and will cause the instrument to fail.
Section 2 - Protection Page 2-3 S1400
Section 3 - Grounding & Isolation
3.1 POWER & GROUND SYSTEMS
Series 33XX DPCs and RTUs (3305, 3310, 3330, 3331, 3332, 3335) utilize DC power systems. With the exception of some 3305 SAPs, AC power supplies are not provided with these units. Series 3305 SAP RTUs and 3335 DPCs are provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing a connection to Earth Ground.
Table 3-1 provides ground connection information for these units.
Model
3305 RTU
3305 SAP None
3310 RTU
3330 DPC
3332 RED
W1A, W1B
See C3A - topic
Grounding Option
W1A, W1B, W1C
See C3A - topic
Grounding Option
CI-3305 - Sup 1
Section 2.2.3
CI-3310 - C3A
CI-3330 - C3A
CI-3330 - C3K
3331 RIO
3335 DPC
Gnd. Jumpers
None
W13A, W13B
See C3A - topic
Grounding Option
Doc. Ref.
CI-3305 - C2
CI-3335 - C3L
CI-3335 - C3A
Location
MI/OB Bd.
Ground Lug
MFIB Bd.
SI Bd.
Jumpers = SI Bd.
Wiring = System
Monitor Module
& Ground Lug
Notes
# 12 AWG Wire
Pin 1 = PCOM (DC Ret.)
Pin 2 = POWER (DC+)
Pin 3 = CHASSIS
#4 AWG - see Figs.
S1-5, -6
#14 AWG Wire - see Figs.
3A-1, -2, -4, -6
#14 AWG Wire - see Figs.
3A-1, -2, -3, 3K-7, 3K-8
# 12 AWG Wire from
SMM - TB1 pin 2 (GND) to Zero Ref. Point - see
Figs 3A-1, -2, -7, -8, -9
#4 AWG Wire from
Chassis Bonding Bolt to
Power Grid Ground
3.2 IMPORTANCE OF GOOD GROUNDS
Series 33XX DPCs and RTUs are utilized in instrument and control systems that must operate continually and within their stated accuracy over long periods of time with minimum attention. Failures resulting from an improperly grounded system can become costly in terms of lost time and disrupted processes. A properly grounded system will help prevent electrical shock hazards resulting from contact with live metal surfaces, provide additional protection of equipment from lightning strikes and power surges, minimize the effects of electrical noise and power transients, and reduce signal errors caused by ground wiring loops. Conversely, an improperly grounded system may exhibit a host of problems that appear to have no relationship to grounding. It is essential that the reader (service technician) have a good under-standing of this subject to prevent needless troubleshooting procedures.
WARNING
This device must be installed in accordance with the National
Electrical Code (NEC) ANSI/NEPA-70. Installation in hazardous locations must also comply with Article 500 of the code.
Section 3 - Grounding & Isolation Page 3-1 S1400
3.3 TRANSIENTS AND INTERFERENCE
The extensive use of low-power integrated circuitry in modern electronic equipment requires proper grounding techniques to insure reliable system operation. The following checklist will help identify some critical areas:
1. All instrumentation devices at the site should be checked so that no potential greater than the standoff voltage can exist within or between devices.
2. To minimize outside signal interference and provide equipment protection from lightning or transients, the earth ground at the site must be tested to insure that its impedance measures less than 10 ohms at 7 MHz. This qualification is essential since a transient potential or an interference signal at the instrument site can vary over the entire electromagnetic spectrum from DC to several hundred MHz.
Note that transients can be produced through natural phenomena and man-made conditions. Natural transients may result from lightning (7-14 MHz), static (many frequencies), and wind (DC charge and static). Man-made transients can result from defective light bulbs or electrical appliances, sudden electrical load shifts, inductive load surges, arcing contacts and poor AC power connections.
3. If radio frequency (RF) interference is present at the input of an instrument, observe if it has a consistent or irregular pattern. Constant interference can come from commercial radio stations, while irregular interference can come from private stations.
Although shielding and grounding will eliminate or minimize most cases of RF interference, obstinate cases may require attenuation filters.
RF interference can also be caused by power companies that apply modulated RF signals to power lines to communicate data. Other RF noise sources include digital clocks, computers, relay contacts, motors transformers, switches, arc welders, etc.
3.4 EARTH GROUND CONNECTIONS
To properly ground a DPC or RTU unit, the units Chassis Ground (post or terminal) must ultimately be connected to a known good Earth Ground. Observe recommendations provided in topics Establishing a Good Earth Ground and Ground Wire Considerations.
3.4.1 Establishing a Good Earth Ground
A common misconception of a ground is that it consists of nothing more than a metal pipe driven into the soil. While such a ground may function for some applications, it will often not be suitable for a complex system of sophisticated electronic equipment. Conditions such as soil type, composition and moisture will all have a bearing on ground reliability.
A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG solid copper wire should be used for the ground wire. The end of the wire should be clean, free of any coating and fastened to the rod with a clamp. This ground connection should be covered or coated to protect it from the weather and the environment.
S1400 Page 3-2 Section 3 - Grounding & Isolation
Figure 3-1 - Basic Ground Rod Installation
Figure 3-2 - Overhead Map of Ground Bed for Gas Metering Station
Section 3 - Grounding & Isolation Page 3-3 S1400
3.4.1.1 Soil Conditions
Before installing a ground rod, the soil type and moisture content should be analyzed.
Ideally, the soil should be moist and moderately packed throughout to the depth of the ground rod. However, some soils will exhibit less than ideal conditions and will require extra attention.
Soil types can be placed into two general categories with respect to establishing and maintaining a good earth ground, i.e., ‘Good Soil’ and ‘Poor Soil.’
To be a good conductor, soil must contain some moisture and free ions (from salts in the soil). In very rainy areas, the salts may be washed out of the soil. In very sandy or arid area the soil may be to dry and/or salt free to a good conductor. If salt is lacking add rock salt
(NaCl); if the soil is dry add calcium chloride (CaCl
2
).
3.4.1.2 Soil Types: Good
Damp Loam
Salty Soil or Sand
Farm Land
Poor
Back Fill
Dry Soil
Sand Washed by a Lot of Rain
Dry Sand (Desert)
Rocky Soil
Ground Beds must always be tested for conductivity prior to being placed into service. A brief description of ground bed testing in ‘Good Soil’ and ‘Poor Soil’ is provided herein.
Details on this test are described in the National Electrical Code Handbook. Once a reliable ground has been established, it should be tested on a regular basis to preserve system integrity.
S1400
Figure 3-3 - Basic Ground Bed Soil Test Setup
Page 3-4 Section 3 - Grounding & Isolation
Figure 3-3 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5 ohms, the ground is good. The lower the resistance, the better the earth ground. If the
Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is indicated, one or more additional ground rods connected 10 feet from the main ground rod should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x
¼-20 cable clamps as illustrated in Figure 3-4). * Note: Megger is a Trademark of the
Biddle Instrument Co. (now owned by AVO International). Other devices that may be used to test ground resistance are “Viboground”; Associated Research,
Inc., “Groundmeter”; Industrial Instruments, Inc., and “Ground-ohmer”; Herman
H. Sticht Co., Inc.
If the Megger still reads more than 10 ohms, mix a generous amount of cooking salt, ice cream salt or rock salt with water and then pour about 2.5 to 5 gallons of this solution around each rod (including the test rods). Wait 15 minutes and re-test the soil. If the test fails, the soil is poor and a ‘Poor Soil Ground Bed’ will have to be constructed.
Figure 3-4 - Basic Ground Bed Soil Test Setup with Additional Ground Rods
Figure 3-5 shows a typical Poor Soil Ground Bed Electrode. A Poor Soil Ground Bed will typically consists of four or more 10-foot long electrodes stacked vertically and separated by earth. Figure 3-6 shows the construction of a Poor Soil Ground Bed. For some poor soil sites, the ground bed will be constructed of many layers of ‘Capacitive Couplings’ as illustrated. In extremely poor soil sites one or more 3’ by 3’ copper plates (12 gauge or 1/16” thick) will have to be buried in place of the electrodes.
Figure 3-5 - Ground Electrode Construction for Poor Soil Conditions
Section 3 - Grounding & Isolation Page 3-5 S1400
3.4.1.3 Dry, Sandy or Rocky Soil
Very dry soil will not provide enough free ions for good conductance and a single ground rod will not be effective. A buried counterpoise or copper screen is recommended for these situations. It will be necessary to keep the soil moist through regular applications of water.
Sandy soil, either wet or dry, may have had its soluble salts leached out by rain water, thereby reducing conductivity of the ground. High currents from lightning strikes could also melt sand and cause glass to form around the ground rod, rendering it ineffective. A buried counterpoise or copper screen is preferred for these installations along with regular applications of salt water.
Rocky soil can pose many grounding problems. A counterpoise or copper plate will probably be required. Constructing a trench at the grounding site and mixing the fill with a hygroscopic salt such as calcium chloride may help for a time. Soaking the trench with water on a regular basis will maintain conductivity.
S1400
Figure 3-6 - Poor Soil Ground Bed Construction Diagram
Page 3-6 Section 3 - Grounding & Isolation
3.5 GENERAL RECOMMENDATIONS
When wiring equipment into a system, the electrical conduit must have a diameter that will accommodate the desired number of wires. The cross- sectional area of the conduit should be large enough to allow the wires to be pulled through without excessive tightness or binding. A conduit that is too tight can shred insulation, damage wiring, and result in possible opens, shorts, or intermittent effects. Such conditions are often difficult to trace because the defect is concealed inside the conduit.
3.5.1 Noise and Signal Errors
Noise and signal errors are often the result of poor wiring and grounding practices. Some common problem areas are listed as follows: o Shielding AIs and AOs.
Very often analog DC signal leads must run parallel to wires radiating AC fields, pulse information, or switching transients. Due to inductive and capacitive pickup, some of this information can leak into an analog I/O and cause peculiar effects in the control systems. To minimize or eliminate this problem, the use of insulated and shielded, twisted lead pairs is recommended between the external devices (transmitters, sensors, etc.) and the instrument inputs
(controllers, recorders, etc.).
The shields of each analog signal source should only be grounded at the input of the in-strument. In some equipment, the shield will connect to the instrument chassis.
In other equipment, a "shield" terminal will be provided with several grounding options. The user should refer to the instrument manual and follow grounding recom-mendations.
o Common Returns.
The use of a single "common" return wire for two or more input signals is not recommended. This approach may introduce system ground loops that cause erroneous readings at the instrument. Shielded transmitter or sensor wires should be grounded at the input of the instrument, or connected to a shield terminal
(where provided) to prevent "sneak" ground paths.
o Discrete Outputs.
Instruments provided with bi-state discrete outputs perform functions such as control switching, alarm switching or pulse duration communications. These outputs are furnished as either open collector or relay contact outputs that operate at low power levels. While these levels are sufficient to operate many devices, some will require much higher power levels. The use of external amplifiers or repeating relays to drive end devices will prevent output overload and add to the reliability of the system.
o Placement of Wiring.
The dressing or physical placement of wiring requires close scrutiny. Cables inside cabinets should be neatly secured at regular intervals.
Cables running between cabinets at different locations should be placed in conduits.
The cable length should allow sufficient slack for routine operational checks and maintenance of the equipment. Wiring from input signal circuits and power circuits should be separated as much as possible to minimize noise and transient pickup.
Power and signal leads should be run in separate conduit to minimize inductive pickup.
Section 3 - Grounding & Isolation Page 3-7 S1400
o Terminal Lugs.
The use of crimp-type terminal lugs as connections for screw terminals should be avoided. Terminal lugs, in many industrial climates, can be affected by hidden corrosion. It is preferable to tin the wire end with solder and loop it around the terminal screw. The screw should be tightened sufficiently to hold the lead in place but not excessively so that the lead is sheared or the screw is stripped.
Equipment furnished with compression-type terminals includes an opening for inserting tinned ends.
3.5.2 General Considerations
The following considerations are provided for the installation of system grounds: i Size of ground wire (running to Earth Ground should be #4 AWG. It is recommended that stranded copper wire is used for this application and that the length should be as short as possible.
i This ground wire should be clamped or brazed to the Ground Bed Conductor (that is typically a stranded copper AWG 0000 cable installed vertically or horizontally).
i The wire ends should be tinned with solder prior to installation.
i The ground wire should be run such that any routing bend in the cable has a minimum radius of 12-inches below ground and 8-inches above ground.
The units Earth Ground Cable should be clamped to an exposed Ground Rod or to an AWG
0000 stranded copper Ground Cable that in turn should be connected to either an Earth
Ground Rod or Earth Ground Bed. Both ends of the units Earth Ground Cable must be free of any coating such as paint or insulated covering as well as any oxidation. The connecting point of the Ground Rod or AWG 0000 Ground Cable must also be free of any coating and free of oxidation. Once the ground connection has been established (at either the Ground
Rod or Ground Cable) it should be covered or coated to protect it from the environment.
3.5.3 Other Grounding Considerations
Instrument enclosures, measuring devices, metal process vats, metal piping, and other associated mechanical and electrical devices should all be grounded. The method of grounding an instrument rack is shown in Figure 3-6. In this application the ground lead typically attaches to a ground bus that is common to all equipment in the rack.
For applications employing equipment that communicates over telephone lines, a lightning arrester Must Be provided. For indoor equipment the lightning arrester must be installed at the point where the communication line enters the building as shown in Figure 3-7. The ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.
Applications that use transmitters or transducers require grounding and shielding. In
Figure 3-8, the ground conductor feeds through the electrical conduit and connects to the ground screw of the transmitter even though the support pipe is grounded. However, if the transmitter uses shielded wiring for its signal output, the shield should not be grounded at the transmitter. For maximum signal accuracy, the shield should only be grounded at one point in the system, typically at the input of the associated equipment.
S1400 Page 3-8 Section 3 - Grounding & Isolation
Figure 3-6 - Grounding of Equipment Housing
Figure 3-7 - Grounding of Phone Line
Section 3 - Grounding & Isolation Page 3-9 S1400
Figure 3-8 - Grounding of Transmitter
S1400
Figure 3-9 - Grounding of Thermometer Well in Gas Line
Page 3-10 Section 3 - Grounding & Isolation
Gas lines also require special grounding considerations. If a gas meter run includes a thermocouple or RTD sensor installed in a thermowell, the well (not the sensor) must be connected to a gas discharge-type lightning arrestor as shown in Figure 3-9. A copper braid, brazed to the thermal well, is dressed into a smooth curve and connected to the arrestor as shown. The curve is necessary to minimize arcing caused by lightning strikes or high static surges. The path from the lightning arrestor to the ground bed should also be smooth and free from sharp bends for the same reason.
The ac power required to operate a system typically includes a service transformer located at the street and a main breaker box and rate meter assembly at the building as shown in
Figure 3-10. The service transformer is grounded at the company's pole, while the breaker box is grounded at the building. A lightning arrestor should be included at the breaker box in each phase of the AC line, and each arrestor should be grounded accordingly.
Figure 3-10 - AC Power Grounding System
Section 3 - Grounding & Isolation Page 3-11 S1400
3.6 GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS
When installing a system that includes a number of Bristol Babcock, Series 33XX
Distributed Process Controllers (DPCs), it is essential to follow the procedures set forth by the National Electrical Code (NEC) to minimize risk of equipment damage and electrical shock.
WARNING
Electrically powered equipment must be properly grounded to protect users from electrical shock and injury. All such devices must be installed, wired, and grounded in accordance with the
National Electrical Code (NEC).
Series 33XX DPCs employ a power grid ground terminal (CHASSIS) and an instrument ground terminal (24VRET) that connects to the "zero reference point" of the system.
Improper grounding of these terminals can produce multiple ground paths throughout the system and result in increased noise pickup and signal offset errors. If more information is required on this subject, the reader should refer to the publications cited at the end of this document.
The examples that follow describe the grounding techniques for several types of Bristol
Babcock systems employing DPCs. Refer to the system description that is closest to your application.
3.6.1 Several DPCs Mounted in Metal Cabinet with Power Supply
A small system can consist of one or more DPCs mounted in a single metal cabinet or rack with a power supply. A power wiring diagram for this arrangement is shown in the example of Figure 8. The following installation procedures apply:
1. Instrument Ground. The instrument ground of the DPCs (24VRET terminal of each
DPC) must connect to a terminal block within the cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all instrument grounds and include termination for a multistranded, insulated, #4 gauge wire (or greater). This wire, which will connect to the "zero reference point" of the facility, must be run through metal conduit (pipe). Only the #4 wire will be contained in this conduit. The conduit must also be connected by bonding strap to the cabinet and facility frame as described in the NEC.
2. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24VRET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers or Correctors, if used with these systems, provide an isolated instrument ground without setting jumpers.
3. AC Power Source. The 24 Vdc power supply requires a 120 Vac power source. The ac power terminals of this supply are identified in Figure 3-11. The 120 Vac wiring for this supply must be contained in cable trays along with the power grid grounding wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical
S1400 Page 3-12 Section 3 - Grounding & Isolation
facility. The cabinet frame and the DPC chassis must be connected with bonding strap at points specified in the NEC.
Figure 3-11 - Grounding for DPCs and Power Supplies in Single Metal Cabinet
4. Grounding of Peripheral Equipment. Some peripheral devices such as printers, CRTs, personal computers, etc., have their internal logic ground connected to the chassis.
This configuration will cause loss of isolation between the DPC's instrument ground and chassis. These devices may still be used providing that opto-isolated circuits,
Section 3 - Grounding & Isolation Page 3-13 S1400
galvanic isolation, or other types of circuitry between the device and the DPC are added to maintain the integrity of the DPC's instrument ground-to-chassis isolation.
3.6.2 Multiple DPC Cabinets with Local Power Supply in Each Cabinet
This application consists of two or more DPC cabinets either separated or clustered together in a room. Each cabinet has its own 24 Vdc power supply. The following procedures apply:
1.
Multi-Cabinet Instrument Grounding using Multiple Supplies. The instrument ground (24VRET terminal) of each DPC in a cabinet must connect to a terminal block within that cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all DPC instrument grounds within that cabinet and include termination for a #4 gauge (or greater), multistranded, insulated wire that will connect to the zero reference point of the facility. This #4 wire will be run through metal conduit (pipe) to the same termination point in the other cabinets. Only the #4 wire will be containe in this conduit. This conduit must also be connected by bonding strap to the cabinet and facility frame as described in the NEC.
2. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers, if used with these systems, provide an isolated instrument ground without setting jumpers.
3. AC Power Source. The 24 Vdc power supply requires a 120 Vac power source. The ac power terminals of this supply are identified in Figure 3-11. The 120 Vac wiring for this supply must be contained in cable trays along with the power grid grounding wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical facility. The cabinet frame and the DPC chassis must be connected with bonding strap at points specified in the NEC.
4. Grounding of Peripheral Equipment. Some peripheral devices such as printers, CRTs, personal computers, etc., have their internal logic ground connected to the chassis.
This configuration will cause loss of isolation between the DPC's instrument ground and chassis. These devices may still be used providing that opto-isolated circuits, galvanic isolation, or other types of circuitry between the device and the DPC are added to maintain the integrity of the DPC's "instrument ground to chassis" isolation.
3.6.3 Multiple DPC Cabinets Powered by Single Power Supply
All of the DPC cabinets in this installation operate from a single power supply which may be installed in one of the cabinets or in a separate cabinet. The following procedures apply:
1. Multi-Cabinet Instrument Grounding using Single Supply. The instrument ground
(24VRET terminal) of each DPC in a cabinet must connect to a terminal block within that cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all instrument grounds within that cabinet and include termination for a multistranded, insulated, #4 gauge wire (or greater).
S1400 Page 3-14 Section 3 - Grounding & Isolation
From: Grounding for the Control of EMI by Hugh W. Denny (see ref. 1)
- Courtesy of Interference Control Technologies -
Figure 3-12 - Elements of a Facility Ground System
2. Routing of Instrument Ground and 24 V Power Wires. The #4 wire, along with +24V and 24VRET wires, are run through conduit trays to the power supply. The #4 wire
Section 3 - Grounding & Isolation Page 3-15 S1400
connects to the 24VRET terminal of the supply and to the zero reference point of the facility. The +24V and 24RET wires connect to corresponding terminals on the power supply.
3.
Cable Trays. Figure 3-12 illustrates the cable tray layout and grounding points of a typical facility. The cabinet frame and the DPC chassis must be connected with bonding strap at points specified in the NEC. The NEC also applies to the connection of the 120 Vac power supply terminals to the line.
4. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers, if used with these systems, provide an isolated instrument ground without setting jumpers.
3.6.4 Multiple Clusters of DPC Cabinets Powered by Local Supplies
A cluster consists of two or more DPC cabinets that may be grouped together as shown in
Figure 9. Several such clusters performing related functions in the same facility make up a multiple cluster system. The following procedures apply:
1. Grounding for DPC Cabinet Cluster using Local Supply. The instrument ground
(24VRET terminal) of each DPC in a cabinet must connect to a terminal block within that cabinet that is electrically isolated from the cabinet frame. This terminal block must provide termination for all instrument grounds within that cabinet and include termination for a multistranded, insulated, #4 gauge wire (or greater) that will connect to the same termination point to other cabinets of that cluster, and to the
24VRET terminal of the local power supply.
2. Routing of Cluster Grounds. The instrument grounds (isolated terminal) from each cabinet cluster must connect to each other and then to a single wire that connects to the zero reference point of the facility. This wire should be #4 gauge minimum
(multistranded and insulated) and be contained in a metal conduit (pipe). A heavier stranded #4/0 gauge could be used to connect each cluster to the zero reference point while the #4 wire instrument grounds could be locally terminated to the #4/0 wire.
The conduit containing this wire must also be connected by bonding strap to the cabinet and facility frame as described in the NEC.
3. AC Power Source. The 24 Vdc power supply of each cluster requires a 120 Vac power source. The ac power terminals of this supply are identified in Figure 3-11. The 120
Vac wiring for this supply must be contained in cable trays along with the power grid grounding wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical facility. The frame of each cabinet and each DPC chassis a cluster must be connected with bonding strap at points specified in the NEC.
4. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330, jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers and Correctors, if used with these systems, provide an isolated instrument ground without setting jumpers.
S1400 Page 3-16 Section 3 - Grounding & Isolation
Section 4 - Lightning Arresters & Surge Protectors
4.1 STROKES & STRIKES
Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will average 18 KA for the first impulse and about half of that for the second and third impulses. Three strokes (impulses) is the average per lightning strike. The number of visible flashes that may be seen is not necessarily the number of electrical strokes.
A lightning strike acts like a constant current source. Once ionization occurs, the air becomes a luminous conductive plasma reaching up to 60,000° F. The resistance of a struck object is of little consequence except for the power dissipation on the object (I 2 x R). Fifty percent of all lightning strikes will have a first impulse of at least 18 KA, ten percent will exceed the 60 KA level, and only about one percent will exceed 120 KA.
4.1.1 Chance of Being Struck by Lightning
The map of Figure 4-1 shows the average annual number of thunderstorm days
(Isokeraunic level) for the various regions within the continental U.S.A. This map is not representative of the severity of the storm or the number of lightning strikes since it does not take into account more than one lightning strike in a thunderstorm day. The
Isokeraunic or Isoceraunic number provides a meteorological indication of the frequency of thunderstorm activity; the higher the Isokeraunic number the greater the lightning strike activity for a given area. These levels vary across the world from a low of 1 to a high of 300.
Within the United States the Isokeraunic level various from a low of 1 to a high of 100.
Figure 4-1 - Average Thunderstorm Days of the Year (for Continental USA)
Section 4 - Lightning & Surge Page 4-1 S1400
Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the
United States there is an average of 30 thunderstorm days per year. Any given storm may produce from one to several strokes. Data on the subject indicates that for an average area within the United States there can be eight to eleven strokes to each square mile per year.
The risk of stroke activity is increased for various areas such central Florida where up to 38 strokes to each square mile per year are likely to occur.
To determine the probability of a given structure (tower, building, etc.) (within your location) being struck, perform the following computation:
1.
Using the map of Figure 4-1 (or a comparable meteorological map for your local), find the Isokeraunic level (I) for your area. Then using Chart 1, find “ A ” for your area.
2.
Refer to Figure 4-1 to find the latitude. Then using Chart 2, find “ B ” for your latitude
(Lat.°).
3.
Multiply “ A ” x “ B ” to get “ C ” .
4.
To calculate the number of lightning strikes per year that are likely to strike a given object (tower, mast, etc.), use the equation that follows (where “ C ” was calculated in step 3 and “ H ” is equal to the height of the object.
Strikes Per Year = ( “ C ” x H 2 ) ÷ (.57 x 10 6 )
Chart 1
I “ A ”
5
10
20
30
40
50
60
70
80
90
100
26
8
85
169
275
402
548
712
893
1069
1306
25
30
35
40
45
Chart 2
LAT.° “ B ”
.170
.200
.236
.280
.325
Note for these charts:
I = Thunderstorm Days Per Year (Isokeraunic Number)
A= Stroke activity for associated Isokeraunic Area
B= Height/Stroke coefficient for associated latitude
For Example: On Long Island, New York (Isokeraunic number 20), Chart 1 gives “A” to equal 85. The latitude is approximately 40°. Referring to Chart 2, “B” is found to be equal to
.28. “C” for this example is equal to 23.80. Using the equation for strikes per year, it is determined that a 100-foot tower has .4 chances per year of being struck by lightning.
Assuming that no other structures are nearby, the tower will more than likely be struck by lightning at least once in three years.
Note: The Isokeraunic activity numbers connoted as I, “A” and “B” in Charts 1 and 2 above are provided for the continental United States. Isokeraunic data for various countries is available from various federal or state Civil Engineering or Meterorelogical organizations. This information is typically available from manufacturers of lightning strike protection equipment (such as Lightning Arresters).
Since BBI Series 33XX units are dc operated systems that are isolated from AC grids, they are typically immune to lightning strikes to power lines or power equipment (except for inductive flashover due to close installation proximity). However, once a radio or modem has been interfaced to a 33XX unit, the possibility of damage due to a lightning strike on
S1400 Page 4-2 Section 4 - Lightning & Surge
power or telephone lines or to a radio antenna or the antenna’s tower must be considered. It is recommended that the additional lightning protection considerations listed below be followed for units installed in areas with a high possibility or history of stroke activity.
Units interfaced to a modem : In series with the phone line (as far away as possible from the equipment) - for indoor installations the lightning arrester should typically be located at the point where the line enters the structure.
Units interfaced to a radio : Mount antenna discharge unit (lightning arrester) as close as possible to where the lead in wire enters the structure. See Antenna Caution below.
4.1.2 Antenna Caution
Each year hundreds of people are killed, mutilated, or receive severe permanent injuries when attempting to install or remove an antenna or antenna lead. In many cases, the victim was aware of the danger of electrocution but failed to take adequate steps to avoid the hazard. For your safety, and for proper installation maintenance, please read and follow the safety precautions that follow - they may save your life .
i When installing or servicing an antenna:
DO NOT use a metal ladder. DO NOT step onto or touch an antenna mast while power is applied to an associated radio unless the radio is a low power (low current) type.
DO NOT work on a wet or windy day, especially during a thunderstorm or when there is lightning or thunder in your area. Dress properly; shoes with rubber soles and heels, rubber gloves, long sleeve shirt or jacket.
i The safe distance from power lines should be at least twice the height of the antenna and mast combination.
i Antenna Grounding per National Electrical Code Instructions:
A.
Use AWG 10 or 8 aluminum or AWG 1 copper-clad steel or bronze wire, or larger as ground wires for both the mast and lead-in. Securely clamp the wire to the bottom of the mast.
B.
Secure lead-in wire from antenna to antenna discharge (lightning arrester) unit and the mast ground wire to the structure (building, shed, etc.) with stand-off insulators spaced from 4 feet (1.22 meters) to 6 feet (1.83 meters) apart.
C.
Mount antenna discharge unit as close as possible to where the lead-in wire enters the structure.
D.
The hole drilled through the wall for the lead-in wire should be just large enough to accommodate the cable. Before drilling this hole, make sure there are no wires or pipes, etc. in the wall.
E.
Push the cable through the hole and form a rain drip loop close to where the wire enters the exterior of the structure.
F.
Caulk around the lead-in wire (where it enters the structure) to keep out drafts.
G.
Install lightning arresters (antenna discharge units). The grounding conductor should be run in as straight a line as practicable from the antenna mast and/or the antenna discharge units to grounding electrode(s).
H.
Only connect the antenna cable to the radio after the mast has been properly grounded and the lead-in cable has been properly connected to lightning arresters which in turn have each been properly connected to a known good earth ground.
Section 4 - Lightning & Surge Page 4-3 S1400
Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram
For all systems it is best to have all communication equipment input/output grounds tied together. Additional communication equipment lightning arresters and surge suppressors should be tied to the same system ground. System ground consists of the tower leg grounds
S1400 Page 4-4 Section 4 - Lightning & Surge
utility ground and bulkhead-equipment ground-stakes that are tied together via bare copper wire.
4.1.3 Ground Propagation
As in any medium, a dynamic pulse, like R.F., will take time to propagate. This propagation time will cause a differential step voltage to exist in time between any two ground rods that are of different radial distances from the strike. With a ground rod tied to a struck tower, the impulse will propagate its step voltage outwardly from this rod in ever-expanding circles, like a pebble thrown into a pond. If the equipment house has a separate ground rod and the power company and/or telephone company grounds are also separate, the dynamic step voltage will cause currents to flow to equalize these separate ground voltages. Then if the coax cable (associated with a radio) is the only path linking the equipment chassis with the tower ground, the surge can destroy circuitry.
4.1.4 Tying it all Together
To prevent this disaster from occurring, a grounding system must be formed which interconnects all grounds together. This will equalize and distribute the surge charge to all grounds, and at the same time, it will make for a lower surge impedance ground system.
This interconnection can be done as a grid, where each ground has a separate line to each other ground, or by using a “rat Race” ring which forms a closed loop (not necessarily a perfect circle) which surrounds the equipment house completely.
By making this interconnection, it will be necessary to use proper I/O protectors for the equipment. Of course, these should be a requirement regardless of whether this grounding technique is used. I/O protectors are used for power lines (even those these don’t feed into a
33XX unit), telephone lines, and also to minimize EMI pick-up from a strike. Ideally it is best to place all I/O protectors on a common panel that has a low inductance path to the ground system. The 33XX units would then have a single ground point from its Chassis
Ground Terminal/Ground Lug to this panel. In lieu of this, the 33XX unit in question should be tied to a ground rod that in turn is connected to the Earth/System Ground created for the site.
Your protected equipment connected to a common single ground system, will now be just like a bird sitting on a high tension wire. When lightning strikes, even with a 50 ohm surge impedance ground system, the entire system consisting of equipment, ground system, building, etc., will all rise together to the one million volt peak level (for example) and will all decay back down together. So long as there is no voltage differential (taken care of by protectors and ground interconnections, there will be no current flow through the equipment and therefore no resulting equipment damage.
4.1.5 Impulse Protection Summary
i Use more than one ground rod.
i Place multi-ground stakes more than their length apart.
i Tie Power, Telco, Tower, Bulkhead and equipment ground together.
i Make all ground interconnect runs that are above ground with minimum radius bends of eight inches and run them away from other conductors and use large solid wire or a solid strap.
i Watch out for dissimilar metals connections and coat accordingly.
Section 4 - Lightning & Surge Page 4-5 S1400
i Use bare wire radials together where possible with ground stakes to reduce ground system impedance.
i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground system.
i Ground the Coaxial Cable Shield (or use an impulse suppressor) at the bottom of the tower just above the tower leg ground connection.
4.2 USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS
Units equipped with radios or modems use lightning arresters and surge protectors to protect equipment from lightning strikes, power surges and from damaging currents that have been induced onto communication lines.
The first line of defense is the Lightning Arrester. These devices typically use gas discharge bulbs that can shunt high currents and voltages to earth ground when they fire. The high current, high voltage gas discharge bulb has a relatively slow response time and only fire when their gas has been ionized by high voltage.
The second line of defense is the Surge Protector, which is made of solid state devices, fires very quickly and conducts low voltages and currents to ground. Surge protectors are built into BBI 9600 bps modems.
Lightning Arresters are applied to circuits as follows: i Equipment or circuits that can be exposed to lightning strikes, falling power lines, high ground currents caused by power system faults, by operational problems on electric railways, etc.
i Equipment installed in dry, windy areas, such as the Great Plains and the
Southwaset Desert in the United States. Wind and wind blown dust can cause high voltages (static) to appear on overhead wires, fences, and metal buildings.
Note: Lightning Arresters may explode if lightning strike is very close. Mount lightning arresters where flying parts won't cause injury to equipment or personnel.
S1400 Page 4-6 Section 4 - Lightning & Surge
Section 5 - Wiring Techniques
5.1 OVERVIEW
This section provides information pertaining to good wiring practices. Installation of Power and “Measurement & Control” wiring is discussed. Information on obscure problems, circulating ground and power loops, bad relays, etc. is presented. Good wire preparation and connection techniques along with problems to avoid are discussed.
5.2 INSTRUMENT WIRING
Each of the rules listed below is briefly discussed; the emphasis herein is placed on the avoidance of problems as well as equipment safety.
Rule 1 - Never utilize common returns.
Rule 2 - Use twisted shielded pairs (with overall insulation) on all Signal/Control circuits.
Rule 3 - Ground cable shields at one end only.
Rule 4 - Use known good earth grounds (Rod, Bed, System) and test them periodically,
Rule 5 - Earth connections must utilize smoothly dressed large wire.
Rule 6 - Perform all work neatly and professionally.
Rule 7 - Route high power conductors away from signal wiring according to NEC Rules.
Rule 8 - Use appropriately sized wires as required by the load.
Rule 9 - Use lightning arresters and surge protectors.
Rule 10 - Make sure all wiring connections are secure.
5.2.1 Common Returns
Use of common returns on I/O wiring is one of the most common causes of obscure and difficult to troubleshoot control signal problems. Since all wires and connections have distributed resistance, inductance and capacitance, the chances of a achieving a balanced system when common returns are present is very remote. Balanced systems (or circuits) are only achieved when all currents and voltages developed in association with each of the common returns are equal. In a balanced system (or circuit) there are no noise or measurment errors introduced due to by “sneak circuits.”
The illustration of Figure 5-1 shows the difference between testing an I/O circuit that is discrete and has no sneak circuits and one that utilizes common returns. Common sense tells us that it is tough to mix up connections to a twisted shielded pair (with overall vinyl covering) to every end device. Do yourself a favor; to make start up easier, DON’T USE
COMMON RETURNS!
Section 5 - Wiring Techniques Page 5-1 S1400
Figure 5-1 - Field Wired Circuits With & Without A Common Return
5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation)
For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly recommended. This type of cable provides discrete insulation for each of the wires and an additional overall insulated covering that provides greater E.M.I. immunity and protection to the shield as well.
S1400 Page 5-2 Section 5 - Wiring Techniques
5.2.3 Grounding of Cable Shields
DO NOT connect the cable shield to more than one ground point; it should only be grounded at one end. Cable shields that are grounded at more than one point or at both ends may have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O signals. This will occur when the ground systems associated with multipoint connections to a cable shield have a high resistance or impedance between them and a ground induced voltage is developed (for what ever reason, i.e., man made error or nature produced phenomena).
5.2.4 Use of Known Good Earth Grounds
33XX units should only have one connection to earth ground. 33XX units (with the exception of 3305 SAPs and DPC 3335s) require the installation of a ground lug, ground bus or ground plate/panel. Since 33XX units are DC-based systems, grounding does not take into account AC power grounding considerations. Earth grounding the unit is absolutely necessary when the unit is equipped with a radio or modem. Additionally these units should be connected to earth ground when they are installed in areas that have frequent lightning strikes or are located near or used in conjunction with equipment that is likely to be struck by lightning or if struck by lightning may cause equipment or associated system failure. Earth Grounds must be tested and must be known to be good before connecting the
33XX unit. Earth grounds must be periodically tested and maintained (see Section 4).
5.2.5 Earth Ground Wires
Earth connections must utilize smoothly dressed large wire. Use AWG 3 or 4 stranded copper wire with as short a length as possible. Exercise care when trimming the insulation from the wire ends. Twists the strands tightly, trim off any frizzes and tin the ends with solder. The earth ground wire should be clamped or brazed to the Ground Bed Conductor
(that is typically a standard AWG 0000 copper cable. The earth ground wire should be run such that any routing bend in the cable is a minimum 8-inch radius above ground or a minimum 12-inch radius below ground.
5.2.6 Working Neatly & Professionally
Take pride in your work and observe all site and maintenance safety precautions. After properly trimming the stranded pair wire ends, twist them in the same direction as their manufacturer did and then tin them with solder. Install the tinned wire end into it’s connector and then secure the associated connector’s clamping screw. Remember to check these connections for tightness from time to time. If solid copper wire is used (in conjunction with the DC Power System or for Earth Ground) make sure that the conductor is not nicked when trimming off the insulation. Nicked conductors are potential disasters waiting to happen. Neatly trim shields and whenever possible, coat them to protect them and prevent shorts and water entry.
Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to being costly.
Section 5 - Wiring Techniques Page 5-3 S1400
5.2.7 High Power Conductors and Signal Wiring
When routing wires, keep high power conductors away from signal conductors. Space wires appropriately to vent high voltage inductance. Refer to the National Electrical Code
Handbook for regulatory and technical requirements.
5.2.8 Use of Proper Wire Size
Series 33XX units utilize compression-type terminals that accommodate up to #12 or #14
AWG gauge wire (see Table 3-1). A connection is made by inserting the bared end (1/4 inch max.) into the clamp beneath the screw and securing the screw.
Allow some slack in the wires when making terminal connections. Slack makes the connections more manageable and minimizes mechanical strain on the PCB connectors.
Provide external strain relief (utilizing Tie Wrap, etc.) to prevent the loose of slack at the
33XX unit.
Be careful to use wire that is appropriately sized for the load. Refer to equipment manufacturer’s Specs. and the National Electrical Code Handbook for information on wire size and wire resistance. After installing the field wiring, test each load to determine if the correct voltage or current is present at the load. If you know the resistance of the field wires
(Circular Mills x Length) you should be able to calculate the load voltage. Conversely, if you know the minimum load voltage and current, you should be able to derive the maximum voltage loss that is allowable due to line resistance and then the correct wire size.
Referring to Figure 5-2, a relay that is picked by 100 mA, with a loop supply voltage of 24V and a total line resistance of 20 ohms, the load voltage (voltage across the relay) should be:
V
L
= V
S
- (V
22 = 24 - 2
C
+ V
C
)
where
V
C where 2V
+ V
C
= (R
C
+ R
= (20 Ω
C
) I
) x 0.1 A
Figure 5-2 - Calculating Load Voltage due to Line Resistance
5.2.9 Lightning Arresters & Surge Protectors
Use lightning arresters in association with any radio or modem equipped unit. BBI 9600 bps modems are equipped with surge protection circuitry. Lightning arresters or Antenna
Discharge Units should be placed on the base of the antenna and at the point where the antenna lead (typically coax) enters the site equipment building. When a modem is used, a lightning arrester should be placed at the point where the phone line enters the site equipment building. If you use a modem (manufactured by other than BBI) it is recom-
S1400 Page 5-4 Section 5 - Wiring Techniques
mended that you also install a surge suppressors or lightning arrester on the phone line as close to the modem as possible. Any unit interfaced to a radio or modem must be connected to a known good earth ground.
5.2.10 Secure Wiring Connections
Make sure that all wiring connections are secure. In time wires that were once round will become flattened due to the pressure applied by screw compression type terminals and site vibrations. After a while these compression screws have a tendency to become loose. Part of a good maintenance routine should be to check and tighten all screws associated with wiring terminal connections. Avoid nicking the wire(s) when stripping insulation.
Remember that nicked conductors will lead to future problems. Also remember to provide some cabling slack and strain relief.
If installing stranded or braided wiring that has not been tinned, be sure to tightly twist the end (in the same direction as manufactured) and then trim off any frizzed wires.
Section 5 - Wiring Techniques Page 5-5 S1400
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DOCUMENT NUMBER: S1400
TITLE:
SITE CONSIDERATIONS For EQUIPMENT INSTALLATION, GROUNDING &
WIRING
ISSUE DATE: SEPT., 2001
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Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Attn: Technical Publications Group, Dept. 315
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1100 Buckingham Street
Watertown, CT 06795
Telephone: (860) 945-2200
ESDS Manual
S14006
4/15/92
CARE AND HANDLING
OF
PC BOARDS
AND
E SD-SENSITIVE
BRISTOL BABCOCK
BLANK PAGE
ESDS Manual
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TABLE OF CONTENTS
PAGE
TOOLS AND MATERIALS REQUIRED 1
TOOLS AND MATERIALS REQUIRED
1. Tools
Anti-Static Field kit. It is recommended that an anti-static field kit be kept on any site where solid-state printed circuit boards and other ESD-sensitive components are handled. These kits are designed to remove any existing static charge and to prevent the build-up of a static charge that could damage a PC board or
ESD-sensitive components. The typical anti-static field kit consists of the following components:
1. A work surface (10mm conductive plastic sheet with a female snap fastener in one corner for ground cord attachment).
2. A 15-foot long ground cord for grounding the work surface.
3. Wrist strap (available in two sizes, large and small, for proper fit and comfort) with a female snap fastener for ground cord attachment.
4. A coiled ground cord with a practical extension length of 10 feet for attachment to the wrist strap.
Toothbrush (any standard one will do)
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2.
Materials
Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent)
Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent)
Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent)
1.
ESD-SENSITIVE COMPONENT HANDLING PROCEDURE
Introduction
Microelectronic devices such as PC boards, chips and other components are electrostatic-sensitive. Electrostatic discharge (ESD) of as few as 110 volts can damage or disrupt the functioning of such devices. Imagine the damage possible from the 35,000 volts (or more) that you can generate on a dry winter day by simply walking across a carpet. In fact, you can generate as much as 6,000 volts just working at a bench.
There are two kinds of damage that can be caused by the static charge. The more severe kind results in complete failure of the PC board or component. This kind of damage is relatively simple, although often expensive, to remedy by replacing the affected item(s). The second kind of damage results in a degradation or weakening which does not result in an outright failure of the component. This kind of damage is difficult to detect and often results in faulty performance, intermittent failures, and service calls.
Minimize the risk of ESD-sensitive component damage by preventing static build-up and by promptly removing any existing charge. Grounding is effective, if the carrier of the static charge is conductive such as a human body. To protect components from
nonconductive carriers of static charges such as plastic boxes, place the component
in static-shielding bags.
This manual contains general rules to be followed while handling ESD-sensitive components. Use of the anti-static field kit to properly ground the human body as well as the work surface is also discussed.
2
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Table 1
Typical Electrostatic Voltages
Electrostatic Voltages
10-20 Percent
Relative Humidity
65-90 Percent
Relative Humidity
Means of Static
Generation
Walking across carpet
Walking over vinyl floor
Worker at bench
Vinyl envelopes for work instructions
Poly bag picked up from bench
Work chair padded with poly foam
35,000
12,000
6,000
7,000
20,000
18,000
1,500
250
100
600
1,200
1,500
2.
General Rules
(1) ESD-sensitive components shall only be removed from their static-shielding bags by a person who is properly grounded.
(2) When taken out of their static-shielding bags, ESD-sensitive components shall
never be placed over, or on, a surface which has not been properly grounded.
(3) ESD-sensitive components shall be handled in such a way that the body does not come in contact with the conductor paths and board components. Handle
ESD-sensitive components in such a way that they will not suffer damage from physical abuse or from electric shock.
(4) EPROMS/PROMS shall be kept in anti-static tubes until they are ready to use and shall be removed only by a person who is properly grounded.
(5) When inserting and removing EPROMS/PROMS from PC boards, use a chip removal tool similar to the one shown in the figure following. Remember, all work should be performed on a properly grounded surface by a properly-grounded person.
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4
Typical Chip Removal Tool
(6) It is important to note when inserting EPROMS/PROMS, that the index notch on the PROM must be matched with the index notch on the socket. Before pushing the chip into the socket, make sure all the pins are aligned with the respective socket-holes. Take special care not to crush any of the pins as this could destroy the chip.
(7) Power the system down before removing or inserting comb connectors/plugs or removing and reinstalling PC boards or ESD-sensitive components from card files or mounting hardware. Follow the power-down procedure applicable to the system being serviced.
(8) Handle all defective boards or components with the same care as new components. This helps eliminate damage caused by mishandling. Do not strip used PC boards for parts. Ship defective boards promptly to Bristol Babcock in a staticshielding bag placed inside static-shielding foam and a box to avoid damage during shipment.
ESDS Manual
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CAUTION
Don't place ESD-sensitive components and paperwork in the same bag.
The static caused by sliding the paper into the bag could develop a charge and damage the component(s).
(9) Include a note, which describes the malfunction, in a separate bag along with each component being shipped. The repair facility will service the component and promptly return it to the field.
3.
Protecting ESD-Sensitive Components
(1) As stated previously, it is recommended that an electrically-conductive anti-static field kit be kept on any site where ESD-sensitive components are handled. A recommended ESD-protective workplace arrangement is shown on page 7. The anti-static safety kit serves to protect the equipment as well as the worker. As a safety feature, a resistor (usually of the one-megohm, 1/2-watt, current-limiting type) has been installed in the molded caps of the wrist strap cord and the ground cord. This resistor limits current should a worker accidently come in contact with a power source. Do not remove the molded caps from grounded cords. If a cord is damaged, replace it immediately.
(2) Be sure to position the work surface so that it does not touch grounded conductive objects. The protective resistor is there to limit the current which can flow through the strap. When the work surface touches a grounded conductive object, a short is created which draws the current flow and defeats the purpose of the current-limiting resistor.
(3) Check resistivity of wrist strap periodically using a commercially-available system tester similar to the one shown in the figure below:
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Note: If a system checker is not available, use an ohmmeter connected to the cable
ends to measure its resistance. The ohmmeter reading should be 1 megohm +/-
15%. Be sure that the calibration date of the ohmmeter has not expired. If the
ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a new one.
4.
Static-safe Field Procedure
(1) On reaching the work location, unfold and lay out the work surface on a convenient surface (table or floor). Omit this step if the table or floor has a built-in ESD-safe work surface.
(2) Attach the ground cord to the work surface via the snap fasteners and attach the other end of the ground cord to a reliable ground using an alligator clip.
(3) Note which boards or components are to be inserted or replaced.
(4) Power-down the system following the recommended power-down procedure.
(5) Slip on a known-good wristband, which should fit snugly; an extremely loose fit is not desirable.
(6) Snap the ground cord to the wristband. Attach the other end of the ground cord to a reliable ground using the alligator clip.
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(7) The components can now be handled following the general rules as described in the instruction manual for the component.
(8) Place the component in a static-shielding bag before the ground cord is disconnected. This assures protection from electrostatic charge in case the work surface is located beyond the reach of the extended ground cord.
A
C
✰
R
R
D
E F
R
R
EARTH GROUND
B
G
FLOOR OF BUILDING
LEGEND
A - Chair with ground (optional)
B - ESD protective floor mat (optional)
C - Wrist strap
D - ESD protective trays, etc.
E - Ionizer
F - Other electrical equipment
G - Workbench with ESD protective table top
✰
NOTE: ALL RESISTORS 1M
Ω
+/-10% 1/2W
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(9) If a component is to undergo on-site testing, it may be safely placed on the grounded work surface for that purpose.
(10) After all component work is accomplished, remove the wrist straps and ground wire and place in the pouch of the work surface for future use.
5.
Cleaning And Lubricating
The following procedure should be performed periodically for all PC boards and when a PC board is being replaced.
CAUTION
Many PC board connectors are covered with a very fine gold-plate.
Do not use any abrasive cleaning substance or object such as a pencil eraser to clean connectors.
Use only the approved cleaner/lubricants specified in the procedure following.
WARNING
Aerosol cans and products are extremely combustible.
Contact with a live circuit, or extreme heat can cause an explosion.
Turn OFF all power and find an isolated, and ventilated area to use any aerosol products specified in this procedure.
(1) Turn the main line power OFF. Blow or vacuum out the component. This should remove potential sources of dust or dirt contamination during the remainder of this procedure.
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(2) Clean PC board connectors as follows: a.
Review the static-safe field procedure detailed earlier.
b.
c.
Following the ESD-sensitive component handling procedures, remove the connectors from the boards and remove the PC boards from their holders.
Use cleaner to remove excessive dust build-up from comb connectors and other connectors. This cleaner is especially useful for removing dust.
d.
Liberally spray all PC board contacts with Inhibitor. The inhibitor:
Provides a long lasting lubricant and leaves a protective film to guard against corrosion e.
f.
Improves performance and reliability
Extends the life of the contacts
Is nonconductive, and is safe for use on most plastics
Clean the comb contacts using a lint-free wiping cloth.
Lightly mist all comb contacts again with Inhibitor.
NOTE: Do not use so much Inhibitor that it drips.
g.
Repeat the above procedure for the other PC boards from the device.
(3) Cleaning PC edge connectors a.
Use cleaner to remove excessive dust build-up from connectors. This cleaner is especially useful for removing dust.
b.
c.
Liberally spray the outboard connector with Inhibitor.
Lightly brush the outboard connector with a soft, non-metallic, bristle brush such as a toothbrush.
9
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e.
Spray the connector liberally to flush out any contaminants.
Remove any excess spray by shaking the connector or wiping with either a toothbrush, or a lint-free wiping cloth.
6.
Completion
(1) Replace any parts that were removed.
(2) Make sure that the component cover is secure.
(3) Return the system to normal operation.
(4) Check that the component operates normally.
10
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DOCUMENT NUMBER: CI-3305
TITLE:
Remote Terminal Unit RTU 3305 Instruction Manual
ISSUE DATE: DEC., 2005
COMMENT/COMPLAINT:
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Mail this page to:
Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Attn: Technical Publications Group, Dept. 315
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
Helicoid Instruments
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2218
Fax: +1 (860) 945-2213
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
Central Region
Bristol Babcock Inc.
300 North Coit Road
Suite 1300
Richardson, TX 75080
Phone: +1 (972) 238-8935
Fax: +1 (972) 238-8198
International Affiliates:
Canada
Bristol Babcock, Canada
234 Attwell Drive
Toronto, Ont. M9W 5B3
Canada
PH: 416-675-3820
FAX: 416-674-5129
Calgary Office
Bristol Babcock, Canada
3812 Edmonton Trail N.E.
Calgary, Alberta T2E 5T6
Canada
PH: 403-265-4808
FAX: 403-233-2914
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
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
RC Rev: 05-Feb-04
Bristol Babcock
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2200
Fax: +1 (860) 945-2213
Website: www.bristolbabcock.com
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
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
United Kingdom
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
Middle East
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
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
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
Asia Pacific
Bristol Babcock, Inc.
PO Box 1987
Bunbury, Western Australia
6231
PH: +61 (0) 8 9791 3654
FAX: +61 (0) 8 9791 3173
Victoria, Australia
PH: +61 (0) 3 9384 2171
FAX: +61 (0) 3 8660 2501
