Remote Automation Solutions Bristol TeleRTU PLUS 3530-25B Owner's Manual

Instruction Manual

CI-3530-25B

Jan., 2007

TeleRTU

™

Plus

Remote Terminal Unit

TeleRTU Plus Model 3530-25B

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

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

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

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

EQUIPMENT APPLICATION WARNING

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

RETURNED EQUIPMENT WARNING

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

ELECTRICAL GROUNDING

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

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

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

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

Bristol Inc.

1100 Buckingham Street, Watertown, CT 06795

Telephone (860) 945-2200

C.

D.

F.

A.

A.

B.

E.

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

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

How to return material for Repair or Exchange

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

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

You can easily obtain a RA number by:

A. FAX

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

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

B. E-MAIL

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

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

C. Mail

Mail the form (GBU 13.01) to

Bristol Inc.

Repair

1100 Buckingham Street

Watertown, CT 06795

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

D. Phone

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

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

Bristol

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

INSTRUMENT OR SYSTEM

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

• Minimize installation, start-up and maintenance costs.

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

• Know your system.

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

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

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

6200.

A Few Words About Bristol Inc.

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

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

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

Getting Additional Information

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

Help Files / Release Notes

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

Contacting Bristol Inc. Directly

Bristol Inc.'s world headquarters are located at 1100 Buckingham Street, Watertown,

Connecticut 06795, U.S.A.

Our main phone numbers are:

(860) 945-2200

(860) 945-2213 (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol Inc.'s Application Support Group can provide telephone support for your technical questions.

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

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

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

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

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

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

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

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

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

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

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

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

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

Visit our Site on the World Wide Web

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

World Wide Web at: www.bristolbabcock.com

Training Courses

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

Contents

Section 1 - INTRODUCTION

Page

1.2.2 TeleRTU CPU Board ................................................................................................ 1-5

1.2.3 Internal Mounting Brackets ....................................................................................... 1-7

1.2.4 Display/Switch Panel Assembly ................................................................................ 1-7

1.2.5 Serial Communications Ports ................................................................................... 1-8

1.2.5.1 BSAP Message Support ........................................................................................... 1-8

1.3 .................................................................................................................. 1-9

1.3.1 Solar Panel Option .................................................................................................... 1-9

1.3.3 Low Power I/O Expansion Board (LPI/O EB) Option .............................................. 1-10

1.3.4 Digital To Relay I/O Option ..................................................................................... 1-11

1.3.5

Low Power Transmitter Interface Board (TIB) Option ............................................. 1-12

1.3.6 Expansion Transmitter Interface Board (ETIB) Option ........................................... 1-13

1.3.7 21V Power Supply Option ....................................................................................... 1-13

1.3.8 Expansion Communications Port RS-232 Board Option ......................................... 1-14

1.3.9 Expansion RS-485 and/or Analog Output Board Option ......................................... 1-15

1.5 MODEL NUMBER ANALYSIS ................................................................................ 1-16

Section 1A - APPLICATION SOFTWARE

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

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

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

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

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

Section 2 - INSTALLATION

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

2.2 MOUNTING THE TeleRTU™ ................................................................................... 2-2

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

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

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

2.2.4.2

JP4 - Security ........................................................................................................... 2-2

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

CI-3530-25B Contents / 0-1

Contents

Page

Section 2 - INSTALLATION (Continued)

2.3.3 Signal Shielding and Grounding ............................................................................... 2-5

2.3.4 Power

2.3.5 Optional Power Distribution Board ............................................................................ 2-6

2.4 WIRING INPUT/OUTPUT SIGNALS ........................................................................ 2-8

2.4.1 .......................................................................................................... 2-9

2.4.2 ....................................................................................................... 2-9

2.4.5.1 RS-232 Network and Local Communications Ports ................................................ 2-12

2.4.5.4 Modem or Radio On Network Port .......................................................................... 2-13

2.5 MOUNTING THE OPTIONAL SOLAR PANEL ....................................................... 2-16

2.5.1 Swivel (Directional Facing) ..................................................................................... 2-16

Tilt

2.6 TeleRTU Plus™ CONFIGURATION ....................................................................... 2-18

2.6.1 Application Software Reference Documents .......................................................... 2-18

2.6.2 Installation & Configuration of Options ................................................................... 2-19

Section 3 - SERVICE

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

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

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

3.3.2 CPU Circuit Board Removal/Replacement ............................................................... 3-4

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

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

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

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

3.4 TROUBLESHOOTING TIPS ................................................................................... 3-10

3.4.1 Battery & Fuse F1 Checks (Processor not running or no power) ........................... 3-10

3.4.3 LCD Display Checks ............................................................................................... 3-11

3.4.4 Field Wiring/Signal Checks ..................................................................................... 3-12

Section 4 - SPECIFICATIONS

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

4.3 CPU BOARD COMMUNICATIONS .......................................................................... 4-1

4.4 CPU BOARD DISCRETE INPUTS ........................................................................... 4-2

4.5 CPU BOARD DISCRETE OUTPUTS ....................................................................... 4-2

4.6 CPU BOARD PULSE INPUTS ................................................................................ 4-2

4.7 CPU BOARD ANALOG INPUTS .............................................................................. 4-3

0-2 / Contents CI-3530-25B

Contents

Page

Section 4 - SPECIFICATIONS (Continued)

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

APPENDICES

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

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

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

Low Power I/O Expansion Board (Replaces Appendix D) ................................PIP-EXPI/OTF

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

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

Digital To Relay I/O Board .................................................................................... Appendix G

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

FreeWave Radio Option For Instruction Manual 3530-25B..................................... Appendix I

21V Power Supply Board Option (DC/DC Converter) ...................................... PIP-353021VS

Low Power Transmitter Interface Board (392950-01-4) .................................... PIP-TIBS3530

Expansion Transmitter Interface Board (392951-01-0) ...................................... PIP-EXPTIBS

Expansion Transmitter Interface Board for 3530-XXX (392960-01-0).............. PIP-EXPTIBTF

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

Expansion RS-485 and/or Analog Output Board for Model 3530-XXX ..........PIP-EXP485/AO

Guidelines for System Grounding ............................................................................... S1400A

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

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

REFERENCED or ASSOCIATED BRISTOL DOCUMENTS

Bristol 9600 bps - PSTN Modem P/N 396039-02-2 Instruction Manual ..................... CI-9600

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

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

REFERENCED OEM MANUALS

MDS 4710A – Remote Data Transceiver (Radio)

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

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

MDS 4710B – Data Transceiver (Radio)

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

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

MDS 9810 – Spread Spectrum Data Transceiver (Radio)

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

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

MDS 9710A Remote Data Transceiver (Radio)

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

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

CI-3530-25B Contents / 0-3

Contents

Page

REFERENCED OEM MANUALS (Continued)

MDS 9710B Data Transceiver (Radio)



FreeWave Radio Spread Spectrum Data Transceiver Model FGRM-501X005

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

0-4 / Contents CI-3530-25B

Section 1

INTRODUCTION

1.1 GENERAL DESCRIPTION

TeleRTU Plus J Model 3530-25B provides 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

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

$ Very low power consumption

$ Two independent serial ports

$ Two line alphanumeric display

$ Two discrete outputs with control capability & Two discrete inputs

$ Four analog inputs

$ Two high speed counter or two pulse inputs

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

1.2 PHYSICAL DESCRIPTION

The TeleRTU Plus J is comprised of the following major components:

$ Enclosure

$ Circuit (CPU) Board

$ Internal mounting brackets

$ Display/Switch Panel Assembly

$ Serial communications ports

$ 12 V 40 Amp. Hour Battery

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

$ Solar Panel option

$ Communications option

$ Power Distribution Board option

$ Low Power I/O Expansion Board option

$ Digital To Relay I/O Board option

$ Expansion Transmitter Interface Board option

$ Expansion Communications Port RS-232 Board option

$ Expansion RS-485 and/or Analog Output Board option

$ Low Power Transmitter Interface Board option

$ 21V Power Supply Board option

TeleRTU Plus™ Introduction / 1-1

1.2.1 Enclosure

The enclosure is a standard Hoffman ® Enclosure. Its external dimensions (excluding the cover latches) are approximately 14.56” high by 12.97” wide by 8.31” deep. An installed

TeleCounter Assembly adds 4.36” to the height. The enclosure consists of two pieces, the body and the Instrument Front Cover. A continuous gasket seals the unit when the Instrument Front Cover is closed. A hinge on the left side (facing the front of the unit) is formed by molded channels on the Instrument Front Cover and body that capture a stainless steel pin. When closed, the Instrument Front Cover is secured by two latches on the enclosures’ right side.

1-2 / Introduction

Figure 1-1 - TeleRTU Plus J

TeleRTU Plus™

TeleRTU Plus™

Figure 1-2 - TeleRTU Plus J with Modem Option

Introduction / 1-3

1-4 / Introduction

Figure 1-3 - TeleRTU Plus J with MDS Radio Option

TeleRTU Plus™

Figure 1-4 - Inside of Instrument Front Cover

1.2.2 TeleRTU CPU Board

The TeleRTU CPU circuit board is mounted horizontally below the battery. It is stood-off from its aluminum mounting bracket by five posts. Screws secure the board to these five mounting posts. The CPU circuit board mounting bracket is mounted to an aluminum bracket, which in-turn is mounted to the bottom of the battery bracket. Two guide rails accommodate installation and removal. Two captive screws secure these brackets to one another.


Figure 1-5 - TeleRTU™ CPU Board

The board is approximately 7.3” tall, 4.6” wide, and 0.7” deep. Both surface mount and through-hole components are located on the component side of the board, and small surface mount components are located on the solder side.

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

1-6 / Introduction TeleRTU Plus™

Connectors and configuration jumpers are located on the top of the board as shown in

Figures 1-5 and 1-6.

Figure 1-6 - Horizontally Mounted CPU Board

1.2.3 Internal Mounting Brackets

A large aluminum backplane bracket attached to the interior rear wall of the enclosure body provides for mounting and support of the steel battery Mounting Bracket and the aluminum Digital To Relay I/O Board Option Mounting Bracket. A steel bracket with a detachable clamping mechanism located near the top of the battery provides for removal or replacement of the battery and is used to clamp the installed battery in place. Aluminum brackets attached to the steel Battery Mounting Bracket provide for the mounting and support of the CPU Board as well as the communications and expansion options. Another bracket attaches to the inside of the Instrument Front cover to support the LCD Display and Switch Panel.

1.2.4 Display/Switch Panel Assembly

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

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

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

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

16 Character LCD Display.

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

When the button is pressed (or a properly configured cable is plugged into the Local Port), the TeleRTU Plus J wakes up from sleep mode and enters calculation mode, where all circuits except the RS-232 transceiver are active. While cycling through the display list, the


calculation interval switches to 1 second. After cycling through the list twice, the calculation interval is restored to the programmed interval and the unit returns to normal operation. Although the RS-232 transceiver is disabled while in calculation mode or sleep mode, the receiver channel dedicated to buffering Receive Data Carrier Detect (RDCD) is always active.

1.2.5 Serial Communications Ports

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

In a BSAP network, the TeleRTU Plus J may only be used as a ‘ Slave Node.

’ As such it is not capable of initiating a BSAP message intended for another node. The TeleRTU Plus J is always an immediate response node.

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

1.2.5.1 BSAP Message Support

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

Poll message

TS/NRT message

Alarm Acknowledge

Alarm Initialization

Peer to Peer

RDB Functions

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

Normal handling.

Normal handling.

Normal handling.

Supports send and poll mode.

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

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

Supports Audit Trial functions, security code functions,

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

PROM link. All subfunctions of these are supported.

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


1.2.6 12V Battery

The 12V Sealed Lead-Acid battery is rated for 40 Amp Hours and is secured by a steel bracket that has a detachable clamp. The battery connects to J2 on the CPU board that is situated just below the battery.

1.2.7 Field Wiring

The TeleRTU supports connection to external devices through its field wiring terminals on the CPU board and the various options. Connections to the following I/O may be provided:

$ Digital Inputs

$ Digital Outputs

$ Pulse Inputs

$ Analog Inputs

$ Analog Output

$ External Communications

$ Relays

1.3 OPTIONS

Options are introduced in sections 1.3.1 through 1.3.9 as follows:

Section 1.3.1 - Solar Panel Option

Section 1.3.2 - Comm. Options (see appropriate modem manual or Appendix H/I for Radio)

Section 1.3.3 - Low Power I/O Expansion Board (LPI/OEB) Option (see PIP-EXPI/OTF)

Section 1.3.4 - Digital To Relay I/O Option (see Appendix G)

Section 1.3.5 - Low Power Transmitter Intf. Board (LPTIB) Option (see PIP-TIBS3530)

Section 1.3.6 - Exp. Transmitter Intf. (ETIB) Option (see PIP-EXPTIBS or PIP-EXPTIBTF)

Section 1.3.7 - 21V Power Supply (DC/DC Converter) Option (see PIP-353021VS)

Section 1.3.8 - Expansion Comm. Port RS-232 Board Option (see PIP-EXP232TF)

Section 1.3.9 - Expansion RS-485 and/or Analog Output Bd. Option (see PIP-EXP485/AO)

The following options will require the use an optional Power Distribution Board (see

Section 2.3.5):

$ 21V Power Supply (DC/DC Converter) $ Low Power Transmitter Interface Board

$ Digital To Relay I/O Board $ Modem Assembly

1.3.1 Solar Panel Option

A 12V 10 watt, 30 watt or 40 watt solar panel can be used with the rechargeable battery.

Solar panels can be mounted to a 2" to 2.375” pipe. The solar panel mounts on a bracket that offers adjustable swivel and fixed tilt angles. Solar panel wires enter the TeleFlow through a liquid tight conduit fitting on the bottom of the enclosure. Internally the solar panel wires connect to the rechargeable battery via the CPU board connector J1’s PWR

(red wire) and GND (black wire) terminals.

1.3.2 Communications Option

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

TeleFlow Plus enclosure. The modem option will typically connect to the rechargeable bat-


tery via CPU Board connectors J2-1 (PWR 1) and J2-8 (GND) or via the optional Power

Distribution Board connectors TB6-1 (Modem+) and TB6-2 (Modem GND). The radio is supplied power from the CPU Board connector J4’s AUX PWR and GND terminals. The modem’s communication lines are interfaced via a wiring harness connected to CPU Board

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

J7, J8 and J10. The FreeWave radio’s communication lines are interfaced between the radio’s 10-pin connector (J1) and CPU Board connector J8.

1.3.3 Low Power I/O Expansion Board (LPI/OEB) Option

The Low Power I/O Expansion Board (LPI/OEB) (see Figure 1-7) measures approximately

4” by 7.25” and mounts piggy-back to the TeleRTU CPU Board. Removable card-edge connectors are provided to accommodate field wiring. The LPI/OEB will only operate with a

Revision 3 or higher TeleRTU CPU Board.

The Low Power I/O Expansion Board provides the following additional I/O capabilities to the TeleRTU Plus:

$ 8 Discrete I/O

All 8 DI/O function as both inputs and outputs. Field terminals for each DI/O are I/O and GND. Each Discrete Input will accept signals from 0 to 16 VDC. The Discrete

Outputs utilize open drain FETs with a maximum working voltage of 16 VDC and a minimum load of 100 mA. DI/Os are not isolated.

$ 4 Analog Inputs (2 support current loop)

Two single-ended Analog Inputs are available for 4 to 20 mA or 1 to 5 V signal operation (Jumper Configurable) and two additional single-ended Analog Inputs are available for 1 to 5 V signal operation only. The two 4-20 mA Inputs will support externally powered transmitters but internally powered 4-20 mA transmitters will require an external power supply. All four channels support low power voltage output transmitters such as Rosemount and Honeywell. Resolution is 12 bits (1.42 mV) and combined error (including linearity, hysteresis and temperature effects) is £ ± 0.2%.

Each Analog Input Channel includes field wiring terminals for signal, transmitter power (+9.5V), and ground.

$ 1 Analog Output

The Analog Output can be configured for 4 to 20 mA or 1 to 5 V operation (Jumper

Configurable). Resolution is 12 bits and combined error including linearity, hysteresis and temperature effects is £ ± 0.2% after calibration.

$ 1 High Speed Counter Input

The High Speed Counter will accept pulses (with an input range from 0 to 16 VDC and up to 10KHz) from CMOS or TTL sources, including transistors, FETs, mechanical relays, or other signaling devices.

$ 1 RS-232 or RS-485 Asynchronous Serial Communication Port

The Asynchronous Serial Port will be either RS-232 or RS-485 compatible (Jumper

Configurable) and will operate at programmable speeds up to 19.2 Kbps.


Figure 1-7 - TeleFlow Plus Low Power I/O Expansion Board (LPI/OEB)

1.3.4 Digital To Relay I/O Option

The Digital To Relay I/O Board (see Figure 1-8) converts one or both TeleFlow Discrete

Output Signals from open drain MOSFET levels to Form C relay output signal using Solid

State Relay (SSR) logic.

Each TeleFlow Discrete Output can be converted to Form C relay output signals which can be configured for opposite or identical conditions, i.e., both Normally Open (NO) or

Normally Closed (NC) or one Normally Open with the other normally Closed.


Figure 1-8 - Digital To Relay I/O Board

1.3.5 Low Power Transmitter Interface Board (TIB) Option

Low Power Transmitter Interface Boards allow up to two (2) Bristol Babcock, Series 3508C

Transmitters to communicate with an ACCOL loaded host TeleFlow 3530-20B Electronic

Gas Measurement Computer (EGMC) or 3530-25B TeleRTU Plus. The EGMC/RTU polls and stores data from each transmitter and communicates with the network. Two LEDS on the LPTI Board [CD (DS1) & RTS (DS2)] indicate the communication status.

The LPTI Board is housed in the TeleRTU Plus enclosure and is interfaced to a TeleFlow

I/O Expansion Board. LPTI Boards are powered by a 12V power supply or battery. The

LPTI Board (Figure 1) is wired to the TeleFlow I/O Expansion Board connector (TB5) and is mounted with Snap Track (holder) and Mounting Bracket.

Figure 1-9 - Low Power Transmitter Interface Board


1.3.6 Expansion Transmitter Interface Board (ETIB) Option

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

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

Electronic Gas Measurement Computer (EGMC) (3530-20B) or TeleRTU Plus (3530-25B).

The EGMC/RTU polls and stores data from each transmitter and communicates with the network. Two LEDS on the ETIB Board [CD (DS1) & RTS (DS2)] indicate the communication status.

The ETIB Board is housed in either the standard TeleFlow Plus or TeleRTU Plus enclosure and is interfaced to a TeleFlow/TeleRTU CPU Board via the CPU Board’s Expansion

Connector. Power from and communication with the host CPU Board is supplied through the Expansion Connector.

Figure 1-10 - Expansion Transmitter Interface Board

1.3.7 21V Power Supply Option

The 21V Power Supply is a continuous mode boost switching type power supply. It is based upon a low power, low noise circuit that produces 21 Volts from a 12 Volt input. Power shutdown is not an option with this unit since it employs a Boost circuit; therefore, the 21V

Power Supply must be powered continuously.

The 21V Power Supply is mainly used in conjunction with Temperature and Pressure

Transmitters which require a higher than +12V but lower than 21.4V ( ± .8V) input supply to operate.


Figure 1-11 - 21V Power Supply (DC/DC Converter) Board

Figure 1-12 – Expansion Communications Port RS-232 Board

1.3.8 Expansion Communications Port RS-232 Board Option

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

232 asynchronous serial communications port to ACCOL-based 3530-XXX models. In addition to assignments of the resident (host) CPU’s “local” and “network” RS-232 ports,


any model 3530-XXX unit equipped with an EXPCOM232 Board can establish RS-232 communications with an external device. An EXPCOM232 Board plugs into the Expansion

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

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

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

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

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

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

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

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

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

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

EXP485/AO Board.

Figure 1-13 - Expansion RS-485 and/or Analog Output Board


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

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

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

XXX.

1.4 ENVIRONMENT

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

Table 1-1 - ENVIRONMENTAL SPECIFICATIONS

TOPIC

Operating Temp. Range

Operating Humidity Range

Transient Susceptibility

Vibration Effect

ESD Susceptibility

EMI Susceptibility

Hazardous Locations

SPECIFICATION

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

15% to 90% RH Noncondensing

Field connected circuits meet the requirements of ANSI/IEEE

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

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

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

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

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

1.5 MODEL NUMBER ANALYSIS

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

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

Table 1-2.


Table 1-2 - MODEL NUMBER BREAKDOWN

Sample Model Number -

3530-25B-AB-CD-EFG-HJKMN ß Table Reference

3530-25B-01-02-110-14110 ß Model Number

A B = PACKAGING

0 1 BASIC PARTS

0 2 SPECIAL

C D = APPLICATION PROGRAM*

H = 21 VDC POWER SUPPLY

0 NONE

1 WITH 21 VDC POWER SUPPLY 1

K = RELAY BOARD

0 2 ACCOL

0 9 CUSTOM PROGRAM

E G = POWER SYSTEM

(* = 0 or 1)

0 NONE

1 WITH RELAY BOARD 1

J = EXPANSION BOARDS

0 * EXTERNAL

1 * 12V, 40AH LEAD ACID BATTERY

10W, SOLAR PANEL SYSTEM

2 0 12V, 40AH LEAD ACID BATTERY


3 0 12V, 40AH LEAD ACID BATTERY


F = COMMUNICATION

0 NONE

2 I/O EXPANSION BOARD

4 EXPANSION TIB

5 EXPANSION RS-232

6 EXPANSION RS-485

7

8

I/O EXPANSION BD; DI/DO & COMM.

I/O EXPANSION BD; DI/DO

F H K M N = POWER DIST. BOARD

(# = any No.)

0 RS-232

1 RADIO

2 MODEM

# # # 0 # NONE

# # # 1 # WITH PWR. DIST. BOARD 1

2 1 # 1 # WITH PWR. DIST. BOARD 1

2 # 1 1 # WITH PWR. DIST. BOARD 1

2 # # 1 1 WITH PWR. DIST. BOARD 1

# 1 1 1 # WITH PWR. DIST. BOARD 1

# 1 # 1 1 WITH PWR. DIST. BOARD 1

# # 1 1 1 WITH PWR. DIST. BOARD 1

1

G = CERTIFICATION J N = LOW POWER TIB

(# = any No.) (** = 2 or 5)

0 NONE

1 CLASS 1, DIV 2 (NON-INCENDIVE) # 0 NONE

** 1 WITH LOW POWER TIB 1

Mounting Kit 621475-01-7 is required. Two boards may be mounted per kit.

Proper kit quantity is determined by the configuration based on selections made.

Note: Table 1-2 is only provided for product identity and not for sales ordering purposes. Field changeable items may not match the unit’s Model

Number as shipped from the factory.


BLANK PAGE

Section 1A

APPLICATION SOFTWARE

3530-15B

3530-20B

3530-20B

3530-20B

3530-25B

3530-25B

3530-35B

3530-35B

3530-45B

3530-45B

3530-50B

3530-50B

3530-50B

3530-55B

3530-55B

1A.1 CATEGORIES OF APPLICATION SOFTWARE

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

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

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

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

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

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

TeleRecorder program loads.

Table 1A-1

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

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

Model #

3530-10B

3530-10B

3530-10B

Program Load

Fixed ‘ C ’ Program

Standard BBI ACCOL Load

User-created ACCOL load




Standard BBI ACCOL Load or 2-Run ACCOL Load





TeleRecorder ACCOL load



TeleCorrector ACCOL load


TeleRecorder ACCOL load


Operator Interface/Configuration

TeleFlow Menu System (TMS)

TMS or UOI Menu System Interface.

- ACCOL Workbench is used to create the load.

- Open BSI Utilities is used to download and communicate.

- User created/modified menus via UOI.

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








UOI Menu System Interface.





UOI Menu System Interface.


TeleFlow 3530-XXX Application Software / 1A-1

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

TeleFlow Corrector, TeleRTU and TeleRecorder series:

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

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

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

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

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

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

1A.2 ACCOL TOOLS SOFTWARE

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

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

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

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

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

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

(document # D4044).

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

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

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

1A2 / Application Software TeleFlow 3530-XXX

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

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

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

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

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

BSI Utilities software, discussed later in this chapter).

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

1A.3 SUPERVISORY SOFTWARE

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


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

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

Among the types of supervisory software currently supported are:

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

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

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

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

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

1A.4 OPEN BSI UTILITIES SOFTWARE

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

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

Corrector, TeleRTU and TeleRecorder units in the network

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

Corrector, TeleRTU and TeleRecorder units

$ Monitor and control Open BSI communications

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

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


Figure 1A-2 - Open BSI Interface Diagram

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

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

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

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

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

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


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

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

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

Manual (document # D5083) for details.

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

1A.5 SYSTEM APPLICATIONS

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

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

1A.5.1 Stand-Alone Unit

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

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

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

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

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

Figure 1A-3 - Basic Stand-Alone Application


1A.5.2 Local Area Network (LAN)

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

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

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

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

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

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

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

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

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

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


1A8 / Application Software

Figure 1A-4 - Local Area Network

TeleFlow 3530-XXX

1A.5.3 Wide Area Network (WAN)

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

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

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

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

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

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

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


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.


Section 2

INSTALLATION

2.1 INSTALLATION IN HAZARDOUS AREAS

A TeleRTU Plus J is furnished in a housing designed to meet the NEMA Type 3 specifications and to operate in a Class I, Division 2, Groups C & D environment with a nonincendive rating (see Appendix A).

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

TeleRTU Plus ™ Installation / 2-1

2.2 MOUNTING THE TeleRTU

J

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

Instrument Front Cover (door - hinged on left side) can be opened for wiring and service.

Make certain that the LCD display and sensor switch is visible and accessible to the on-site operator. There should also be clearance for the optional Solar Panel (if required). The basic unit measures 14.56" in height by 12.97" in width by 8.31" in depth

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

2.2.1 Temperature Limits

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

2.2.2 Vibration Limits

Check the mounting pipe or wall for mechanical vibration. Make sure that the TeleRTU

Plus is not exposed to a level of vibration that exceeds those given in the specifications. The

TeleRTU Plus limits are 2g for 15-150 Hz & 1g for 150-2000 Hz.

2.2.3 Opening The Instrument Front Cover

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

TeleRTU J CPU Board and on the various options. The Instrument Front Cover is hinged on the left side and is secured on the right side by upper and lower latches.

2.2.4 CPU Board Configuration

(see Figure 2-2)

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

2.2.4.1 JP3 - Battery Backup Enable

When JP3 is open, the battery is disabled. When JP3 is installed, the battery maintains the contents of the RAM and the Real Time Clock while power is less than 3.6 VDC. When main power is connected and is greater than 3.6VDC, no current will be drawn from the backup battery regardless of the state of JP3.

2.2.4.2 JP4 - Security (Manufacturing Tests Only)

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

2-2 / Installation TeleRTU Plus ™

2.2.4.3 JP5 - Manual Reset

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

TeleRTU Plus ™

Figure 2-2 - TeleRTU J CPU Board

Installation / 2-3

2.3 WIRING NOTES

The field wiring terminals on the TeleRTU J CPU Board are accessed by opening the

Instrument Front Cover. The CPU Board is mounted horizontally (on edge) below the battery such that the wiring connectors on the board's card edge are facing the front of the unit. Note: Exercise care when installing a conduit fitting or field wiring to prevent damage to the CPU Board and/or other system components.

2.3.1 Wire Routing

Wiring will enter the TeleRTU Plus J through holes in the bottom of the case. Up to seven holes may be provided in the bottom of the case (in addition to the center hole that is plugged). The purpose of each of these holes (see Figure 2-3) is provided as follows:

$ (1) - A .75” hole is provided to accommodate the power input wires from the optional Solar

Panel, all DI/O, the Auxiliary Analog Input and the Pulse Input Wiring. This hole accommodates a .75” Liquid Tight Nonmetallic Conduit Fitting and is plugged when the unit is factory shipped.

$ (2) A .437" hole accommodates the local port jack.

$ (3) A .5" hole is plugged.

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

$ (5) A .5" hole is accommodates the Solar Panel wiring. When the optional Solar Panel is not installed, this hole should be plugged.

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

$ (7) Solderless Ground Lug

2-4 / Installation

Figure 2-3 - TeleRTU Plus (Bottom) Wiring Holes

TeleRTU Plus ™

2.3.2 Terminal Connections

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

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

2.3.3 Signal Shielding and Grounding

TeleRTU Plus units are provided with a Ground Lug that is situated on the bottom of the enclosure. Only units equipped with a modem MUST have the Ground Lug connected to a known good earth ground using wire no larger than #4 AWG in size. A cabinet ground cable situated inside the enclosure provides the interconnection between the modem’s protective surge circuitry and the unit’s Ground Lug. The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize signal errors caused by electromagnetic interference (EMI), radio frequency interference (RFI) and transients (see Supplement S1400A).

2.3.4 Power Connections

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

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

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

$ J1 - Solar Panel Power Jack

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

J1 Pin

#

1

2

J1 Pin

Name

PWR

GND

Connection

SP Red Wire

SP Black Wire

Table 2-1 - Solar Panel Power Jack J1

$ J2 - Primary Power Jack

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

J2 Pin

#

1

2

J2 Pin

Name

Connection

PWR1 Red Wire Battery (+), Modem (TB4+) or Relay Bd.

GND Blk. Wire Battery (-), Modem (TB4-) or Relay Bd.

Table 2-2 - Primary Power Plug J2


$ J3 - Secondary Power Jack

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

J3 Pin

#

1

2

J3 Pin

Name

Connection

PWR2 Battery (+)

GND Battery (-)

Table 2-3 - Secondary Power Jack J3

$ J4 - Auxiliary Power Output Jack

The auxiliary power output connector can be used to supply power to a communications device such as a Radio or Modem Option. This jack acts as an output supply that originates at the Primary Power Source. This output is not fused, so a fuse should be installed elsewhere in the circuitry. This fuse should not exceed a 2.5 Amp rating.

Connection to a load is accommodated as follows:

J4 Pin

#

1

2

J4 Pin

Name

Connection

AUX PWR +12 VDC

GND Ground/return

Table 2-4 - Auxiliary Power Output Jack J4

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

If you want the modem powered continuously, and

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

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

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

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

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

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

Reference Manual , document# D4044).

2.3.5 Optional Power Distribution Board

Because of power distribution restrictions (CPU Board connector wiring capacity), power is routed through a Power Distribution Board when an option (other than the I/O Expansion

Board, Expansion TIB or a Radio) is installed (see Figures 2-4, 2-5).


Figure 2-4 - Power Distribution Board

Figure 2-5 - Power Distribution Board Schematic/Wiring Diagram

Power Distribution Boards (Relay Boards, 21V Power Supply Boards, Low Power TIB

Boards and Modems) are mounted to the TeleRTU in question using a Snap Track and Dual

PCB Mounting Bracket (see Figure 2-6).


Figure 2-6 - Power Distribution Board and Other Options

Snap Track Mounting Diagram

2.4 WIRING INPUT/OUTPUT SIGNALS

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

Outputs, four (4) Analog Inputs and two (2) 0-16V Pulse Input. Additionally, terminations are provided for the Local and Network Communication Ports. The connections for each type

I/O and the Communication Ports are described in sections 2.4.1 through 2.4.5.4.


Figure 2-7 - Discrete Input Wired to TeleRTU J

TeleRTU Plus ™

2.4.1 Discrete Inputs

(See Figure 2-7)

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

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

J5 Pin Signal

1 DIN0

2 GND

Function

Discrete Input 0

Ground

Table 2-5 - Discrete Input Connections to J5

J6 Pin Signal

1 DIN1

2 GND

Function

Discrete Input 1

Ground

Table 2-6 - Discrete Input Connections to J6

2.4.2 Discrete Outputs

(See Figure 2-8)

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

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

TeleRTU Plus ™

Figure 2-8 - Discrete Output Wired to TeleRTU J

J5 Pin

2

3

Signal

GND

Function

Ground

DOUT 0 Discrete Output 0

Table 2-7 - Discrete Output Connections to J5


J6 Pin

2

3

Signal

GND

Function

Ground

DOUT 1 Discrete Output 1

Table 2-8 - Discrete Output Connections to J6

2.4.3 Pulse Inputs

(See Figure 2-9)

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

(see Figure 2-9).

Figure 2-9 - Pulse Input Wired to TeleRTU

J9 Pin

1

2

3

4

Signal

GND

Function

Ground

PULSE1 Pulse Input 1

GND Ground

PULSE2 Pulse Input 2

Table 2-9 - Pulse Input Connections to J9

2.4.4 Analog Inputs

(See Figure 2-10)

The 1 to 5 V Auxiliary Analog Inputs AIN1 through AIN4 can be supplied source power

(nominally +9.5V) to J10 Pin 2, J11 Pin 2, J12 Pin 2 or J13 Pin 2 (Excitation), respectively, through the CPU Board’s Transmitter Excitation Regulator which has a 20mA current limit. The resolution of the analog input is nominally ±15 Bits 186 m V.


TeleRTU Plus ™

Figure 2-10 - Analog Input Wired to TeleRTU

J10 Pin

1

2

3

Signal

AIN1

EXC1

GND

Function

Analog Input 1

Excitation

Ground

Table 2-10 - Analog Input Connections to J10

J11 Pin

1

2

3

Signal

AIN2

EXC2

GND

Function

Analog Input 2

Excitation

Ground


J12 Pin

1

2

3

Signal

AIN3

EXC3

GND

Function

Analog Input 3

Excitation

Ground



J13 Pin

1

2

3

Signal

AIN4

EXC4

GND

Function

Analog Input 4

Excitation

Ground


2.4.5 Communication Ports

2.4.5.1 RS-232 Network and Local Communications Ports

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

Figure 2-11 - PC Connected to TeleRTU J Local Port

2.4.5.2 Local Port

D Conn. Pin #

& Wire Color

5 (Black)

3 (Red)

2 (White)

N/A

VII

Plug Pin #

6

7

2

1*

J7 Pin #

& Wire Color

1 (Black)

3 (White)

2 (Red)

4 (Green)

RTU Signal

Name

GND

LRXD

LTXD

Wake Up

N/A 4* 1 (Brown) GND

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

Wiring Harness. Pins 7 & 8 of the D-Type Connector are shorted together.

Table 2-14 - Local Port/PC Interconnect Cable Wiring


2.4.5.3 Network Port

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

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

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

CPU Pin

#

J7-4

J8-1

J8-2

J8-3

J8-4

J8-5

J8-6

Name

Modem D-Conn.

# & Wire Color

WAKEUP N/A

GND 5 (Green)

RDCD

RDTR

1 (Gray)

4 (Yellow)

RCTS

RRTS

RRXD

7 (Violet)*

7 (Orange)

2 (Blue)

Radio Conn. # &

Wire Color

MDS/FreeWave

6/N/A (Yellow)

7/6 (Black)

8/8 (Green)

N/A

5/10 (Brown)

4/9 (Blue)

3/7 (White)

TeleRTU Plus

Function

Wake Up

Ground

Data Carrier Detect Input

Data Term. Ready Output

Clear To Send Input

Request To Send Output

Receive Data Input

J8-7

J10-1

RTXD

AIN1

3 (Brown)

N/A

2/5 (Red)

21 (Orange)

Transmit Data Output

Analog Input 1

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

CPU board connector J8-5 (RRTS).

Table 2-15 - Network Port Connections to the CPU Board

2.4.5.4 Modem or Radio On Network Port

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

Table 2-15 above. Table 2-16 provides the power interconnects required for optional modem or radio usage. Table 2-16 also provides the 2-wire phone connections associated with the

BBI PSTN modem.

TeleRTU

Conn.

& Sig. Name

J2-1 (PWR1)

J2-2 (GND)

-

-

Radio

Conn.

& Sig. Name

-

-

Modem

396039-02-2 Conn.

& Sig. Name

J4-1 (AUX PWR) 13.8V (+Pwr.) TB4-2 (EXTVDC)

J4-2 (GND)

J4-2 (GND) -

-

13.8V (-Pwr.) TB4-1 (GND)

TB1-1 (T/R)

TB1-2 (T/R)

Modem

400000-01-6 Conn.

& Sig. Name

-

-

TB4-1 (EXTVDC)

TB4-2 (GND)

J1-3 (T/R-1)

J1-4 (T/R-2)

Port

Usage

Power (+)

Pwr. Gnd.

Mod. Power (+)

Pwr. Gnd.

Phone Line

Phone Line

Table 2-16 - Wire Listing for Modem & Radio Power Connections

Illustrations of a radio and a modem equipped TeleRTU Plus J are provided in Figures 2-12 and 2-13 respectively. The option in question is secured to a bracket that accommodates its installation or removal. The option slides easily into or out of the horizontal guide rails on the fixed Option Mounting Bracket, which in turn is attached to the left side of the Battery

Mounting Bracket.



Figure 2-12 - TeleRTU Plus with MDS Radio Installed

TeleRTU Plus ™

TeleRTU Plus ™

Figure 2-13 - TeleRTU Plus with Modem Installed


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

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

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

2.5 MOUNTING THE OPTIONAL SOLAR PANEL

The Solar Panel Systems are to be mounted to a 2” to 2-3/8” pipe as illustrated in Figures 2-

14, 2-15 & 2-16. The Muffler (Pipe) Clamps are secured via four 1/4-20 nuts and washers.

2.5.1 Swivel (Directional Facing)

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

2.5.2 Tilt Angle

The 10 Watt Solar Panel Mounting Bracket provided by Bristol Babcock is designed to mount the 10 Watt Solar Panel at a fixed 45° ( ± 2 ° ) tilt angle (see Figure 2-14). The 30 Watt and 40 Watt Solar Panel Systems (Figures 2-15 & 1-16 respectively) have adjustable tilt angles.

Figure 2-14 - 10 Watt Solar Panel System Mounting Diagram



Table 2-17 shows the angle (from horizontal) at which the Solar Panel should be installed in order to maximize annual energy output. At most latitudes, performance can be improved by less of an angle during the summer and more of an angle during the winter.

LATITUDE INSTALLATION ANGLE

0-4° 10° from Horizontal

5-20°

21-45°

Add 5° to the Local Latitude


46-65°

66-75°


80° from Horizontal

Table 2-17 - Solar Panel Tilt Angle for 30 Watt & 40 Watt Solar Panels



2.6 TeleRTU Plus

J

CONFIGURATION

To configure the TeleRTU Plus J follow the steps listed below:

1. Install appropriate I/O wiring to the CPU Board’s removable terminal blocks. Install the options field wiring to the appropriate removable terminal blocks (see Section

2.3, 2.3.1 through 2.3.5, 2.4, and 2.4.1 through 2.4.4).

2. Configure the Jumpers on the CPU Board (see Sections 2.2.4 through 2.2.4.3).

3. Connect DC Power to TeleRTU CPU Board (12 VDC Battery connected to P2 should be plugged into J2 on the CPU Board).

4. Connect the Local Port of the TeleRTU Plus™ to a PEI, apply power and download the ACCOL Load.

5. After receiving the ACCOL Load, the TeleRTU J should be performing its on line operation.

2.6.1 Application Software Reference Documents

Categories of application software are discussed in Chapter 1A.

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


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

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

D5081 Open BSI Utilities Manual - for information on setting up communications between the

PC and the BBI controller network

D5082 Open BSI Scheduler Manual - for information on setting up scheduled data collections

D5083 Open BSI Collection & Export Utilities Manual - for information on using the Open BSI

Data Collector

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

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

2.6.2 Installation & Configuration of Options

For information on removal/replacement and service of the various options see Table 2-18.

Option

Low Power I/O Expansion Board

Low Power Transmitter Intf. Bd.

Digital To Relay I/O Board

Document

PIP-EXPI/OTF

PIP-TIBS3530

Appendix G -

Notes

for 392950-01-4

MDS Radio

FreeWave Radio

Appendix H

Appendix I

21V Pwr. Supply (DC/DC Converter) PIP-353021VS

Expansion Transmitter Intf. Bd.

PIP-EXPTIBS

Expansion Transmitter Intf. Bd.

Expansion Comm. Port RS-232 Bd.

Expansion RS-485 and/or AO Bd.

9600 bps PSTN Modem

9600 bps PSTN Modem

Isolated RS-485 Interface Bd.

PIP-EXPTIBTF

PIP-EXP232TF

PIP-EXP485/AO -

CI-9600

CI-9600TF

PIP-ISORS485

-

-

-

for 392951-01-0 for 392960-01-0 for 396039-02-2 for 400000-01-6

Externally Mounted on DIN Rail

Table 2-18 - Options Installation/Configuration Reference


BLANK PAGE

Section 3

SERVICE

3.1 INTRODUCTION

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

Isolation information for the TeleRTU J Plus model 3530-25B.

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

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

Figure 3-1 - Local Port Communications Setup

3.2 ACCESSING PARTS FOR TESTING OR REPLACEMENT

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

If these procedures cannot be performed properly, the unit should be returned to Bristol

Babcock for factory evaluation and repairs.

TeleRTU Plus J Service / 3-1

Warning

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

Caution

PC board components can be damaged by electrostatic discharges (ESD) during disassembly, reassembly, and test procedures. Use grounded wrist straps and surface pads when working near or handling the Main Circuit Board. See attached instruction supplement S14006 for proper grounding and handling techniques.

3.3 COMPONENT REMOVAL & REPLACEMENT PROCEDURES

The following major items are covered in this section:

$ Lead Acid Battery

$ CPU Board

$ On Board Fuse

$ On Board Battery

$ LCD Display/Switch Panel Assembly

The following options are covered in appendices:

$ Optional Low Power I/O Expansion Board (see PIP-EXPI/OTF)

$ Optional Low Transmitter Interface Board (see PIP-TIBS3530)

$ Optional Digital To Relay I/O Board (see Appendix G)

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

$ Optional 21V Power Supply Board (see PIP-353021VS)

$ Optional Expansion Transmitter Interface Board (see PIP-EXPTIBS for 392951-01-0 or PIP-EXPTIBTF for 392960-01-0)

$ Optional Expansion Comm. Port RS-232 Board (see PIP-EXP232TF)

$ Optional Expansion RS-485 and Analog Output Board (see PIP-EXP485/AO)

3.3.1 Lead Acid Battery Removal/Replacement Procedure

(see Figure 3-2)

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

2. Open the Instrument Front Cover.

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

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

4. Loosen the two 11/32” nuts that secure the Battery Clamp Bracket to the Battery

Bracket and carefully remove the Battery Clamp Bracket.

3-2 / Service TeleRTU Plus J

5. Remove the battery leads (wires) from the battery post and then carefully raise and remove the battery.

6. To replace the battery:

Follow steps 3 through 5 in reverse order, replacing rather than removing the item in question. Make sure that the battery is clamped in place by the Battery Clamp Bracket.

Close and secure the Instrument Front Cover.

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


3.3.2 CPU Circuit Board Removal/Replacement

(see Figure 3-3)

Note:

The CPU Board is not to be removed under any circumstances unless the TeleFlow has been moved to an ESD safe area (see ESDS Manual S14006). The CPU Board should typically only be removed to replace the on board Lithium Battery or Fuse

F1 or to install the optional Expansion Board.


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

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

3. Remove all other harnesses from the CPU Board’s front edge connectors, i.e., P1 and P3 through P13. If an optional I/O Expansion Board is installed, remove the I/O wiring connectors from its front edge

4. Remove the two screws that secure the CPU Board’s Sliding Mounting Bracket to the

Fixed Bracket on the bottom of the Battery Bracket. Carefully slide the CPU Board

(and optional I/O Expansion Board if present) toward the front of the unit and remove harness connections from J14 (Front Panel Switch), J17 (Display Module)., J15

(TeleCounter) and J16 (Wakeup Switch).

Note:

Exercise extreme care to avoid damage to surface mounted components.

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

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

Wiring Harnesses, etc. Note: This operation should only be performed in an ESD safe work area. The optional Expansion Board can now be removed (5 screws) for direct replacement or the CPU Board, CPU Board Battery (see Section 3.3.4) or CPU

Board Fuse (F1) (see Section 3.3.3) can be replaced.

If you are replacing the CPU Board and an optional Expansion Board is present, remove the 5 screws that secure the Expansion Board to its 5 standoffs and then


remove the 5 standoffs that secure the CPU Board to its Sliding Bracket. If, however; the expansion option is not present, simply remove the 5 screws that secure the CPU

Board to its mounting standoffs.

7. To Replace the CPU Board:

Follow steps 2 through 6 in reverse order, replacing rather than removing the item in question.

8. Close and latch the Instrument Front Cover.

3.3.3 Removal/Replacement of the On Board Fuse F1

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


2. Follow steps 2 through 6 of section 3.3.2.

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

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

5. To replace the CPU Board (with Expansion Board if present) Follow steps 2 through 6 of Section 3.3.2 in reverse order, replacing rather than removing the item in question.

6. Close and latch the Instrument Front Cover.

3.3.4 Removal/Replacement of the On Board Battery

Note:

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

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

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


2. Remove the CPU Board (see Section 3.3.2).

3. If it is desired to save the contents of RAM, it will be necessary to install the Main

Battery Power Supply at J2 prior to removal of the Lithium Battery.

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

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

6. Disconnect the Main Battery Power Supply from J2.


7. Follow steps 2 through 6 of Section 3.3.2 in reverse order, replacing rather than removing the item in question.

3.3.5 Removal/Replacement of the Display/Switch Panel Assembly


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

3. Remove all other harnesses from the CPU Board’s front edge connectors. If an optional

I/O Expansion Board is installed, remove the I/O wiring connectors from its front edge



(and optional I/O Expansion Board if present) toward the front of the unit and remove harness connections from J17 (Display Module) and J16 (Wakeup) at the rear of the board. Note: The following connectors do not require removal from the CPU Board, J15

(TeleCounter) and J14 (Front Panel).

Note:

Exercise extreme care to avoid damage to surface mounted components.

5. Carefully remove the cable assembly associated with the LCD Display/Switch Panel

Assembly’s switch. This will require opening the three (3) Flat Cable Mount clamps (2 on the door and 1 on the Fabricated Panel within the enclosure).

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

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

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

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

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

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

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

9. To replace the LCD Display/Switch Panel assembly:

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


Figure 3-4 - Inside View of Instrument Front Cover

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

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

Cable so that it is aligned with the two Flat Cable Mounts (clamps) on the inside of the door.


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

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

Cable Mounts on the inside of the door.

- Close the 2 Flat Cable Mounts on the inside of the door.

- Install the Switch Panel cable connector into connector J17 on the CPU Board. Note:

The cable’s white conductor should be adjacent to J17 pin 1.

- Close the Flat Cable Mount on the Fabricated Panel to capture the Display/Switch

Panel Cables.

- Install the Wakeup cable connector to connector J16 on the CPU Board. Note: This cable can be plugged in either way, i.e., it is not polarity sensitive. Close the 2 Flat

Cable Mounts on the inside of the door.

10. Slide the CPU Board via its Sliding Mounting Bracket into the Fixed Bracket on the bottom of the Battery Bracket. Replace the 2 screws which secure these Sliding

Mounting Bracket to the Fixed Bracket.

11. Carefully replace all connectors to the front edge of the optional Expansion Board (if present) and then to the front edge of the CPU Board (replacing Battery Power Connector P2 last).

12.

Close and secure the Door.

3.3.6 Removal/Replacement of the Modem or Radio Options

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

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

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

3.4 TROUBLESHOOTING TIPS

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

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

The CPU Board requires a Supply Voltage of 5.4 to 16 (VDC) for normal operation. PWR1

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

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

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

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

Board.


PIN #

J4-1

J4-2

J3-1

J3-2

J2-1

J2-2

J1-1

J1-2

PIN

NAME

AUX PWR

GND

PWR 2

GND

PWR 1

GND

PWR

GND

CONNECTION

+5 to +16 (VDC)

Ground/Return

Battery +

Battery -

Battery +_

Battery -

Solar Panel +

Solar Panel -

PURPOSE

Auxiliary Power Output

Auxiliary Power Output

Secondary Power Input

Secondary Power Input

Primary Power Input

Primary Power Input

Solar Power Input

Solar Power Input

Table 3-2 - Power Plugs J6, J7 & J8

3.4.2 LED Checks:

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

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

Flash 5/Sec. = Communications or Calculation Mode.

Short Flash 1/Sec. = Sleep Mode.

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

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

$ These LEDs flash alternately during download to the FLASH PROM.

3.4.3 LCD Display Checks

On initial system startup, the LCD will indicate that a warm or cold start is in progress. In the case of a cold start (for new units received from the factory), the LCD Display will prompt the user as follows:

AWAITING ACCOL DOWNLOAD

The user must download an ACCOL load to continue. The display will then scroll through its list twice. Verify that the LCD displays the fol-lowing messages:

1. Date & Time

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

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

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

4. TeleFlow Version X.X

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

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

J3 and the Green LED (D27).

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

Board and the Display Board.


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

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

3.4.4 Field Wiring/Signal Checks

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

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

Connectors (see Table 3-3). For field wiring associated with the Digital to Relay I/O Board see Appendix G. For field wiring associated with the Low Power I/O Expansion Board, the

Low Power TIB, the 21V Power Supply, the Expansion TIB, the Expansion Comm Port RS-

232 Board or the Expansion RS-485 and/or Analog Output Board see the appropriate

Product Information Packages

PIN# Signal

J5-1 DIN 0

J5-2 GND

J5-3 DOUT 0

J6-1 DIN 1

J6-2 GND

J6-3 DOUT 1

J7-1 GND

J7-2 LTXD

J7-3 LRXD

Function

Discrete Input 0

Ground

Discrete Output 0

Discrete Input 1

Ground

Discrete Output 1

Ground

Transmit Data Input

Receive Data Output

Notes

See Section 2.4.1

See Section 2.4.1 & 2.4.2

See Section 2.4.2

See Section 2.4.1

See Section 2.4.1 & 2.4.2

See Section 2.4.2

See Section 2.4.5.2

See Section 2.4.5.2

See Section 2.4.5.2

J7-4 WAKEUP Wakeup Signal

J8-1 GND Ground

J8-2 RDCD

J8-3 RDTR


Data Term Ready Output

See Section 2.4.5.2 & 2.4.5.3

See Section 2.4.5.3

See Section 2.4.5.3

See Section 2.4.5.3

J8-4 RCTS

J8-5 RRTS

J8-6 RRXD

J8-7 RTXD

Clear To Send Input


Receive Data Input


See Section 2.4.5.3

See Section 2.4.5.3

See Section 2.4.5.3

See Section 2.4.5.3

J9-1 GND

J9-2 PULSE 1

J9-3 GND-

J9-4 PULSE 2

Ground

Pulse Input 1

Ground

Pulse Input 2

See Section 2.4.3

See Section 2.4.3

See Section 2.4.3

See Section 2.4.3

J10-1 AIN1

J10-2 EXC1

J10-3 GND

J11-1 AIN2

J11-2 EXC2

J11-3 GND

J12-1 AIN3

J12-2 EXC3

J12-3 GND

J13-1 AIN4

J13-2 EXC4

J13-3 GND

Analog Input 1

Excitation

Ground

Analog Input 2

Excitation

Ground

Analog Input 3

Excitation

Ground

Analog Input 4

Excitation

Ground

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

See Section 2.4.4

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


Section 4

SPECIFICATIONS

4.1 ENVIRONMENTAL CONDITIONS

Temperature:

Relative Humidity:

Vibration Effect:

Transient Susceptibility:

ESD Susceptibility:

EMI Susceptibility:

EMI Radiation:

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

5% to 90% (noncondensing)

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

SAMA PMC 33.1-1978.

Meets the requirements of ANSI/IEEE C37.90.1-

1989 (formerly IEEE 472) for surge withstand capability.

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

Meets the requirements of IEC 801-3 level 3

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

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

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

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

C & D hazardous locations (See Appendix A).

4.2 CPU, MEMORY & PROGRAM INTERFACE

Processor:

Memory:

80C188EB, 16-bit microprocessor operating at

8MHz.

- 256K bytes Flash PROM.

- 512K bytes of Battery Backed Static RAM.

RAM Battery Backup: Lithium battery (3.6V) with 5000 hours cumulative backup.

4.3 CPU BOARD COMMUNICATIONS

Communication Ports: Two asynchronous ports standard

TeleRTU Plus™ Specifications / 4-1

Signal:

Local Port:

Network Port:

Communication Rates:

Protocol:

RS-232 Levels

For configuration, data collection, etc.

For Radio or Modem

Selectable from 1200 bps to 19.2 Kbps

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

2111 & 2629. Interface compatible for use with

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

4.4 CPU BOARD DISCRETE INPUTS

No. of Inputs:

Input Voltage Range:

Input Threshold:

2 DIs

0 to 16Vdc

High = 3.6V (Min)

Low = 0.98V (Max)

Pullup Voltage:

Input Leakage:

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

15uA (Max)

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

Allowable Source Leakage: 7uA (Max)

4.5 CPU BOARD DISCRETE OUTPUTS

No. of Outputs:

Switched Voltage Range:

Load:

Off-state Leakage:

2 DOs

0 to 16Vdc (Transorb Clamped)

100mA Max.

8uA (Typical), 100uA (Max)

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

4.6 CPU BOARD PULSE INPUTS

No. of Inputs:

Voltage Range:

2

0 to 16V

4-2 / Specifications TeleRTU Plus™

Minimum Frequency:

Maximum Frequency:

(0-5V Square Wave)

Minimum Pulse Width:

Input Threshold (Low)

Input Threshold (High)

Accumulator Capacity:

DC

9kHz (Max.) (Low Impedance Source)

200 Hz (Open Collector or Dry Contact)

100 uSecs

1.95V (Typical), 1.50V (Minimum)

2.95V (Typical), 3.50V (Maximum)

65535 Pulses

4.7 CPU BOARD ANALOG INPUTS

No. of Inputs:

Input Range:

Resolution:

Accuracy (Calibrated):

4.8 POWER

4 AIs

1 to 5Vdc

±15 BITS, 186 µ V

±0.03%

Operating Voltage

Ripple Voltage Tolerance

(# 60Hz)

Operating Current

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

Max. = 100mVpp

Noise Voltage Tolerance

Connector Type (J2 & J3):

Wire Size

Fuse Type & Rating

4.9 AUXILIARY POWER

Output Voltage

Typ. = 81mA Communication Mode

(Max. = 90mA)

Typ. = 63mA Calculation Mode

(Max. = 68mA)

Typ. = 0.9mA Sleep Mode

(Max. = 1.6mA)

Max. = 100mVpp

Pluggable Weidmuller

Max. = 14AWG

350mA (Schurter 3402.0043)

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

Vin = Power at the PWR Connector

Iload = Load Current

Ron = On Resistance

TeleRTU Plus™ Specifications / 4-3

Max. Load Current

On Resistance

Leakage:

4.10 BACKUP BATTERY

Type

Capacity

Voltage

Discharge Current (Backup)

1.8A Continuous (2.5A Momentary)

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

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

Tadiran TL-5134 (Lithium Thionyl Chloride)

1 Ah

3.6Vdc (Nominal)

Max. = 60uA

4-4 / Specifications TeleRTU Plus™

TeleRTU

Special Instructions for Class I, Division 2 Hazardous Locations

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

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

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

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

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

Electrical Code for installation in Canada.

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

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

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

5.

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

6.

WARNING: EXPLOSION HAZARD - Substitution of components may impair suitability for use in Class I, Division 2 environments.

7.

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

8.

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

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

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

9710 or 9810) or (FreeWave Spread Spectrum Radio) that is used in conjunction with a 10W, 16.5V

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

Table A1 - CPU Board Customer Wiring Signal Names

Signal Name

SOLAR

PWR

PWR 1 & 2

AUX

POWER

DIN 0 & 1

DOUT 0 & 1

11/20/2000

Signal Description

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

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

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

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

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

Appendix A, Document CI3530-25B Page 1 of 2

TeleRTU


LRXD, LTXD,

& WAKEUP

RDCD, RDTR,

RCTS, RRTS,

RRXD, RTXD

Pulse 1 & 2

AI EXC &

AIN1 - 4

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

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

Remote communications port (for radio or modem). Refer to 3530-25B Model

Spec. and ¶ 10 of this document.

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

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

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

11/20/2000 Appendix A, Document CI3530-25B Page 2 of 2

Product Information Package

PIP-EXP I/O TF

February, 2008

Low Power I/O Expansion Board


Part No. 392927-XX-X

(For TeleFlow Plus, TeleRTU Plus, TeleRTU Module & TeleRecorder)

For the following Instruction Manuals:

CI-3530-20B, CI-3530-25B, CI-3530-35B & CI-3530-55B

Remote Automation Solutions

www.EmersonProcess.com/Remote



These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process

Management, Remote Automation Solutions division (RAS) for further information.


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


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


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.


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.

Remote Automation Solutions

A Division of Emerson Process Management

1100 Buckingham Street, Watertown, CT 06795

F.

A.

C.

D.

A.

B.

E.

B.

WARRANTY

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

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

Warranties on goods sold by, but not manufactured by RAS are expressly limited to the terms of the warranties given by the manufacturer of such goods.

All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or modified without RAS consent, (iii) not installed, maintained and operated in strict compliance with instructions furnished by RAS or (iv) worn, injured or damaged from abnormal or abusive use in service time.

These warranties are expressly in lieu of all other warranties express or implied (including without limitation warranties as to merchantability and fitness for a particular purpose), and no warranties, express or implied, nor any representations, promises, or statements have been made by RAS unless endorsed herein in writing. Further, there are no warranties which extend beyond the description of the face hereof.

No agent of RAS is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.

REMEDIES

Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies RAS in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to the RAS Watertown office, unless the RAS Watertown office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by RAS proves to be defective in material and workmanship. RAS is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to RAS, the Buyer can arrange to have a RAS service person come to the site. The Service person's transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.

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


Before a product can be returned to Remote Automation Solutions (RAS) for repair, upgrade, exchange, or to verify proper operation, Form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the RAS

Watertown Repair Dept. to effectively and efficiently process the repair order.


A. FAX

Completing the form (GBU 13.01) and faxing it to (860) 945-2220. A RAS Repair Dept. representative will return the call (or other requested method) with a RA number.

B. E-MAIL

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

. A RAS Repair Dept. representative will return E-

Mail (or other requested method) with a RA number.

C. Mail



A Division of Emerson Process Management


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

D. Phone

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


Repair Authorization Form (on-line completion)

Remote Automation Solutions (RAS)

( Providing this information will permit Bristol, also doing business as Remote Automation Solutions (RAS) 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.

•


•


•

Return to Customer


•


√

in

“returned” B,C, or D of part III below)


Address No.

Bill to :

Purchase Order:


Ship to:

Contact Name:

Phone: Fax: E-Mail:

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

Model No./Part No. Description:

Range/Calibration: S/N:


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?


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

B. If product were found to exceed the warranty period, would you like the product: repaired returned replaced scrapped?

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

D. If RAS 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: Remote Automation Solutions, Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: 860-945-2442 Fax: 860-945-2220

Form GBU 13.01 Rev. D 12/04/07

Emerson Process Management

Training

GET THE MOST FROM YOUR EMERSON

INSTRUMENT OR SYSTEM





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

For information or to enroll in any class, go to http://www.EmersonProcess.com/Remote and click on “Training” or contact our training department in Watertown at (860) 945-2343.

PIP-EXPI/OTF

LOW POWER I/O EXPANSION BOARD

PT. Number 392927-XX-X


TABLE OF CONTENTS

2.1

2.1.1

2.1.2

2.2

2.2.1

2.2.2

2.2.3

2.2.4

2.2.5

2.3

SECTION TITLE

1.1

1.1.1

PAGE #


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

Configuration Hardware ................................................................................................... 2

Section 2 - INSTALLATION & SERVICE

REMOVAL/REPLACEMENT & INSTALLATION OF THE LPI/OEB.......................... 5

Removal/Replacement of the Low Power I/O Expansion Board..................................... 5

Installation of the Low Power I/O Expansion Board....................................................... 7

I/O CONFIGURATION & WIRING ................................................................................. 9

LPI/OEB Discrete Input Wiring (TB4)............................................................................. 9

LPI/OEB Discrete Output Wiring (TB4) .......................................................................... 9

LPI/OEB Analog Input Wiring (TB2)............................................................................. 10

LPI/OEB Analog Output Wiring (TB3) .......................................................................... 12

LPI/OEB High Speed Counter Wiring (TB3) ................................................................. 13

RS-232/RS-485 COMMUNICATIONS ........................................................................... 13

Section 3 - TROUBLESHOOTING

3.1

FIELD WIRING SIGNAL CHECKS .............................................................................. 15


4.1

4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6

4.2

INPUT/OUTPUT SPECIFICATIONS............................................................................ 16

Discrete Inputs ................................................................................................................ 16

Discrete Outputs.............................................................................................................. 16

Analog Inputs................................................................................................................... 16

Analog Outputs................................................................................................................ 17

Communication Port........................................................................................................ 18

High Speed Counter ........................................................................................................ 18

ENVIRONMENTAL SPECIFICATIONS....................................................................... 18

Supplements

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

PIP-EXPI/OTF Page 0-1 Table Of Contents

Section 1

INTRODUCTION

1.1 GENERAL INTRODUCTION

The Low Power I/O Expansion Board (LPI/OEB) measures approximately 4” by 7.25” and mounts piggy-back on either the TeleFlow or TeleRTU CPU Board. Removable card-edge connectors are provided to accommodate field wiring. A 1.25” by 1.2” cutout area is incorporated into the board’s design to accommodate mounting of the Multivariable Transducer’s Wet End Connector and Balance Board onto the TeleFlow CPU Board. The

LPI/OEB operates in conjunction with Revision 3 and higher TeleFlow CPU Boards and with TeleRTU CPU Boards. Three versions of the LPI/OEB are available; fully populated version P/N 392927-01-2 (see Figure 1), depopulated version that supports DI/DO and the

Comm. Port P/N 392927-02-0 and a depopulated version that supports DI/DO only P/N

392927-03-9.

PIP-EXPI/OTF

Figure 1 - Low Power I/O Expansion Board

Page 1 Low Power I/O Expansion Board

The Low Power I/O Expansion Board provides the following additional I/O capabilities to the TeleFlow Plus EGMCs, TeleRTU Plus and TeleRTU Module RTUs and TeleRecorders:

• 8 Discrete I/O

All eight DI/O function in both input and output capacities. Field terminals for each

DI/O are I/O and GND. Each Discrete Input will accept signals from 0 to 16 VDC. The

Discrete Outputs utilize open drain FETs with a maximum working voltage of 16 VDC and a minimum load of 100 mA. DI/Os are not isolated.

• 4 Analog Inputs (available on 392927-01-2 only)

Two single-ended Analog Inputs are available for 4 to 20 mA or 1 to 5 VDC signal operation (Jumper Configurable) and two additional single-ended Analog Inputs are available for 1 to 5 VDC signal operation only. The two 4-20 mA Inputs will support externally powered transmitters; however, internally powered 4-20 mA transmitters will require an external power supply. All four channels support low power voltage output transmitters such as Rosemount and Honeywell. Resolution is 12 bits (1.42 mV) and combined error (including linearity, hysteresis and temperature effects) is ≤

± 0.2%. Each Analog Input channel includes field wiring terminals for signal, transmitter power (+9.5V), and ground. Note: Analog Inputs are designated AI5 through AI8; AI1 through AI4 are assigned to the TeleRTU CPU.

• 1 Analog Output (available on 392927-01-2 only)

The Analog Output can be configured for 4 to 20 mA or 1 to 5 VDC operation (Jumper

Configurable). Resolution is 12 bits and combined error including linearity, hysteresis and temperature effects is ≤ ± 0.2% after calibration.

• 1 High Speed Counter Input (available on 392927-01-2 only)

The High Speed Counter input will accept pulses (with an input range from 0 to 16

VDC and up to 10KHz) from CMOS or TTL sources, including transistors, FETs, mechanical relays, or other signaling devices.

• 1 RS-232 or RS-485 Asynchronous Serial Communications Port (not on 392927-03-9)

Note: Only supported by units with TeleFlow/ACCOL Firmware

The Asynchronous Serial Communications Port can be jumper configured for either

RS-232 or RS-485 operation at programmable speeds of up to 19.2 Kbps.

1.1.1 Configuration Hardware

Fully populated Low Power I/O Expansion Boards contain 8 potentiometers, 15 Jumper

Blocks and 5 removable card-edge (Terminal Blocks) connectors. Tabulated information about Terminal Block, Jumper and Potentiometer assignments are contained in Tables 1, 2 and 3 respectively.

Table 1 - Low Power I/O Exp. Board Terminal Block Assignments

TB # PIN # MNEMONIC

TB1 1

TB1 2

TB2 1

AIN5 TB2

TB2

EXC6

AIN6

TB2 6

TB2

TB2

2

TB2 3

TB2 4

5

7

8

GND

AIN7

AIN8

DESCRIPTION

+21V

-21V

EXCITATION

ANALOG IN 5

5

GROUND

EXCITATION

ANALOG IN 6

6

GROUND

ANALOG IN 7

ANLOG IN 8

Low Power I/O Expansion Board Page

2

PIP-EXPI/OTF

Table 1 - Low Power I/O Exp. Bd. Terminal Block Assignments (Continued)

TB # PIN # MNEMONIC

TB2 9

TB3 1

TB3 2

TB3

TB4

TB4

3 HSC

TB3 4

TB4

TB4

TB4

TB4

TB4 6

TB4 9

TB4

TB4

1

2

4

5

7

8

10

11

GND

DIO1

DIO2

TB4 3

DIO3

DIO4

DIO5

DIO6

GND

DIO7

DIO8

GND

TB5 2

DTR

TB5 4

RTS/TX-

TB5 6

TB5 7

DESCRIPTION

GROUND

GROUND

HIGH SPEED CNTR

GROUND

DISCRETE IN/OUT 1

DISCRETE IN/OUT 2

GROUND

DISCRETE IN/OUT 3

DISCRETE IN/OUT 4

GROUND

DISCRETE IN/OUT 5

DISCRETE IN/OUT 6

GROUND

DISCRETE IN/OUT 7

DISCRETE IN/OUT 8

GROUND

DCD

RS232

RS232/485

RTS/XMIT

REC

XMIT

Table 2 - Low Power I/O Exp. Bd. User Configurable Jumper Block Assignments

JUMPER #

JP6

JP6

JP6

JP7

JP8

JP8

JP8

JP9

POSITION

2-7 (only)

2-7 & 4-5

1-2, 3-6 & 4-5 Configuration for Internally Sourced Current Input (AIN5)

JP7 1-4

All Open

2-7 (only)

2-7 & 4-5 Configuration for Non-Isolated Current Input (AIN6)

1-2, 3-6 & 4-5 Configuration for Internally Sourced Current Input (AIN6)

JP9 1-4

All Open

PURPOSE

Configuration for 1-5V Analog Input (AIN5)

Configuration for Non-Isolated Current Input (AIN5)



Configuration for Internally Sourced Current Input (AIN5)




Configuration for Internally Sourced Current Input (AIN6)

Used in conjunction with 1-5V Analog Input - leaves 9.5V

JP10 1-2

JP10 2-3

JP11 1-2

JP11 2-3

JP17 1-2 regulated power supply ON continuously.

Used in conjunction with 1-5V Analog Input - shuts down the

9.5V power supply during TeleFlow CPU SLEEP Mode.

Used in conjunction with an internally sourced 4-20 mA Current

Loop Analog Input - leaves current loop powered continuously.

Used in conjunction with an internally sourced 4-20 mA Current

Loop Analog Input - shuts down the internal current loop when the TeleFlow CPU is in SLEEP Mode.

JP13, 14, 16 JP13 to JP16 RS-232 Signals present at TB5 - RS-485 Converter asleep.

JP13, 14, 16 JP14 to JP16 RS-485 Signals present at TB5 - RS-232 Converter asleep.

JP15 1-2

Used in conjunction with RS-485 Communications

Installed = Transmit End Node (120-Ohm) Termination

Used in conjunction with RS-485 Communications

Installed = Receive End Node (120-Ohm) Termination

PIP-EXPI/OTF Page 3 Low Power I/O Expansion Board

Table 2 - Low Power I/O Exp. Bd. User Configurable Jumper Block Assignments

(Continued)

JUMPER # POSITION

JP19 1-2

JP19 2-3

JP20 1-2

JP21 1-2

JP22 1-2

JP22 2-3

PURPOSE

Used in conjunction with Analog Output - Current Loop output configuration.

Used in conjunction with Analog Output - Voltage output configuration.

Used with RS-485 Communications for RX Pull-up.

Install at End Node with (120-Ohm) RX Termination Installed.

Used with RS-485 Communications for RX Pull-down.

Install at End Node with (120-Ohm) RX Termination Installed.

RS-232 - RTS to CTS Loopback

RS-232 - Use External CTS

Table 3 - Low Power I/O Board Potentiometer Assignments

POT. #

R29

R30

R33

R36

R37

R45

R48

R49

POTENTIOMETER USAGE

Analog Input #7 circuitry offset calibration


1-5V Analog Output Adjustment - 1V point



1-5V Analog Output Adjustment - 5V point

4-20mA Analog Output Adjustment - 4mA point

4-20mA Analog Output Adjustment - 20mA point

Note All potentiometer adjustments require the use of TeleFlow Diagnostics


4

PIP-EXPI/OTF

Section 2

INSTALLATION & SERVICE

2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE LPI/OEB

2.1.1 Removal/Replacement of the Low Power I/O Expansion Board

Low Power I/O Expansion Board Field Upgrade Kits contain the following major parts:

1. Low Power I/O Expansion Board

2.

Five #4-40 - .188” x .469” Standoffs & Five #4-40 - .408” x .469” Standoffs*

* Use these Standoffs (BBI P/N SK100210M) if the others are insufficient!

3.

Five #4-40 x 3/16” Pan Head Screws - (May be required in lieu of original screws).

To remove an installed Low Power I/O Expansion Board, follow steps 1 through 7 below. To replace the Low Power I/O Expansion Board, follow steps 2 through 6 below in reverse order, installing rather than removing the item in question and then perform step 7.


2. Disconnect the wiring harness connectors associated with power, i.e., P10, P8, P7 and

P6 from the TeleFlow CPU Board or P1, P2, P3 and P4 from the TeleRTU CPU Board.

3. Disconnect I/O connectors P5, P13 and P14 from the TeleFlow CPU Board or P5, P6, P7,

P8, P9, P10, P11, P12 and P13 from the TeleRTU CPU Board.

4. Disconnect I/O connectors TB1, TB2, TB3, TB4 and TB5 from the Low Power I/O

Expansion Board.

5. Remove the two screws that secure the sliding bracket to the fixed bracket and carefully slide the CPU Board (with non-removed cabling) and I/O Expansion Board toward the front of the unit until the sliding bracket is free of the fixed bracket. In the case of

Model 3530-35B, skip this step. In the case of the TeleRecorder (3530-55B) remove the four screws that secure the Blank Plate or Display Mounting Plate to the four long standoffs.

6.

Remove the five screws that secure the Low Power I/O Expansion Board to its mounting stand-offs and unplug I/O Expansion Board (Connector P1) from CPU Board (Connector

J2).

Note: If a replacement LPI/OEB is available follow steps 2 through 6 in reverse order (after configuring the LPI/OEB), installing rather than removing the item in question If a replacement I/O Expansion Board is not immediately available and the unit must be placed back into operation

(without expanded I/O) follow steps 2 through 5 in reverse order, installing rather than removing the item in question. Then go to step 7.

7. Close and secure the Door.


Figure 2A - I/O Expansion Board Mounted to TeleFlow Plus CPU Board

Figure 2B - I/O Expansion Board Mounted to TeleRTU Plus CPU Board

Figure 2C - I/O Expansion Board Mounted to TeleRTU Module CPU Board

Figure 2D - I/O Expansion Board Mounted to TeleRecorder CPU Board


6

PIP-EXPI/OTF

2.1.2 Installation of the Low Power I/O Expansion Board


2. Disconnect the wiring harness connectors associated with power, i.e., P10, P8, P7 and

P6 from the TeleFlow CPU Board or P1, P2, P3 and P4 from the TeleRTU CPU Board.

3. Disconnect I/O connectors P5, P13 and P14 from the TeleFlow CPU Board or P5 through

P13 from the TeleRTU CPU Board.

4. For Models 3530-20B & 3530-25B remove the two screws that secure the sliding bracket to the fixed bracket and carefully slide the CPU Board (with non-removed cabling toward the front of the unit until the sliding bracket is free of the fixed bracket. In the case of Model 3530-35B, skip this step. In the case of the TeleRecorder (3530-55B) remove the four screws that secure the Blank Plate or Display Mounting Plate to the four long standoffs.

5.

Remove the five screws that secure the CPU Board to its standoffs.

6. Install the appropriate five standoffs supplied with the I/O Expansion Option in place of the five screws removed in step 5. In the case of the TeleRecorder, replace the

BlankPlate or Display Mounting Plate that was removed in step 4.

7. Route field wiring cable(s) associated with the I/O Expansion Board into the TeleFlow

Plus, TeleRTU Plus or TeleRecorder through a ¾” conduit fitting (user installed) (see

Figure 3A, 3B or 3C) on the bottom of the enclosure. Configure the LPI/OEB Jumpers

(see Table 2 and Section 2.2).

PIP-EXPI/OTF

Figure 3A - Bottom View of TeleFlow Plus

Page 7 Low Power I/O Expansion Board

Figure 3B - Bottom View of TeleRTU Plus

Figure 3C - Bottom View of TeleRecorder

8 Install the I/O Expansion Board by aligning its connector P1 with CPU Board Connector J2 and then securing the boards with either the five screws removed in step 5, or the five screws supplied with the kit. Connect I/O Wiring to the appropriate removable

I/O Expansion Board Connectors (TB1, TB2, TB3, TB4 and TB5) (see Section 2.2).

Connect the wiring harness connectors associated with power, i.e., P10, P8, P7 and P6 on the TeleFlow CPU Board or P1, P2, P3 and P4 on the TeleRTU CPU Board. Connect

I/O connectors P5, P13 and P14 to the TeleFlow CPU Board or P5, P6, P7, P8, P9, P10,

P11, P12 and P13 to the TeleRTU CPU Board.

9. Close and secure the Instrument front Cover.


8

PIP-EXPI/OTF

2.2 I/O CONFIGURATION & WIRING

Figure 4 - LPI/OEB Discrete Input Configuration

2.2.1

LPI/OEB Discrete Input Wiring (TB4)

(see Figure 4 and Table 4)

Discrete Inputs have a range of 0-16 Vdc ± 10% and have surge suppression but are not isolated. A Discrete Input is activated by closing the connection between DI/On and Ground

(GND) with a Dry Contact (such as a transistor, mechanical relay, TTL, CMOS and other devices which provide from 0-16 Vdc). The Discrete Input (DI) is lightly pulled up to 5V.

2.2.2 LPI/OEB Discrete Output Wiring (TB4)


Each Discrete Output is wired to an open drain capable of switching up to +16 Vdc at

100mA. Surge suppression is provided via 16V bi-directional Transorbs across each out-put; however, since these outputs are not isolated, caution must be exercised to ensure that the load current does not adversely affect operation of the TeleFlow Plus or related devices.

Table 4 - Low Power I/O Expansion Board Discrete I/O Terminal Designations

TB4 Pin # Pneumonic

1 DIO1

2 DIO2

Description

Discrete In/Out 1

Discrete In/Out 2

4

5

7

8

10

11

DIO3

DIO4

DIO5

DIO6

DIO7

DIO8

Discrete In/Out 3

Discrete In/Out 4

Discrete In/Out 5

Discrete In/Out 6

Discrete In/Out 7

Discrete In/Out 8


Figure 5 - LPI/OEB Discrete Output Configuration

2.2.3 LPI/OEB Analog Input Wiring (TB2)

(see Figures 6 through 8 and Table 5)

Up to 4 single ended analog inputs can be wired to the I/O Expansion Board. Analog Inputs

5 and 6 can be configured as 1-5 V non-isolated inputs, 4-20 mA non-isolated inputs, or 4-20 mA loops powered internally and referenced to the board’s analog ground (AGND). When configured for internally powered current loop operation (which can be turned off when the

CPU Board is in SLEEP mode), an external 21V power supply is required. Analog Inputs 7 and 8 can only be configured for 1-5 V non-isolated input operation

Figure 6 - LPI/OEB Non-Isolated 4-20mA Current Source AI Configuration


10

PIP-EXPI/OTF

Figure 7 - LPI/OEB 1-5V Non-Isolated Voltage Analog Input Configuration

Figure 8 - LPI/OEB 4-20 mA Internally Sourced Analog Input Configuration


Table 5 - LPI/OEB Analog Input Terminal Designations

TB# Pin # Pneumonic

TB1-1

TB1-2

+21VEXT

21VGND

Description

External +21VDC

External 21V Gnd.

TB2-2 AIN5 Analog Input #5

TB2-3 GND Ground

TB2-5 AIN6 Analog Input #6

TB2-6 GND Ground

TB2-7

TB2-8

AIN7

AIN8

Analog Input #7

Analog Input #8

TB2-9 GND Ground

2.2.4 LPI/OEB Analog Output Wiring (TB3)


Figure 9 - LPI/OEB Analog Output Configuration


12

PIP-EXPI/OTF

The single analog output can be configured for 4 to 20 mA or 1 to 5 V operation. The analog output section of the LPI/OEB consists of a bus interface, a one channel Digital to Analog

Converter (DAC) and signal conditioning circuitry designed to generate a 4-20 mA output or a 1-5 V output. Jumper JP19 controls selection. When set in position 1-2, JP19 configures the analog output for current loop operation. When set in position 2-3, Jumper JP19 configures the analog output for 1 to 5 V operation.

2.2.5 LPI/OEB High Speed Counter Wiring (TB3)

(see Figure 10 & Table 1)

The High Speed Counter input circuitry is powered from the 5V power source on the

LPI/OEB. The HSC Input is configured as a dry contact input with filtering and surge protection. Field connections are HSC and GND. The frequency range of the HSC is DC to

10KHz. Field devices can be open collector transistors, open drain FETs or dry contacts.

Figure 10 - LPI/OEB High Speed Counter Configuration

2.3

RS-232/RS-485 COMMUNICATIONS

Terminal Block TB5 can be configured to support RS-232 or RS-485 communications (see

Figure 11).

For RS-232 operation the following configuration jumpers must be set:

JP13 Jumper to JP16

JP22 Pin-1 to Pin-2 for RTS to CTS Loopback or Pin-2 to Pin-3 for use with an external

CTS

For RS-485 operation the following configuration jumpers must be set:

JP14 Jumper to JP16

JP15 - 120 Ohm TX Termination (at end nodes ONLY)

JP17 - 120 Ohm RX Termination (at end nodes ONLY)

JP20 - RX Pull-up (Install at end node with RX Term. Installed)

JP21 - TX Pull-up (Install at end node with TX Term. Installed)


Figure 11 - RS-232/485 Communication Configuration Diagram


14

PIP-EXPI/OTF

Section 3

TROUBLESHOOTING

3.1 FIELD WIRING SIGNAL CHECKS

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

Check wiring for continuity, shorts & opens. Check the I/O signals at the card-edge connectors (see Figures 4 through 10 as follows):

Figure 4 - LPI/OEB Discrete Input Configuration

Figure 5 - LPI/OEB Discrete Output Configuration

Figure 6 - LPI/OEB Non-Isolated 4-20 mA Current Source Analog Input Configuration

Figure 7 - LPI/OEB 1-5V Non-Isolated Voltage Analog Input Configuration

Figure 8 - LPI/OEB 4-20 mA Internally Sourced Analog Input Configuration

Figure 9 - LPI/PEB Analog Output Configuration

Figure 10 - LPI/OEB High Speed Counter Configuration

If RS-232 or RS-485 communications problems are encountered, check Low Power I/O

Expansion Board Configuration Jumpers for proper configuration (see Table 2). Check communication signals at card-edge Connector TB5 (see Table 1 and Figure 11 - RS-232/485

Communication Configuration Diagram).


Section 4


4.1 INPUT/OUTPUT SPECIFICATIONS

4.1.1 Discrete Inputs

Number of DIs: 8 selectable non-isolated DI Max. (Note: Any DI/O configured for DO operation diminishes the number of DIs, i.e., if 6 DI/O are configured for DO operation, only 2 DI/O can be configured for DI operation)

Input Type:

Input Current:

Surge Suppression/protection:

0 - 16 Vdc

5mA ± 10% (Contact Closure)

16V Bi-directional Transient Absorption Zeners

Across input

4.1.2 Discrete Outputs

Number of DOs: 8 selectable non-isolated DO Max. (Note: Any DI/O configured for DI operation diminishes the number of DOs, e.g., if 6 DI/O are configured as DI operation, only 2 DI/O can be configured for DO operation)

Output Type:

Surge Suppression/Protection:

Open Drain 16Vdc @ 100mA

16V Bi-directional Transient Absorption

Zeners across output

4.1.3 Analog Inputs

Number of Inputs: 2 Analog Single Ended Inputs (Selectable Current

Input or Voltage Input operation)

Input Type:

2 Analog Single Ended Inputs (Voltage Input only)

1-5 Volt dc or

4-20 mA Current Loop (Externally Sourced)

Accuracy: or

4-20 mA Current Loop (Internally Sourced)

(Requires external 21V Power Supply)

At room temperature +25 ° C (77 ° F)

V/I


16

PIP-EXPI/OTF

-20 ° C to +70 ° C (-4 ° F to +158 ° F)

V/I

-40 ° C to +70 ° C (-40 ° F to +158 ° F)

V/I

Input Filtering: Single Pole (50 msec time constant) 300 msec to

± 0.1% of input value

Settling time of any selected AI is 18 μ sec to .01%

Input Impedance:

Common Mode Range:

Surge Suppression/Protection:

Common Mode Rejection Ratio 47 to 63 Hz is 90dB

Normal Mode Rejection at 60 Hz is 26dB

1-5 V Input - 195 kohms

4-20 mA Input - 250 ohms

0V to +5V

4.1.4 Analog Outputs

Number of Outputs:

Accuracy:

22V Bi-directional Transient Absorption Zeners across input

Output Range:

1

4-20 mA into a 250 ohm load or

1-5 VDC @ 5mA Max.

At room temperature +25

± 0.1% of Span

° C (77 ° F)

At

± 0.2% of Span

At

± 0.3% of Span

° C (-40 ° F to +158 ° F)

Setting Time:

Isolation:

100 msec to .1%

Surge Suppression: 16V Unidirectional Transient Absorption Zeners output

Outputs are not isolated and are referenced to

Analog Ground

4.1.5 Communication Port

Configuration: RS-232 or RS-485 (Jumper Selectable)


ESD: RS-232 - 16V Bi-directional Transient Absorption


RS-485 - 5V Bi-directional Transient Absorption


4.1.6 High Speed Counter

Number of Inputs:

Input Type:

Input Current:

Input Frequency:

Input Impedance:

Surge Suppression:

1

Voltage

5mA ± 10% (open collector/contact closure)

DC to 10kHz

4.7 kohms ± 10% for 16V input range

16V Bi-directional Transient Absorption Zeners across input

4.2 ENVIRONMENTAL SPECIFICATIONS

Temperature: Operating: -40 ° C to +70 ° C (-40 ° F to +158 ° F)

-40 ° C to +85 ° C (-40 ° F to +185 ° F)

Relative Humidity:

Vibration:

15-95% RH Non-condensing

10 to 500 Hz at 1g on axis per SAMA PMC-31-1 without damage or impairment

ESD Susceptibility: Field connected circuits are designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV

EMI Capability: Designed to coexist inside a shielded enclosure with the TeleFlow or TeleRTU electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics

Transient Susceptibility: Field connected circuits are designed to meet the requirements of ANSI/IEEEC37.90.1-1989 (Formerly IEEE 472) for surge withstand capability.

Part Numbers: 392927-01-2 - Fully Populated LPI/OEB

392927-02-0 - Depopulated has DI/DO and Comm.

392927-03-9 - Depopulated has DI/DO only


18

PIP-EXPI/OTF



1. The BBI Low Power I/O Expansion Board (LPI/OEB) is listed by Underwriters

Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups

A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive BBI LPI/OEB Board. In the event of a conflict between the LPI/OEB Board User Manual (PIP-EXPI/OTF) 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-EXPI/OTF - LPI/OEB Board Page 1 of 1

BLANK PAGE

Low Power I/O Expansion Board


PIP-EXPI/OTF

February, 2008




Watertown, CT 06795

Phone: +1 (860) 945-2262

Fax: +1 (860) 945-2525 www.EmersonProcess.com/Remote



6338 Viscount Rd.

Mississauga, Ont. L4V 1H3

Canada

Phone: 905-362-0880

Fax: 905-362-0882 www.EmersonProcess.com/Remote

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Viveros de la Colina No 238

Col. Viveros de la Loma

Tlalnepantla, Mexico 54080 www.EmersonProcess.com/Remote


Bristol Babcock, Ltd.

Blackpole Road

Worcester, WR3 8YB

United Kingdom

Phone: +44 1905 856950

Fax: +44 1905 856969 www.EmersonProcess.com/Remote


Bristol Digital Systems Australasia

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/Remote

NOTICE

“Remote Automation Solutions (“RAS”), division of Emerson Process

Management shall not be liable for technical or editorial errors in this manual or omissions from this manual. RAS MAKES NO WARRANTIES,

EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH

RESPECT TO THIS MANUAL AND, IN NO EVENT SHALL RAS BE LIABLE

FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL

DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION,

LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS

INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND

POWER, AND CLAIMS OF THIRD PARTIES.

Bristol, Inc., Bristol Babcock Ltd, Bristol Canada, BBI SA de CV and the Flow

Computer Division are wholly owned subsidiaries of Emerson Electric Co. doing business as Remote Automation Solutions (“RAS”), a division of

Emerson Process Management. FloBoss, ROCLINK, Bristol, Bristol

Babcock, ControlWave, TeleFlow and Helicoid are trademarks of RAS. AMS,

PlantWeb and the PlantWeb logo are marks of Emerson Electric Co. The

Emerson logo is a trademark and service mark of the Emerson Electric Co.

All other trademarks are property of their respective owners.

The contents of this publication are presented for informational purposes only. While every effort has been made to ensure informational accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. RAS reserves the right to modify or improve the designs or specifications of such products at any time without notice. All sales are governed by RAS’ terms and conditions which are available upon request.

© 2008 Remote Automation Solutions, division of Emerson Process

Management. All rights reserved.


CI-3530-25B

Jan., 2007

DIGITAL TO RELAY I/O BOARD

TeleRTU Plus

Appendix G


Appendix G

DIGITAL TO RELAY I/O BOARD


SECTION TITLE

1.1

1.1.1

1.1.2

2.1

2.1.1

2.1.2

2.2

2.2.1

3.1

3.1.1

3.1.2

PAGE #


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

Configuration Hardware ...................................................................................................1

Jumper Settings.................................................................................................................2


REMOVAL/REPLACEMENT & INSTALLATION OF THE DTRI/OB..........................3

Removal/Replacement of the Digital to Relay I/O Board ................................................3

Installation of the Digital to Relay I/O Board Option .....................................................4

FIELD WIRING .................................................................................................................6

Terminal Connections........................................................................................................6

Section 3- SPECIFICATIONS

DIGITAL TO RELAY I/O BOARD SPECIFICATIONS...................................................8

Input Requirements...........................................................................................................8

Output Requirements ........................................................................................................8

CI-3530-25B Appendix G Page 0-1 Table Of Contents

Section 1

INTRODUCTION


The Digital to Relay I/O Board accepts up to two discrete input signals from an open drain

SFET device (TeleRTU DOs) and convert them to Form C relay output signals using Solid

State Relay (SSR) logic. The minimum current load will be 100mA. Figure 1 provides a component view of the Digital to Relay I/O Board.

Each of the TeleRTU's Discrete Outputs is converted to Form C relay output signals which can be configured for opposite or identical state conditions, i.e., both Normally Open (NO) or Normally Closed (NC) or one Normally open with the other Normally Closed.

1.1.1 Configuration Hardware

The Digital to Relay I/O Board contains ten (10) Jumpers which allow the user to configure contacts for Normally Open/Normally Closed states. Contacts associated with each of the

Form C Relays may be configured for identical or opposite states. Note: Jumper Pairs

W3/W5, W4/W6, W7/W9 and W8/W10 must be set in opposite states.

CI-3530-25B Appendix G

Figure 1 - Digital to Relay I/O Board

Page 1 Digital to Relay I/O Board

1.1.2 Jumper Settings

The commons associated with each form C Relay (R0COM and R1COM) have the option of being tied to the TeleFlow Power Ground or to a floating Ground. Jumper W1 is associated with Outputs R0A and R0B and W2 is associated with outputs R1A and R1B. When Jumper

W1 is installed the common (C) associated with Outputs R0A and R0B is tied to TeleRTU

Power ground; when Jumper W1 is not installed, the common will be floating. When

Jumper W2 is installed the common (C) associated with Outputs R1A and R1B is tied to

TeleFlow Power ground; when Jumper W2 is not installed, the common will be floating.

Table 1 - Jumper Settings versus Form C Relay Output States

JUMPERS

W3/W5

R0A

STATE

JUMPERS

W4/W6

R0B

STATE

JUMPERS

W7/W9

R1A

STATE

JUMPERS

W8/W10

R1B

STATE

IN/OUT NO IN/OUT NO IN/OUT NO IN/OUT NO

OUT/IN NC OUT/IN NC OUT/IN NC OUT/IN NC

Table 1 provides the relationship between Jumper settings and Form C Relay Outputs.

CI-3530-25B Appendix G Page 2 Digital to Relay I/O Board

Section 2


2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE DTRI/OB

2.1.1 Removal/Replacement of the Digital to Relay I/O Board

An installed Digital to Relay I/O Board option will contain the following parts:

1. Digital To Relay I/O Board (with removable 12 Position Terminal Block)

2. Relay Board Bracket

3. Snap Track

4. Relay Board Cable

5. Two #8-32 x 1/4” SEM Screws

6. Two #10-32 x 3/8” SEM Screws

Figure 2 - Digital to Relay I/O Board Mounting Diagram with

Power Distribution Board, Low Power TIB Board & 21V Power Supply Board


To remove an optional Digital to Relay I/O Board, follow steps 1 through 4 below. To replace the Digital to Relay I/O Board follow steps 2 and 3 below in reverse order, installing rather than removing the item in question and then perform step 4.

1. Open the Instrument Front Cover (Door).

2. Unplug the removable Terminal Block (with wiring harness installed) from the optional

Digital to Relay I/O Board.

3. Slide the Digital to Relay I/O Board toward the front of the unit and out of the Snap

Track.

Note: If a replacement Digital to Relay I/O Board is available follow steps 2 through 3 in reverse order (after configuring the DTRI/OB - see Section 1.1) installing rather than removing the item in question. If a replacement Digital to

Relay I/O board is not immediately available the TeleRTU Plus may be placed back into operation without the use of DO1 and DO2.

4. Close and Secure the Door.

Figure 3 - Bottom View of TeleRTU Plus

2.1.2 Installation of the Digital to Relay I/O Board Option


2. Install the Snap Track onto the appropriate Dual PCB Mounting Bracket (if not already mounted) using the two (2) #8-32 x 1/4” SEM Screws (see Figure 2).

3. Configure the Digital to Relay I/O Board Jumpers (see Section 1.1).


4. Install the Dual PCB Mounting Bracket (with Snap Track) onto the TeleRTU Plus

Fabricated Panel (lower right corner) using the two (2) #10-32 x 3/8” SEM Screws (see

Figure 2).

5. Connect one end of the four-wire Relay Board Cable to the Digital to Relay I/O Board

Connector P1 and the other end to the CPU Board (J2 and J5 - see Figure 5). Note:

Power to the Digital to Relay I/O Board may be provided by the CPU Bd. or a Power

Distribution Board (if present) (see Table 2 and Figures 4 & 5).

6. Route field wiring cable(s) associated with the Digital to Relay I/O Board into the

TeleRTU Plus through a 3/4” conduit fitting (user installed) (see Figure 3) on the bottom of the enclosure. Connect I/O Wiring to the Digital to Relay Board Terminal Block J1

(see Section 2.2.1, Table 2 & Figure 5).

7. Close and Secure the Instrument Front Cover.

Figure 4 - Power Distribution Board Schematic/Wiring Diagram


2.2 FIELD WIRING


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

Table 2 - Digital To Relay I/O Board Connections to J1/P1

J1 Pin Signal Function Wiring Connections

1 R1B Relay 1 Output B To Field

2

3

4

R1A

R1COM

Relay 1 Output A

Relay 1 Common

CHASSIS GND Chassis Ground

To Field

To Field (See W2)

CPU Bd. Gnd Lug

5

6

R0COM

ROB

Relay 0 Common To Field (See W1 - Section 1.1.1)

Relay 0 Output B To Field

7

9

10

11

12

ROA Relay 0 Output A To Field

8 - - -

POWER GND Power Ground CPU Bd. J2 Pin 2 or Pwr. Dist. Bd.

TB4 Pin 2 (Black Wire)

POWER - DC Power - 6/12 Vdc CPU Bd. J2 Pin 1 or Pwr. Dist. Bd.

TB4 Pin 1 (Red Wire)

DOUT0 Discrete Output 0 CPU Bd. J5 Pin 3 (Yellow Wire)

DOUT1 Discrete Output 1 CPU Bd. J6 Pin 3 (Orange Wire)

The TeleRTU CPU Board provides two independent firmware controlled open drain outputs which can be used for control or signaling functions. Each output is wired to the source terminal of an N Channel MOSFET capable of switching up to 16 Volts at up to 100mA.

When closed, the FET shorts the output to ground with resistance of .5 Ohms or less. These outputs are protected by 16V Transorbs. Since these outputs are not isolated, caution must be exercised to ensure that the load current does not affect operation of the TeleRTU or related devices.

These outputs may be wired directly to field circuitry or to field circuitry via the Digital to

Relay I/O Board (see Figure 5). Table 2 provides the wiring connections for the TeleRTU

CPU Board and the Digital to Relay I/O Board.

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


Figure 5 - TeleRTU Discrete Outputs Wired Through Digital to Relay I/O Board


Section 3


3.1 DIGITAL TO RELAY I/O BOARD SPECIFICATIONS

3.1.1 Input Requirements

Power Source Range:

SSR

Maximum MOSFET Sink Current:

3 to 15 Vdc

20 mA (both SSRs in Normally Closed mode)

3.1.2 Output Requirements

Contact

Maximum Current:

Maximum

Minimum

3 Amps at 25°C (1.5 Amps @ 70°C)



CI-3530-25B

May, 2006


RADIO INSTALLATION GUIDE for MDS

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

Appendix H


Appendix H

RADIO INSTALLATION GUIDE

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


SECTION TITLE


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


3.1

3.1.1

3.1.2

3.1.3

3.2

3.2.1

3.2.2

3.2.3

3.3

3.3.1

3.3.2

3.3.3

3.4

2.1.1 Radio

2.1.2

Installation of the Radio Option into a Radio Ready TeleRTU Plus ................................... 4

2.1.3

2.2

Installation of the Radio Option into a Non-Radio Ready TeleRTU Plus ........................... 5

WIRING LISTS.................................................................................................................... 6


GENERAL SPECIFICATIONS............................................................................................ 8

Model 4710 General Specs ................................................................................................ 8

Model 9710 General Specs. ............................................................................................... 8

Model 9810 General Specs. ............................................................................................... 9

TRANSMITTER SPECIFICATIONS ................................................................................... 9

Model 4710 Transmitter Specs. .......................................................................................... 9

Model 9710 Transmitter Specs. ........................................................................................ 10

Model 9810 Transmitter Specs. ........................................................................................ 10

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

Model 4710 Receiver Specs. ............................................................................................ 10



ENVIRONMENTAL SPECIFICATIONS............................................................................ 12

REFERENCED OEM MANUALS

MDS 4710A – Remote Data Transceiver (Radio)

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

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

MDS 4710B – Data Transceiver (Radio)



MDS 9810 – Spread Spectrum Data Transceiver (Radio)

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

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

CI-3530-25B Appendix H Page 0-1 Table Of Contents

Appendix H

RADIO INSTALLATION GUIDE

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


REFERENCED OEM MANUALS (Continued)

MDS 9710A Remote Data Transceiver (Radio)

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

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

MDS 9710B Data Transceiver (Radio)



CI-3530-25B Appendix H Page 0-2 Table Of Contents

BLANK PAGE

Appendix H

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



Each TeleRTU J Plus

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

"Radio Ready" unit. Radio Ready units contain all hardware required to field install a Bristol provided

MDS Radio, except the radio, mounting screws, radio power cable, antenna, and the external antenna cable. Radio Ready units can be ordered with or without an optional Polyphaser (Lightning/Impulse

Suppresser) (see Figures 1, 2 & 5).

A Bristol supplied MDS Data Transceiver (Radio) Option mounts inside the TeleRTU Plus Enclosure and is secured to a Sliding Bracket by four screws.

TeleRTU Plus units equipped with the MDS Radio Option discussed herein utilize the following additional hardware:

1.

MDS Radio Transceiver (Choice of five models):

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

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

Model 9810 (900MHz -Spread Spectrum)

2.

Fixed Mounting Bracket (with (2) PC Card Guides, (2) ¼ Turn Clip-On Receptacles, and (2) Push-On

Retainers).

3.

Sliding Mounting Bracket (with (2) studs, (2) washers and (2) stud ejector springs

4.

TeleRTU Plus/Radio Interface Cable (392635-01-1) - Radio 12 Conductor Plug (P2) to CPU Board

Connectors P5 & P13 (see Table 2).

5.

2-Wire Radio Power Cable (392638-01-0) - Connects to the Radio Power Connector and J6 of

TeleFlow) (see Table 1).

6.

(4) #6-32 x ¼” SEM Screws (for securing Radio to Sliding Bracket)

7.

(4) #6-32 x 3/8” Flat Head Screws (for securing Fixed Mounting Bracket to Battery Bracket).

8.

Internal Coaxial Antenna Cable or Polyphaser and Polyphaser Cable.

1.2 LEDs

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

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

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

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

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

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

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

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

CI-3530-25B Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide Page 1

Figure 1 - TeleRTU Plus with Radio and optional Polyphaser

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

Moderate

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

Page 2 Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide CI-3530-25B

DCD - Carrier Detect Flashing = Radio is receiving valid data frames.

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

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

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

Section 2 – INSTALLATION & SERVICE

2.1 RADIO REMOVAL/REPLACEMENT & INSTALLATION

DANGER

MDS Radio 4710A/B, 9710A/B & 9810 provided by Bristol are approved for use in

Class I, Groups C & D, Division 2, Hazardous Locations. The installer must be familiar with hazardous location installation guidelines before installation or maintenance is undertaken. Do not begin radio installation or service to the

TeleRTU Plus unless the area is known to be non-hazardous. Refer to the apropriate appendix of the MDS Installation, Operation & Field Maintenance Manual applicable to the radio in question, for approved conditions under which the

MDS radio can be installed in hazardous locations.

AVOID OPERATING EQUIPMENT DURING AN ELECTRICAL STORM. THE

IMPULSE SUPPRESSOR MAY SAVE EQUIPMENT FROM DANGER, BUT SHOULD

NOT BE CONSIDERED AS BEING SAFE FOR PERSONNEL.

2.1.1 Radio Removal/Replacement Procedure

To remove the Radio Transceiver follow steps 1 through 6 below. To replace the Radio Transceiver follow steps 2 through 5 below in reverse order, installing rather than removing the item in question and then perform step 6.


2.

Remove the Internal Antenna Cable or Polyphaser Cable from the bottom of the radio.

3.

Remove the Power Harness from the bottom of the radio. The radio’s Power Harness is secured by a built-in screw-in/out type fastener.

4.

Using a screwdriver, turn counterclockwise the Slotted Studs which secure the radio’s Sliding Bracket to the radio’s Fixed Bracket. Slide the radio toward the front of the unit and out of the Fixed Bracket.

Remove the Radio Interface Cable from the bottom of the radio by unscrewing the 25-pin D-type connector mounting screws.

5.

If replacing the radio, remove the four #6-32 x ¼” SEM Screws that secure the radio to the Sliding

Bracket.



Figure 2 - MDS Radio Option Mounting Diagram

2.1.2 Installation of the Radio Option into a Radio Ready TeleRTU Plus

Radio Ready TeleRTU Plus units contain all the hardware required (except the radio, radio power cable, mounting screws, external antenna cable and antenna) to accommodate installation and operation of the radio option.

1.

Open the Instrument Front Cover.

2.

Using a screwdriver, turn counterclockwise the Slotted Studs which secure the radio’s Sliding Bracket to the radio’s Fixed Bracket on the left side of the Battery Bracket and remove the Sliding Bracket.

3.

Secure the radio to the Sliding Bracket via four #6-32 x ¼” SEM Screws.

4.

Install the Radio Interface Cable into the radio’s 25-pin D-type connector on the bottom of the radio and tighten the harness connector mounting screws.


5.

Slide the radio and Sliding Bracket into the radio’s Fixed Bracket and turn the Slotted Studs clockwise to lock the radio in place.

6.

Insert the Power Cable into the bottom of the radio. The radio’s Power Cable is secured by a built-in screw-in/out type fastener.

7.

Install the Internal Antenna Cable or Polyphaser Cable into the bottom of the radio.

8.

Close and secure the Door.

9. Connect the user supplied antenna cable to the polyphaser or antenna cable connection on the bottom of the TeleRTU Plus.

Figure 3 - Bottom View of MDS Radios

2.1.3 Installation of the Radio Option into a Non-Radio Ready TeleRTU Plus

1.

Open the Instrument Front Cover.

2.

Remove the Lead Acid Battery (see Section 3.3.1).

3.

Install the Fixed Mounting Bracket (with (2) PC Card Guides) to the left side of the Battery Mounting

Bracket via four #6-32 x 3/8” Flat Head Screws.

4.

Mount the radio onto the Sliding Mounting Bracket via four #6-32 x 1/4" SEM Screws.

5.

Connect the Radio Interface Cable to the 25-pin D-Type Connector on the bottom of the radio.

6.

Connect the Radio Power Cable to the 13.8 VDC Power Connector on the bottom of the radio.


7.

Install the radio mounted on the Sliding Bracket assembly into the Fixed Mounting Bracket and secure the brackets by turning the two fastening Studs (on the Sliding Bracket) clockwise.

8.

Install the battery (see Section 3.3.1).

9.

Remove the Seal plug from the bottom of the enclosure. If a Polyphaser is not present, connect the

Antenna Cable’s Right Angle N-Type Male Coaxial Connector to the Female N-Type Coaxial Antenna

Connector on the bottom of the radio. Install the other end of this cable (N-Type Female Coaxial

Bulkhead Jack to the bottom of the enclosure (see Figure 6).

If a Polyphaser is utilized, connect one end of the Radio to Polyphaser Cable to the radio and the other end to the Polyphaser. Note; Both ends of this cable have N-Type Male Coaxial Cable

Connectors.

10.

Referring to Table 1, connect the other end of the Radio Interface Cable to the CPU Board.

11. Connect the bare wire end of the Radio Power Cable to J6 as follows:

Red Wire = J6-1 = PWR 1

Blk Wire = J6-2 = GND

12.

Connect the user supplied antenna cable to the Polyphaser or Antenna Cable connection on the bottom of the TeleFlow Plus.


2.2 WIRING LISTS

TeleFlow/Radio Interface Cable (392635-01-1)

CPU Pin #

CPU Board

Sig. Name

Radio D-Conn. #

& Wire Color

Radio D-Conn.

Signal Name

Function

J13-2

J13-3

J13-4

J13-5

J13-6

J13-7

RDCD

RDTR

RCTS

RRTS

RRXD

RTXD

8 (Green)

N/A

5 (Brown)

4 (Blue)

3 (White)

2 (Red)

DCD (Out)

CTS (Out)

RTS (In)

RXD (Out)

TXD (In)

J14-8 AI 21 RSSI

Ground


Data Term. Ready Output

Clear To Send Input


Receive Data Input


Receive Signal Strength

Indicator/Analog Input

Table 1- TeleRTU Plus/Radio Interface Cable (392635-01-1) Wire List

(MDS Radio Interface Cable)

Radio Power Cable (392638-01-0)

RADIO

Pwr. Conn.

COLOR

TeleFlow CPU

SIGNAL

+ RED 1

− BLK 2

16.5 V Max

13.8 V Typ.

GND

Table 2- Radio Power Cable (392638-01-0) Wire List


Figure 4 - Radio Power Cable 392638-01-0

Figure 5 – TeleRTU Plus/Radio Interface Cable 392635-01-1

Note:

The orange RRSI conductor (Receive Strength Signal Indicator) can be used to monitor the receiver's signal strength when a volt meter is placed across RRSI (Orange) and Ground (CPU Connector J13-1).

Figure 6 - Mounting Diagram for Internal & External Coaxial Antenna Cable


Figure 7 - Mounting Diagram for Polyphaser/Polyphaser Cable

& External Coaxial Antenna Cable


3.1 GENERAL SPECIFICATIONS

3.1.1 Model 4710 General Specs.

Frequency Band:

Frequency Increments:

Frequency Stability:

380-512 MHz

6.25 kHz or 5 kHz (factory configurable)

1.5 PPM, -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)

Primary Power:

Voltage: 13.8 Vdc nominal

(10.5 - 16 Vdc Operating Range)

1.8 A nominal, 2.5 A maximum TX Supply Current:

RX Supply Current:

Reverse Polarity Protection:


Frequency Band:

Frequency Increments:


150 mA (< 16 mA in Sleep Mode)

Diode across primary input

800-960 MHz

6.25 kHz or 5 kHz (factory configurable)

1.5 PPM, -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)


Primary Power:

Voltage:

TX Supply Current:

RX Supply Current:



Frequency Band:

Frequency Hopping Range:


Primary Power:

Voltage:

TX Supply Current:

RX Supply Current:

Standby Current (Sleep Mode):


3.2 TRANSMITTER SPECIFICATIONS

3.2.1 Model 4710 Transmitter Specs.

Frequency Range:

Power Output:

Duty Cycle:

Output Impedance:


RF Channel Bandwidth:

Spurious & Harmonic Emissions:

Response Time:

13.8 Vdc nominal

(10.5- 16 Vdc Operating Range)

1.8 A nominal, 2.5 A maximum

150 mA (< 16 mA in Sleep Mode)


902-928 MHz part 15 Spread Spectrum Band

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

±

0.00015% (1.5 PPM), -30

°

C to +60

°

C,

(-22

°

F to +140

°

F) For all Models

13.8 Vdc nominal

(10.5- 26.0 Vdc Operating Range)

<400 mA

<125 mA

<30 mA


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

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

Connector

Continuous

50 Ohms

1.5 PPM, -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)

12.5 kHz

-65 dBc

5 ms


Time-out Timer:


Frequency Range:

Power Output:

Duty Cycle:

Output Impedance:



Spurious & Harmonic Emissions:

Response Time:

Time-out Timer:


Frequency Band:

Power Output:

Duty Cycle:

Output Impedance:


Spurious Emissions:

Harmonic Emissions:

Transmitter Keying:

3.3 RECEIVER SPECIFICATIONS

3.3.1 Model 4710 Receiver Specs.

Frequency Range:

Page 10

Internal; programmable from 1-255 seconds in

1-second increments

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

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

Connector

Continuous

50 Ohms

1.5 PPM, -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)

12.5 kHz

-65 dBc

5 ms

Internal; programmable from 1-255 seconds in

1-second increments

902-928 MHz Part 15 Spread Spectrum Band.

.1 to 1 Watt (20-30 dBm ± 1dB)

Continuous

50 Ohms

±

0.00015% (1.5 PPM), -30

°

C to +60

°

C,

(-22

°

F to +140

°

F) For all Models

-60 dBc

-80 dBc

Data activated

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

Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide CI-3530-25B


Intermodulation:

IF Selectivity:

Desensitization:

Spurious and Image Rejection:


Sensitivity:

Squelch Opening Time:


Frequency Range:


Intermodulation:

IF Selectivity:

Desensitization:



Sensitivity:

Squelch Opening Time:


Frequency Band:


Intermodulation:

Desensitization:


CI-3530-25B

1.5 PPM, -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)

75 dB minimum (EIA)

65 dB minimum at adjacent Channel

65 dB minimum on 12.5 kHz Channel

85 dB minimum

12.5 kHz

12 dB SINAD at -110 dBm

2 ms

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

1.5 PPM, -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)

75 dB minimum (EIA)

65 dB minimum at adjacent Channel

65 dB minimum on 12.5 kHz Channel

85 dB minimum

12.5 kHz

12 dB SINAD at -110 dBm

2 ms

902-928 MHz Part 15 Spread Spectrum Band.

±0.00015% (1.5 PPM), -30

°

C to +60

°

C,

(-22

°

F to +140

°

F) For all Models

75 dB minimum (EIA)

65 dB minimum (EIA) on 12.5 kHz Channels

70 dB minimum

Appendix H – MDS 4710A/B, 9710A/B & 9810 Radio Installation Guide Page 11

Bit Error Rate:


3.4.1 MDS Models 4710, 9710 & 9810

Temperature Range:

Humidity:

Less than 10

-6

at -110 dBm

Full Performance -30

°

C to +60

°

C,

(-22

°

F to +140

°

F)

95% at +40

°

C (104

° F)


Appendix I

FreeWave RADIO OPTION

For Instruction Manual

CI-3530-25B

Issue: 04/2002

FREE

W AVE

Model Number: DGRO9RFS

RS232

6V

Serial Number: XXX-XXXX

FCC ID: KNY-205-108213

Canada: 2329 102 336A

FreeWavw Technologies, Inc.

Boulder, CO 80301. This device complies with

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

1

Bristol Babcock

Appendix I

FreeWave RADIO OPTION


SECTION TITLE

1.1

1.2

2.1

2.1.1

2.1.2

2.1.3

2.2

2.3

3.1

3.2

3.3

3.4

PAGE #


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

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


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

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

Installation of the Radio Option into a Radio Ready TeleFlow Plus.............................. 7

Installation of the Radio Option into a Non-Radio Ready TeleFlow Plus...................... 8

WIRING LISTS................................................................................................................ 10

ADDITIONAL FreeWave INFORMATION ................................................................... 10


GENERAL SPECIFICATIONS ...................................................................................... 11

TRANSMITTER SPECIFICATIONS ............................................................................. 11

RECEIVER SPECIFICATIONS ..................................................................................... 11

ENVIRONMENTAL SPECIFICATIONS....................................................................... 12

Reference Document

FreeWave Spread Spectrum Wireless Data Transceiver User Manual

FreeWave Technologies, Inc.

1880 South Flatiron Court

Boulder, CO 80301

CI-3530-25B Appendix I Page 0-1 Table Of Contents

Section 1

INTRODUCTION


The TeleRTU J Plus may be ordered with a FreeWave Radio installed, i.e., "Radio

Equipped," or as a “ Radio Ready ” unit. Radio Ready units contain all hardware required to field install a BBI provided FreeWave Radio except the radio, antenna and external antenna cable. The FreeWave Radio option can be used with or without an optional

Polyphaser (Lightning/Impulse Suppresser). Radio Ready units can be ordered with or without an optional Polyphaser (see Figures 1 through 7).

The BBI supplied FreeWave Wireless Data Transceiver (Radio) Option mounts inside the

TeleRTU J Plus Enclosure and is secured to sliding bracket via (4) 4-40 x 1/4 pan head screws.

TeleRTUs (model 3530-25B) equipped with the FreeWave Radio Option utilize the following additional hardware:

1. FreeWave Wireless Data Transceiver

2. Fixed Mounting Bracket (with (2) PC Card Guides, (2) ¼ Turn Clip-On Receptacles, and (2) Push-On Retainers).

3. Sliding Mounting Bracket (with (2) studs, (2) washers and (2) stud ejector springs

4.

Radio/TeleRTU Interface Cable (396369-01-4) - 10-Pin Jack Connector (MTA-100) connects to the radio while the eight (8) open-ended wires (see Table 4) are connected to

CPU Board Connectors J4/P4 (Power) and J8/P8 (Network).

5.

(4) #4-40 x 1/4 Pan Head Screws (for securing radio to Sliding Bracket)

6.

(4) #6-32 x 5/16 Flat Head Screws (for securing Fixed Mounting Bracket to Battery

Bracket).

7.

Internal Coaxial Antenna Cable or Polyphaser and Polyphaser Cable.

1.2 LEDs

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

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

CD - Carrier Detect LED

TX Transmit LED

CTS - Clear To Send LED

CI-3530-25B Appendix I Page 1 FreeWave Radio Option

Table 1 - LED Status in Point to Point Communications

Condition

Power Disconnected

Connected, no repeater, sending sparse data

Master calling slave through repeater

Master connected to

Repeater, not to slave

Repeater connected to slave

Mode 6, disconnected

Setup Mode

Master Slave Repeater

CD TX CTS CD TX CTS CD TX CTS

SR SR SR SR O BR SR O BR

SG IF IF SG IF IF

SR SD

FO SD

SG

SR

IF

O

SG SG

SR

SR

IF

BR

SG

SR

SR

SG

SR

SG

O

O

IF

O

SG

BR

BR

IF

SG

SR

SR

SG

SG

O

SD

IF

SG

BR

SR

IF

SG

Table 1 & Table 2 Legend:

BR

FO

IF

O

SD

SG

SR

Blinking Red

Flashing Orange

Intermittent Flash Red

Off

Solid Red, Dim

Solid Green

Solid Red, Bright

Table 2 - LED Status in Multipoint Communications

Condition

Power Disconnected

Repeater & slave connected to master, no data

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

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

Master Slave Repeater

CD TX CTS CD TX CTS CD TX CTS

SR SD O SR O BR SR O BR

SR

SR

SG-

SR

SD

SD

SD

O

O

IF

SG

SG

SG

O

O

IF

SR*

SR*

SR*

SG

SG

SG

SD

SD

SR

SR*

SR*

SR*

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

FreeWave Radio Option Page 2 CI-3530-25B Appendix I

Figure 1 - FreeWave Radio

Figure 2 - Sliding Mounting Bracket installation Diagram


Section 2


2.1 RADIO REMOVAL/REPLACEMENT & INSTALLATION

DANGER

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

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

AVOID OPERATING EQUIPMENT DURING AN ELECTRICAL STORM. THE

IMPULSE SUPPRESSOR MAY SAVE EQUIPMENT FROM DANGER, BUT

SHOULD NOT BE CONSIDERED AS BEING SAFE FOR PERSONNEL.

2.1.1 Radio Removal/Replacement Procedure

To remove the Radio follow steps 1 through 6 below. To replace the Radio perform step 5 of section 2.1.2 and the follow steps 2 through 6 below in reverse order, installing rather than removing the item in question and then perform step 7.


2. Remove the Internal Antenna Cable or Polyphaser Cable from the top of the radio.

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

4. Using a screwdriver, turn counter-clockwise the Slotted Studs which secure the radio’s

Sliding Mounting Bracket to the radio’s Fixed Mounting Bracket. Slide the radio toward the front of the unit and out of the Fixed Mounting Bracket.

5. Disconnect the Radio/TeleFlow Interface Cable (396369-01-4) from the lower edge of the radio and remove the FreeWave Radio (installed on the Sliding Mounting Bracket).

6. If replacing the radio, remove the four screws that secure the radio to the Sliding

Mounting Bracket and remove the FreeWave Radio.



Figure 3 - FreeWave Radio Option Installed in TeleRTU Plus

(without Polyphaser Option) - Front View


Figure 4 - FreeWave Radio Option Installed in TeleRTU Plus

(without Polyphaser Option) - Side View


2.1.2 Installation of the Radio Option into a Radio Ready TeleRTU Plus

Radio Ready TeleRTUs contain all the hardware required (except the radio, internal and external antenna cables and antenna) to accommodate installation and operation of the radio option.


2. Using a screwdriver, turn counterclockwise the Slotted Studs which secure the radio’s

Sliding Bracket to the radio’s Fixed Bracket on the left side of the Battery Bracket and remove the Sliding Bracket.

3. Secure the radio to the Sliding Mounting Bracket via four #4-40 x 1/4 Pan Head Screws

(see Figures 2 & 6).

4. Install Radio Cable (396306-01-2) between the radio’s RF connector and the bottom of the TeleRTU Plus enclosure (see Figures 3, 4 & 7) (also see Section 2.3.1 of CI-3530-

25B). Note: If an optional Polyphaser is used install Radio Cable (396306-02-0) between the radio’s RF connector and the top of the Polyphaser (within the enclosure) (see Figure 7). TeleFlow enclosures that support a Polyphaser have a

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

Option) have a .580” diameter mounting hole.

5.

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

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

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

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

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

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

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

Table 3 - Setup Menu Terminal Settings

PARAMETER

Baud Rate

Data Rate

Parity

Stop Bits

Parity Check

Carrier Detect

SETTING

19,200

8

None

1

None/Off

None/Off


Figure 5 - Cable Diagram for Radio to PC Interface

6. Install the TeleFlow Radio Interface Cable (396369-01-4) onto Radio Connector J1. (see

Figures 1 & 4).

7. Slide the radio and Sliding Mounting Bracket into the radio’s Fixed Mounting Bracket and turn the Slotted Studs clockwise to lock the radio in place (see Figures 3 & 6).

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

9. Connect the user supplied antenna cable to the polyphaser or antenna cable connection on the bottom of the TeleRTU (see Figures 3, 4 & 7).


2.1.3 Installation of the Radio Option into a Non-Radio Ready TeleRTU Plus


2. Remove the Lead Acid Battery (see Section 3.3.1 of CI-3530-25B).

3. Install the Fixed Mounting Bracket (with (2) PC Card Guides) to the left side of the

Battery Mounting Bracket via four #6-32 x 5/16” Flat Head Screws.

4. Mount the radio onto the Sliding Mounting Bracket via four #4-40 x 1/4 Pan Head

Screws (see Figures 2 & 5).

5. Perform step 5 of section 2.1.2.

6. Install Radio Cable (396306-01-2) between the radio’s RF connector and the bottom of the TeleRTU Plus enclosure (see Figures 3, 4 & 7) (also see Section 2.3.1 of CI-3530-

25B). Note: If an optional Polyphaser is used install Radio Cable (396306-02-0)


between the radio’s RF connector and the top of the Polyphaser (within the enclosure) (see Figure 7). TeleFlow enclosures that support a Polyphaser have a

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

Option) have a .580” diameter mounting hole.

7. Install the TeleFlow Radio Interface Cable (396369-01-4) onto Radio Connector J1. (see

Figures 1 & 4).

8. Slide the radio and Sliding Bracket into the radio’s Fixed Bracket and turn the Slotted

Studs clockwise to lock the radio in place.

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

10. Connect the user supplied antenna cable to the polyphaser or antenna cable connection on the bottom of the TeleRTU Plus (see Figures 3, 4 & 7).


Figure 6 - FreeWave Radio Mounted on Sliding Mounting Bracket


Figure 7 - Partial View - TeleRTU Plus with Polyphaser Installed

2.2 WIRING LISTS

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

CPU Pin #

J4-1

J4-2

J8-1

CPU Board

Sig. Name

AUX PWR

GND

GND

Wire Pin. #

& Color

01 (Red)

04 (Black)

06 (Black)

J8-2

J8-4

J8-5

J8-6

J8-7

RDCD

RCTS

RRTS

RRXD

RTXD

Note: Pins 2 & 3 are not used.

08 (Green)

10 (Brown)

09 (Blue)

05 (Red)

07 (White)

Radio

Signal Name

B+

GND

GND

DCD (Out)

CTS (Out)

RTS (In)

TXD (Out)

RXD (In)

Function

DC Power (+)

DC Power (-) Ground

Ground

Data Carrier Detect Output

Clear To Send Output

Request To Send Input


Receive Data Input

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

2.3 ADDITIONAL FreeWave INFORMATION

The FreeWave Spread Spectrum Wireless Data Transceiver User Manual contains indepth details on modem parameters, operation, installation, tuning transceiver performance, and more. Copies of the FreeWave Spread Spectrum Wireless Data Transceiver User Manual can be obtained from FreeWave Technologies, Inc. (electronically) by contacting their Technical Support Group.

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

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


Section 3



Frequency:

Power Requirements:

Transmit Current:

Receive Cuurrent:

Idle Current:

Operating Modes:

3.3 RECEIVER SPECIFICATIONS

Sensitivity:

902 - 928 MHz

650 mA at 12V for 1W

600 mA at 8.5V for 400mW

100 mA at 12V

65 mA at 12V

Point-to-Point

Point-to-Multipoint

Peer-to-Peer

Store and Forward Repeater

Data Transmission:

Error Detection:

Data Encryption:

Link Throughput:

Interface:

32 Bit CRC, resend on error

Substitution, dynamic key

115 Kbaud

RS-232, 1200 Baud to 115.2 Kbaud,

Async., full duplex

3.2 TRANSMITTER SPECIFICATIONS

Output Power:

Range:

Modulation:

Occupied Bandwidth:

1W (+30 dBm) at 9.5V to 18.0V

400mW (+25 dBm) at 7.5V to 9.5V

20 Miles - Line of sight distance with unity gain antenna at 900 MHz.

GFSK, 120 kBs - 170 kBs

230 kHz

-108 dB at 10 -6 raw BER


Selectivity: 40 dB at fc ±230kHz

60 dB at fc ±460 kHz


Temperature Range:

Humidity:

Full Performance -40 ° C to +60 ° C,

(-40 ° F to +140 ° F)

5% to 90% (noncondensing)


21 Volt Power Supply

Board

Part No. 392947-01-3

(For TeleFlow Plus & TeleRTU Plus)

For The Following BBI Instruction Manuals:

CI-3530-20B & CI-3530-25B


Bristol Babcock

PIP-353021VS

- 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.

TeleFlow TM and TeleRTU TM are trademarks of Bristol Babcock. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.

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.



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.


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.


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.


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).



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

ESD-sensitive components.

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 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 THAT EXTEND BEYOND THE

DESCRIPTION OF THE FACE HEREOF.


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, trans-portation 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 ar-range 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.


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.


A. FAX

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


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


Bristol Babcock Inc.

Repair Dept.


Watertown, CT 06795

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

D. Phone

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


&VMWXSP &EFGSGO -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.

•


•


•

Return to Customer

Part I

Please be aware of the Non warranty standard charge:

•



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

√

in “returned”

Address No.

Bill to :


Ship to:


Purchase Order:

Phone: Fax:

Contact Name:____________________________________

E-Mail:


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,




3.

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


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


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.



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


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.



Contacting Bristol Babcock Directly

Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,



(860) 945-2200

(860) 945-2213 (FAX)



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 regarding ACCOL products, Open BSI Utilities , as well as

Bristol's Enterprise Server 7 / Enterprise Workstation 7 products, call (860) 945-2286.




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 .


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.


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



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-353021VS

21V POWER SUPPLY BOARD OPTION


SECTION TITLE

1.1


DESCRIPTION................................................................................................................... 1

2.1

2.1.1

2.1.2

2.2

2.2.1


REMOVAL/REPLACEMENT & INSTALLATION OF THE 21V

POWER SUPPLY OPTION ............................................................................................... 2

Removal/Replacement of the 21V Power Supply Option .................................................. 2

Installation of the 21V Power Supply Option .................................................................... 3

FIELD WIIRING ................................................................................................................ 4

Terminal Connections......................................................................................................... 4


3.1

3.2

3.3

GENERAL SPECIFICATIONS ......................................................................................... 6

PERFORMANCE SPECIFICATIONS .............................................................................. 6

ENVIRONMENTAL SPECIFICATIONS ......................................................................... 6

Supplements

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

Reference Documents

Low Power I/O Expansion Board Product Information Package....................................... PIP-EXPI/OTF

TeleFlow Plus - Electronic Gas Measurement Computer (3530-20B) Instruction Manual CI-3530-20B

TeleRTU Plus - Remote Terminal Unit (3530-25B) Instruction Manual ............................. CI-3530-25B

PIP-353021VS Page 0-1 Table Of Contents

BLANK PAGE

Section 1

INTRODUCTION

1.1 DESCRIPTION

The 21V Power Supply is a continuous mode boost switching type power supply. It is based upon a low power, low noise circuit that produces 21 Volts from a 12 Volt input. Fuse F1

(500 mA Slow Blow) is provided to protect the TeleFlow/TeleRTU power source from failures within 21V Power Supply. Fuse F2 (350 mA Fast Blow) is provided to protect the 21V Power

Supply circuitry from short circuits on an output.

Power shutdown is not an option with this unit since it employs a Boost circuit; therefore, the 21V Power Supply must be powered continuously. 21V Power Supplies receive input power (12V) from connector TB3 of the Power Distribution Board. The Power Distribution

Board is required because of CPU Board connector wiring capacity restrictions, i.e., the connectors only accommodate up to #14 AWG wire.

Four (4) mounting holes (one in each corner) are provided to accommodate a #4 mounting screw. However, these units are typically Snap Track mounted on a Dual PCB Mounting

Bracket (see Figure 2)).

The 21V Power Supply is mainly used in conjunction with Temperature and Pressure

Transmitters which require a higher than +12V but lower than 21.4V ( ± .8V) input supply to operate.

PIP-353021VS

Figure 1 - 21V Power Supply Board

Page 1 21V Power Supply Board

Section 2


2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE

21V POWER SUPPLY OPTION

2.1.1 Removal/Replacement of the 21V Power Supply Option

An installed 21V Power Supply option will contain the following parts:

1. 21V Power Supply Board (with removable Terminal Blocks)

2. Dual PCB Mounting Bracket

3. 2 Snap Tracks

4. Power Distribution Board (with removable Terminal Blocks)

5. Two #8-32 x ¼” SEM Screws

6. Two #8-32 x 3/8” Pan Head Screws and Two #7-32 Elastic Locking Nuts

Figure 2 - 21V Power Supply Option Major Components

TeleFlow Plus or TeleRTU Plus with Power Distribution Board

PIP-353021VS Page 2 21V Power Supply Board

To remove the optional 21V Power Supply, follow steps 1 through 4 below. To replace the

21V Power Supply follow steps 2 and 3 below in reverse order, installing rather than removing the item in question and then perform step 4.


2. Unplug the removable Terminal Blocks (with wiring harnesses installed) from the optional 21V Power Supply Board.

3. Slide the 21V Power Supply Board toward the front of the unit and out of the Snap

Track.

Note: If a replacement 21V Power Supply Board is available follow steps 2 through 3 in reverse order, installing rather than removing the item in question.


Figure 3 - Bottom View of TeleRTU Plus (Similar to TeleFlow Plus)

2.1.2 Installation of the 21V Power Supply Option


2. If the unit in question already contains a Power Distribution Board, but only has one

Snap Track, the other Snap Track will have to be installed. This will require removal of the two (2) #8-32x3/8” Pan Head Screws and the two (2) #8-32 Elastic locking Nuts which secure the Power Distribution Board’s Snap Track to the Dual PCB Mounting

Bracket. Secure the second Snap Track to the Dual PCB Mounting Bracket as shown in

Figure 2 using two (2) #8-32 x 3/8” Pan Head Screws and two (2) #8-32 Elastic Locking

Nuts. Slide the Power Distribution Board into the Snap Track as illustrated in Figure 2.


3. Connect power wiring (14 AWG) between the Power Distribution Board (PDB) and the

21V Power Supply Board’s input terminals and between the 21V Power Supply’s output terminals and the appropriate terminals on the Low Power I/O Expansion Board

(LPI/OEB) (see Table 1 and Figure 4). Route field wiring cable(s) (14 AWG) associated with the item to be powered, e.g., a 3508B Transmitter into the TeleFlow Plus or

TeleRTU Plus through a ¾” conduit fitting (user supplied) on the bottom of the enclosure

(see Figure 3). Connect Transmitter wiring to the appropriate LPI/OEB terminals (see

Figure 4).




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


21V Power Supply Boards contain two terminal blocks that accommodate interface connections to the 3530-20B or 3530-25B, power and field wiring connections. TB1 is a threeposition terminal block that provides input power connection from the Power Distribution

Board. Four-position Terminal Block (TB2) provides +21V power and ground to the Low

Power I/O Expansion Board (LPI/OEB) (see PIP-EXPI/OTF) which will power external devices requiring 21V power such as 3508B Transmitters.

TABLE 1 - 21V POWER SUPPLY BOARD TERMINAL DESIGNATIONS

21VPS

TB#

TB1-1

TB1-2

TB1-3

TB2-1

TB2-2

TB2-3

TB2-4

TB

ASSIGNMENT

+12VIN

12VGND

CONNECTION to PDB.

TB3-1

TB3-2

CHASSISGND N/A

+21V N/A

21VGND

+21V

21VGND

N/A

N/A

N/A

CONNECTION to LPI/OEB

N/A

N/A

N/A

TB1-1

TB1-2

N/A

N/A

21V Power Supply Boards may be connected to transmitters that require a higher than +12V but lower than 21.4V ( ± .8V) input supply to operate. The supply is wired across the +12VIN and 12VGND terminals of the 21V Power Supply Board. The input voltage range is

+10.8Vdcc to +16Vdc.

The +21V Power Supply Option is typically powered from the 3530’s power source (battery).

Because of power distribution restrictions (CPU Board connector wiring capacity), power must be routed through a Power Distribution Board (see Figures 2 & 4). Power Distribution

Boards are mounted to the 3530 in question using a Snap Track and Dual PCB Mounting


Bracket identical to the ones used for the LPTIB Board and the Digital to Relay I/O Board options.

PIP-353021VS

Figure 4 - 21V Power Supply Board Field Wiring

Page 5 21V Power Supply Board

Section 3



ESD Susceptibility:

EMI Compatibility:


Field connected circuits are designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV.

Designed to coexist within a shielded enclosure with the TeleFlow (3530-20B) or the TeleRTU

(3530-25B) electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

Field connected circuits are designed to meet the requirements of ANSI/IEEEC37.90-1998

(Formerly IEEE 472) for surge withstand capability.

3.2 PERFORMANCE SPECIFICATIONS

Input Voltage (Vin):

Input Current (Iin):

Output Voltage (Vout):

Output Current (Iout):

Ripple/Noise:

Efficiency:

Short Circuit Protection Fuses:

10.8V to 16V (dc)

100 mA (Typ. @ 12V & 50mA load)

140 mA (Max. over Temp. @ 50 mA load)

21.4V ± 0.8V

50 mA (Max.)

20mV (Max. P-P)

88% (Typ.)

F1 = 500 mA (Slow Blow)

F2 = 350 mA (Fast Blow)


Operating Temperature:

Storage Temperature:

Relative Humidity:

Vibration:

-40°C to +60°C (-40°F to +140°F)

-40°C to +85°C (-40°F to +185°C)

15% - 95% Non-condensing

1G for 10Hz to 500Hz per PMC-31-1

(without damage or impairment)


21 Volt Power Supply Board


1. The BBI 21 Volt Power Supply 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 BBI 21 Volt Power Supply Board. In the event of a conflict between the BBI 21 Volt Power Supply Board User Manual (PIP-353021VS) 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.




07/21/00 Appendix A, Document PIP-353021VS Page 1 of 1

BLANK PAGE

READER RESPONSE FORM

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

DOCUMENT NUMBER: PIP-353021VS

TITLE:

21V Power Supply Board Option Product Information Package

ISSUE DATE: JAN., 2003

COMMENT/COMPLAINT:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Mail this page to:

Bristol Babcock Inc.


Watertown, CT 06795

Attn: Technical Publications Group, Dept. 315

Bristol Babcock


Watertown, CT 06795

Phone: (860) 945-2200

Fax: (860) 945-2213

Website: www.bristolbabcock.com

U.S.A. Locations:

Northern Region



Watertown, CT 06795

Phone: (860) 945-2381

Fax: (860) 945-2525

[email protected]

Southwest Region


2000 Governor's Circle

Suite F

Houston, TX 77092-8731

Phone: (713) 685-6200

Fax: (713) 681-7331

[email protected]

Western Region


1609 South Grove Avenue

Suites 106 & 107

Ontario, CA 91761

Phone: (909) 923-8488

Fax: (909) 923-8988

[email protected]

Southeast Region


317 S. North Lake Blvd.

Suite 1016

Altamonte Springs, FL 32701

Phone: (407) 740-7084

Fax: (407) 629-2106

[email protected]

Helicoid Instruments


Watertown, CT 06795

Phone: (860) 945-2218

Fax: (860) 945-2213 [email protected]

Dallas District Office


777 South Central

Expressway

Suite 1-C

Richardson, TX 75080

Phone: (972) 238-8197


International Affiliates :

Canada

Bristol Babcock, Canada

234 Attwell Drive

Toronto, Ont. M9W 5B3

Canada

PH: 416-675-3820

FAX: 416-674-5129 [email protected]

Mexico

BBI, S.A. de C.V.

Ejercito Nacional No. 718, 4

Piso

Colonia Polanco

Mexico, D.F. 11560

Mexico

PH: 52-555-254-5281

FAX: 52-555-254-3408

[email protected]

Sales Office New Mexico


906 San Juan Blvd., Suite A

Farmington, NM 87401

Phone: (505) 320-5046

Fax: (505) 327-3273

[email protected]

Communications

Technology Group



Suite 1016


Phone: (407) 629-9464


United Kingdom

Bristol Babcock Ltd.

Vale Industrial Estate

Stourport Road

Kidderminster

Worcestershire DY11 7QU

United Kingdom

PH: +44 (0) 1562 820001

FAX: +44 (0) 1562 746721 [email protected]

Australia

Bristol Babcock, Inc.

22 Hastie St.

PO Box 1987

Banbury, Western Australia

6230

PH: 61 (0)8 9791 3654

FAX: 61 (0)8 9791 3173 [email protected]

Calgary Office


3812 Edmonton Trail N.E.

Calgary, Alberta T2E 5T6

Canada

PH: 403-265-4808


Villahermosa Office

BBI, S.A. de C.V.

Av. Plomo No.2

Bodega No. 1 - Ciudad

Industrial

Villahermosa, Tabasco 86010

Mexico

PH: 52-993-353-3142

FAX: 52-993-353-3145 [email protected]

Middle East



Stourport Road

Kidderminster


United Kingdom

PH: +44 (0) 1562 820001



PIP-TIBS3530

Mar., 2007 TeleFlow Plus & TeleRTU Plus

Low Power Transmitter Interface

Board Part No. 392950-01-4

For The Following Bristol Instruction Manuals:

CI-3530-20B & CI-3530-25B




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.


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 .










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.





A. FAX



B. E-MAIL



C. Mail


Bristol Inc.

Repair


Watertown, CT 06795


D. Phone



Bristol




Date___________________ RA #___________________SH


•


•


•

Return to Customer

Line No.____________


•


√

in “returned”



Address No.

Bill to :

Purchase Order:

Phone:


Ship to:

Fax:


Contact Name: ____________________________________

E-Mail:




1.







A.


B.


C.


D.





____________________________________________________________________________________________________



Bristol

Training










6200.


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






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.


Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,



(860) 945-2200

(860) 945-2213 (FAX)



During regular business hours, Bristol's Application Support Group can provide telephone support for your technical questions.



















PIP-TIBS3530

LOW POWER TRANSMITTER INTERFACE BOARD

PT. NO. 392950-01-4


SECTION TITLE

1.1

1.1.1

1.2

1.3


DESCRIPTION ...................................................................................................................1

Transmitter Operation .........................................................................................................1

LED INDICATORS ............................................................................................................2

JUMPER JP1.......................................................................................................................2

2.1

2.1.1

2.1.2

2.2

2.2.1

3.1

3.2


REMOVAL/REPLACEMENT & INSTALLATION OF THE LPTIB..............................3

Removal/Replacement of the Low Power Transmitter Interface Bd. .................................3

Installation of the Low Power Transmitter Interface Board Option ...................................4

FIELD WIIRING.................................................................................................................5

Terminal Connections .........................................................................................................5


GENERAL SPECIFICATIONS..........................................................................................8

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

SUPPLEMENTS

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

PIP-TIBS3530 Page 0-1 Table Of Contents

BLANK PAGE

Section 1

INTRODUCTION

1.1 DESCRIPTION

Low Power Transmitter Interface Boards allow up to two (2) Bristol, Series 3508 or Series

3808 Transmitters to communicate with an ACCOL loaded host TeleFlow 3530-20B

Electronic Gas Measurement Computer (EGMC) or 3530-25B TeleRTU. The EGMC/RTU polls and stores data from each transmitter and communicates with the network. Two

LEDS on the LPTI Board [CD (DS1) & RTS (DS2)] indicate the communication status.

The LPTI Board is housed in the TeleFlow Plus or TeleRTU Plus enclosure and is interfaced to a TeleFlow I/O Expansion Board. LPTI Boards are powered by a 12V power supply or battery. LPTI Boards contain one jumper (JP1) for configuration purposes.

The LPTI Board (Figure 1) is wired to the TeleFlow I/O Expansion Board connector (TB5) and is mounted with Snap Track (holder) and Mounting Bracket as illustrated in Figure 2.

1.1.1 Transmitter Operation

3508 Series

Each 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 Transmitters wired to the TI Board must be operated in the minimum current mode (3.8 mA). This mode is 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 - Transmitter Interface Board P/N 392950-01-4

PIP-TIBS3530 Page

3808 MVT Series

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.

1.2 LED INDICATORS

The LPTIB contains two LEDs which have the following functions: Carrier Detect (CD) and

Request to Send (RTS). When the board is sending a Request To Send, LED DS2 (RTS) will be ON and LED DS1 (CD) will be OFF. Conversely, when the LPTIB is receiving data from a 3508/3808 Transmitter, LED DS2 (RTS) will be OFF and LED DS1 - Carrier Detect (CD) will be ON.

1.3 JUMPER JP1

Jumper JP1 is used to configure the LPTIB for operation with one or two 3508/3808

Transmitters. If only one 3508/3808 Transmitter is to be connected to the LPTIB, Jumper

JP1 must be installed across JP1-1 and JP1-2. Additionally, when only one 3508/3808

Transmitter is to be connected to the LPTIB, it must be connected to connector TB1. When two 3508/3808 Transmitters are connected to the LPTIB, Jumper JP1 must be removed and stored in either JP1-1 or JP1-2.

PIP-TIBS3530 Page

Section 2


2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE LPTIB

2.1.1 Removal/Replacement of the Low Power Transmitter Interface Bd.

An installed LPTI Board option will contain the following parts:

1. LPTI Board (with removable Terminal Blocks

2. Dual PCB Mounting Bracket

3. Snap Track

4. LPTI Board Cables (Power & RS-232 Intf.)

5. Two #8-32 x ¼” SEM Screws

6. Two #8-32 x 3/8” Pan Head Screws and Two #7-32 Elastic Locking Nuts

Figure 2 - Low Power Transmitter Interface Board Mounting Diagram

TeleFlow Plus or TeleRTU with Power Distribution Board, 21V Power Supply

Board & Digital To Relay I/O Board

PIP-TIBS3530 Page

To remove the optional Low Power Transmitter Interface Board follow steps 1 through 4 below. To replace the Low Power Transmitter Interface Board follow steps 2 and 3 below in reverse order, installing rather than removing the item in question and then perform step

4.


2. Unplug the removable Terminal Blocks (with wiring harnesses installed) from the optional Low Power Transmitter Interface Board.

3. Slide the Low Power Transmitter Interface Board toward the front of the unit and out of the Snap Track.

Note: If a replacement Low Power Transmitter Interface Board is available follow steps 2 through 3 in reverse order (after configuring Jumper JP1

(see Section 1.3), installing rather than removing the item in question.



2.1.2 Installation of the Low Power Transmitter Interface Board Option


2. If the unit in question already contains a Power Distribution Board, but only has one

Snap Track, the other Snap Track will have to be installed. This will require removal of the two (2) #8-32x3/8” Pan Head Screws and the two (2) #8-32 Elastic locking Nuts which secure the Power Distribution Board’s Snap Track to the Dual PCB Mounting

Bracket. Secure the second Snap Track to the Dual PCB Mounting Bracket as shown in

Figure 2 using two (2) #8-32 x 3/8” Pan Head Screws and two (2) #8-32 Elastic Locking

PIP-TIBS3530 Page

Nuts. Configure the LPTIB for operation with one or two 3508/3808 Transmitters. If only one 3508/3808 Transmitter is to be connected to the LPTIB, Jumper JP1 must be installed across JP1-1 and JP1-2. Additionally, when only one 3508/3808 Transmitter is to be connected to the LPTIB, it must be connected to connector TB1. When two

3508/3808 Transmitters are connected to the LPTIB, Jumper JP1 must be removed and installed in JP1-1 or JP1-2. Slide the LPTI Board into the Snap Track (see Figure 2).

3. Connect power wiring (14 AWG) and RS-232 Interface wiring (20 to 14 AWG) to LPTIB.

Route field wiring cable(s) (20 to 14 AWG) associated with the LPTI Board into the

TeleFlow Plus or TeleRTU Plus through a ¾” conduit fitting (user installed) on the bottom of the enclosure (see Figure 3). Connect Transmitter wiring to the appropriate

LPTI Board Terminal Connectors (TB1 and TB2) (see Section 2.2.1, Table 1 & Figure 4).






LPTI Boards contain four terminal blocks that accommodate interface connections to the

3530-20B or 3530-25B, power and field wiring connections. TB1 & TB2 are two-position

Terminal Blocks, which connect to the signal/power inputs of the transmitters. Threeposition Terminal Block (TB3) connects to the 3530-20B or 3530-25B power source. Fiveposition Terminal Block TB4 provides an RS-232 interface with the host 3530-20B/25B.

TABLE 1 - LPTI BOARD TERMINAL DESIGNATIONS

LPTIB

TB#

LPTIB

TB NAME

TB1-1 XMTR1-

CONNECTION if PDB.

Is Present

3508/3808-

3530-20B

CONNECTION

If no PDB.

3508/3808-

3530-25B

CONNECTION

If no PDB.

3508/3808-

TB1-2 XMTR1+ 3508/3808+ 3508/3808+

TB2-1 XMTR2- 3508/3808- 3508/3808- 3508/3808-

TB2-2 XMTR2+ 3508/3808+ 3508/3808+

TB3-1 SHUTDOWN N/A

TB3-2 +12VIN TB5-1 of PDB.

TB3-3 +12VRET

TB4-1 GND

TB5-2 of PDB.

N/A N/A

CPUB J8-1 or J6-1 CPUB J2-1 or J4-1

CPUB J8-2 or J6-2 CPUB J2-2 or J4-2

GND of LPI/OB TB5-1 LPI/OB TB5-1 LPI/OB TB5-1

TB4-2 CTS

TB4-3 RTS

TB4-4 RXD

TB4-5 TXD

RTS of LPI/OB TB5-5

CTS of LPI/OB TB5-4

TXD of LPI/OB TB5-7

RXD of LPI/OB TB5-6

LPI/OB TB5-5

LPI/OB TB5-4

LPI/OB TB5-7

LPI/OB TB5-6

LPI/OB TB5-5

LPI/OB TB5-4

LPI/OB TB5-7

LPI/OB TB5-6

Note: PDB = Power Distribution Board

PIP-TIBS3530 Page

LPTI Boards may be connected to internally powered transmitters (see Figure 4). In the case of an Internally Powered Transmitter (powered from LPTIB’s on-board +12V Supply/Regulator) an external +12 Vdc power supply is wired to LPTI Board connector TB3 as shown in Figure 4. The supply is wired across the +12VIN and +12VRET terminals. The input voltage range is +10.8Vdcc to +16Vdc.

LPTIB’s are typically powered from the 3530’s power source (battery). Because of power distribution restrictions (CPU Board connector wiring capacity), power is typically routed through a Power Distribution Board (see Figures 5 & 6). Power Distribution Boards are mounted to the 3530 in question using a Snap Track and Dual PCB Mounting Bracket identical to the ones used for the LPTI Board and the Digital to Relay I/O Board options.

Figure 4 - Internally Powered Transmitter Field Wiring

PIP-TIBS3530 Page

Figure 5 - Mounted Power Distribution Board

Figure 6 - Power Distribution Board Schematic/Wiring Diagram

PIP-TIBS3530 Page

Section 3



Communication Interface:

3508/3808 Interface:

ESD Susceptibility:

RS-232 ( ± 3V minimum)

FSK Modem - Bell 202 Compatible

(1200 Hz/2200 Hz modulation)

Baud Rate is 1200


EMI Compatibility: Designed to coexist within a shielded enclosure with the TeleFlow (3530-20B) or the TeleRTU (3530-25B) electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

Transient Susceptibility: Field connected circuits are designed to meet the requirements of ANSI/-

IEEEC37.90-1998 (Formerly IEEE 472) for surge withstand capability.




Relative Humidity:

Vibration:

-40°C to +60°C (-40°F to +140°F)

-40°C to +85°C (-40°F to +185°C)


1G for 10Hz to 500Hz per PMC-31-1 (without damage or impairment)

PIP-TIBS3530 Page

Low Power Transmitter Interface Board


1. The Bristol Low Power Transmitter Interface Board (LPTIB) is listed by Underwriters


A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive Bristol LPTIB Board. In the event of a conflict between the LPTIB Board User Manual (PIP-TIBS3530) and this document, always follow the instructions in this document.






03/24/2007 Appendix A of PIP-TIBS3530 - LPTIB Board Page 1 of 1

BLANK PAGE

BLANK PAGE


Low Power Transmitter Interface Board Part No. 392950-01-4

PIP-TIBS3530

Mar., 2007


Bristol, Inc.


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.


Canada

Phone: 905-362-0880

Fax: 905-362-0882 www.EmersonProcess.com/Bristol


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



Blackpole Road

Worcester, WR3 8YB

United Kingdom

Phone: +44 1905 856950

Fax: +44 1905 856969 www.EmersonProcess.com/Bristol


Bristol, Inc.




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.


PIP-EXPTIBS

Mar., 2007 TeleFlow Plus & TeleRTU Plus

Expansion Transmitter Interface

Board Part No. 392951-01-0


CI-3530-20B & CI-3530-25B


















Telephone (860) 945-2200

WARRANTY












FACE HEREOF.


REMEDIES







A. FAX



B. E-MAIL



C. Mail


Bristol Inc.

Repair


Watertown, CT 06795


D. Phone



Bristol




Date___________________ RA #___________________SH


•


•


•

Return to Customer

Line No.____________


•


√

in “returned”



Address No.

Bill to :

Purchase Order:

Phone:


Ship to:

Fax:


Contact Name: ____________________________________

E-Mail:




1.







A.


B.


C.


D.





____________________________________________________________________________________________________



Bristol

Training










6200.













(860) 945-2200

(860) 945-2213 (FAX)






















PIP-EXPTIBS

EXPANSION TRANSMITTER INTERFACE BOARD

PT. Number 392951-01-0



SECTION TITLE

1.1

1.1.1

1.2

1.3

PAGE #


DESCRIPTION................................................................................................................... 1

Transmitter Operation......................................................................................................... 1

LED INDICATORS............................................................................................................ 2

JUMPER JP1 ...................................................................................................................... 2

2.1

2.1.1

2.1.2

2.2

2.2.1


REMOVAL/REPLACEMENT & INSTALLATION OF THE ETIB................................ 3

Removal/Replacement of the Expansion Transmitter Interface Board .............................. 3

Installation of the Expansion Transmitter Interface Board Option .................................... 6

FIELD WIRING ................................................................................................................. 7

Terminal Connections......................................................................................................... 7


3.1

3.2

GENERAL SPECIFICATION............................................................................................ 9

ENVIRONMENTAL SPECIFICATIONS ......................................................................... 9

SUPPLEMENTS

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

PIP-EXPTIBS Page 0-1 Table Of Contents

BLANK PAGE

Section 1

INTRODUCTION

1.1 DESCRIPTION

Expansion Transmitter Interface Boards (ETIBs) allow up to two (2) Bristol, Series 3508C

Transmitters to communicate with an ACCOL loaded host TeleFlow Plus Electronic Gas

Measurement Computer (EGMC) (3530-20B) or TeleRTU Plus (3530-25B). The EGMC/RTU polls and stores data from each transmitter and communicates with the network. Two

LEDS on the ETIB Board [CD (DS1) & RTS (DS2)] indicate the communication status.

The ETIB Board is housed in either the standard TeleFlow Plus or TeleRTU Plus enclosure and is interfaced to a TeleFlow/TeleRTU CPU Board via the CPU Board’s Expansion Connector. Power from and communication with the host CPU Board is supplied through the

Expansion Connector. ETIB Boards contain one jumper (JP1) for configuration purposes.


Each 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 Transmitters wired to the TI Board must be operated in the minimum current mode (3.8 mA). This mode is 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.


PIP-EXPTIBS Page

1.2 LED INDICATORS

The ETIB contains two LEDs which have the following functions: Carrier Detect (CD) and

Request to Send (RTS). When the board is sending a Request To Send, LED DS2 (RTS) will be ON and LED DS1 (CD) will be OFF. Conversely, when the ETIB is receiving data from a

3508 Transmitter, LED DS2 (RTS) will be OFF and LED DS1 - Carrier Detect (CD) will be

ON.

1.3 JUMPER JP1

Jumper JP1 is used to configure the ETIB for operation with one or two 3508 Transmitters.

If only one 3508 Transmitter is to be connected to the ETIB, Jumper JP1 must be installed across JP1-1 and JP1-2. Additionally, when only one 3508 Transmitter is to be connected to the ETIB, it must be connected to connector TB1. When two 3508 Transmitters are connected to the ETIB, Jumper JP1 must be removed and stored in either JP1-1 or JP1-2.

PIP-EXPTIBS Page

Section 2


2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE ETIB

2.1.1 Removal/Replacement of the Expansion Transmitter Interface Bd.

An installed ETIB option will contain the following parts:

1. Expansion Transmitter Interface Board (ETIB) (with removable Terminal Blocks)

2. Three #8-32 x 1/4

”

SEM Screws

3. Three #4-40 x 15/32

”

Standoffs

Figure 2 - Expansion Transmitter Interface Bd. Mounted on TeleFlow CPU Board

PIP-EXPTIBS Page

Figure 3 - Expansion TIB Mounted on TeleRTU CPU Board

To remove the optional Expansion Transmitter Interface Board, follow steps 1 through 7 below. To replace the ETIB Board follow steps 2 and 6 below in reverse order, installing rather than removing the item in question and then perform step 7 (see Figures 4 & 5).

Note:

Any PC Board is not to be removed under any circumstances unless the

TeleFlow/TeleRTU has been moved to an ESD safe area (see ESDS Manual S14006).

The CPU Board should typically only be removed to replace the on board Lithium

Battery or Fuse F1 or to install an optional I/O Expansion Board or an Expansion

TIB Board.

PIP-EXPTIBS Page


2. Disconnect power by removing harness connector plug (P8 for TeleFlow - P2 for

TeleRTU) from the CPU Board edge connector (J8 for TeleFlow - J2 for TeleRTU).

3. Unplug the remaining removable Terminal Blocks (with wiring harnesses installed) from the CPU Board’s front edge connectors.

4. Unplug the removable Terminal Blocks (with wiring harnesses installed) from the optional ETIB Board.

Figure 4 - Horizontally Mounted TeleFlow CPU & Expansion ETIB


Fixed Bracket on the bottom of the Battery Bracket. Carefully slide the CPU Board (and optional ETIB Board) toward the front of the unit and remove harness connections from the Front Panel Switch (J12 on TeleFlow CPU - J14 on TeleRTU CPU), the Display

Module (J2 on TeleFlow CPU - J17 on TeleRTU CPU), the Wakeup Switch (J3 on

TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards connector J1 associated with the Multivariable Transducer.

Figure 5 - Horizontally Mounted TeleRTU CPU & Expansion ETIB

6. Remove the 3 screws that secure the ETIB Board to the standoffs and carefully remove the ETIB Board toward the front of the unit.

PIP-EXPTIBS Page

Note: If a replacement Expansion Transmitter Interface Board is available follow steps 2 through 6 in reverse order (after configuring Jumper JP1

(see Section 1.3), installing rather than removing the item in question.



2.1.2 Installation of the Expansion Transmitter Interface Board Option

1. Open the Instrument Front Cover and remove the CPU Board (see Section 2.1.1 - steps

2 through 5).

2. Replace the three screws that secure the CPU Board to the Mounting standoffs with #4-

40 x 15/32

”

Standoffs (see Section 2.1.1 - Figures 4 & 5).

3. Install the ETIB Board onto the CPU Board in question making sure that the

Expansion Connectors properly mate. Secure the ETIB Board to the three mounting standoffs with three #8-32 x 1/4

”

screws.

4. Reinstall the CPU Board (with ETIB) into the TeleFlow or TeleRTU (see Section 2.1.1).

5. Install 3508 Transmitter wiring to the ETIB Board (see Section 2.2.1). Wiring should be routed through a 3/4

”

conduit fitting (user installed) on the bottom of the enclosure (see

Figure 6).


PIP-EXPTIBS Page





ETIB Boards contain two terminal blocks that field wiring connections to the transmitter(s). TB1 & TB2 are two-position Terminal Blocks which connect to the signal/power inputs of the transmitters.

Figure 7 - Internally Powered Transmitter Field Wiring

PIP-EXPTIBS Page

TABLE 1 - ETIB BOARD TERMINAL DESIGNATIONS

LPTIB

TB#

LPTIB

TB NAME

CONNECTION if PDB.

Is Present

TB1-1 XMTR1- 3508-

TB1-2 XMTR1+ 3508+

TB2-1 XMTR2- 3508-

3530-20B

CONNECTION

If no PDB.

3508-

3508+

3508-

3530-25B

CONNECTION

If no PDB.

3508-

3508+

3508-

TB2-2 XMTR2+ 3508+ 3508+ 3508+

ETIB Boards may be connected to internally powered transmitters. Connection to internally powered transmitters (powered from ETIB’s on-board +12V Supply/Regulator) is illustrated in Figure 7.

PIP-EXPTIBS Page

Section 3




3508-10C/30C Interface:

ESD Susceptibility:

EMI Compatibility: comparable or superior to associated electronics.






Designed to coexist within a shielded enclosure with the TeleFlow (3530-20B) or the TeleRTU (3530-25B) electronics. EMI radiation is insignificant and susceptibility is

Field connected circuits are designed to meet the requirements of ANSI/-





Relative Humidity:

Vibration:

-40°C to +60°C (-40°F to +140°F)

-40°C to +85°C (-40°F to +185°C)


1G for 10Hz to 500Hz per SAMA PMC-31-1


PIP-EXPTIBS Page

BLANK PAGE

Expansion Transmitter Interface Board


1. The Bristol Expansion Transmitter Interface Board (ETIB) is listed by Underwriters


A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive Bristol ETIB Board. In the event of a conflict between the ETIB Board User Manual (PIP-EXPTIBS) and this document, always follow the instructions in this document.




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.


03/14/2007 Appendix A of PIP-EXPTIBS - ETIB Board Page 1 of 1

BLANK PAGE

BLANK PAGE


Expansion Transmitter Interface Board Part No. 392951-01-0

PIP-EXPTIBS

Mar., 2007


Bristol, Inc.


Watertown, CT 06795

Phone: +1 (860) 945-2262



Bristol Canada

6338 Viscount Rd.


Canada

Phone: 905-362-0880






11540 Mexico, D.F.

Mexico

Phone: (52-55)-52-81-81-12




Blackpole Road

Worcester, WR3 8YB

United Kingdom

Phone: +44 1905 856950



Bristol, Inc.




Phone: +61 (8) 9725-2355






TeleFlow

™



Bristol, Inc.


PIP-EXPTIBTF

Mar., 2007 TeleFlow Series 3530-10B/15B/20B/25B/35B/50B

Expansion Transmitter Interface

Board Part No. 392960-01-0


CI-3530-10B, CI-3530-15B, CI-3530-20B,

CI-3530-25B, CI-3530-35B & CI-3530-50B


















Telephone (860) 945-2200

WARRANTY












FACE HEREOF.


REMEDIES







A. FAX



B. E-MAIL



C. Mail


Bristol Inc.

Repair


Watertown, CT 06795


D. Phone



Bristol




Date___________________ RA #___________________SH


•


•


•

Return to Customer

Line No.____________


•


√

in “returned”



Address No.

Bill to :

Purchase Order:

Phone:


Ship to:

Fax:


Contact Name: ____________________________________

E-Mail:




1.







A.


B.


C.


D.





____________________________________________________________________________________________________



Bristol

Training










6200.













(860) 945-2200

(860) 945-2213 (FAX)






















PIP-EXPTIBTF

EXPANSION TRANSMITTER INTERFACE

BOARD

PT. Number 392960-01-0



SECTION TITLE


1.1 DESCRIPTION .................................................................................................... 1

Operation ........................................................................................ 1

1.2 Features................................................................................................................ 2

1.3 JUMPER


REMOVAL/REPLACEMENT & INSTALLATION OF THE ETIB................... 3

Removal/Replacement of the Expansion Transmitter Interface Board ............ 3

2.1

2.1.1

2.1.1.1

2.1.1.2

Installation/Removal for Models 3530-10B, -15B & -50B.................................. 3

Installation/Removal for Models 353-20B & -25B............................................ 10

2.1.1.3 Installation/Removal for Model 3530-35B........................................................ 12

2.2 FIELD

2.2.1.1

2.2.1.2

2.2.1.3

WIRING ................................................................................................. 13

2.2.1 Terminal

Terminal Connections for Model 3808 Transmitters....................................... 14

Terminal Connections for a single Model 3508 Transmitter........................... 14

Trminal Connections for two Model 3508 Transmitters.................................. 15


3.1 GENERAL

SPECIFICATIONS ......................................................... 17

SPECIFICATION ........................................................................... 17

3.2 ENVIRONMENTAL

SUPPLEMENTS

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

PIP-EXPTIBTF Page 0-1 Table Of Contents

BLANK PAGE

Section 1

1.1 DESCRIPTION

INTRODUCTION

Expansion Transmitter Interface Boards (ETIBs) allow up to two (2) Bristol, Series 3508 or

Series 3808 Transmitters to communicate with an ACCOL loaded host TeleFlow or

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

TeleRTU, TeleRTU Plus or TeleRTU Module (3530-15B/25B/35B) or a TeleFlow Corrector

(3530-50B). The TeleFlow EGMC/RTU/Corrector polls and stores data from each transmitter and communicates with the network.

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

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


3508 Series

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 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.

PIP-EXPTIBTF


Page 1 Expansion TIB Option

3808 MVT Series

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.

1.1.2 Features

• ESD & Transient Susceptibility

Field connected circuitry has been designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV and the requirements of ANSI/IEEE

C37.90.1-1989 (formerly IEE 472) for surge withstand capability.

• EMI Compatibility

ETIB Boards have been designed to coexist inside a shielded enclosure with the

TeleFlow ™ electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

• Mounting

The ETIB Board measures 3.75” (9.525cm) in width x 4.0” (10.160cm) in height and mounts piggy-back on a TeleFlow or TeleRTU CPU Board.

1.2 JUMPER JP1

Jumper JP1 is used to configure the ETIB for operation with one or two 3508/3808 Transmitters. If only one 3508/3808 Transmitter is to be connected to the ETIB, Jumper JP1 must be installed across JP1-1 and JP1-2. Additionally, when only one 3508/3808

Transmitter is to be connected to the ETIB, it must be connected to connector TB1. When two 3508/3808 Transmitters are connected to the ETIB, Jumper JP1 must be removed and stored in either JP1-1 or JP1-2.

Expansion TIB Option Page 2 PIP-EXPTIBTF

Section 2


2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE ETIB

2.1.1 Removal/Replacement of the Expansion Transmitter Interface Bd.

An installed ETIB option will contain the following parts:

1. Expansion Transmitter Interface Board (ETIB) (with removable Terminal Blocks)

2. Three #4-40 x 15/32” Standoffs (Note: Models 3530-10B, -15B & -50B will also contain

Three (3) #4-40 x .188” Standoffs & Two (2) #4-40 x 1/8” SEM Screws)

3. Modified PC Shield Assembly (for models 3530-10B, -15B & -50B)

WARNING

Never attempt to service a TeleFlow or TeleRTU while it is powered and operating in a hazardous environment.

Either the area must be made safe or the unit must be powered down, unwired, unmounted, and taken to a safe, non-hazardous area.

WARNING

Never attempt to install or remove any components

(PCBs, Field Wiring, Transducers, etc.) while the unit is powered and running. Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module or component in question, as well as other associated circuit boards. Always turn off the external/internal power source, including any additional supply sources used for externally-powered

I/O circuits, before changing or adding any components.

CAUTION

Place any related critical processes under manual or auxiliary control prior to shutting down or performing any of the steps discussed herein.

2.1.1.1 Installation/Removal for Models 3530-10B, -15B & -50B

To install the optional ETIB option into a model 3530-10B, -15B or -50B, follow steps 1 through 13 below. To remove the optional ETIB Board, see step 14. Note: The Instrument

Front Cover must be open.

1.

To open the Instrument Front Cover, remove the lock if present and turn each of the three captive screws a quarter (1/4) turn counterclockwise.

PIP-EXPTIBTF Page 3 Expansion TIB Option

Note:

The CPU Board is not to be removed under any circumstances unless the unit has been moved to an ESD safe area (see ESDS Manual - S14006).

2.

Remove the Power Plug(s), Solar Panel Power Plug, and the Auxiliary Power Plug as required, from the CPU Board in question.

3.

Remove the optional radio or modem if installed.

To remove an optional modem :

Disconnect the phone wires. Loosen the four (4) screws that secure the Modem/Radio

Mounting Plate (with modem) to the Battery Mounting Bracket. Slide the modem to the left and remove it and then disconnect the D-Type connector from the modem.

To remove an optional radio :

Disconnect the Radio/TeleFlow Interface Cable from the bottom of the Radio. Unplug the 2-wire power connector associated with the 2-wire Radio Power Interface Cable from the bottom of the Radio. Loosen the four (4) screws that secure the Modem/Radio

Mounting Plate (with radio) to the Battery Mounting Bracket. Slide the radio to the left and remove it.

4.

Remove the Battery(s) (if present).

To remove the battery(s) from units without an optional modem or radio :

Hold the battery securely and remove the Left Battery Mounting Bracket (secured with 2 screws. Loosen the screws which secure the Right Battery Mounting Bracket

(Carefully remove the battery (with wiring harness). Remove the Right Battery

Mounting Bracket.

To remove the battery(s) from units with an optional modem or radio :

Carefully remove the battery (with wiring harness). Note: You may have to loosen the two left 1/4-20 x 3/8” screws that secure the left side of the Battery Mounting Bracket and the Main Mounting Bracket to the rear of the unit.

While holding the Main

Mounting Bracket, remove the four (4) 1/4-20 x 3/8” screws and lock washers that secure the Battery Mounting Bracket and Main Mounting Bracket to the rear of the unit. Remove the Battery Mounting Bracket and temporarily reinstall the four screws to secure the Main Mounting Bracket to the 3530-10B or 3530-15B.

5.

Disconnect the Local Port, Network Port, RTD, and Field I/O wires from the CPU

Board connectors by unplugging their associated Terminal Plugs (front edge of CPU).

6. Carefully remove the PC Shield which is secured to the Main Mounting Bracket by 2

(#4-40 x 1/4”) screws and to the CPU Board by 2 (#4-40 x 1/4”) screws.

7. Remove the screw (location ‘A’ in Figures 2 & 3) and the two (2) #4-40 x 5/8” Standoffs

(location ‘B’ in Figures 2 & 3) which secure the CPU Board to the Main Mounting

Bracket. Replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

8.

Align the ETIB Board Connector P1 with CPU Board Connector J4 (for 3530-10B) or

J18 (for 3530-15B). Push the EXPCOM232 Board toward the CPU Board until

Connector P1 is fully seated.


Figure 2 - TeleFlow CPU Board – Installation Drawing #1

9.

Secure the ETIB Board to the CPU Board by installing three (3) #4-40 x .188”

Standoffs at Locations ‘A’ & ‘B’ (see Figures 2 & 3).

10. Carefully install the Modified PC Shield, securing it to the Main Mounting Bracket (at locations ‘C’) with two (2) #4-40 x 1/4” screws and to the CPU Board (at locations ‘B’) with two (2) #4-40 x 1/8” SEM screws (see Figures 4, 5, 6 & 7).

11. Follow steps 2 through 6 in reverse order, replacing rather than removing the item in question.


12.

Install 3508/3808 Transmitter wiring to the ETIB Board (see Section 2.2.1). Wiring should be routed through a ¾” conduit fitting (user installed) on the bottom of the enclosure.

Figure 3 - TeleRTU CPU Board – Installation Drawing #1

13.


14. To remove an optional ETIB Board, follow steps 1 through 6 (unplug the Field Wiring

Terminals during step 5). Remove the PC Shield along with the three Standoffs that


secure the ETIB Board to the CPU Board. Then unplug the ETIB Board from the CPU

Board in question.

PIP-EXPTIBTF

Figure 4 - TeleFlow CPU Board (with ETIB Installed)

Installation Drawing #2


Figure 5 - TeleRTU CPU Board (with ETIB Installed)

Expansion TIB Option


Page 8 PIP-EXPTIBTF

Figure 6 - 3530-10B & 3530-50B (with ETIB Installed)

PIP-EXPTIBTF

Figure 7 - 3530-15B (with ETIB Installed)


2.1.1.2 Installation/Removal for Models 3530-20B & -25B

To install the optional ETIB Board into a model 3530-20B or 3530-25B, follow steps 1 through 10 below. To remove the optional ETIB Board, perform steps 1 and 2 and then follow steps 4 through 9 in reverse order, removing rather than installing the item in question after the system has been shut down. Note: The Instrument Front Cover must be open.

1.

Open the Instrument Front Cover

2.

Disconnect power by removing harness connector plug (P8 for TeleFlow - P2 for


Expansion TIB Option

Figure 8 - 3530-20B CPU (with ETIB Installed)

Page 10 PIP-EXPTIBTF

3.

Unplug the remaining removable Terminal Blocks (with wiring harnesses installed) from the CPU Board’s front edge connectors.

4.

Remove the two screws that secure the CPU Board’s Sliding Mounting Bracket to the


(and optional ETIB Board) toward the front of the unit. Remove harness connections from the Front Panel Switch (J12 on the TeleFlow CPU - J14 on TeleRTU CPU), the

Display Module (J2 on TeleFlow CPU - J16 on TeleRTU CPU), the Wakeup Switch (J3 on TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards connector J1

(associated with the Multivariable Transducer).

Figure 9 - 3530-25B CPU (with ETIB Installed)

5.

Remove the three screws (of five) that secure the CPU Board to the Sliding Mounting

Bracket (locations ‘A’ & ‘B’ in Figures 2 & 3) and replace these items with the three new #4-40 x 15/32” Standoffs.


Note:


6.

Align the ETIB Board Connector P1 with CPU Board Connector J4 (for 3530-20B) or

J18 (for 3530-25B). Push the ETIB Board toward the CPU Board until Connector P1 is fully seated.

7.

Secure the ETIB Board to the CPU Board by installing three (3) #4-40 x 1/4” SEM screws as illustrated in Figures 8 & 9.

8.

Install 3508/3808 Transmitter wiring to the ETIB Board (see Section 2.2.1). Wiring should be routed through a ¾” conduit fitting (user installed) on the bottom of the enclosure.

9. Close and secure the Instrument Front Cover.

2.1.1.3 Installation/Removal for Models 3530-35B

To install the optional ETIB Board into a model 3530-35B, follow steps 1 through 7 below.

To remove the optional ETIB Board, perform step 1 and then follow steps 5 through 7 in reverse order, removing rather than installing the item in question after the system has been shut down.

1.

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


3. Remove harness connections from the Front Panel Switch (J14), the Display Module

(J16) and the Wakeup Switch (J16).

4. Remove the three screws (of five) that secure the CPU Board to the RTU Mounting


Note:


5. Align the ETIB Board Connector P1 with CPU Board Connector J18. Push the ETIB

Board toward the CPU Board until Connector P1 is fully seated.

6.

Secure the ETIB Board to the CPU Board by installing three (3) #4-40 x 1/4” SEM screws as illustrated in Figure 10.

7.

Install 3508/3808 Transmitter wiring to the ETIB Board (see Section 2.2.1).


Figure 10 - 3530-35B (with ETIB Installed)






2.2.1.1 Terminal Connections for Model 3808 Transmitters

ETIB Boards contain two terminal blocks that are used to provide field wiring connections to up to two Model 3808 Transmitters. TB1 & TB2 are two-position Terminal Blocks which connect to the signal/power inputs of the Transmitters.

JP1 Note:

If only one Transmitter is connected to the ETIB,

Jumper JP1 must be INSTALLED across JP1-1 & JP1-2.

When two Transmitters are connected to the ETIB,

Jumper JP1 must be REMOVED. Store the Jumper on

Jumper Post JP1-1 or JP1-2.

Note:

When only one Transmitter is connected to the ETIB, it

MUST BE connected to TB1.

Figure 11 - Internally Powered Model 3808 Transmitters - Field Wiring Diagram

ETIB Boards may be connected to up to two internally powered Model 3808 Transmitters.

Connection to internally powered Model 3808 Transmitters (powered from ETIB’s on-board

+12V Supply/Regulator) is illustrated in Figure 11.

2.2.1.2 Terminal Connections for a single Model 3508 Transmitter

The two-position Terminal Block TB1 is utilized to provide field wiring connections to an internally powered Model 3508 Transmitter.


JP1 Note:

Jumper JP1 must be INSTALLED across JP1-1 & JP1-2.

Figure 12 - Internally Powered Model 3508 Transmitter - Field Wiring Diagram

Connection to an internally powered Model 3508 Transmitter (powered from the ETIB’s onboard Supply/Regulator) is illustrated in Figure 12.

2.2.1.3 Terminal Connections for two Model 3508 Transmitters

ETIB Boards contain two terminal blocks that are used to provide field wiring connections for up to two Model 3508 Transmitters. TB1 & TB2 are two-position Terminal Blocks which connect to the signal/power inputs of the Transmitters. When using two Model 3508

Transmitters, an external 21 Volt (dc) power supply must be utilized (see Figure 13).


JP1 Note:

Jumper JP1 must be REMOVED. Store the Jumper on

Jumper Post JP1-1 or JP1-2.

TeleFlow CPU Connector J5-5

TeleRTU CPU Connector J6-2

GND

External 21V

Power Supply

Figure 13 - Externally Powered Model 3508 Transmitters - Field Wiring Diagram


Section 3




3508/3808 Interface:

ESD Susceptibility:

EMI Compatibility:




Baud rate is 1200


Designed to coexist within a shielded enclosure with the TeleFlow (3530-10/20B) or the TeleRTU (3530-15B/25B) electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

Transient Susceptibility: Field connected circuits are designed to meet the requirements of ANSI/-





Relative Humidity:

Vibration:

-40°C to +60°C (-40°F to +140°F)

-40°C to +85°C (-40°F to +185°C)


1G for 10Hz to 500Hz per SAMA PMC-31-1



BLANK PAGE

Expansion Transmitter Interface Board


1. The Bristol Expansion Transmitter Interface Board (ETIB) is listed by Underwriters


A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive Britol ETIB Board. In the event of a conflict between the ETIB Board User Manual (PIP-EXPTIBTF) and this document, always follow the instructions in this document.






03/14/2007 Appendix A of PIP-EXPTIBTF - ETIB Board Page 1 of 1


Expansion Transmitter Interface Board Part No. 392960-01-0

PIP-EXPTIBTF

Mar., 2007


Bristol, Inc.


Watertown, CT 06795

Phone: +1 (860) 945-2262



Bristol Canada

6338 Viscount Rd.


Canada

Phone: 905-362-0880






11540 Mexico, D.F.

Mexico

Phone: (52-55)-52-81-81-12




Blackpole Road

Worcester, WR3 8YB

United Kingdom

Phone: +44 1905 856950



Bristol, Inc.




Phone: +61 (8) 9725-2355






TeleFlow

™



Bristol, Inc.

EXPANSION COMMUNICATIONS

PORT RS-232 BOARD

Part No. 392970-01-5

(For Models 3530-XXX)


CI-3530-10B, CI-3530-15B, CI-3530-20B, CI-3530-25B,

CI-3530-35B, CI-3530-40B, CI-3530-45B & CI-3530-50B


Bristol Babcock

PIP-EXP232TF

– December, 2003

NOTICE

Copyright Notice




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


Bristol Babcock.






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

Babcock.


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.







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.


Telephone (860) 945-2200

A.

B.

C.

D.

E.

F.

A.

B.

WARRANTY




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







FACE HEREOF.


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.




(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.


A. FAX



B. E-MAIL



.


C. Mail



Repair Dept.


Watertown, CT 06795


D. Phone



&VMWXSP&EFGSGO-RG6ITEMV%YXLSVM^EXMSR*SVQ


Date___________________ RA #___________________SH_ Line No.____________

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

•


•


•

Return to Customer

Part I

Please be aware of the Non warranty standard charge:

•


√

in “returned” B,C, or D of part III below)


Address No.

Bill to :


Ship to:


Purchase Order:

Phone: Fax:

Contact Name:____________________________________

E-Mail:



Description


Reason for return : Failure Upgrade

S/N

Verify Operation Other

1.





3.

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


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.


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?







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

Form GBU 13.01

Rev. A

Bristol Babcock

Training







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.



6200.

BLANK PAGE











(860) 945-2200

(860) 945-2213 (FAX)














9464 .


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.







PIP-EXP232TF

EXPANSION COMMUNICATIONS PORT

RS-232 BOARD

PT. Number 392970-01-5



1.1

1.1.1

1.1.2

1.2

1.3

1.3.1

SECTION TITLE PAGE #


DESCRIPTION................................................................................................................... 1

Function .............................................................................................................................. 1

Features............................................................................................................................... 2

COMPONENT IDENTIFICATION................................................................................... 2

INSTALLATION COMPATIBILITY................................................................................ 2

Restrictions ......................................................................................................................... 2

2.1

2.1.1

2.1.1.1

2.1.1.2

2.1.1.3

2.2


EXPCOM232 REMOVAL/REPLACEMENT & INSTALLATION................................. 3

Installation/Removal of the EXPCOM232 Board .............................................................. 3

Installation/Removal for Models 3530-10B, -15B, -40B, -45B & -50B ............................ 3

Installation/Removal for Models 3530-20B & -25B ........................................................ 10

Installation/Removal for Models 3530-35B ..................................................................... 11

RS-232 WIRING............................................................................................................... 12


3.1

3.2

PERFORMANCE SPECIFICATIONS ............................................................................ 15

ENVIRONMENTAL SPECIFICATIONS ....................................................................... 15

SUPPLEMENTS


Special Instructions for Class I, Division 1 Hazardous Locations ..............................................Appendix B

PIP-EXP232TF Page 0-1 Table Of Contents

BLANK PAGE

Section 1

INTRODUCTION

1.1 DESCRIPTION

1.1.1 Function

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

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

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

EXPCOM232 Boards measure 4.0” by 3.75” and utilizes a 7-position Industrial 3.5mm pitch plugable connector to interface with an external RS-232 device. 16V bi-directional

Transient Absorption Zener Diodes are placed across all RS-232 outputs.

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

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

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

PIP-EXP232TF

Figure 1 - Expansion Communications Port RS-232 Board

Page 1 EXPCOM232 Option

1.1.2 Features

· Low Power

+5V @ 20mA (Max) regulated power is supplied by the host/parent 3530-XXX via the

40-pin Expansion Interface Connector P1.

· ESD & Transient Susceptibility

The RS-232 I/O circuitry has been designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV and the requirements of ANSI/IEEE


· EMI Compatibility

EXPCOM232 Boards have been designed to coexist inside a shielded enclosure with the TeleFlow ä electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

· Mounting

The EXPCOM232 Board measures 3.75” (9.525cm) in width x 4.0” (10.160cm) in height and mounts piggy-back on a TeleFlow or TeleRTU CPU Board.

· RS-232 Serial Port

EXPCOM232 Boards provide an additional RS-232 serial port that is programmable for rates up to 19.2Kbps. 3530-XXX units equipped with the EXPCOM232 Board can communicate with a local RS-232 device even though a radio or modem may be installed on the CPU Board’s network port.

1.2 COMPONENT IDENTIFICATION

EXPCOM232 Boards do not contain LEDs, switches or configuration jumpers. Two connectors are provided; 40-pin connector P1 mates with the host 3530-XX-X (connector J4 -

TeleFlow CPU or J18 - TeleRTU CPU) and accommodates the TTL interface between the two entities, while 7-pin connector TB1 mates with the RS-232 device that is being interfaced to the 3530-XXX. Additionally, the 3.5mm pitch plugable connector TB1 is removable from its mating EXPCOM232 Board socket.

1.3 INSTALLATION COMPATIBILITY

An EXPCOM232 Board can be installed into any of the following 3530-XXX models:

3530-10B - TeleFlow

3530-15B - TeleRTU

3530-35B - TeleRTU Module

3530-40B - TeleFlow ECR

3530-20B - TeleFlow Plus 3530-45B - TeleRecorder

3530-25B - TeleRTU Plus 3530-50B - TeleFlow Corrector

1.3.1 Restrictions

The 3530-XXX in question must be equipped with ACCOL application software. 3530-XXX units support installation of only one optional piggyback mounted Expansion Board (I/O,

Comm. or TIB).

EXPCOM232 Option Page 2 PIP-EXP232TF

Section 2


2.1 EXPCOM232 REMOVAL/REPLACEMENT & INSTALLATION

2.1.1 Installation/Removal of the

EXPCOM232 Board

In addition to hardware normally contained within the 3530-XXX in question, units with an installed EXPCOM232 Option will contain the following major parts.

1.

Expanded Communications Port RS-232 Board (EXPCOM232)

2.

Three #4-40 x 15/32” Standoffs (Note: Models 3530-10B, - 15B, -40B, -45B & -50B will also contain Three (3) #4-40 x .188” Standoffs & Two (2) #4-40 x 1/8” SEM Screws)

3.

Modified PC Shield Assembly (for models 3530-10B, -15B, -40B, -45B & -50B)

WARNING

Never attempt to service a TeleFlow, TeleRTU,

TeleRecorder or TeleFlow Corrector while it is powered and operating in a hazardous environment. Either the area must be made safe or the unit must be powered down, unwired, unmounted, and taken to a safe, nonhazardous area.

WARNING

Never attempt to install or remove any components

(PCBs, Field Wiring, Transducers, etc.) while the unit is powered and running. Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module or component in question, as well as other associated circuit boards. Always turn off the external/internal power source, including any additional supply sources used for externally-powered

I/O circuits, before changing or adding any components.

CAUTION


2.1.1.1 Installation/Removal for Models 3530-10B, -15B, -40B, -45B & -50B

To install the optional EXPCOM232 Board into a model 3530-10B, -15B, -40B, -45B or -

50B, follow steps 1 through 14 below. To remove the optional EXPCOM232 Board, see step

15. Note: The Instrument Front Cover must be open.

1.


PIP-EXP232TF Page 3 EXPCOM232 Option

Note:


2.


3.








4.





Mounting Bracket.




Mounting Bracket, remove the four (4) 1/4-20 x 3/8” screws and lock washers that secure the Battery Mounting Bracket and Main Mounting Bracket to the rear of the unit. Remove the Battery Mounting Bracket and temporarily reinstall the four screws to secure the Main Mounting Bracket to the 3530-10B, 15B, -45B or -50B.

5.

Disconnect the Local Port, Network Port, RTD, and Field I/O wires from the CPU Bd.

connectors by unplugging their associated Term. Plugs on the front edge of the CPU.






Note:


8.

Align the EXPCOM232 Board Connector P1 with CPU Board Connector J4 (for 3530-

10B, 40B or -50B) or J18 (for 3530-15B & -45B). Push the EXPCOM232 Board toward the CPU Board until Connector P1 is fully seated.



9.

Secure the EXPCOM232 Board to the CPU Board by installing three (3) #4-40 x .188”

Standoffs at locations ‘A’ and ‘B’ (see Figures 2 & 3).

10. Carefully install the Modified PC Shield, securing it to the Main Mounting Bracket (at locations ‘C’) with two #4-40 x 1/4” screws and to the CPU Board (at locations ‘B’) with two (2) #4-40 x 1/8” SEM screws (see Figures 4, 5, 6 & 7).

11. Follow steps 2 through 6 in reverse order, replacing rather than removing the item in question.


12.

Connect wiring between the EXPCOM232 Board and the DTE/DCE device to which it is to be interfaced (see Section 2.2).

13.

Configure the new network port in the ACCOL Load resident in the host 3530-XXX device.


14.


15. To remove an optional EXPCOM232 Board, follow steps 1 through 6 (unplug the RS-

232 cable during step 5). Remove the PC Shield along with the three Standoffs that


secure the EXPCOM232 Board to the CPU Board. Then unplug the EXPCOM232

Board from the CPU Board in question.

Figure 4 - TeleFlow CPU Board (with EXPCOM232 Installed)



Figure 5 - TeleRTU CPU Board (with EXPCOM232 Installed)



Figure 6 - 3530-10B, 3530-40B & 3530-50B (with EXPCOM232 Installed)

Figure 7 - 3530-15B & 3530-45B (with EXPCOM232 Installed)



To install the optional EXPCOM232 Board into a model 3530-20B or 3530-25B, follow steps

1 through 11 below. To remove the optional EXPCOM232 Board, perform steps 1 and 2 and then follow steps 4 through 9 in reverse order, removing rather than installing the item in question after the system has been shut down. Note: The Instrument Front Cover must be open.

1.


2.


TeleRTU) from the CPU Board edge connector (J8 for TeleFlow – J2 for TeleRTU).

Figure 8 - 3530-20B CPU (with EXPCOM232 Installed)

3.


4.



(and optional EXPCOM232 Board) toward the front of the unit. Remove harness connections from the Front Panel Switch (J12 on the TeleFlow CPU - J14 on TeleRTU

CPU), the Display Module (J2 on TeleFlow CPU - J16 on TeleRTU CPU), the Wakeup

Switch (J3 on TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards connector J1 (associated with the Multivariable Transducer).

5.



Note:


6.

Align the EXPCOM232 Board Connector P1 with CPU Board Connector J4 (for 3530-

20B) or J18 (for 3530-25B). Push the EXPCOM232 Board toward the CPU Board until


7.

Secure the EXPCOM232 Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figures 8 & 9.


Figure 9 - 3530-25B CPU (with EXPCOM232 Installed)

8.

Route the RS-232 cable through a ¾” conduit fitting (user installed) on the bottom of the enclosure.

9.


10.




To install the optional EXPCOM232 Board into a model 3530-35B, follow steps 1 through 8 below. To remove the optional EXPCOM232 Board, perform step 1 and then follow steps 5 through 7 in reverse order, removing rather than installing the item in question after the system has been shut down.

1.





4.

Remove the three screws (of five) that secure the CPU Board to the RTU Mounting


Note:


5.

Align the EXPCOM232 Board Connector P1 with CPU Board Connector J18. Push the

EXPCOM232 Board toward the CPU Board until Connector P1 is fully seated.


6.

Secure the EXPCOM232 Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figure 10.

7.


8.


Figure 10 - 3530-35B (with EXPCOM232 Installed)

2.2 RS-232 WIRING

Table 2-1 and Figure 11 must be referenced to configure the RS-232 cable. Pin 2 of TB1 =

DCD (Data Carrier Detect - DCD). DCD can be used to awaken the 3530-XXX in question from power conservation (sleep) mode. This signal is not supplied by DTE equipment.


PIP-EXP232TF

Figure 11 - EXPCOM232 Wiring Diagrams

Page 13 EXPCOM232 Option

Either an RS-232 level control signal (high) can be supplied to TB1-2, or TB1-2 may be connected to the EXC signal on the CPU Board. It must be noted that as long as TB1-2

(DCD) remains HIGH, the 3530-XXX in question will remain awake. Therefore, if TB1-2 is connected to an EXC signal on the resident CPU Board, power conservation will be defeated, thus reducing the battery back-up time.

RS-232 cables are typically short (20’ or less in length). When significant distances are a factor (i.e., between an EXPCOM232 Board and the remote Data Terminal Device (DTE) to which it is desired to communicate), the RS-232 Port (TB1) cable can be connected to the

RS-232 Port of a modem or that of a BBI Isolated RS-485 Board (see Table 2-1).

Table 2-1

EXPCOM232 Board (DTE) & DCE/DTE - RS-232 Port Pin Assignments

EXPCOM232

RS-232 – TB1

DTE

2 - DCD (In)

6 - RXD (In)

7 - TXD (Out)

3 - DTR (Out)

1 - GND

-

5 - RTS (Out)

4 - CTS (In)

-

EXPCOM232

RS-232 TB1 or

3530 Network

Port J13/J8

DTE

-

7 - TXD (Out)

6 - RXD (In)

-

1 - GND

-

4 - CTS (In)

5 - RTS (Out)

-

Modem

9-Pin – J4

DCE

1 - DCD (Out)

2 - RXD (Out)

3 - TXD (In)

4 - DTR (In)

5 - GND

6 - DSR (Out)

7 - RTS (In)

8 - CTS (Out)

9 - N/A

PC

(RS-232)

3310/30/35

3305

3332

Notes 1 & 2

BBI

Isolated RS-485

Board Option

J1

DTE

-

DTE

-

DTE

-

3 - TXD (Out) 2 - TXD (Out) 7 - TXD (Out)

2 - RXD (In)

-

4 - RXD (In)

-

6 - RXD (In)

-

5 - GND

-

8 - CTS (In)

7 - RTS (Out)

-

9 - GND

-

6 - CTS (In)

5 - RTS (Out)

-

1 - GND

-

4 - CTS (In)

5 - RTS (Out)

-

Note 1: Ports BIP1 & BIP2

BIP1 and BIP2 are RS-562 Ports (RS-232 compatible.

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

A & C are RS-423 Ports (RS-232 compatible).

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

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

A, B, C, D, G, H, I & J are RS-562 Ports (RS-232 compatible).

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

ECB’s 392589-01-0 & 392589-02-8

A, B, C, D, I & J are RS-232 Ports

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

CEB’s 392043-01-7 & 392058-01-4

A, B, C & D are RS-423 Ports (RS-232 compatible)




Section 3



Baud Rate (Max.):

Power Requirements:

Transient Protection:

RS-232 Outputs:

RS-232 Inputs:

RS-232 Ground:

RS-232 Interface Connector:

19.2K Asynchronous

+5Vdc @ 20mA Max. (Regulated)

16V Bi-directional Transient Absorption Zeners across all

RS-232 outputs

TXD (TB1-7)

DTR (TB1-3)

RTS (TB1-5)

DCD (TB1-2)

RXD (TB1-6)

CTS (TB1-4)

GND (TB1-1)

7-Pin Industrial 3.5mm Pitch Plugable Connector




Humidity:

ESD Susceptibility:

EMI Compatibility:


-40 ° to +60 ° (C) [-40 ° to 140 ° (F)]

-40 ° to +85 ° (C) [-40 ° to 185 ° (F)]

15% to 90% RH (Non-Condensing)

Meets the requirement of IEC 801-2 for ESD withstand

Capability up to 10KV.

Designed to coexist inside a shielded enclosure with the

TeleFlow electronics. EMI radiation is insignificant and

Susceptibility is comparable or superior to associated

Electronics.

Designed to meet the requirements of ANSI/IEEE

C37.90.1-1989 (Formerly IEEE 472) for surge withstand

Capability.


BLANK PAGE

Expansion Communications Port RS-232 Board


1. The BBI Expansion Communications Port RS-232 Board is listed by Underwriters


A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive BBI Expansion Communications Port RS-232

Board. In the event of a conflict between the Expansion Communications Port RS-232

Board User Manual (PIP-EXP232TF) and this document, always follow the instructions in this document.






07/17/2000 Appendix A of PIP-EXP232TF - EXPCOM232 Board Page 1 of 1

BLANK PAGE

Expansion Communications Port RS-232 Board for 3530-XXX

Special Instructions for Class I, Division 1 Hazardous Locations

1.

A version of the Expansion Communications Port RS-232 Board is available that is listed by Underwriters Laboratories (UL) as intrinsically safe for use in Class I, Division

1, Groups C and D hazardous locations. Read this document carefully before installing an intrinsically safe Expansion Communications Port RS-232 Board. Refer to the

Expansion Communications Port RS-232 Board User’s Manual (PIP-EXP232TF) for general information. In the event of a conflict between the Expansion Communications

Port RS-232 Board User’s Manual and this document, always follow the instructions in this document.

2.

Unless the Expansion Communications Port RS-232 Board is used in conjunction with an IStran Communications Interface Assembly (see CI-3530-Istran) it may not be used in a Class I, Division 1 hazardous location.

3.

When a TeleFlow equipped with an Expansion Communications Port RS-232 Board is used in a Class I, Division 1 location, it must be used in conjunction with a BBI IStran

Communications Interface and installed per instruction manual CI-3530-IStran and

PIP-EXP232TF.

4.

The IStran and Expansion Communications Port RS-232 Board can be located in a nonhazardous or Division 2 rated area, while the TeleFlow can reside in a Division 1, 2 or nonhazardous area.

A suitable enclosure must be provided for the IStran. When the IStran is mounted in a

Division 2 area, the nonhazardous interface connections shall be made in accordance with Article 501-4(b) of the National Electrical Code NFPA 70.

CAUTION

When connecting the IStran and Expansion Communications

Port RS-232 Board to a TeleFlow that is mounted in a Division

1 area, wire all circuits using wiring methods specified in article 504 of the National Electrical Code NFPA 70. Contact your IStran supplier for assistance.

When installing an Expansion Communications Port RS-232

Board in a TeleFlow that is mounted in a Division 2 area, ensure that the area is nonhazardous before connecting or disconnecting the nonhazardous interface.

5.

Figures B1 through B4 show variations of approved connections to the Expansion

Communications Port RS-232 Board via a BBI IStran Communications Interface

Assembly.

12/12/03 Appendix B - Document PIP-EXP232TF Page 1 of 3



Figure B1 - Intrinsically Safe System with Radio and EXPCOM232 Board

(with Single Power Source)

Figure B2 - Intrinsically Safe System with Modem and EXPCOM232 Board

(with Single Power Source)




Figure B3 - Intrinsically Safe System with Modem and EXPCOM232 Board

(with Independent Power Sources)

Figure B4 - Intrinsically Safe System with Radio and EXPCOM232 Board

(with Independent Power Sources)


BLANK PAGE



DOCUMENT NUMBER: PIP-EXP232TF

TITLE:

EXPANSION COMMUNICATIONS PORT RS-232 BOARD (for Models 3530-XXX)

Product Information Package

ISSUE DATE: DEC., 2003

COMMENT/COMPLAINT:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Mail this page to:



Watertown, CT 06795


Bristol Babcock


Watertown, CT 06795

Phone: +1 (860) 945-2200

Fax: +1 (860) 945-2213



Northern Region



Watertown, CT 06795

Phone: +1 (860) 945-2381

Fax: +1 (860) 945-2525

[email protected]

Gulf Coast Region



Suite F


Phone: +1 (713) 685-6200

Fax: +1 (713) 681-7331

[email protected]

Western Region



Suites 106 & 107

Ontario, CA 91761

Phone: +1 (909) 923-8488

Fax: +1 (909) 923-8988

[email protected]




Suite 1016


Phone: +1 (407) 740-7084

Fax: +1 (407) 629-2106

[email protected]



Watertown, CT 06795

Phone: +1 (860) 945-2218

Fax: +1 (860) 945-2213 [email protected]

Central Region


777 South Central

Expressway

Suite 1-C


Phone: +1 (972) 238-8197


International Affiliates:

Canada


234 Attwell Drive


Canada

PH: 416-675-3820


Mexico

BBI, S.A. de C.V.



11540 Mexico, D.F.

Mexico

PH: (52-55)-52-81-81-12

FAX: (52-55)-52-81-81-09

[email protected]

Rocky Mountain Region




Phone: +1 (505) 320-5046

Fax: +1 (505) 327-3273

[email protected]

Communications




Suite 1016


Phone: +1 (407) 629-9464


United Kingdom


Blackpole Road

Worcester, WR3 8YB

United Kingdom

PH: +44 (0) 1905 856950


Asia Pacific


PO Box 1987

Bunbury, Western Australia

6231

PH: +61 (0) 8 9791 3654

FAX: +61 (0) 8 9791 3173 [email protected]

Victoria, Australia

PH: +61 (0) 3 9384 2171

FAX: +61 (0) 3 8660 2501

Calgary Office




Canada

PH: 403-265-4808



BBI, S.A. de C.V.

Av. Plomo No.2


Industrial


Mexico

PH: 52-993-353-3142


Middle East


Blackpole Road

Worcester, WR3 8YB

United Kingdom

PH: +44 (0) 1905 856950


RC Rev: 13-Jun-03

EXPANSION RS-485 and/or

ANALOG OUTPUT BOARD

Series No. 392971-XX-X

(For Models 3530-XXX)


CI-3530-10B, CI-3530-15B, CI-3530-20B, CI-3530-25B,

CI-3530-35B, CI-3530-40B & CI-3530-50B


Bristol Babcock

PIP-EXP485/AO

- January 2003

NOTICE

Copyright Notice






Bristol Babcock.






If additional in-formation is required, the purchaser is advised to contact Bristol

Babcock.


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.







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


Telephone (860) 945-2200

A.

B.

C.

D.

E.

F.

A.

B.

WARRANTY




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







FACE HEREOF.


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.




(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.


A. FAX



B. E-MAIL



.


C. Mail



Repair Dept.


Watertown, CT 06795


D. Phone



Bristol Babcock Inc. Repair Authorization Form


Date___________________ RA #___________________SH_ Line No.____________


· Evaluate / Test / Verify Discrepancy

· Repair / Replace / etc. in accordance with this form

· Return to Customer

Part I

Please be aware of the

·

Non warranty standard charge:

There is a $100 minimum evaluation charge, which is applied to the repair if applicable ( or D of part III below)


Ö in “returned” B,C,

Address No.

Bill to :


Ship to:


Purchase Order:

Phone: Fax:

Contact Name: ____________________________________

E-Mail:



Description


Reason for return : Failure Upgrade

S/N

Verify Operation Other

1.





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


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.


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?







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

Form GBU 13.01

Rev. A

Bristol Babcock

Training







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.



6200.

BLANK PAGE











(860) 945-2200

(860) 945-2213 (FAX)














9464 .


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







PIP-EXP485/AO

EXPANSION RS-485 COMMUNICATIONS and/or ANALOG OUTPUT BOARD

PT. Number 392971-XX-X



1.1

1.1.1

1.1.2

1.2

1.3

1.3.1



DESCRIPTION................................................................................................................... 1

Function .............................................................................................................................. 1

Features............................................................................................................................... 2

COMPONENT IDENTIFICATION................................................................................... 3

INSTALLATION COMPATIBILITY................................................................................ 3

Restrictions ......................................................................................................................... 3

2.1

2.1.1

2.1.1.1

2.1.1.2

2.1.1.3

2.2


EXP485/AO REMOVAL/REPLACEMENT & INSTALLATION ................................... 4

Installation/Removal of the EXP485/AO Board ................................................................ 4

Installation/Removal for Models 3530-10B, -15B, -40B & -50B ...................................... 4

Installation/Removal for Models 3530-20B & -25B ........................................................ 11

Installation/Removal for Models 3530-35B ..................................................................... 13

RS-485 and AO WIRING ................................................................................................. 14

3.1

3.2

3.3


PERFORMANCE SPECIFICATIONS ............................................................................ 16

ENVIRONMENTAL SPECIFICATIONS ....................................................................... 16

ENTITY PARAMETERS (INTRINSICALLY SAFE EXPAO Bd.) ............................... 17

SUPPLEMENTS


Special Instructions for Class I, Division 1 Hazardous Locations ..............................................Appendix B

PIP-EXP485/AO Page 0-1 Table Of Contents

BLANK PAGE

Section 1

INTRODUCTION

1.1 DESCRIPTION

1.1.1 Function

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

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

Analog Output circuit. The EXP485/AO Board plugs into the Expansion Connector of the

TeleFlow or TeleRTU CPU Board, is stood-off by three 15/32” long hex standoffs and is secured via three screws or standoffs depending on the model. The CPU Board Expansion

Connector supplies power and 3530-XXX communication to the EXP485/AO Board.

EXP485/AO Boards measure 4.25” by 3.75” and utilizes a 9-position Industrial 3.5mm pitch plugable connector to interface (RS-485) to a series of remote 3530-XXX devices and or a single 1-5Vdc or 4-20mA AO device.

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

Interface signals are available at TB1 of the EXP485/AO. When the SLEEP+ & SLEEPsignals (supplied by the Master 3530-XXX) are Low and High respectively, the remote

3530-XXX CPU Boards will be awakened. If no activity is required, the EXP485/AO Board‘s serial communications controller (SCC) chip and RS-485 drivers can be put to sleep (low power mode) along with the host/parent 3530-XXX and the SLEEP+ and SLEEP- signals will be set High and Low respectively.

Figure 1 - EXP485/AO Board (with RS-485 & Configurable AO)

PIP-EXP485/AO Page 1 EXP485/AO Option

Figure 2 - EXPAO Board (with 1-5Vdc AO and without RS-485)

1.1.2 Features

· Low Power

+5Vdc @ 20mA (Max) regulated power and 5.8Vdc to 16Vdc @ 50mA (Max) unregulated power are supplied by the host/parent 3530-XXX via the 40-pin

Expansion Interface Connector P1.

· ESD & Transient Susceptibility

The RS-485 I/O circuitry has been designed to meet the requirements of IEC 801-2 for ESD withstand capability up to 10KV and the requirements of ANSI/IEEE


· EMI Compatibility

EXP485/AO Boards have been designed to coexist inside a shielded enclosure with the TeleFlow ä electronics. EMI radiation is insignificant and susceptibility is comparable or superior to associated electronics.

· Mounting

The EXP485/AO Board measures 3.75” (9.525cm) in width x 4.25” (10.795cm) in height and mounts piggy-back on a TeleFlow or TeleRTU CPU Board.

· RS-485 Comm. Port

EXP485/AO Boards provide an RS-485 communications port that is programmable for asynchronous rates up to 19.2Kbps. 3530-XXX units equipped with the

EXP485/AO Board can communicate with a network of 3530-XXX units (equipped

EXP485/AO Option Page 2 PIP-EXP485/AO

with EXP485/AO Boards), even though a radio or modem may be installed on the

CPU Board’s network port.

1.2 COMPONENT IDENTIFICATION

EXP485/AO Boards do not contain LEDs or switches. Fully populated EXP485/AO Boards

(P/N 392971-01-0) are provided with seven (7) configuration jumpers (see Figures 1 & 11).

Depopulated EXPAO Boards (P/N 392971-02-0) are factory set for 1-5Vdc AO operation and don’t have configuration jumpers (see Figure 2). Two connectors are provided; 40-pin connector P1 mates with the host 3530-XX-X (connector J4 - TeleFlow CPU or J18 - TeleRTU

CPU) and accommodates the TTL interface between the two entities, while 9-pin connector

TB1 mates with the RS-485 device that is being interfaced to the 3530-XXX and/or an analog output device. Additionally, the 3.5mm pitch plugable connector TB1 is removable from its mating EXP485/AO Board socket.

1.3 INSTALLATION COMPATIBILITY

An EXP485/AO Board can be installed into any of the following 3530-XXX models:

3530-10B - TeleFlow

3530-15B - TeleRTU

3530-35B - TeleRTU Module

3530-40B - TeleFlow ECR

3530-20B - TeleFlow Plus 3530-50B - TeleFlow Corrector

3530-25B - TeleRTU Plus

1.3.1 Restrictions

The 3530-XXX in question must be equipped with ACCOL application software. The

TeleFlow Plus (3530-20B), TeleRTU Plus (3530-25B) and the TeleRTU Module (3530-35B) support installation of either a Low Power I/O Expansion Board (LPI/OEB), an

EXPCOM232 Board, or the EXP485/AO Board discussed herein, i.e., YOU CAN ONLY

INSTALL ONE (1) OF THESE ITEMS .

EXP485/AO Board (P/N 392971-01-0) is fully populated and supports RS-485 network communications and interface to either a 1-5Vdc or a 4-20mA analog output device.

P/N 392971-02-0 is a depopulated version of the EXP485/AO Board and only supports interface to a 1-5Vdc analog output device. Connector TB1 has two usable pins (08 = AO and 09 = AOGND). This version is designed for use in a Class I, Division 2, Groups C and D nonincendive environment or a Class I, Division 1, Groups C and D intrinsically safe environment.

Intrinsically safe EXPAO Boards can be installed in 3530-XXX units with 6V Lead Acid or

7.2V Lithium battery systems.


Section 2


2.1 EXP485/AO REMOVAL/REPLACEMENT & INSTALLATION

2.1.1 Installation/Removal of the

EXP485/AO Board

In addition to hardware normally contained within the 3530-XXX in question, units with an installed EXP485/AO Option will contain the following major parts.

1.

Expanded Comm. Port RS-485/AO Board (EXP485/AO)

2.

Three (3) #4-40 x 15/32” Standoffs (Note: Models 3530-10B, -15B, -40B & -50B will also contain Three (3) #4-40 x .188” Standoffs & Two (2) #4-40 x 1/8” SEM Screws)

3.

Modified PC Shield Assembly (for models 3530-10B, -15B, -40B & -50B)

WARNING

Never attempt to service a TeleFlow, TeleFlow ECR, TeleRTU or

TeleFlow Corrector while it is powered and operating in a hazardous environment. Either the area must be made safe or the unit must be powered down, unwired, unmounted, and taken to a safe, nonhazardous area.

WARNING

Never attempt to install or remove any components (PCBs, Field

Wiring, Transducers, etc.) while the unit is powered and running.

Doing so can cause sudden electrical transients or imbalances that are capable of causing damage to the module or component in question, as well as other associated circuit boards. Always turn off the external/internal power source, including any additional supply sources used for externally-powered I/O circuits, before changing or adding any components.

CAUTION


2.1.1.1 Installation/Removal for Models 3530-10B, -15B, -40B & -50B

To install the optional EXP485/AO Board into a model 3530-10B, -15B, -40B or -50B, follow steps 1 through 14 below. To remove the optional EXP485/AO Board, see step 15. Note: The

Instrument Front Cover must be open.

1.



Note:


2.


3.








4.





Mounting Bracket.




Mounting Bracket, remove the four (4) 1/4-20 x 3/8” screws and lock washers that secure the Battery Mounting Bracket and Main Mounting Bracket to the rear of the unit. Remove the Battery Mounting Bracket and temporarily reinstall the four screws to secure the Main Mounting Bracket to the 3530-10B, 15B, -45B or -50B.

5.

Disconnect the Local Port, Network Port, RTD, and Field I/O wires from the CPU

Board connectors by unplugging their associated Terminal Plugs on the front edge of the CPU.






Note:


8.

Align the EXP485/AO Board Connector P1 with CPU Board Connector J4 (for 3530-

10B or -50B) or J18 (for 3530-15B). Push the EXP485/AO Board toward the CPU

Board until Connector P1 is fully seated.



9.

Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x .188”

Standoffs at locations ‘A’ and ‘B’ (see Figures 3 & 4).

10. Carefully install the Modified PC Shield, securing it to the Main Mounting Bracket (at locations ‘C’) with two #4-40 x 1/4” screws and to the CPU Board (at location ‘B’) with two (2) #4-40 x 1/8” SEM screws (see Figures 5, 6, 7 & 8).

11.

Follow steps 2 through 6 in reverse order, replacing rather than removing the item in question.


12.

Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to which it is to be interfaced (see Section 2.2).

13.



14.


15. To remove an optional EXP485/AO Board, follow steps 1 through 6 (unplug the RS-485 cable during step 5). Remove the PC Shield along with the three Standoffs that secure


the EXP485/AO Board to the CPU Board. Then unplug the EXP485/AO Board from the CPU Board in question.

Figure 5 - TeleFlow CPU Board (with EXP485/AO Installed)



Figure 6 - TeleRTU CPU Board (with EXP485/AO Installed)



Figure 7 - 3530-10B, 3530-40B & 3530-50B (with EXP485/AO Installed)

EXP485/AO Option

Figure 8 - 3530-15B (with EXP485/AO Installed)

Page 10 PIP-EXP485/AO


To install the optional EXP485/AO Board into a model 3530-20B or 3530-25B, follow steps 1 through 11 below. To remove the optional EXP485/AO Board, perform steps 1 and 2 and then follow steps 4 through 9 in reverse order, removing rather than installing the item in question after the system has been shut down. Note: The Instrument Front Cover must be open.

1.


2.



PIP-EXP485/AO

Figure 9 - 3530-20B CPU (with EXP485/AO Installed)

Page 11 EXP485/AO Option

3.


4.



(and optional EXP485/AO Board) toward the front of the unit. Remove harness connections from the Front Panel Switch (J12 on the TeleFlow CPU - J14 on TeleRTU

CPU), the Display Module (J2 on TeleFlow CPU - J16 on TeleRTU CPU), the Wakeup

Switch (J3 on TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards connector J1 (associated with the Multivariable Transducer).

Figure 10 - 3530-25B CPU (with EXP485/AO Installed)

5.




Note:


6.

Align the EXP485/AO Board Connector P1 with CPU Board Connector J4 (for 3530-

20B) or J18 (for 3530-25B). Push the EXP485/AO Board toward the CPU Board until


7.

Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figures 9 & 10.

8.

Route the RS-485 and AO cables through a ¾” conduit fitting (user installed) on the bottom of the enclosure.

9.


10.




To install the optional EXP485/AO Board into a model 3530-35B, follow steps 1 through 8 below. To remove the optional EXP485/AO Board, perform step 1 and then follow steps 5 through 7 in reverse order, removing rather than installing the item in question after the system has been shut down.

1.





4.

Remove the three screws (of five) that secure the CPU Board to the RTU Mounting


Note:


5.

Align the EXP485/AO Board Connector P1 with CPU Board Connector J18. Push the

EXP485/AO Board toward the CPU Board until Connector P1 is fully seated.

6.

Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x 1/4”

SEM screws as illustrated in Figure 11.

7.



8.


Figure 11 - 3530-35B (with EXP485/AO Installed)

2.2 RS-485 and AO WIRING

Figure 12 must be referenced to configure the RS-485 cable. It is recommended that a low capacitance 24-gauge communications grade 2-twisted pair cable such as Belden 9842 be used for RS-485 networking.


Figure 12 - EXP485/AO Wiring Diagrams




Section 3



Baud Rate (Max.):

Power Requirements:

Transient Protection:

RS-485 Inputs/Outputs:

Analog Output Pins:

Interface Connector:

19.2K Asynchronous

+5Vdc @ 20mA Max. (Regulated)

+5.8Vdc to +16Vdc @ 50mA Max. (Unregulated)

5V Bi-directional Transient Absorption Zeners across all

RS-485 communication points

12V Bi-directional Transient Absorption Zeners across the

AO points (when configured for 1-5Vdc operation)

16V Bi-directional Transient Absorption Zeners across the

AO points (when configured for 4-20mA operation)

TXD/RDX+ (TB1-3)

TXD/RXD- (TB1-4)

SLEEP+ (TB1-5)

SLEEP(TB1-6)

AO (TB1-8) - 1-5Vdc @ 5mA Max. ONLY on

392971-02-0

(TB1-8) - 1-5Vdc @ 5mA Max. or 4-20mA on

392971-01-0

AOGND (TB1-9) - Analog Output Ground/Return

9-Pin Industrial 3.5mm Pitch Plugable Connector




Humidity:

Vibration:

RFI Susceptibility:

EMI Compatibility:

-40 ° to +60 ° (C) [-40 ° to 140 ° (F)]

-40 ° to +85 ° (C) [-40 ° to 185 ° (F)]

15% to 90% RH (Non-Condensing)

10 to 500 Hz at 1g on any axis per SAMA PMC-31-1 without damage or impairment.

Meets the requirement of IEC 1000-4-6 level 2 (3V/M) from 150kHz to 80MHz.

Designed to coexist inside a shielded enclosure with the

TeleFlow electronics. EMI radiation is insignificant and

Susceptibility is comparable or superior to associated

Electronics.


Surge Susceptibility:

EMI Radiated:

Designed to meet the requirements of ANSI/IEEE

C37.90.1-1989 (Formerly IEEE 472) for surge withstand capability.

Designed to meet the requirements of IEC 1004-4-3 for radiated emissions.

3.3 ENTITY PARAMETERS (INTRISICALLY SAFE EXPAO Bd.)

F1: .125A

R66:

D20/D21:

Voc:

Vmax:

Isc:

Imax:

Ca:

Ci:

La:

Li:

200 Ohms ±5%, .5W

6.2V ±5%

6.51V

15V

34.3mA

150mA

400µF

0µF

80mH

0mH


BLANK PAGE

Expansion RS-485 and/or Analog Output Board


1. The BBI Expansion RS-485 and/or Analog Output (EXP485/AO) Board is listed by

Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I,

Division 2, Groups C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive BBI Expansion RS-485 and/or

Analog Output Board. In the event of a conflict between the Expansion RS-485 and/or

Analog Output Board User Manual (PIP-EXP485/AO) and this document, always follow the instructions in this document.






12/14/2001 Appendix A of PIP-EXP485/AO - EXP485/AO Board Page 1 of 1

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


1.

A version of the Expansion RS-485 and/or Analog Output (EXP485/AO) Board is available that is listed by Underwriters Laboratories (UL) as intrinsically safe for use in

Class I, Division 1, Groups C and D hazardous locations. Read this document carefully before installing an intrinsically safe Expansion RS-485 and/or Analog Output Board.

Refer to the Expansion RS-485 and/or Analog Output Board User’s Manual (PIP-

EXP485/AO) for general information. In the event of a conflict between the Expansion

RS-485 and or Analog Output User’s Manual and this document, always follow the instructions in this document.

2.

Only the depopulated version of the Expansion RS-485 and/or Analog Output Board

(EXP485/AO) (P/N 392971-02-0) may be used in a Class I, Division 1 hazardous location.

3.

TeleFlow models 3530-10B, 3530-40B and 3530-50B approved for use in Class I,

Division 1, Groups C and D hazardous locations and equipped with the EXP485/AO

Board option may reside in a Division 1, 2 or nonhazardous area. 3530-XXX units not approved for use in a Class I, Division 1 environment may contain an EXP485/AO Board but can only reside in a Class I, Division 2 or nonhazardous area.

CAUTION

When connecting the Expansion Analog Output Board to a

TeleFlow that is mounted in a Division 1 area, wire all circuits using wiring methods specified in article 501-4(A) of the

National Electrical Code NFPA 70.

When installing an Expansion RS-485 and/or Analog Output

Board (EXP485/AO) into a TeleFlow that is mounted in a

Division 2 area, ensure that the area is nonhazardous before connecting or disconnecting the nonhazardous interface.

4.

Intrinsically safe TeleFlows equipped with an intrinsically safe EXPAO Board (P/N

392971-02-0) do not include any internal communications options.

01/11/02 Appendix B - Document PIP-EXP485/AO Page 1 of 1



DOCUMENT NUMBER: PIP-EXP485/AO

TITLE:

EXPANSION RS-485 and/or ANALOG OUTPUT BOARD (for Models 3530-XXX)

Product Information Package

ISSUE DATE: JAN., 2003

COMMENT/COMPLAINT:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Mail this page to:



Watertown, CT 06795


Bristol Babcock


Watertown, CT 06795

Phone: (860) 945-2200

Fax: (860) 945-2213



Northern Region



Watertown, CT 06795

Phone: (860) 945-2381

Fax: (860) 945-2525

[email protected]

Southwest Region



Suite F


Phone: (713) 685-6200

Fax: (713) 681-7331

[email protected]

Western Region



Suites 106 & 107

Ontario, CA 91761

Phone: (909) 923-8488

Fax: (909) 923-8988

[email protected]




Suite 1016


Phone: (407) 740-7084

Fax: (407) 629-2106

[email protected]



Watertown, CT 06795

Phone: (860) 945-2218


Dallas District Office


777 South Central

Expressway

Suite 1-C


Phone: (972) 238-8197


International Affiliates :

Canada


234 Attwell Drive


Canada

PH: 416-675-3820


Mexico

BBI, S.A. de C.V.

Ejercito Nacional No. 718, 4

Piso

Colonia Polanco

Mexico, D.F. 11560

Mexico

PH: 52-555-254-5281

FAX: 52-555-254-3408

[email protected]

Sales Office New Mexico




Phone: (505) 320-5046

Fax: (505) 327-3273

[email protected]

Communications




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Phone: (407) 629-9464


United Kingdom



Stourport Road

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United Kingdom

PH: +44 (0) 1562 820001


Australia


22 Hastie St.

PO Box 1987

Banbury, Western Australia

6230

PH: 61 (0)8 9791 3654

FAX: 61 (0)8 9791 3173 [email protected]

Calgary Office




Canada

PH: 403-265-4808



BBI, S.A. de C.V.

Av. Plomo No.2


Industrial


Mexico

PH: 52-993-353-3142


Middle East



Stourport Road

Kidderminster


United Kingdom

PH: +44 (0) 1562 820001


Supplement Guide - S1400A

Issue: 04/03

TeleFlow

TM

SITE CONSIDERATIONS

For

EQUIPMENT INSTALLATION,

GROUNDING

&

WIRING

A Guide for the Protection of

Site Equipment & Personnel

In the Installation of

Series 3530-XX-X Instrumentation

Bristol Babcock

NOTICE

Copyright Notice






Bristol Babcock.

Supplement Guide S1400A

SITE CONSIDERATIONS FOR EQUIPMENT

INSTALLATION, GROUNDING & WIRING


4.1

4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.2

3.1

3.1.1

3.2

3.3

3.3.1

3.3.1.1

3.3.1.2

3.3.1.3

3.3.2

3.3.2.1

3.3.3

3.4

3.4.1

3.4.2

SECTION TITLE

1.1

1.2

2.1

2.1.1

2.2

2.2.1

2.2.2

2.3

PAGE #


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

Modem Grounding Kit 621495-01-8. ............................................................................. 3-1

IMPORTANCE OF GOOD GROUNDS.........................................................................3-2

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

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

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

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

Dry, Sandy or Rocky Soil................................................................................................3-5

Ground Wire Considerations. ........................................................................................3-6

Modem Ground Wiring Diagrams .................................................................................3-7

Other Grounding Considerations. ...............................................................................3-20

ISOLATING EQUIPMENT FROM THE PIPELINE .................................................3-21

Meter Runs Without Cathodic Protection...................................................................3-21

Meter Runs With Cathodic Protection ........................................................................3-22

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 S1400A Page 0-1 Table Of Contents

Supplement Guide S1400A

SITE CONSIDERATIONS FOR EQUIPMENT

INSTALLATION, GROUNDING & WIRING


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


Section 5 - WIRING TECHNIQUES

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

7.

TeleFlow Modem Grounding Kit 621495-01-8 Installation Instructions - PIP-3530MGKI; Bristol Babcock,

Watertown, CT 06795

Supplement S1400A Page 0-2 Table Of Contents

Section 1 - Overview

1.1 INTRODUCTION

This document provides information pertaining to the installation of TeleFlow 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

Construction of the TeleFlow with respect to grounds, isolation and electrical considerations is discussed. 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 S1400A

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

TeleFlow 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 S1400A

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 a TeleFlow 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 TeleFlow mounting and supporting, transducer mechanical and electrical connections, TeleFlow 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-3530-XX-X

See Appendix B of CI-3530-XX-X

See Section 3

See Section 4

See Section 4

See Section 2.3

S1400A 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 If pipe mounted, is a cathodic charge present on the pipe? Should the

TeleFlow be isolated?

8 How close is other equipment? Can someone safely touch this equipment and a TeleFlow simultaneously?

9 Determine equipment ground requirements. How will the TeleFlow and its related wiring be grounded? Consider Earth Ground, Circuit

Ground, Conduit Ground, Site Grounds, Manifold grounded or not?

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

Reference Section

See Section 4.1.2

See Section 3.4

See Section 2.3

See Section 3

See Section 2.3

2.3

OTHER SITE SAFETY CONSIDERATIONS

Overhead or underground power or communication cables must be identified prior to installing a new unit. Accidentally cutting, shorting or simply just contacting power, ground, communication or process control I/O wiring can have potentially devastating effects on site equipment, the process system and or personnel.

Don’t assume that it is safe to touch adjacent equipment, machinery, pipes, cabinets or even the earth itself. Adjacent equipment may not have been properly wired or grounded, may be defective or may have one or more loose system grounds. Measure between the case of a questionable piece of equipment and its earth ground for voltage. If a voltage is present, something is wrong.

AC powered equipment with a conductive case should have the case grounded. If you don’t see a chassis ground wire, don’t assume that it is safe to touch this equipment. If you notice that equipment has been grounded to pipes, conduit, structural steel, etc., you should be leery. Note: AWWA’s policy on grounding of electric circuits on water pipes states,

“The American Water Works Association (AWWA) opposes the grounding of electrical systems to pipe systems conveying water to the customer’s premises….”

Be sure that the voltage between any two points in the instrument system is less than the stand-off voltage. Exceeding the stand-off voltage will cause damage to the instrument and will cause the instrument to fail.

Section 2 - Protection Page 2-3 S1400A

Section 3 - Grounding & Isolation

3.1 POWER & GROUND SYSTEMS

TeleFlow GFCs, TeleFlow ECRs, TeleFlow Correctors, TeleRTUs and TeleRecorders are similar in that they all have basically two system grounds, i.e., Chassis Gnd and

CPU/Circuit Ground. Chassis Ground is galvanically isolated from CPU/Circuit Ground by

500V (ac/dc). A jumper on the CPU Board would (if installed) place these two ground systems at the same potential and thus eliminate the 500V galvanic isolation. Installation of this jumper is not recommended. CPU/Circuit Ground consists of Power, Analog, Digital, and Comm. Grounds (all common).

Teleflows are DC (+6V or +12V) systems. AC power supplies are not provided with

TeleFlows. The TeleFlow’s Electronics are galvanically isolated from the case and should not be affected by cathodic protection or other EMF on the pipeline. Grounding to the pipeline, i.e., completing a connection between the 3530-XXX Ground Lug and the mounting media (valve, manifold, pipeline, etc.) is not recommended even if the media in question is earth grounded. When grounding a TeleFlow, always connect directly to a known good Earth Ground.

NOTE

Never connect the CPU Board’s Ground Lug to Earth Ground. The

CPU Board’s CPU/Circuit Ground must always be isolated from the case. The TeleFlow/TeleRTU/TeleRecorder case is to be connected to

Earth Ground.

NOTE

Some 3530-20Bs and 3530-25Bs have been factory shipped with the

Cabinet Ground Cable connected to the CPU Board’s Ground Ring.

Remove this ground connection from the CPU Board. This cable should be removed (or electrically isolated) if a modem is not present. If a modem is present, the Cabinet Ground Cable should be connected to the modem.

3.1.1 Modem Grounding Kit 621495-01-8

Some TeleFlows (3530-10B), TeleRTUs (3530-15B), TeleRecorders (3530-45B) and TeleFlow

Correctors (3530-50B) have been shipped without a system Ground Lug. These units must be modified before they can be properly connected to earth ground. Product Information

Package PIP-3530-MGKI provides the information required to properly install the TeleFlow

Modem Grounding Kit (621495-01-8). This kit may also be used to support a TeleRTU

Module (3530-35B).

The TeleFlow Modem Grounding Kit consists of the following items: i Hex Nut - #10-32 i Cabinet Ground Cable i Self-Locking Nut - #10-32 UNF i Flat Washer - #10 i Ground Lug

Section 3 - Grounding & Isolation Page 3-1 S1400A

i Pan Head Screw - #10-32 x 3/4”) i Pan Head Screw - - #4-40 x 3/8” i Self-Locking Nut - #4-40 UNC i Hex Nut - #4-40

3.2 IMPORTANCE OF GOOD GROUNDS

Model 3530-XXXs are utilized in instrument and control systems that must operate continually and within their stated accuracy over long periods of time with minimum attention. Since many system sites are unmanned and located in remote areas, 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 understanding of this subject to prevent needless troubleshooting procedures.

WARNING

This device must be installed in accordance with the National

Electrical Code (NEC) ANSI/NEPA-70. Installation in hazardous locations must also comply with Article 500 of the code. For information on the usage of Model 3530-XXX units in Class I, Division

2, Groups C & D Hazardous and Nonhazardous locations, see appendix A of the applicable CI-3530-XXX manual. For information on the usage of Models 3530-10B, 3530-40B & 3530-50B in Class I,

Division 1, Groups C & D Hazardous locations, see appendix B of CI-

3530-10B, CI-3530-40B or CI-3530-50B.

3.3

EARTH GROUND CONNECTIONS

To properly ground a TeleFlow (3530-10B/20B/40B), TeleRTU (3530-15B/25B),

TeleRecorder (3530-45B/55B) or TeleFlow Corrector (3530-50B), connect the Earth Ground wire between the Ground Lug on the bottom of the case and a known good Earth Ground.

Observe recommendations provided in topics Establishing a Good Earth Ground and

Ground Wire Considerations. Note: In the case of the TeleRecorder (3530-55B), connection to a known good Earth Ground is only required when a BBI 9600 PSTN modem is installed.

3.3.1 Establishing a Good Earth Ground

A common misconception of a ground is that it consists of nothing more than a metal pipe driven into the soil. While such a ground may function for some applications, it will often 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,

S1400A Page 3-2 Section 3 - Grounding & Isolation

free of any coating and fastened to the rod with a clamp. This ground connection should be covered or coated to protect it from the weather and the environment.

Figure 3-1 - Basic Ground Rod Installation

3.3.1.1 Soil Conditions

Before installing a ground rod, the soil type and moisture content should be analyzed.

Ideally, the soil should be moist and moderately packed throughout to the depth of the ground rod. However, some soils will exhibit less than ideal conditions and will require extra attention.

Soil types can be placed into two general categories with respect to establishing and maintaining a good earth ground, i.e., ‘Good Soil’ and ‘Poor Soil.’

To be a good conductor, soil must contain some moisture and free ions (from salts in the soil). In very rainy areas, the salts may be washed out of the soil. In very sandy or arid area the soil may be to dry and/or salt free to a good conductor. If salt is lacking add rock salt

(NaCl); if the soil is dry add calcium chloride (CaCl

2

).

3.3.1.2 Soil Types: Good

Damp Loam

Salty Soil or Sand

Farm Land

Poor

Back Fill

Dry Soil

Sand Washed by a Lot of Rain

Dry Sand (Desert)

Rocky Soil

Ground Beds must always be tested for conductivity prior to being placed into service. A brief description of ground bed testing in ‘Good Soil’ and ‘Poor Soil’ is provided herein.

Details on this test are described in the National Electrical Code Handbook. Once a reliable


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

Figure 3-2 - Basic Ground Bed Soil Test Setup

Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods

Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5 ohms, the ground is good. The lower the resistance, the better the earth ground. If the


Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is indicated, one or more additional ground rods connected 10 feet from the main ground rod should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x

¼-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the

Biddle Instrument Co. (now owned by AVO International). Other devices that may be used to test ground resistance are “Viboground”; Associated Research,

Inc., “Groundmeter”; Industrial Instruments, Inc., and “Ground-ohmer”; Herman

H. Sticht Co., Inc.

If the Megger still reads more than 10 ohms, mix a generous amount of cooking salt, ice cream salt or rock salt with water and then pour about 2.5 to 5 gallons of this solution around each rod (including the test rods). Wait 15 minutes and re-test the soil. If the test fails, the soil is poor and a ‘Poor Soil Ground Bed’ will have to be constructed.

Figure 3-4 shows a typical Poor Soil Ground Bed Electrode. A Poor Soil Ground Bed will typically consists of four or more 10-foot long electrodes stacked vertically and separated by earth. Figure 3-5 shows the construction of a Poor Soil Ground Bed. For some poor soil sites, the ground bed will be constructed of many layers of ‘Capacitive Couplings’ as illustrated. In extremely poor soil sites one or more 3’ by 3’ copper plates (12 gauge or 1/16” thick) will have to be buried in place of the electrodes.

Figure 3-4 - Ground Electrode Construction for Poor Soil Conditions

3.3.1.3 Dry, Sandy or Rocky Soil

Very dry soil will not provide enough free ions for good conductance and a single ground rod will not be effective. A buried counterpoise or copper screen is recommended for these situations. It will be necessary to keep the soil moist through regular applications of water.

Sandy soil, either wet or dry, may have had its soluble salts leached out by rain water, thereby reducing conductivity of the ground. High currents from lightning strikes could also melt sand and cause glass to form around the ground rod, rendering it ineffective. A buried counterpoise or copper screen is preferred for these installations along with regular applications of salt water.

Rocky soil can pose many grounding problems. A counterpoise or copper plate will probably be required. Constructing a trench at the grounding site and mixing the fill with a hygroscopic salt such as calcium chloride may help for a time. Soaking the trench with water on a regular basis will maintain conductivity.

Any TeleFlow, TeleRTU, TeleRecorder or TeleFlow Corrector, may be connected to Earth

Ground via its Ground Lug; however, units equipped with a BBI 9600 bps PSTN modem must be connected to Earth Ground. Units with phone modems require the use of a


lightning arrestor. The lightning arrestor must be situated at the point where the communication line enters the building.

Figure 3-5 - Poor Soil Ground Bed Construction Diagram

3.3.2 Ground Wire Considerations

i Ground wire size should be AWG 4. 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 insertion into the TeleFlow

Ground Lug.

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.


3.3.2.1 Modem Ground Wiring Diagrams

Figure 3-6A/B - TeleFlow Modem Ground Wiring - for 3530-10B, -15B, 45B & -50B

Figure 3-7A/B - TeleFlow/TeleRTU Plus Modem Ground Wiring - for 3530-20B & -25B

Figure 3-8A/B - TeleFlow Plus Modem Ground Wiring - for 3530-20B

Figure 3-9A/B - TeleRTU Plus Modem Ground Wiring - for 3530-25B

Figure 3-10A/B - TeleFlow/Corrector/TeleRTU Modem Ground Wiring (Side View)

Figure 3-11A/B - TeleRecorder (3530-45B) Modem Ground Wiring (Front View)

Figure 3-12

Figure 3-13

- TeleRecorder (3530-55B) Modem Ground Wiring (Front View)

- Earth Grounding Of TeleFlow Modem & Case

Figure 3-6A - TeleFlow Modem (396039-02-2) Ground Wiring


S1400A

Figure 3-6B - TeleFlow Modem (400000-01-6) Ground Wiring

Page 3-8 Section 3 - Grounding & Isolation

Figure 3-7A - TeleFlow/TeleRTU Plus Modem (396039-02-2)

Ground Wiring

(Side View)


S1400A

Figure 3-7B - TeleFlow/TeleRTU Plus Modem (400000-01-6)

Ground Wiring

(Side View)


Figure 3-8A - TeleFlow Plus Modem (396039-02-2) Ground Wiring

(Front View)


S1400A

Figure 3-8B - TeleFlow Plus Modem (400000-01-6) Ground Wiring

(Front View)


Figure 3-9A - TeleRTU Plus Modem (396039-02-2)

Ground Wiring

(Front View)


S1400A

Figure 3-9B - TeleRTU Plus Modem (400000-01-6)

Ground Wiring

(Front View)


Figure 3-10A - 3530-10B/15B/50B Modem (396039-02-2) Ground Wiring (Side View)

Figure 3-10B - 3530-10B/15B/50B Modem (400000-01-6) Ground Wiring (Side View)


Figure 3-11A - 3530-45B Modem (396039-02-2) Ground Wiring (Front View)


Figure 3-11B - 3530-45B Modem (400000-01-6) Ground Wiring

(Front View)


Figure 3-12 - 3530-55B Modem (400000-01-6) Ground Wiring

(Front View)

Figure 3-13 shows a model 3530-10B (TeleFlow) installation. An AWG 4 solid copper ground wire has been connected to the Ground Lug on the bottom of the enclosure and to

Earth 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.


Note:

3530-40B not shown but similar to 3530-10B/15B/50B without modem.

3530-55B not shown (see Figure 3-12). Connect AWG 4 Earth Ground

Cable to Ground Lug when a BBI 9600 bps PSTN Modem is installed.

Figure 3-13

- Earth Grounding Of TeleFlow Modem & Case

Note that the recommended grounding convention for a model 3530-XXX is to install the specified AWG 4 Earth Ground Cable between the Ground Lug (on the bottom of the unit in


question) and a known good Earth Ground. Some models may be equipped with an optional radio. Units equipped with the radio option (not shown) may have an optional polyphaser

(lightning arrester) installed. Regardless of the 3530-XXX configuration, an Earth Ground

Cable should always be installed between the units Ground Lug and a known good Earth

Ground.

3.3.3 Other Grounding Considerations

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 3-14. The ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.

For units that are installed outdoors, it is recommended that the lightning arrester be installed to an Earth Ground (Bed) that is not common to the one used by the associated

3530-XXX.

Figure 3-14 - Grounding of Phone Line

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 3-15. 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.

Figure 3-15 - Grounding of Thermometer Well in Gas Line

Remove this ground connection from the CPU Board. This cable should be removed (or electrically isolated) if a modem is not present. If a modem is present, the Cabinet Ground Cable should be connected to the modem.

3.4 ISOLATING EQUIPMENT FROM THE PIPELINE

3.4.1 Meter Runs Without Cathodic Protection

TeleFlows (3530-10B, 3530-20B & 3530-40B) may be mounted directly on the pipeline or remotely on a vertical stand-alone two-inch stand-pipe (see Figure 3-16). The Earth Ground

Cable is to run between the TeleFlow’s Ground Lug and Earth Ground (Rod or Bed) even though the TeleFlow'’s Multivariable Transducer may be grounded to the pipeline.

TeleFlow Correctors (3530-50B) are typically mounted directly to a Turbine Meter. The

Earth Ground Cable is to run between the TeleFlow Corrector’s Ground Lug and Earth

Ground (Rod or Bed). If any pressure transmitters or pulse transducers are remotely mounted, connect their chassis grounds to the pipeline or earth ground.


Figure 3-16 - 3530-10B/20B/40B Remote Installation without Cathodic Protection

3.4.2 Meter Runs With Cathodic Protection

Dielectric isolators are available from Bristol Babcock and are always recommended as an added measure in isolating the TeleFlow (3530-10B or 3530-20B) from the pipeline even though the TeleFlow does provide 500V galvanic isolation from the pipeline and should not be affected by cathodic protection or other EMF on the pipeline. TeleFlows (3530-10B, 3530-

20B & 3530-40B) may be mounted directly on the pipeline (see Figure 3-17) or remotely on a vertical stand-alone two-inch stand-pipe (see Figure 3-18). It is recommended that isolation fitting always be used in remotely mounted meter systems. An isolation fittings or gasket should be installed between the following connections: i all conductive tubing that runs between the pipeline and mounting valve manifold and/or the units miltivariable pressure transducer i all conductive connections or tubing runs between the GFC and turbine meter, pulse transducer, or any input other device that is mounted on the pipeline i any Temperature Transducer, Pressure Transmitter, etc. and their mount/interface to the pipeline.


Mount the GFC (3530-10B/20B) or ECR (3530-40B) on a stand-alone vertical 2-inch pipe.

The ground conductor connects between the GFC/ECR’s Ground Lug and a known good earth ground. Connect the cases of Temperature Transducers, Pressure Transmitters, etc., to the known good earth ground. If the mounting 2-inch pipe is in continuity with the pipeline it will have to be electrically isolated from the GFC/ECR. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU 3140. This black tubing will easily slip over the 2-inch pipe and then after uniform heating (e.g., with a rose-bud torch) it electrically insulates and increases the strength of the pipe stand.

See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds.

Figure 3-17 - 3530-10B/20B/40B Direct Mount Installation

(with Cathodic Protection)


Figure 3-18 - 3530-10B/20B/40B Remote Installation

(with Cathodic Protection)


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 S1400A

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 TeleFlow (3530-XXX) units are battery operated systems that are isolated from AC grids (as they don’t draw power from them), 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 installed into a model 3530-XXX, the

S1400A Page 4-2 Section 4 - Lightning & Surge

possibility of damage due to a lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower must be considered. Model 3530-XXX’s equipped with a radio may have an optional BBI supplied lightning arrester installed. Units equipped with modems have built in Surge Protection circuitry. 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 equipped with 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 equipped with a radio : Mount antenna discharge unit (lightning arrester) as close as possible to where the lead in wire enters the structure. For an exposed (outdoor)

3530-XXX, in the proximity of the unit. 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.


Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram

For all systems it is best to have all communication equipment input/output grounds tied together. In the case of TeleFlow (3530-XXX) this is accomplished via the unit’s Ground

Lug. However additional communication equipment lightning arresters and surge suppres-


sors should be tied to the same system ground. System ground consists of the tower leg grounds utility ground and bulkhead-equipment ground-stakes that are tied together via bare copper wire.

4.1.3 Ground Propagation

As in any medium, a dynamic pulse, like R.F., will take time to propagate. This propagation time will cause a differential step voltage to exist in time between any two ground rods that are of different radial distances from the strike. With a ground rod tied to a struck tower, the impulse will propagate its step voltage outwardly from this rod in ever-expanding circles, like a pebble thrown into a pond. If the equipment house has a separate ground rod and the power company and/or telephone company grounds are also separate, the dynamic step voltage will cause currents to flow to equalize these separate ground voltages. Then if the coax cable (associated with a radio) is the only path linking the equipment chassis with the tower ground, the surge can destroy circuitry.

4.1.4 Tying it all Together

To prevent this disaster from occurring, a grounding system must be formed which interconnects all grounds together. This will equalize and distribute the surge charge to all grounds, and at the same time, it will make for a lower surge impedance ground system.

This interconnection can be done as a grid, where each ground has a separate line to each other ground, or by using a “rat Race” ring which forms a closed loop (not necessarily a perfect circle) which surrounds the equipment house completely.

By making this interconnection, it will be necessary to use proper I/O protectors for the equipment. Of course, these should be a requirement regardless of whether this grounding technique is used. I/O protectors are used for power lines (even those these don’t feed into a

TeleFlow 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 Teleflow (3530-XXX) would then have a single ground point from its

Ground Lug to this panel. In lieu of this, the 3530-XXX 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.


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.


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 S1400A

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.

S1400A 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

TeleFlow (models 3530-XXX) should only have one connection to earth ground. This connection is provided via the Ground Lug that is situated on the bottom of the unit. Some older units will require the installation of this ground lug when a connection to earth ground becomes absolutely necessary, i.e., when a radio or modem is added to the unit.

Since model 3530-XXX’s are DC-based systems, grounding does not take into account AC power grounding considerations. Earth grounding the 3530-XXX unit (case) 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

TeleFlow. 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. The only earth ground connection permitted to the

TeleFlow must be made via the unit’s Ground Lug. Make sure that the connection at the

TeleFlow’s Ground Lug is secure.

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.

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

TeleFlows utilize compression-type terminals that accommodate up to AWG 14 gauge wire.

A connection is made by inserting the bared end (1/4 inch max.) into the clamp beneath the screw and securing the screw.

Allow some slack in the wires when making terminal connections. Slack makes the connections more manageable and minimizes mechanical strain on the PCB connectors.

Provide external strain relief (utilizing Tie Wrap, etc.) to prevent the loose of slack at the

TeleFlow.

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

S1400A Page 5-4 Section 5 - Wiring Techniques

Discharge Units should be placed on the base of the antenna and at the point where the antenna lead (typically coax) enters the site equipment building. When a modem is used, a lightning arrester should be placed at the point where the phone line enters the site equipment building. If you use a modem (manufactured by other than BBI) it is recommended that you also install a surge suppressors or lightning arrester on the phone line as close to the modem as possible. Any unit equipped with a radio or modem must be connected to a known good earth ground via the units Ground Lug.

5.2.10 Secure Wiring Connections

Make sure that all wiring connections are secure. In time wires that were once round will become flattened due to the pressure applied by screw compression type terminals and site vibrations. After a while these compression screws have a tendency to become loose. Part of a good maintenance routine should be to check and tighten all screws associated with wiring terminal connections. Avoid nicking the wire(s) when stripping insulation.

Remember, nicked conductors will lead to future problems. Also remember to provide some cabling slack and strain relief.

If installing stranded or braided wiring that has not been tinned, be sure to tightly twist the end (in the same direction as manufactured) and then trim off any frizzed wires.


BLANK PAGE



DOCUMENT NUMBER: S1400A

TITLE:

TeleFlow

TM

SITE CONSIDERATIONS For EQUIPMENT INSTALLATION,

GROUNDING & WIRING

ISSUE DATE: APRIL, 2003

COMMENT/COMPLAINT:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Mail this page to:



Watertown, CT 06795


Bristol Babcock


Watertown, CT 06795

Phone: +1 (860) 945-2200

Fax: +1 (860) 945-2213



Northern Region



Watertown, CT 06795

Phone: +1 (860) 945-2381

Fax: +1 (860) 945-2525

[email protected]

Gulf Coast Region



Suite F


Phone: +1 (713) 685-6200

Fax: +1 (713) 681-7331

[email protected]

Western Region



Suites 106 & 107

Ontario, CA 91761

Phone: +1 (909) 923-8488

Fax: +1 (909) 923-8988

[email protected]




Suite 1016


Phone: +1 (407) 740-7084

Fax: +1 (407) 629-2106

[email protected]



Watertown, CT 06795

Phone: +1 (860) 945-2218


Central Region


777 South Central

Expressway

Suite 1-C


Phone: +1 (972) 238-8197


International Affiliates:

Canada


234 Attwell Drive


Canada

PH: 416-675-3820


Mexico

BBI, S.A. de C.V.



11540 Mexico, D.F.

Mexico

PH: (52-55)-52-81-81-12

FAX: (52-55)-52-81-81-09

[email protected]

Rocky Mountain Region




Phone: +1 (505) 320-5046

Fax: +1 (505) 327-3273

[email protected]

Communications




Suite 1016


Phone: +1 (407) 629-9464


United Kingdom



Stourport Road

Kidderminster


United Kingdom

PH: +44 (0) 1562 820001


Asia Pacific


PO Box 1987

Bunbury, Western Australia

6231

PH: +61 (0) 8 9791 3654

FAX: +61 (0) 8 9791 3173 [email protected]

Victoria, Australia

PH: +61 (0) 3 9384 2171

FAX: +61 (0) 3 8660 2501

Calgary Office




Canada

PH: 403-265-4808



BBI, S.A. de C.V.

Av. Plomo No.2


Industrial


Mexico

PH: 52-993-353-3142


Middle East



Stourport Road

Kidderminster


United Kingdom

PH: +44 (0) 1562 820001


RC Rev: 27-Mar-03

ESDS Manual

S14006

4/15/92

CARE AND HANDLING

OF

PC BOARDS

AND

E SD-SENSITIVE

COMPONENTS

BRISTOL BABCOCK

BLANK PAGE

ESDS Manual

S14006

4/15/92


PAGE

TOOLS AND MATERIALS REQUIRED 1

ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 2

1. Introduction 2

2. General Rules 3

3. Protecting ESD-Sensitive Components 5

4. Static-Safe Field Procedure 6

5. Cleaning and Lubricating 8

6. Completion 10

TOOLS AND MATERIALS REQUIRED

1. Tools

Anti-Static Field kit. It is recommended that an anti-static field kit be kept on any site where solid-state printed circuit boards and other ESD-sensitive components are handled. These kits are designed to remove any existing static charge and to prevent the build-up of a static charge that could damage a PC board or

ESD-sensitive components. The typical anti-static field kit consists of the following components:

1. A work surface (10mm conductive plastic sheet with a female snap fastener in one corner for ground cord attachment).

2. A 15-foot long ground cord for grounding the work surface.

3. Wrist strap (available in two sizes, large and small, for proper fit and comfort) with a female snap fastener for ground cord attachment.

4. A coiled ground cord with a practical extension length of 10 feet for attachment to the wrist strap.

Toothbrush (any standard one will do)

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2.

Materials

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

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

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

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

ESDS Manual

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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.

3

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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

S14006

4/15/92

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:

5

ESDS Manual

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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.

6

ESDS Manual

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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

7

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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.

8

ESDS Manual

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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

ESDS Manual

#S14006

4/15/92 d.

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

TeleFlow

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 TeleFlow Instruction Manual CI-3530-25B

Manufacturer

Power-Sonic

Corp.

Tadiran

Electronics

General Description

Bristol Babcock Part Number or Media Notes

Sealed Lead-Acid Battery 395407-04-4 (12V - 40AH)

Lithium/Thionyl Chloride

Battery

390618-03-9 (3.6V - On-board)

04/01/98 Appendix Z - CI-3530-25B 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


ABS Plastic

COMPONENTS

Lead

Sulfuric Acid

Hydrogen


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]

B

MSDS No.- T-36-01 (Revision. -G)

Q u a l i t y F i r s t

MATERIAL SAFETY DATA SHEET

SECTION 1- CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

Manufacturer Name- Tadiran Batteries Ltd., P. O. Box 1, Kiryat Ekron, Israel 70500.

US office address- 2 Seaview Blvd. Port Washington NY 11050

Emergency Telephone No. – CHEMTREC: 1-800-424-9300

Tel. for information: 1-516-621-4980

Tel. for information 972-8-944-4503

Products Name: Primary Lithium Thionyl Chloride (Li/SOCl

2

) cells and batteries, Nonrechargeable. Cells include the models of TL, TLH, and TLL, 3.6V series.

SECTION 2- COMPOSITION, INFORMATION ON INGREDIENTS

Ingredient Name

Lithium Metal (Li)

CAS # % ACGIH (TLV) OHSA

(PEL)

7439-93-2 <5% Not Established None

CHIP

Classification

F: R14/15

C: R34

Thionyl Chloride (SOCl

Lithium Chloride (LiCl)

2

) 7719-09-7 <47

7447-41-8

%

1 ppm

(5 mg/M 3 )

<2% Not Established

R: 14/15, 34

S: (1/2), 8,43,45

5 mg/m 3 R: 14,20/22,29,

35.

S: (1/2),26,36/

37/39, 45

Carbon (C)

Aluminum Chloride (AlCl

3

1333-86-4 <6% 3.5 mg/m

) 7446-70-0 <5% 2 mg/m 3

3 3.5

(Al salt, soluble)

R:

S:

45

34

(1/2),7/8,28,

SECTION 3 - HAZARD IDENTIFICATION

The lithium Thionyl chloride batteries described in this MSDS are hermetically sealed units, which are not hazardous when used according to the recommendations of the manufacturer.

Under normal condition of use of the batteries, the electrode materials and the liquid electrolyte they contained are non-reactive provided the battery integrity is maintained. Risk of exposure exists only in case of mechanical, electrical or thermal abuse. Thus the batteries should not short circuit, recharge, puncture, incinerate, crush, immerse in water, force discharge, or expose to temperatures above the temperature range of the cell or battery. In these cases there is risk of fire or explosion

MSDS SOCl2 G rev GB.doc

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SECTION 4- FIRST AID MEASURES


In case of battery rupture, explosion, or major leakage, evacuate personnel from contaminated area and provide good ventilation to clear out corrosive fumes, gases or the pungent odor. Seek immediate medical attention.

Eyes -

First rinse with plenty of water for 15 minutes (remove contact lenses if easily possible), and then seek medical attention.

Skin -

Remove contaminated clothes and rinse skin with plenty of water or shower for

15 min. Refer to medical attention.

Inhalation -

Remove to fresh air, rest, and half-upright position, use artificial respiration if needed, and refer to medical attention.

Ingestion -

rinse mouth,

DO NOT

induce vomiting, give plenty of water to drink, and refer to medical attention.

SECTION 5- FIRE FIGHTING MEASURES

FLAMMABLE LIMIT IN AIR: NA

EXTINGUISHING MEDIA:

1. Lith- X (Class D extinguishing media) is the

only

effective on fires involving a few lithium batteries. If the cells are directly involved in a fire

DO NOT USE:

WATER,

SAND, CO

2

, HALON, and DRY POWDER OR SODA ASH EXTINGUISHERS.

2. If the fire is in adjacent area and the cells that are either packed in their original containers or unpacked, the fire can be fought based on fueling material, e.g., paper and plastic products. In these cases the use of copious amounts of

cold

water is effective extinguishing media. Storage area may employ sprinkler system with cold water.

AUTO-IGNITION: NA

SPECIAL FIRE FIGHTING PROCEDURES: Wear self-contained breathing apparatus to avoid breathing of irritant fumes (NIOSH approved SCBA & full protective equipment). Wear protective clothing and equipment to prevent body contact with electrolyte solution.

Fire may be fought, but only from safe fire-fighting distance. Evacuate all persons from immediate area of fire.

UNUSUAL EXPLOSION AND FIRE EXPLOSION: Battery may explode when subject to: excessive heat (above 150ºC), recharged, over-discharged (discharge below 0V), punctured and crushed. During thermal decomposition generation of chlorine (Cl

2

), hydrogen chloride (HCl), and sulfur dioxide (SO

2

) can be formed.

SECTION 6- SPILL OR LEAKAGE PROCEDURES

PROCEDURES TO CONTAIN AND CLEAN UP LEAKS OR SPILLS: The material contained within the battery would only be released under abusive conditions.

In the event of battery rapture and leakage: contain the spill while wearing proper protective clothing and ventilate the area. Than, cover with sodium carbonate


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B


(Na

2

CO

3

) or 1:1 mixture of soda ash and slaked slime. Keep away from water, rain, and snow. Placed in approved container (after cooling if necessary) and disposed according to the local regulations.

NEUTRALIZING AGENT: Sodium carbonate (Na

2 and slaked slime.

CO

3

) or 1:1 mixture of soda ash

WASTE DISPOSAL METHOD: Product decomposed by water must be neutralized.

May be added to waste water in sufficiently diluted form.

PRECAUTIONS IN HANDLING AND STORING; Avoid short-circuiting, overcharging and heating to high temperatures. Store the batteries in dry and cool area and keep container dry and tightly closed in well-ventilated area. Store away from food and drink.

OTHER PRECAUTIONS; Never attempt to disassemble, machine, or otherwise modify batteries or injury may result.

SECTION 7- HANDLING AND STORAGE

The batteries should not be opened, destroyed or incinerate, since they may leak or rupture and release to the environment the ingredients that they normally contained in the hermetically sealed container.

HANDLING-

Do not short circuit terminals, or expose to temperatures above the temperature rating of the battery, over charge the battery, forced over-discharge

(voltage below 0.0V), throw to fire.

Do not crush or puncture the battery, or immerse in liquids.

STORAGE-

Storage preferably in cool (below 30ºC), dry and ventilated area, which is subject to little temperature change.

Do not place the battery near heating equipment, nor expose to direct sunlight for long periods. Elevated temperatures can result in shortened battery life and degrade performance.

Keep batteries in original packaging until use and do not jumble them.

Do not store batteries in high humidity environment for long periods.

OTHER-

the cells and the batteries are not rechargeable batteries and should not be charged.

Applying pressure and deforming the battery may lead to disassembly followed by eye skin and throat irritation.

Follow manufacturers recommendations regarding maximum recommended current and operating temperature range.

SECTION 8 - EXPOSURE CONTROLS & PERSONAL PROTECTION

RESPIRATORY PROTECTION: None necessary under normal use. In case of abuse and leak of liquid or fumes, use NIOSH approved Acid Gas Filter Mask or Self-

Contained Breathing Apparatus.

VENTILATION: Not necessary under normal use. In case of abuse, use adequate mechanical ventilation (local exhaust) for battery that vent gas or fumes.

PROTECTIVE GLOVES: None under normal use. In case of spill use PVC or Nitrile gloves of 15 mils (0.015 inch) or thicker.


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EYE PROTECTION: Use ANSI approved chemical worker safety goggles or face shield.

OTHER PROTECTIVE EQUIPMENT: Chemical resistance clothing is recommended along with eye wash station and safety shower should be available meeting ANSI design criteria.

WORK HYGIENIC PRACTICES: Use good chemical hygiene practice. Wash hands after use and before drinking, eating or smoking. Launder contaminated cloth before reuse.

SUPPLEMENTARY SAFETY AND HEALTH DATA: If the battery is broken or leaked the main hazard is the electrolyte. The electrolyte is mainly solution of Lithium chloride (LiCl), and aluminum chloride (AlCl

3

) in Thionyl chloride (SOCl

2

).

Fires may be fought but only from safe fire fighting distance, evacuate all persons from immediate area of fire.

Prevent heating of the battery, charging the battery, discharge to predetermined limit, do not crush, disassemble, incinerate or short circuit.

SECTION 9- PHYSICAL DATA

BOILING POINT (760 mm Hg)

VAPOR PRESSURE (mm Hg, 25ºC)

VAPOR DENSITY (air=1)

NA, unless individual components exposed



DENSITY (gr/cc)

VOLATILE BY VOLUME (%)

> 1 gr/cc

NA

EVAPORATION RATE (butyl acetate=1) NA, unless individual components exposed

PHYSICAL STATE Solid

SOLUBILITY IN WATER (% by weight) NA, unless individual components exposed

PH

APPEARANCE

ODOR


Geometric Solid Object

If leaking, gives off pungent corrosive odor

SECTION 10- STABILITY AND REACTIVITY

STABLE OR NOT STABLE Stable

INCOMPATIBILITY (MATERIAL TO AVOID) Strong mineral acids, water and alkali solutions.

HAZARDOUS

DECOMPOSITION

PRODUCTS

1. Reaction of lithium with water: Hydrogen (H

2 hydroxide (LiOH).

), Lithium

2. Thermal decomposition over 150ºC: Sulfur oxides, (SO

2

SO

3

), Sulfur chorides (SCl

2

, S

2

Cl

2

), Chlorine (Cl

2 oxide (Li

2

O).

,

), Lithium

3. Electrolyte with water: Hydrogen Chloride (HCl) and SO

2

DECOMPOSITION TEMPERATURE (ºF)

NA

HAZARDOUS POLYMERIZATION: May Occur____ Will Not Occur __X__

CONDITIONS TO AVOID Avoid mechanical abuse, and electrical abuse such as short-circuiting, overcharge, over-discharge,

(voltage reversal) and heating.


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SECTION 11- TOXICOLOGICAL INFORMATION


THRESHOLD LIMIT VALUE (TLV) AND SOURCE: NA

HEALTH HAZARD ACUTE AND CHRONIC: Inhalation, skin contact, eye contact and ingestion are not likely by exposure to sealed battery.

Inhalation, skin contact and eye contact are possible when the battery is opened.

Exposure to internal contents, the corrosive fumes will be very irritating to skin, eyes and mucous membranes. Overexposure can cause symptoms of non-fibrotic lung injury and membrane irritation.

Carcinogenicity- NTP: No

Carcinogenicity- IARC: No

Carcinogenicity- OSHA: No

Explanation of Carcinogenicity- No ingredient of a concentration of 0.1% or greater is listed as a carcinogen or suspected carcinogen.

SIGNS AND SYMPTOMS OF OVEREXPOSURE: Exposure to leaking electrolyte from ruptured or leaking battery can cause:

Inhalation

- Burns and irritation of the respiratory system, coughing, wheezing, and shortness of breath.

Eyes

- Redness, tearing, burns. The electrolyte is corrosive to all ocular tissues.

Skin

- The electrolyte is corrosive and causes skin irritation and burns.

Ingestion

- The electrolyte solution causes tissue damage to throat and gastro/ respiratory track.

MEDICAL CONDITION AGGRAVATED BY EXPOSURE: Preexisting skin, asthma and respiratory diseases are generally aggravated by exposure to liquid electrolyte vapors or liquid. For further information refer to section 4.

SECTION 12- ECOLOGICAL INFORMATION

1. When properly used and disposed the battery does not present environmental hazard.

2. The battery does not contain mercury, cadmium, or lead.

3. Do not let internal components enter marine environment. Avoid release to waterways, wastewater or ground water.

SECTION 13- DISPOSAL CONSIDERATIONS

1. Disposal must be in accordance with the applicable regulations in every country and state.

2. Disposal of the Lithium batteries should be performed by permitted, professional disposal firms knowledgeable in Federal, State or Local requirements of hazardous waste treatment and hazardous waste transportation.

3. Incineration should never be performed by battery users, but eventually by trained professional in authorized facility with proper gas and fume treatment.

4. Recycling of battery can be done in authorized facility, through licensed waste carrier.


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SECTION 14- TRANSPORTATION /SHIPPING


Lithium batteries UN number 3090, class 9 (miscellaneous)

Lithium batteries contained in equipment, UN number 3091, class 9 (miscellaneous).

Packing instructions for 3090- ICAO 903 for air transport

IMDG 903 for sea transport

ADR/RID 903 and 903a for road /rail transport

Packing instructions for 3091- ICAO 912/918 for air transport

IMDG 903 for sea transport

ADR/RID 903 and 903a for road /rail transport

In the USA transportation is according to Code of Federal Regulations (CFR 49

Chapter 1, paragraph 173.185)

A list of Tadiran batteries and cells that are subject to transport regulations and those that are exempted can be obtained from Tadiran Batteries Ltd.

Identification and labeling in compliance with the product drawing should include the battery title, nominal voltage, lot number and warning.

SECTION 15- REGULATORY INFORMATION

1. The transport of the lithium batteries is regulated by the United Nations, “Model

Regulations on Transport of Dangerous Goods”, 13 revised edition-2003 (special provisions 188, 230, and 310).

2. Within the US the lithium batteries and cells are subject to shipping requirements under 49 CFRCh. 1, paragraph 173.185, “lithium batteries”.

3. Shipping of lithium batteries in aircrafts are regulated by the International Civil

Aviation Organization (ICAO) and the International Air Transport Association

(IATA) 2003 requirements in Special Provisions A45, A88 and A99.

4. Shipping of lithium batteries on sea are regulated the International Maritime

Dangerous Goods (IMDG) 2002 requirements in special provisions 188, 230 and 310.

5. Shipping of lithium batteries on Road and Rail, 2002 requirements in special provisions 188, 230 and 310.

6. The internal component (thionyl chloride) is hazardous under the criteria of the

Federal OHSA Hazard Communication Standard 29 CFR 1920.1200.

SECTION 16- OTHER INFORMATION/DISCLAIMER

The information and the recommendations set forth are made in good faith and believed to be accurate at the date of preparation. The present file refers to normal use of the product in question. Tadiran Batteries makes no warranty expressed or implied.


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BLANK PAGE


Customer Instruction Manual

CI-3530-25B

Jan., 2007


Bristol, Inc.


Watertown, CT 06795

Phone: +1 (860) 945-2262



Bristol Canada

6338 Viscount Rd.


Canada

Phone: 905-362-0880






11540 Mexico, D.F.

Mexico

Phone: (52-55)-52-81-81-12




Blackpole Road

Worcester, WR3 8YB

United Kingdom

Phone: +44 1905 856950



Bristol, Inc.




Phone: +61 (8) 9725-2355






TeleFlow

™



Bristol Inc.