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Bristol ControlWave Model 3820-EX (Explosion

1. Create a new control strategy E 2 2 from scratch The project is already built You would only need to rebuild it if you modify the standard version Bristol ControlWave Firmware gt Designer Library Development a 1 I O Configuration Wizard Environment A The standard gas measurement project is factory A tested You would only need to test it if you ve 2 Test Project Sontehwave Project made modifcations est your Projec UO Simulator Th dard i d i e standard gas measurement project is already IEC 61131 Real Time System H sch ERC le HES deu Ge a loaded You would only need to download it if oad executable E pen ownloader can perform j Bristol Firmware downloads ControlWave Designer can also you ye made modifcations Open BSI be used to download and test hardware Downloader Process Automation y Retrieve Data and 4 Use standard ControlWave EFM Plus web pages Controller JS Configure Your System and Flash Configuration Utility with standard FCP IEC 61131 Real Time System jo file to perform configuration Web pages Other software Bristol Firmware a using in which the ActiveX Controls ActiveX controls Executable project g FLASH have been placed Configuration Parameters Configuration HTML eg no Baal NW Utility for setting Real Time and Historical Data addresses etc 5 Web pages running Project Pah ae in Internet Explorer PROCESS I O BOARDS Third OPC Server rk A P
2. Contrast R43 L 1 1 ss Battery General Backup Purpose s5 DIP Switch Figure 2 8 CPU Module Component Identification Diagram 2 3 2 2 Communication Ports A ControlWave XFC can be configured as a Master or Slave node on either a MODBUS network or a BSAP network A variety of communication schemes are available Three communication ports are available and are accessible on the Wiring Plate Assembly These communication ports are designated as follows CI ControlWave XFC Installation amp Operation 2 15 COM1 Port 1 RS 232 8 Pins on Terminal Block J2 labeled LOCAL Half Duplex operation only COM2 Port 2 RS 232 7 Pins on Terminal Block J2 labeled NETWORK Full Half Duplex operation COMBS Port 3 RS 485 8 Pins on Terminal Block J2 labeled RS 485 Half Duplex operation only Communication Ports COM1 COM2 and COM3 support serial asynchronous operation as listed above Any communication port COM1 COM2 or COM3 can be configured for local communications i e connected to a PC loaded with ControlWave Designer and OpenBSI software Diagrams of RS 232 485 interfaces and connectors are shown in Figures 2 9 and 2 10 Hardware connector pin wiring assignments are provided in Tables 2 2A through 2 2C 2 3 2 3 RS 232 amp RS 485 Interfaces ControlWave XFC RS 232 amp RS 485 communication schemes are discussed herein RS 232 Ports An RS 232 interface supports Point to Poi
3. O 1 0 Loe 1 8 Introduction CI ControlWave XFC communications via a 3 wire half duplex cable All communication ports are Tranzorb protected to 15KV ESD 1 3 3 2 CPU Memory Boot downloader FLASH Boot download code is contained in a single 512 Kbyte uniform sector FLASH IC This device resides on the local bus operates at 3 3V and is configured for 8 bit access 10 Position DIP Switch see Table 1 2 provides user configuration settings such as enabling disabling Recovery Mode Core Updump WINDIAG etc Note Recovery Mode will be initiated if CPU Switch SW1 positions 9 and 10 are both set ON or OFF when a reset occurs FLASH Memory The base version of the CPU Module has 8Mbytes of 3 3V simultaneous read write DL FLASH memory The CPU Board contains one 63 pin FBGA site that accepts an 8 Mbytes 3 3V DL FLASH IC FLASH memory is 16 bits wide System Firmware and the Boot Project are stored here No hardware write protection is provided for the FLASH array System Memory SRAM The base version of the CPU Module has 2Mbytes of soldered down static RAM im plemented with one 1M x 16 asynchronous SRAM that is configured as a 1M x 16 bit array All random access memory retained data is stored in SRAM During power loss periods SRAM is placed into data retention mode powered by a backup 3 0V lithium battery SRAMs operate at 3 3V and are packaged in 63 pin FBGA sites Critical system information that must
4. fEl bone PT TT T E My computer Figure F 3 Sign On Off Web Page F 4 1 1 Selecting a Node and Signing On The user must choose the Node they want to sign on to from the RTU Name list box The user must enter the Username and Password The user must then click on the Sign On button If the sign on attempt is successful the message Access Granted will appear in green text within the message area Failure messages appear in red text and informational messages appear in black text CI ControlWave XFC Appendix F F 3 F 4 1 2 Signing Off from the Node To sign off from a Node the user must click on the Sign Off push button If the sign off attempt is successful the message Sign Off Successful will appear in green failures are in red Note For Security Maintenance functions refer to CW MICRO Quick Setup Guide D5124 Part 2 Configuring User Accounts amp Privileges F 4 2 Locating Nodes The user may identify which node s they would like to communicate with by using the Locator page The Nodes can be identified either by loading a proxy file or by loading Open BSI information In either case they will be displayed as icons in a tree on the left side of the page The Node Locator Web page is accessible by clicking on the Security category button and choosing the Locate Nodes drop down menu selection ControlWave Load Proxy File Info Load Opens Info Delete Selected Reset RTU Info Node Name
5. RTU Security Sign On Off Locate Nodes Contacts Station Meter Run E OE i my computer Figure F 4 Locate Nodes Web Page F 4 3 Contacts A list of Bristol Inc offices is provided under the topic Contacts The Contacts Page is accessible by clicking on the Security category button and choosing the Contacts drop down menu selection F 5 STATION CATEGORY FUNCTIONS The standard application program for the ControlWave XFC allows the user to configure a station with up to four meter runs Users must configure Station parameters from the Station Configuration category section of WebBSI Seven Web Pages are accessible from the Station Configuration category section of WebBSI F 4 Appendix F CI ControlWave XFC e Summary Section F 5 1 e Sampler amp Odorizer Section F 5 2 e Mechanical Counter Section F 5 3 e Nominations Section F 5 4 e Flow Control Section F 5 5 e Run Switching Section F 5 6 LU Radio amp Modem Control Section F 5 7 F 5 1 Station Summary Station Summary Web Pages display corrected and uncorrected flow rates and volumes for the station and each run Corrected Volumes Uncorrected Volumes and Accumulated Energy totals are displayed for the previous hour and previous day Station Summary Firmware Major Minor Station ID Program Name Program Revision Station Identification ed Unnamed _Station MxXFCI_3 1 3 60 000 ms System Voltage Input 13 85 Ram Backup Battery Status OK Web Page
6. ZS seins Oey Parameters Signa FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG FLWCNTL ENA CFG Search Critena s BESES nly Description FALSE TOTRUE STATUS CHAI TRUE TOFALSE STATUS CHAI FALSE TO TRUE STATUS CHA TRUE TOFALSE STATUS CHA FALSE TO TRUE STATUS CHA TRUE TOFALSE STATUS CHAI FALSE TO TRUE STATUS CHAI TRUE TOFALSE STATUS CHA FALSE TO TRUE STATUS CHA TRUE TOFALSE STATUS CHA FALSE TO TRUE STATUS CHAI Show Statistics Audit Seq Global Geo Figure F 24 Meter Run Audit Trail Web Page Both Alarms amp Events Selected When View Audit Trail is selected the Meter Run Audit Trail Web Page see Figure F 24 will be displayed Meter Run Audit Trail Web page buttons allow the user to Collect Data Save Parameters Search Criteria and Show Statistics Additionally the Meter Run Audit Trial Web page posts the Total of Records Collected near the top right side of the page When the page is initially opened only the 24 most recent records are gathered To view more records the user may scroll down using the Vertical Scroll Bars F 8 3 View Signal List Signal List Information Collect List Floating Point Format CI ControlWave XFC Number List Number to be viewed Start Index List Element to start collecting Max Signals to Collect Number of Signals to coll
7. gt TOR N RS 232 gt ToT Ki coma Internally toitrom Powered py gt To V or Ext Powered Al 2 Example peers Simplified coal 11 30Vdc Internally 11 30Vdc Powered AO Examples 1 5V Al 1 Example 4 20mA Analog Input Externally Analog Output Wiring Diagram Powered Wiring Diagrams 1 5V Analog Input Wiring Diagram Figure 3 2 Terminal Plate Field I O Wring Diagram CI ControlWave XFC Service 3 5 3 4 GENERAL SERVICE NOTES Certain questions or situations frequently arise when servicing the ControlWave XFC Some items of interest are provided in Sections 3 4 1 through 3 4 4 3 4 1 Extent of Field Repairs Field repairs to a ControlWave XFC are strictly limited to the replacement of complete assemblies Component replacement on a ControlWave XFC Printed Circuit Board PCB constitutes tampering and will violate the warranty Defective ControlWave XFC compo nents Function Module or Multivariable Transducer MVT must be returned to Bristol Babcock for authorized service 3 4 2 Maintaining Backup Files It is essential to maintain a backup disk of each application load file to guard against an accidental loss of process configuration data Without a backup record it will be necessary to reconfigure the entire application load that can be a very time consuming procedure Always play it safe and keep backup copies of your operating system loads A copy of the
8. D SubPkts Sent D Inv SubPkts D Ack Timeout D Discard Quota D Out of Order D Fail Over Fails D Send Error For Help press F1 SS zl D Inbon Windows Mess y Exploring C public 9 Obsiace Microsoft Vi DY Microsoft Word btp E NetView Cha yo 11 36 AM Figure 3 3 Netview Startup Menu Example with Multiple Networks 2 To start the WINDIAG program go to the Start Program s menu select OpenBSI Tools then select Utilities Programs and then select Diagnostics iy diag Manual Testing RTU F Manual Testing RTU RTU Type ContiolWave XFC For Help press F1 Figure 3 4 WINDIAG Main Diagnostics Me 3 Once WINDIAG has been entered the Main Diag Menu of Figure 3 4 will appear 4 Select the module to be tested Enter any prompted parameters slot etc WINDIAG will perform the diagnostics and display pass fail results 3 8 Service CI ControlWave XFC 5 After all diagnostic testing has been performed exit the WINDIAG program and then exit the Netview Program if there aren t any other ControlWave XFC units to be tested When you close the Netview program you will be prompted as to whether or not you want to close the OpenBSI program select Yes 6 Set ControlWave XFC CPU Switch SW1 8 to the ON Open position and then cycle the power OFF then ON The ControlWave XFC should resume normal operation 3 5 1 Diagnostics Using WINDIAG ControlWave XFC electroni
9. To minimize your engineering and development time we have adopted the international standard for PLC programming IEC 61131 3 ControlWave Designer is a fully IEC 61131 3 compliant programming environment for the ControlWave family of products ControlWave Designer includes all five IEC 61131 3 process languages for batch continuous and discrete control Function Block Diagram Structured Text Sequential Function Chart Ladder Logic Diagram and Instruction List ControlWave Designer includes an extensive library of more than 200 basic IEC 611831 3 functions and function blocks common to many IEC 61131 3 based products These include e Flip flops Counters amp Timers e Ladder diagram functions coils and contacts etc e Numerical Arithmetic amp Boolean functions Sine Cosine Add Sub Square Root And Or etc e Selection amp Comparison Min Max Greater than Equal Less than etc e Type conversions Integer to Real Boolean to Word etc 1A 2 3 ACCOL III In addition to the basic functions and function blocks ControlWave Designer brings the benefit of over twenty years of SCADA and plant control experience in Bristol Babcock s ACCOL III function block library ACCOL III includes over sixty function blocks valuable for use in oil amp gas water amp waste and process measurement amp control applications Further ACCOL III is designed to take full advantage of the significant features offered by ControlWav
10. Additionally the I O Board provides 3 3Vdc logic power to the CPU Board 1 8Vdc used by the ARM microprocessor is generated on the CPU Board derived from the 3 3Vdc 1 2 ControlWave PROGRAMMING ENVIRONMENT ControlWave programming environment uses industry standard tools and protocols to provide a flexible adaptable approach for various process control applications in the gas water treatment wastewater treatment and industrial automation business CI ControlWave XFC Introduction 1 3 ControlWave XFC units provide an ideal platform for remote site automation measurement and data management in the oil and gas industry The control strategy file created and downloaded into the controller is referred to as a ControlWave project The ControlWave XFC ships from Bristol Babcock with a standard ControlWave project pre configured for gas flow measurement already loaded and ready to run The ControlWave programming environment consists of a set of integrated software tools which allow a user to modify the standard gas flow measurement project to fit the needs of their own particular application as well as to create test implement and download a different ControlWave project if desired IF YOU RE CREATING YOUR OWN PROJECT IF YOU RE USING THE STANDARD GAS MEASUREMENT PROJECT Build your Project
11. Assembly Figure 2 5 ControlWave XFC Housing Assembly Rotation Diagram Mount the ControlWave XFC on a stand alone vertical horizontal 2 inch pipe or on a wall or panel The ground conductor connects between the ControlWave XFC s Chassis Ground CI ControlWave XFC Installation amp Operation 2 11 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 when used is in continuity with the pipeline it may have to be electrically isolated from the ControlWave XFC Use a strong heat shrink material such as RAYCHEM WCSM 68 22 EU 3140 This black tubing will easily slip over the 2 inch pipe and then after uniform heating e g with a rose bud torch it electrically insulates and increases the strength of the pipe stand See BBI Specification Summary F1670SS 0a for information on PGI Direct Mount Systems and Manifolds Transducer to Manifold Dielectric Isolation Kit Multivariable Transducer Dielectric Gasket amp Flange Seals 2 Valve Block Manifold Top Washers 4 Bottom Washers 4 Mounting Bolts 4 AWG 14 Ground Wire if from Internal Ground Shown AWG 4 Ground Wire if from External Ground Lug P Ground Rod or System Figure 2 6 ControlWave XFC Direct Mount Installation with Cathodic Protection Note Direct Mount installation of a M
12. GPT Section 1 3 6 RTD Probe Section 1 3 7 1 3 1 Housing ControlWave XFCs are housed in an explosion proof enclosure case that is cast from 356 aluminum External dimensions are approximately 6 16 high by 5 00 wide by 6 19 deep When present the Multivariable Transducer adds 3 02 while the Gage Pressure Transducer adds 1 72 to the height of the unit The housing consists of the main body and two threaded covers i e the Front Display Cover and ther Rear Wiring Cover The Front Display Cover provides a viewing window for the LCD display In normal operation the display remains running after the unit has been configured and placed into service Acess to the Terminal Plate is gained by removing the Rear Wiiring Cover CI ControlWave XFC Introduction 1 5 1 3 2 ControlWave XFC Function Module Internally the circuit boards are stood off and mated to a Terminal Plate via an assembly called the Function Module The Function Module is secured to the inside of the ControlWave XFC case via four scews To replace a printed circuit board the rear cover must first be removed before removing the four screws that secure the Function Module Once the Function Module has been removed the individual circuit boards are accessable for removeal replacement 1 3 3 CPU Board Assembly The multilayer CPU Board provides ControlWave XFC CPU I O monitor control memory and communication functions ControlWave XFC CPU Boards operate o
13. Main function The Main function selection is used to enable disable the nomination function If this signal is set to the disable state nomination will not occur Quantity units The Quantity units selection is used to set the target units as MCF or MMBTU Control mode Control mode provides for the selection of either the Valve Control or Flow Control modes of nomination operation Status The Status signal is an output of the nominations algorithm that indicates whether there is currently a nominations period in progress The user may change the state of this signal to end an in progress nomination immediately or to start the next period immediately see Manually Starting Ending a Nomination Period Stop Mode The Stop mode selection allows the user to automatically have the valve closed i e shut in on stop mode or left in the last position upon reaching the target or programmed end period Daily Only Mode When Daily mode is enabled only the programmed start and end hours are used by the ControlWave XFC the Start Stop days are ignored i e nomination begins and ends within a 24 hour period every day F 8 Appendix F CI ControlWave XFC Alarm at a level of The Alarm at a level of setting can be configured as percentage of Volume MCF or Energy MMBTU This feature allows the ControlWave XFC to provide an alarm logical nomination alarm or indication to an operator or computer that a specified amount of target h
14. Modem Control Configuration Web Page is accessible for users by selecting Radio amp Modem Control F 5 7 1 Radio Modem Control Mode Enable Disable Radio Modem Control via a control button to the right of Radio Modem Control Mode F 5 7 2 Common Properties Local Address Local Address of the ControlWave XFC is set via the RTU Configuration Parameters Page in NETVIEW or LOCAL VIEW Group Number Group Address of the ControlWave XFC This is set via the RTU Configuration Parameters Page in NETVIEW or LOCAL VIEW Activate Radio Modem on Local Port Active When using any of the radio modem port scheduling modes Radio Sensing Hourly Daily or Daylight Port 2 the Radio Modem Port is inactive unless communications are scheduled However by enabling the Activate Radio on Local Port Active mode Port 1 the Local Port can be used to control the state of Port 2 F 5 7 3 Radio Sensing Mode Radio sensing allows a user to activate the radio for very short time intervals specified in milliseconds under Listen Time Out every so many milliseconds specified in seconds under Listen Interval to sense a valid BSAP message on the radio s carrier frequency If a CI ControlWave XFC Appendix F F 15 message is not detected the radio is deactivated If a message is detected the radio is left activated until it responds after which it remains ON for another listen time interval If no more valid messages are detected th
15. Replace the Rear Wiring Cover 1 Rear Wiring Housing Cover 2 Function Module Mounting Screws 3 Function Module items 9 10 12 amp 13 4 MVT Cable 5 Multivariable Transducer MVT 6 Housing Case 7 Data Plate 8 Front Display Housing Cover 9 Terminal Plate 10 CPU Bd Assembly 10 11 11 Cover O Ring 12 1 O Bd Assembly 13 LCD Display Assembly 1 MVT Cable Plugs in Here 11 Figure 3 1 ControlWave XFC Component Identification Diagram CI ControlWave XFC Service 3 3 3 3 TROUBLESHOOTING TIPS 3 3 1 Power Checks One bulk power source can be connected to the Terminal Plate Connector J6 provides 2 in put terminal connections for bulk power see Figure 3 2 J6 1 4VIN 6Vdc to 30Vdc J6 2 Chassis Ground CHASSIS Bulk supply voltages can be checked at J6 using a voltmeter or multimeter The maximum and minimum input power switch points can be tested with the use of a Variable dc Power Supply connected between J6 1 and J6 2 By increasing the input voltage starting at less than 5 4Vdc you can determine the point at which the unit will turn on i e the point at which the LCD Display comes ON Vt By decreasing the input voltage starting at 16Vdc you can determine the point at which the unit turns off i e the point at which the LCD Display goes OFF Vt If the value of the bulk power supply s output approaches the value of Vt or Vt it should be replaced by a
16. Units X 1000 10000 0000 Odorizer Configuration Output Mode Analog Point ID DO Point ID 1 2 I Dieses gudden Scale Factor Units Pulse Frequency Units X 1000 1 0000 SCF HOUR 1000 0000 Curr Odor Demand Current AO Value Injection Counts Fant jules Couns 6 000 AO Zero amp Span 0 0000 D ee Wane ion Coun SS Alarm Configuration Alarm DI Point ID Sampler Alarm D 4 NORMAL 0 Disabled Figure F 6 Sampler amp Odorizer Configuration Web Page CI ControlWave XFC Appendix F F 5 F 5 2 Sampler and Odorizer Configuration See section F 5 2 1 for Sampler Configuration or F 5 2 2 for Odorizer Configuration F 5 2 1 Sampler Configuration The user may enable or disable the Sampler by using the Enable Disable button If enabled the Sampler will operate at a frequency set by the Pulse Frequency setpoint in cubic feet Users must select which Digital Output DO Point will be used A running count of samples taken will be displayed Users may reset this count by pressing the Reset Count button F 5 2 2 Odorizer Configuration Users may enable or disable the Odorizer by using the Enable Disable button The user also selects the Output Mode i e Analog Output or Digital Output If the Analog Output Mode is selected Analog Point ID 1 is assigned If the Digital Output Mode is selected the Digital Output Point to be used is selected via the DO Point ID field When the Analog Output Mode is selected the user must set the Scale Facto
17. application load can be loaded into ControlWave XFC FLASH memory and or saved to a PC s Hard Drive as a ZIP file 3 5 WINDIAG DIAGNOSTICS Bristol s WINDIAG program provides menu driven diagnostics that have been de signed to assist a technician or Process Engineer in troubleshooting the various ControlWave XFC circuits For more detailed descriptions of ControlWave XFC Windows Diagnostics than those provided herein see Document D4041A Chap ters 1 amp 7C Bristol s WINDIAG Software is a diagnostic tool used for testing ControlWave XFC elec tronics including I O circuitry CPU memory communications ports etc for proper per formance The ControlWave XFC must be communicating with a PC equipped with the WINDIAG program CPU Board configuration switch SW1 8 must be set to the OFF Closed position to enable diagnostics Communication between the ControlWave XFC with without application loaded and the PC can be made via a Local or Network Port with the following restrictions e CPU Board Switch SW1 8 must be OFF to run the WINDIAG program Setting SW1 8 OFF will prevent the Boot Project from running and will place the unit into diagnostic mode e Any ControlWave XFC communication port can be connected to the PC Process Engi neer s Interface provided their port speeds and configuration match e g baud rate parity stop bits protocol etc This can be accomplished via user defined Soft Switches e Setting CPU Bo
18. compliant third party software packages A set of ControlWave XFC web pages is provided to set configuration parameters for the standard gas flow measurement project running in the unit These web pages use Bristol Babcock specific ActiveX controls for retrieval of real time data values and communication statistics from the unit The ActiveX controls are compatible with Microsoft Internet Explorer Alternatively developers can place the ActiveX controls in third party ActiveX compatible containers such as Visual BASIC or Microsoft Excel User defined Web Pages Users can place the same ActiveX controls into their own web pages to provide a customized human machine interface HMI to the Control Wave XFC Flash Configuration Utility Parameters such as the BSAP local address IP ad dress etc are set using the Flash Configuration Utility accessible via Open BSI LocalView or NetView The ControlWave XFC ships with a standard Flash Con figuration Profile FCP file with default configuration parameters already set 1 3 PHYSICAL DESCRIPTION ControlWave XFC gas flow computers are comprised of the following major components Housing with LCD Display Section 1 3 1 Function Module Section 1 3 2 CPU Board Assembly Section 1 3 3 I O Board Assembly Section 1 3 4 Terminal Plate Section 1 3 5 ControlWave XFCs can be factory configured with the following options Multivariable Transducer MVT or Gage Pressure Transducer
19. d Spray the connector liberally to flush out any contaminants e Remove any excess spray by shaking the connector or wiping with either a toothbrush or a lint free wiping cloth 6 Completion 10 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 Customer Instruction Manual Cl ControlWave XFC ControlWave XFC Explosion Proof GFC Oct 2006 Emerson Process Management Bristol Inc 1100 Buckingham Street Watertown CT 06795 Phone 1 860 945 2262 Fax 1 860 945 2525 www EmersonProcess com Bristol Emerson Electric Canada Ltd Bristol Canada 6338 Viscount Rd Mississauga Ont L4V 1H3 Canada Phone 905 362 0880 Fax 905 362 0882 www EmersonProcess com Bristol Emerson Process Management BBI S A de C V Homero No 1343 3er Piso Col Morales Polanco 11540 Mexico D F Mexico Phone 52 55 52 81 81 12 Fax 52 55 52 81 81 09 www EmersonProcess com Bristol Emerson Process Management Bristol Babcock Ltd Blackpole Road Worcester WR3 8YB United Kingdom Phone 44 1905 856950 Fax 44 1905 856969 www EmersonProcess com Bristol Emerson Process Management Bristol Inc 22 Portofino Crescent Grand Canals Bunbury Western Australia 6230 Mail to PO Box 1987 zip 6231 Phone 61 8 9725 2355 Fax 61 8 8 9725 2955 www EmersonProcess com Bri
20. gt ToT 5 RTS S CcTS E RS 232 E DTRIE z2 DCDIG of SS gh H SE Loop Wires AWG 24 RS 232 Cable Wires AWG 22 TEE EE EE al ControlWave XFC coms Term Plate Term Block me ies _ c gt To J To RS 485 Alojoloja a2a gt To Power CS T 7 R8232 v Rb485 F R Notes Loop Wires AWG 24 7 Cable Wires AWG 22 RS485 Figure 2 14 Model 3808 Transmitter to CW XFC RS 485 Comm Cable Diagram CI ControlWave XFC Installation amp Operation 2 23 Figures 2 13 and 2 14 detail the RS 232 and RS 485 wiring connections required between the ControlWave XFC and the Model 3808 Transmitter Model 3808 Transmitters can be connected to a ControlWave XFC via a half duplex RS 485 Network An illustration of this network is provided in Figure 2 15 AR T Chex V R485 R Figure 2 15 ControlWave XFC to 3808s RS 485 Network Diagram 2 3 6 Power Wiring amp Distributi
21. to settle before allowing another run switching action to occur F 14 Appendix F CI ControlWave XFC F 5 6 2 Runl amp 2 Properties When a run is in Manual Mode selected by the Run Auto Manual button the valve may be opened or closed by right clicking on the field to the right of the Current Valve Command and toggling the valve When a run is in Auto Mode and Run Switching is enabled the valve is controlled by the run switching logic If the Target Rank of a run is 1 the valve will always be open The Call Next Run Setpoint SP is the value if the process variable DP Frequency or Flow Rate that will cause the next run to open The process variable for calling runs is the PV from the run selected as Target Rank 1 If the run with Target Rank 1 is open and the run with Target Rank 2 is not open when the PV for Target Rank 1 exceeds the Call Next Run SP the Target Rank 2 will be opened Likewise if the PV for Target Rank 2 drops below the Call Prev Run SP the highest ranked run that is open will be closed Call Next Deadband is the amount of time that the PV has to be greater than the Call Next Run SP value before the next run will be opened Call Previous Deadband is the amount of time that the PV has to be less then the Call Prev Run SP value before the lowest rank run will be closed Valve Control DO Point is the digital output point used for valve control F 5 7 Radio and Modem Control The Radio amp
22. 0 ccceccessccesssscecesssececeeseeeeceeseseecesseseeeesseseeeesseeaeeseseaaees 2 16 MO WAV AIG ze EE 2 18 VO Wire Connections e ieden ENEE ebe ue 2 18 Shielding and Grounding ccccccccssccccesssececesssececeesececseseeeeseseeeesesseeeesesseeeeseaeeeesaas 2 19 Non isolated Discrete Input Output Connector Block A8 2 19 Discrete Input Output Configurations c ccccccscecesssssecessseceeeseseeeeeessesaeeessseaeessenaaees 2 19 Non isolated Analog Input Connector Block Ja 2 19 Analog Input Configurations cccccccccsssecessessesecsecececsesaeeecsesaeeecsesaeeecsesaeeeesesaeeeessaas 2 20 CI ControlWave XFC CI ControlWave XFC ControlWave XFC Model 3820 EX Explosion Proof Gas Flow Computer SECTION 2 3 3 5 2 3 3 5 1 2 3 3 6 2 3 3 6 1 2 3 4 2 3 4 1 2 3 5 2 3 6 2 3 6 1 2 3 6 2 2 3 6 3 2 3 7 2 4 2 4 1 2 4 2 2 4 2 1 2 4 2 2 2 4 2 3 2 4 3 2 4 4 2 4 5 3 1 3 2 1 3 2 2 3 2 3 3 2 4 3 3 1 3 3 2 3 3 3 3 3 4 3 4 3 4 1 3 4 2 3 5 3 5 1 3 5 1 1 3 5 1 2 3 6 3 7 TABLE OF CONTENTS TITLE PAGE Section 2 INSTALLATION amp OPERATION Continued Non isolated Analog Output Connector Block Ja 2 20 Analog Output Conbheuratons erent sterre s EEEN EEEIEE EE EErEE Eenh 2 20 Non isolated High Speed Counter Input Connector JD 2 20 High Speed Counter Confteuratpons 2 20 EAR RE 2 21 Bendable RTD Installations E 2 22 Connection to a Model 3808 Transmitter 2 23 Power Wiring amp Dis
23. 000 LIVE Pst Temperature Point ID Modbus Transmitter Source BSAP Transmitter 1 4 Zeros amp Spans 1 4 Analog Input 3 1 1 Live Input Value Input Control Live Override Value In Use Units 0 000 LIVE DEG_F Frequency Input Auto Adjust Input Run 1 Only Source Point ID Main Rotor Point ID Sense Rotor Point ID Runi 1 High Speed Counter 1 2 Auto Adjust Configuration Run2 2 Live Input Value Counts Input Control Live Override Override Value Frequency Value In Use Frequency Units o UVE D Hz Heating Value Source AGAS AGAS Chromatograph Manual Entry Value Units Value Units Value Units 6 000 BTUFT3 0 000 BTUISCE 1000 000 BTU SCF Value In Use Units 9 000 BIUFI3 Figure F 15 Meter Run I O Configuration Web Page F 6 2 1 Differential Pressure Static Pressure and Temperature Inputs To select the source for pressure differential pressure and temperature the user selects Source Point ID and either the BSAP Address or MODBUS Address Analog Input is used when a transmitter is connected to the ControlWave XFC via a 4 20mA or 1 5Vdc signal The user must then select the Point ID on the I O board to which the transmitter is physically connected In addition the zero and span settings and the engineering units must be assigned by clicking the Zeros amp Spans link Wet End is used when the internal transmitter is used No other configuration is required BSAP is selected when an external Brist
24. 13 RED SIE 1 13 FIELD WIRING eege xian caave seca x saccades sanciaasaviies tassieca EKAN AA TAENSA SARRA ANELEE LATAN iaaa 1 13 FUNCTIONS osre aa AEA ARAA RELEE EERE ECAA A ae Ea ENEE ANE 1 14 Data ACQuiSition ccsc csscccsceassacdecasteeecssenacba cesta ARa EETA EAL Aa NERE 1 14 Flow and Volume Calculations 0 cccccccccssscccesssececesssececesseeecssseeesessaeeessssaeeseseeaeeeenes 1 15 Flow Rate and Flow Time Calculations AOA3 eccccecesesteceeeesseeeeesseeeeeeseeeeee 1 15 Flow Rate Calculations and Flow Time Accumulations AGAT cc cccccscceseesteeeeees 1 15 Extension Calculation and Analog Averagng 1 15 Energy Calculation ccccccccccssscccesssececeesseeecesesseeecseseeeeseaeeeeeesaeeeenesseeeesesaeeeseesaeeensaes 1 16 Volume and Energy Integration ccccccccccecceeeesensececeeeeeseesnaeceeeesenesesaeaeeeeeenseeeenaees 1 16 Downstream Pressure Tan 1 16 AY CHIVES sciicdiesasesviadeishviestesvvie denis deusnias vind davane ee that husdianve ead a taueaaavia suida te maaan nade E iE 1 16 Hourly Historical Data Log 1 16 Daily Historical Data Log ccccceessssececeeeeeesennececececeseesnaececeeeeeeseeueaeeeeeesenssesnnaeees 1 17 Periodic Historical Data Log 1 17 Alarm and Event Storage cccscscccccsnsttesdenetecncssaiteccesstdecccssinesdedasttedcessttesegnalteddedeletecdeeites 1 17 LCD Display cccccccccccssscccessscecessseeecseseeeeesesseeeecssseeesscsaeecseseeaeeseeaeesscseeeeseeeesaeseseeaees 1 18 Ree RER
25. 35 days this ensures that the previous period of hourly data is always resident in ControlWave XFC FLASH memory The following items are stored in the Hourly Data Log Corrected Volume Uncorrected Volume 1 16 Introduction CI ControlWave XFC Accumulated Energy Average Static Pressure Average Temperature Average Differential Pressure Average Specific Gravity Average Heating Value Flow Time Uncorrected Count Each log entry also contains the date and time The ControlWave XFC has a Hourly Historical Log for each of two runs 1 5 3 2 Daily Historical Data Log The Daily Data Log holds one record for every contract day The contract hour may be changed by the user The daily log holds 62 entries this ensures that the previous calendar month of daily data is always resident in ControlWave XFC FLASH memory The following items are stored in the Daily Data Log Corrected Volume Uncorrected Volume Accumulated Energy Average Static Pressure Average Temperature Average Differential Pressure Average Specific Gravity Average Heating Value Flow Time Uncorrected Count Each log entry also contains the date and time The ControlWave XFC has a Daily Historical Log for each of the two runs 1 5 3 3 Periodic Historical Data Log The periodic data log holds one record for every log interval Log interval is 15 minutes The Periodic Historical Data Log holds 1440 records or four days
26. An overview of the seven main configuration steps are provided herein Step 1 Hardware Configuration This involves unpacking the ControlWave XFC mounting the unit wiring I O terminations connecting any permanent communication cables making proper ground connections connecting a communication cable to a PC workstation and setting switches To install and configure the ControlWave XFC follow Hardware Configuration steps 1 through 8 below 1 Remove the unit from its carton and install it at the assigned work site see Section 2 3 1 Dimensions are provided in Section 4 6 of this manual 2 Remove the Front Display Cover unscrew and make sure that the Lithium Backup Battery has been enabled i e Backup Battery Jumper JP1 on the CPU Board on the inside of the Instrument Front Cover should be installed on its jumper posts Configure the CPU Board s DIP Switch see Section 2 3 2 1 2 2 Installation amp Operation CI ControlWave XFC 3 Configure Connect appropriate communication port s see Sections 2 3 2 2 amp 2 3 2 3 Connect COMM Port 1 or 2 of the ControlWave XFC depending on CPU Board Switch SW1 settings see Section 2 3 3 1 to a Communication Port of a PC typically PC COMM Port 1 Note Also see Section 2 4 4 Replace the Front Display Cover removed in step 2 4 Remove the Rear Wiring Cover unscrew and install I O wiring to the Terminal Plate Assembly see Section 2 3 3 Install a communications cable to a M
27. BBI S A de C V Homero No 1343 3er Piso Col Morales Polanco 11540 Mexico D F Mexico PH 52 55 52 81 81 12 FAX 52 55 52 81 81 09 Mexico bristolbabcock com 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 bbivsa prodigy net mx Bristol Babcock PART OF THE EC FKI GROUP OF COMPANIES 1100 Buckingham Street Watertown CT 06795 Phone 1 860 945 2200 Fax 1 860 945 2213 Website www bristolbabcock com Western Region Bristol Babcock Inc 1609 South Grove Avenue Suites 106 amp 107 Ontario CA 91761 Phone 1 909 923 8488 Fax 1 909 923 8988 WesternUS bristolbabcock com Rocky Mountain Region Bristol Babcock Inc 906 San Juan Blvd Suite A Farmington NM 87401 Phone 1 505 320 5046 Fax 1 505 327 3273 NewMexUS bristolbabcock com United Kingdom Bristol Babcock Ltd Blackpole Road Worcester WR3 8YB United Kingdom PH 44 0 1905 856950 FAX 44 0 1905 856969 enquiries bristol babcock com Middle East Bristol Babcock Ltd Blackpole Road Worcester WR3 8YB United Kingdom PH 44 0 1905 856950 FAX 44 0 1905 856969 enquiries bristol babcock com Southeast Region Bristol Babcock Inc 317 S North Lake Blvd Suite 1016 Altamonte Springs FL 32701 Phone 1 407 740 7084 Fax 1 407 629 2106 SoutheastUS bristolbabcock com Communicat
28. Choose Flash for the mode Name Enter a name for the View Mode File in the Name field CI ControlWave XFC Installation amp Operation 2 27 Location If you want to store the View Mode File in a directory other than that shown in the Location field enter the new location there or use the Browse push button to find the directory New View Mode EN Cancel Location He D OpenBsI Browse Figure 2 17 Local View New View Mode Menu When the Mode Name and Location have been specified click on the Create push button to activate the Communication Setup Wizard Step 1 Communication Setup Choose the communication port you want in the What port would you like to use field see Figure 2 18 Click on the Next pushbutton to activate the next wizard Communication Setup Step 1 x What port would you like to use com D Would you like auto baud rate detection Yes please No Thank you What baud rate Would pou like to use 28400 Advanced Parameters Finish Cancel Help Figure 2 18 Communication Setup Step 1 Menu Step 2 Flash RTU Setup In the Flash RTU Setup Wizard you need not set the RTU type or local address since these are unused in this mode Click on the Next push button to activate the Flash Data Setup Wizard 2 28 Installation amp Operation CI ControlWave XFC Flash RTU Setup Step 2 of 3 u What is the type of the
29. Flow Computer installations For orifice and other differential meters ControlWave XFC has been designed to integrate a DP P T smart Multivariable Transducer with excellent performance over the full range of operating pressure and temperature conditions For linear meters such as turbine and ultrasonic meters ControlWave XFC doesn t overlook the importance of pressure and temperature corrections and utilizes smart P T circuitry to provide high accuracy over the full range of operating conditions e Process Controller or Remote Terminal Unit RTU applications Process Controller and RTU applications don t suffer performance limitations of flow computers with expanded hardware User configurable I O provides AI O DI O and HSC functionality 1A 1 1 Hardware Features e Wide operating temperature range 40 to 80 C 40 to 176 F e Designed for operation in Nonincendive Class I Div 2 Groups A B C amp D Hazardous Locations and Explosion Proof Class I Divison 1 Groups C amp D Hazardous Locations UL approval meets CE requirements see Appendices A amp B respectively e ARMQ9 Processor provides exceptional performance and low power consumption e Standard three serial communication ports One RS 232 Local One RS 232 Network amp One RS 485 e I O siutuated on one circuit board provides cost effective I O for small RTU applications 1A 1 2 Firmware and Software Features e Standard application load for up to two r
30. GROUNDROD ONEPER N CONDUCTOR 1 f x L STRANDED COPPER CABLE SOIL LINE AWG 0000 a BRINGALL CONDUCTORS TO THE SURFACE b INSTALL WITHOUT KINKS OR SHARP BENDS BURRY TO DEPTH OF AT LEAST 3 FEET DEEPER IN DRY SOIL g _ RADIUS AT LEAST 12 Sa a DRIVE 7 OR MORE AS REQUIRED 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 1 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 CaClz 3 3 1 2 Soil Types Good Poor Damp Loam Back Fill Salty Soil or Sand Dry Soil Farm Land 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
31. If the Battery is removed from the CPU Module due to replacement when the CPU Module has been removed power should not be applied before one minute has passed unless SW1 5 on the CPU has been set OFF SW1 6 set ON will enable the user to perform a remote download of System Firmware on units equipped with Boot PROM version 4 7 or higher and System PROM version 4 7 or higher SW1 8 set OFF prevents the Boot Project from running and places the unit into diagnostic mode SW1 8 must be set OFF to run the WINDIAG program resident on the local PC see Section 3 5 When SW2 8 has been set ON diagnostics is disabled SW1 8 must be set to the ON position for normal system operation i e for the Boot project to run Note If both SW1 3 and SWI1 8 are set OFF closed all communication ports will be set to 9600 bps operation SW1 9 amp SW1 10 are multiplexed to provide operator control of Local Mode or Recovery Mode functunality Recovery Mode is used to upgrade the XFC s firmware and for Core 2 14 Installation amp Operation CI ControlWave XFC updumps Local Mode is used for normal operation When both SW1 9 and SW1 10 are set ON or OFF or with SW1 9 set ON and SW1 10 set OFF Recovery Mode is enabled Local Mode is enabled when SW1 9 is OFF and SW1 10 is ON REAR op LI OOOCOOCO0O d a A S Note Connectors not shown are for Factory Use ONLY oOoo0oo0000000 e
32. Installation of Power and Measurement amp 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 achie
33. PC see the Systems Variables section of the ControlWave Designer Programmer s Handbook D5125 The system SRAM is specified to have a standby current of 40uA maximum plus 2uA for the RTC For a system containing 2MB of System SRAM a worst case current draw of 42uA allows a battery life of approximately 7142 hours LCD Interface hardware consists of a MSP430F436 micro controller and a contrast circuit utilizing a small potentiometer R43 The micro controller is responsible for the LCD initialization sequence and control via commands from the SPI port 1 8Vdc used by the ARM microprocessor is generated on the CPU Module derived from the regulated 3 3Vdc logic power 1 6 Introduction CI ControlWave XFC REAR SG OOOOOOOOOO 0 N N a a Note Connectors not shown are for Factory Use ONLY OOOCOOOCO000O0 CR1 WD IDLE CR2 LCD Contrast R43 A 1 1 a Battery General 3 Backup Purpose 5 DIP 7 Switch H FRONT Figure 1 4 ControlWave XFC CPU CI ControlWave XFC Introduction 1 7 Basic CPU components and features are summarized as follows e LH7A400 System on Chip 32 bit ARM9TDMI RISC Core microprocessor e 512KB FLASH Boot Downloader 29LV040B 90 nS 8 bit access e 2MB SRAM 3 3V 1024K x 16 17nsec with Battery Back up e 8MB simultaneous read write FLASH TSOP site e 3 seria
34. Seconds Figure F 11 Radio and Modem Control Configuration Web Page F 16 Appendix F CI ControlWave XFC F 5 7 4 Hourly Mode Start Time Offset Into Hour Seconds Start Time Offset Into Hour Seconds specifies a user supplied offset which is used when computing the radio modem On Time Start Time Offset is a factor used to calculate the On Time Poll Time Per Node Seconds Poll Time Per Node Seconds sets the duration of time seconds allocated for com munications per node Poll Time Per Node time is also used to calculate the On Time Poll Time Per Group Seconds Poll Time Per Group Seconds sets the duration of time seconds allocated for com munications per group Poll Time Per Group time is also used to calculate the On Time Listen Time Seconds Listen Time Seconds is the amount of time in seconds that the radio modem will be enabled for at the scheduled time i e the enabled time before it will shut off due to the lack of com munications Re Calculate Next On Time If the user makes any changes to the items that affect the On Time it must re calculate the Next On Time using this button Next On Time Hour Minute Second When the Radio Modem Control Mode is selected for Hourly Daily or Daylight these values represent the next time that the radio will be turned on Turn Off Delay Seconds Turn Off Delay Seconds is the amount of time in seconds that the radio modem will remain enabled after succes
35. Temperature 0 000 DEG_F Avg Temperature 6 000 DEG_F Avg Diff Pressure 0 000 INH20 Avg Diff Pressure 0 000 INH20 Avg Spec Gravity 0 000 Avg Spec Gravity 0 000 Avg Heating Value 0 000 BTUFTI Avg Heating Value 0 000 BTU FT3 Flow Time 0 000 MINUTES Flow Time 0 000 MINUTES Reset Meter Run s Measurement Type f Figure F 13B Meter Run Overview 1992 AGA3 Orifice Meter Web Page Flow Rate x1000 The instantaneous value is provided Accumulated Volume and Accumulated Energy Read Only fields are provided for the Current Hour and Current Day CI ControlWave XFC Appendix F F 19 Accumulated Volume Accumulated Energy Avg Static Pressure Avg Temperature Avg Diff Pressure Avg Specific Gravity Avg Heating Value and Flow Time Read Only fields are provided for the Previous Hour and Previous Day The following five fields accommodate user changes Meter ID a string signal identifying the meter run default is Run n n the Run Contract Hour The user enters the Contract Hour for the start of the current day here Current Heating Value Units The user may select the Heating Value units from a drop down menu default units are BTU Ft Flow Rate Units The user may select the Flow Rate units from a drop down menu default units are Ft Hour Energy Rate x1000000 The user may select the Energy Rate Energy Units from a drop down menu default units are BTU The user may
36. The Bulk DC supply 6Vdc to 80Vdc connects to Terminal Block J6 on the Terminal Plate and is converted regulated and filtered to produce 3 3Vdc The I O Board circuit is fused at 875A F1 Terminal Plate Connector J6 provides 2 input connections for bulk power J6 1 VIN 6 0Vdc to 30 0Vdc J6 2 VIN Supply Ground Bulk Supply 1 Pos Term S1 VIN Bulk Supply 1 Neg Term S VIN Figure 2 16 Terminal Plate Connector J6 Primary Power Wiring 2 3 6 3 ControlWave XFC System Grounding ControlWave XFC Cases are optionally provided with a Ground Lug that accommodates up toa 4 AWG wire size A ground wire should be run between the Case s Ground Lug see Figure 2 2 and a known good Earth Ground The following considerations are provided for the installation of ControlWave XFC system grounds see 1400CW e Chassis Ground Lug to Earth Ground wire size should be 4 AWG It is recommended that stranded copper wire is used and that the length should be as short as possible e 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 e The wire ends should be tinned with solder prior to insertion into the Chassis Ground Lug Note Use a high wattage Soldering Iron e 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 groun
37. Version 1 3 Station Totals Corrected Flow Rate x1000 0 000 SCFMIOUR Energy Rate x1000000 0 000 BTUsHOUR Uncorrected Flow Rate x1000 0 000 ACF HOURL Previous Hour Previous Day Corrected Volume x1000 0 000 SCF Corrected Volume x1000 0 000 SCF Uncorrected Volume x1000 0 000 SCF Uncorrected Volume x1000 0 000 SCF Accumulated Energy x1000000 0 000 BTU Accumulated Energy x1000000 0 000 BTU Meter Run 1 ID Run 1 Corrected Flow Rate x1000 0 000 SCFHOUR Uncorrected Flow Rate x1000 0 000 SCF HOUR Prev Hour Corrected Volume x 1000 0 000 SCFIHOUR Prev Hour Uncorrected Volume x1000 0 000 SCFMOUR Prev Hour Acc Energy x 1000000 0 000 BTU Prev Day Corrected Volume x1000 0 000 SCFHOUR Prev Day Uncorrected Volume x1000 0 000 SCFHOUR Prav Day Acc Energy x1000000 0 000 BTU Meter Run 2 ID Run 2 Corrected Flow Rate x1000 0 000 SCFHOUR Uncorrected Flow Rate x1000 0 000 SCFHOUR Prev Hour Corrected Volume x1000 0 000 SCF HOUR Prev Hour Uncorrected Volume x1000 0 000 SCFHOUR Prav Hour Acc Energy x1000000 0 000 BTU Prev Day Corrected Volume x1000 0 000 SCFHOUR Prev Day Uncorrected Volume x1000 0 000 SCFHOUR Prav Day Acc Energy x1000000 0 000 BTU Runs 1 8 3 BiDirectional Support Disabled Figure F 5 Station Summary Web Page Sampler amp Odorizer Output Configuration Sampler Configuration Units Sample Count Sampler DO Point ID Reset Count rs SCF HOUR H 1 SCH Disabled Pulse Frequency
38. also be specified Both arrangements are described as follows Standard Process Flange Two process flanges containing the connection ports are as sembled to the Differential Transmitter Port designations L and H are stamped on the body of the flanges Ports accept 1 4 18 NPT pipe connections on 2 1 8 in centers for connection to orifice taps or a standard three valve manifold These process flange connections are illustrated at the top of Figure 2 4 PROCESS FLANGE CONNECTIONS Al E F O ka O O 1 4 18 NPT AD N Ka l 2 1 Il MANIFOLD BLOCKS Both Set Left 1 2 14 NPT gi uer MANIFOLD BLOCKS 9 i Both Set Inward lt MANIFOLD BLOCKS d E Both Set Outward SEH Figure 2 4 Process Flange and Optional Manifold Block Connectors CI ControlWave XFC Installation amp Operation 2 9 The two process flange assemblies are held in place by four bolts and nuts When the bolts are removed the flanges can be repositioned so that the connections can emanate from the front rear or bottom of the transmitter Care should be taken not to damage the sensor module assembly during this procedure Once the flange has been positioned the bolts should be tightened in an alternating sequence to about 20 30 foot pounds of torque Optional Process Manifold Blocks Process manifold blocks may be installed on the transmitter to permit the use of connector assemblies having different connection centers The manifold blocks which are oval in
39. amp 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 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 8530MGKI Bristol Babcock Watertown CT 06795 Supplement S1400CW Page 0 2 Table Of Contents Section 1 Overview EE 1 1 INTRODUCTION This document provides information pertaining to the installation of ControlWave systems more specifically information covering reasons theory and techniques for protecting your personnel and equipment from electrical damage Your instrument system affects the quality of service provided by your company and many aspects of its operational safety Loss of instruments means lost production and profits as well as increased expenses Information contained in this document is for educational purposes Bristol Babcock makes no warranties or guarantees on the effectiveness or the safety of techniques described herein Where the safety of installations and personnel is concerned refer to the National Electrical Code Rules and rules of local regulatory agencies 1 2 MAJOR TOPICS Topics are covered in seven sections designed to pinpoint
40. 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 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 The safe distance from power lines should be at least twice the height of the antenna and mast combination e 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
41. battery power supply with the correct out put 3 3 2 LCD Display System Status Codes ControlWave XFCs contain an LCD Display that is utilized to display system status codes and application data once the unit is running its application load System status codes are provided in Table 3 1 Table 3 1 LCD Display System Status Codes LOCH Indication Display Definition Flashed at startup 3 3 3 LED Checks ControlWave XFCs contain two red LEDs that provide operational and diagnostic func tions as follows 3 4 Service CI ControlWave XFC Watchdog LED ON Watchdog Condition OFF Normal Operation Idle LED ON Idle Note To save power the IDLE LED should be ON for only 2 seconds every minute i e 2 out of 60 seconds 3 3 4 Wiring Signal Checks Check I O Field Wires at the Terminal Blocks on the Terminal Plate Check wiring for con tinuity shorts amp opens Check I O signals at their respective Terminal Blocks see Figure 3 2 HSC 1 Example Internally Sourced High Speed Counter Wiring Diagram DO 1 Example DI 1 Example Ext Powered Dry Contact External Discrete Output Discrete Input Signal Wiring Diagram Wiring Diagram Generator gt Max Load RTD Input En RTD Excitation W RTD Sense RTD Return RS 485 ry COM3 g ee to from d o Model 3808 J6 5 COM2 COM1 COM3 J2 i
42. can be viewed and if desired changed via the Flash Configuration Utility which is accessible from LocalView or NetView When connecting the ControlWave XFC to the PC local or network for the first time you should be aware of the communication port default parameter settings provided below see Figures 2 8 and 2 9 Note Communication port factory defaults can be enabled anytime by setting CPU Board Switch SW2 3 to the OFF position CPU Switch SW2 8 must be set OFF to run the WINDIAG program COM1 From the factory RS 232 Communications Port COM1 defaults to 115 2 kdb 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation To test COM1 using the WINDIAG program CPU Switch SW2 8 must be OFF and it must not be in use COM1 provides a three wire RS 232 interface typically to a hand held computer and wakes up when energy appears on its RXD receive terminal COM2 From the factory RS 232 Communications Port COM2 defaults to 9600 baud RS 232 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation Note By setting CPU Switches SW1 8 OFF the boot project will be prevented from running and the unit will be placed into diagnostic mode To test COM2 using the WINDIAG program it must be configured for 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation either via Soft Switch configuration or by setting CPU Switches SW2 8 OFF and it must not be in use Connection to a PC requi
43. circuit is specifically identified in this document as nonincendive the circuit is unrated Unrated circuits must be wired using wiring methods as specified in article 501 4 b of the National Electrical Code NEC NFPA 70 for installations in the United States or as specified in Section 18 152 of the Canadian Electrical Code for installation in Canada All communications ports terminate on a Terminal Block J2 on the Terminal Plate within the enclosure Wiring to this connector J2 is unrated No connections may be made to communication ports unless the user ensures that the area is known to be nonhazardous Connections to the Local Port is temporary and must be short in duration to ensure that flammable concentrations do not accumulate while it is in use WARNING No connections may be made to the ControlWave XFC Model 3820 EX Gas Flow Computer s RS 232 communication ports in a Class I Division 1 area No connections may be made to the RS 232 communication ports unless the user ensures the area is known to be nonhazardous WARNING EXPLOSION HAZARD Do Not disconnect power connections within the ControlWave XFC Enclosure J6 unless the area is known to be nonhazardous WARNING EXPLOSION HAZARD Substitution of major components may impair suitability for use in Class I Division 1 environments WARNING EXPLOSION HAZARD The area must be known to be nonhazardous before servicing replacing the unit and before installing or remov
44. 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 ESDS Manual 514006 4 15 92 Materials e Inhibitor Texwipe Gold Mist Chemtronics Gold Guard or equivalent e Cleaner Chemtronics Electro Wash Freon TF or equivalent Wiping cloth Kimberly Clark Kim Wipes or equivalent ESD SENSITIVE COMPONENT HANDLING PROCEDURE Introduction Microelectronic devices such as PC boards chips and other components are electro static 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 diffic
45. helpful to re move the Rear Window Housing Cover and use a free hand to help guide the MVT Cable under the CPU Board Remove the Function Module 5 To replace the Function Module you must first plug the MVT Interface Cable into connector P1 near the bottom of the I O Board Then align the replacement Function Module with the Case such that Terminal Plate connector J4 is positioned at the bottom and insert the unit into the Case Replace the four screws removed in step 4 and all cables removed in steps 3 and 2 Replace the Rear Wiring Cover 3 2 3 Removal Replacement of the MVT or GPT Transducer 1 If the ControlWave XFC is running place any critical control processes under manual control 2 Remove the Rear Wiring Cover and shut down the unit by disconnecting power at the Terminal Plate Terminal Block connector TB6 Disconnect all I O connections including RTD wiring from the Terminal Plate Remove the CW XFC from the manifold and take it to a depot repair area that supports proper ESD control 3 Disconnect the MVT GPT Interface Cable from the I O Board This will require the removal of the units Function Module see steps 1 through 4 of Section 3 2 2 4 Loosen the Allen Screw that secures the Multivariable MVT or Gage Pressure Transducer GPT to the case and then unscrew and remove the MVT GPT 5 To install a replacement MVT follow steps 4 through 1 in reverse order Make sure the MVT GPT O Ring Seal is in place and apply anti sei
46. 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 Use more than one ground rod Place multi ground stakes more than their length apart Tie Power Telco Tower Bulkhead and equipment ground together Make all ground interconnect runs that are above ground with minimum radius bends of eight inches and run them away from other conductors and use large solid wire or a solid strap Section 4 Lightning amp Surge Page 4 5 S1400CW e Watch out for dissimilar metals connections and coat accordingly Use bare wire radials together where possible with ground stakes to reduce ground system impedance Use I O protectors Phone line Radio with a low inductance path to the ground system 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 amp SURGE PROTECTORS Units equipped with radios or modems use lightning arresters and surge protectors to protect equipment from ligh
47. hours of backup service Power is only drawn from the battery when the unit looses power NOTE If the Lithium backup battery is disconnected or removed when power is off the contents of SRAM on the CPU Board will not be retained Once a Lithium backup battery has been removed don t install a replacement battery for at least one minute unless SW1 5 on the CPU Board has been set OFF 2 4 OPERATIONAL DETAILS ControlWave XFC electronic flow computers are shipped from the factory with firmware that allows the unit to be configured in conjunction with an IEC 61131 application program This section provides information as follows Steps required to download the application load and place the unit into Run mode Steps required to download system firmware Operation of the CPU Board Switch SW1 mode functions Soft Switch Configurations and Communication Ports Operational details on the use of the BBI WINDIAG program for fault isolation are provided in Chapter 3 2 4 1 Downloading the Application Load Any ControlWave XFC must have a configured application load before it can be placed into operation For units not shipped with the Standard Load this will require connection of the ControlWave XFC to a PC running Windows NT 4 0 or higher Windows 2000 or Windows XP Professional and equipped with ControlWave Designer software amp OpenBSI software Configuration of the application load must be performed by an individu
48. 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 BBD it is recommended that you also install a surge suppressors or lightning arrester on the phone line as close to the modem as possible Any unit interfaced to a radio or modem must be connected to a known good earth ground 5 2 10 Secure Wiring Connections Make sure that all wiring connections are secure In time wires that were once round will become flattened due to the pressure applied by screw compression type terminals and site vibrations After a while these compression screws have a tendency to become loose Part of a good maintenance routine should be to check and tighten all screws associated with wiring terminal connections Avoid nicking the wire s when stripping insulation Remember nicked conductors will lead to future problems Also remember to provide some cabling slack and strain relief If installing stranded or braided wiring that has not been tinned be sure to tightly twist the end in the same direction as manufactured and then trim off any frizzed wires Section 5 Wiring Techniques Page 5 5 S1400CW READER RESPONSE FORM Please help us make our documentation more useful to you If you have a complaint a sug gestion 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 j
49. on the Browse button to locate it A user would then click on Load from File This will update the recipe with the information CI ControlWave XFC Appendix F F 37 from the file To load the configuration to the ControlWave XFC the user would click on Write to RTU By defaults the RCP files are stored in the following folder C OpenBSI WebXFC Config The RCP file can be edited with a text editor such as WordPad Users may save a configuration from one meter use a text editor to change the configuration parameters for a different meter and read the configuration from the file and download the modified configuration to a new meter Users may modify the value of a signal from the Meter Run Save Load Configuration page A user would highlight the signal that needs to be modified and then click on the Modify Signal button A dialog box will open with the Signal Name and Value Users may either enter the new value for String Signals and Analog Signals or select the new value from the drop down menu for logical signals To write the change down to the ControlWave XFC the user must click on Write to RTU To ensure a saved configuration the user must click on Write to File Typical Steps 1 Open Page Values from DefaultMXFC RCP are shown If there is another con figuration that the user would like to use skip to Step 7 2 Update Values with actual settings by clicking on Load from RTU 3 Review settings and make modifi
50. select the Energy Rate Rate Units from a drop down menu default units are HOUR Reset Meter Run s Measurement Type This button bottom of menu allows the user to reset the meter run s measurement type if a mistake has occurred during configuration F 6 1 2 AGA7 Frequency Meter If the meter is configured as a Linear Meter following Read Only items are displayed Active Flow Calculation Always AGA7 Corrected Flow Rate Instantaneous Value Uncorrected Flow Rate Instantaneous Value Current Heating Value Instantaneous Value Energy Value Instantaneous Value The following information is displayed for the Current Hour and Current Day Corrected Volume Uncorrected Volume Accumulated Energy The following information is displayed for the Previous Hour and Previous Day Corrected Volume Uncorrected Volume Accumulated Energy Average Static Pressure Average Temperature Average Specific Gravity Average Heating Value Flow Time There are five fields that allow the user to make changes Meter ID a string signal identifying the meter run default is Run n n the Run F 20 Appendix F CI ControlWave XFC Contract Hour Users enter the Contract Hour for the start of the Contract Day here Current Heating Value Units The user may select the Heating Value units from a drop down menu default units are BTU Ft Flow Rate Units The user may select the Flow Rate units from a drop do
51. silicone based materials in aerosol applications that has been developed by the silicone industry www SEHSC com or contact the Dow Corning customer service group 9 PHYSICAL AND CHEMICAL PROPERTIES Physical Form Liquid Color Colorless Odor Characteristic odor Specific Gravity 25 C 0 965 Viscosity 100 cSt Freezing Melting Point Not determined Boiling Point gt 65 C Vapor Pressure 25 C Not determined Vapor Density Not determined Solubility in Water Not determined pH Not determined Volatile Content Not determined Note The above information is not intended for use in preparing product specifications Contact Dow Corning before writing specifications 10 STABILITY AND REACTIVITY Chemical Stability Stable Hazardous Hazardous polymerization will not occur Polymerization Conditions to Avoid None Materials to Avoid Oxidizing material can cause a reaction 11 TOXICOLOGICAL INFORMATION Special Hazard Information on Components No known applicable information DOW CORNING CORPORATION Material Safety Data Sheet DOW CORNING 200 R FLUID 100 CST 12 ECOLOGICAL INFORMATION Environmental Fate and Distribution Air This product is a high molecular weight liquid polymer which has a very low vapour pressure lt 1 mm Hg As a result it is unlikely to become an atmospheric contaminant unless generated as an aerosol This product has a very low water solubi
52. 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 d La K es EARTH GROUND LS me pE LEGEND Chair with ground optional ESD protective floor mat optional Wrist strap ESD protective trays etc lonizer Other electrical equipment Workbench with ESD protective table top x NOTE ALL RESISTORS 1M Q 10 1 2W ESDS Manual S14006 4 15 92 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 proce dure 1 Tu
53. stream F 7 4 Gas Components The Raw value of each gas component from the chromatograph will be displayed for each stream Fixed values for each gas component may be entered for each stream F 7 5 Chromatograph Component Range Setup Values of BTU Specific Gravity and each gas component of each stream are compared to user configured high and low allowable limits These limits are set from the Chromatograph Component Range Setup Web Page accessible from the Chromatograph Setup Web Page If a component is found to be outside the user defined limits the value will be clamped at the closest configured limit It also checks the sum of the components if the sum is outside the configurable limits a Boolean signal is set indicating so If any component or the total is out of range either fixed or last values will be used F 32 Appendix F CI ControlWave XFC mn am IJ mn um mn am IL mn um mn am IL mn um mn am mn um mn mm LI mn am mn am IL mn um mn am mn um mn am IL mn um mn TI am IL mn um 100 00000000 100 00000000 0 00000000 0 00000000 0 00000000 0 00000000 F Figure F 22 Chromatograph Component Range Setup Web Page F 8 LOGS CATEGORY FUNCTIONS Four WebBSI Web Pages are accessible under the Logs Category Section of WebBSI these are View Archives Section F 8 1 View Audit Trail Section F 8 2 View Signal List Section F 8 3 Collection Section F 8 4 F 8 1 Meter Run Archive Files When View Archive ha
54. the soil moist through regular applications of water Sandy soil either wet or dry may have had its soluble salts leached out by rain water thereby reducing conductivity of the ground High currents from lightning strikes could also melt sand and cause glass to form around the ground rod rendering it ineffective A buried counterpoise or copper screen is preferred for these installations along with regular applications of salt water Rocky soil can pose many grounding problems A counterpoise or copper plate will probably be required Constructing a trench at the grounding site and mixing the fill with a hygroscopic salt such as calcium chloride may help for a time Soaking the trench with water on a regular basis will maintain conductivity Units with phone modems require the use of a lightning arrester The lightning arrester must be situated at the point where the communication line enters the building S1400CW Page 3 4 Section 3 Grounding amp Isolation AWG 0000 Copper Wire Lead a J 6 Dirt Fill eter Fee en ep ease Dak Deed ed Da Sok ed eer gee Dusting of Calcium Chloride REECH pda ae d E EE Electrode eer 9 Sa 6 ma 6 wn ees Re odode AM Dusting of Calcium Chloride Each Layer may be a capacitive coupling consisting of 5 or 6 Electrodes TE Capacitive Coupling Capacitive Coupling Electrodes in Parrallel Electrodes in Star on same Layer or on same Layer Figure 3 5 Poor Soil Ground Bed
55. this manual 3 2 1 Accessing Components for Testing Testing and replacement of ControlWave XFC components should only be performed by technically qualified persons Familiarity with disassembly and test procedures described in this manual are required before starting Any damage to the ControlWave XFC result ing from improper handling or incorrect service procedures will not be covered under the product warranty agreement If these procedures cannot be performed properly the unit should be returned to Bristol with prior authorization from Bristol Babcock for factory evaluation and repairs CI ControlWave XFC Service 3 1 3 2 2 Removal Replacement of the Function Module 1 If the ControlWave XFC is running place any critical control processes under manual control 2 Remove the Rear Wiring Cover and shut down the unit by disconnecting power at the Terminal Plate Terminal Block connector TB6 3 Unplug Terminal Block communication cable connector J2 RTD connector J3 and I O wiring connectors J4 and J5 Push wires and plugs into the conduit so the Ter minal Plate can clear the Housing when the Function Module is removed 4 Remove the four screws that secure the Function Module to the Case and carefully remove the Function Module far enough to facilitate disconnection of the MVT Inter face cable from Connector P1 on the I O Board Disconnect the MVT Interface Cable from connector P1 near the bottom of the I O Board Note It may be
56. 0 cccccecccccccscssssssececesccscsessnceceecececsesensuaeeecececsessnsnseassececeseseesnees 1A 4 Real time ActiveX Control 1A 4 ActiveX Controls dees ee EE 1A 5 Required Software ccccccccccssssscesssseeessseecesseeeeeessesaeeecsesseeeesesseeeesesaeeeeseseeeeeneseeeenaes 1A 5 Historical Data Collection 1A 5 OPC Ee ee de eege ee 1A 5 ControlWave OPEN NETWORK CONNFEOTIVIDN 1A 6 Communication Drotocols 1A 6 Ee E 1A 6 Modbus Protocol ere EE EE 1A 7 Generic Serial Interface onionenn o nin etini REONE OEE RE 1A 7 Section 2 INSTALLATION amp OPERATION INSTALLATION IN HAZARDOUS AREAS ccccccccceccscccsssceesseceeseecesseceesseseeseeeeseeees 2 1 SITE LOCATION CONSIDKRRATIONS 2 2 Temperature amp Humidity Limits cccccccccesssececesssececeesseeeecessseeeessseeeeesseeeessseeeenss 2 2 Vibration RE 2 2 ControlWave XFC INSTALLATION CONFIGURATION sss sosnsssesseesssosseessseessesee 2 2 Mounting the ControlWave SC 2 5 Connection to the Multivariable Transducer MV 2 9 Connection of the Gage4 Pressure Transducer GP 2 10 tee Roter EE 2 10 Process Pipeline Connection Meter Runs without Cathodic Protection 2 10 Process Pipeline Connection Meter Runs with Cathodic Drotectton 2 12 CRU Board Configuration 2s 0 ccccseceeccicegeenndeadoescecsdesncecdebeacedsdeoncssddeestedsievsecedecvennadddesce 2 13 CPU Board Switch SW1 Confeuraton 2 13 Communication Dorte En 2 15 RS 232 amp RS 485 Interfaces
57. 100 Buckingham Street Watertown CT 06795 Telephone 860 945 2200 WARRANTY Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety 90 days from the date of delivery of repaired goods whichever is longer Warranties on goods sold by but not manufactured by Bristol are expressly limited to the terms of the warranties given by the manufacturer of such goods All warranties are terminated in the event that the goods or systems or any part thereof are i misused abused or otherwise damaged ii repaired altered or modified without Bristol s consent iii not installed maintained and operated in strict compliance with instructions furnished by Bristol or iv worn injured or damaged from abnormal or abusive use in service time THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND NO WARRANTIES EXPRESS OR IMPLIED NOR ANY REPRESENTATIONS PROMISES OR STATEMENTS HAVE BEEN MADE BY BRISTOL UNLESS ENDORSED HEREIN IN WRITING FURTHER THERE ARE NO WARRANTIES WHICH EXTEND BEYOND
58. 152 of the Canadian Electrical Code for installation in Canada All communications ports terminate on a Terminal Block J2 on the Terminal Plate within the enclosure Wiring to this connector J2 is unrated No connections may be made to communication ports unless the user ensures that the area is known to be nonhazardous Connections to the Local Port is temporary and must be short in duration to ensure that flammable concentrations do not accumulate while it is in use WARNING EXPLOSION HAZARD Do Not disconnect power connections within the ControlWave XFC Enclosure J6 unless the area is known to be nonhazardous WARNING EXPLOSION HAZARD Substitution of major components may impair suitability for use in Class I Division 2 environments WARNING EXPLOSION HAZARD The area must be known to be nonhazardous before servicing replacing the unit and before installing or removing I O wiring WARNING EXPLOSION HAZARD Do Not disconnect equipment unless power has been disconnected and the area is known to be nonhazardous A bendable RTD may be supplied with the ControlWave XFC Connection to the RTD is approved as a nonincendive circuit so that Division 2 wiring methods are not required Signal connectors available for customer wiring are listed in Table Al I O Connections are unrated and must be wired using Div 2 wiring methods Table Al Terminal Plate Connector Customer Wiring Connectors Connector W
59. 188 Ir 1 720 ay 50 14 NPT gt K 3 020 _ Male Fitting 25 18 NPT Pipe Fittings 1 625 lt 5 188 gt Al A 6 156 1 788 75 14 NPT Plastic 7 Threaded A A Conduit Conduit 6 156 3 842 4 032 g y y un ES Figure 4 2 ControlWave XFC Enclosure Dimensions 4 6 Specifications CI ControlWave XFC ControlWave XFC Special Instructions for Class I Division 2 Hazardous Locations Bristol Inc s ControlWave XFC Model 3820 EX Gas Flow Computer is listed by Underwriters Laboratories UL as nonincendive and is suitable for use in Class I Division 2 Groups A B C and D hazardous locations or nonhazardous locations only Read this document carefully before installing a nonincendive ControlWave XFC Model 3820 EX Gas Flow Computer Refer to the ControlWave XFC Model 3820 EX Gas Flow Computer User s Manual for general information In the event of a conflict between the ControlWave XFC Model 3820 EX Gas Flow Computer User s Manual and this document always follow the instructions in this document The ControlWave XFC Model 3820 EX Gas Flow Computer includes both nonincendive and unrated field circuits Unless a circuit is specifically identified in this document as nonincendive the circuit is unrated Unrated circuits must be wired using Div 2 wiring methods as specified in article 501 4 b of the National Electrical Code NEC NFPA 70 for installations in the United States or as specified in Section 18
60. 232 Transceivers When port is set for half duplex operation CTS must go low after RTS goes low RS 232 Comm Port 2 supports RTS DTR CTS and DCD control signals All RS 232 Comm port I O signals are protected by LCDA12C surge protectors to 4KV ESD 2 16 Installation amp Operation CI ControlWave XFC 3305 3310 3330 3335 9 Pin Male D Connector CW Series or PC 9 Pin Female D Connector MEO To P2 Pin 14 RER To P2 Pin 10 3 L 2 CW Series 9 Pin Female D Connector H i Wa AL CW 1 DTR 6 6 CcTS z 2 TXD_ To P2 Pin 9 7 0CD SERXD_ To P2 Pin 8 To P2 Pin 14 Pl D To P2 Pin 13 2 7XD_6 To P2 Pin 9 To P2 Pin 12 EK To P2 Pin 8 To P2 Pin 14 E 3305 3310 3330 3335 9 Pin Male D Connector Pl PC CW XFC 9 Pin Female D Connector BR To P2 Pin 5 RAD O To P2 Pin 6 CW XFC Term Plate Term Block CW XFC Term Plate Term Block CW XFC Term Plate Term Block Term Plate Term Block DR To P2 Pin 7 J2 Full duplex Null Modem Cable PC CW PPP Protocol Half duplex Cable ICH Full duplex Cable PPP Protocol Half duplex Cable Fig A Comm Intf Cables for PC amp CW where CW any ControlWave Series Unit RS 232 Comm Port Looking into Wire Terminal Side of Cable Connectors Fig B Comm Intf Cables for 3305 33 10 3330 3335 Looking into Wire Terminal Side of Cable Connect
61. 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 10 08 2006 Appendix B Document CI ControlWave XFC Page 2 of 2 ControFvVave XFC Appendix F USING ControlWave XFC WebBSI Web Pages PC Laptop ControlWave XFC Computer Issue 04 2006 Bristol DABAAJOIJUOZ SECTION Fd F 1 1 F 2 F 2 1 F 3 F 4 F 4 1 F 4 1 1 F 4 1 2 F 4 2 F 4 3 F 5 F 5 1 F 5 2 F 5 2 1 F 5 2 2 F 5 3 F 5 4 F 5 4 1 F 5 4 1 1 F 5 4 1 2 F 5 4 1 3 F 5 4 1 4 F 5 4 1 5 F 5 5 F 5 5 1 F 5 5 2 F 5 5 3 F 5 5 4 F 5 6 F 5 6 1 F 5 6 2 F 5 7 F 5 7 1 F 5 7 2 F 5 7 3 F 5 7 4 F 5 7 5 F 5 7 6 F 5 7 7 F 6 F 6 1 APPENDIX F ControlWave XFC Using ControlWave XFC WebBSI Web Pages TABLE OF CONTENTS TITLE PAGE BIN Abs OW TGR VLIW E F 1 Viewing Web Bolles eene eege EEGEN F 1 INSTALLING WebBSI SOFTWARE amp ControlWave XFC Web Dages F 1 Communication Connections cccccccccsssessssececececeesssseaeceeccecsesensaeceec
62. 6 of D5081 If a Bristol Babcock network already exists You will need to add the ControlWave XFC to the existing network using Net View s RTU Wizard Chapter 6 of the Open BSI Utilities Manual document D5081 includes different sub sections depending upon whether you are adding the unit to a BSAP network or an IP network Step 7 If applicable download new or modified control strategy OPTIONAL If you modified the standard XFC program or substituted your own program compile and download the new or modified program into the unit using either ControlWave Designer or the Open BSI 1131 Downloader In this case you download the control strategy into the BOOT project area of FLASH memory this ensures that if the ControlWave XFC is reset or if there has been a failure of the backup battery the control strategy can be restarted from the beginning i e from the BOOT project in FLASH memory To download the project see Section 2 4 1 G 2 3 1 Mounting the ControlWave XFC When mounting one of these units it is to be positioned in accordance with the following restrictions The unit is to be positioned vertically with the Transducer MVT or GPT at its base Only units equipped with a Multivariable Transduver may be mounted directly to the Main meter run utilizing a Process Manifold or they can be mounted remotely to a vertical or horizontal 2 pipe via a pipe clamp bracket and adapter blocks see Figure 2 2A Units
63. 7 3 and 9 of this document J3 Pins 1 through 3 RTD Interface Field Wired Refer to 8 of this document J4 Pins 1 through 11 AI O Interface amp Field Power Analog Input Output Field Wiring amp Unit supplied 15Vdc Field Power Field I O wiring connector is unrated refer to T 9 of this document Appendix B Document CI ControlWave XFC Page 1 of 2 ControlWave XFC Special Instructions for Class I Division 1 Hazardous Locations Table Al Terminal Plate Connector Customer Wiring Connectors Continued Connector Wiring Notes J5 Pins 1 through 9 Discrete Input Output Field Wiring Field I O wiring connector is unrated refer to 19 of this DI O Interface document J5 Pins 9 through 12 High Speed Counter Input Field Wiring Field T O wiring connector is unrated refer to 19 of HSC Interface this document J6 Pins 1 and 2 Power Interface Power connector is unrated refer to 19 of this document Input Power Note These wires should only be installed removed when the item PCB in question is installed removed or when checking wiring continuity The area must be known to be nonhazardous before servicing replacing the unit and before installing or removing PCBs Connectors or individual I O or Power wires Refer to 16 7 amp 8 of this document All input power and I O wiring must be performed in accordance with Class I Division 2 wiring methods as defined in Article
64. A Optional Input Power J6 is run through a circuit that current limits the on board V supply for ATs and AO s and the field power for HSC devices The power supply operates from 6 0 to 380Vdc A supervisory circuit monitors the incoming power and the supply voltages The supplies are shut down when the incoming voltage drops to a level of 5 46Vdc or less The I O Board provides the interface hardware necessary to interconnect the assigned field I O circuits Non isolated power is generated and regulated by the I O Board that provides 3 6Vdc for all logic and bulk power for I O field circuits and provides 3 3Vdc to the CPU Board 1 3 4 1 I O Board Connectors I O Boards are equipped with 7 connectors that function as follows see Table 1 3 1 10 Introduction CI ControlWave XFC Table 1 3 I O Board Connector Summary Ref Pins Function Notes From Term Block J6 on Term Plate CPU SPI Power Interface To From CPU Board Connector P2 J5 000000000001 J2 J6 CK OO 00 OO 00TA kk see nn nn nn nn ng le 5 pp RRnnnnnnn wl J4 0000000000 P1 MVTIGPT Intf Figure 1 5 ControlWave XFC I O Board Note J1 and J8 are for Factory Use ONLY 1 3 5 Terminal Plate Input Output Communications Input Power and RTD wiring are connected to the Terminal Plate accessed by removing the Rear Wiring Cover 1 3 5 1 Field I O Wiri
65. A7 with selectable AGA8 Gross or AGA8 Detail e Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail e Includes run switching e Includes an auto selector PID flow pressure control algorithm per run or per station e Interfaces to a chromatograph and provides energy throughput as well as composition information e Resides on a BSAP SCADA network e Supports samplers and odorizers e Provides audit trail and archives e Includes a nominations function e Allows the user to select engineering units including English and metric 1A 3 1 OpenBSI Simply Creative OpenBSI Open Bristol System Interface is a set of network setup communication diagnostic and data viewing utilities that provide access to both ControlWave and Network 3000 controllers and RTUs OpenBSI is the only product available in the industry to bring such unique functionality and ease of use to the network level At the core is the communication interface written as a Windows communication server API through which CI ControlWave XFC Product Features amp Overview 1A 3 other client applications communicate with the Bristol networks OpenBSI supports both serial BSAP protocol and Ethernet Internet Protocol communication to ControlWave and Network 3000 RTUs and controllers 1A 3 2 OpenBSI Utilities Above this communication layer are a group of applications known as OpenBSI Utilities These client utilities communicate through the server to collect and manage data ga
66. ATU Ve or CWave_Micro CWave_EFM CWave_GFC CWave_XFC CWave_LP etc What is the local address of the fi e RATU that you like to connect to Finish Cancel Help Figure 2 19 Flash RTU Setup Menu Step 3 Flash Data Setup Complete the following fields in the Flash Data Setup Wizard Please enter the name of the binary file to Flash To upgrade system firmware you must specify the path and name of a binary BIN file on your hard disk containing the firmware Click on Finish to install the specified BIN file in FLASH memory at the RTU Once the Flash download has begun you will NOT be allowed to shut down LocalView unless you cancel the download or it has been completed The progress of the Flash download will be displayed in the window Any mismatch in file versions or if the type of BIN file does not match the type of RTU the download will be aborted Flash Data Setup Step 3 of 3 x Please enter the name of the binary file to flash d DA0penBSNcwe0420 bin Open Location of Flash Master File E ACCOLS Browse Finish Cancel Help Figure 2 20 Flash Data Setup Menu Note Substitute cwx0440 bin for cwe04 CI ControlWave XFC Installation amp Operation 2 29 Path and filename of BIN file Total number of bytes in BIN file o Be Local View myflash LVG Iof x File View Mode Help 4 File to Flash Dowriload xo penB
67. Base Temperature Required and Contract Base Temperate is entered here Deg F Base Pressure Required or Contract Base Pressure is entered here psia The following outputs from the AGA3 calculation are displayed MSCHIH Flow rate in thousands of standard cubic feet per hour Low Flow Cut Off Cutoff if the DP drops below the low flow cut off value or OK C Prime Orifice Flow Constant Fn Numeric Conversion factor which includes Ev the velocity of approach factor CD Orifice Coefficient of Discharge Y Expansion Factor Fpb Pressure Base Factor Ftb Temperature Base Factor Ftf Flowing Temperature Facture Fpv Supercompressibility Factor Fm Additional Correction Factor Extension Square Root of the product of Diff Pressure and Static Pressure DP x SP Reynolds Number Computed Pipe Reynolds Number F 28 Appendix F CI ControlWave XFC BCF Base Correction Zb Zf F 6 3 2 Frequency Flow Equation Setup If the user configures a meter as a linear meter the AGA7 Calculation page appears see Figure F 19 Densisty Switch Users may select whether a density meter or Gravitometer is used as an input to the equation Gravitometer Press Switch Users may save the default value for Pressure or Volume entered in the Gravitometer Press Used field Gavitometer Temp Switch Users may use the default temperature value of the value entered in the Gravitometer Temp Used field Specific Gravity S
68. C ControlWave XFC RS 485 Port Pin Assignments From To lst To nth Master Slave Slave TR Note When wiring to four wire RS 485 Ports connect TR to TXD amp RXD and connect TR to TXD and RXD Note Pins 1 2 3 4 amp 9 of BBI Series 3305 3310 3330 3335 amp 3340 RTU DPC RS 485 Comm Ports are assigned as follows 1 TXD 2 TXD 3 RXD 4 RXD amp 9 ISOGND 2 3 3 I O Wiring ControlWave XFCs are provided with Card Edge Terminal Blocks that accommodate field wiring Wiring is routed into the enclosure through a 4 Conduit Fitting 2 3 3 1 I O Wire Connections ControlWave XFC electronic flow computers utilize Terminal Blocks equipped with compression type terminals that accommodate up to 14 AWG wire A connection is made 2 18 Installation amp Operation CI ControlWave XFC by inserting the wire s bared end 1 4 max into the clamp beneath the screw and securing the screw The wire should be inserted fully so that no bare wires are exposed to cause shorts If using standard wire tin the bare end with solder to prevent flattening and improve conductivity Allow some slack in the wires when making terminal connections The slack makes the connections more manageable and minimizes mechanical strain on the terminal blocks For safety reasons and to prevent accidental damage to a user supplied external bulk DC Power Supply it is recommended that the pluggable Power Terminal Block J6 on the Termina
69. C Power System or for Earth Ground make sure that the conductor is not nicked when trimming off the insulation Nicked conductors are potential disasters waiting to happen Neatly trim shields and whenever possible coat them to protect them and prevent shorts and water entry Section 5 Wiring Techniques Page 5 3 S1400CW Remember loose connections bad connections intermittent connections corroded connec tions etc are hard to find waste time create system problems and confusion in addition to being costly 5 2 7 High Power Conductors and Signal Wiring When routing wires keep high power conductors away from signal conductors Space wires appropriately to vent high voltage inductance Refer to the National Electrical Code Handbook for regulatory and technical requirements 5 2 8 Use of Proper Wire Size ControlWaves utilize compression type terminals that accommodate up to 14 AWG gauge wire A connection is made by inserting the bared end 1 4 inch max into the clamp beneath the screw and securing the screw Allow some slack in the wires when making terminal connections Slack makes the connections more manageable and minimizes mechanical strain on the PCB connectors Provide external strain relief utilizing Tie Wrap etc to prevent the loose of slack at the ControlWave Be careful to use wire that is appropriately sized for the load Refer to equipment manufacturer s Specs and the National Electrical Code Handbook for in
70. CB in question is installed removed or when checking wiring continuity The area must be known to be nonhazardous before servicing replacing the unit and before installing or removing PCBs Connectors or individual I O or Power wires Refer to 16 7 amp 8 of this document All input power and I O wiring must be performed in accordance with Class I Division 2 wiring methods as defined in Article 501 4 b of the National Electrical Code NFPA 70 for installations within the United States or as specified in Section 18 152 of the Canadian Electrical Code for installation in Canada Appendix A Document CI ControlWave XFC Page 2 of 2 ControlWave XFC Special Instructions for Class I Division 1 Hazardous Locations Bristol Inc s ControlWave XFC Model 3820 EX Gas Flow Computer is listed by Underwriters Laboratories UL as explosion proof and is suitable for use in Class I Division 1 Groups C and D hazardous locations or nonhazardous locations Read this document carefully before installing an explosion proof ControlWave XFC Model 3820 EX Gas Flow Computer Refer to the ControlWave XFC Explosion Proof Gas Flow Computer User s Manual for general information In the event of a conflict between the ControlWave XFC Explosion Proof Gas Flow Computer User s Manual and this document always follow the instructions in this document The ControlWave XFC Explosion Proof Gas Flow Computer includes both nonincendive and unrated field circuits Unless a
71. CORNING 200 R FLUID 100 CST 4 FIRST AID MEASURES Eye Immediately flush with water Skin No first aid should be needed Inhalation No first aid should be needed Oral No first aid should be needed Comments Treat symptomatically 5 FIRE FIGHTING MEASURES Flash Point gt 214 F gt 101 1 C Closed Cup Autoignition Not determined Temperature Flammability Limits in Air Not determined Extinguishing Media On large fires use dry chemical foam or water spray On small fires use carbon dioxide CO2 dry chemical or water spray Water can be used to cool fire exposed containers Fire Fighting Measures Self contained breathing apparatus and protective clothing should be worn in fighting large fires involving chemicals Use water spray to keep fire exposed containers cool Determine the need to evacuate or isolate the area according to your local emergency plan Unusual Fire Hazards None Hazardous Decomposition Products Thermal breakdown of this product during fire or very high heat conditions may evolve the following hazardous decomposition products Carbon oxides and traces of incompletely burned carbon compounds Silicon dioxide Formaldehyde 6 ACCIDENTAL RELEASE MEASURES DOW CORNING DOW CORNING CORPORATION Material Safety Data Sheet DOW CORNING 200 R FLUID 100 CST Containment Clean up Determine whether to evacuate or isolate the area according to your local emergency
72. Construction Diagram 3 3 2 Ground Wire Considerations ControlWave ControlWave MICRO ControlWave EFM GFC XFC Control WaveRED ControlWave REDIO amp ControlWave I O Expansion Rack ControlWave Chassis are provided with a Ground Lug that accommodates up to a 4 AWG wire size A ground wire must be run between the Chassis Ground Lug and a known good Earth Ground The cases of the various ControlWave Modules are connected to Chassis Ground when they have been installed and secured via their two Captured Panel Fasteners As an extra added precaution it is recommended that a 14 AWG wire be run from PSSM Power Connector TB2 5 Chassis Ground PSSM Connector TB1 3 for ControlWave MICRO unit SCM Connector TB1 3 for ControlWave EFM to the same known good Earth Ground ControlWaveLP Process Automation Controller A 14 AWG ground wire must be run from the ControlWaveLP s PSSB Terminal TB2 3 Chassis Ground to a known good Earth Ground In lieu of a direct connection to Earth Section 3 Grounding amp Isolation Page 3 5 S1400CW Ground it is recommended that the unit s Chassis Ground Terminal be connected to a conductive mounting panel or plate a user supplied Ground Lug or a user supplied Ground Bus The panel lug or bus in turn must be connected to a known good Earth Ground via a 4 AWG wire General Considerations The following considerations are provided for the installation of ControlWave system grounds Size of groun
73. E M I immunity and protection to the shield as well S1400CW Page 5 2 Section 5 Wiring Techniques 5 2 3 Grounding of Cable Shields DO NOT connect the cable shield to more than one ground point it should only be grounded at one end Cable shields that are grounded at more than one point or at both ends may have a tendency to induce circulating currents or sneak circuits that raise havoc with I O signals This will occur when the ground systems associated with multipoint connections to a cable shield have a high resistance or impedance between them and a ground induced voltage is developed for what ever reason Le man made error or nature produced phenomena 5 2 4 Use of Known Good Earth Grounds ControlWave units should only have one connection to earth ground For ControlWave and ControlWave MICRO Process Automation Controllers ControlWave MICRO ControlWave EFM Electronic Flow Meters ControlWave GFC XFC Gas Flow Computers and ControlWave I O Expansion Racks this connection is provided via the Ground Lug that is situated on the bottom of the unit ControlWaveLPs require the installation of a ground lug ground bus or ground plate panel Since ControlWave units are DC based systems grounding does not take into account AC power grounding considerations Earth grounding the unit is absolutely necessary when the unit is equipped with a radio or modem Additionally these units should be connected to earth ground when they are installed in a
74. ELL LITHIUM MANGANESE DIOXIDE COIN BATTERIES CAS NO Not applicable Effective Date 8 8 03 Rev 3 A IDENTIFICATION Formula Mixture Mixture Manganese Dioxide 1313 13 9 Propylene Carbonate 108 32 7 Lithium 7439 93 2 Graphite synthetic 7440 44 0 1 2 Dimethoxyethane 110 71 4 Lithium Perchlorate 7791 03 9 B PHYSICAL DATA Boiling Point Molecular Weight NA Synonyms Lithium Manganese Dioxide Coin Cells 3V DL2016 DL2025 DL2430 DL2450 DL2032 DL1616 DL1620 Specific Gravity H20 1 Vapor Density air 1 Vapor Pressure NA NA mm Hg Evaporation NA F NA ge NA Ether 1 by volume NA NA NA Volatiles Solubility in Water NA NA pH NA Appearance Color Flash Point and Test Method s Flammable Limits in Air by volume C REACTIVITY Lower Saturation in Air Coin cells Contents dark in color NA Autoignition Temperature Melting Point Freezing Point NA F NA Re F NA G F F ec F 1 2 Dimethoxyethane Approximately 3 7 of contents 42 8 F 6 C Closed Cup Upper NA Conditions to Avoid Do not heat crush disassemble short circuit or recharge Incompatible Materials Contents incompatible with strong oxidizing agents IF MULTIPLE INGREDIENTS INCLUDE CAS NUMBERS FOR EACH Footnotes Not applicable Conditions to Avoid Not applicable Hazardous Decomposition Products Thermal degradation may produce hazardou
75. GEN 1 18 BSAP Message Gupport aiaa Eaa a aana NEA aa areia aias 1 19 Discrete and Analog I O XFC Functionality ccccccccccsssecesseeeeeesseeeeessseaeeesssenaees 1 19 Flow Rate Control DDC Gog control using DI 1 19 Pulse Output for External Totalizer or Sampler ccccccccesssseecessseceeeesseeeeseenaeens 1 19 Nomination TEE 1 20 Self KE ERR 1 20 CI ControlWave XFC Contents 0 1 CI ControlWave XFC ControlWave XFC Model 3820 EX Explosion Proof Gas Flow Computer SECTION 1A 1 1A 1 1 1A 1 2 1A 2 1A 2 1 1A 2 2 1A 2 3 1A 3 1A 3 1 1A 3 2 1A 3 3 1A 3 3 1 1A 3 3 2 1A 3 4 1A 3 5 1A 4 1A 4 1 1A 4 1 1 1A 4 1 2 1A 4 1 3 2 1 2 2 2 2 1 2 2 2 2 3 2 3 1 2 3 1 1 2 3 1 2 2 3 1 8 2 3 1 4 2 3 1 5 2 3 2 2 3 2 1 2 3 2 2 2 3 2 3 2 3 3 2 3 3 1 2 3 3 2 2 3 3 3 2 3 3 3 1 2 3 3 4 2 3 3 4 1 0 2 Contents TABLE OF CONTENTS TITLE PAGE Section 1A PRODUCT FEATURES amp OVERVIEW PRODUCT OVERVIEW cccccccccsssssccceesssccceessseccsessssescesssececeesseesceesseesssessecsssonsnees 1A 1 Hardware Features 1A 1 Firmware and Software Features 1A 1 PRODUCT FAMILY COMPATIBILITY cccccccccsscccessssececsssseeecsssseeeesssseeeesesaes 1A 2 Open Standards for Programming Network Config and Communication 1A 2 ControlWave Designer with ACCOL DI 1A 2 ACCOM MM EE 1A 2 STANDARD APPLICATION DROOGRANM 1A 3 OpenBSI Simply Creative 1A 3 Open BSE Utilities 2 0 0
76. Instruction Manual CLC IWave XFC a S ControlWave XFC ControlWave XFC Explosion Proof Gas Flow Computer aen A Bristol EMERSON www EmersonProcess com Bristol Process Management 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 main tenance Should problems arise that are not covered sufficiently in the text the pur chaser 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 WA
77. MOST FROM YOUR BRISTOL BABCOCK INSTRUMENT OR SYSTEM e Avoid Delays and problems in getting your system on line e Minimize installation start up and maintenance costs e Make the most effective use of our hardware and software e Know your system Transducer to Manifold Dielectric Isolation Kit Multivariable d Transducer f e i a N Dielectric Gasket S SA amp Flange Seals 2 E i IS Valve Block Manifold ave Sg Top Washers 4 LG ae Dielectric Bolt Sleeves 4 Bottom Washers 4 Mounting Bolts 4 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
78. NUTES Previous Hour Previous Day Accumulated Volume x1000 0 000 SCF Accumulated Volume x1000 0 000 SCF Accumulated Energy x1000000 0 000 BTU Accumulated Energy x1000000 0 000 BTU Avg Static Pressure 0 000 PSI Avg Static Pressure 0 000 PSI Avg Temperature 0 000 DEG F Avg Temperature 0 000 DEG F Avg Diff Pressure 0 000 INH20 Avg Diff Pressure 0 000 INH20 Avg Spec Gravity 0 000 Avg Spec Gravity 0 000 Avg Heating Value 0 000 BTU FT3 Avg Heating Value 0 000 BTUJFT3 Flow Time 0 000 MINUTES Flow Time 0 000 MINUTES Reset Meter Run s Measurement Type Figure F 13A Meter Run Overview 1985 AGA3 Orifice Meter Web Page Meter Run Overview for Run 1 GFC Time 04 25 2006 14 04 11 DP 0 000 mo Pipe Diameter 4 026 SP T Orifice Diameter 2 000 gt gt gt FlowDirection gt gt gt Meter ID Run 1 Contract Hour 7 Active Flow Calculation AGA3I 1992 Current Heating Value 0 000 BTU SCF Flow Rate x1000 0 000 SCF HOUR Energy Rate x1000000 BTU HOUR 0 000 Current Hour Current Day Accumulated Volume x1000 0 000 scr Accumulated Volume x1000 0 000 SCF Accumulated Energy x1000000 0 000 BTU Accumulated Energy x1000000 0 000 BTU Flow Time 0 000 MINUTES Flow Time 0 000 MINUTES Previous Hour Previous Day Accumulated Volume x1000 0 000 scr Accumulated Volume x1000 0 000 SCF Accumulated Energy x1000000 0 000 BTU Accumulated Energy x1000000 0 000 BTU Avg Static Pressure 0 000 PSI Avg Static Pressure 0 000 PS Avg
79. OARD SPECIFICATIONS sssssssssssoesssssessssssessssssssesssessssssseessesssessssssssesssessseessees 4 2 External Power Monitor Specs cccccccesssssscecececeecsesesnscecececeesessnnsseceeeceeesesessseeeeeeeees 4 2 Power Supply Sequencer Specs ccccccccccccecsesssseceeceecceceesesseseceeccsesenesssseeeeeeeeseesersaeees 4 2 Non isolated Digital Input Output Circuitry Hpecs 4 3 Non isolated Analog Input Output Circuitry Specs ccccccccsscceceesseceeceesseeeeseseeeeneaes 4 3 Non isolated High Speed Counter Input Circuitry Specs cccccccceccceceesessenseceeeeees 4 4 Function Module Terminal Plate Connectors 4 4 TERMINAL PLATE SPECIFICATIONS 2 00 cccccccseceessccessseeesseceeseeceeeeesseseesseeeeeeeees 4 4 ENVIRONMENTAL SPECIFICATIONS c ccccsscccssccsssceesseceesseceseeeesseesesseceeseeensees 4 5 DIMENSION EE EE 4 5 APPENDICES SUPPLEMENTAL INSTRUCTION Special Instructions for Class I Division 2 Hazardous Locations Appendix A Special Instructions for Class I Division 1 Hazardous Locations Appendix B Using ControlWave XFC WebBSI Web Dages Appendix F MATERIAL SAFETY DATA SHEETS cceccccccccssececeessececneseeeeneaeeeeeneaas Appendix Z Site Considerations for Equipment Installation Grounding amp Wiring S1400CW Care and Handling of PC Boards and ESD Sensitive Components sssss10s0s0 14006 REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS 0 4 Contents WINDIAG Win
80. Operation CI ControlWave XFC program see Step 4 above If you modify the standard XFC program you may need to modify the standard web pages If you create your own application program instead of using the standard one you may create your own web pages using Bristol Babcock ActiveX controls discussed in the Web_BSI Manual document D5087 You can use whichever HTML creation package you want to create the pages however all ControlWave XFC related web pages whether standard or user created must be viewed within Microsoft Internet Explorer Web pages are stored on a PC workstation Step 6 Create an Open BSI Network Containing the ControlWave XFC or ADD the ControlWave XFC to an Existing Open BSI Network In order for the ControlWave XFC unit to function as part of a Bristol Babcock network it is necessary to include it in the Bristol Babcock network If no Bristol Babcock network exists You need to run Open BSI s NetView software on the PC workstation in order to define a Bristol Babcock network A series of software wizards are used to define a Network Host PC a network and the RTUs controllers assigned to the network Finally com munication lines must be specified which handle the address assigned to the Control Wave XFC Chapters 3 and 4 of the Open BSI Utilities Manual document D5081 include quick start examples for performing these steps More detailed information is included in the NetView chapter Chapter
81. PPERCABLE y SNE _ CLAMP ORBRAZE Kk eh D GROUND BED CONDUCTOR Figure 3 6 Grounding of Phone Line S1400CW Page 3 6 Section 3 Grounding amp Isolation For applications employing equipment that communicates over telephone lines a lightning arrester Must Be provided For indoor equipment the lightning arrester must be installed at the point where the communication line enters the building as shown in Figure 3 6 The ground terminal of this arrester must connect to a ground rod and or a buried ground bed Gas lines also require special grounding considerations If a gas meter run includes a thermocouple or RTD sensor installed in a thermowell the well not the sensor must be connected to a gas discharge type lightning arrester as shown in Figure 3 7 A copper braid brazed to the thermal well is dressed into a smooth curve and connected to the arrester as shown The curve is necessary to minimize arcing caused by lightning strikes or high static surges The path from the lightning arrester to the ground bed should also be smooth and free from sharp bends for the same reason THERMOMETER WELL BRAZE NNECTION SS S o COPPER BRAID AWG 4 OR LARGER a E 2 DRESSED TO SMOOTH CURVE GAS DISCHARGE TUBE METER RUN ER LIGHTNING ARRESTOR A PIPE SUPPORT 1 DIA y SOILLINE S RADIUS 12 IN dt FOUNDATION CLAMP OR BRAZE ER GROUND BED Se se v i STRANDED COPPER CABLE AWG 0000 Figure 3 7 Gr
82. Poor Soil is provided herein Details on this test are described in the National Electrical Code Handbook Once a reliable S1400CW Page 3 2 Section 3 Grounding amp Isolation ground has been established it should be tested on a regular basis to preserve system integrity Megger nuny Test Rod Temp for Testing Potential Rod Current Rod Temp for Testing 50 Ft or more Copper Weld Ground Rod Figure 3 2 Basic Ground Bed Soil Test Setup Test Rod Temp for Testing Current Rod Temp for Testing 10 Ft 10 Ft Copper Weld Copper Weld Ground Rod Ground Rod Copper Weld Ground Rod Figure 3 3 Basic Ground Bed Soil Test Setup with Additional Ground Rods Figure 3 2 shows the test setup for Good Soil conditions If the Megger reads less than 5 ohms the ground is good The lower the resistance the better the earth ground If the Section 3 Grounding amp Isolation Page 3 3 S1400CW Megger reads more than 10 ohms the ground is considered poor If a poor ground is indicated one or more additional ground rods connected 10 feet from the main ground rod should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1 x 14 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 V
83. RNING 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 in struments 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 14006 at the back of this manual for proper care and handling of ESD sensitive components Bristol 1
84. SI Network Edition or OpenBSI Local Edition with the WebBSI ActiveX controls installed and registered on the PC see appropriate document for details ControlWave XFC Web pages will be installed in the following directory as the default C OpenBSI WebXFC and the default startup page will be CW_MICRO_XFC htm CI ControlWave XFC Appendix F F 1 PC Laptop ControlWave XFC Computer ControlWave XFC WebBSI MENU SYSTEM Figure F 1 ControlWave XFC Connected to PC via the Local Communications Cable F 2 1 Communication Connections The ControlWave XFC communicates with the PC through the Local Port as shown in Figures F 1 amp F 2 or through the Network if configured The Local Port has been provided specifically for installation startup and on site configuration and data collection Local communications between the ControlWave XFC and the PC is provided over a standard ControlWave null modem cable ControlWave XFC COMPUTER Local Port Comm Port 1 Terminal Plate Looking into Wire Terminal Side of To P2 Pin 7 Cable Connectors To P2 Pin 5 To P2 Pin 6 Figure F 2 ControlWave XFC Pc to Local Port Cable Connection Diagram Connecto
85. SI cwm0410 bin Signatwe FE GE A Total Bytes to Download 2E 840704 Progress of the flash download These fields do Se p NOT apply to p e Downloaded at address Droe S ControlWave series units Total number of Bytes Downloaded Joes Cancel Flash Download For Help press F1 Message area Mod indicates unsaved changes If necessary click here to LVG file to cancel the flash download Number of bytes already downloaded Figure 2 21 Local View Downloading System Firmware Menu 2 4 2 2 Using Hyperterminal to Upgrade ControlWave XFC Firmware A special 3 wire communication cable see Figure 2 9C must be connected to COM1 of the ControlWave XFC and to any RS 232 port on the associated PC The PC s RS 232 port used for this purpose must be set to run at 115 2 Kbaud ControlWave XFC CPU Board Switch SW1 positions 9 and 10 must both be set to the ON or OFF position or SW1 9 set ON and SW1 10 set OFF 1 2 If not already running apply power to the associated PC Start the HyperTerminal program on the PC Note HyperTerminal is a Windows 95 or newer application utility program If using HyperTerminal for the first time set the communications properties for the PC Port being utilized via the Properties Menu as follows Bits per second 115200 Data bits 8 Parity None Stop bits 1 and Flow control None and then click OK Set CPU Board Switch SW1 for Recovery Mode i e set CPU Boa
86. Supplement S1400CW Page 0 1 Table Of Contents Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION GROUNDING amp WIRING EEN TABLE OF CONTENTS SECTION TITLE PAGE Section 5 WIRING TECHNIQUES Continued 5 2 2 Use of Twisted Shielded Pair Wiring with Overall Insulat on 5 2 5 2 3 Grounding of Cable Shields c ccccccccessscceeeessececeessseeecescaeeeseeseeecssaeeeeseseeeeseeeeeenees 5 3 5 2 4 Use of Known Good Earth Grounds sssssssessssseessesesesseresssesetssrrssssrtetssrresssseessssrresso 5 3 5 2 5 Earth Ground Wires siccccissieccasssencetssveaceaasaviccassannecasaviiceaaseniccasaveiccaasavbiecsaaebdveaanvaaceataannes 5 3 5 2 6 Working Neatly amp Professionally cccccccccsssececssseececceesaeeecsesaeeecsesaeseesesaeeecsesaeeeseneaaes 5 3 5 2 7 High Power Conductors and Signal Wumg 5 4 5 2 8 Use of Proper Wire Size cccccccccccceceessssscececeeseeessaeceeececsesesssaeseeeeecsesesssaeeeeeeeesenensaaeees 5 4 5 2 9 Lightning Arresters amp Surge Drotectors 5 4 5 2 10 Secure Wiring Connectonsg 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 8 Lightning Strike Protect Roy B Carpenter Jr amp Mark N Drabkin Ph D Lightning Eliminators
87. 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 80 days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship Bristol is not responsible for any costs of removal dismantling or reinstallation of allegedly defective or defective goods If a Buyer does not wish to ship the product back to Bristol the Buyer can arrange to have a Bristol service person come to the site The Service person s transportation time and expenses will be for the account of the Buyer However labor for warranty work during normal working hours is not chargeable Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation from use of the information herein or from t
88. TION DOT Road Shipment Information 49 CFR 172 101 Not subject to DOT Ocean Shipment IMDG Not subject to IMDG code Air Shipment IATA Not subject to IATA regulations Call Dow Corning Transportation 989 496 8577 if additional information is required 15 REGULATORY INFORMATION Contents of this MSDS comply with the OSHA Hazard Communication Standard 29 CFR 1910 1200 TSCA Status All chemical substances in this material are included on or exempted from listing on the TSCA Inventory of Chemical Substances EPA SARA Title Ill Chemical Listings Section 302 Extremely Hazardous Substances None Section 304 CERCLA Hazardous Substances None Section 312 Hazard Class Acute No Chronic No Fire No Pressure No Reactive No Section 313 Toxic Chemicals None present or none present in regulated quantities DOW CORNING CORPORATION Material Safety Data Sheet DOW CORNING 200 R FLUID 100 CST Supplemental State Compliance Information California Warning This product contains the following chemical s listed by the State of California under the Safe Drinking Water and Toxic Enforcement Act of 1986 Proposition 65 as being known to cause cancer birth defects or other reproductive harm None known Massachusetts No ingredient regulated by MA Right to Know Law present New Jersey CAS Number Wt Component Name 63148 62 9 gt 60 0 Polydimethylsiloxane Pennsylvania CAS Number Component Nam
89. TIONAL ControlWave XFC explosion proof gas flow computers are shipped with the XFC program already loaded However you can create your own application specific control strategy using ControlWave Designer This involves opening a new project using the CWMicro template defining I O points using the I O Configurator and creating a program using one or more of the five supported IEC 61131 languages FBD ST SFC LD or IL Some of these languages are text based others use graphical diagrams The choice is up to you depending upon your particular application The ControlWave MICRO Quick Setup Guide document D5124 includes a simple LD example Additional examples are included in the manual Getting Started with ControlWave Designer document D5085 More detailed information about ControlWave Designer and IEC 61131 is included in the ControlWave Designer Reference Manual document D5088 The ACCOL3 Firmware Library which is automatically accessible through the template referenced above includes a series of function blocks which perform a variety of process control and communication functions These can be included within your program to per form various duties including PID control alarming calculations etc Detailed information about each function block is included in the ControlWave Designer on line help files On the variables declaration page s in ControlWave Designer you will need to mark any variable you want to make a
90. The IEEE standard is an 8 uS by 20 uS 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 x R Fifty percent of all lightning strikes will have a first impulse of at least 18 KA ten percent will exceed the 60 KA level and only about one percent will exceed 120 KA 4 1 1 Chance of Being Struck by Lightning The map of Figure 4 1 shows the average annual number of thunderstorm days Isokeraunic level for the various regions within the continental U S A This map is not representative of the severity of the storm or the number of lightning strikes since it does not take into account more than one lightning strike in a thunderstorm day The Isokeraunic or Isoceraunic number provides a meteorological indication of the frequency of thunderstorm activity the higher the Isokeraunic number the greater the lightning strike activity for a given area These levels vary across the world from a low of 1 to a high of 300 Within the United States the Isokeraunic level varies
91. VT equipped unit without Cathodic protection is similar to that of Figure 2 6 except it doesn t utilize the Transducer to Manifold Dielectric Isolation Kit 2 3 1 5 Process Pipeline Connection Meter Runs with Cathodic Protection Dielectric isolators are available from Bristol Babcock and are always recommended as an added measure in isolating the ControlWave XFC from the pipeline even though the enclosure does provide some galvanic isolation from the pipeline and should not be affected by cathodic protection or other EMF on the pipeline ControlWave XFCs equipped with a MVT may be mounted directly on the pipeline see Figure 2 6 or remotely on a vertical horizontal stand alone two inch pipe or on a wall or panel see Figure 2 7 ControlWave XFCs equipped with a GPT can only be mounted on a vertical horizontal stand alone two inch pipe or on a wall or panel It is recommended that isolation fitting always be used in remotely mounted meter systems An isolation fittings or gasket should be installed between the following connections e all conductive tubing that runs between the pipeline and mounting valve manifold and or the units Multivariable Transducer MVT 2 12 Installation amp Operation CI ControlWave XFC e all conductive connections or tubing runs between the ControlWave XFC gas flow computer and a turbine meter pulse transducer or any other I O device that is mounted on the pipeline e any Temperature Transducer Pressure Tran
92. Wave XFC Firmware It is possible to download system firmware into an unattended remote ControlWave XFC This function can only be accomplished if CPU Board Switch SW1 6 associated with the unit in question is set in the ON position factory default The procedure for performing a remote download of system firmware is discussed in Appendix J of the Open BSI Utilities Manual document D5081 Note Remote upgrade of ControlWave XFC Firmware 2 32 Installation amp Operation CI ControlWave XFC requires Boot PROM version 4 7 or higher and System PROM version 4 7 or higher 2 4 3 Operation of CPU Switch SW1 Mode Functions CPU Board Switch SW1 is a 10 position DIP Switch Its mode functions are served via switch positions 9 and 10 and are listed in Table 2 6 Table 2 6 CPU Mode Switch SW1 Assignments Recovery Mode Local Mode Control SW Function Setting SW1 9 10 Recovery Local Both ON OFF or SW1 9 ON amp SW1 10 OFF Recovery Mode Mode SW1 9 OFF amp SW1 10 ON Local Mode Recovery Mode Recovery Mode is used for either a firmware upgrade see Section 2 4 2 or a core updump see Section 3 6 Local Mode Local Mode should be selected for normal running operations 2 4 4 Soft Switch Configuration and Communication Ports Firmware defined soft switches that control many default settings for various system operating parameters such as BSAP Local Address EBSAP Group Number three 3 com munication port parameters etc
93. abinets or even the earth itself Adjacent equipment may not have been properly wired or grounded may be defective or may have one or more loose system grounds Measure between the case of a questionable piece of equipment and its earth ground for voltage If a voltage is present something is wrong AC powered equipment with a conductive case should have the case grounded If you don t see a chassis ground wire don t assume that it is safe to touch this equipment If you notice that equipment has been grounded to pipes conduit structural steel etc you should be leery Note AWWA s policy on grounding of electric circuits on water pipes states The American Water Works Association AWWA opposes the grounding of electrical systems to pipe systems conveying water to the customer s premises Be sure that the voltage between any two points in the instrument system is less than the stand off voltage Exceeding the stand off voltage will cause damage to the instrument and will cause the instrument to fail Section 2 Protection Page 2 3 S1400CW Section 3 Grounding amp Isolation SSL __s a__z7 3 1 POWER amp GROUND SYSTEMS ControlWaves utilize DC power systems AC power supplies are not provided with Con trolWave units ControlWave ControlWave MICRO ControlWave EFM GFC EFC ControlWaveRED ControlWaveREDIO and ControlWave I O Expansion Racks are provided with a Ground Lug that accommodates up to a 4 AWG size wi
94. addition HSCI circuitry contains conditioning circuitry that limits the maximum frequency of an input signal to 10kHz Two wire HSC inputs are internally sourced and don t support contact debounce functionality HSC circuitry is supported by the 12 point Terminal Block Assembly J5 on the Terminal Plate These may also be used as discrete inputs DIs Field inputs are from driven signals Each HSC input is configured as a 16 bit high speed counter 2 3 3 6 1 High Speed Counter Configurations HSC Modules provide a total of 2 HSC inputs with surge protection Field wiring assignments are provided in Figure 2 10 2 20 Installation amp Operation CI ControlWave XFC HSC 1 Example Internally Sourced High Speed Counter Wiring Diagram DO 1 Example DI 1 Example Ext Powered Dry Contact External Discrete Output Discrete Input Signal Wiring Diagram Wiring Diagram Generator P 400mA dh Max Load RTD Input SEL RTD Excitation SE RTD Sense 7 RTD Return H RS 485 9 BN COM3 ki i Ce to from S S Model WK 3808 O Se Ei Dt N io lt OQMB lt ON lt ORKC SE L W r J4 Ek aah rs 232 l S COM b to from Internally Powered m a 14 gt To V or Ext Powered Al 2 Gas Example SS ST Power i ifi Supply Simplified Supe 11 30Vdc Internally 11 30Vdc Powered AO Examples 1 5V Al 1 E
95. al familiar with the various programming tools The following software user documentation is referenced Getting Started with ControlWave Designer Manual D5085 ControlWave Designer Reference Manual D5088 Open BSI Utilities Manual D5081 Web_BSI Manual D5087 An application load download can be initiated i e from ControlWave Designer or from the OpenBSI 1131 Downloader for ControlWave XFC Nodes 2 26 Installation amp Operation CI ControlWave XFC 1 Make sure that the CPU Switch SW1 is set in Local Mode i e SW1 9 set to the OFF position and SW1 10 set to the ON position Note From the factory COM1 defaults to 115 2 kbd RS 232 using the BSAP Protocol Don t connect COM1 to a PC unless the PC s RS 232 port in question has been configured for BSAP operation 2 Once the ControlWave XFC project has been defined communications and con figuration parameters have been set perform the download according to either ControlWave Designer see D5088 chapter 11 or The Open BSI 1131 Downloader see D5081 Chapter 7 3 After the download has been completed leave CPU Switch SW1 in the Local Mode position 2 4 2 Upgrading ControlWave XFC Firmware The ControlWave XFC CPU ships from the factory with system firmware already installed If an upgrade of the system firmware is required use one of the procedures below to download the new or replacement firmware from the PC Upgrade of system fir
96. 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 assis tance in using this product from the following sources Help Files Release Notes Many Bristol software products incorporate help screens In addition the software typically includes a read me release notes file detailing new features in the product as well as other information which was available too late for inclusion in the manual Contacting Bristol Inc Directly Bristol s world headquarters is located at 1100 Buckingham Street Watertown Connecticut 06795 U S A Our main phone numbers are 860 945 2200 860 945 2213 FAX Regular office hours are Monday through Friday 8 00AM to 4 30PM Eastern Time excluding holidays and scheduled factory shutdowns During other hours callers may leave messages using Bristol s voice mail system Telephone Support Technical Questions During regu
97. ansport Environmental Effects These batteries pass the U S EPA s Toxicity Characteristic Leaching Procedure and therefore maybe disposed of with normal waste GMEL 2033 3 Page 3 of 4 F EXPOSURE CONTROL METHODS Engineering Controls General ventilation under normal use conditions Eye Protection None under normal use conditions Wear safety glasses when handling leaking batteries Skin Protection None under normal use conditions Use butyl gloves when handling leaking batteries Respiratory Protection None under normal use conditions Other Keep batteries away from small children G WORK PRACTICES Handling and Storage Store at room temperature Avoid mechanical or electrical abuse DO NOT short or install incorrectly Batteries may explode pyrolize or vent if disassembled crushed recharged or exposed to high temperatures Install batteries in accordance with equipment instructions Replace all batteries in equipment at the same time Do not carry batteries loose in pocket or bag Normal Clean Up Not applicable Waste Disposal Methods No special precautions are required for small quantities Large quantities of open batteries should be treated as hazardous waste Dispose of in accordance with federal state and local regulations Do not incinerate since batteries may explode at excessive temperatures GMEL 2033 3 Page 4 of 4 H EMERGENCY PROCEDURES Steps to be taken if material is relea
98. appearance mate with the transmitter s process flange The blocks may be installed in several positions to achieve different connection centers as shown in Figure 2 4 MVT Interface Cable An interface connected to the top of the MVT is factory connected to Connector P1 near the bottom of the rear side of the System Controller amp I O Board assembly This cable is keyed to simplify installation 2 3 1 2 Connection to a Gage Pressure Transducer GPT One optional Gage Pressure Transducer GPT secured to the bottom of the enclosure can be provided in lieu of a MVT with each ControlWave XFC Gage Pressure Transducers are equipped with a 1 2 14 NPT male pipe fitting see Figures 2 2B amp 2 3 2 3 1 3 Case Rotation Once mounted the Case XFC Housing can be rotated up to 180 in either direction i e clockwise or counterclockwise The Case XFC Housing must not be rotated from its shipped position any more than 180 clockwise or counterclockwise CAUTION ControlWave XFC may be damaged if the Case XFC Housing is rotated more than 180 from its shipped position To rotate the XFC Housing the setscrew that locks the Multivariable Transducer MVT to the XFC Housing must be removed with a 3mm Hex Wrench Once the XFC Housing has been turned to the desired position be sure to replace and tighten the set screw see Figure 2 5 2 3 1 4 Process Pipeline Connection Meter Runs without Cathodic Protection ControlWave XFCs equip
99. ard Switch SW1 3 OFF will force ports COM2 and COM3 to 9600 baud 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation e Setting CPU Switches SW1 3 and SW1 8 OFF prevents the Boot Project from running places the unit into diagnostic mode and forces communication ports COM1 COM2 and COMB to operate at 9600 baud COM1 can also be set to 9600 bps operation via user de fined Soft Switches 3 6 Service CI ControlWave XFC COM1 From the factory RS 232 Communications Port COM1 defaults to 115 2 kbd RS 232 using the BSAP Protocol Note Port COM1 will be configured for RS 282 op eration at 9600 baud by setting CPU Switches SW1 3 and SW1 8 OFF This will prevent the boot project from running and places the unit into diagnostic mode CPU Board Switch SW1 8 must be set OFF to run the WINDIAG program Connec tion to a PC requires the use of a three wire cable see Figure 2 11 or 2 12 Communication Port COM1 is located on the Terminal Plate assembly and is la beled the LOCAL Port it has three terminals as follows J2 5 RXD J2 6 TXD J2 7 Ground G COM2 From the factory RS 232 Communications Port COM2 defaults to 9600 baud 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation RS 232 Note Port COM1 will be configured for RS 282 operation 115 2 kbd by set ting CPU Switches SW1 OFF CPU System Controller Board Switch SW1 8 must be set OFF to run the WINDIAG program Connec
100. arty a software v Data From Field Input Devices Open BSI Utilities e g DataView Harvester 3 Figure 1 3 ControlWave Control Strategy Software Diagram The tools that make up the programming environment are e ControlWave Designer load building package offers several different methods for generating and debugging control strategy programs including function blocks ladder logic structured languages etc The resulting process control load programs are fully compatible with IEC 61131 3 standards Various communication methods as offered including TCP IP serial links as well as communication to Bristol Babcock s Open BSI software and networks e The I O Configuration Wizard accessible via a menu item in ControlWave Designer allows you to define process I O modules in the ControlWave and con figure the individual mapping of I O points for digital and analog inputs and outputs e The ACCOL3 Firmware Library which is imported into ControlWave Designer includes a series of Bristol Babcock specific function blocks These pre programmed 1 4 Introduction CI ControlWave XFC function blocks accomplish various tasks common to most user applications including alarming historical data storage as well as process control algorithms such as PID control The OPC Server Object Linking and Embedding OLE for Process Control allows real time data access to any OPC Object Linking and Embedding OLE for Process Control
101. as been reached The number entered 1 to 100 sets the percentage at which the logical nomination alarm will occur The status of this setting i e whether or not a nomination alarm has occurred can be determined via the Alarm Status signal see Figure F 8 Alarm Status When the amount specified in Alarm at a Level of Y is reached the value of the signal will be set true CURRENT NOMINATION PERIOD This section allows the operator to view the following information associated with a nomination which is currently in progress Start day hour The actual time and day of the month when the current nomination period started is displayed This may be the programmed time or the time at which an operator manually started a period Stop day hour The programmed end time and day of the month at which the current nomination period will end If using the Fast approach mode the period may end sooner 1 e when the target is reached If using the daily nomination feature the stop date day will show 0 to indicate that only the hour matters Target value x 1000 The Target value provides the value of Volume Energy to be delivered during this period Amount Delivered x 1000 The Amount Delivered reading provides the actual amount of volume energy delivered so far during this period Percent elapsed time This signal shows the percentage of time which has elapsed for the current nomination period e g 4 hours into a 100 hour nomina
102. at isolation fitting always be used in remotely mounted meter systems An isolation fittings or gasket should be installed between the following connections S1400CW Page 3 8 Section 3 Grounding amp Isolation e all conductive tubing that runs between the pipeline and mounting valve manifold and or the units multivariable pressure transducer e all conductive connections or tubing runs between the ControlWave EFM GFC and turbine meter pulse transducer or any input other device that is mounted on the pipeline e any Temperature Transducer Pressure Transmitter etc and their mount interface to the pipeline 2 Pipe mounting Package Note Mounting Pipe does not contact the Main Pipeline Transducer to Manifold Dielectric Isolation Kit Multivariable Transducer MVT Dielectric Gasket A amp Flange Seals 2 Valve Block Manifold Top Washers 4 K Dielectric Bolt Sleeves 4 Bottom Washers 4 Mounting Bolts 4 lt AWG 4 Ground Wire lt Ground Rod or System Figure 3 9 ControlWave EFM Installation is similar to EFM GFC XFC Direct Mount Installation with Cathodic Protection The ground conductor connects between the ControlWave EFM GFC XFC s Ground Lug and a known good earth ground Connect the cases of Temperature Transducers Pressure Transmitters etc to the known good earth ground If the mounting 2 inch pipe
103. be retained during power outages or when the system has been disabled for maintenance is stored here Data includes Last states of all I O historical data retain variables and pending alarm messages not yet reported The SRAM supports 16 bit accesses 1 3 3 3 CPU Board Battery Enable Configuration Jumper ControlWave XFC CPU Board is provided with 1 User Configuration Jumper that functions to enable disable the backup lithium battery e JP1 Battery Backup Jumper Installed Battery Enabled Removed Stored Battery Disabled 1 3 3 4 CPU Board LEDS Two red LEDs provide for the following status conditions when lit WD indicates a Watchdog condition has been detected IDLE indicates that the CPU has free time at the end of its execution cycle Normally IDLE should be ON for only 2 seconds every minute i e 2 out of 60 seconds to save power When the Idle LED is OFF continuously it indicates that the CPU has no free time and may be overloaded 1 3 3 5 CPU Board General Purpose Configuration Switch SW1 CPU System Controller Board Ten position DIP Switch SW1 is provided for user configuration settings Table 1 2 provides details on SW1 settings CI ControlWave XFC Introduction 1 9 Table 1 2 ControlWave XFC CPU Board Switch SW1 Assignments Note Except for SW1 4 ON Factory Default SW Function Setting ON Factory Default Watchdog Enable 5 Watchdog circuit is enabled F Watchdog circuit is disabled O O ON Wri
104. ble state no nomination will be performed Status The Status signal is an output of the nominations algorithm that indicates whether there is currently a nominations period in progress The user may change the state of this signal to end an in progress nomination immediately or to start the next period immediately see Manually Starting Ending a Nomination Period in Section F 5 8 F 5 5 2 Flow Control Enable Pressing the button to the right of Enable will allow the operator to toggle between PID Flow Control Enabled and Disabled It is recommended that GAIN INTEGRAL and DERIVATIVE adjustments be checked before turning a controller ON Warning Do not enable PID Flow Control without first checking the external process control loop The initial values displayed on the PID Menu may drive some critical processes beyond the extremes of safe limits This could result in fire explosion property damage and injury to persons When setting the WebBSI Web Page parameters make sure the associated process is observed and protected Setpoint x1000 This field contains the operating point at which the flow rate is to be controlled Set point units are MSCFH with a default setting of 1000 MSCF per Hour To change the Setpoint value right click on the field and select Change Signal Value Gain Gain controls the amount of output change resulting from a change of the measured variable The default value of 1 00 is typically used as a star
105. cations as required using the Modify Signal button 4 Click on Write to RTU 5 Select the file to save the configuration to by clicking on Browse Find an existing file to update or enter the name of a new file to create 6 Click on Write to File FINISHED 7 Select another file to use by clicking on Browse and the desired RCP file 8 Click on Load from File Return to Step 2 F 10 SPECIAL FUNCTIONS A special Sync Date amp Time web page see Figure F 28 is accessible from the Special Functions Category Section of WebBSI 04 25 2006 15 32 39 Figure F 28 Sync Date amp Time Web Page Display F 38 Appendix F CI ControlWave XFC ControlWave XFC Material Safety Data Sheets A Material Safety Data Sheet is provided herein to comply with OSHA s Hazard Com munication Standard 29 CFR 1910 1200 This standard must be consulted for specific requirements Material Safety Data Sheets are provided below MSDS for ControlWave XFC Instruction Manual CI ControlWave XFC Manufacturer General Description Part Number DURACELL 3V Lithium Manganese Dioxide Battery Bristol Inc Battery Part Number 395620 01 5 DL 2450 Manufacturer General Description Media Notes oe Fluid Pressure Transducer Media Fill 10 03 2006 Appendix Z CI ControlWave XFC MSDS Gillette Environment Health and Safety 37 A Street Needham MA 02492 Tel 781 292 8151 Page of 4 MATERIAL SAFETY DATA SHEET NAME DURAC
106. ccessible to external programs such as Open BSI s DataView utility as PDD Similarly any variables which should be collected into a database or exported using the OLE for Process Control OPC Server must be marked as OPC Variables marked as OPC can be built into a text file by the OpenBSI Signal Extractor The text file can then be used in the creation of a database for human machine interface HMI software such as OpenEnterprise or Iconics Genesis These HMI software packages require that the Datatype conversion enable option be selected when generating the file using Signal Extractor Information about the OpenBSI Signal Extractor is included in Chapter 12 of the Open BSI Utilities Manual document D5081 Once the program has been created it is assigned to an executable task The entire project is then saved and compiled NOTE From this point on the order of steps may be varied somewhat depending upon the requirements of the user s application NOTE If you modify the standard XFC program you may need to modify the standard web pages associated with it See Step 5 below Step 5 Use Standard Web Pages Provided to Select Options in the Standard Control Strategy or Create Your Own Application Specific Web Pages The ControlWave XFC has a standard set of web pages for configuration purposes stored on a PC that lets you enter parameters and configuration options for the standard GFC 2 4 Installation amp
107. ccommodates input power as follows e TB3 External User supplied power Battery or Regulated Power Supply 6 to 30Vdc 1 3 5 3 Terminal Plate Communication Port Connections Connections to two RS 232 and one RS 485 communication ports are provided via connector J2 see Section 2 3 2 2 and Section 2 3 2 3 1 3 6 Multivariable or Gage Pressure Transducer The Multivariable Transducer MVT pressure assembly is connected to the process manifold either directly or by tubing while the Gage Pressure Transducer GPT MUST ONLY be connected via tubing In the body of the transducer metal diaphragms are exposed to the gas Solid state strain gauge sensors in the neck of the transducer measure the pressure applied to the diaphragms and produce proportional electrical signals The neck of the MVT GPT Transducer extends into the bottom of the enclosure with the body of the transducer outside the enclosure The MVT GPT cable connector is factory mated with I O Board assembly connector P1 1 3 7 RTD Probe A 100 ohm platinum bulb using the DIN 48760 curve is optionally available BBI supplied RTDs are provided with three wires the return lead connects to the RTD terminal while the two junction leads Sense and Excitation connect to the RTD terminals RTDs provided with a bendable conduit and a plastic bushing can only be used in Division 2 installations Division I installations require the use of an RTD Connection Head used in conjunction w
108. checks and other indications of system health An appropriate alarm is generated if any test fails Bristol Babcock s WINDIAG program provides menu driven diagnostics that have been designed to assist a technician or Process Engineer in troubleshooting the various ControlWave XFC circuits see Document D4041A Chapters 1 amp 7C 1 20 Introduction CI ControlWave XFC Section 1A PRODUCT FEATURES amp OVERVIEW gt E gt E gt Lh_ _ Ee T T 1A 1 PRODUCT OVERVIEW ControlWave products have been designed and integrated as a highly adaptable high performance Distributed Open Controller family with exceptional networking capability that provides a complete Process Automation Management Solution ControlWave XFC gas flow computers have been designed with an emphasis on providing high performance with low power consumption scalability and modularity ControlWave XFC Cases support to 2 main circuit boards i e the CPU Board and the I O Board ControlWave XFC gas flow computers have been designed as an ideal platform for remote site automation measurement and data management within the oil amp gas industry ControlWave XFC units are extremely effective in Flow Computer Process Controller or Remote Terminal Unit capacities as follows e API 21 1 Electronic Flow Meter Flow Computer application ControlWave XFC units offer a cost effective and competitive match to all industry meters used in Electronic Flow Measurement and
109. configured F 6 1 Meter Run Overview See section F 6 1 1 for AGA3 Orifice Meters or F 6 1 2 for AGA7 Frequency Meters F 6 1 1 AGA3 Orifice Meter If the meter is configured as an Orifice Meter the following Read Only items are displayed Differential Measurement oO Linear Measurement Figure F 12 Meter Run Type Configuration WebPage Pipe Diameter amp Orifice Diameter To change these items select Flow Equation from the left side menu section DP Differential Pressure SP Static Pressure and T Temperature Live Values from the Transmitters being used for calculation selected via the I O Configuration Page Active Flow Calculation AGA3I 1992 or AGA3 1985 To change an item select Flow Equation from the left side menu section Current Heating Value The instantaneous value is provided F 18 Appendix F CI ControlWave XFC Meter Run Overview for Run 1 GFC Time o4 esyean6 14 00 41 DP Pipe Diameter 4026 Sp Orifice Diameter 2 000 T 0 000 INH20 gt gt gt FlowDirection gt gt gt Meter ID Run 1 Contract Hour 7 Active Flow Calculation AGAJTERM 1985 Current Heating Value 0 000 BTUJSCF Flow Rate x1000 0 000 SCF HOUR Energy Rate x1000000 BTU HOUR 0 000 Current Hour Current Day Accumulated Volume x1000 0 000 SCF Accumulated Volume x1000 0 000 SCF Accumulated Energy x1000000 0 000 BTU Accumulated Energy x1000000 0 000 BTU Flow Time 0 000 MINUTES Flow Time 0 000 MI
110. cribed herein will require the following equipment 1 PC with null modem interface cable amp Bristol s WINDIAG Software 2 Loop back wires for RS 232 amp RS 485 see Figure 3 9 The following test equipment can be used to test the Power Supply Sequencer Module 1 DMM Digital Multimeter 5 1 2 digit resolution 2 Variable DC Supply Variable to 30Vdc 2 5A with vernier adjustment When ControlWave XFC gas flow computers are serviced on site it is recommended that any associated processes be closed down or placed under manual control This precaution will prevent any processes from accidentally running out of control when tests are con ducted Warning Harmful electrical potentials may still be present at the field wiring terminals even though the ControlWave XFC s power source may be turned off or dis connected Do not attempt to unplug termination connectors or perform any wiring operations until all the associated supply sources are turned off and or disconnected Warning Always turn off the any external supply sources used for externally powered I O circuits before changing any printed circuit boards 3 2 COMPONENT REMOVAL REPLACEMENT PROCEDURES This section provides information on accessing ControlWave XFC components for testing as well as removal replacement procedures Note While performing steps 3 2 1 through 3 2 4 observe proper grounding practices for the control of ESD see document S14006 at the end of
111. cs can be tested using the WINDIAG program From WIN DIAG s Main Diagnostics Menu see Figure 3 4 the following diagnostic tests can be per formed CPU amp Peripherals Diagnostic Checks the CPU Board except for RAM amp PROM FLASH PROM RAM Diagnostic Checks the CPU Board s RAM and PROM FLASH hardware Communications Diagnostic Checks Comm Ports 1 2 and 3 The External loop back tests require the use of loop back wires Analog Output Diagnostic Checks AOs on the System Controller amp I O Board Analog Input Diagnostic Checks Als on the System Controller amp I O Board Discrete I O Diagnostic Checks DIs or DOs on the the System Controller amp I O Board High Speed Counter Diagnostic Checks HSCs on the the System Controller amp I O Bd Display Diagnostics Checks Display hardware 3 5 1 1 Communications Diagnostic Port Loop back Test WINDIAG s Communications Diagnostic Menu see Figure 3 7 provides for selection of the communication port to be tested Depending on the type of network RS 232 or RS 485 and the port in question different loop back wires are required as follows Port 1 RS 232 uses a single loop back wire see Figure 3 5 Port 2 RS 232 uses three loop back wires see Figure 3 5 Port 3 RS 485 doesn t require loop back wiring This group of tests verifies the correct operation of the Communication Interface COM1 COM2 and COMB can be tested with this diagnostic The Contro
112. d 2 3 7 Operation of the Lithium Backup Coin cell Battery CPU Boards are equipped with a Coin cell Socket BT1 that accommodates a 3 0V 300 mA hr lithium coin cell A supervisory circuit on the CPU Board is used to switch to battery power when the regulated 3 3Vdce VCC falls out of specification The CPU Board switches the battery voltage to the VBAT3 3 hardware signal which provides backup power for the real time clock RTC and the system SRAM on the CPU Module CI ControlWave XFC Installation amp Operation 2 25 For a unit containing 2MB of SRAM a worst case current draw of 42uA allows a battery life of approximately 7142 hours Jumper JP1 on the front of the CPU Board see Figure 2 8 must be installed to enable the battery For maximum shelf life the battery may be isolated from the circuit by removing Jumper JP1 JP1 s suitcase jumper can be stored on either of its pins CPU Boards are shipped with the Lithium backup battery installed Removal of the backup battery requires the removal of the Front Display Cover and the CPU Board To remove the backup battery on the rear side of the CPU Board pry up the Battery Securing Tab on the Coin cell Battery Socket and then remove the battery using a pair of tweezers or needle nose pliers Install the replacement battery Note This step will not be required until units have been in operation for an extended period of time normally many years as the battery life is approximately 7142
113. d cw HyperTerminal lol x File Edit View Call Transfer Help h E E Send File Oils Sal Receive File Capture Text Send Text File Capture to Printer Boot System Firmware Debug Mode Program System Flash Flash is about to be erased Hit Y to continue Initializing Flash cocci snes eee Se Ready to receive Start transmit with XMODEM 1K plus CRC CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCECCCCCCCCCCCCCCCCCCCCCCCCCCCCCC Sends a file to the remote system Figure 2 23 HyperTerminal FLASH Download Menu Ready to Download Transfer Send File Selected CI ControlWave XFC Installation amp Operation 2 31 Send File F zX Folder C Filename Browse Protocol TE modem D fend Close Cancel Figure 2 24 HyperTerminal Flash Download Send File Dialog Box 6 Close the HyperTerminal program The null modem cable connected between the ControlWave XFC and the PC can be removed if desired 7 Set CPU Switch SW1 for Local Mode i e set SW1 9 OFF and SW1 10 ON Then switch power OFF ON 1K Xmodenm file send for CWMICRO1 Sending D MyFiles CWE0410 bin Packet 51 Error checking CRC Retries jo Total retries o Last error File nm 45k of 818K Elapsed 00 00 05 Remaining 00 01 25 Throughput Eat cps cps bps Figure 2 25 HyperTerminal FLASH Download Download in Process 2 4 2 3 Remote Upgrade of Control
114. d wire running to Earth Ground should be 4 AWG It is recommended that stranded copper wire is used for this application and that the length should be as short as possible This ground wire should be clamped or brazed to the Ground Bed Conductor that is typically a stranded copper AWG 0000 cable installed vertically or horizontally The wire ends should be tinned with solder prior to installation The ground wire should be run such that any routing bend in the cable has a minimum radius of 12 inches below ground and 8 inches above ground The units Earth Ground Cable should be clamped to an exposed Ground Rod or to an AWG 0000 stranded copper Ground Cable that in turn should be connected to either an Earth Ground Rod or Earth Ground Bed Both ends of the units Earth Ground Cable must be free of any coating such as paint or insulated covering as well as any oxidation The connecting point of the Ground Rod or AWG 0000 Ground Cable must also be free of any coating and free of oxidation Once the ground connection has been established at either the Ground Rod or Ground Cable it should be covered or coated to protect it from the environment 3 3 3 Other Grounding Considerations y PHONE LINE S AT DEMARKATION POINT INSTALL COMMUNICATIONS x LIGHTNING ARRESTER ON POLE OR OUTSIDE F BUILDING AWG 10 COPPER WIRE gt SMOOTHLY DRESSED EI COMMUNICATIONS GROUND ROD gt M RADIUS 121N STRANDED CO
115. ditio nS neeaaea e E a a Eder 3 2 3 3 1 2 SOE PVCS aaea AE ON OAE A E OAA OEE cts ides E A AEE 3 2 3 3 1 3 Dry Sandy or Rocky Sol 3 4 3 3 2 Ground Wire Considerations cccccccccessessssssceceeececsenssececececesecesessaceeeeeeeesesssseaeeeeeess 3 5 3 3 3 Other Grounding Considerations cccccccsessseceseceesessnseceeecececesesesssseeeeeeeesesssteseeeeeens 3 6 3 4 ISOLATING EQUIPMENT FROM THE DIUDRLINR ccc ccccesceceesssseeeesseaeees 3 7 3 4 1 Meter Runs Without Cathodic Protection ssssssessssesssessesssseserersesssssssesrreessssssesereess 3 7 3 4 2 Meter Runs With Cathodic Protection 0 cccccesseceecceceesensececececcecsesensaeceeeeeesenensaaeees 3 7 Section 4 LIGHTNING ARRESTERS amp SURGE PROTECTORS 4 1 STROKES amp STRIKES E 4 1 4 1 1 Chance of Being Struck by Lightning cccccccssceceessececeeseeeeseseeeseessaeeeesesaeeseneaaes 4 1 4 1 2 Antenna Cation E 4 3 4 1 3 Ground Propagation cccccccccccssscecssssececssssececessseeeeesesaeeeessseeeeseeeeeseseeeeseseeeseseaeeeenes 4 5 4 1 4 Tying itall Together rainira ranis eanna SEENEN EES SEENEN 4 5 4 1 5 Impulse Protection Bumm are 4 5 4 2 USE OF LIGHTNING ARRESTERS amp SURGE PROTKRODORS 4 6 Section 5 WIRING TECHNIQUES 5 1 OVERVIEW eege ENEE ENEE 5 1 5 2 INSTRUMENT WIRING u ccccccccccccescssccccccssesscsssecesccucessesssessesccuseesesnesesesesesseesessaeess 5 1 5 2 1 Common Returns srecna perie aean e aea aa ENEE Eege 5 1
116. dows Diagnostics for Bristol Controllers cccccesssseceeeeeeees D4041A Open BSI Utilities Mantal 5 siccciscgsavunasereeeiasasaiexesnceaessaaaduereasssaeesidaiannnnseavenensieaeenae D5081 Getting Started with ControlWave Designer D5085 Wor BSE aa ani EE D5087 ControlWave Designer Reference Manual D5088 ControlWaveMICRO Quick Setup Guide D5124 ControlWave Designer Programmer s Handbook cccccccsessececececeeseesenssaeeeeees D5125 Mach View User o Wi E D5131 CI ControlWave XFC Section 1 ControlWave XFC INTRODUCTION SEET 1 1 GENERAL DESCRIPTION Model 3820 EX ControlWave XFC explosion proof gas flow computers have been designed to perform as the ideal platform for direct mount oil gas main automation measurement and data management in the oil and gas industry ControlWave XFCs measure differential pressure and static pressure and temperature for up to two runs and compute flow for both volume and energy In addition to operation in an unprotected outdoor environment the ControlWave XFC explosion proof gas flow computer provides the following key features Model 3820 EX Hardware Packaging Features e 32 bit ARM9 processor LH7A400 provides exceptional performance and low power consumption e Wide operating temperature range 40 to 80 C 40 to 176 F e Two Board System Platform CPU Comm Power Management and I O Board e Battery backup for the real time clock and the system s SRAM is provided b
117. e 1A 2 Product Features amp Overview CI ControlWave XFC Briefly this library includes function blocks for Average Compare Totalize Scheduling amp Sequencing PID amp Lead Lag AGA gas flow and liquids calculations File handling In addition ControlWave ensures data integrity in the event of a communication interruption by storing critical time stamped alarm and historical data in the controller memory This data is then securely retrieved when communication is restored 1A 3 STANDARD APPLICATION PROGRAM ControlWave XFC can come with or without a base application program that satisfies API 21 1 requirements for a meter station using up to two meter runs Using ControlWave Designer the user can readily modify this load to add or subtract functions increase the number of runs etc Overview of the base application load e Uses pre configured web pages for user readings configuration and maintenance web pages can be modified and new pages configured to work with a modified application load Application load is object oriented Standard configuration is a one run station Each run can be orifice turbine or ultrasonic meter type Flow calculations include the following e AGA38 1985 NX 19 e AGA38 1992 with selectable AGA8 Gross or AGA8 Detail e AGA7 NX 19 e AGAT with selectable AGA8 Gross or AGA8 Detail e Auto Adjust AGA7 NX 19 e Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail e Instromet Modbus AG
118. e 63148 62 9 Polydimethylsiloxane 16 OTHER INFORMATION Prepared by Dow Corning Corporation These data are offered in good faith as typical values and not as product specifications No warranty either expressed or implied is hereby made The recommended industrial hygiene and safe handling procedures are believed to be generally applicable However each user should review these recommendations in the specific context of the intended use and determine whether they are appropriate R indicates Registered Trademark Supplement Guide S1400CW Issue 04 05 A Guide for the Protection of Site Equipment amp Personnel In the Installation of ControlWave Process Automation Controllers Bristol Babcock NOTICE Copyright Notice The information in this document is subject to change without notice Every effort has been made to supply complete and accurate information However Bristol Babcock assumes no responsibility for any errors that may appear in this document Request for Additional Instructions Additional copies of instruction manuals may be ordered from the address below per attention of the Sales Order Processing Department List the instruction book numbers or give complete model number serial or software version number Furnish a return address that includes the name of the person who will receive the material Billing for extra copies will be according to current pricing schedules ControlWave is a re r
119. e DIs and 4 non configurable externally powered DOs Each DI provides either a 60uA source current from 3 6Vdc Open drain MOSFETs associated with each DO provide up to 400mA each 30Vdc to an externally powered device Field wiring assignments are provided in Figure 2 10 2 3 3 4 Non isolated Analog Input Connector Block J4 see Figure 2 10 ControlWave XFCs contain field interface circuitry for up to three 8 Analog Inputs 1 to 5V operation Field power source can be from the ControlWave XFC s V supply where V Input Power 6Vde and doesn t exceed 15Vdc or an external 11 to 30Vdc power source Each AI signal is channeled through signal conditioning circuitry that provides a 2 Hertz low pass filter a transorb for surge suppression multiplexer and an A to D Converter ADC CI ControlWave XFC Installation amp Operation 2 19 2 3 3 4 1 Analog Input Configurations Analog Input circuitry supports inputs from 1 5V devices Field wiring assignments are provided in Figure 2 10 Note Cable shields associated with AI wiring should be connected to the ControlWave XFC s Chassis Ground Post on the Terminal Plate 14 AWG wire size Max 2 Ground Posts are provided Multiple shield terminations will require a user supplied copper ground bus This ground bus must be connected to the ControlWave XFC s Chassis Ground Lug using up to a 4 AWG wire size and must accommodate a connection to a known good Earth Ground i
120. e XFC Appendix F F 31 Common Fixed Data When COMMON is selected fixed chromatograph values for all runs will come from the Stream 1 fixed values When INDIVIDUAL is selected fixed chromatograph values will come from the individual stream assigned to each run Port Number When a chromatograph is present this is the port number on the Control Wave XFC that the chromatograph is connected to The Default Port in the load is Port 3 MODBUS Address When a chromatograph is present this is the MODBUS Address 1 246 of the chromatograph Serial or IP Select the appropriate Interface for the Chromatograph IP Address Enter the IP Address of the Chromatograph in dotted decimal format e g XXX XXX XXX XXX F 7 2 Stream Assignment and Setup The Daniel 2251 can provide gas properties for up to 4 individual streams The standard application program allows the user to assign any stream to any meter run up to two streams and two runs Each meter run may be assigned to the same stream or each may be assigned to a different stream In the event of a chromatograph failure the user may assign either fixed values to use for each gas component or the last good values retrieved from the chromatograph This mode is selectable on a per stream basis F 7 3 Analysis Data The Raw values of BTU and Specific Gravity from the Chromatograph will be displayed for each stream Fixed values for BTU and Specific Gravity may be entered for each
121. e XFC for Flow Rate Control Sections F 5 5 1 through F 5 5 4 provide information on the four major functions accessible from the Flow Control amp Valve Control Web Page see Figure F 9 Flow Control amp Valve Control Nomination Function Disabled Status Stopped Flow Control Enable Disabled SetPoint Ramp Rate eons Setpoint x1000 0 0000 M3 HOUR 100 0000 poo aa 0 0000 Gain 1 0000 Integral 1 0000 Derivative 0 0000 Current Data Deadband 1 0000 Percent Flow Rate x1000 0 0000 M3 HOUR qe 2292 M3 HOUR Valve Travel 30 0000 Seconds Time Pressure Override set one or both to enable override Maximum 0 0000 KPA Pressure Tap Location Relative to the Control Valve Minimum 0 0000 KPA Up Stream Valve Control Control Type Analog Output AO Zero amp Span Current Data Analog Output Point ID 1 Analog Output 0 00 Raise ra Point 1 LL Raise DO Off Lower re Point 2 j Eower O of Output Control Auto Not applied under PID Flow Control Manual Analog 0 00 AO Ramp Rate 1 00 per Second Output Manual Raise Output SSS Manual Lower Output SS Figure F 9 Flow Control amp Valve Control Web Page CI ControlWave XFC Appendix F F 11 Users are cautioned to test the regular override controller actions to verify correct valve movement for all expected conditions F 5 5 1 Nomination Function The Nominations Function provides for enabling disabling the nominations feature see Section F 5 3 If this signal is set to the disa
122. e and Path each box and checking Save Archive Data the file will be saved by clicking OK on the Save Parameters Dialog The file saved is a binary file To view the file the user may use the Data File Conversion Utility or the UOI Dump Utility UOIDMP exe By clicking on the Floating Point Format button the user may change the way Analog Values are displayed By clicking on the File Definition button the user can view how the archive file is configured Additionally the Meter Run Archive Web page provides the number of Fields Collected and Records Collected under the Stats field F 8 2 Meter Run Audit Trail The ControlWave XFC keeps an Audit Trail Buffer capable of storing the most recent 500 Alarms and the most recent 500 Events Internally these buffers are maintained separately to prevent recurring alarms from overwriting configuration audit data F 34 Appendix F CI ControlWave XFC Externally they are reported to the user as a single entity Both operate in a circular fashion with new entries overwriting the oldest entry when the buffer is full Collect Data Say fe SEG Ad atiis Eer Date Time 15 09 54 000 12 MAY 2005 15 13 18 000 12 MAY 2005 15 16 31 000 12 May 2005 15 17 04 000 12 May 2005 15 17 07 000 12 MAY 2005 15 20 15 000 12 MAY 2005 15 20 18 000 12 May 2005 15 23 35 000 12 May 2005 15 23 38 000 12 May 2005 1 15 28 03 000 12 May 2005 i 15 28 05 000 12 May 2005 Request Audit Collection
123. e main meter run directly or via two pipes see Figures 2 4 through 2 6 The unit must be positioned so that the front of the assembly is visible and the unit is accessible for service i e replacement of the Lithium Battery or installation removal of any field wiring etc Make certain that the LCD Display is accessible and visible to the on site operator Power wiring should not be connected to its source until the unit has been mounted and grounded at a designated work site I O wiring external power wiring RTD cabling local comm port and network RS 232 and RS 485 Communication Port cabling enter the top of the unit though 3 4 14 NPT conduit fittings I O wiring may be routed through the right side of the unit when facing the front This requires that the hole plug be removed and replaced with a 3 4 14 NPT Conduit Fitting If a bendable RTD is used it will be provided with a 2 8 Installation amp Operation CI ControlWave XFC weather proof conduit fitting for installation in Class I Division 2 Groups C amp D locations only 2 3 1 1 Connection to a Multivariable Transducer MVT One Multivariable Transducer MVT secured to the bottom of the enclosure can be provided with each ControlWave XFC Figure 2 4 details MVT process flange and optional manifold block connector mounting dimensions The MVT provides connection ports on the process flange as the standard arrangement Optional manifold blocks may
124. e main Bristol Inc number 860 945 2200 if you are unsure which office covers your particular area Visit our Site on the World Wide Web For general information about Bristol Inc and its products please visit our site on the World Wide Web at www bristolbabcock com Training Courses Bristol s Training Department offers a wide variety of courses in Bristol hardware and software at our Watertown Connecticut headquarters and at selected Bristol regional offices throughout the year Contact our Training Department at 860 945 2343 for course information enrollment pricing and scheduling CI ControlWave XFC ControlWave XFC Explosion Proof Gas Flow Computer INSTALLATION FORWARD NOTE for all ControlWave XFC Installers READ THIS SECTION FIRST This manual has been designed for the following audience e Customer Site Engineers who must plan for the installation and implementation of the ControlWave XFC e Instructors who must become familiar with and teach Field Engineers Technicians on the installation operation and repair of ControlWave XFC e Field Engineers Technicians who must install and service the ControlWave XFC Installation instructions for the ControlWave XFC are provided in Section 2 of this manual Section 2 Installation amp Operation provides a detailed overview of the installation and operation of the ControlWave XFC Section 2 provides all the information required for instructors who are trainin
125. e 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 57x 10 Chart 1 Chart 2 I A LAT B 5 8 25 170 10 26 30 200 20 85 35 236 30 169 40 280 40 275 45 325 50 402 60 548 70 712 Note for these charts 80 893 I Thunderstorm Days Per Year Isokeraunic Number 90 1069 A Stroke activity for associated Isokeraunic Area 100 1306 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
126. e radio returns to sense mode This mode allows the system to use as little energy as possible to detect traffic throughout the day Energy usage depends on the activation time and activation rate INTERVAL Assuming a 1 watt radio then a 200 millisecond listening period every 5 seconds is equivalent to 04 watts Users can configure the Interval and Rate Listening period to suit their energy needs Radio Sensing occurs between the START HOUR and END HOUR specified by the operator Radio amp Modem Control Configuration Radio Modem Control Mode No Control Common Properties Local Address 1 Activate Radio Modem on Local Port Active Group Number 0 Disabled Start Hour Listen Interval Start Time Offset Into Hour Poll Time Per Node Poll Time Per Group Listen Time Re Calculate Next On Time Daily Mode Hour Offset Day Light Mode Start Hour Day Light Mode Start Minute Current Hour Radio On Time Day Radio On Time Month Radio On Time Radio Sensing Mode 0 End Hour 23 Listen Time Out 50 msec 4000 msec Hourly Mode 5 Gennes Next On Time Hour Next On Time Minute Next On Time 5 Seconds Second 0 Turn Off Delay 5 26 Seconds 18 Seconds Seconds Re Calculate Daily Mode Day Light Mode Day Light Mode End Hour Day Light Mode End Minute Statistics Previous SE Hour Radio On 0 Time Day Radio On Time Month Radio On Time Seconds Seconds 0 Seconds Seconds 0
127. e to a leaking battery b Absorption Not anticipated 4 Eye Contact Irritation may occur following exposure to a leaking battery 5 Other Not applicable E ENVIRONMENTAL IMPACT 1 Applicable Regulations A ingredients listed in TSCA inventory 2 DOT Hazard Class Not applicable 3 DOT Shipping Name Not applicable While lithium batteries are regulated by IATA and ICAO the type of lithium batteries offered for sale by DURACELL are considered non hazardous per provision A45 of the IATA Dangerous Goods Regulations and provision A45 of the ICAO Technical Instructions For The Safe Transport Of Dangerous Goods By Air Per section A45 of the IATA and ICAO regulations properly marked labeled and packaged DURACELL consumer lithium batteries which are of the solid cathode type with less than 1g lithium per cell and less than 2g lithium per battery are exempt from further regulation When these batteries are separated to prevent short circuits and properly packaged in strong packaging except when installed in electronic devices they are acceptable for air transport as airfreight without any other restrictions In addition when installed in equipment or when no more than 24 cells or 12 batteries meeting the A45 provision are shipped they are not subject to special packaging marking labeling or shipping documentation requirements Thus these batteries are not considered hazardous under the current regulations and are acceptable for air tr
128. e valve opens to increase the flow rate Increasing demand will cause the valve to open more Should conditions occur that cause the pressure to exceed the maximum pressure limit the override will take control and close the valve to maintain the configured maximum pressure Should the valve attempt to close and reduce pressure below the configured minimum pressure the override will take control to maintain the minimum pressure When the pressure tap is configured as Upstream the action is reversed 1 e when the maximum pressure is exceeded the valve will open to lower the pressure When the minimum pressure is exceeded the valve will be closed F 5 5 4 Valve Control A user may select the Valve Control type Le Analog Output or Raise Lower control via the Digital Outputs If the operator selects Analog Output control Analog Output 1 will be used by default Current Data will show the value of the Analog Output in percent 4mA 0 20mA 100 CI ControlWave XFC Appendix F F 13 Users may set the valves Output Control into either Manual or Automatic Auto When Manual Mode has been selected the current value of the Analog Output will be frozen Users may change the Manual Analog Output value by right clicking on the field and entering a new value When the mode is changed back to Automatic the valve control starts from the last Manual value entered for Bumpless transfer If the user selects Raise Lower Mode the DO associated
129. ect Starts list collection Select this button to change the appearance of Floating Point Values Appendix F F 35 Signal List Signal List Information Number 3 Start Index D Max Signals to Collect fio Signal Name Data Type Alarm Control Manual GV GC_ 1_FIXED_BTU GV GC_ 1_FIXED_C3 GV GC_S1_FIXED_CH4 GV GC_ 1_FIXED_CO2 GV GC_ 1_FIXED_IC4 at GV GC_ 1_FIXED_ICS CE GV GC_S 1_FIXED_N2 GV GC_ 1_FIXED_NC4 GV GC_S1_FIXED_NC5 Signals Collected 10 Figure F 25 Signal List Web Page F 8 4 Archive File Collection When Collection is selected an Archive File Collection Web Page see Figure F 26 will be displayed Log Break Configuration buttons are provided on the Archive File Collection Web Page to enable disable log breaks for configuration changes and Gas Chromatograph operation and configuration Log Breaks are Disabled by default Archive File Collection for Run 1 Station Name NM NM Station Name 2222 Directory C OpenBSI WebxFC Logs Directory C OpenBS WebxFC Logs Log Number Type Description Audit Audit Trail AUD Log Break Configuration ____Disabled__ Gas Chromatograph __Disabled Figure F 26 Archive File Collection Web Page F 36 Appendix F CI ControlWave XFC F 9 LOAD SAVE CATEGORY FUNCTION One WebBSI Web page is accessible under the Load Save Category Section of WebBSI this is called the Meter Run Save Load Configuration Web
130. ed to create user defined pages to access ControlWave The web pages are populated with these pre configured ActiveX controls and are stored at the PC 1A 3 3 2 Required Software Microsoft Internet Explorer Bristol Babcock ActiveX controls OpenBSI LocalView or NetView 1A 3 4 Historical Data Collection High Historical Data Integrity The ControlWave Historical Data Collection system offers exceptional historical data integrity by providing time stamped historical data storage in ControlWave flash memory The historical data is collected through OpenBSI on a scheduled or demand basis and converted to CSV and ODBC compliant file formats for use in spreadsheets and reports If data is missed due to a communication failure it is collected when the communication is reestablished and the PC historical database is back filled with the missing data This distributed historical database architecture provides the greatest data reliability and integrity during communication or PC failure Another important historical feature is the Audit storage and collection system The Audit Trail is a file stored in ControlWave flash memory containing significant events and time stamped alarms The alarms stored in the Audit system provide a historical archive in addition to the real time alarm reporting system This file is also collected through OpenBSI and presented as a text file in the PC This functionality is extremely useful in providing an event trail d
131. eeesesestaseeeceeesenes F 2 Weblol PROGRAM STARTUP ee ee ee ee EC Ee F 2 SECURITY CATEGORY PUN CW LA F 3 Sionin OnO enger F 3 Selecting a Node and Signing ON F 3 Signing Off from the Node F 4 LOCA time Nod Sienen an AnA AE AA A E E RE F 4 e EE F 4 S LATION CATEGORY FUNCTIONS nnter nn aE vincent F 4 LATION ERT deed ege DASS eegen HA Sampler and Odorizer Configuration ccccccccccesssececsesseeeceesseeeceesseeecsessseeecseseeeeneaaes F 6 Sampler Configuration seeneniit iriri enro ar iE EEOAE AE S i F 6 Odorzer Conn eurai one EE E ANETE F 6 Mechanical Counter Configuration ccccccccsssssssecececeesesssseceeececeesessaeceeceeesesenssaeeeeess F 6 Kl Ste CG F 7 Nomination Operations suiccesssveieceassdssoseasicee sass ceeseveseecseasdeses besieged EENS dee F 7 Enabling the Nomination Function ccccsesscececeeessennececeeceeeeeseeseaaececeeeenseesenteaeesenens F 8 Beginning a Nomination PDenod F 10 Ending a Nomination Derod aiei ai aei F 10 Changing the Nomination Target F 10 Manually Starting Ending a Nomination Deriod F 11 Flow Control amp Valve Control F 11 Klee CG F 12 Fow Controls 6c0 iaa E acne E EE A T actica ee caassbeeacansest OET F 12 Pressure Override set one or both to enable override cccccssccesessseceessseeeeeeeeeaees F 13 Valve COTO Do a EEE EE A E EEES F 13 R n Swite hina deineann EE A TENE E EOE R OA ETO AE a F 14 Common Properties cccccccccesssssscecesececeessssececececcece
132. egistered trademark of Bristol Babcock Other trademarks or copy righted products mentioned in this document are for information only and belong to their respective companies or trademark holders Copyright c 2005 Bristol Babcock 1100 Buckingham St Watertown CT 06795 No part of this manual may be reproduced in any form without the express written permission of Bristol Babcock Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION GROUNDING amp WIRING PE TABLE OF CONTENTS SECTION TITLE PAGE Section 1 INTRODUCTION 1 1 GENERAL INTRODUCTION ccc conceded weenie ete ied eae eed 1 1 1 2 MAJOR Kl L 1 1 Section 2 PROTECTION 2 1 PROTECTING INSTRUMENT OVODEMS 2 1 2 1 1 Quality Is Conformance To Requirements ccccccccceessssssceceeeceeeessnsseeeeeeeseeessnssaeeeeees 2 1 2 2 PROTECTING EQUIPMENT amp DERGONNRL 2 1 2 2 1 Considerations For The Protection of Dersonnel 2 2 2 2 2 Considerations For The Protection of Koummment 2 2 2 3 OTHER SITE SAFETY CONGIDERATIONSG ccccccccccccceccecessssssceeeeeceeeerssseeeeeeeees 2 3 Section 3 GROUNDING amp ISOLATION 3 1 POWER amp GROUND SYSTEMS serpesrivirrsssrrsirrissr irirn niinko sitk Kitto stt sn Keent srania 3 1 3 2 IMPORTANCE OF GOOD GROUNDR reisas 3 1 3 3 EARTH GROUND CONNROTIONS inienn irea iik 3 1 3 3 1 Establishing a Good Earth Ground cccccscssccceceesesensececececeeesesesnaeceecceesesesssseaeeeeeess 3 1 3 3 1 1 GU Con
133. eississrirrerrreirssarriirrioirsiirrenttrititrraa k Errar EriAN EARANN AN Rana 1 1 ControlWave PROGRAMMING ENVIRONMENTT 1 3 PHYSICAL DESCRIDITION ccccccccccssececesssececeeesseeecseseeeeessaeeecsesaeeeeesesaeeeesesaeeeesaas 1 5 SE 1 5 ControlWave XFC Function Module 1 6 CPU Board Asgem bleifs ENEE EIERE ENNEN 1 6 CPU Board Connector Di 1 8 CRU Memory ss cssccccaassccaietassevecdiaveaecaas iniiai aussi NaN ARASEN AAS TANS RSE AE ES NRA Enans ANAE iaai 1 9 CPU Board Battery Enable Configuration Jumper 1 9 BREED 1 9 CPU Board General Purpose Configuration Switche WI 1 9 WO Board Ass erly vs iccscasicccasaastaccscaescvessaviadecaaasnccdsavinccsaa atin casaannvessar aseisaseuvedanveneceaaded 1 10 VO Board Connectors isicsccaciivsecsassasucescaiesesncdinueandedveaccdiausast vduscnaadaaeadediaasenid tastanedvevses 1 10 Terminal Plates isccsicascecesevieinascdebeciasviesed sbsceatacaus a E chtatdeasaasennaaa ce 1 11 Field VO Wiring cccccccccssccccesssececesssececesseeeccssaeeeeseaeeecessseeeeessaeeesessaeeeensaeeesesseeeneea 1 11 Non isolated Analog UO 1 11 Non isolated Digital UO 1 12 Non isolated High Speed Counter Inputs ccccecccccecesssececeesseeeeesseeeesesaeeeeseseeeeee 1 12 Optional RTD Input Probe ccc ccccccceessceeessseceeeeseeeeeeeseeeeeesseeeeceseeeeeeeseseaeeeeseeaaeens 1 13 Terminal Plate Input Power Connection 1 18 Terminal Plate Communication Port Connection 1 18 Multivariable or Gage Pressure Transducer 1
134. enei a sanetedisaetdsveagssdessraresiveaseeedstaees F 23 Alarm Configuration Accessed via Meter Run I O Conbeuraton F 24 Flow Egq ati ns serscincoononee einiaid oE i A EREE E Rii F 25 Orifice Flow Equation Hetun F 25 Differential Measurement F 25 1985 AGAS Equation Confeuraton irei ireiiii F 25 1992 AGAS Equation Confeuraton irent eE nE EET EaR iae F 27 Frequency Flow Equation Hetun F 29 Supercompressibility Setup ssr rrrcirrniisrrrirrisi irruti stnrns errnet SEEN ESSEEN EENE EEEE F 30 CHROMATOGRAPH CATEGORY FUNCTIONS sseassessezcsarsssacerat arrai niskara F 31 opereiert Ee F 31 Stream Assignment and Setup ccccccsssscccssssececssssececsessececeeseeecsesseeecsesseeeessseeeeseaas F 32 A tially sis Dieter F 32 Gas ee F 32 Chromatograph Component Range Setup cccsccccesssscecessseeeesesseeeesssueeeesssseeeensea F 32 LOGS CATEGORY FUNCTION EE F 33 Meter Run Archive les F 33 Meter Run Audit Trial erir en re O O R O EOS F 34 View Sigal RE EE F 35 Archive File Collection syecoesscvetas shastie tans ceeeste cddaceedad ccesurdcavanes a a a F 36 LOAD SAVE CATEGORY FUNCTION E F 37 SPECIAL FUNCTION S accion nnd TIERES KIIREET F 38 CI ControlWave XFC Appendix F Using ControlWave XFC WebBSI Web Dages 0 2 Appendix F Using ControlWave XFC WebBSI Web Pages F 1 GENERAL OVERVIEW The ControlWave XFC is configured and monitored using WebBSI Web pages developed specifically for the standard application program The Web pages a
135. equipped with a Gage Pressure Transducer can ONLY be mounted to a vertical or horizontal 2 pipe via a pipe clamp bracket and adapter blocks see Figure 2 2B If used the 2 pipe is to be anchored in cement deep enough to conform to local building codes associated with frost considerations The basic unit measures CI ControlWave XFC Installation amp Operation 2 5 approximately 6 156 in height by 5 00 in width by 6 190 in depth A GPT Transducer adds approximately 1 720 to the height of the unit while a MVT Transducer adds approximately 3 020 to the height of the unit see Figures 2 2 and 2 3 Note Units equipped with a Gage Pressure Transducer CANNOT be directly mounted to the Main meter run VERTICAL E Fe MOUNTING F O CA WI T J ia Ch _ HORIZONTAL pmen d MOUNTING J d a D a WII VO ee ees y Si Figure 2 2A ControlWave XFC P
136. ere psig The following outputs from the AGA3 calculation are displayed MSCF H Flow rate in thousands of standard cubic feet per hour Low Flow Cut Off Cutoff if the DP drops below the low flow cut off value or OK C Prime Orifice Flow Constant Fb Basic Orifice Factor F 26 Appendix F CI ControlWave XFC Fr Reynolds Number Factor Y Expansion Factor Fpb Pressure Base Factor Ftb Temperature Base Factor Ftf Flowing Temperature Facture Fg Specific Gravity Factor Extension Square Feet of the Product of Differential Pressure and Static Pressure F 6 3 1 3 1992 AGA3 Equation Configuration The user must configure the inputs to the equation Pressure Tap The user must toggle between pressure tap settings Flange Upstrm and Flange Dnstrm Low Flow Cut Off When the differential pressure drops below the low flow cut off value the flow rate will be set to zero Default units are inches of water H20 1992 AGA3 Equation Configuration for Run 1 Click Here to Select AGAITERM 1985 AGA3I 1992 Version Inputs Outputs Name Value Units Name Value Pressure Tap E Flange UpSirm 4 Flow 0 000 Low Flow Cut Off 0 2500 INH20 Flow Units FT3 HOUR Orifice Diam 2 0000 INCH Low Flow Cut Off Cutott Pipe Diam 4 0260 INCH C Prime 0 000 Orifice Material Stainless Fn 0 000 Pipe Material Carbon CD 0 000 isentropic Exponent 1 30 E 0 000 Adjust Press 14 73 PSI Y 0 000 Diff Press 0 000 INH20 Fpb 0 000 Static Pre
137. eseseaeeeeecsesesesaeseeeeeesesensaaaaeeeeeeeees F 14 Runi amp 2 Properties sccccccscdicces cacevscacassevedeavabecassdoncedan ENa EEAS EEN F 15 Radio and Modem Control F 15 Radio Modem Control Mode F 15 Common Properties cccccccccessesssceceeececsessssececccecceceessssaaeeeeececsensaeeeeeeeeeesensaaaaeeeeeeeees F 15 Radio Sensing Mode F 15 Or ly MO TT F 17 Daily EE F 17 Day Light Mode F 17 SE E F 17 METER RUN CATEGORY BPUNCTIONS ss viescidieciicieieninsmanintiwnns F 18 Meter Run Overview ccccscsecsssssesesssseesecssseececeeseeeecsesaeeeceeesaeeseeesaeesesesaeeeesesaesecneaaes F 18 CI ControlWave XFC Appendix F Using ControlWave XFC WebBSI Web Pages 0 1 SECTION F 6 1 1 F 6 1 2 F 6 2 F 6 2 1 F 6 2 2 F 6 2 3 F 6 2 4 F 6 3 F 6 3 1 F 6 3 1 1 F 6 3 1 2 F 6 3 1 8 F 6 3 2 F 6 4 Bo F 7 1 F 7 2 F 7 3 F 7 4 F 7 5 F 8 F 8 1 F 8 2 F 8 3 F 8 4 F 9 F 10 APPENDIX F ControlWave XFC Using ControlWave XFC WebBSI Web Pages TABLE OF CONTENTS TITLE PAGE AGAS Orifice Meter ccscsssssecesnccessccssscecssncecessccesacsssaseecssaaeensccessuscseaaeceseasesseeenes F 18 AGAT Frequency Meter icceccccssescieenctececdincetesdieiebeadieutec EO OAO EO O OAE F 20 Meter Run VO Confeuraton F 21 Differential Pressure Static Pressure and Temperature Inputs sssss snssssssssssee0r1s F 22 HV OQt enGy INput 0 ecedevcen sveedssdeizcesiedevenses Liege Eed Eege edd F 23 Heating Value Up utc ocres e
138. et Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail e Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail e Includes run switching e Includes an auto selector PID flow pressure control algorithm per run or per station e Interfaces to a chromatograph and provides energy throughput as well as composition information requires the optional Expansion Communications Module e Resides on a BSAP SCADA network e Supports samplers and odorizers e Provides audit trail and archives e Includes a nominations function e Allows the user to select engineering units including English and metric The primary function of the ControlWave XFC is to measure the flow of natural gas in accordance with API American Petroleum Institute and AGA American Gas Association standards Items below implement and supplement the primary function e Data acquisition see Section 1 5 1 Flow calculations see Section 1 5 2 Data archives see Section 1 5 3 Audit trail archives see Section 1 5 3 4 Local display see Section 1 5 4 Communications see Section 1 5 5 Control outputs see Section 1 5 6 Status inputs see Section 1 5 6 Self test and diagnostics see Section 1 5 7 1 5 1 Data Acquisition The process inputs used by the ControlWave XFC are static pressure differential pressure and temperature for orifice measurement or static pressure temperature and frequency input for positive displacement PD turbine or ultrason
139. formation 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 Vi Vs Vc F Vo where Vce Vc Rc zk Rc I 22 24 2 where 2V 20Q x0 1A ANS lt yY l gt SUPPLY an Ge j LOAD Sec Ze r KA BEN K Ve is the loss in the conductor It is equal to the Resistance of the Conductors times the Current through them Vs Ve Ve V Figure 5 2 Calculating Load Voltage due to Line Resistance 5 2 9 Lightning Arresters amp Surge Protectors Use lightning arresters in association with any radio or modem equipped unit BBI 9600 bps modems are equipped with surge protection circuitry Lightning arresters or Antenna S1400CW Page 5 4 Section 5 Wiring Techniques Discharge Units should be placed on the base of the antenna and at the point where the antenna lead typically coax enters the site equipment building When a modem
140. from a low of 1 to a high of 100 10 H 30 30 z j a 20 45 om i 30 40 5 40 30 ep 20 C 40 10 A i l a 20 i l 30 4 50 40 50 i 30 35 35 i ep A0 EI L on SH eg I01 a w 50 i En 50 8 510 i 30 SH 10 10 a 60 20 30 40 A ee Leben 80 60 70 25 25 50 40 30 30 80 Figure 4 1 Average Thunderstorm Days of the Year for Continental USA Section 4 Lightning amp Surge Page 4 1 S1400CW Thunderstorms are cloud formations that produce lightning strikes or strokes Across the United States there is an average of 30 thunderstorm days per year Any given storm may produce from one to several strokes Data on the subject indicates that for an average area within the United States there can be eight to eleven strokes to each square mile per year The risk of stroke activity is increased for various areas such central Florida where up to 38 strokes to each square mile per year are likely to occur To determine the probability of a given structure tower building etc within your location being struck perform the following computation 1 Using the map of Figure 4 1 or a comparable meteorological map for your local find the Isokeraunic level I for your area Then using Chart 1 find A for your area 2 Refer to Figure 4 1 to find the latitude Then using Chart 2 find B for your latitude Lat 3 Multiply A x B to get C 4 To calculate th
141. g individuals unfamiliar with the ControlWave XFC It is also intended to support anyone who needs to learn how to install and operate the Control Wave XFC for the first time or as a reference document for those who are already familiar with the unit NOTE A Windows driven diagnostic tool referred to as WINDIAG is provided on the OpenBSI Software CDROM WINDIAG is documented in instruction manual D4041A Window Diagnostics for Bristol Controllers Bristol s WINDIAG program provides menu driven diagnostics that have been designed to assist a technician or Process Engineer in troubleshooting the various ControlWave XFC circuits A brief overview is provided in Section 3 5 of this manual For more detailed descriptions of ControlWave XFC Windows Diagnostics than those provided herein see Document D4041A Chapters 1 and 7C CI ControlWave XFC Installation Forward CI ControlWave XFC ControlWave XFC Model 3820 EX Explosion Proof Gas Flow Computer SECTION 1 1 1 2 1 3 1 3 1 1 3 2 1 3 3 1 3 3 1 1 3 3 2 1 3 3 3 1 3 3 4 1 3 3 5 1 3 4 1 3 4 1 1 3 5 1 3 5 1 1 3 5 1 1 1 3 5 1 2 1 3 5 1 3 1 3 5 1 4 1 3 5 2 1 3 5 3 1 3 6 1 3 7 1 4 1 5 1 5 1 1 5 2 1 5 2 1 1 5 2 2 1 5 2 3 1 5 2 3 1 1 5 2 3 2 1 5 2 4 1 5 3 1 5 3 1 1 5 3 2 1 5 3 3 1 5 3 4 1 5 4 1 5 5 1 5 5 1 1 5 6 1 5 6 1 1 5 6 2 1 5 6 3 1 5 7 TABLE OF CONTENTS TITLE PAGE Section 1 ControlWave XFC INTRODUCTION GENERAL DESCRIPTION er
142. g the open system network technologies available through TCP IP Ethernet OPC and Microsoft DNA as well as pseudo standards such as Modbus and Open Modbus ControlWave can provide a total Process Automation Management Solution for in plant LAN based networks and Wide Area Network SCADA systems With the exceptional connectivity provided by the ControlWave network access to real time data and operating conditions historical data maintenance and performance data are all available to the global network ControlWave provides the needed information to the plant floor technician operator engineer supervisor and corporate management even external customers 1A 4 1 Communication Protocols Like all Bristol Babcock products ControlWave supports BSAP Bristol Standard Asyn chronous Protocol Modbus DF1 DNP 3 serial and serial ASCII as standard functions These protocols are implemented in Flashware so no additional hardware is required to use any one or a combination of all protocols 1A 4 1 1 BSAP Protocol BSAP All Bristol Babcock Network 3000 and ControlWave RTU and controller products support BSAP protocol BSAP is widely accepted as providing exceptional data integrity and greatly simplifies communication between controllers BSAP is provided with interfaces for Master Slave vertical networks and Client Server horizontal networks In either case variable lists are created in each controller that are easily passed from server to cl
143. grammed time because of the time required to close open valves or complete other actions The days are valid even if the daily nomination mode is active 3 Program all the configuration items for the NEXT Nomination Period such as start and stop times and target value 4 Set the desired parameters for NOMINATION CONTROL such as Quantity units Control mode Stop mode Daily only mode and Alarm at a level of and then set the Main function signal to the Enable State 5 If a radio or modem is to be used in conjunction with a logical nomination alarm access the Radio amp Modem Control Configuration Web Page see Figure F 12 via the Radio Control button See Section F 5 6 to configure the radio or modem for logical nomination alarms F 5 4 1 2 Beginning a Nomination Period When no nomination period is in progress the ControlWave XFC compares the NEXT start date and time to the current time If the date and time match or time only for the daily nomination mode a new period is begun The current time is copied into the CURRENT START signals and the next target is copied into the current target The ac cumulators for the current period are zeroed and the current stop time is set to the next start time If the PID mode is selected a new flow setpoint is calculated and stored in the setpoint signal The PID setpoint is recalculated every 15 minutes and whenever any parameter is changed F 5 4 1 3 Ending a Nomination Period If s
144. h selectable AGA8 Gross or AGA8 Detail Instromet Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail e WebBSI Web pages are preconfigured for all user operations e Additional standard application programs will be introduced on a continual basis e Using our ControlWave Designer IEC 61131 3 Programming Environment any user or third party can modify the standard application or create a completely customized program full support from Bristol Babcock is available every step of the way CI ControlWave XFC Introduction 1 1 e ControlWave XFCs are compatible with Bristol Babcock s TeleFlow series in software and networking solutions for SCADA and EFM Electronic Flow Meter data editing management and are similar in all operations ControlWave XFC explosion proof gas flow computers are furnished in an explosion proof enclosure In addition to the explosion proof case enclosure the gas flow computer hardware is comprised of an internal Function Module and either a Multivariable Transducer MVT or a Gage Pressure Transducer GPT that is mounted on the bottom of the enclosure The Function Module consists of a CPU Board System Controller amp I O Board an LCD Display Module a Terminal Plate Assembly and mounting hardware Sharp s LH7A400 System on Chip Advanced RISC Machine ARM microprocessor with 32 bit ARM9TDMI Reduced Instruction Set Computer RISC is the core of
145. he purchase or use by Buyer its em ployees or other parties of goods sold under said agreement How to return material for Repair or Exchange Before a product can be returned to Bristol for repair upgrade exchange or to verify proper operation form GBU 13 01 must be completed in order to obtain a RA Return Authorization number and thus ensure an optimal lead time Completing the form is very important since the information permits the Bristol Repair Dept to effectively and efficiently process the repair order You can easily obtain a RA number by A FAX Completing the form GBU 13 01 and faxing it to 860 945 3875 A Bristol Repair Dept representative will return call or other requested method with a RA number B E MAIL Accessing the form GBU 13 01 via the Bristol Web site www bristolbabcock com and sending it via E Mail to brepair bristolbabcock com A Bristol Repair Dept representative will return E Mail or other requested method with a RA number C Mail Mail the form GBU 13 01 to Bristol Inc Repair Dept 1100 Buckingham Street Watertown CT 06795 A Bristol Repair Dept representative will return call or other requested method with a RA number D Phone Calling the Bristol Repair Department at 860 945 2442 A Bristol Repair Depart ment 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 co
146. he target or leave it in its last position Figure F 8 Nomination Web Page F 5 4 1 Nomination Operation See sections F 5 4 1 1 through F 5 4 1 5 CI ControlWave XFC Appendix F F 7 F 5 4 1 1 Enabling the Nomination Function The nomination function runs once per calculation cycle after the volume and energy accumulations have been updated by the ControlWave XFC To setup and enable this feature follow the steps below 1 Setup of the nominations feature depends on the desired control mode selection i e the Fast approach mode or PID mode Fast approach mode is the default mode for nominations If the desired control mode is the Fast approach mode proceed to step 2 however if the desired control mode selection is the PID mode you must first program all the PID tuning parameters such as gain and integral Note DON T enable the PID flow control algorithm or the ControlWave XFC will automatically disable nomination When properly configured the ControlWave XFC will automatically enable the PID flow control algorithm during nomination periods 2 Select the Nomination Web Page Figure F 8 via the Nomination button under the Station Category Function also see Figure F 9 A description of the menu entries Figure F 8 used to implement the nomination func tion follows NOMINATION CONTROL In addition to the Time this section of the Nomination Web Page provides the following eight areas for nomination setup selection
147. hut in on stop mode is in use the current period will end when the target accumulation is reached At this time the ControlWave XFC attempts to close the control valve If PID control is being used the setpoint is set to 0 0 the current cycle will ramp down accordingly When the flow rate reaches 0 0 the current cycle accumulations and the actual end time are copied into the LAST signals If the valve fails to close the volume will continue to accumulate until the programmed end time If the shut in on stop mode is not in use the nomination period continues until the programmed end time F 5 4 1 4 Changing the Nomination Target To change the target of the next period the user should change the NEXT TARGET signal F 10 Appendix F CI ControlWave XFC F 5 4 1 5 Manually Starting Ending a Nomination Period When a Nomination Period is not in progress the user can immediately begin the NEXT period by setting the Status signal to the ON state The current start time will reflect the time that the user started the cycle The target and stop times used will be those of the NEXT period The user may immediately end a nomination period which is in progress by setting the Status signal to the OFF state The current time will be stored as the LAST stop time F 5 5 Flow Control amp Valve Control The Flow Control amp Valve Control Web Page Figure F 9 is accessible via the Flow Control button The PID Controller is utilized in the ControlWav
148. iboground 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 Braze on AWG 0000 Drill Holes Copper Wire Lead y as ss es Ss 6 5 S68 a Pack with Satt 1 Diameter Copper Pipe 10 Long 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
149. ic meters Static pressure and differential pressure may be obtained from the Multivariable Transducer connected to the ControlWave XFC I O Board assembly The inputs may also be derived 1 14 Introduction CI ControlWave XFC from external smart Multivariable Transmitters using either the BSAP or MODBUS protocols Alternatively the inputs may be obtained via the local I O Modules using analog transmitters The standard ControlWave XFC application program allows various combinations of inputs to be selected for a two run metering station Regardless of the operating mode or the calculation interval the ControlWave XFC acquires samples as follows Differential pressure once per second Static pressure once per second Flowing temperature once per second All self test and compensation values at intervals of 4 seconds or less ao op 1 5 2 Flow and Volume Calculations The ControlWave XFC performs a complete flow calculation using the process variables every second Each calculation includes instantaneous rate according to API 14 3 compressibility according to AGA 8 Detail or Gross method and updates of all volumes totals and archive averages The user can select AGA3 NX 19 1985 AGA3 AGA8 AGA7 NX 19 or AGA7 AGA8 1 5 2 1 Flow Rate and Flow Time Calculations AGA3 For orifice flow measurement the differential pressure value is compared to a flow cutoff value every second If the differential pressure is less than the flow cutoff
150. ient or slave to master BSAP meets the definition of an industry standard open architecture protocol because if conforms to ISO standards 2629 1745 and 2111 it is not proprietary in that Bristol Babcock does not charge a license fee and makes the protocol and documentation available to anyone While BSAP is an open protocol the added functionality of the messages provides much more capability than is found in other networks e Global time synchronization 1A 6 Product Features amp Overview CI ControlWave XFC Time stamped Alarm reporting Historical archive data transfer Audit file transfer On line program editing Diagnostics Communication statistics 1A 4 1 2 Modbus Protocol Modbus Modbus is often considered a de facto standard protocol because broad usage as either the primary or a secondary offering in many measurement and control related products Even with its common use Modbus protocol actually has many variations Consider Modbus RTU and Modbus ASCII Master amp Slave Serial and TCP IP Open Modbus In addition there are consideration regarding supported function codes floating point values and byte order Bristol Babcock supports the following Modbus serial and TCP IP Open Modbus Ethernet Master and Slave Modbus RTU and ASCII Modes 1 7 8 15 amp 16 Integer and IEEE 4 byte floating point 1A 4 1 3 Generic Serial Interface The Generic Serial Interface is a user programmable Master and Slave protocol
151. iety of Inputs and Outputs see Section 1 3 3 2 While using the standard application program inputs and outputs required for measurement and control are mapped to the application using the configuration Web pages Analog Alarm limits for variables required by the standard application program are defined via the configuration Web pages Discrete Input alarms associated with the standard application program can be enabled or disabled on a per point basis via the configuration Web pages Control algorithms flow control sampler control odorant control etc are selected via the configuration Web pages 1 5 6 1 Flow Rate Control DDC jog control using PID When the user configures the ControlWave XFC to perform flow rate control the two digital output signals are wired to the Open and Close inputs of a controller The ControlWave XFC uses a Proportional Integral Derivative PID algorithm to cause the measured rate of flow to match a user entered setpoint When the flow rate is below the setpoint the Open output is pulsed When the flow rate is above the setpoint the Close output is pulsed The PID equation calculates the duration of the Open or Close pulse The minimum pulse duration is 1 0 seconds The user changeable parameters are Flow Setpoint in MSCFH Deadband in of setpoint Proportional Gain Integral Time in repeats minute e Derivative Time in seconds Valve Travel Time full close to full open e Process Control Li
152. inaw Road Customer Service 989 496 6000 Midland Michigan 48686 Product Disposal Information 989 496 6315 CHEMTREC 800 424 9300 MSDS No 01013190 Revision Date 2002 12 09 Generic Description Silicone Physical Form Liquid Color Colorless Odor Characteristic odor NFPA Profile Health 0 Flammability 1 Instability Reactivity 0 Note NFPA National Fire Protection Association 2 OSHA HAZARDOUS COMPONENTS None present This is not a hazardous material as defined in the OSHA Hazard Communication Standard 3 EFFECTS OF OVEREXPOSURE Acute Effects Eye Direct contact may cause temporary redness and discomfort Skin No significant irritation expected from a single short term exposure Inhalation No significant effects expected from a single short term exposure Oral Low ingestion hazard in normal use Prolonged Repeated Exposure Effects Skin No known applicable information Inhalation No known applicable information Oral No known applicable information Signs and Symptoms of Overexposure No known applicable information Medical Conditions Aggravated by Exposure No known applicable information The above listed potential effects of overexposure are based on actual data results of studies performed upon similar compositions component data and or expert review of the product Please refer to Section 11 for the detailed toxicology information DOW CORNING CORPORATION Material Safety Data Sheet DOW
153. ing I O wiring WARNING EXPLOSION HAZARD Do Not disconnect equipment unless power has been disconnected and the area is known to be nonhazardous A RTD may be supplied with the ControlWave XFC Connection to the RTD is approved as a nonincendive circuit Note A bendable RTD with a plastic bushing as utilized in Division 2 installations may NOT be used in a Division 1 area as it renders the area non explosion proof Use a RTD Connection Head and explosion proof conduit for Division 1 installations Signal connectors available for customer wiring are listed in Table Al I O Connections are unrated and must be wired using wiring methods as specified in article 501 4 b of the National Electrical Code NEC NFPA 70 for installations in the United States or as specified in Section 18 152 of the Canadian Electrical Code for installation in Canada Table Al Terminal Plate Connector Customer Wiring Connectors Connector J2 Pins 1 through 4 Wiring Notes RS 485 Comm Port Connectors For external Network Comm Refer to Model Spec and fT 3 amp 9 of this document RS 485 Comm Port amp Power connections for Model 3808 Transmitter J2 Pins 5 7 RS 232 Comm Port Connectors For temporary external Network Comm Refer to RS 232 Local Comm Port Model Spec and 1 3 and 9 of this document 10 03 2006 J2 Pins 8 14 RS 232 Network Comm Port RS 232 Comm Port For external Network Comm Refer to Model Spec and
154. ing of the various events and alarms that have an impact on the calculated and reported rates and volumes The second type is historical data which includes records of rates and volumes and other signals over time When an archive log becomes full new entries replace the oldest entries in the log Where feasible both forms of archive data conform to the requirements of the API Chapter 21 the Committee on Gas Measurement s GFC document Specifically the averages of the process variables stored in the data archive are for flowing periods appropriate to their usage in the equations and any gas related parameter designated an event that is changed by an operator either remotely or locally causes an entry in the audit log The ControlWave XFC supports the breaking of a log period when an operator entered parameter is changed When this occurs the log period in process is closed out a log is made and a new log is begun This feature is disabled by default and may be enabled by the operator Note To prevent several very short logs from being created due to a series of successive configuration changes the ControlWave XFC will not create a log which contains less than 60 seconds flowing or otherwise of data Therefore if a user enters 15 configuration changes over a 2 minute period the log will only be broken twice 1 5 3 1 Hourly Historical Data Log The Hourly Data Log holds one record for every contract hour Hourly logs hold 840 entries or
155. ions Technology Group Bristol Babcock Inc 317 S North Lake Blvd Suite 1016 Altamonte Springs FL 32701 Phone 1 407 629 9464 Fax 1 407 629 2106 orlandoRFgroup bristolbabcock com Asia Pacific Bristol Babcock Inc PO Box 1987 Bunbury Western Australia 6231 PH 61 0 8 9791 3654 FAX 61 0 8 9791 3173 dtrench bdsa com au Victoria Australia PH 61 0 3 9384 2171 FAX 61 0 3 8660 2501 ESDS Manual R S14006 4 15 92 CARE AND HANDLING OF PC BOARDS AND ESD SENSITIVE COMPONENTS AN BRISTOL BABCOCK ESDS Manual S14006 4 15 92 TABLE OF CONTENTS PAGE TOOLS AND MATERIALS REQUIRED 1 ESD SENSITIVE COMPONENT HANDLING PROCEDURE 2 1 Introduction 2 2 General Rules 3 3 Protecting ESD Sensitive Components 5 4 Static Safe Field Procedure 6 5 Cleaning and Lubricating 8 6 Completion 10 TOOLS AND MATERIALS REQUIRED 1 Tools Anti Static Field kit It is recommended that an anti static field kit be kept on any site where solid state printed circuit boards and other ESD sensitive compo nents 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
156. ipe Mounting Diagram Unit shown with MVT 2 6 Installation amp Operation CI ControlWave XFC MOUNTING P gt S i HORIZONTAL i E MOUNTING a EE Figure 2 2B ControlWave XFC Pipe Mounting Diagram Unit shown with GPT CI ControlWave XFC Installation amp Operation 2 7 J A ES _ Weather Proof 4 938 RTD Bushing Class Div 2 ONLY 9 176 lt i c E Sec Le 7 876 l C y e 5188 l DP GP 8 50 14 NPT tj SR 3 020 Male Fitting e y 25 18 NPT Pipe Fittings 1 625 lt 5 188 gt lt 4 630 KI 75 14 NPT 813 4 gt AA 6 156 1 788 75 14 NPT Plastic Threaded A A Conduit Conduit 6 156 Plug Plug 2 685 3 842 4 032 E d y A Ee EC E Figure 2 3 ControlWave XFC Dimensions Drawing The Multivariable Transducer MVT is bolted to a process manifold which in turn is connected to th
157. ired MSCF IH Flow rate in thousands of standard cubic feet per hour MSCF H Max The maximum flow value allowed through the meter at the maximum frequency input F 6 4 Supercompressibility Setup When the 1985 AGA8 calculation is selected the Supercompressibility Fpv value is calculated using the NX 19 equations When the 1992 AGA3 calculation is used the Flowing Zf and Base Zb compressibility factors are calculated using either the AGA8 Detail or AGA8 Gross module The AGA8 Gross module provides either G C N or HV G modes Supercompressibility Configuration for Run 1 Selected Compressibility Calculation nig Click to Select gt M19 AGAB Detail AGAB Gross Inputs Outputs Name Value Name Value Outputs Value Gross Mode Mode 2 CH 0 000 FPV 1 000 Static Pressure 0 000 N2 0 000 ZBase 0 000 Base Pressure 14 73 co 0 000 Z Flowing 0 000 Temperature 0 000 Ca 0 000 Base Temp 60 00 Ca 6 000 BTU 6 000 Ic 0 000 Spec Gravity 0 000 NC 6 000 Ic 0 000 NC 6 000 NC 6 000 NC 0 000 He 6 000 HO 6 00 HS 0 00 H 6 00 co 0 00 0 0 00 NC 0 00 Waff 0 00 He 6 00 Ar 0 00 Figure F 20 Supercompressibility Configuration Web Page If the Base Pressure or Base Temperature differ from Standard conditions 14 73 psia 60 F and the 1992 AGA3 calculation is in use an AGA8 Detail or AGA8 Gross module will be F 30 Appendix F CI ControlWave XFC executed to calculate standard compressibility Zs for the defined ga
158. iring Notes J2 Pins 1 through 4 RS 485 Comm Port Connectors For external Network Comm Refer to Model Spec and fT 3 RS 485 Comm Port amp Power of this document Use Div 2 wiring methods connections for Model 3808 Transmitter J2 Pins 5 7 RS 232 Comm Port Connectors For temporary external Network Comm Refer to RS 232 Local Comm Port Model Spec and 1 3 of this document J2 Pins 8 14 RS 232 Comm Port For external Network Comm Refer to Model Spec and fT 3 of this RS 232 Network Comm Port document Use Div 2 wiring methods J3 Pins 1 through 3 Field Wired Refer to 8 of this document RTD Interface J4 Pins 1 through 11 Analog Input Output Field Wiring amp Unit supplied 15Vdc Field Power Field I O wiring AI O Interface amp Field Power connector is unrated use Div 2 wiring methods J5 Pins 1 through 9 Discrete Input Output Field Wiring Field I O wiring connector is unrated use Div 2 wiring DI O Interface methods J5 Pins 9 through 12 High Speed Counter Input Field Wiring Field HO wiring connector is unrated use Div 2 HSC Interface wiring methods J6 Pins 1 and 2 Power Interface Power connector is unrated Div 2 wiring methods Input Power 10 03 06 Appendix A Document CI ControlWave XFC Page 1 of 2 Note 10 03 06 ControlWave XFC Special Instructions for Class I Division 2 Hazardous Locations These wires should only be installed removed when the item P
159. is in continuity with the pipeline it will have to be electrically isolated from the ControlWave EFM GFC XFC Use a strong heat shrink material such as RAYCHEM WCSM 68 22 EU 3140 This black tubing will easily slip over the 2 inch pipe and then after uniform heating e g with a rose bud torch it electrically insulates and increases the strength of the pipe stand Section 3 Grounding amp Isolation Page 3 9 S1400CW See BBI Specification Summary F1670SS 0a for information on PGI Direct Mount Systems and Manifolds KI KI l m z T ducer to Manifold i rans Dielectric Isolation Kit l i Multivariable Transducer l MVT l Dielectric Gasket e amp Flange Seals 2 7 AWG 4 Ground Wire gi ae Valve Block Manifold LY g ve Si wa Top Washers 4 fs oN l e o gt Dielectric Bolt Sleeves 4 Isolating ege Bottom Washers 4 Fittings i 8 i Mounting Bolts 4 2 Pipe mounting Package Note Mounting Pipe does not contact the Main Pipeline Clamp s Ground Rod or System Figure 3 10 ControlWave EFM Installation is similar to GFC XFC Remote Installation with Cathodic Protection S1400CW Page 3 10 Section 8 Grounding amp Isolation Section 4 Lightning Arresters amp Surge Protectors EE 4 1 STROKES amp STRIKES Lightning takes the form of a pulse that typically has a 2 uS rise and a 10 uS to 40 uS decay to a 50 level
160. ith conduit 1 4 FIELD WIRING ControlWave XFC explosion proof gas flow computers support connection to external field devices through its field wiring terminals on the Function Module s Terminal Plate Connections to the following types of external devices may be made e RTD e Digital Outputs DOs e Battery Power Supply e Analog Inputs Als e Pulse Inputs HSCs e Communications RS 232 amp RS 485 e Digital Inputs DIs e Analog Output AO e Relays CI ControlWave XFC Introduction 1 13 1 5 FUNCTIONS ControlWave XFC can come with or without a base application program that satisfies API 21 1 requirements for a meter station using up to two meter runs Using ControlWave Designer the user can readily modify this load to add or subtract functions increase the number of runs etc An overview of the base application load is provided below e Uses pre configured web pages for user readings configuration and maintenance Web pages can be modified and new pages configured to work with a modified application load e Application load is object oriented e Standard configuration is a two run station e Each run can be orifice turbine or ultrasonic meter type e Flow calculations include the following e AGA3 1985 NX 19 e AGA3 1992 with selectable AGA8 Gross or AGA8 Detail e AGAT7 NX 19 e AGAT with selectable AGA8 Gross or AGA8 Detail e Auto Adjust AGA7 NX 19 e Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail e Instrom
161. ium RAM Dattere 3 2 TROUBLESHOOTING TIPS erreseina ien anae aeaii riak is 3 4 Power Checks mecres EE ESA 3 4 LCD Display System Status Codes 3 4 EAR ed 3 4 Wiring Signal CHECKS sarisini EENEG dE 3 5 GENERAL SERVICE NOTES 3 6 Extent of Field Repair 3 6 Maintaining Backup Piles iseiscc secsinsgesacsntevccaiadues svntas eecasanyea E E A cence 3 6 WINDIAG DIAGNOSTICS 00 ccecceccceccsseceeececeneeeeaaeceeaeeceeeeeceaeeeeaaeeeneeeecsaeeesaeeneaeeeeeeeees 3 6 Diagnostics Using WINDIAG c cccccccccessssceeessseeeeessneeeeecsneeecesssaaeecssseaeeesseaseessseaaeens 3 9 Communications Diagnostic Port Loop back Dest 3 9 Serial Comm Port Eternal Loop back Test Procedure cccceesssceeeesseeeeeeeseeeeseaes 3 9 CORE UPDUMD EEN 3 11 CALIBRATION CHECKS vescciints coniciiedensadiace sbeadealaccdidie eaadenlaceaaave evnhadouaeshdanceedsasnaabendere 3 11 CI ControlWave XFC Contents 0 3 CI ControlWave XFC ControlWave XFC Model 3820 EX Explosion Proof Gas Flow Computer SECTION 4 1 4 2 4 3 4 4 4 4 1 4 4 2 4 4 3 4 4 4 4 4 5 4 4 6 4 5 4 6 4 7 TABLE OF CONTENTS TITLE PAGE Section 4 SPECIFICATIONS CPU MEMORY amp PROGRAM INTERFACE u cccccccccccscccsseceesseceeseecesseesesseceeseeensees 4 1 COMMUNICATION PORTS ou ccecccccssecesscccessceesseceesseceseecsseceeesseceeeecseeeesseceeseeensees 4 1 INPUT POWER SPECIFICATIONS o oo eccccccccccsscceesseceeseeccsseceesseceeseeceseeeesseeessseeeeseeees 4 2 HO B
162. 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 Caulk around the lead in wire where it enters the structure to keep out drafts Install lightning arresters antenna discharge units The grounding conductor should be run in as straight a line as practicable from the antenna mast and or the antenna discharge units to grounding electrode s 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 Q H Section 4 Lightning amp Surge Page 4 3 S1400CW Antenna Mast e or Tower a SS Stand Off KN gInsulators Radio Bulkhead Power Service Coax Support Equipment QS SH gt S X Coaxial vy 4 ims Cable Dip gt Phone Loop Wire Antenna Discharge Unit Put Another J 8 On The Building L Bulkhead Power Telephone en Ground Ground Ground S P Tested Tested Tested a WARNING NX Connect All Grounds A AWG 0000 Copper Wire Before Equipping Tower gt Connects All Rods Tower Ground Tested On Each Leg Antenna Base _ Standoff Insulators P Every 4 6 Feet R A 1 3 to 2 Meters T
163. l Comm ports e SPITO Bus Interface three separate chip selects e Spread Spectrum clock for lower EMI e Serial Real Time Clock with battery backup e 10 Position general purpose switch bank e Coin cell socket accepts a 3 0V 300mA hr lithium battery e Display Module 1 3 3 1 CPU Board Connector P2 CPU Board connector P2 provides the interface to connector J7 on the XFC I O Board see Table 1 1 Table 1 1 CPU Board Connector P2 I O Intf Signals Pins 24 amp 25 are not used Signal Name Description Power Ground 1 8 Volt Power 3 3 Volt Power T O Reset Power Good 6 IPC LPEDLZCLE PWRFAIL I 8 vm LNUDNIOOM 9 SPICK L b Clock I SPI Master In Slave Out SPI Master Out Slave In oO 13 232TxXp2 SCC COM COM1 COM2 COM2 oO 17 232RTS8 LOONMS LO 18 232TXD3 LCONMS COM2 O 20 232DTR LOONMS COM3 COM3 Oo 23 Doc i Spare ChipSelect _ _ CPU Board Serial Comm Port Connectors see Section 1 5 5 The CPU Module supports up to three serial communication ports COM1 COM2 amp COM3 COM1 provides a 3 wire half duplex RS 232 interface and is referenced on the Terminal Plate as the Local Port COM1 operates by sencing RS 232 levels on the TX or RX terminals COM2 provides a 7 wire RS 232 interface and supports half full duplex operation When the ControlWave XFC has been configured for Auto DTR Mode the DCD signal must be high before COM2 becomes operational COM3 supports RS 485 T O O 0
164. l Plate Assembly be disconnected until the entire unit has been wired and hardware configured Sections 2 3 6 1 amp 2 3 6 2 provide details on DC Power Connector wiring 2 3 3 2 Shielding and Grounding The use of twisted pair shielded and insulated cable for I O signal wiring will minimize signal errors caused by electromagnetic interference EMI radio frequency interference RFI and transients When using shielded cable all shields should only be grounded at one point in the appropriate system This is necessary to prevent circulating ground current loops that can cause signal errors 2 3 3 3 Non isolated Discrete Input Output Connector Block J5 see Figure 2 10 ControlWave XFCs contain field interface circuitry for up to 2 Discrete Digital Inputs and 4 Discrete Digital Outputs Surge Suppression and signal conditioning is provided for each DI DO circuits consist of an open drain MOSFETs and Surge Suppression DI O circuitry utilizes a 12 point Terminal Block Assembly J5 that is located on the Terminal Plate DI O circuitry provides internally sourced DI operation for Dry Contacts pulled internally to 3 6Vdc when the field input is open Each DI is protected with a surge suppressor DI filtering is 15 milliseconds DO circuitry utilizes open drain MOSFETs and surge sup pressors The DOs sink current to digital ground 2 3 3 3 1 Discrete Input Output Configurations Terminal Plate Terminal Block J5 supports two non configurabl
165. l micro organisms earthworms or subsequent crops grown in the soil Bioaccumulation This product is a liquid and is a high molecular weight polymer Due to its physical size it is unable to pass through or be absorbed by biological membranes This has been confirmed by testing or analogy with similar products Fate and Effects in Waste Water Treatment Plants This product or similar products has been shown to be non toxic to sewage sludge bacteria Ecotoxicity Classification Criteria Hazard Parameters LC50 or EC50 High Medium Acute Aquatic Toxicity mg L lt 1 gt 1 and lt 100 Acute Terrestrial Toxicity lt 100 gt 100 and lt 2000 This table is adapted from Environmental Toxicology and Risk Assessment ASTM STP 1179 p 34 1993 This table can be used to classify the ecotoxicity of this product when ecotoxicity data is listed above Please read the other information presented in the section concerning the overall ecological safety of this material 13 DISPOSAL CONSIDERATIONS DOW CORNING CORPORATION Material Safety Data Sheet DOW CORNING 200 R FLUID 100 CST RCRA Hazard Class 40 CFR 261 When a decision is made to discard this material as received is it classified as a hazardous waste No State or local laws may impose additional regulatory requirements regarding disposal Call Dow Corning Corporate Environmental Management 989 496 6315 if additional information is required 14 TRANSPORT INFORMA
166. lWave XFC com munication port that is connected to the PC local or network and used for running these tests can t be tested until diagnostics has been established via one of the other ports i e to test all Con trolWave XFC communication ports via WINDIAG communications with the PC will have to be established twice each time via a different port It should be noted that the ControlWave XFC communication port that is connected to the PC RS 232 or RS 485 must be good for WINDIAG to run the Communications Diagnostics 3 5 1 2 Serial Comm Port External Loop back Test Procedure Connect external loop back wire s on the Terminal Plate to the Communications Port to be tested see Figures 3 5 Note The RS 485 port doesn t require loopback wires 1 Type 1 2 or 3 for the port to test 2 Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5 CI ControlWave XFC Service 3 9 3 Click on RUN button next to External loop back e Test responses a Success All sections of test passed b Failure TXD RXD Failure CTS RTS Failure e Execution time lt 5 sec NETWORK LOCAL RS485 00o yI a DAOIS Rx SE MELL EEE G 5 2 AMM rn A Ka gt Comm Port 2 D mm Port 1 SUS Pee E KH Loopback Loopback Wires Wire Figure 3 5 RS 232 Loop back Wires Communications Diagnostic bd Fa Number of Passes om C Continuous Repeat after Error C Continuous Stop after Er
167. lar business hours Bristol s Application Support Group can provide telephone support for your technical questions For technical questions about TeleFlow products call 860 945 8604 For technical questions about ControlWave call 860 945 2394 or 860 945 2286 For technical questions regarding Bristol s OpenEnterprise product call 860 945 3865 or e mail seada bristolbabcock com For technical questions regarding ACCOL products OpenBSI Utilities UOI and all other software except for ControlWave and OpenEnterprise products call 860 945 2286 For technical questions about Network 3000 hardware call 860 945 2502 You can e mail the Application Support Group at bsupport bristolbabcock com 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 orlandoRFgroup bristolbabcock com 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 th
168. ld download parameters and configure IP and soft switch parameters DataView is an on line utility used to collect and display several types of process data including signal values data array values signal lists and audit trail information Operators have the ability to alter signal values Multiple DataView windows may be open simultaneously 1A 3 3 Real time ActiveX Controls One of the many benefits OpenBSI brings to you is our use of open standards such as ActiveX Controls ActiveX is another of the Microsoft standards which allow plug and play with any ActiveX container using Microsoft ActiveX container technology such as Visual Basic HTML web pages and Microsoft Excel The set of available ActiveX Controls provides the basic functions necessary to com municate and collect data from ControlWaves 1A 3 3 1 ActiveX Controls 1A 4 Product Features amp Overview CI ControlWave XFC e Security 56 bit encryption allows the user to sign on to the RTU e Signal Value displays signal values in various formats e Comm Statistics works with a standard page that displays the RTU s communication statistics e Configuration Info works with a standard page that displays and allows the user to change RTU Configuration information e Historical Collect and view historical archive and audit files The IP compliant ControlWave opens the door for owner controlled access via web pages Any generic web page builder can be employ
169. lity lt 100 ppb As it has a specific gravity of lt 1 if discharged to water it will initially form a surface film As the product is non volatile and has a high binding affinity for particulate matter it will adsorb to particulates and sediment out If discharged to surface water this product will bind to sediment If discharged in effluent to a waste water treatment plant the product is removed from the aqueous phase by binding to sewage sludge If the sewage sludge is subsequently spread on soil the silicone product is expected to degrade Degradation This product polydimethylsiloxane degrades in soil abiotically to form smaller molecules These in turn are either biodegraded in soil or volatilized into the air where they are broken down in the presence of sunlight Under appropriate conditions the ultimate degradation products are inorganic silica carbon dioxide and water vapour Due to the very low water solubility of this product standard OECD protocols for ready and inherent biodegradability are not suitable for measuring the biodegradability of this product The product is removed gt 80 during the sewage treatment process Environmental Effects Toxicity to Water Based on analogy to similar materials this product is expected to exhibit low toxicity to Organisms aquatic organisms Toxicity to Soil Organisms Experiments show that when sewage sludge containing polydimethylsiloxane is added to soil it has no effect on soi
170. locate precise amounts of gas flow during specific time periods These periods are called nomination periods A nomination may be set for any duration of time not to exceed one month The volume to be delivered nominated during a nomination period is the target Targets may be specified in terms of volume or energy Users set a nomination period by keying in the desired day of the month and hour to begin the period and the desired day of the month and hour to end the period The daily nomination feature is used if the user desires the same start stop times every day A unit programmed with a daily nomination will ignore the programmed start and end day numbers and will perform the nomination in question at the same time once per day The delivery of the nominated quantity volume or energy during the nomination period may be performed via one of the two unique schemes listed below Valve Control The Valve Control method overrides PID flow control and allows the valve to be independently controlled thus permiting full flow of gas through the meter in order to arrive at the target volume or energy as quickly as possible without regard to the programmed end time Flow Control The Flow Control method internally enables the PID flow control algorithm in order to hit the target volume energy at exactly the programmed end time The user programs the ControlWave XFC via the Stop Mode button to either close the valve upon reaching t
171. locations see appendix A of the applicable Customer Instruction CI manual For information on the usage of ControlWave units in Class I Division 1 Groups C amp D Hazardous locations see appendix B of the applicable Customer Instruction CI manual 3 3 EARTH GROUND CONNECTIONS To properly ground a ControlWave unit the units Chassis Ground post or terminal must ultimately be connected to a known good Earth Ground Observe recommendations provided in topics Establishing a Good Earth Ground and Ground Wire Considerations 3 3 1 Establishing a Good Earth Ground A common misconception of a ground is that it consists of nothing more than a metal pipe driven into the soil While such a ground may function for some applications it will often Section 3 Grounding amp Isolation Page 3 1 S1400CW not be suitable for a complex system of sophisticated electronic equipment Conditions such as soil type composition and moisture will all have a bearing on ground reliability A basic ground consists of a 3 4 inch diameter rod with a minimum 8 foot length driven into conductive earth to a depth of about 7 feet as shown in Figure 3 1 Number 3 or 4 AWG solid copper wire should be used for the ground wire The end of the wire should be clean free of any coating and fastened to the rod with a clamp This ground connection should be covered or coated to protect it from the weather and the environment PROTECTION BOX COPPERWELD CLAMP de EIT BSA
172. m High Speed Counter to Auto Adjust Module In this case the user selects which point will be used for the Main Rotor and which point will be used for the Sense Rotor Further configuration of the Auto Adjust Turbine Meter is performed via the Auto Adjust Configuration Page For a description of the items on the Auto Adjust Configuration Page see the ACCOL3 Function Block Help Documentation If the user selects the Auto Adjust Configuration button the Auto Adjust Configuration for Run Web Page will appear see Figure F 16B This page provides Calibtration Data Configuration Data and Calculated Factors F 6 2 3 Heating Value Input The user has three options for the source of the heating value Manual Entry Chromatograph or AC AN Manual Entry is selected when the heating value will be directly entered This value may be entered via the Meter Run I O Configuration Web Page or may be written to a signal externally Chromatograph is selected when the heating value is read directly from the chromatograph via the MODBUS interface AGA5 is selected when the component mole values are fed into the AGA5 equation Source of the component mole values is determined by settings made on the Chromatograph Setup Page CI ControlWave XFC Appendix F F 23 Auto Adjust Configuration for Run 1 Return to I O Configuration Calibration Data Blade Tip Sensor Factor BTSF 1 0000 Main Rotor Factor KM 3279 6128 Sensor Rotor Fac
173. major areas of concern for the protection of site equipment and personnel The following overview is provided for each of the major sections e 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 e Section 3 Grounding amp Isolation Information pertaining to what constitutes a good earth ground how to test and establish such grounds as well as when and how to connect equipment to earth grounds is provided e Section 4 Lightning Arresters amp Surge Protectors Some interesting information dealing with Lightning strikes and strokes is presented in technical and statistical form along with a discussion of how to determine the likelihood of a lightning strike Protecting equipment and personnel during the installation of radios and antenna is discussed in a review of the dangers to equipment and personnel when working with antennas Reasons for the use of lightning arresters and surge protectors are presented along with overviews of how each device protects site equipment e Section 5 Wiring Techniques Installation of Power and Measurement amp Control wiring is discussed Information on obscure problems circulating ground a
174. mer pulse for use by the application software see Table 4 1 and referenced Tables Table 4 1 CPU Board Connector Summary Function Notes Factory Test ONLY Ee 4 2 COMMUNICATION PORTS Connector Port Baud Rate Terminations Terminal Plate COM1 RS 232 Term Block J2 5 through J2 7 COM2 RS 232 Term Block J2 8 through J2 14 COMB RS 485 Term Block J2 1 through J2 4 300 to 115Kbps for RS 232 300 to 38 4Kbps for RS 485 Pluggable maximum wire size is 16 gauge Table 4 2 RS 232 Port COM1 2 Pin Assignments Pin Signal Port t Description RS 232 RS 232 Signals J 2 10 COM2 Request To Send Output COM2 Clear To Send Input COM2 Data Terminal Ready Output J 2 13 COM2 Data Carrier Detect Input COM2 Signal Power Ground CI ControlWave XFC Specifications 4 1 Table 4 3 RS 485 Port COM3 Model 3808 Intf Port Pin Assignments Pin Signal Description RS 485 RS 485 Signals Signal Power Ground Transmit Receive Pos I O J2 4 Ta Power for 3808 Transmit Receive Neg I O V 4 3 INPUT POWER SPECIFICATIONS Note Voltages are dc unless otherwise specified Operating Range 6 0V to 30 0V Shutdown occurs at 5 46V nominal Electrical Isolation None Surge Suppression 30V Transorb to GND Meets ANSI IEEE C37 90 1978 Fusing 3875A Slow Blow 4 4 HO BOARD SPECIFICATIONS 4 4 1 External Power Monitor Specs Input Signal Inpu
175. mes are posted to the lower characters Signal names may include units up to 20 characters in length which scroll across the bottom row 1 5 5 Communications A ControlWave XFC can be configured as a Master or Slave node on either a MODBUS network or a BSAP network Up to three serial communication ports are contained on the ControlWave XFC I O Board assembly and are user accessible via the Terminal Plate Communication ports are designated as follows Communication Ports COM1 COM2 amp COM3 support serial asynchronous operation Any serial communication port can be configured for local communications i e connected to a PC loaded with ControlWave Designer and OpenBSI software Term Plate Connector J2 COM1 Referred to as the Local Port 3 Pin RS 232 Half Duplex Oeration COM2 Referred to as the Network Port 7 Pin RS 232 Full Half Duplex Oeration COMB 3 Pin RS 485 Half Duplex Operation RS 232 Ports An RS 232 interface supports Point to Point half duplex COM1 2 and full duplex COM2 communications 20 feet maximum using data quality cable Half duplex communications supported by the ControlWave XFC utilize MODBUS or BSAP protocol while full duplex is supported by the Point to Point PPP protocol ControlWave XFC RS 232 port COM2 utilizes the null modem cable Figure 2 9A to interconnect with other devices such as a PC printer another ControlWave XFC GFC ControlWave MICRO ControlWave EFM or C
176. miting Pressure Override Limits The flow control algorithm runs once per second 1 5 6 2 Pulse Output for External Totalizer or Sampler When the ControlWave XFC is configured to provide a pulse output based on volume the operator provides a control volume and a pulse duration After each calculation cycle an internal volume accumulator is compared to the control volume If the accumulator exceeds the control volume then a pulse is output and the accumulator is reduced by the volume CI ControlWave XFC Introduction 1 19 represented by the pulse The pulse output may be used to drive an external totalizer odorizer gas sampler or similar device 1 5 6 3 Nominations The nomination function allows a user to establish a time period over which an accumulation count of volume or energy that is delivered during the period is monitored and compared to a configured nomination value When the nomination value is reached the system will perform an action such as opening or closing a valve Prior to nomination being reached the volume energy will be compared to a configured alarm level and an alarm will be generated when the volume energy reaches or exceeds the defined specified level 1 5 7 Self Test amp Diagnostics The ControlWave XFC periodically runs a series of diagnostics to verify the operational status of various system components The tests include transducer parameters main and backup battery voltages software sanity
177. mpletion of Parts II amp III A copy of the completed Repair Authorization Form with issued RA number should be in cluded with the product being returned This will allow us to quickly track repair and return your product to you Bristol Inc Repair Authorization Form off line completion Providing this information will permit Bristol Inc to effectively and efficiently process your return Completion is required to receive optimal lead time Lack of information may result in increased lead times Date RA SH Line No Standard Repair Practice is as follows Variations to this is Please be aware of the Non warranty standard charge practice may be requested in the Special Requests section e There is a 100 minimum evaluation charge which is e Evaluate Test Verify Discrepancy applied to the repair if applicable V in returned e Repair Replace etc in accordance with this form B C or D of part III below e Return to Customer Part I Please complete the following information for single unit or multiple unit returns Address No office use only Address No office use only Bill to Ship to Purchase Order Contact Name Phone Fax E Mail Part II Please complete Parts II amp III for each unit returned Model No Part No Description Range Calibration S N Reason for return Failure J Upgrade J Verify Operation O Other 1 Describe the conditi
178. mware via LocalView FLASH Mode requires OpenBSI 5 1 or newer If you have an older version of OpenBSI FLASH upgrades are to be performed via Hyperterminal You will need a binary BIN system firmware file that is read as follows cwx0440 bin where cwx is the product code and 0440 is the release Upgrade of an unattended ControlWave XFC can be accomplished from a remote PC This capability is introduced in Section 2 4 2 3 2 4 2 1 Using LocalView to Upgrade ControlWave XFC Firmware NOTE Your ControlWave XFC must be set to Recovery Mode ENABLE ON prior to per forming the FLASH upgrade then set to Recovery Mode DISABLE OFF after the upgrade On ControlWave XFCs this is accomplished via CPU Board Switch SW1 Set both SW1 9 and SW1 10 to either the ON or OFF position or SW1 9 set ON and SWI1 10 set OFF for Recovery Mode To disable Recovery Mode set SW1 9 OFF and SW1 10 ON A special 3 wire communication cable see Figure 2 9C must be connected to COM1 of the ControlWave XFC and to any RS 232 port on the associated PC The PC s RS 232 port used for this purpose must be set to run at 115 2 Kbaud ControlWave XFC CPU Board Switch SW1 positions 9 amp 10 must both be set ON or OFF or SW1 9 set ON and SW1 10 set OFF Start LocalView Choose FLASH Enter A Name Click on Create Start LocalView by clicking on Start gt Programs gt OpenBSI Tools gt LocalView The New View Mode dialog box will appear see Figure 2 17 Mode
179. n lieu of a direct connection from a Terminal Plate Ground Post and to all AI cable shields Shield wires should use an appropriate Terminal Lug and should be secured to the copper bus via industry rugged hardware screw bolt lock washer and nuts 2 3 3 5 Non isolated Analog Output Connector Block J4 see Figure 2 10 ControlWave XFCs contain field interface circuitry for one Analog Output that is configured for 4 20mA sink operation Field power source can be from the ControlWave XFC or an external 11 to 30Vdc power source The V source tracks the unregulated supply voltage to 15V and is current limited to approximately 80mA Analog Output circuit consists of a 16 bit resolution Digital to Analog Converter DAC anda V to I circuit The 16 bit DAC drives the V to I circuitry 2 3 3 5 1 Analog Output Configurations The Analog Output circuitry supports 4 20mA devices The maximum external load that can be connected to the 4 20mA output is 450 ohms with an external 11V power source or 1000 ohms with an external 24V power Source AO operation requires either an 11 to 30Vdc power source connected to the 4 to 20 mA device and grounded to the AO ground terminal or the XFC furnished V supply 2 3 3 6 Non isolated High Speed Counter Input Connector J5 see Figure 2 10 Non isolated High Speed Counter Input HSC circuitry supports a total of 2 inputs provided with surge suppression bandwidth limiting and 20 microsecond 50kH z filtering In
180. nd power loops bad relays etc is presented Good wire preparation and connection techniques along with problems to avoid are discussed This sections list the ten rules of instrument wiring Section 1 Overview Page 1 1 S1400CW Section 2 Protection 2 1 PROTECTING INSTRUMENT SYSTEMS Electrical instrumentation is susceptible to damage from a variety of natural and man made phenomena In addition to wind rain and fire the most common types of system and equipment damaging phenomena are lightning power faults communication surges amp 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 amp 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 req
181. nd removal from the esophagus be done endoscopically under direct visualization Batteries beyond the esophagus need not be retrieved unless there are signs of injury to the GI tract or a large diameter battery fails to pass the pylorus If asymptomatic follow up x rays are necessary only to confirm passage of larger batteries Confirmation by stool inspection is preferable under most circumstances If mouth area irritation burning has occurred rinse the mouth and surrounding area with clear tepid water for at least 15 minutes Notes to Physician For information on treatment telephone 202 625 3333 collect Potential leakage of less than 50 milligrams of propylene carbonate CAS 108 32 1 and dimethoxyethane CAS 110 71 4 Dimethoxyethane readily evaporates Under certain misuse conditions and by abusively opening the battery exposed lithium can react with water or moisture in the air causing potential thermal burns or fire hazard Replaces 1461 The information contained in the Material Safety Data Sheet is based on data considered to be accurate however no warranty is expressed or implied regarding the accuracy of the data or the results to be obtained from the use thereof MSDS 4 8 95 GMEL 2033 3 DOW CORNING CORPORATION Material Safety Data Sheet DOW CORNING 200 R FLUID 100 CST 1 IDENTIFICATION OF THE SUBSTANCE AND OF THE COMPANY Dow Corning Corporation 24 Hour Emergency Telephone 989 496 5900 South Sag
182. nfiguration and FLASH files SW1 2 must be set to the ON position see Section 2 4 4 Table 2 1 CPU Board Switch SW1 User Configurations Note Except for SW1 4 amp SW1 10 ON Factory Default SW Function Setting ON Factory Default N Watchdog circuit is enabled F Watchdog circuit is disabled Write to Soft Switches and FLASH files F Soft Switches configurations and FLASH files are locked Retain values in SRAM during restarts F Force system to reinitialize SRAM SW1i 7 NA ON Normal Operation don t allow WINDIAG to run test WINDIAG OFF Disable boot project allow WINDIAG to run test Both ON OFF or SW1 9 ON amp SW1 10 OFF Recovery Mode Mode SW1 9 OFF amp SW1 10 ON Local Mode Boot PROM version 4 7 or higher and System PROM version 4 7 or higher SW1 3 set OFF forces the use of Soft Switches as set per factory default see Section 2 4 4 For use of user defined Soft Switches SW2 3 must be set to the ON position Note If both SW1 3 and SWI1 8 are set OFF closed all communication ports will be set to 9600 bps operation SW1 4 set OFF and used in conjunction with SW1 9 and SW1 10 will cause the Control Wave XFC to perform a Core Updump see Section 3 6 SW1 5 set OFF forces the ControlWave XFC to reinitialize SRAM when the unit recovers from a low power or power outage condition When set ON the contents of SRAM will be retained and utilized when the system restarts Note
183. ng Field I O Wiring is supported by Connectors on the Terminal Plate Assembly as follows Non isolated Analog Input Output Connector J4 Section 1 3 5 1 1 Non isolated Digital Input Output Connector J5 Section 1 3 5 1 2 Non isolated High Speed Counter Input Connector J5 Section 1 3 5 1 3 Optional RTD Input Connector J3 Section 1 3 5 1 4 1 3 5 1 1 Non isolated Analog I O also see Sections 2 3 4 5 through 2 3 4 6 1 Terninal Plate Term Block connector J4 provides interface to three single ended Analog Inputs and 1 Analog Output respectively Three field terminals on J4 are assigned for CI ControlWave XFC Introduction 1 11 each Analog Input AI field power applied to each Analog Input can be supplied by an external power source or from a ControlWave XFC produced unregulated field power supply V where V Input Power 6Vdc and doesn t exceed 15Vdc Each Analog Input support 1 5V operation Als are supplied with a two hertz low pass filter and surge suppression via 16Vdc Transorbs Analog Output circuitry consists of a 16 bit resolution Digital to Analog Converter and a V to I circuit and provides a 4 20mA current sink Figure 1 6 ControlWave XFC Terminal Plate 1 3 5 1 2 Non isolated Digital I O also see Section 2 3 4 4 Terninal Plate Term Block connector J5 provides interface to 2 Digital Inputs and 4 Digital Outputs All Digital Inputs support dry contac
184. nt half duplex Network and Local Ports and full duplex Network Port COM2 communications 20 feet maximum using data quality cable Half duplex communications supported by the ControlWave XFC utilize MODBUS or BSAP protocol while full duplex is supported by the Point to Point PPP protocol The ControlWave XFC RS 232 Network port may utilize a null modem cable Figure 2 9A Top to interconnect with other devices such as a PC printer another ControlWave series unit when the ControlWave XFC is communicating using the full duplex PPP protocol A half duplex cable Figures 2 9A Bottom may be utilized with the Network Port when the ControlWave XFC is connected to another ControlWave series unit If communicating with a Bristol series 3305 3310 3330 or 3335 RTU DPC one of the cables shown in Figure 2 9B must be used Refer to Figure 2 9C to connect the ControlWave XFCs Local serial RS 232 Port COM1 to a PC or a model 3808 Transmitter Note The following facts regarding ControlWave XFC RS 232 serial communication port COM2 should be observed when constructing communications cables e DCD must be high to transmit except when dialing a modem e Each RS 232 transceiver has one active receiver while in power down mode disabled the DCD signal is connected to the active receiver CTS must be high to transmit When port is set for full duplex operation RTS is always ON DTR is always high when port is active DTR enables RS
185. ob by giving you correct complete and useful documentation DOCUMENT NUMBER S1400CW TITLE ControlWave SITE CONSIDERATIONS For EQUIPMENT INSTALLATION GROUNDING amp WIRING ISSUE DATE APR 2005 COMMENT COMPLAINT Mail this page to Bristol Babcock Inc 1100 Buckingham Street Watertown CT 06795 Attn Technical Publications Group Dept 315 U S A Locations Northern Region Bristol Babcock Inc 1100 Buckingham Street Watertown CT 06795 Phone 1 860 945 2381 Fax 1 860 945 2525 NorthernUS bristolbabcock com Helicoid Instruments 1100 Buckingham Street Watertown CT 06795 Phone 1 860 945 2218 Fax 1 860 945 2213 jmcgrail bristolbabcock com International Affiliates Canada Bristol Babcock Canada 234 Attwell Drive Toronto Ont M9W 5B3 Canada PH 416 675 3820 FAX 416 674 5129 info bristolbabcock ca Calgary Office Bristol Babcock Canada 3812 Edmonton Trail N E Calgary Alberta T2E 5T6 Canada PH 403 265 4808 FAX 403 233 2914 janet bristolbabcock ca RC Rev 05 Feb 04 Gulf Coast Region Bristol Babcock Inc 2000 Governor s Circle Suite F Houston TX 77092 8731 Phone 1 713 685 6200 Fax 1 713 681 7331 SouthwestUS bristolbabcock com Central Region Bristol Babcock Inc 300 North Coit Road Suite 1300 Richardson TX 75080 Phone 1 972 238 8935 Fax 1 972 238 8198 dallas bristoloabcock com Mexico
186. odel 3808 Transmitter if required see Section 2 3 5 5 Install a ground wire between the Enclosure s Ground Lug or Ground screw on the Termional Plate Assembly and a known good Earth Ground see Section 2 3 6 3 6 If required install the RTD Probe see Section 2 3 4 7 Connect DC Power wiring to the Terminal Plate Assembly see Sections 2 3 6 1 amp 2 3 6 2 Replace the Rear Wiring Cover removed in step 4 8 Apply power to the ControlWave XFC Now continue with Steps 2 through 7 below and Section 2 4 1 and the ControlWave XFC will be ready for on line operation Step 2 Software Installation on the PC Workstation ControlWave Designer software will have to be installed on the PC if the ControlWave XFC is being utilized in an application other than that supported by the standard load This is accomplished by installing the ControlWave Designer Package from the Open BSI CD ROM You must install the Open BSI Network Edition For information on minimum system requirements and more details on the installation see the installation procedure in Chapter 2 of the Open BSI Utilities Manual document D5081 If you have an older version of ControlWave Designer already installed Beginning with ControlWave Designer Version 3 3 the copy protection key dongle is NOT required Prior to installing ControlWave Designer 3 3 or newer you MUST remove the hardware dongle from the parallel port of your PC workstation Otherwise when
187. of 15 minute data The following items are stored in the Periodic Historical Data Log Flowing Differential Pressure Flowing Static Pressure Flowing Temperature Frequency Each log entry also contains the date and time The ControlWave XFC has a Periodic Historical Data Log for each of four runs 1 5 3 4 Alarm and Event Storage The ControlWave XFC keeps an Audit Trail Buffer capable of storing the most recent 500 Alarms and the most recent 500 Events Internally these buffers are maintained CI ControlWave XFC Introduction 1 17 separately to prevent recurring alarms from overwriting configuration audit data Externally they are reported to the user as a single entity Both operate in a circular fashion with new entries overwriting the oldest entry when the buffer is full The following circumstances cause an entry to be made in the Audit Trail Buffer Any operator change to a ControlWave XFC configuration variable Any change in the state of a ControlWave XFC alarm signal A system restart Certain other system events 1 5 4 LCD Display In normal operation the display stays on after the unit is configured and placed in service ControlWave XFC Display Assembly contains an upper row consisting of a LCD character and nine 7 Segment LCD characters and a bottom row consisting of six 14 Segment LCD characters Signal values controlled by the application load are posted to the upper characters and signal na
188. ol Babcock Smart Transmitter either the TeleTrans or the MVT is used via RS 485 communications The only configuration required is to assign the BSAP address 1 127 of the BBI Smart Transmitter connected to the RS 485 port MODBUS is selected when an external Smart Transmitter is used via RS 485 communications The MODBUS interface supports the register list of the Rosemount 3095 smart multivariable transmitter No additional configuration is required Note This func tionality is only available when the Expansion Communications Module is used If a Zeros amp Spans Button is pressed an Analog Input Configuration Web Pge Menu will appear see Figure F16A Zero Span and Units can be configured for analog inputs 1 F 22 Appendix F CI ControlWave XFC through 3 The Analog Input Configuration Web Page also allows the user to enable diable the Damping function 100 000 NO EET r 0 000 100 000 Figure F 16A Analog Input Configuration Web Page Accessed from Meter Run I O Configuration Web Page F 6 2 2 Frequency Input The frequency input must be brought into one of the two high speed counter HSC inputs on the I O board Users select the two I O points to which the typical turbine PD or ultrasonic meter is connected However if using an Invensys Auto Adjust Turbo Meter both HSC inputs are used to select the Auto Adjust Algorithm To select the Auto Adjust Algorithm the user will toggle the push button under Source fro
189. omponents Handle ESD sensitive components in such a way that they will not suffer damage from physical abuse or from electric shock 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 When inserting and removing ERPROMS 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 ESDS Manual S14006 4 15 92 Typical Chip Removal Tool 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 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 Handle all defective boards or components with the same care as new compo nents This helps eliminate damage caused by mishandling Do not strip used PC boards for parts Ship defective boards promptly to Bristol Babcock in a static shielding bag placed inside static shielding foam and a box to avoid damage during
190. on Primary Power is applied to Connector J6 of the Terminal Plate Assembly J6 1 amp J6 2 GND where GND The XFC will operate from 6 30Vdc however 12V minimum is required when using the analog output option e External User Supplied Power Supply 6 0Vdc to 30 0Vdc ControlWave XFC Pluggable Terminal Blocks utilize compression type terminals that accommodate up to 14 AWG wire A connection is made by inserting the wire s bared end 1 4 max into the clamp adjacent to the screw and then securing the screw The wire should be inserted fully so that no bare wires are exposed to cause shorts If using standard 2 24 Installation amp Operation CI ControlWave XFC wire tin the bare end with solder to prevent flattening and improve conductivity Allow some slack in the wires when making connections The slack makes the connections more manageable and helps to minimize mechanical strain on the terminal blocks 2 3 6 1 Bulk Power Supply Current Requirements ControlWave XFC electronic flow computers are designed to operate from a 6Vdc to 30Vde Bulk Power input The maximum current required for a particular ControlWave XFC is 5mA plus 4mA for each active communication port regardless of the bulk supply voltage plus any current up to 20mA used to supply the AO This current consumption is based on a standard Gas Flow Computer application load 2 3 6 2 Power Wiring One Bulk DC supply can be connected to the ControlWave XFC
191. on headers are provided for remote terminations 4 4 4 Non isolated Analog Input Output Circuitry Specs Non isolated Analog Inputs Number of Inputs 3 Single Ended Inputs 1 5V Input Type Externally Powered Voltage Input 1 5 Vde Input Impedance 1 Meg ohm Non isolated Analog Outputs Number of Outputs 1 AO 4 20mA Sink CI ControlWave XFC Specifications 4 3 4 20mA Output Compliance 375 ohm load with Internal Power Source 45 ohm volt load with Power Source up tp 30Vdc General AI AO Circuitry Specs Accuracy Analog Input 0 1 of Span 25 C 77 F 0 3 of Span 40 C to 80 C 40 F to 176 F Analog Output Current Output 0 1 of Span 25 C 77 F 0 2 of Span 20 C to 70 C 4 F to 158 F 0 3 of Span 40 C to 80 C 40 F to 176 F 4 4 5 Non isolated High Speed Counter Input Circuitry Specs Number of Inputs Input Configuration Input Frequency Input filtering T State Voltage 0 State Voltage Electrical isolation Surge Suppression 2 HSC Inputs per Module Internally Sourced Dry Contact 10kHz Max 20 microseconds above 1 5V below 1 5V None Transorb between signal and ground Meets ANSI IEEE C37 90 1978 4 4 6 Function Module Terminal Plate Connectors see Tables 4 4 amp 4 5 Ref Table 4 4 User Connector Summary Pins Function Communication Ports Intf Connector RTD Interface Connector Analog I O Interface C
192. onnector Digital I O amp High Speed Counter Intf Connector Main Power Intf Connector 4 5 TERMINAL PLATE SPECIFICATIONS Comm Wiring T O Wiring 4 4 Specifications Pluggable Term Block maximum wire size is 16 gauge Pluggable Term Block maximum wire size is 14 gauge CI ControlWave XFC RTD Wiring Pluggable Term Block maximum wire size is 14 gauge Input Power Wiring Pluggable Term Block maximum wire size is 14 gauge Table 4 5 Terminal Plate Input Power Terminal Block Assignments TERM NAME FUNCTION J6 1 VIN Bulk Supply 1 Pos Term 1 VIN Bulk Supply 1 Neg Term S VIN Figure 4 1 Terminal Block J6 Primary Power Connector 4 6 ENVIRONMENTAL SPECIFICATIONS Temperature Operating 40 to 176 F 40 to 80 C Storage 40 to 185 F 40 to 85 C Relative Humidity 0 95 Non condensing Vibration 2g for 10 150 Hz 1g for 150 2000 Hz RFI Susceptibility In conformity with the following standards IEC 1000 4 3 Level 2 3V meter 80MHz to 1000MHz ESD Field connected circuits meet the requirements of IEC 1000 4 2 for ESD withstand capability up to 4KV 4 7 DIMENSIONS Enclosure see Figure 4 2 CI ControlWave XFC Specifications 4 5 6 190 jes Installed Weather Proof RTD Bushing Class I Div 2 ONLY Se Lo 7 876 lt 5
193. ons 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 ET Ethernet Modem PLM OW or 4W or SNW JOther __ 3 What is the Firmware revision What is the Software amp 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 O repaired returned replaced scrapped B If product were found to exceed the warranty period would you like the product LJrepaired returned replaced scrapped C If product is deemed not repairable would you like your product O returned I replaced scrapped D If Bristol is unable to verify the discrepancy would you like the product O returned O replaced CT see below Continue investigating by contacting the customer to learn more about the problem experienced The person to contact that has the most knowledge of the problem is phone If we are unable to contact this person the backup person is phone Special Requests Ship prepaid to Bristol Inc Repair Dept 1100 Buckingham Street Watertown CT 06795 Phone 860 945 2442 Fax 860 945 3875 Form GBU 13 01 Rev B 04 11 06 Bristol Training GET THE
194. ontrol Wave unit a ControlWave I O Expansion Rack or a ControlWaveLP unit when the ControlWave XFC is communicating using the full duplex PPP protocol RS 485 Ports ControlWave XFC can use an RS 485 communication port for network communications to multiple nodes Essentially the master and the first slave transmit and receive data on opposite lines all slaves from the first to the nth are paralleled daisy chained across the same lines The master node should be wired to one end of the RS 485 cable run A 24 gauge paired conductor cable such as Belden 9848 should be used No termination resistors are required operating at 19 200 baud a 4000 network is supported For user 1 18 Introduction CI ControlWave XFC convienience a V and ground terminal are provided on either side of the RS 485 Port for use in powering model 3808 Transmitters Note Only half duplex RS 485 networks are supported Comm Port Defaults From the factory COM1 defaults to 115 2 kbd using the BSAP Protocol The remaining serial communication ports 1 e COM2 and COMBS default as follows COM2 BSAP Slave 9600 Baud COM3 BSAP Master 9600 Baud for use with Bristol Babcock 3808 MVT Transmitters 1 5 5 1 BSAP Message Support The ControlWave XFC supports the same subset of BSAP messages as the other ControlWave products 1 5 6 Discrete and Analog I O XFC Functionality ControlWave XFC explosion proof gas flow meters are equipped with a var
195. operator The unit measures approximately 6 156 in height by 5 000 in width by 6 192 in depth A Gage Pressure Transducer adds approximately 1 720 to the height of the unit while a Multivariable Transducer adds approximately 3 020 to the height of the unit Information on mounting the ControlWave XFC assembly at an installation site is provided in Section 2 3 1 Mounting the ControlWave XFC 2 2 1 Temperature amp Humidity Limits ControlWave XFC gas flow computers have been designed to operate over a 40 to 176 F to 40 to 80 C temperature range with storage at up to 185 F 85 C and a 0 to 95 Relative Humidity range Make sure that the ambient temperature and humidity at the measuring site remains within these limits Operation beyond these ranges could cause output errors and erratic performance Prolonged operation under extreme conditions could also result in failure of the unit 2 2 2 Vibration Limits Check the mounted unit for mechanical vibrations Make sure that the ControlWave XFC is not exposed to a level of vibration that exceeds those given in the specifications ControlWave XFCs maintain proper operation while subjected to a 2 0g acceleration over 10 150 Hz and a 1 0g acceleration for 150 2000 Hz 2 3 ControlWave XFC INSTALLATION CONIGURATION ControlWave XFC explosion proof gas flow computers are shipped from the factory with all components wired and mounted Overview of Configuration
196. ors Fig C Comm Intf Cables for PC 3 Wire Looking into Wire Terminal Side of Cable Connectors Figure 2 9 Communication Ports RS 232 Cable Wiring Diagram Table 2 2A RS 232 Ports COM1 Terminal Plate Connector J2 Pin Assignments Pin Signal RS 232 Description RS 232 Signals Receive Data Input 6 TXD Transmit Data Output CI ControlWave XFC CW XFC Term Plate Term Block Installation amp Operation 2 17 Table 2 2B RS 232 Ports COM2 Terminal Plate Connector J2 Pin Assignments Description RS 232 RS 232 Signals Transmit Data Output Receive Data Input Request To Send Output Data Terminal Ready Output Data Carrier Detect Input 14_ GND Table 2 2C RS 485 Port COM3 Terminal Plate Connector J2 Pin Assignments Pin Signal Description RS 485 RS 485 Signals GND SS RS 485 Ports ControlWave XFC can use an RS 485 communication port for local network com munications to multiple nodes up to 4000 feet away Since this interface is intended for network communications Table 2 3 provides the appropriate connections for wiring the master Let slave and nth slave The master node should be wired to one end of the RS 485 cable run A 24 gauge paired conductor cable such as Belden 9843 should be used Note Only half duplex RS 485 networks are supported Table 2 2C provides connector pin assignments for Comm Port COM3 Table 2 3 RS 485 Network Connections see Table 2 2
197. ounding of Thermometer Well in Gas Line 3 4 ISOLATING EQUIPMENT FROM THE PIPELINE 3 4 1 Meter Runs Without Cathodic Protection ControlWave EFM GFC XFC s may be mounted directly on the pipeline or remotely on a vertical stand alone two inch pipe see Figure 3 8 The Earth Ground Cable is to run between the ControlWave EFM GFC XFC s Ground Lug and Earth Ground Rod or Bed even though the ControlWave EFM GFC XFC s Multivariable Transducer may be Section 8 Grounding amp Isolation Page 3 7 S1400CW grounded to the pipeline If any pressure transmitters or pulse transducers are remotely mounted connect their chassis grounds to the pipeline or earth ground AWG 4 Ground Wire 2 Pipe mounting Package Clamp s Ground Rod or System Figure 3 8 ControlWave EFM Installation is similar to GFC XFC Remote Installation without Cathodic Protection 3 4 2 Meter Runs With Cathodic Protection Dielectric isolators are available from Bristol Babcock and are always recommended as an added measure in isolating the ControlWave EFM GFC XFC from the pipeline even though the ControlWave EFM GFC XFC does provide 500V galvanic isolation from the pipeline and should not be affected by cathodic protection or other EMF on the pipeline ControlWave EFM GFC XFC may be mounted directly on the pipeline see Figure 3 9 or remotely on a vertical stand alone two inch stand pipe see Figure 3 10 It is reeommended th
198. ower oo D Coaxial Cable Drip SS H Antenna Loop Se Discharge L A Unit 4 2 To Tested 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 ControlWave units this is accomplished via the unit s Chassis Ground Typically at a ground lug ground bus or ground plate However additional S1400CW Page 4 4 Section 4 Lightning amp Surge communication equipment lightning arresters and surge suppressors should be tied to the same system ground System ground consists of the tower leg grounds utility ground and bulkhead equipment ground stakes that are tied together via bare copper wire 4 1 3 Ground Propagation As in any medium a dynamic pulse like R F will take time to propagate This propagation time will cause a differential step voltage to exist in time between any two ground rods that are of different radial distances from the strike With a ground rod tied to a struck tower the impulse will propagate its step voltage outwardly from this rod in ever expanding circles like a pebble thrown into a pond If the equipment house has a separate ground rod and the power company and or telephone company grounds are also separate the dynamic step voltage will cause currents to flow to equalize these separate ground voltages Then if the coax cable associated with a radio is the only path linking the e
199. page see Figure F 27 This page allows a user to save configuration parameters from a ControlWave XFC or load a saved configuration down to a ControlWave XFC The page opens from defaults and the information displayed is retrieved from the following file C OpenBSI WebXFC Config DefaultMXFC RCP The information displayed is returned from this file If a user has made changes to the configuration of the unit upgrade of the values can be changed by clicking on Load from RTU The values in the configuration now reflect the actual configuration of the unit Users may save their configuration to a file First the user should select the file where the configuration should be save This is done by clicking on Browse and selecting an existing file or by typing in a new file name to save the configuration After the file has been selected the date is saved by clicking on Write to File Load from RTU Load from File Modify Signal Write to RTU Delete Signal Floating Point Format Load Signal List es 4 S e dei GV SAMPLER_ENA GV Samp_PRate GYV Samp_Track GV Samp_DO_Point GV Mech_1_Enable GG Mech 1 Int Count GV Mech 2 Enable GGV Mech 3 Int Court GV MIX_DP_Damp_Enable GV MIN GP Damp Enable GV MIX_RTD_Damp_Enable GV OdorEnable Figure F 27 Meter Run Save Load Configuration Web Page A user may download a previously saved configuration to the ControlWave XFC Users would select the file to download to the unit by clicking
200. pecific Gravity of the gas being measured is displayed here FPV Supercompressibility Factor is displayed here 0 045923 0 045923 Figure F 19 Frequency Flow Equation Setup Web Page K Factor Units Users may select whether the factor is in units of CuFt Count or Counts CuFt K Factor Actual Gas Volume represented per count is entered here The relationship is controlled by the K Factor Units switch If the K Factor Units switch is set to CuFt Count and each pulse from the meter represents 100 cubic feet the K Factor is entered as 100 If the K Factor Units switch is set to Counts CuFt and each pulse from the meter represents 100 cubic feet the K Factor is entered as 1 100 or 0 01 Frequency Input The frequency from the meter Hz is displayed here Frequency Input Max If the frequency input exceeds the Frequency Input Max value the Frequency Input Max value is used in the flow equation CI ControlWave XFC Appendix F F 29 Static Pressure Actual values in use for the calculation Temperature Actual values in use for the calculation Pressure Adjustment Average Barometric Pressure psia Base Pressure Required or Contract base pressure psia Base Temperature Required or Contract base temperature Deg F Calibration Factor Sometimes referred to as Meter Factor this is an adjustment factor issued by the meter manufacturer to account for known meter adjustments The default 1 1 e no adjustments requ
201. ped with an optional Multivariable Transducer MVT may be mounted directly on the pipeline or remotely on a vertical or horizontal stand alone two inch pipe or on a wall or panel ControlWave XFCs equipped with an optional Gage Pressure Transducer GPT may ONLY be mounted remotely Le on a vertical or horizontal stand alone two inch pipe or on a wall or panel The Earth Ground Cable is to run between the ControlWave XFC s Ground Lug and Earth Ground Rod or Bed even though the ControlWave XFC units equipped with a MVT or GPT Transducer may be grounded to the pipeline If any pressure transmitters or pulse transducers are remotely mounted connect their chassis grounds to the pipeline or earth ground Note Remote installation of a unit without Cathodic protection is similar to that of Figure 2 6 except it doesn t utilize the Transducer to Manifold Dielectric Isolation Kit see Figure 2 7 2 10 Installation amp Operation CI ControlWave XFC CW XFC Housing Rotated 180 Degrees Max Rotation dE ER CW XFC Housing E ES ER CW XFC Housing Rotated 90 Degrees Rotated 90 Degrees Counterclockwise TwIsT coum E Clockwise a E 8 LI a LJ E J Si Mm i F gj im L Wa meee ControlWave XFC Housing As Shipped Housing Assembly N Use a 3mm Hex Wrench amp to Loosen Tighten MVT Assembly Set Screw Multivariable Transducer MVT
202. plan Observe all personal protection equipment recommendations described in Sections 5 and 8 For large spills provide diking or other appropriate containment to keep material from spreading If diked material can be pumped store recovered material in appropriate container Clean up remaining materials from spill with suitable absorbant Clean area as appropriate since some silicone materials even in small quantities may present a slip hazard Final cleaning may require use of steam solvents or detergents Dispose of saturated absorbant or cleaning materials appropriately since spontaneous heating may occur Local state and federal laws and regulations may apply to releases and disposal of this material as well as those materials and items employed in the cleanup of releases You will need to determine which federal state and local laws and regulations are applicable Sections 13 and 15 of this MSDS provide information regarding certain federal and state requirements Note See section 8 for Personal Protective Equipment for Spills Call Dow Corning Corporation 989 496 5900 if additional information is required 7 HANDLING AND STORAGE Use with adequate ventilation Avoid eye contact Use reasonable care and store away from oxidizing materials 8 EXPOSURE CONTROLS PERSONAL PROTECTION Component Exposure Limits There are no components with workplace exposure limits Engineering Controls Local Ventilation Gene
203. pplying pressure against the sheath to force the Tip of the RTD Probe into the bottom of the thermowell so that the Probe Tip is in contact with the thermowell tighten the Nut 9 16 open end wrench against the 7 8 Fitting Body see Figure 2 12 Sheath RTD EXC Excitation RTD Sense RTD Return Three Wire Bulb ControlWave XFC Terminal Plate Figure 2 11 3 Wire RTD Temperature Input Wiring Bushing Conduit Sheath 7 8 Fitting Body Div 2 ONLY i cael Probe Tip 9 16 Nut Figure 2 12 RTD Probe Installation Removal Diagram 2 22 Installation amp Operation CI ControlWave XFC 2 3 5 Connection to a Model 3808 Transmitter A Model 3808 Transmitter Digital can be interfaced to a ControlWave XFC via either an RS 232 or an RS 485 communication scheme Communication schemes and cable lengths are determined the type of communication port utilized In general RS 232 communications are utilized when the Model 3808 Transmitter is situated within 25 feet of the ControlWave XFC i e for local communications Communications can be achieved with transmitters up to 4000 feet away remote communications via the RS 485 scheme ControlWave XFC com2 Term Plate Term Block gt To 3808 POWER gt TO RS485 8 TXD e o To R x DN DIS
204. quipment chassis with the tower ground the surge can destroy circuitry 4 1 4 Tying it all Together To prevent this disaster from occurring a grounding system must be formed which interconnects all grounds together This will equalize and distribute the surge charge to all grounds and at the same time it will make for a lower surge impedance ground system This interconnection can be done as a grid where each ground has a separate line to each other ground or by using a rat Race ring which forms a closed loop not necessarily a perfect circle which surrounds the equipment house completely By making this interconnection it will be necessary to use proper I O protectors for the equipment Of course these should be a requirement regardless of whether this grounding technique is used I O protectors are used for power lines even those these don t feed into a ControlWave unit telephone lines and also to minimize EMI pick up from a strike Ideally it is best to place all I O protectors on a common panel that has a low inductance path to the ground system The ControlWave units would then have a single ground point from its Chassis Ground Terminal Ground Lug to this panel In lieu of this the ControlWave unit in question should be tied to a ground rod that in turn is connected to the Earth System Ground created for the site Your protected equipment connected to a common single ground system will now be just like a bird sitting on a
205. r The Scale Factor is a ratio of the amount of odorant to be injected per cubic foot of gas Users must know the maximum output of the Odorizer and calculate the ratio accordingly The Current Odor Demand is the raw value of the odorant required If this value is greater than that which is allowed by the AO Zero and Span the actual odorizer output will be clamped to the maximum AO value When the Digital Output Mode is used the user must enter the frequency of the pulses per volume through the meter in cubic feet F 5 3 Mechanical Counter Configuration The Mechanical Counter Configuration section of the Sampler amp Mechanical Counter Configuration Web Page is used to simulate a mechanical counter An Enable Disable button is used to activate deactivate this function Synchronization of the ControlWave XFC Counter with an external Mechanical Counter is achieved via the Initial Count field Determination of the volume of gas per pulse is performed utilizing the Pulse Frequency field Current Count is the actual number of pulses received by the unit Users must select which HSC Input will be used with the Mechanical Counter GES Ree aaa Set Initial Count Ge L Figure F 7 Mechanical Counter Configuration Web Page F 6 Appendix F CI ControlWave XFC F 5 4 Nomination Users configure the nominations control from the Nomination WebPage Nominations functionally provide the user with the ability to set the ControlWave XFC to al
206. r J2 on the ControlWave XFC Terminal Plate F 3 WebBSI PROGRAM STARTUP Ensure that the Local Communications Cable connections at both the ControlWave XFC amp the PC are secure F 2 Appendix F CI ControlWave XFC If the WebBSI Web pages for the ControlWave XFC have been assigned as the default Web pages for a node in OpenBSI they can be invoked either from OpenBSI by right clicking on the appropriate RTU and selecting RTU gt WebPage Access Web pages are also accessible by selecting Start gt Programs gt OpenBSI Tools gt WebPage Access gt CW XFC Pages Seven Category Functions are provided as follows Section F 4 Security Section F 7 Chromatograph Section F 10 Special Functions Section F 5 Station Section F 8 Logs Section F 6 Meter Run Section F 9 Load Save FA SECURITY CATEGORY FUNCTIONS Three Web pages are accessible from the Security category section of WebBSI e Sign On Off Section F 4 1 e Contacts Section F 4 3 e Locate Nodes Section F 4 2 F 4 1 Signing On Off When the WebBSI Web pages for the ControlWave XFC are first accessed the SIGN On Off Web page is displayed A user must select the RTU Name from the drop down menu If using OpenBSI Network Edition this drop down menu will include all nodes available on the network If using OpenBSI Local Edition only the default node RTU will be available ControlWave Node Name IRTU Security Station Meter Run Chromatograph
207. ral Ventilation None should be needed Recommended Personal Protective Equipment for Routine Handling Eyes Skin Suitable Gloves Inhalation Suitable Respirator Use proper protection safety glasses as a minimum Washing at mealtime and end of shift is adequate No special protection needed No respiratory protection should be needed None should be needed Personal Protective Equipment for Spills Eyes Skin Use proper protection safety glasses as a minimum Washing at mealtime and end of shift is adequate DOW CORNING CORPORATION Material Safety Data Sheet DOW CORNING 200 R FLUID 100 CST Inhalation Suitable No respiratory protection should be needed Respirator Precautionary Measures Avoid eye contact Use reasonable care Comments When heated to temperatures above 150 degrees C in the presence of air product can form formaldehyde vapors Formaldehyde is a potential cancer hazard a known skin and respiratory sensitizer and an irritant to the eyes nose throat skin and digestive system Safe handling conditions may be maintained by keeping vapor concentrations within the OSHA Permissible Exposure Limit for formaldehyde Note These precautions are for room temperature handling Use at elevated temperature or aerosol spray applications may require added precautions For further information regarding aerosol inhalation toxicity please refer to the guidance document regarding the use of
208. rd Switches SW1 9 and SW1 10 such that both are ON or OFF or Set SW1 9 ON and SW1 10 OFF Apply power to the ControlWave XFC The resident BIOS will initialize and test the hardware this process is referred to as POST Power On Self Test 2 30 Installation amp Operation CI ControlWave XFC From the Hyperterminal Recovery Mode menu Figure 2 22 press the F key to enter FLASH download A message will be displayed warning that the FLASH is about to be erased press the Y key at the prompt The screen will display dots as the flash devices are being erased this could take a few minutes cw HyperTerminal iol x File Edit view Call Transfer Help Del as ols l b Boot System Firmware d Debug Mode f Program System Flash t Tests Enter Option Connected 0 00 08 ansiw fi152008 N 1 SCROLL Kaes NUM Capture Print echo Figure 2 22 HyperTerminal Recovery Mode Menu 5 When the FLASH is ready for download the letter C will be displayed on the screen In the HyperTerminal command bar click on Transfer and then Send File see Figure 2 23 In the Send File Dialog Box see Figure 2 24 select 1KXmodem for the protocol enter the filename of the appropriate bin file in the format CWXxxxxx bin where xxxxx varies from release to release Click on the Send button to start the download see Figure 2 24 When the HyperTerminal Recovery Mode Menu of Figure 2 22 appears the download has complete
209. re for establishing a connection to Earth Ground In the case of the ControlWaveLP a Chassis Ground termination terminal TB2 Pin 3 that accepts up to a 14 AWG size wire is provided on the unit s Power Supply Sequencer Board 3 2 IMPORTANCE OF GOOD GROUNDS ControlWave units see above are utilized in instrument and control systems that must operate continually and within their stated accuracy over long periods of time with minimum attention Failures resulting from an improperly grounded system can become costly in terms of lost time and disrupted processes A properly grounded system will help prevent electrical shock hazards resulting from contact with live metal surfaces provide additional protection of equipment from lightning strikes and power surges minimize the effects of electrical noise and power transients and reduce signal errors caused by ground wiring loops Conversely an improperly grounded system may exhibit a host of problems that appear to have no relation ship to grounding It is essential that the reader service technician have a good under standing of this subject to prevent needless troubleshooting procedures WARNING This device must be installed in accordance with the National Electrical Code NEC ANSI NEPA 70 Installation in hazardous locations must also comply with Article 500 of the code For information on the usage of ControlWave units in Class I Division 2 Groups C amp D Hazardous and Nonhazardous
210. re stored and displayed on a personal computer PC and use either OpenBSI Network edition or Local edition to interface to the ControlWave XFC Web pages provide Sign on to the ControlWave XFC Invoke menus to configure the ControlWave XFC for operation Read current gas flow and total information Set the ControlWave XFC Date and Time Change the ControlWave XFC network address Collect amp Display the Daily Hourly Periodic amp Audit Logs F 1 1 Viewing WebBSI WebBSI is best viewed under these conditions e The Internet Explorer window should be maximized or be viewed full screen e The resolution of the monitor should be at least 800x600 or above preferably 1024x768 or above e The color depth should be at least 16 bit high color or above preferably 24 bit true color or above e The text size of Internet Explorer should be Medium or smaller preferably Medium e JavaScript and ActiveX Controls should be enabled in Internet Explorer Pop up Help windows for WebBSI Web pages can be accessed by clicking the Help button on the left side of WebBSI Web pages The help windows must be closed in order to open another On pages that contain tables of controls e A white background on a control means that it is read write e A beige background on a control means that it is read only F 2 INSTALLING WebBSI SOFTWARE amp ControlWave XFC Web Pages The WebBSI software requires a PC computer running either OpenB
211. reas that have frequent lightning strikes or are located near or used in conjunction with equipment that is likely to be struck by lightning or if struck by lightning may cause equipment or associated system failure Earth Grounds must be tested and must be known to be good before connecting the ControlWave Earth grounds must be periodically tested and maintained see Section 4 5 2 5 Earth Ground Wires Earth connections must utilize smoothly dressed large wire Use AWG 3 or 4 stranded copper wire with as short a length as possible Exercise care when trimming the insulation from the wire ends Twists the strands tightly trim off any frizzes and tin the ends with solder The earth ground wire should be clamped or brazed to the Ground Bed Conductor that is typically a standard AWG 0000 copper cable The earth ground wire should be run such that any routing bend in the cable is a minimum 8 inch radius above ground or a minimum 12 inch radius below ground 5 2 6 Working Neatly amp 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 D
212. rent limiting resistor Check resistivity of wrist strap periodically using a commercially available system tester similar to the one shown in the figure below ESDS Manual 514006 4 15 92 Note If a system checker is not available use an ohmmeter connected to the cable ends to measure its resistance The ohmmeter reading should be 1 megohm 15 Be sure that the calibration date of the ohmmeter has not expired If the ohmmeter reading exceeds 1 megohm by 15 replace the ground cord with a new one Static safe Field Procedure 1 On reaching the work location unfold and lay out the work surface on a convenient surface table or floor Omit this step if the table or floor has a built in ESD safe work surface 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 Note which boards or components are to be inserted or replaced Power down the system following the recommended power down procedure Slip on a kKnown good wristband which should fit snugly an extremely loose fit is not desirable Snap the ground cord to the wristband Attach the other end of the ground cord to a reliable ground using the alligator clip ESDS Manual 14006 4 15 92 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
213. res the use of an RS 232 Null Modem cable see Figure 2 9 COM8 RS 485 Communications Port COM3 defaults to 9600 baud 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation To test COM3 using the WINDIAG program it must not be in use Note CPU Switch SW1 8 must be set OFF to run the WINDIAG program In lieu of the use of an RS 232 Port an RS 485 CI ControlWave XFC Installation amp Operation 2 33 cable see Tables 2 2C amp 2 3 can be connected between COM3 and the PC s RS 485 Port 2 4 5 Display Assembly In normal operation the display stays on after the unit is configured and placed in service ControlWave XFC Display Assembly contains an upper row consisting of a LCD character along with nine 7 Segment LCD characters and a bottom row consisting of six 14 Segment LCD characters Signal values controlled by the application load are posted to the upper characters and signal names are posted to the lower characters Figure 2 26 shows the front of the CPU Board with factory installed Display Assembly 0009000090090 Contrast R43 wel Battery Backup Figure 2 26 ControlWave XFC CPU Board 2 34 Installation amp Operation CI ControlWave XFC Section 3 SERVICE E 3 1 SERVICE INTRODUCTION This section provides general diagnostic and test information for the ControlWave XFC The service procedures des
214. rn 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 ESDS Manual 14006 4 15 92 Clean PC board connectors as follows Review the static safe field procedure detailed earlier Following the ESD sensitive component handling procedures remove the connectors from the boards and remove the PC boards from their holders Use cleaner to remove excessive dust build up from comb connectors and other connectors This cleaner is especially useful for removing dust Liberally spray all PC board contacts with Inhibitor The inhibitor Provides a long lasting lubricant and leaves a protective film to guard against corrosion e Improves performance and reliability Extends the life of the contacts o 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 Cleaning PC edge connectors a Use cleaner to remove excessive dust build up from connectors This cleaner is especially useful for removing dust Liberally spray the outboard connector with Inhibitor Lightly brush the outboard connector with a soft non metallic bristle brush such as a toothbrush ESDS Manual 514006 4 15 92
215. ror Port to Test com D Baud Rate to Test ALL ASYNC D Number of Failures Status Idle Pass Status Test RUN External loop back Error Status Note Port needs to be configured for BSAP mode and tested with those parameters selected Verify loopback plug is inserted in the tested port Return to Menu Figure 3 6 WINDIAG s Communications Diagnostic Menu 3 10 Service CI ControlWave XFC 3 6 CORE UPDUMP In some cases a copy of the contents of SRAM can be uploaded to a PC for evaluation by Bristol Inc engineers This upload is referred to as a Core Updump A Core Updump may be required if the ControlWave XFC electronic flow meter repeatedly enters a Watchdog State thus ill effecting system operation A Watchdog State is entered when the system crashes i e a CPU timeout occurs due to improper software operation a firmware glitch etc In some cases the Watchdog State may reoccur but may not be logically reproduced Crash Blocks a function of firmware provided for watchdog troubleshooting are stored in CPU RAM The user can view and save the Crash Blocks by viewing the Crash Block Statistic Web Page see Chapter 4 of the Open BSI Technician s Toolkit D5087 Crash Block files should be forwarded to Bristol Inc for evaluation If additional information is required to evaluate the condition a Core Updump may be requested by Bristol Once the file generated by the Core Updump has been fo
216. rwarded to Bristol it will be evaluated and the results will be provided to the user Follow the four steps below to perform a Core Updump 1 Set CPU Board Switch SW1 1 OFF Disable Watchdog Circuit If Switch SW1 4 is ON set it to OFF Enable Core Updump Note The factory default setting for SW1 4 is OFF 2 Connect ControlWave XFC Comm Port 1 to a PC using a special 3 wire Cable see Figure 2 9C 3 Set CPU Board Switches SW1 9 and SW1 10 so that both are in either the ON position or the OFF position or set SW1 9 ON and SW1 10 OFF 4 Start the PC s HyperTerminal Program at 115 2kbaud and generate a file using the 1KX Modem protocol Save the resulting Core Updump in a file to be forwarded to BBI for evaluation When the Core Updump has been completed set the CPU Board Switch SW1 as follows SW1 9 is in the OFF position amp SW1 10 is in the ON position 3 7 CALIBRATION CHECKS Calibration of the MVT or GPT and the RTD are performed using OpenBSI s TechView Program see document D5131 TechView User s Guide CI ControlWave XFC Service 3 11 Section 4 SPECIFICATIONS KEE 4 1 CPU MEMORY amp PROGRAM INTERFACE Processor Memory Real Time Clock Connectors Ref Pins Sharps LH7A400 32 bit System on Chip with 32 bit ARM9TDMI RISC Core 8 Mbytes of simultaneous read write FLASH 2 Mbyte of on board SRAM 512 Kbytes FLASH Boot Downloader Contained in SC520 generates a 1 second ti
217. s cabinets etc or to earth itself Never assume that adjacent or peripheral equipment has been properly installed and grounded Determine if this equipment and the ControlWave unit in question can be touched simultaneously without hazard to personnel and or equipment 8 Before embarking to remote locations where there are few or no human inhabitants ask a few simple questions like should I bring water food hygienic materials first aid kit etc Be Prepared 9 Observe the work habits of those around you for your own safety Some of the items that a service person should consider before ever going on site can be ascertained by simply asking questions of the appropriate individual Obviously other safety considerations can only be established at the installation site 2 2 2 Considerations For The Protection of Equipment Always evaluate the site installation service environment and equipment Understand the various physical interfaces you will be dealing with such as equipment mounting and supporting ControlWave analog and digital circuits power circuits communication circuits and various electrical grounds Table 2 2 provides a general guideline for evaluating the equipment protection requirements of an installation site Table 2 2 Equipment Protection Site Safety Evaluation Guide Reference Section Environment Class I Division 2 Nonincendive See Appendix A of CI Manual Environment Class I Division 1 Intrinsicall
218. s been selected the Meter Run Archive Files WebBSI Web Page will be displayed see Figure F 23 Meter Run Archive Files Web Pages provide three types of archive files i e Hourly Daily amp 15 Minute for each of the two runs Meter Run Archive File Web page pushbuttons allow the user to Collect Data Save Parameters Search Criteria select Floating Point Format and show File Definition Users can select one of the following Archive Collection Parameters File Number To Collect Select from oldest record or Freeze Date Time Users can select the archive file Hourly CI ControlWave XFC Appendix F F 33 Daily or 15 Minutes for the run in question by entering a number from 1 to 12 in the field adjacent to File Number Figure F 23 Meter Run Archive File Web Page Hourly Archive Shown Meter Run ID Hourly Daily 15 Minute Run Archive Archive Archive Number Number Number Pd Run EE GE 2 3 2 Rum 4 5 6 The Web page opens by default configured to view Archive 1 R1 HOURLY To view another archive the user will enter the desired archive number in the File Number field and then press the Collect Data button To save the collected archive data the user would press the Save Parameters button A Save Parameters dialog box will appear which will allow the user to select the file name to save the data as and select the folder to save the data in After selecting the file Nam
219. s composition The calculation of Zs will be done once per minute or whenever a related gas constant changes Users may select which Supercompressibility equation to use on a per run basis The user will click on the appropriate button to select the calculation equation to be used The selected compressibility calculation will be shown When using the AGA8 Gross Calculation the user must select the Gross Model or the Gross Mode calculation The user may change the Base Pressure and the Base Temperature for this screen Flowing Static Pressure Flowing Temperature BTU and Specific Gravity in use are displayed on this page Values of the gas components used to calculate the Supercompressibility are displayed along with the FPV Zflowing and ZBase values calculated by the Supercompressibility equation in use F 7 CHROMATOGRAPH CATEGORY FUNCTIONS The standard application program is configured for communicating with a Daniel 2251 Gas Chromatograph via a serial MODBUS interface Users will configure the Chromatograph interface from the Chromatograph Setup Web Page Figure F 21 Component Range Setup 0 dog Figure F 21 Chromatograph Setup Web Page F 7 1 Communication Settings Mode Enabled Disabled When this signal is ENABLED a chromatograph is present and gas component data is provided by the chromatograph interface When this signal is DISABLED the fixed values for the gas component data are used CI ControlWav
220. s fumes of manganese and lithium oxides of carbon and other toxic by products NA NOT AVAILABLE GMEL 2033 3 Page 2 of 4 D HEALTH HAZARD DATA Occupational Exposure Limits PEL s TLV s etc 8 Hour TWAs Manganese Dioxide as Mn 5 mg m Ceiling OSHA 0 2 meim ACGIH Gillette 1 2 Dimethoxyethane 0 15 ppm Gillette Graphite all kinds except fibrous 2 mg m synthetic ACGIH 15 mg m total OSHA 5 mg m respirable OSHA These levels are not anticipated under normal consumer use conditions Warning Signals Not applicable Routes Effects of Exposure These chemicals and metals are contained in a sealed can For consumer use adequate hazard warnings are included on both the package and on the battery Potential for exposure should not exist unless the battery leaks is exposed to high temperature is accidentally swallowed or is mechanically physically or electrically abused 1 Inhalation Not anticipated Respiratory and eye irritation may occur if fumes are released due to heat or an abundance of leaking batteries 2 Ingestion An initial x ray should be obtained promptly to determine battery location Batteries lodged in the esophagus should be removed immediately since leakage burns and perforation can occur as soon as 4 6 hours after ingestion Irritation to the internal external mouth areas may occur following exposure to a leaking battery a Contact Irritation may occur following exposur
221. sed to the environment or spilled in the work area Evacuate the area and allow vapors to dissipate Increase ventilation Avoid eye or skin contact DO NOT inhale vapors Clean up personnel should wear appropriate protective gear Remove spilled liquid with absorbent and contain for disposal Fire and Explosion Hazard Extinguishing Media Batteries may burst and release hazardous decomposition products when As for surrounding area Dry exposed to a fire situation See Sec C chemical alcohol foam water or carbon dioxide For incipient fires carbon dioxide extinguishers are more effective than water Firefighting Procedures Cool fire exposed batteries and adjacent structures with water spray from a distance Use self contained breathing apparatus and full protective gear I FIRST AID AND MEDICAL EMERGENCY PROCEDURES Eyes Not anticipated If battery is leaking and material contacts eyes flush with copious amounts of clear tepid water for 30 minutes Contact physician at once Skin Not anticipated If battery is leaking irrigate exposed skin with copious amounts of clear tepid water for a least 15 minutes If irritation injury or pain persists consult a physician Inhalation Not anticipated Respiratory and eye irritation may occur if fumes are released due to heat or an abundance of leaking batteries Remove to fresh air Contact physician if irritation persists Ingestion Consult a physician Published reports recomme
222. sful communications have been established and completed The radio will remain active for the time period specified at the Turn Off Delay F 5 7 5 Daily Mode Daily Mode Hour Offset When the Daily Mode is selected the radio modem will be turned on once during the day The Daily Mode Hour Offset determines which hour 0 23 that the radio will be turned on On Time Minutes and On Time Seconds are calculated F 5 7 6 Day Light Mode A user may want to conserve battery power by using the radio modem only during day light hours This is accomplished by selecting Daylight as the Radio Modem Control Mode Users select the start of day light using the Day Light Mode Start Hour and Day Light Mode Start Minute fields Users select the end of day light using the Day Light Mode End Hour and Day Light Mode End Minute field F 5 7 7 Statistic Current Previous Hour Radio On Time Current Previous Day Radio On Time Current Previous Month Radio On Time CI ControlWave XFC Appendix F F 17 F 6 METER RUN CATEGORY FUNCTIONS Up to four WebBSI Web Pages are accessible under the Meter Run Category Section of WebBSI these include e Overview Section F 6 1 e Flow Equation Section F 6 3 e HO Configuration Section F 6 2 e Compressibility Setup Section F 6 4 The Web Page of Figure F 12 will appear when either the Overview or Flow Equation category has been selected if a Meter Run Type Differential or Linear has not been
223. shipment ESDS Manual 14006 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 9 damage the componeni s Include a note which describes the malfunction in a separate bag along with each component being shipped The repair facility will service the component and promptly return it to the field Protecting ESD Sensitive Components 1 As stated previously it is recommended that an electrically conductive anti static field kit be kept on any site where ESD sensitive components are handled A recommended ESD protective workplace arrangement is shown on page 7 The anti static safety kit serves to protect the equipment as well as the worker As a safety feature a resistor usually of the one megohm 1 2 watt current limiting type has been installed in the molded caps of the wrist strap cord and the ground cord This resistor limits current should a worker accidently come in contact with a power source Do not remove the molded caps from grounded cords If a cord is damaged replace it immediately 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 cur
224. smitter etc and their mount interface to the pipeline Transducer to Manifold Dielectric Isolation Kit Multivariable Transducer MVT Dielectric Gasket amp Flange Seals 2 Valve Block Manifold Top Washers 4 Dielectric Bolt Sleeves 4 Bottom Washers 4 Mounting Bolts 4 Isolating i Fittings AWG 14 Ground Wire if from Internal Ground Shown AWG 4 Ground Wire if from External Ground Lug lt Ground Rod or System Figure 2 7 ControlWave XFC Remote Installation with Cathodic Protection 2 3 2 CPU Board Configuration To configure the CPU Controller Board DIP Switch SW1 must be set see Section 2 3 2 1 the Backup Battery should be enabled by installing Jumper JP1 onto its posts and Communication Ports must be wired see Sections 2 3 2 2 through 2 3 2 3 The CPU Board is situated behind the Front Display Cover see Figures 2 1 amp 2 8 2 3 2 1 CPU Board Switch SW1 Configuration ControlWave XFC CPU Board DIP Switch SW1 must be set for the desired performance options Table 2 1 provides an overview of switch settings SW1 1 set OFF will disable the system from entering a watchdog state when a crash or system hangup occurs Setting SW1 1 OFF prevents the system from automatically restarting CI ControlWave XFC Installation amp Operation 2 13 SW1 2 set OFF prevents changing the Soft Switches other configurations and FLASH files i e these items are locked To change Soft Switch co
225. sociation AWWA Additionally installation at various customer sites may be performed in conjunction with a safety manager or utility personnel with HAZMAT hazardous material training on materials present or potentially present as required by OSHA the customer etc Section 2 Protection Page 2 1 S1400CW 2 2 1 Considerations For The Protection of Personnel Always evaluate the site environment as if your life depended on it Make sure that you understand the physical nature of the location where you will be working Table 2 1 provides a general guideline for evaluating an installation site Table 2 1 Installation Site Safety Evaluation Guide Guide Indoor or outdoor Dress Appropriately 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 If in a tunnel bunker etc watch out for a build up of toxic or flammable gases Make sure the air is good Watch out for local varmint bees spiders snakes etc Hazardous or Non Hazardous Environment Wear appropriate safety equipment and perform all necessary safety measures Before installing any equipment or power or ground wiring make sure that there are no lethal life threatening voltages between the site where the instrument will be installed and other equipment pipe
226. ss PSI Ftb 0 000 Temperature DEG_F Fif 0 000 Spec Gravity 0 000 For 0 000 Z Flowing 0 000 FPV 8 000 ZBase 0 000 Fm 0 000 Base Temp 60 00 DEG_F Extension 0 000 Base Press 14 73 PSI Reynolds Number 0 000 Viscosity 0 00000690 Ibmjft sec BCF 0 000 Figure F 18B 1992 AGA3 Orifice Flow Equation Setup Web Page Orifice Diameter Orifice diameter is entered here Default units are inches Pipe Diameter Diameter of the pipe is entered here Default units are inches Orifice Temp Coefficient Orifice coefficient of thermal expansion is entered here Inches per Inch degree F CI ControlWave XFC Appendix F F 27 Pipe Temp Coefficient Pipe coefficient of thermal expansion is entered here Inches per Inch degree F Isentropic Exponent Gas Isentropic Exponent is entered here This should not be changed unless the Gas Isentropic Exponent is known to be other than the 1 3 value given in the 1992 American Gas Association AGA3 Report Adjust Press Users enter Average Barometric Pressure here psia Diff Press Actual value in use is displayed here Static Pressure Actual value in use is displayed here Temperature Actual value in use is displayed here Spec Gravity Specific Gravity of the gas being measured is displayed here Z Flowing Flowing compressibility Factor Zf generated from the AGA8 calculation referenced to upstream conditions Z Base Base compressibility Factor from the AGA8 Gross calculation
227. stol The information in this document is subject to change without notice Every effort has been made to supply complete and accurate information However Bristol Inc assumes no responsibility for any errors that may appear in this document If you have comments or questions regarding this manual please direct them to your local Bristol sales representative or direct them to one of the addresses listed at left Bristol Inc does not guarantee the accuracy sufficiency or suitability of the software delivered herewith The Customer shall inspect and test such software and other materials to his her satisfaction before using them with important data There are no warranties expressed or implied including those of merchantability and fitness for a particular purpose concerning the software and other materials delivered herewith TeleFlow is a trademark of Bristol Inc The Emerson logo is a trade mark and service mark of Emerson Electric Co Other trademarks or copyrighted products mentioned in this document are for information only and belong to their respective companies or trademark holders Copyright c 2006 Bristol Inc 1100 Buckingham St Watertown CT 06795 No part of this manual may be reproduced in any form without the express written permission of Bristol Inc ZS EMERSON
228. strike protection equipment such as Lightning Arresters Since ControlWave ControlWave MICRO ControlWave EFM GFC XFC Control WaveLP and ControlWaveEXP units are de operated systems that are isolated from AC grids they are typically immune to lightning strikes to power lines or power equipment except for inductive flashover due to close installation proximity However once a radio or S1400CW Page 4 2 Section 4 Lightning amp Surge modem has been interfaced to a ControlWave ControlWave MICRO ControlWave EFM GFC XFC ControlWaveLP or ControlWaveEXP the possibility of damage due to a lightning strike on power or telephone lines or to a radio antenna or the antenna s tower must be considered It is recommended that the additional lightning protection considerations listed below be followed for units installed in areas with a high possibility or history of stroke activity Units interfaced to a modem In series with the phone line as far away as possible from the equipment for indoor installations the lightning arrester should typically be located at the point where the line enters the structure Units interfaced to a radio Mount antenna discharge unit lightning arrester as close as possible to where the lead in wire enters the structure See Antenna Caution below 4 1 2 Antenna Caution Each year hundreds of people are killed mutilated or receive severe permanent injuries when attempting to install or remove an antenna or
229. t Change Signal Value Valve Travel Time Valve Travel Time is the amount of time it takes a Control Valve to go from being fully open to fully closed or visa versa The default value is 30 Seconds To change the Valve Travel Time value right click on the field and select Change Signal Value Current Data Flow Rate x1000 The Flow Rate value is Read Only data it is the present calculated flow rate per hour F 5 5 38 Pressure Override set one or both to enable override When the PID controller is active in flow control mode it will adjust a pressure valve to maintain the established flow rate setpoint Pressure override is used in situations where full line pressure should not be applied to the downstream equipment or in circumstances where a minimum pressure must be maintained Maximum amp Minimum A Maximum and Minimum pressure can be configured which set the PID controller to switch to pressure control mode whenever the line pressure attempts to go outside the defined limits The pressure override mode becomes active when either or both limits are set to a non zero value Pressure Tap Location Relative to the Control Valve The Pressure Tap location is specified as either upstream UPSTRM or downstream DNSTRM with respect to the control valve The action of the override controller depends on the configured Tap location When the pressure tap is configured as Downstream of the control valve pressure will rise as th
230. t inputs that are pulled internally to 3 6 Vdc when the field input is open Source current will be 60uA from the 3 6V supply 15 millisecond input filtering protects against contact bounce Digital Outputs have a 30V operating range and are driven by Open Drain FETs that sink 400 mA Max at 30Vdc The maximum output frequency is 1 Hz Transorbs provide surge suppression between each signal and ground 1 3 5 1 3 Non isolated High Speed Counter Inputs also see Sections 2 3 4 7 Terninal Plate Term Block connector J5 also provides the interface to two externally sourced single ended High Speed Counter Inputs HSCI Signal conditioning circuitry provides 20 microsecond filtering All Input circuits have surge suppression HSC inputs support externally generated internally sourced input signals 1 12 Introduction CI ControlWave XFC High Speed Counter inputs are sourced from V with a source current of 200uA and a maximum input frequency of 10kHz 1 3 5 1 4 Optional RTD Input Probe also see Section 2 3 6 Terminal Plate Term Block connector J3 provides connection to a 100 ohm platinum bulb using the DIN 43760 curve The common three wire configuration is accommodated In this configuration the return lead connects to the RTD terminal while the two junction leads Sense and Excitation connect to the RTD terminals 1 3 5 2 Terminal Plate Input Power Connections A 2 position Terminal Block is provided on the Terminal Plate and a
231. t power after fuse and Diode Input Range 0 to 80Vdc Resolution 12 Bit Accuracy Calibrated 100mV 25 C 77 F Calibrated 200mV over 40 to 80 C 40 to 176 F 4 4 2 Power Supply Sequencer Specs Signals Monitored Input Power Sequencer Switchpoints 3 3V Max ON Switchpoint 3 15V 3 3V Min OFF Switchpoint 3 00V 1 8V Max ON Switchpoint 1 72V 1 8V Min OFF Switchpoint 1 64V Sequencer Output Signals PFDLYCLK Timing on power down 2msec after POWER FAIL VIN100M timing on power Up 1800msec delay for Good Power POWERGOOD incoming power 3 3V amp 1 8V in Spec 4 2 Specifications CI ControlWave XFC 4 4 3 Non isolated Digital Input Output Circuitry Specs Non isolated Digital Inputs Number of Inputs 2 DI Internally Sourced Dry Contact operation Input Filtering 15 milliseconds Input Current 60uA nominal State Voltage below 1 5V T State Voltage above 1 5V Electrical Isolation None Surge Suppression Transorb between signal and ground Meets ANSI IEEE C37 90 1978 Non isolated Digital Outputs Number of Outputs 4DO Output Configuration Open Drain Externally Powered Maximum Load Current 400mA each 30Vdc Electrical Isolation None Surge Suppression Transorb between signal and ground Meets ANSI IEEE C37 90 1978 General DI DO Circuitry Specs Terminations Pluggable max wire size is 14 gauge for local terminations Two 14 pin mass terminati
232. tatic pressure and temperature are reported This allows monitoring of static pressure and temperature during shut in periods CI ControlWave XFC Introduction 1 15 1 5 2 3 1 Energy Calculation The ControlWave XFC offers the option of using a fixed volumetric heating value or calculating the energy content of the gas according to AGA Report No 5 1 5 2 3 2 Volume and Energy Integration Volume and energy are each integrated and accumulated at the end of every calculation cycle The volume for a cycle is the calculated rate multiplied by the flow time for that cycle The energy for a cycle is calculated by multiplying the volume at BASE conditions by the heating value 1 5 2 4 Downstream Pressure Tap The multivariable transducer typically measures static pressure from an integral tap on the upstream high pressure leg of the differential pressure connection Static pressure can be measured at the downstream pressure tap with the measurement taken from the low pres sure side to the high pressure side In this installation the differential signal from the transducer is negative If while using the integral smart Multivariable Transmitter MVT the user selects the downstream tap location during MVT configuration the MVT firmware changes the sign of the differential pressure to provide a positive DP value 1 5 3 Archives The ControlWave XFC stores two distinct types of archive data The first type is Audit Trail data which is a record
233. te to Soft Switches and FLASH files Soft Switches OFF Soft Switches configurations and FLASH files are locked Soft Switches OFF Ignore Soft Switch Configuration and use factory defaults See Section 3 6 OFF Core Updump Enabled via SW1 9 amp SW1 10 ON Retain values in SRAM during restarts ARAM Control OFF Force system to reinitialize SRAM O SW1 6 System Firmware N Enable remote download of System Firmware Load Control OFF Disable remote download of System Firmware L SW1 7 TNA ON Normal Operation don t allow WINDIAG to run test Enable WINDING OFF Disable boot project allow WINDIAG to run test SW1 9 10 Recovery Local Both ON OFF or SW1 9 ON amp SW1 10 OFF Recovery Mode Mode SW1 9 OFF amp SW1 10 ON Local Mode Boot PROM version 4 7 or higher and System PROM version 4 7 or higher 1 3 4 I O Board Assembly The I O Board assembly mounts against the Terminal Plate at the rear end of the Function Module i e the end furthest away from the the CPU Board This board contains two Microcontrollers that handles the following functions e Multivariable Transducer MVT or Gage Pressure Transducer GPT Interface e Analog to Digital circuitry that monitors an external RTD and the unit s power source e Process I O circuitry consisting of the following e Three 1 5V Analog Inputs Optional e Two Discrete Inputs and Four Discrete Sink Outputs e Two High Speed Counters e One Analog Output 4 to 20m
234. the CPU Board In addition to the microprocessor and control logic the CPU Board includes 2MB of battery backed Static RAM SRAM 512kB Boot Downloader FLASH 8MB simultaneous read write FLASH SPI I O Bus Serial Real Time Clock Display Interface and three Communication Ports a 3 wire RS 232 Local Port COM1 a 7 wire RS 232 Network Port COM2 and a 2 wire RS 485 Network Port COM3 H With GPT With MVT Figure 1 1 3820 EX ControlWave XFC Models 1 2 Introduction CI ControlWave XFC 1 Rear Wiring Housing Cover 2 Function Module Mounting Screws 3 Function Module items 9 10 12 amp 13 4 MVT Cable 5 Multivariable Transducer MVT 6 Housing Case 7 Data Plate 8 Front Display Housing Cover 9 Terminal Plate 10 CPU Bd Assembly 10 11 11 Cover O Ring 12 1 O Bd Assembly 13 LCD Display Assembly MVT Cable Plugs in Here Figure 1 2 ControlWave XFC Isometric Views Component Identification Diagram Shown with MVT The I O Board contains I O field interface circuitry and non isolated power circuitry Non isolated power is generated and regulated by the I O Board that provides 3 6Vdc for all logic and bulk power for I O field circuits from a bulk source of 6Vdc to 30Vdc
235. thered from the network generate files based on collected historical data collect alarms and monitor and control OpenBSI communications Communication engine for PC applications Supports ControlWave and Network 3000 serial and IP protocols RS 232 Dial line cellular radio CDPD satellite and Ethernet connections Provides on line download amp signal variable changes Allows network configuration through NetView PC and Network communication diagnostics OPC Server for interfacing to most HMI software Harvester collects historical data on request or scheduled basis NetView is the basic configuration and application interface for all network operations NetView uses a tree structure for network graphical display in the Windows Explorer style Network nodes can be added on line by simply dragging the node Icon into the tree This invokes a configuration Wizard simplifying network setup Through the NetView Wizard the necessary network parameters are entered for node and IP address alarm and message routing and network communication media Once configured selecting any node allows direct access to the common OpenBSI utilities to reprogram download a new application to the node review communication statistics view real time data through DataViewer and edit controller RTU properties Local Configuration Wizard allows local communication with any attached Control Wave controller or RTU to download system flashware upgrades configure co
236. ting point final gain is usually less To change the Gain value right click on the field and select Change Signal Value Integral Integral determines the time it will take the PID to correct an error in the measured variable The number of times the output is adjusted in a given time period is specified in seconds An entry of 60 seconds can be used as a starting point this would provide one 1 repeat per minute To change the Integral value right click on the field and select Change Signal Value Derivative Derivative compensates for a rapidly changing measured variable The time is specified in seconds SECS and most applications will use a setting of zero 0 To change the Derivative value right click on the field and select Change Signal Value F 12 Appendix F CI ControlWave XFC Deadband Deadband provides a means of specifying a window in which the variable does not affect the output This entry is in percent of the SETPOINT signal As an example a 5 entry would mean that the controller output must exceed the present setpoint by 5 before the output is changed To change the Deadband value right click on the field and select Change Signal Value Max Flow Rate x1000 Max Flow Rate represents the maximum flow rate allowed If the number entered in the Setpoint field exceeds the Max Flow Rate value the Max Flow Rate value will be used To change the Max Flow Rate x1000 value right click on the field and selec
237. tion The user must configure the inputs to the equation Pressure Tap The user must select Pressure Tap type and location The type is defined Flange or Tap and the location is defined as Upstream or Downstream Pressure Tap is selected as follows DOWNSTREAM FLANGE UPSTREAM FLANGE DOWNSTREAM PIPE UPSTREAM PIPE VG G b r CI ControlWave XFC Appendix F F 25 Low Flow Cut Off When the differential pressure drops below the low flow cut off value the flow rate will be set to zero Default units are inches of water Orifice Diameter Orifice diameter is entered here Default units are inches Pipe Diameter Diameter of the pipe is entered here Default units are inches Orifice Constant K AGA3 1985 Orifice constant is entered here Adjust Press Users enter Average Barometric Pressure here Diff Pressure Actual value of Differential Pressure Inches H20 are displayed here Static Pressure Actual value of Static Pressure psig are displayed here Temperature Actual value of Temperature Deg F are displayed here Specific Gravity Specific Gravity of the gas being measured is displayed here Click Here to Select AGAJI d Figure F 18A 1985 AGA3 Orifice Flow Equation Setup Web Page FPV Supercompressibility Factor FPV is displayed here Base Temperature Required or Contract Base Temperature is entered here Deg F Base Pressure Required or Contract Base Pressure is entered h
238. tion period would cause this value to be 4 0 Percent Delivered This signal provides the percentage of target delivered to this point in the current nomination period NEXT NOMINATION PERIOD This section allows the operator to set view the following parameters associated with the next nomination which is to be programmed has been programmed Note New entries must be made prior to the ending of the current nomination period Start day hour The actual start day of the month 1 31 and start hour 0 23 when the next nomination period is to start is displayed or entered The start day is ignored if the daily nomination feature is enabled CI ControlWave XFC Appendix F F 9 Stop day hour The actual stop day of the month 1 31 and stop hour 1 23 when the next nomination period is to end is displayed or entered The stop day is ignored if the daily nomination feature is enabled Target Value x 1000 The Target value is used to set the value of Volume Energy to be delivered during the next nomination period LAST NOMINATION PERIOD This section allows the operator to view information associated with the last nomination period which was completed Information displayed remains valid until the next time a nomination period ends when the information is up graded to reflect the new last nomination period Start and end times stored here indicate the actual time that the nomination period ended which is not necessarily the pro
239. tion to a PC requires the use of an RS 232 Null Modem cable see Figure 2 9 Communication Port COM2 is located on the Terminal Plate assembly and is la beled the NETWORK Port it has seven terminals as follows J2 8 TXD J2 9 RXD J2 10 RTS J2 11 CTS J2 12 DTR J2 13 DCD J2 14 Ground G COM3 RS 485 Communications Port COM3 defaults to 9600 baud 8 bits no parity 1 stop bit BSAP ControlWave Designer protocol operation In lieu of the use of an RS 232 Port an RS 485 cable see Tables 2 3 amp 2 5 can be connected between COM3 and a PC s RS 485 Port RS 485 Communication Port COM3 is located on the Terminal Plate assembly and has four terminals as follows J2 1 Ground G J2 2 TR J2 3 TR J2 4 V To use the WINDIAG program place any critical process associated with the Control Wave XFC unit in question under manual control WINDIAG cannot be run while the ControlWave XFC application is running Set CPU Board Switch SW1 8 to the OFF position Perform steps 1 through 6 below 1 Start the OpenBSI NetView Program A menu similar to Figure 3 3 will appear CI ControlWave XFC Service 3 7 NetView C accol current ndf File Edt Security View Window Help Dis a gil el del accol current ndf ES BSAPNet RTU PRTUEng LoadFie PRTUEng BF Pre Descriptor Primary IP Add 290211130 Seconday IP Add B000 E Pru f com Ay IPLINE D Pis Sent
240. tning 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 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 Equipment installed in dry windy areas such as the Great Plains and the Southwest Desert in the United States Wind and wind blown dust can cause high voltages static to appear on overhead wires fences and metal buildings Note Lightning Arresters may explode if lightning strike is very close Mount lightning arresters where flying parts won t cause injury to equipment or personnel S1400CW Page 4 6 Section 4 Lightning amp Surge Section 5 Wiring Techniques EE 5 1 OVERVIEW This section provides information pertaining to good wiring practices
241. tor KS 5173 5527 Average Relative Adjustment ABAR 9 9189 Configuration Data Abnormal delta Abar high limit in percent ABH 3 0000 Abnormal delta Abar low limit in percent ABL 3 0000 Normal delta Abar high limit in percent WBH 1 0000 Normal delta Abar low limit in percent WBL 1 0000 Adjusted and unadjusted flow total scaling factor INCR 0 0000 Mechanical output factor Kmo 0 0000 Calculated Factors Adjusted Volume rate in CF per second Vai 0 0000 Average Main rotor rate in CF per second Pmavg 0 0000 Average Sensor rotor rate in CF per second Psavg 0 0000 Main rotor adjusted volume Vm 0 0000 Sensor rotor adjusted volume Vs 0 0000 Internal 60 second timer R60 31 0000 Internal 512 second 8 53 minute timer R512 1951 0000 Internal count of Main rotor pulses C25k 0 0000 Main rotor frequency in pulses per second Pmif 0 0000 Sensor rotor frequency in pulses per second Psif 0 0000 Delta time between function block executions DeltaT 1 0000 Calculated Outputs Adjusted flow rate in CF per hour Rate 0 0000 Unadjusted Main rotor rate in CF per second Vmi 0 0000 Unadjusted Sensor rotor rate in CF per second Vsi 0 0000 Calculated PER from calibration in Delta Abar 0 0000 Adjusted volume change since the last function block execution Total adjusted volume TotA 0 0000 Total unadjusted volume TotM 0 0000 Delta Va 0 0000 Figure F 16B Auto Adjust Configuration for Run Web Page Accessed from Meter Run I O Configuration Web Page F 6 2 4 Alarm Config
242. tribution cccccccccsssceccessssceeeesseeecesseeeeseesesaesesseeaeessseaaeessseaaees 2 24 Bulk Power Supply Current Requirements ssssnssesesssesssssessssseesessesssseteesssressssereesse 2 25 Power WINNE ed iE E ATE E Ee N E 2 25 ControlWave XFC System Grounding ccceccsceceessececeesseeeeeeseeeeseaeeeeseseeeeneaes 2 25 Operation of the Lithium Backup Coin cell Batter 2 25 OPERATIONAL DETAILS 200 cece ceecccecccceeseceeneeceaeeeeaaecseneeccaeeeeaaecseaeecseeeecsaeeseaaaeennees 2 26 Downloading the Application Load 2 26 Upgrading ControlWave XFC Firmware 0 ccccccccessecesssssceeessseeeeesseseeeessneaeessseaaees 2 27 Using LocalView to Upgrade ControlWave XFC Firmware ss sssesssssesesssesesesseee 2 27 Using Hyperterminal to Upgrade ControlWave XFC Rurmeare 2 30 Remote Upgrade of ControlWave XFC Firmware s ssssessssssssessesssssesesseesssssrsssseeees 2 33 Operation of CPU Switch SW1 Mode Functeons 2 33 Soft Switch Configuration and Communication Porte 2 33 Display Asse miiy oar E E EET ETTE TR 2 34 Section 3 SERVICE SERVICE INTRODUCTION tege EEA E EET OTE EO 3 1 COMPONENT REMOVAL REPLACEMENT DROCKEDURRG 3 1 Accessing Components for Testing ccccccsscsssesssscecesseeceseesnsaeesssneeeeeeseneaeesssnsaeesseenaees 3 1 Removal Replacement of the Function Module 3 2 Removal Replacement of the MVT or GPT Transducer cccccccceesseceeesesseeeeessteeeeees 3 2 Removal Replacement of the Lith
243. ue 0 000 BIUsFTs Flow Time 0 000 MINUTES Flow Time 0 000 MINUTES Reset Meter Run s Measurement Type Figure F 14 Meter Run Overview AGA7 Frequency Meter Web Page F 6 2 Meter Run I O Configuration Retrieving Configuration Please Wait will initially be posted on the WebBSI Web Page when I O Configuration has been selected followed by the Meter Run I O Configuration Web Page see Figure F 15 The Meter Run I O Configuration Web Page provides the mechanism for assigning the source for the inputs to the meter run calculations From this page the user would assign specific transmitters and meters to a meter run The user may select from analog transmitters connected to I O points or from Smart Transmitters using BSAP or MODBUS connected via an RS 485 serial port In addition the user would select the source of the heating value whether it is from a chromatograph and analog inputs or manually entered CI ControlWave XFC Appendix F F 21 Meter Run I O Configuration for Run 1 Flow Direction ees Alarm Configuration Differential Pressure Point iD Modbus Transmitter Source BSAP Transmitter 1 4 Zeros amp Spans 1 4 Analog Input 4 1 1 Live Input Value Input Control Live Override Value In Use Units 0 000 LIVE 0 000 INH20 Static Pressure Point ID Modbus Transmitter Source BSAP Transmitter 1 4 Zeros amp Spans 1 4 Analog Input 2 1 1 Live Input Value Input Control Livef Override Value In Use Units 0
244. uirements 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 en vironments 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 in stallation practices will minimize injury equipment failure and the customer frustrations that accompany failing and poorly operating equipment of even the finest design Ad ditionally 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 1 e their understanding of the equipment site conditions and the requirements for a quality installation 2 2 PROTECTING EQUIPMENT amp PERSONNEL ControlWave installations must be performed in accordance with National Electrical Code Rules electrical rules set by local regulatory agencies and depending on the customer environment gas water etc other national state and local agencies such as the American Water Works As
245. ult 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 ESDS Manual 14006 4 15 92 Table 1 Typical Electrostatic Voltages Electrostatic Voltages Means of Static 10 20 Percent 65 90 Percent Generation Relative Humidity Relative Humidity 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 1 2 General Rules ESD sensitive components shall only be removed from their static shielding bags by a person who is properly grounded 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 ESD sensitive components shall be handled in such a way that the body does not come in contact with the conductor paths and board c
246. un API 21 1 EFM operation e Additional application loads e g well automation with plunger lift control are also available CI ControlWave XFC Product Features amp Overview 1A 1 e Full user programming environment ControlWave Designer with ACCOL III is available for modification of existing loads as well as creation of custom loads e Full suite of function blocks for flow calculations audit trail historical archive data management communication and process control is included e File management including video images e Fully supported by a complete HMI and network communication software suite Bristol Babcock s OpenBSI 1A 2 PRODUCT FAMILY COMPATIBILITY Not only is ControlWave XFC scalable it is also compatible with Bristol Babcock s ControlWave family ControlWave XFC is fully software compatible with the original ControlWave which provides greater I O capacity 1A 2 1 Open Standards for Programming Network Config and Communication Only ControlWave brings the perfect combination of industry standards to minimize learning engineering and implementation costs By adhering to such industry standards as Ethernet TCP IP Microsoft Windows COM DCOM FTP OLE and ActiveX ControlWave is able to achieve the highest degree of openness in control system architecture and bring the optimal process efficiency and productivity needed to ensure a successful system implementation 1A 2 2 ControlWave Designer with ACCOL III
247. uration Accessed via Meter Run I O Configuration Enable Disable the alarm function on a per point basis Units and Current Value are read from the I O source F 24 Appendix F CI ControlWave XFC 3000 000 100 000 50 000 Gas Figure F 17 Alarm Configuration Web Page Accessed from Meter Run I O Configuration Web Page Alarm Limit are set via the appropriate alarm limit point Deadband dead bands represent a range just below the high limits or just above the low limits in which the alarm variable remains in an alarm state despite the fact that its value no longer exceeds the alarm limit Should the alarm variable rapidly fluctuate above and below the alarm limit without the use of dead band settings the system will be flooded with alarm messages F 6 3 Flow Equations When the user pushes the Flow Equation button on the left side of the menu the Flow Equation Setup Web Page that is appropriate for the meter type will appear If the meter type has not been configured the screen shown for Figure F 13 will appear A user must then select the Meter Run Type to be used F 6 3 1 Orifice Flow Equation Setup F 6 3 1 1 Differential Measurement If the user configures the meter as a Differential Measurement type the Flow Equation defaults to the AGA3 1985 equation Users may change to the AGA3 1992 equation by toggling the push button labeled Click Here to select AGA3I 1992 F 6 3 1 2 1985 AGA3 Equation Configura
248. uring communication or PC downtime or other system problem Archive Collection collection and storage to disk of the ControlWave archive data Audit Collection collection and storage to disk of the ControlWave audit data Exports data files to third party CSV amp ODBC applications DDE compliant for use with other popular Windows applications 1A 3 5 OPC Server With industry demand for open standards ControlWave answers the call by embracing technologies that open the door for maximizing your efficiency and productivity The OPC standard was developed by the OPC Foundation comprised of hardware and software suppliers from the process control community OPC allows the engineer to select best in class hardware and software with confidence in their interoperability Our OpenBSI OPC CI ControlWave XFC Product Features amp Overview 1A 5 Server was among the first to comply with the OPC Foundation alarm and event server specification OPC Data Access 1 0a amp 2 0 compatible Windows NT 2000 amp XP Compatible with both ControlWave and Network 3000 systems 32 bit multi threading multi processor design Automatic database builder Integrated real time data monitor Supports OPC Browse interface Supports both serial communications and IP Ethernet connections Supports COM DCOM amp OLE Automation Primary and Background polling scheme OPC Alarm amp Event Server support 1A 4 ControlWave OPEN NETWORK CONNECTIVITY By embracin
249. used to send and receive messages typically with third party serial ASCII devices This protocol can be used to interface with such devices and message boards card readers and many measurement devices CI ControlWave XFC Product Features amp Overview 1A 7 Section 2 INSTALLATION amp OPERATION 2 1 INSTALLATION IN HAZARDOUS AREAS Each ControlWave XFC gas flow computer is furnished in an explosion proof case designed to operate in nonincendive Class I Division 2 Groups C amp D hazardous locations and in Class I Division 1 explosion proof environments see Appendices A amp B 1 Rear Wiring Housing Cover 2 Function Module Mounting Screws 3 Function Module items 9 10 12 amp 13 4 MVT Cable 5 Multivariable Transducer MVT 6 Housing Case 7 Data Plate 8 Front Display Housing Cover 9 Terminal Plate 10 CPU Bd Assembly 10 11 11 Cover O Ring 12 1 0 Bd Assembly 13 LCD Display Assembly MVT Cable Plugs in Here 11 Figure 2 1 ControlWave XFC with MVT Isometric Views Component Identification Diagram CI ControlWave XFC Installation amp Operation 2 1 A Dimensional drawing of the unit is provided in Figure 2 3 and at the end of Chapter 4 2 2 SITE LOCATION CONSIDERATIONS Check all clearances when choosing an installation site Make sure that the ControlWave XFC can be opened for wiring and service Make sure that the LCD Display is visible and accessible to the on site
250. value flow is considered to be zero for that second Hourly and Daily flow time is defined to be the number of seconds for which the differential pressure exceeded the cutoff value for the period The values for static and differential pressure temperature and flow extensions are used as inputs to the flow equations Users may select API 14 3 AGA8 1992 and AGA8 calculations with compressibility being calculated according to AGA Report No 8 1992 with 1993 errata Both the DETAIL method and the two GROSS methods of characterization described in AGA8 are supported Users may also select the AGA3 1995 and NX 19 flow equations to calculate the rate of flow 1 5 2 2 Flow Rate Calculations and Flow Time Accumulations AGA7 When using PD meters turbine meters or ultrasonic meters the flow rate is calculated by applying the correction factor computed by the AGA7 calculations to the frequency of the input pulses When the frequency drops below 1 Hz the flow rate estimate is set to zero however volume calculations are still accumulated The flow time recorded is the time for which the flow rate is non zero 1 5 2 3 Extension Calculation and Analog Averaging For orifice meters a flow extension is calculated every second The extension is the square root of the product of the absolute upstream static pressure times the differential pressure This extension is used in the flow rate calculation When there is no flow arithmetic averages of s
251. ved when all currents and voltages developed in association with each of the common returns are equal In a balanced system or circuit there are no noise or measurment errors introduced due to by sneak circuits The illustration of Figure 5 1 shows the difference between testing an I O circuit that is discrete and has no sneak circuits and one that utilizes common returns Common sense tells us that it is tough to mix up connections to a twisted shielded pair with overall vinyl covering to every end device Do yourself a favor to make start up easier DON T USE COMMON RETURNS Section 5 Wiring Techniques Page 5 1 S1400CW Field Wired Circuit Without A Common Return Meter gt i End J NOTE Without A Common Return There are No Sneak Circuits amp Testing Is Easy Field Wired Circuit With A Common Return source e 2 m as i 4 5 e l scommon WAN i NOTE With A Common Return Sneak Circuits Are Created A Lot Of Equipment Must Be Disconnected To Find A Sneak Circuit Figure 5 1 Field Wired Circuits With amp 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
252. ver an extended temperature range with long term product reliability ControlWave XFC CPU Boards are based on a 32 bit ARM9YTDMI RISC Core Processor The CPU Board is specified to operate with a system clock speed of 14 MHz The Microcontroller is packaged in a 256 pin Plastic Ball Grid Array In addition to the microprocessor memory and control logic the CPU Board includes one fixed RS 232 communication Port COM1 one 2 wire RS 232 communication port Local Port and a two wire RS 485 communication port COM3 CPU Memory consists of 2MB of battery backed Static RAM SRAM 512kB Boot Downloader FLASH and 8MB simultaneous read write FLASH Interface to field I O is provided through an I O Bus Connector CPU Boards are provided backup power via a coin cell socket that accepts a 3 0V 300mA hr lithium battery This 3 0V battery provides backup power for the real time clock and the system s Static RAM SRAM Backup power is enabled when the Battery Backup Jumper JP1 is installed If the 3 8Vdc that powers the unit goes out of specification VCC 10 a supervisory circuit on the CPU is used to switch to battery power For maximum shelf life the battery may be isolated from the circuit by removing the Backup Battery Jumper JP1 from position 1 to 2 and then storing it on either pin If the Real time clock looses its battery backup a ControlWave Designer system variable bit QUEST_DATE is set This bit can be used to post a message or alarm to the
253. with raising the valve must be selected and a separate DO must be selected for lowering the valve When the Raise Lower Mode is being used the Current Data section will display if the Raise DO is Off or Raising and it will display the Lower DO state i e Off or Lowering In the Manual Control mode users may select whether to Raise or Lower the valve by using the Manual Raise or Manual Lower Output buttons If the valve is raising and the operator pushes the Manual Lower Output button the Raise Output will be automatically set to Off If the valve is lowering and the Manual Raise Output button is pressed the Lower DO will automatically be set Off When switching back and forth between the Automatic and Manual Modes both Raise and Lower DOs will be set to Off F 5 6 Run Switching Sections F 5 6 1 and F 5 6 2 provide information on run switching properties see Figure F 10 Enable Disable Run Switching via a button to the right of Run Switching SCFMOUR Figure F 10 Run Switching Web Page F 5 6 1 Common Properties Current Rank shows how many runs are required to be open Maximum Rank is selected by the user from 1 to 2 Process Variable PV Selection can be Differential Pressure Frequency or Flow Rate The Transition Time is the amount of time required to allow run switching to access opening or closing a run Valve Settle Time is the amount of time allowed after the Transition Time for the process variable PV
254. wn menu default units are Ft Hour Energy Rate x1000000 The user may select the Energy Rate Energy Units from a drop down menu default units are BTU The user may select the Energy Rate Rate Units from a drop down menu default units are HOUR Reset Meter Run s Measurement Type This button bottom of menu allows the user to reset the meter run s measurement type if a mistake has occurred during configuration Meter Run Overview for Run 1 GFC Time 04 25 2006 14 17 41 Meter ID Run 1 Contract Hour 7 Active Flow Calculation AGAT Current Heating Value 0 000 BTUJSCF Corrected Flow Rate x1000 0 000 SCFHOUR Energy Rate x1000000 BTU HOUR 0 000 Uncorrected Flow Rate x1000 0 000 ACFH Current Hour Current Day Corrected Volume x1000 0 000 SCF Corrected Volume x1000 0 000 SCF Uncorrected Volume x1000 0 ACF Uncorrected Volume x1000 H ACF Accumulated Energy x1000000 0 000 BTU Accumulated Energy x1000000 0 000 BTU Flow Time 0 000 MINUTES Flow Time 0 000 MINUTES Previous Hour Previous Day Corrected Volume x1000 0 000 SCF Corrected Volume x1000 0 000 SCF Uncorrected Volume x1000 0 000 ACF Uncorrected Volume x1000 0 000 ACF Accumulated Energy x1000000 0 090 BTU Accumulated Energy x1000000 0 000 BTU Avg Static Pressure 0 000 PSI Avg Static Pressure 0 000 PSI Avg Temperature n 000 DEG_F Avg Temperature 0 000 Der Avg Spec Gravity 0 000 Avg Spec Gravity 0 000 Avg Heating Value 0 000 BIUFTS Avg Heating Val
255. xample 4 20mA Analog Input Externally Analog Output Wiring Diagram Powered Wiring Diagrams 1 5V Analog Input Wiring Diagram Figure 2 10 ControlWave XFC Terninal Plate Field I O Wiring Diagrams 2 3 4 RTD Wiring A 3 wire RTD may be provided with the ControlWave XFC Connector J3 on the Terminal Plate Assembly accommodates a removable three wire Terminal Block J3 This connector accommodates a 100 ohm platinum bulb using the DIN 48760 curve CI ControlWave XFC Installation amp Operation 2 21 ControlWave XFC s utilize the common three wire con figuration In this configuration the Return lead connects to RTD and the two junction leads Sense and Excitation connect to RTD and RTD EXC Connection between the RTD and System Controller Module is wired as follows Table 2 4 RTD Connections to Terminal Plate Connector J3 J3 Pin Signal Function Wire Color RTD EXC 2 RTD Sense Red Never ground the RTD Cable Shield at both ends or allow it to come in contact with metal lic conductive conduit as multiple ground paths could cause RTD input errors 2 3 4 1 Bendable RTD Installation WARNING ONLY use a bendable RTD supplied with a plastic bushing for Division 2 installations as this will render the Housing Non Explosion Proof Use an RTD Connection Head and Conduit for Division 1 installations To install the RTD Probe screw the Fitting Body into the thermowell with a 7 8 open end wrench While a
256. y Safe See Appendix B of CI Manual Other Safe or unrated area 2 Earth Ground Established by mechanical electrical or See Section 3 both or not at all 3 Is the area prone to lightning strikes See Section 4 Are there surge suppressors installed or to be installed See Section 4 5 Are there overhead or underground power or com See Section 2 3 munication cables in the immediate area S1400CW Page 2 2 Section 2 Protection Table 2 2 Equipment Protection Site Safety Evaluation Guide Continued Guide Reference Section 6 Is there an antenna in the immediate area See Section 4 1 2 7 How close is other equipment Can someone safely touch this See Section 2 3 equipment and a ControlWave simultaneously Determine equipment ground requirements How will the See Section 3 ControlWave and its related wiring be grounded Consider Earth Ground Circuit Ground Conduit Ground Site Grounds Are there any obviously faulty or questionable power or ground See Section 2 3 circuits 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 c
257. y a 3 0V 300mA hr lithium coin cell battery located on the CPU Module e Very low power consumption minimizes costs of solar panel battery power systems e Integral Multivariable Transducer MVT with smart performance for DP or GP measurement or Gage Pressure Transducer for GP measurement e Three serial communications ports Two RS 232 amp One RS 485 e Integral 2 line LCD operates in a continuous cycle mode e Optional I O includes 2 Digital Inputs DI 2 High Speed Counter Inputs HSC 4 Digital Outputs DO 3 Analog Inputs AI and 1 Analog Output AO es RTD input e Explosion Proof Class I Division 1 Groups C amp D Locations see Appendix B or Nonincendive Class I Division 2 Groups A B C and D Hazardous Locations see Appendix A e Readily integrates with Bristol Babcock model 2808 and 3808 MVT low power transmitters for explosion proof installations e Cost effective for small chart replacement or RTU Process Controller applications Model 3820 EX Firmware Software Features Preprogrammed to meet API 21 1 requirements for a two run metering station with networking via BSAP or Modbus e Functions as a Process Controller or Remote Terminal Unit RTU e Standard Application Program supports the following Flow calculations e Calculates AGA3 1995 NX 19 AGA38 1992 with selectable AGA8 Gross or AGA8 Detail AGAT NX 19 AGA7T with selectable AGA8 Gross or AGA8 Detail Auto Adjust AGA7 NX 19 Auto Adjust AGA7 wit
258. you subsequently start ControlWave Designer it will operate only in DEMO mode and will limit the available system resources IMPORTANT When you start ControlWave Designer you will be reminded to register the software Unregistered software can only be used for a maximum of 30 days For more information on the registration process see Chapter 2 of the Open BSI Utilities Manual document D5081 Step 3 Establish Communications using either LocalView or NetView and Run the Flash Configuration Utility Communications must be established with the ControlWave XFC using either LocalView or NetView The ControlWave XFC ships from the factory with a default Flash configuration Most users will need to edit this configuration to set the IP address if using PPP BSAP local address user accounts and port parameters This can be done in one of two ways e Either open the supplied Flash Configuration Profile FCP file and modify it directly in the Flash Configuration Utility or in a text editor CI ControlWave XFC Installation amp Operation 2 3 e Or retrieve existing Flash Parameters directly from the unit and edit them in the Flash Configuration Utility Detailed information on the Flash Configuration Utility and LocalView is included in Chapter 5 of the Open BSI Utilities Manual document D5081 NetView is described in Chapter 6 of that same manual Step 4 Modification of the Application Specific Control Strategy OP
259. ze compound as required When installing a MVT GPT into the bottom of the Case Housing screw it in all the way and then back off approximately one turn and orient the Flange for the de sired High and Low settings 3 2 4 Removal Replacement of the Lithium RAM Battery The ControlWave XFC s Lithium RAM battery cannot be replaced while power is on Once the RAM battery has been replaced the unit will still execute its FLASH based application load Boot Project upon power up but all of the current process data will have been lost Upon power up the unit will act as though it had just been booted and it will revert back to the initial values specified in its application load The battery may be disabled by remov ing parking the CPU s Battery Backup Jumper JP1 1 If the ControlWave XFC is running place any critical control processes under manual control 2 Remove the Rear Wiring Cover and shut down the unit by disconnecting power at the Terminal Plate Terminal Block connector TB6 3 2 Service CI ControlWave XFC 3 Remove the four screws that secure the Function Module to the Case and remove the Function Module far enough to facilitate access to the CPU s Lithium Battery 4 Remove and replace the Lithium Battery on the rear of the CPU Board 5 Align the Function Module with the Case such that Terminal Plate connector J4 is positioned at the bottom and insert the unit into the Case Replace the four screws removed in step 3

Bristol ControlWave Model 3820-EX (Explosion

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