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GB600-SERIES CONTROLLERS

1. KIXCEL I P OR DOC0358A e SERVO VALVE Figure 2 13 Discrete Output Terminal Wiring Rev 9 99 2 41 GB600 Series Instruction Manual 2 5 12 Intrusion Switch Wiring The intrusion switch is a momentary contact switch used to detect whether the door to the enclosure is open or closed The switch which has a normally closed contact is designed to be mounted in the controller enclosure When the normally closed contacts are wired to a Discrete Input DI on the I O Card of the controller as shown in Figure 2 14 an Off status contacts open is detected when the door is closed and an On status contacts closed when the door is open See Section 5 for more information about the DI channel Using GRIDLINK the DI switch status can be configured to generate an alarm when the door is open I O Card Option A6079W WMF Figure 2 14 Intrusion Switch Wiring 2 5 13 Connecting Communications Wiring The GridBoss controller has the flexibility to communicate to external devices using different protocols Communications take place either through the operator interface port LOI or the Host port COM1 A special 3 pin connector provides a port for an operator interface device Wiring for the Host port is connected using screw terminals on the optional communications card 2 5 13 1 Operator Interface Port Wiring Figure 2
2. GridBoss Kixcel Pilot District Regulator SRU Inlet MS Outlet Figure 2 3 District Regulator The District Regulator can accept remote operational changes from the Host The District Regulator and Low Pressure Point have the ability to communicate with each other and the Host on the same communications port or on separate communications ports If two communication ports are used the LOI is used for peer to peer communications between the DR and the LPP while COM1 is used for Host communications If only one communications port is used the LPP DR and Host all use COM1 The DR has a dedicated communications link with its corresponding Low Pressure Point through the LOI or COM1 The DR does not log an event for LPP communications that write to the low pressure point value or for a regular verification of the LPP communications The DR records the last time the LPP successfully communicated with the DR in the Last LPP Comm Time field Rev 9 99 2 414 GB600 Series Instruction Manual 2 3 2 1 District Regulator Alarms An Alarm Log documents alarms such as when the DR sends a Spontaneous Report by Exception SRBX or RBX message to the Host upon LPP communications failure or Kixcel failure monitor alarm The alarm is sent as a standard I O alarm Besides standard alarms informing you of high or low alarm limits and the intrusion switch DI alarm
3. DO 5V 1 2K SELF POWERED ANA DISCRETE DEVICE 4 T CONTROL Figure 5 8 Discrete Outputs 5 10 Rev 9 99 GB600 Series Instruction Manual 5 5 5 Analog Output Analog outputs AOs provide a current output for powering analog devices The I O Card analog output is a 4 20 mA loop signal with a maximum voltage of 24 Vdc from the isolated power supply The analog output uses a 12 bit D A converter and a volt to current converter One 4 20mA analog output is provided on the I O Card It is designated AO Point Number B1 and is connected as follows Positive load Negative load At the District Regulator if an Analog Output AO is used to send the Setpoint signal to the Kixcel an Analog Input Al can be used to verify the position of the Kixcel The AI is compared to the AO to ensure that the Kixcel is approximately within the set Deadband A schematic representation of the field wiring connections to the analog output channel is shown in Figure 5 9 The AO can provide loop current to non powered field devices The analog output provides a 0 to 22 milliamp current source output at terminal Terminal is isolated from the controller common Figure 5 9 shows wiring for a controller powered current loop device AO DE GRIDBOSS POWERED lt b CONTROL LOOP DEVICE B1 Figure 5 9 Analog Output Field W
4. Al EXTERNAL T Current Limit Vs SELF POWERED DEVICE T 12 24 VDC 22 mA max Sl SIGNAL 1 TO 5 VDC Figure 5 7 Voltage Signal on I O Card Analog Input Rev 9 99 5 9 GB600 Series Instruction Manual 5 5 4 Discrete Outputs Discrete outputs DOs provide a solid state switch to control relays and power small electrical loads DO functions supported are Sustained discrete outputs Momentary discrete outputs Slow pulse train outputs The I O Card provides two discrete output channels The discrete output channel is a normally open single pole single throw switch An LED turns on to show when the switch is closed The discrete outputs are solid state switches enabled by individual signals from the processor I O lines The solid state switches are capable of handling 24 Vdc at 300 mA For use as the control output for a District Regulator Controller the Discrete Outputs may be configured as standard DOs A pair of Discrete Outputs acting as a Timed Duration Output for open close control can be used to control the Kixcel instead of an AO The discrete output on the I O Card can be used in a toggle mode a latched mode and a timed duration output TDO mode The discrete outputs provided on the I O Card are designated DO Point Number B5 and B6 They are connected as follows Positive load Negative load Figure 5 8 shows a typical discrete output wiring diagram
5. ooooocconocccnccnnnancnonnconncnonccnnnccnnnanos 2 10 Input Terminal Wiring eee eeseeeeeeeneeseneeeeeeees 2 29 Inputs COnf Surin ss E 3 9 Inputs and Outputs oooooccocccnonccnonanononcnnnnnononccnonacinnecos 2 15 Trnstallation ccceeeceeeeccceeeeseceeeeeeceeteeceeesaeeeeesseeees 1 15 Communications Cards cccsccceesssceeeeeeteeeeeees 4 9 AAA Koseski esre Spaa 1 10 VO Expansion Calderas 5 3 Ki a ociosas 2 37 E AY E odia tias ia A 2 Intrusion SwitCh ooooooooooonccnnnnnnnnnnnnnnnnnos 1 9 1 17 5 5 WINE a o S 2 42 A TR 1 13 J JUMPOLs seesisstyadsehs steals a REEE AEE TR EEEE SS 2 47 K AA E E E 1 2 1 6 2 4 Trnstallation coooococnnnnncononcccnnonncnnnnnnoconnncnnnnnnncnnnnnno 2 37 WATS ss occ Seces pected tere Se Bet ro teeter he 2 36 Kixcel Actuator Manual ccecsccceesseeeeeeteeeeeteeees 1 3 Rev 9 99 L LED is 2 23 LED Indicator i ennn e e 3 15 LEDs Communications Cards 0eeeeeeee 4 4 4 6 4 8 VO Cardin iii 5 12 Lightning Protection Module oooconnncccnonccconccononccnnncnno 1 9 Tins tal ati Oth eri teesdeee fed A 2 TEP E A 1 Troubleshooting ooooooccononcccnnoooccnoncccnocnnnnnnononnnnns A 4 A E A 3 A NN 3 15 Lime Charts lisis e 2 32 Liquid Crystal Display ooooconnonociocccnonncnonncnnne 1 5 2 23 Load Profiles cacaos iia 2 5 2 6 Local Operator Interface DQ unisex 1 6 1 9 2 23 TOD War md a oe 2 42 LON ne oath et ae thea wha
6. Power Consumption Device mW Quantity Duty Cycle Sub Total 12V System mW Pin Pinax Main Electronics Board includes minimum built in I O power 190 400 1 N A consumption RTD and PM Kixcel I P or Servo Valve T O Expansion Card 210 210 1 N A T O Card Analog Input 90 365 T O Card Analog Output 130 650 T O Card Discrete Output 0 110 Two DOs for TDO T O Card Discrete Input 0 30 Intrusion Switch T O Card Pulse Input 0 70 Built in Discrete Output load dependent with a maximum of 15 0 4 1 volts and 0 3 amps Serial Communications Card 30 N A Dial up Modem Communications 250 N A Card Radio from Section 1 7 2 1 of 2 Radio from Section 1 7 2 2 of 2 NOTE The Kixcel I P Servo Valve and Radio s values are based upon the type of device you are installing 1 20 Rev 9 99 GB600 Series Instruction Manual 1 7 2 Determining Radio Power Consumption In determining power requirements for radios the duty cycle for the radio must be estimated The duty cycle is the percentage of time the radio is transmitting TX For example if a radio is transmitting 1 second out of every 60 seconds and for the remaining 59 seconds the radio is drawing receive RX power the duty cycle is Duty Cycle TX time TX time RX time 1 sec 60 sec 0 0167 To calculate the total power consumed by a radio obtain t
7. CAUTION Before installing the Kixcel make sure the actuator supplied is suitable for the intended application with respect to environmental conditions and the voltage and frequency of available line power To avoid the possibility of personal injury caused by electrical shock disconnect all power to the actuator before removing the cover NOTE This wiring procedure only pertains to the Type 662 Kixcel Please refer to your user documentation specific to the type of Kixcel I P or servo valve you are actually installing 2 5 9 1 Kixcel Setup The Kixcel requires setup similar to the following procedure l Le 3 6 Connect the pilot regulator to an air supply Adjust the pilot for O pressure Count turns required to bring the pilot the outlet pressure to a maximum pressure for the utility application Adjust the pilot to 0 pressure and disconnect the air Do not move the pressure adjustment on the pilot Configure the Kixcel dip switches SW1 down for 4 20 mA command signal SW2 up 4 12 mA command signal off SW3 up 12 20 mA command signal off SW4 up for current command signal SWS5 up is 0 to 10 volts and down is 0 to 5 volts The command signal uses the current so position is not a factor SW6 selects the shaft rotation direction for increasing the signal The position varies with the type of gearbox used with the Kixcel Select the position that increases the pilot regulator pressure as the inp
8. Charge Input POWER CHG Auxiliary Radio Power RADIO Pressure Module P DP Operator Interface port LOI Discrete Output DO Resistance Temperature Detector RTD Communications card connector P3 ff 0 The input terminal wiring is arranged on the lower edge of the Main Electronics Board The terminal designations are printed on the circuit board Refer to Figure 2 4 2 5 2 Connecting Ground Wiring The GridBoss controller and related components must be connected to an earth ground The National Electrical Code NEC governs the ground wiring requirements for all line powered devices Refer to Section 1 for further details There is a ground bar located inside the enclosure at the top right hand side This ground bus bar is electrically bonded to the enclosure and provides screw compression terminals to connect shields from T O wiring line power earth ground and other device earth grounds as needed An external lug on the bottom outside of the enclosure refer to Figure 2 5 provides a place to connect an earth ground to the enclosure Although this ground lug is electrically connected to the ground bar Rev 9 99 2 29 GB600 Series Instruction Manual through the enclosure steel it is recommended that a ground wire also be connected between the ground lug and the ground bar It is recommended that 14 AWG wire be used for the ground wiring Make sure the installation has only one ground poin
9. Point Number The rack and number of an I O point as installed in the ROC FloBoss or GridBoss controller PSTN Public switched telephone network PT Process Temperature PTT Push to talk signal Pulse Transient variation of a signal whose value is normally constant PV Process variable R RAM Random Access Memory In a ROC it is used to store history data most user programs and additional configuration data RBX Report by exception In a ROC it always refers to spontaneous RBX in which the ROC contacts the host to report an alarm condition RFI Radio frequency interference RI Ring Indicator modem communications signal ROM Read only memory Typically used to store firmware RTD Resistance Temperature Detector RTS Ready to Send modem communications signal RTV Room Temperature Vulcanizing typically a sealant or caulk like silicone rubber RXD Received Data communications signal S SAMA Scientific Apparatus Maker s Association Sensor Module The SM provides static pressure inputs to the GridBoss Controller for the pressure calculation Soft Points A type of ROC FloBoss or GridBoss point with generic parameters that can be configured to hold data as desired by the user SP Setpoint or Static Pressure SPI Slow Pulse Input G 4 Rev 9 99 GB600 Series Instruction Manual SRAM Static Random Access Memory Stores data as long as powe
10. 35 dBm APPROVALS Maximum Output Level 0 dBm nominal into 600 ohms LED Indicators TXD RXD AA and OH Connector RJ11 6 pin Surge Protection Conforms to FCC part 68 Surge Isolation 1000 Vac and 1500 volt peak Certification FCC Part 68 approved Approved by CSA for hazardous locations Class Division 2 Groups C and D Rev 9 99 4 17 GB600 Series Instruction Manual This page intentionally left blank 4 18 Rev 9 99 GB600 Series Instruction Manual SECTION 5 INPUT OUTPUT CARD 5 1 SCOPE This section describes the Input Output 1 0 Card which provides additional inputs and outputs such as required by the GB601 District Regulator DR Controller A discrete input DI on the I O Card can be connected to the optional intrusion switch for both the GB601 and GB602 units NOTE Although the GridBoss System has extensive input and output requirements not all of the capabilities of the I O Card are used 5 2 SECTION CONTENTS This section contains the following information _ 5 3 E z 5 Scope 5 1 5 1 Section Contents 5 2 5 1 T O Card Installation 5 4 5 3 Pulse Inputs 5 5 2 5 6 Analog Inputs 5 5 3 5 8 Discrete Outputs 5 5 4 5 10 I O Card LEDs 5 6 5 12 roubleshooting 5 7 5 12 Specifications 5 8 5 13 Rev 9 99 Section Page Number 5 1 GB600 Series Instruction Manual 5 3 DESCRIPTION The I O Card shown in Figure 5 1 provides additional i
11. GB602 Low Pressure Point Controller Fisher Control s microprocessor based unit that provides remote pressure monitoring and control in a GridBoss system GFA Ground fault analysis GND Electrical ground such as used by the ROC FloBoss or GridBoss controller power supply GP Gauge Pressure GRIDLINK Configuration software used to configure GridBoss controllers to gather data as well as most other functions I J I O Input Output IEC Industrial Electrical Code G 2 Rev 9 99 GB600 Series Instruction Manual K Kbytes Kilobytes kHz Kilohertz Kixcel An actuator that receives a control signal Analog Output or Discrete Output pair from the GB601 and converts the signal into an outlet pressure to adjust the Setpoint at the DR L LCD Liquid Crystal Display Display only device used for reading data LED Light emitting diode LOI Local Operator Interface Refers to the serial RS 232 port on the ROC FloBoss or GridBoss controller through which local communications are established typically for configuration software running on a PC LPM Lighting Protection Module Use this module to provide lightning and power surge protection for ROC FloBoss and GridBoss units that use I O M mA Milliamp s one thousandth of an ampere MCU Master Controller Unit MPU Micro processor Unit mW Milliwatts or 0 001 watt mV Millivolts or 0 001 volt N NEC
12. National Electrical Code NEMA National Electrical Manufacturer s Association O OH Off Hook modem communications signal Off line Accomplished while the target device is not connected by a communications link For example off line configuration is configuring a ROC a FloBoss or a GridBoss controller in a electronic file that is later loaded into the units Ohms Units of electrical resistance On line Accomplished while connected by a communications link to the target device For example on line configuration is configuring a ROC while connected to it so that current parameter values are viewed and new values can be loaded immediately OP Operator Port see LOI Opcode Type of message protocol used by the ROC FloBoss or GridBoss controller to communicate with the ROCLINK GRIDLINK or GV101 software as well as host computers with ROC driver software Rev 9 99 G 3 GB600 Series Instruction Manual P Q Parameter A property of a point that typically can be configured or set by the user For example the Point Tag ID is a parameter of an Analog Input point Parameters are normally edited by using configuration software running on a PC PC Personal computer PI Pulse Input PID Proportional Integral and Derivative control Point Software oriented term for an I O channel or some other function such as a flow calculation Points are defined by a collection of parameters
13. alarms that occur automatically include DR low battery voltage which is checked against the Low Battery Voltage Limit DR temperature or pressure transmitter point fail which checks Point Fail High and Low Limits and checks for Point Fail alarms from the AI alarm code DR output failure assuming output position feedback is connected LPP communications failure did not receive a valid LPP communication since the maximum Check In Time for DRs RBX alarming for the DR low battery voltage DR Outlet Pressure Point Fail and DR Temperature Point Fail must be set at individual I O points For the Low and High Point Fail Limits use the Low and High Alarms of the I O alarming When an alarm occurs special actions are taken based upon what alarm is generated Refer to Table 2 1 2 12 Rev 9 99 GB600 Series Instruction Manual Table 2 1 District Regulator Alarms Alarm Actions DR temperature point fail Change PID Control to Outer Loop Control if it was in Outer Loop with Adaptive Control DR regulator outlet pressure Change PID Control to Manual Mode and set output to transmitter point fail Default Output DR low battery voltage Change PID Control to Manual Mode and set output to Default Output DR output failure RBX message sent to Host if enabled and change PID Control to Manual Mode LPP communications failure RBX message sent to Host if enabled and change PID Control to Inner Loop Mode us
14. 13 Table 2 2 Low Pressure Point Alarms 66 2 15 Table 2 3 District Regulator Inputs and Outputs 2 16 Table 2 4 Low Pressure Point Inputs and Outputs 2 16 Table 2 5 DR Default History Points 0 0 0 2 17 Table 2 6 LPP Default History Points 2 17 Table 2 7 Discrete OUtpUt oooocnnncccnoncnonccnonanonccnnnnnos 2 25 Table 3 1 PI Connections oooooonocccnonccconccconccinnncinnncnno 3 6 Table 4 1 EIA 232 Communications Cards LED dicta 4 4 Table 4 2 EIA 485 Communications Cards LED INI CatOrs ve secicstedieienee rn ar 4 6 Table 4 3 Modem Card LED Indicators 4 8 Temperature 1 4 1 5 1 11 2 17 2 25 2 26 3 2 See RTD raid 3 2 Terminal Witihg ineno i a e 2 28 Tests Atomatic nein a is 2 26 Time of Day Load Profiles ooooonccnnnonincccnnncn 2 6 2 9 Time rInt rr pt e noia ira 2 26 Totaling Power Requirements ooonoococnnonccinoncncnnonncnonos 1 21 Troubleshooting coococnocnnocccnonncnononanccionananccnnno 2 44 2 45 Communication Cards ooococcccncncnnnonininanono 4 14 5 12 LED Indicativos iio ies 3 15 Lightning Protection Module oooooonnnonccnnnooncccnnnnos A 4 Pressure Mod le senini treaa 3 15 Replacing Main Electronics Board eeeeee 2 50 AN 2 45 TED rt italia do iii 4 4 4 6 4 8 Type 662 Kixcel Manual 1 3 U Units da 3 10 Rev 9 99 V A sner a E E 1 11 Voltage snenia e ae ae T 1 21 W Warm Start eea oe NEEESE
15. 14 5 to 16 volts de at a maximum load of 1 amp operates from either 115 or 230 volts AC line power and has a hazardous approval rating The power supply can be ordered as a 115 or 230 volt unit By default the power supply is set to 115 volts To change the power supply voltage remove the power supply from the controller The AC voltage switch is located at S1 on the back of the power supply The installation and wiring of the AC voltages must meet local code and the requirements stated with the charger for compliance to Class I Division 2 hazardous requirements In installations where battery backup is used the AC power supply also functions as a battery charger The unit provides a fully regulated output that is protected from overcurrent conditions When charging batteries temperature compensation of the output voltage is also provided Battery temperature is sensed by a thermistor supplied connected to terminals T1 and T2 on the power supply For connection to the controller when battery backup is being used refer to Figure 2 9 Note that batteries are connected to the BAT and BAT terminals while the power supply is connected to the CHG and CHG terminals The maximum voltage that can be applied to the charging terminals is 22 volts DC Through its DC monitor terminals the AC power supply provides a means for monitoring its DC output remotely allowing an alarm to be produced when power is interrupted The charger circuitry on the
16. 2 4 8 2 26 ow Power Modes 2 4 8 1 2 26 onnecting the Controller to Wiring 2 5 2 28 roubleshooting and Repair 2 7 2 4 onnecting Main Power Wiring Overview 2 5 3 2 3 Battery Connections 2 5 4 2 3 Solar Panel Charge Connections 2 5 5 2 3 AC Power Supply Battery Charger 2 5 6 2 34 Auxiliary Output Power RTD Wiring 2 5 10 2 39 Intrusion Switch Wiring 2 5 12 2 42 onnecting Communications Wiring 2 5 13 2 4 HT Too Backup Procedure Before Removing Power 2 7 1 2 4 Resetting the 2 7 2 2 4 arm Start 2 7 2 1 2 46 old Start 2 7 2 2 2 4 umper Reset 2 7 2 3 2 4 A fter Installing Components 2 7 3 2 4 a Replacing the Main Electronics Board 2 7 4 2 5 Pressure Module Replacement 2 7 5 2 52 Specifications 2 8 2 5 NOTE An I P or servo valve may be used in place of the Kixcel To ensure ease of readability Kixcel is used throughout this manual to represent all devices Rev 9 99 GB600 Series Instruction Manual 2 3 PRODUCT FUNCTIONS This section describes the functions of the GridBoss controller most of which are determined by its firmware and must be configured by using the GRIDLINK Configuration Software The features and applications provided by the hardware and firmware include Adaptive Predictive Control for gas distribution using Load Profiles and Control Mode Levels District Regulator used to maintain a user defined Setpoint e Low Pressure Point used to measure the
17. 2 46 Watchdog Software and Hard Wal 8 ooooccocccconccconcnconnnonnnncnnnnnn 2 26 Weekday Load Profiles oooononnnnnccnonccnocononcncnnonccnnne 2 6 Weekend Load Profiles ooooonnccnnnoconnonccononconnorcncnnnnos 2 6 WIDE 2 28 Auxiliary Radio POWeT oocooooconnnoococnncconnccnonnnonnno 4 11 Battery Connections oooccconccconcncnoncconancnonncconacinnnss 2 31 Battery Power Charger oooonnoncccconooconcnononancnonncncnno 2 32 COMMUNICATIONS occcccooocccnnnnnnnoncnonnnnncnnnnncnnnnnnncnnnno 2 42 Communications Cards sses 4 11 Dial Up Modem Communications Cards 4 13 Discrete Outputs 23 51 crciic aie elo 2 41 EIA 485 Communications Cards ooconoccnnonccnonncnnne 4 12 GTOUNGING see niente hie nae 2 29 Grounding RequirementS oooncocccnonncnoncnnnncnonncnnnos 1 13 HOS insano kde ahd pecan A E 4 11 T O Card Analog Inputs ooonoccnnccnnncccnoanconcninnanncnno 5 8 T O Card Analog OutpUtS coooconoccconcconaconaninoncc nnne 5 11 I O Card Discrete InputS oooonnoccnonccconcccnonccnanonancnn 5 5 I O Card Discrete Outputs 0 00 0 eee eeeeeeeeeee renee 5 10 I O Card Pulse Inputs ocoonnoccnnccnonononacinanoconanacinnass 5 6 VO WIN Sica tota 1 14 Input Terminal Siv inse sesen ienei iiei epr 2 29 Intrusion SWitCh oococcnnonccccnoonccnnnonncononcconnnnncnnnono 2 42 A R E EA E ENEE 2 36 Lightning Protection Module ooooccnnnccnnocccnncccnnnnos A 3 l O EEREN E seen E eteletea tented 2 43 Main P
18. 200 us Sample Period 50 ms minimum 5 13 GB600 Series Instruction Manual I O Card Specifications Continued DISCRETE OUTPUTS Quantity Type 2 dry contact solid state relay outputs Terminals normally open contact common Contact Rating 120 Vdc 0 3 A maximum Isolation 3000 volts Frequency 5 Hz maximum ANALOG OUTPUT Quantity Type One 4 20 mA loop signal output Terminals positive output and common Range 4 to 20 mA with 0 to 22 mA overranging Resolution 12 bits Accuracy 0 1 of full scale output Settling Time 100 us maximum Reset Action Output goes to zero percent output or last value software configurable on power up warm start or on watchdog time out 5 14 DIMENSIONS 0 8 in H by 5 4 in W by 6 3 in L 21 mm by 137 mm by 160mm WEIGHT 0 9 lb 0 1 kg nominal ENVIRONMENTAL Meets the Environmental specifications of the controller in which the card is installed including Temperature and Voltage Surge specifications CLASSIFICATION FCC Class A and CISPR 22 computing device APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups C and D Rev 9 99 GB600 Series Instruction Manual FISHER APPENDIX A LIGHTNING PROTECTION MODULE A 1 SCOPE This appendix describes the Lightning Protection Module LPM used with the GridBoss System Topics covered include Product Description Initial Installation Co
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20. A ooh kote 2 23 Low Power Modes ccsscceeeseseeeeesseeeeeeenseeessnees 2 26 Low Pressure PoOint csccccccccccccceeeeeeeeeeees 1 4 2 13 Al tos at sa 2 14 BOL a ia 1 1 INPUTS isis in e 2 16 EPR ts tica lato cs a e teal 1 3 LPM Lightning Protection Module ocooooccnnnnnccccnnonccnnono A 1 M Main Electronics Board 000 1 5 2 1 2 21 2 22 A O 2 50 Manual Mode occccccnnnnnnnnnnnonnnnnonnnonoccnononococccnncnnnos 2 6 2 7 MG eect en aeo a AeA AEE E ROEE evs 2 21 NY LAE m Te A NO 3 9 Microprocessor see eeeeeseeceeseeeceteeeeeeeteeeesaes 1 5 2 21 Minute Historical LO8 ooooocnocccnoncnonnconncnnancnnnnnnccnnne 2 18 Mode Levels ideas 2 6 Modem Communications Cald oooocnncoccnooccnnnnncnnnncnnnonos 4 6 MOSFET ysis schist avin artes alisios 2 41 Mounting cialis tiran 1 15 Ral tools 1 16 N National Electrical Code i CAERE E T lalo 1 12 O Off ModE coito illa 2 6 OD AEA EIE E E ETEA OEE CE REE 4 8 Operaatiot opipa noen eeaeee ane a eaae a REN 1 26 Operator Interface Port ooooccnoncnonccnonononncnnnnnos 2 23 2 42 TOD E OE EE E EE E E ty sent 1 6 1 9 WELDS ae add iadaiici s 2 43 l 3 GB600 Series Instruction Manual OPHION Senik iaa e dalicii lacada 1 8 Outer Loop Mode cocoocccncccocccconcnoncnonancnonanonanccnnnos 2 6 2 7 P Di AA OESE AS E EE Set S E AEE 2 48 Periodic Timer InterrUpt oooconnnnccnonccnonnnonnnnononccnnnccnonacinnacos 2 26 Phase Lock Loop a nere arere n E A EAA
21. Actuator Part Number D102273X012 e Ree 1 4 PRODUCT OVERVIEW Both GridBoss controllers are 32 bit microprocessor based devices One is the GB601 District Regulator DR Controller and the other is the GB602 Low Pressure Point LPP Controller The DR is automated with a Kixcel The GridBoss System automates the delivery of natural gas at an optimized and adequate pressure for distribution systems The GB601 provides functions required for measuring the inlet and outlet pressure of the District Regulator and the GB602 measures the line pressure at the Low Pressure Point The GB601 DR Controller computes historical load profiles based on ambient temperature and time of day to determine the predicted Setpoint of the District Regulator By using historical load profiles and relaying the Setpoint and average temperature originating at the GB602 LPP Controller to the District Regulator the DR automates the delivering of natural gas at an optimized and adequate pressure The GridBoss System predicts system requirements to improve system integrity and reduces the average system pressure The District Regulator controls the regulator and stores the historical load profile for the pressure versus the time of day and temperature The controllers provide on site functionality and support remote monitoring pressure monitoring data archival communications and control The controller design allows you to configure specific applications includi
22. Detector RTD input Input Output I O Card optional on GB602 Operator interface LOD port Communications ports COM1 for optional Host communications card User Level Security Up to 28 amp hour battery capacity 21 amp hour capacity with optional AC power supply Extensive applications firmware 16 1 10 9 19 1 2 Physically the GridBoss controllers consist of a printed circuit Main Electronics Board and a display housed in a compact weather tight case The case is a NEMA 4 windowed enclosure that can mount on a wall or a pipestand A protective cover is provided for the display to protect it from adverse weather conditions Refer to Figure 1 1 The steel enclosure protects the electronics from physical damage and harsh environments The enclosure consists of two pieces the body and the front cover A foam rubber gasket seals the unit when the cover is closed The cover hinge located on the left side is stainless steel and fastened to the body with machine screws allowing removal of the cover The cover is secured by a lockable hasp The enclosure is fabricated from carbon steel Enclosure external dimensions including the Pressure Module PM are approximately 16 56 inches high by 13 80 inches wide by 7 25 inches deep 420 mm by 350 mm by 184 mm The Pressure Module mounts to the bottom of the enclosure with four bolts 1 4 Rev 9 99 GB600 Series Instruction Manual The enclosure contains the Main Ele
23. Main Electronics board provides reverse polarity protection and reverse discharge protection so no external circuitry is required to perform this function The circuitry prevents overcharging by comparing the battery voltage to a maximum limit If this limit is exceeded the battery charge cycle is immediately terminated and cannot be re initiated until the voltage has dropped below the maximum limit 2 34 Rev 9 99 GB600 Series Instruction Manual A al o A Ql O zag y o DOCO306B AC POWER Figure 2 8 AC Power Supply Wiring POWER INTERNAL gt HI aI TERMINAL BLOCK POWER SUPPLY M BAT CHG ae DC AC OUTPUT INPUT 5 AMP Li L2 GR FUSE 115 230 VAC 47 63 Hz _ Figure 2 9 AC Power Supply Connections Rev 9 99 2 35 GB600 Series Instruction Manual 2 5 7 Auxiliary Output Power The auxiliary output power connections are on a fixed terminal block connector labeled RADIO Refer to Figure 2 10 These terminals can supply power pass through to external devices such as a radio The power for this connector originates at the battery connection terminal and is not fused or controlled on the Main Electronics Board Fusing should be installed in the auxiliary output wiring and should not
24. PID control Logic and sequencing control for one user defined Function Sequence Table FST program Communications based on the ROC protocol o gt oo oo o User level security Refer to Section 2 3 for more information about the functionality provided by the firmware Rev 9 99 1 7 GB600 Series Instruction Manual 1 4 2 Options and Accessories The GB600 Series controllers support the following options and accessories Communications Cards for DR LPP Host communications COM1 Radio for Host communications Bracket for one internally mounted radio AC Power Supply Battery Charger Local Operator Interface LOI cable Lightening Protection Module LPM Batteries Solar Panels ff 1 Oe OH oo 2 Intrusion Switch A variety of plug in communication cards are available that allow you to customize the controller installation for most communications requirements COM1 provides the necessary communications to receive data to and from the LPP and DR controllers and provides an interface for the Host communications In addition a Host computer can remotely configure and take control of the DR and LPP controllers through the COM1 port The LPP controller can communicate with up to five DRs These cards permit serial communication protocols as well as dial up modem communications One card of the following types can be accommodated EJA 232 RS 232 for asynchronous serial communications EIA 485 RS 48
25. PM sensor and a radio The GB602 may also be solar powered The GB602 LPP has a dedicated communications link with its corresponding DR Controller A GB602 LPP which can communicate with up to five GB601 DRs initiates communications with the DR controller The GB602 also initiates and accepts communications with a Host The operator interface LOI port located on the bottom left hand side of the enclosure refer to Figure 1 1 provides for a direct local link between the controller and a personal computer through an Operator Interface Cable With the personal computer running the GRIDLINK Configuration Software you can configure the functionality of a GridBoss controller and monitor its operation User level security can be enabled or disabled for the LOI port The Host communications port located at COM1 is available for use with an optional communications card to permit serial communication protocols and dial up modem communications User level security can be enabled or disabled for the Host communications port COM1 Through this port the DR and LPP controllers can communicate periodically with a central Host The Host gathers the history data and checks the status and health of the system Alarm limits can be set in the Host to monitor the system and improve overall system integrity The DR and LPP controllers have the ability to communicate with each other and the Host on the same communications port or on separate communications p
26. The LED is on for a space and off for a mark 4 3 1 1 Radio Power Cycling This function is available with the EIA 232 communications card to provide power savings when using a radio for communications Power cycling control for a radio is accomplished through the Data Terminal Ready DTR signal on the EI A 232 communications card Connect wiring as described in Section 4 5 1 Configure the radio power cycling using the Radio Control feature as described in the GRIDLINK User Manual NOTE If you require two radios one for peer to peer and one for peer to host one of the radios must be mounted outside of the GridBoss enclosure 4 4 Rev 9 99 GB600 Series Instruction Manual 4 3 2 ElA 485 Serial Communications Card The EIA 485 communications cards meet EIA 485 specifications for differential RS 485 asynchronous transmission of data over distances of up to 4000 feet Refer to Figure 4 2 The EIA 485 drivers are designed for true multi point applications with multiple devices on a single bus This is an optional interface communications card for the host port which activates COM1 The P1 connector on the EI A 485 communication card plugs into the Main Electronics Board at P3 The interface lines of RTS are supported to control transmission RTS must be active during TXD The default values for the EIA 485 communications card are 9600 Baud Rate 8 Data Bits 1 Stop Bit No Parity 10 millisecond Key On Delay and 10 mill
27. To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 2 28 CAUTION Rev 9 99 GB600 Series Instruction Manual 2 5 1 Terminal Wiring Connections The Main Electronics Board connectors use compression terminals the pulse input counter uses a removable connector that accommodate wiring up to 14 AWG American Wire Gauge in size The connections are made by baring the end of a copper wire 4 inch maximum inserting the bared end into the clamp beneath the termination screw and then securing the screw The wire should be fully inserted with a minimum of bare wire exposed to prevent short circuits To make connections unplug the left hand connector from its socket insert each bared wire end into the clamp beneath its termination screw secure the screw and then plug the connector back in The inserted wires should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain on the circuit board and to provide enough clearance to unplug connectors or to allow the Main Electronics Board to swing out This allows access to the batteries without tedious removal of the field wiring The terminations on the Main Electronics Board use removable connectors and accommodate wiring up to 14 AWG in size The following connectors are used on the Main Electronics Board Battery Input POWER BAT
28. describes the Sensor Module SM which provides static pressure inputs to the GridBoss Controller for the pressure calculation 3 1 1 Section Contents This section contains the following information poa E o 5 E g o Section Page Number ios T Scope Noa b N YW ha Description Analog Inputs 3 2 1 3 3 Pulse Inputs 3 2 2 3 3 Process Connections 3 3 3 roubleshooting 3 7 3 15 Specifications 3 8 3 16 3 2 DESCRIPTION The primary function of the controller is to measure the pressure of natural gas using pressure metering in accordance with the American Petroleum Institute API and American Gas Association AGA standards The GB601 measures the inlet and outlet pressure at the District Regulator and the GB602 measures the average pressure at the Low Pressure Point The Sensor Module can be configured for Metric or English units The Sensor Module senses static line pressures from direct process connections At the Low Pressure Point the Sensor Module converts and reads the static line input pressure The LPP calculates the inlet pressure average over a minute and compares it to the Setpoint Deadband If the inlet average pressure is out of range of the Setpoint Deadband a message containing the new calculated change in the Setpoint for the Inner Loop and the average pressure is sent to the DR GB600 Series Instruction Manual At the District Regulator the Sensor Module converts and reads t
29. either during initialization or run time the Point Fail bit in the Analog Input alarm code is set and if alarms are enabled an alarm is entered in the Alarm Log The measurement in the Sensor Module for the static pressure inputs can be any combination of these ranges 0 to 5 psig 0 to 30 psig O to 300 psig or O to 1000 psia Read the label on the Sensor Module to view the specific pressures ranges The Sensor Module informs the Main Electronics Board that it is ready for an update at least once per second The controller converts this value and stores it in the proper analog input for access by other functions within the controller If an update does not occur in the one second interval the sensor is re initialized and a Point Fail alarm is set if the sensor does not respond to the initialization Calibration is performed through the AI Calibration routine As described in Section 3 5 use the GRIDLINK Configuration Software to configure all analog input points required for pressure metering Refer to the GRIDLINK User Manual 3 2 Rev 9 99 GB600 Series Instruction Manual e P8 P9 P10 N PLL DOO C O Oi O GOODS 8808 A OSs 6 P DP Ribbon Cable Q e P I Terminal Block LJ P
30. every minute along with any change in Inner Loop Setpoint from the LPP If the time of day load profiles are already created then the DR uses the current load profiles for modifying the Inner Loop Setpoint and continues to develop both profiles An LPP may communicate with up to five DRs and each DR may have different gains so the LPP calculates a change in Inner Loop Setpoint for each DR The LPP regularly communicates the average pressure and change in Inner Loop Setpoint to each DR after the Check in Time has expired if the average pressure has not varied from the Setpoint by more than the Deadband The Check in Time has a maximum limit of eight hours The District Regulator executes the PID control loops at a maximum rate of once per second and can limit the output of the Inner Loop and Setpoint When power is applied to the controller the LED on the Pressure Module flashes and the LCD displays information based on the type of controller and user defined information When the District Regulator receives communications from the Low Pressure Point the controller records and time stamps the input pressure at Low Pressure Point The LPP calls the DR s when the pressure at the LPP exceeds the range of a Setpoint plus or minus a Setpoint Deadband The LPP transfers data from the DR to determine if the DR Kixcel or the Inner Loop Setpoint should be increased or decreased If required the DR sends an output signal AO or TDO to the Kixcel to adjust the Set
31. exceed the size of the fuse in the battery harness wiring The terminals are labeled for positive voltage and for common If power to the radio or other device needs to be cycled to conserve power recommended when batteries are used use an E A 232 communications card and connect wiring for switched radio power as described in Section 4 Configure radio power cycling control as detailed in the GRIDLINK Configuration Software User Manual Form A6074 O ID OOOO ok Fi RADIO P DP lt Radio or other constant powered device Figure 2 10 Auxiliary Power Terminals 2 5 8 Pressure Module Sensor Wiring For information on Pressure Module wiring refer to Section 3 2 5 9 Type 662 Kixcel Installation A Kixcel can receive input power as 120 240 Vac or optionally 24 to 36 Vdc which is connected at terminal block TB1 An AC power selection switch is used to determine whether input power is 120 Vac or 240 Vac It is important to check this switch and set it properly before applying power For DC power verify correct polarity of field wiring on the terminal block before applying power Refer to the 2 36 Rev 9 99 GB600 Series Instruction Manual Type 662 Kixcel Remote Control Pilot Drive Actuator Instruction Manual Form 5419 or documentation specific to the type of device you are installing Refer to Figure 2 11
32. for the various RTD probes are Terminal 4 Wire RTD 3 Wire RTD 2 Wire RTD REF Red Jumper to Jumper to Red Red Jumper to REF Red Jumper to REF White White White Jumper to RET RET White White Jumper to 2 40 Rev 9 99 GB600 Series Instruction Manual 2 5 11 Discrete Output Wiring A discrete output is provided on the Main Electronics Board at the I O terminal blocks Refer to Figure 2 13 One possible application for this output is to use it as one of a pair of DOs for controlling a Kixcel actuator This discrete output channel is software configured as DO Point A4 The DO channel uses a MOSFET to switch current limited battery power to the positive terminal The negative terminal is internally connected to battery negative A blocking diode a 22 volt transorb and a back EMF diode are included to protect the controller electronics Because the output is not isolated care must be used to ensure that the load on it does not affect the operation of the controller This may include installation of back EMF diodes and MOVs on the load The load should be connected as follows DO Positive load DO Negative load O P8 da P11 aaa Jai Jaja SISISISIS B ie S RADIT BAUR i BLK Rh af REF ae ao O Po O E O Pa 2 221 AE d 2 2O S S S A
33. needs to be reloaded perform the remaining steps 4 Select Download from the File menu and in the resultant sub menu 5 Select Disk Config to GridBoss 6 In the dialog box that appears see Figure 2 19 select the File Name you entered in step 4 Section 2 7 1 Backup Procedure Before Removing Power on page 2 45 and click OK 7 Select the portions see Figure 2 20 of the configuration you want to load or restore 8 Press F8 Download to restore the controller configuration Rev 9 99 2 49 GB600 Series Instruction Manual File Name C ROCLINK Files COMM FCF Figure 2 19 Open Configuration File Download Configuration File Name BACKUP gcf SSS XXXXXXX A e be E6 Cancel F3 Downl oada Figure 2 20 Download Configuration 2 7 4 Replacing the Main Electronics Board Refer to Figure 2 4 Proceed as follows to replace the Main Electronics Board CAUTION There is a possibility of losing the device configuration and historical data while performing the following procedure As a precaution save the current configuration and historical data to permanent memory as instructed in Section 2 7 1 2 50 Rev 9 99 GB600 Series Instruction Manual Rev 9 99 CAUTION When installing units in a hazardous area make sure installation components selected are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non haz
34. terminals LOI on the Main Electronics Board 2 4 4 2 Host Port COM1 The Host port also called the COM1 port is activated by the installation of the optional communications card COM is used to monitor or alter the Low Pressure Point GB602 or the District Regulator GB601 from a remote site using a Host and configuration software The Host port automatically configures itself based upon the specific communications card installed The Host port supports baud rates up to 19 2k COM1 also supports the log on security feature of the GridBoss controller if the Security on COM1 is Enabled in GRIDLINK The Host port is capable of initiating a message in support of Spontaneous Report by Exception SRBX or RBX and Store and Forward Refer to the GRIDLINK Configuration Software User Manual For installations using radio communications battery power can be conserved by cycling power to the radio or a cellular telephone The power cycling control for a radio is acquired through the Data Terminal Ready DTR signal on the optional EIA 232 communications card Refer to the GRIDLINK Configuration Software User Manual concerning radio power control The radio is connected to the signal wiring terminals located on the E A 232 communications card Refer to Section 4 NOTE If you require two radios one for peer to peer and one for peer to host one of the radios must be mounted outside of the GridBoss enclosure The communications connectors on the Main
35. the LCD Enters the Doze mode Shuts down communications ae sale ale Wakes up from Doze mode by the Real Time Clock alarm set in step 1 and rechecks the voltage to see if operation is possible If the voltage is greater than the low low alarm limit for analog input point number El a normal restart sequence initiates Rev 9 99 2 27 GB600 Series Instruction Manual 2 5 CONNECTING THE CONTROLLER TO WIRING The following paragraphs describe how to connect the GridBoss controller to power ground I O devices and communications devices Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment The field wiring terminations are accessed by opening the front door The terminal wiring is arranged on the lower edge of the Main Electronics Board The terminal designations are printed on the circuit board Refer to Figure 2 4 This section includes 0 19 1091999 9 9 2 Terminal Wiring Connections Connecting Ground Wiring Connecting Main Power Wiring Battery Connections Solar Panel Charge Connections AC Power Supply Battery Charger Auxiliary Output Power Pressure Module Sensor Wiring Type 662 Kixcel Installation RTD Wiring Discrete Output Wiring Intrusion Switch Wiring Connecting Communications Wiring Operator Interface Port Wiring Host Port Wiring CAUTION Always turn the power to the GridBoss controller off before you attempt any type of wiring
36. to 132 Vac or 207 to 264 Vac 47 to 63 Hz Input Power 10 to 14 Vdc at 020 amp maximum USER INTERFACE 2 line by 16 character LCD Continually updates approximately every 3 seconds See Environmental specification for operating temperature 1 0 CARD See Specifications Sheet 3 10B1 Rev 9 99 RTD INPUT BUILT IN Quantity Type Single input for a 2 3 or 4 wire RTD element 4 wire RTD sensor supplied for the GB601 Terminals Ref current source signal positive input signal negative input and Ret return common Sensing Range 50 to 100 C 58 to 212 F Accuracy includes linearity hysteresis repeatability 0 56 C 1 0 F over sensing range Ambient Temperature Effects per 28 C 50 F 0 50 C 90 F for process temperatures from 40 to 100 C 40 to 212 F Filter Band pass hardware filter Resolution 16 bits Conversion Time 100 usec Sample Period 1 sec minimum DISCRETE OUTPUT BUILT IN Quantity Type 1 sourced high side switched output Terminals positive output negative common Voltage Same as applied to Battery Input minus 0 7 volts Frequency 1 5 Hz maximum Sample Period 200 milliseconds minimum Current Limit 300 mA automatic reset ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F excluding LCD display which is 25 to 70 C 13 to 158 F Storage Temperature 50 to 85 C 58 to 185 F Op
37. volume of communication between the LPPs and their associated DR controllers As the daily load profiles accumulate at the DR the communication volume drops After a sufficient training period the DR operates in a predictive mode The training period takes approximately two weeks The DR controller sets the outlet pressure based on the actual temperature and the stored time of day profile and then adjusts the pressure as necessary Rev 9 99 2 5 GB600 Series Instruction Manual Two load profiles are generated Y pressure versus outside temperature pressure versus time of day The DR Controller creates and stores one temperature load profile that contains a coefficient for calculating an adjustment to the DR outlet pressure Setpoint based on the ambient temperature The DR Controller creates and stores two time of day load profiles with 1440 entries each that represent the adjustments to the DR outlet pressure Setpoint for each minute of the day One profile is the Weekday load profile for Monday through Friday and one profile is the Weekend and Holiday load profile for Saturday Sunday and holidays The Weekend profile can be used for up to 30 dates specified as holidays that you establish using GRIDLINK The LPP Controller is left permanently in place to update the load profiles if there are long term changes in the system loading The LPP Controller also provides rapid notification of pressure emergencies Other than emergency
38. 0 RADIO ppp Sf S PANE l o U o0 00 oo9 No DOCO361A Swing out Panel Figure 2 7 Battery and Solar Panel Connections Rev 9 99 2 33 GB600 Series Instruction Manual 2 5 6 AC Power Supply Battery Charger The optional AC Power Supply is used as the primary source of power for the GB601 and GB602 in line powered installations The AC power supply is used to convert AC line power to DC power for use with the controller and its associated accessories The unit is designed to be used either as a power supply only or as a combination power supply and battery charger The AC power supply occupies the leftmost position in the battery compartment of the GridBoss controller see Figure 2 8 When the AC power supply is installed up to 21 amp hours of battery backup capacity is available The internal AC power supply which provides a nominal 12 volt DC output
39. 1 The RTS and DTR control lines are supported The EIA 232 communications card defaults are 9600 baud rate 8 data bits 1 stop bit no parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay The maximum baud rate is 19 2k The EIA 232 communications card includes LED indicators that display the status of the RXD TXD DTR DCD and RTS signal control lines LED indicators are detailed in Table 4 1 Mating Connector fal R2 1 x nl O R4 cR3 O R3 5 Q mas O Q1 O LEDs RO om _ PS Radio Power Control Terminals Host Port Terminals Figure 4 1 EIA 232 Serial Communications Card Rev 9 99 4 3 GB600 Series Instruction Manual Table 4 1 EIA 232 Communications Cards LED Indicators LEDs STATUS AND ACTIVITY DCD The DCD data carrier detect LED lights when a valid carrier is detected DTR The DTR data terminal ready LED lights when a signal from the processor specifies the GridBoss controller is ready to answer an incoming message When the DTR goes off no communications occur through the COM1 port RTS The RTS ready to send LED lights when a signal from the processor specifies the GridBoss controller is ready to transmit RXD The RXD receive data LED blinks when the receive signal is being received from the communications card The LED is on for a space and off for a mark TXD The TXD transmit data LED blinks when transmit signal data is being received from the processor
40. 1 Calls Current Value 3 Number of Calls from District Regulator 2 DR 2 Calls Current Value 4 Number of Calls from District Regulator 3 DR 3 Calls Current Value 5 Number of Calls from District Regulator 4 DR 4 Calls Current Value 6 Number of Calls from District Regulator 5 DR 5 Calls Current Value 7 Battery Voltage AIN E 1 EU Average History points for the controller are configured using GRIDLINK and are selected in the History Setup screen located in the History menu s Setup option All history points in a controller may be configured as desired All history points are configured using Point Type Logical Number and Parameter Number TLP Rev 9 99 2 17 GB600 Series Instruction Manual 2 3 5 1 Minute Historical Log The GridBoss controller has a 60 minute Historical Log for the LPP and DR history point parameters The Minute Historical Log stores the last 60 minutes of data from the current minute Thus the controller has one hour of minute history Each history point has Minute Historical Log entries unless the history point is configured for FST controlled logging The District Regulator samples ambient temperature regulator inlet pressure regulator outlet pressure output signal to the Kixcel position and battery voltage once a second it then stores one hour of minute averages to the Minute Historical Log The Low Pressure Point samples the low pressure point value and battery voltag
41. 15 displays the operator interface LOI port which is located on the bottom of the controller enclosure and factory wired to a terminal block at the bottom of the Main Electronics Board The LOI port provides connections for a built in EIA 232 communications interface to a configuration and monitoring device The configuration and monitoring device typically is an IBM compatible computer A prefabricated operator interface cable is available as an accessory from Fisher 2 42 Rev 9 99 GB600 Series Instruction Manual The LOI port is how the controller normally communicates with the GRIDLINK Configuration Software This port is compatible with RS232 signals An RTS terminal is provided on the Main Electronics Board not routed to the cannon connector and is intended for future applications The following table shows the signal routing between the Main Electronics Board terminations and the cannon style connector Main Board Cannon Connector Signal BLK 1 Common WHT 2 RXD RED 3 TXD om gt COOO OCEZ OOODPSISSS 3 BAT CHG B RED REF _ RET FEN A aA aS AA NS z 2 5 Th DOCO356A Figure 2 15 Operator Interface Wiring 2 5 13 2 Host Port Wiring The Host port provides communications access to
42. 2 26 PID Cotrol Mode Levels ooonocconocccnonccconncnoncncnnnnononcnn 2 6 PM See Pressure Modules siidine rns 1 5 Polarity ct 1 26 2 26 Power Auxiliary Output Radio eee eeeeeseeeeeeeeeeeeee 2 36 Battery Connections ooooccooccnonccnonnnononccnanccnonccnnenos 2 31 Before REMOVING eani arin ore a 2 45 Charge Connections asiishi enrere a 2 32 CONSUMPtlOM e otitis id 1 19 1 20 COMtrO EE EEEE E E EA 2 20 Cycling for RadiO coooconoccnonccconcccnonnconncnonncnanacinnnos 4 4 Doze Mode iol e hln iii 2 27 T O Requirements coooocconcccnocncnonncnnnononccnonac nncnonacos 1 20 A ise Ken a Sene Eee a aR i 2 26 Man DG E 2 31 A ie le att atte ete eed 2 26 Radio Requirements sccceeesseeeesteeeeeeneeeees 1 21 Requirements E 1 12 Solar POVE e E ASS 1 12 1 22 Standby Mod ren eisenii ansat fi 2 26 Surge Protection soseen to e eresi aeaeaie 1 13 Terminal Connecti0NS oocooccconoccnonnc onncnonccnnncnnenos 2 29 Totaling Requirements ccsscceeesseeeeseeeeeees 1 21 WIP dolina 2 28 2 31 Power Cycling Radio vis ins id 2 36 NA 1 9 2 32 2 34 Pr UT div IO 1 4 Pressure Module cuida tein tats 1 5 Calibration vivido ii obits 3 11 ConfiguratiOM ooconocccnncncnonnninnononncnonacinncnanac nne 3 2 3 9 Connection iia iii iii tic 3 4 PM 3 1 Replacement nesrec it dei 2 52 SPecifications ceseceeseeesseneseveceeseetenenersonens 3 16 WISE 3 6 Pressure MONItOTINB oooccooccnoncnononccnonccnonccno
43. 2 42 Communications Cards oooooooonnoonononononononononnnnnnnos 1 8 4 1 DESCTIPLONS eie a E E aa 4 2 Dial Up Modem nenene a iae 4 6 ELA 2 48 E E EE urs EAE 4 3 ELA A oa alle 4 5 Installation ooooonnnnononononononononononocnononononcnnnnnnnnnonononos 4 9 LED Indicators inicia 4 4 4 6 4 8 O snn T a 4 10 Replacing ennn a tetas a a as 4 14 SPecifications ooooncononcnnonononacnnnnononanno ron a 4 16 Troubleshooting ccecceeeseeeceeeeeeeeeeeeneeeesenees 4 14 WIDE ici oie vaa 4 11 Configuration Pressure Module cccccsseeessesesesseeeeeees 3 2 3 9 Configuring mputs oonnoncnnncccnonccnonncconccconcconnnconnncnno 3 9 Connections Process Inputs ania sd 3 5 Control Mode Levels oocccccccccccncccnonancnancnocononnnnoo 2 6 D Daily Historical Logs c ccesssceceeeeeeseeeeteeeeeenees 2 18 Data Terminal Ready ooooooocononcconnnonccnononconnncncnonnncno 2 24 DC Power QUICE crenistria n 2 31 Diagnostieiesrcoicn n i elie iste gles 1 5 Dial Up Modem Communications Cards 4 6 4 7 4 15 SPecCiticatlONs 2 5 coszch ssecvs sh sssoeghweisDsiesssiseessevesdeess 4 17 WALID 5055s 22s cobs Phe eor e rie e iea aiaee a 4 13 Discrete Input mail ad 5 5 Using Pulse Inputs ininsert aiae 5 7 Wiring VO Caldas 5 5 Discrete Outputs cut larisa sonda desde 2 25 TE 2 41 l 1 GB600 Series Instruction Manual Witing NO Cardin dct talado 5 10 District Regulator oooooocnnnncccnoncncnnnnc
44. 3 4 is assumed to be opening and closing an isolated switch of some type 3 6 Rev 9 99 GB600 Series Instruction Manual PI on SM s ve SELF POWERED A PI Filter and PULSE DEVICE Level Detection COM Y Figure 3 3 Pulse Input from Field Powered Device PI on SM CONTROLLER s v POWERED m PULSE DEVICE lave Deon COM NY Figure 3 4 Pulse Input from SM Powered Contact Closure A controller powered field device that uses a switch to ground a shorting switch can be accommo dated by wiring the device between the and COM terminals and also connecting the S and terminals together Note that the power for the pulse device in Figure 3 5 is shown coming from the Radio power terminals on the controller however another suitable 12 volt source could be used Rev 9 99 3 7 GB600 Series Instruction Manual PI ON SM SIGNAL S ENN s CONTROLLER POWERED 7 PI Filter and PULSE DEVICE COM a Level Detection POWER EXTERNAL PUSE MAIN BOARD oS 12 Volt Radio Power NOTES Connect this wire only for a contact closure from relay contacts or a solid state relay with an open collector or open drain Locate fuse close to RADIO power conn
45. 4 INITIAL INSTALLATION The LPM plugs into any of the 3 position field terminal block sockets used to wire I Os Refer to Figure A 2 YX L O WIRING CONNECT GREEN WIRE TO ENCLOSURE S GROUND BAR OR GROUND LUG Figure A 2 Lighting Protection Module Installation A 2 Rev 9 99 GB600 Series Instruction Manual To add an LPM to protect an I O card perform the following steps CAUTION If you are installing an LPM on a controller currently in service and there is a field device connected to the I O channel that receives the LPM make sure the field device will not be left in an undesirable state when it is disconnected from the controller CAUTION When installing units in a hazardous area ensure that the components selected are labeled for use in such areas Change components only in an area known to be non hazardous CAUTION Be sure to use proper electrostatic handling such as wearing a grounded wrist strap or components on the circuit cards may be damaged 1 Unplug the field wiring termination block from the channel for which the LPM is going to be installed 2 Plug the LPM into the field wiring terminal block socket located in step 1 3 Connect the LPM ground wire to the ground bus bar This ground bar must in turn be connected to a good earth ground Do not use the power system ground for this connection 4 Transfer any field wiring from the unplugged termination block to th
46. 5 for asynchronous serial communications Dial up modem for communications over a telephone network Stand offs on the Main Electronics Board allow the optional communications cards to be added easily Refer to Section 4 for more information One radio can be mounted inside a GridBoss enclosure using the optional radio bracket see Section 1 6 The radio bracket allows a radio up to 2 25 inches high to be mounted securely in the battery compartment inside the enclosure Power for the radio can be controlled through the EIA 232 communications card Clearance is provided for the radio antenna cable to exit the bottom of the enclosure If you require two radios one for peer to peer and one for peer to host one of the radios must be mounted outside of the enclosure 1 8 Rev 9 99 GB600 Series Instruction Manual An internal AC power supply is available from Fisher as a factory installed option The AC power supply converts AC line power to DC power for use by a GridBoss controller and its associated accessories The power supply typically is used in line powered installations If a battery is used in the line powered installation the AC supply also functions as a battery charger The unit provides a fully regulated temperature compensated output that is protected from overcurrent conditions The AC supply is factory installed in the battery compartment of the controller enclosure Refer to Section 2 for details concerning the AC power supply
47. 5 2 ElA 485 Communications Card Wiring The EIA 485 communications card provides for RS 485 signals on the host port located at COM1 Wiring should be twisted pair cable This board also provides additional protection for the external wiring and the board circuitry LEDs are provided for diagnostic functions The terminals and their functions are as follows Terminal Function A RS485 positive B RS485 negative GND Ground 4 12 Rev 9 99 GB600 Series Instruction Manual 4 5 3 Dial Up Modem Communications Card Wiring The dial up modem card interfaces to a PSTN line through the RJ11 jack located at J2 with two wires The dial up modem card provides for a telephone interface on the host port that is capable of both answering and originating phone calls The dial up modem card also provides electronics that conserve power when the phone line is not in use The dial up modem card provides some protection from transients on the phone lines however if the potential for lightning damage is high additional surge protection for the phone lines should be installed outside the GridBoss enclosure LEDs are provided for diagnostic functions The dial up modem card provides a modular phone RJ11 jack that directly interfaces to phone line connections The RJ11 connector signals and their functions are RJ11 Signal 1 2 3 Tip 4 Ring 5 6 Rev 9 99 4 13 GB600 Series Instruction Manual 4 6 TROUBLESHOOTING AND REPAIR There are no user s
48. 6 volts BAT BAT CHG CHG _ Up to 22 volts Figure 2 6 Power Input Terminal Connector To make power connections 1 Unplug the left hand connector from its socket located at P8 on the Main Electronic Board 2 Insert each bared wire end into the clamp beneath its termination screw 3 Secure the screw 4 Plug the connector back into the socket at P8 As described in sections 2 5 4 and 2 5 5 connect the batteries if used to the BAT and BAT terminals Connect the DC charging source solar panels or AC power supply to the CHG and CHG terminals Make sure the hook up polarity is correct NOTE If you are connecting a solar panel that has its own regulator connect the panel instead to the BAT and BAT terminals 2 5 4 Battery Connections The battery connections are made to the electronics board by the removable terminal block labeled POWER These connections provide the input power for the controller electronics As many as four 12 volt sealed lead acid batteries wired in parallel are connected to these terminals which are labeled BAT for battery positive and BAT for battery negative Input power is monitored by diagnostic Analog Input Point E1 Rev 9 99 2 31 GB600 Series Instruction Manual CAUTION The maximum voltage that can be applied to the BAT terminals without damage to the electronics is 16 volts dc The GridBoss enc
49. Due to the power requirements associated with the Kixcel the DR controller normally requires an AC power supply The local operator interface LOD port provides for a direct local connection between the DR or LPP and a personal computer using an Operator Interface Cable With the personal computer PC running the GRIDLINK Configuration Software you can configure the functionality of the controller units and monitor their operation The Operator Interface Cable is available as an accessory from Fisher The optional Lightning Protection Module LPM provides additional protection from any high voltage transients that may occur in field wiring for Analog Inputs AIs LPMs are available from Fisher Refer to Appendix A for additional information The GridBoss enclosures can hold up to four sealed lead acid batteries The 12 volt batteries provide approximately 7 amp hours each resulting in up to 28 amp hours of backup capacity or up to 21 amp hours of backup capacity when used with an AC power supply The batteries are mounted behind the electronics swing out panel and are retained by the panel when it is secured The batteries are connected to a wiring harness that allows the batteries to be changed without removing power from the unit Input wiring is connected at the POWER wiring terminal connector A solar panel can be installed to recharge the backup batteries of a controller it connects to the POWER charge inputs on the Main Electronics Boa
50. E Keep in mind that a solar panel bigger than 11 watts will violate CSA Class L Division 2 Group C and D ratings Be sure to use approved connectors on the bottom of the GridBoss enclosure for routing the power wiring NOTE If the solar panel contains its own regulator connect it instead to the BAT and BAT terminals The power source solar panels or line charger provides power for the charging of the backup batteries Overcharging is prevented by comparing the battery cell voltage to a maximum limit If this limit is exceeded the battery charge cycle is immediately terminated and cannot be re initiated until the cell voltage has dropped below the maximum limit 2 32 Rev 9 99 GB600 Series Instruction Manual The charge connections are on the removable connector labeled Power These connections provide the input voltage and power for the battery charging circuitry A 12 volt solar panel or a line charger with regulated 14 5 to 16 volt output can be directly connected to these terminals The charger circuitry provides reverse polarity protection and reverse discharge protection so no external circuitry is required The maximum voltage that can be applied to the charger terminals is 22 volts dc The terminals are labeled CHG for charge input positive and CHG for charge input negative Refer to Figure 2 7 P11 I ut ooooo0o0000
51. Electronics Board provide the controller with electrical access and mounting provisions for the optional communications cards The communications cards mount directly on the connectors at P3 on the Main Electronics Board and are held in place with three compression stand offs The stand offs on the Main Electronics Board pass through the communications card The communications cards available for the District Regulator and Low Pressure Point controllers allow the options of serial data communication and modem communications Refer to Section 4 2 24 Rev 9 99 GB600 Series Instruction Manual 2 4 5 Built In Discrete Output The built in Discrete Output may be used as a standard DO This includes one of the DOs required by the Timed Duration Output mode A pair of Discrete Outputs acting as a Timed Duration Output for open close control can be used to control the Kixcel I P or servo valve Typically the built in DO is not used and the two DOs on the I O card are used for TDO control The built in discrete output is located at DO Point Number A4 Refer to Table 2 7 Table 2 7 Discrete Output Output voltage ON Battery voltage 0 7 volts Output voltage OFF 0 volts Output Current 0 3 amp maximum Maximum voltage 22 volts maximum clamping occurs Refer to Section 2 5 11 Discrete Output Wiring on page 2 41 for more information 2 4 6 RTD Input The GridBoss controller supports a direct input from a Resistance Temperature Detec
52. Field Automation Systems GB600 SERIES CONTROLLERS of the GridBoss System Instruction Manual Form A6075 September 1999 Loose leaf version Part Number D301132X012 Bound version Contact FAS GB600 Series Instruction Manual Revision Tracking Sheet September 1999 This manual may be revised periodically to incorporate new or updated information The date revision level of each page is indicated at the bottom of the page opposite the page number A major change in the content of the manual also changes the date of the manual which appears on the front cover Listed below is the date revision level of each page Page Revision All 9 99 Notice The GB600 Series Controllers described in this manual were developed with the assistance of the Gas Research Institute GRI The firmware contained in the GB600 Series Controllers is copyrighted by Fisher Controls International with portions copyrighted by GRI Fisher Controls International Inc 1999 All rights reserved Printed in the U S A While this information is presented in good faith and believed to be accurate Fisher Controls does not guarantee satisfactory results from reliance upon such information Nothing contained herein is to be construed as a warranty or guarantee express or implied regarding the performance merchantability fitness or any other matter with respect to the products nor as a recommendation to use any product or process in conflict with a
53. Instruction Manual OOO A INSTALL USING GROUND BAR SCREWS MONA EDO GROUND BAR HEX NUT LOCK WASHER oo 00 ert SECTION A A DOCO362A Figure 1 2 Intrusion Switch Mounting for GB600 Series Enclosures 1 18 Rev 9 99 GB600 Series Instruction Manual 1 7 POWER CONSUMPTION CALCULATION A GridBoss controller s power consumption determines power supply and battery sizing for both line and solar power Table 1 1 provides information to assist in determining power requirements The controller has low power consumption due to a typical duty cycle of 10 to 20 for its microprocessor the other 80 to 90 of the time the microprocessor is shut off with external wake up signals reactivating it The Power Consumption Calculation section includes gt Rev 9 99 Determining I O Channel Power Consumption Determining Radio Power Consumption Totaling Power Requirements Solar Powered Installations Batteries Determining Battery Requirements GB600 Series Instruction Manual 1 7 1 Determining I O Channel Power Consumption In estimating total I O power requirements the duty cycle of each I O channel must be estimated For example if a discrete output is active for 15 seconds out of every 60 seconds the duty cycle is Duty Cycle Active time Active time Inactive time 15 sec 60 sec 0 25 Table 1 1 Power Consumption of the Controller and Powered Devices
54. Manual 2 3 6 Security The GridBoss controller provides for security within the unit A maximum of 16 log on identifiers IDs may be stored In order for the unit to communicate the log on ID supplied to the GRIDLINK Configuration Software must match one of the IDs stored in the controller The Operator Interface port Security on LOD has security Enabled by default The Host port COM1 can likewise be configured to have security protection but is disabled by default Refer to the GRIDLINK Configuration Software User Manual concerning security 2 3 7 Function Sequence Tables FST The GridBoss controller supports FST user programmability The FST program can be from 200 to 300 lines of code depending upon the FST The FST code resides in static RAM and is backed up to flash memory when the Save Configuration function is issued through the GRIDLINK Configuration Software See the GRIDLINK Configuration Software User Manual and the Function Sequence Table User Manual Form A4625 2 3 8 Power Control The Power Control function is used with the RS 232 communications card to provide power savings when using a radio or cell telephone for communications Two modes of Power Control are possible Second and Minute In Second mode the time base for the timers is in 100 millisecond increments and is primarily used with radios In Minute mode the time base for the timers is in 1 minute increments that are kept in tune with the Real Time Clock a
55. Memory validity ff oo Oo o The controller operates with 8 to 15 volts of dc power The LCD becomes active when an input voltage with the proper polarity and startup voltage of 10 8 volts or greater is applied to the POWER terminal block provided the power input fusing protection is operational The battery low and high tests ensure that the controller has the correct voltage to operate in a safe mode The software watchdog is controlled by the Main Electronics Board This watchdog checks the software for validity every 1 2 seconds If necessary the software is automatically reset The hardware watchdog is controlled by the Main Electronics Board and monitors the power to the hardware If this voltage drops below 4 75 volts the controller is automatically shut down RTD automatic temperature compensation is tested at approximately every 5 degrees Celsius temper ature change of the board temperature Voltage for charging the super capacitor is checked to ensure that it is continuously applied when the controller is powered A memory validity self test is performed to ensure the integrity of memory 2 4 8 1 Low Power Modes The processor used in the controller is capable of low power operation under predetermined conditions These features are available because of the Phase Lock Loop PLL used to control the speed of the system clock The base crystal frequency is 3 6863 MHz and is raised by the PLL to 14 7 MHz for normal system operat
56. Mid 1 Cancel Figure 3 11 AI Set Midpoint 1 10 If desired calibrate Midpoint 2 such as 50 of range for the Analog Input Enter the Dead Weight Tester Value in engineering units and press the Set Mid 2 pushbutton Refer to Figure 3 12 Otherwise use the Done pushbutton and proceed to Step 12 Rev 9 99 3 13 GB600 Series Instruction Manual Set Midpoint Point Analog input Dead Weight Tester Value Live Reading 51 Figure 3 12 Al Set Midpoint 2 11 If desired calibrate Midpoint 3 such as 75 of range for the Analog Input Enter the Dead Weight Tester Value in engineering units and press the Set Mid 3 pushbutton Refer to Figure 3 13 Otherwise use the Done pushbutton and proceed to Step 12 Set Hidpoint 3 Point Analog input Dead Weight Tester Value Live Reading TT Figure 3 13 AI Set Midpoint 3 12 Press the Done pushbutton to close the main calibration window Figure 3 7 and unfreeze the associated input 3 14 Rev 9 99 GB600 Series Instruction Manual 3 7 TROUBLESHOOTING There are no field repair or replacement parts associated with the Sensor Module Return the Sensor Module to your Fisher Representative for repair or replacement Refer to Section 3 1 LED Indicator on page 3 15 3 7 1 LED Indicator The Sensor Module contains an LED indicator viewable when the enclosure case is open Refer to Figure 3 1 The status of the Sensor Module is indicated by the LED The Status LED i
57. Mode Adaptive Mode tuning includes both information from the DR Inner Loop and the LPP Outer Loop in addition biases based on the time of day and temperature load profiles are also calculated and used 2 6 Rev 9 99 GB600 Series Instruction Manual NOTE All changes to the control modes are logged to the Event Log Manual Mode occurs when you manually adjust the Control Output In Manual Mode no PID Proportional Integral and Derivative control occurs Time of day and temperature load profiles are not generated In Manual Mode LPP does not communicate with that DR again until the value entered in the Error Time Delay for DRs field has been meet After the Error Time Delay period the LPP communicates with the DR to determine if it is in the Outer Loop Mode or Adaptive Mode The Error Time Delay for DRs should always be less than the Check in Time for DRs In Inner Loop Mode a single PID loop compares the Outlet Pressure of the District Regulator with a manually entered Setpoint and uses the regulator Outlet Pressure for the process variable If the difference between the Output Pressure and Setpoint is greater than the Error Deadband a change in output is calculated Otherwise no calculation occurs The Control Output has a Maximum Output and Minimum Output limit which the calculated output cannot exceed The Inner Loop contains a default Kixcel Default Output position entry If the DR battery or outlet pressure transduc
58. Point uses the Pressure Module to acquire the inlet pressure at the low pressure point in the system and has a selectable operating range 0 5 psig to 0 1000 psia The pressure sensors are accurate to 1 of range 2 16 Rev 9 99 GB600 Series Instruction Manual 2 3 5 History Points A total of fifteen history points may be accessed in the controller At the District Regulator Controller the first nine history points are pre configured Refer to Table 2 5 At the Low Pressure Point Controller the first seven history points are pre configured Refer to Table 2 6 Table 2 5 DR Default History Points History Definition Point Type Type of Point Archiving 1 Inner Loop Ambient Temperature Value APC 1 TMPVAL Average 2 Differential Pressure AIN A 1 EU Average 3 Inner Loop Regulator Input Pressure DRC 1 PRSVAL Average 4 Inner Loop Regulator Output Pressure DRC 1 OUTVAL Average 5 Inner Loop Regulator Output Pressure Monitor DRC 1 MONVAL Average 6 Inner Loop Coefficient of Temperature APC 1 TCOEFF Current Value 7 Inner Loop Adaptive Error APC 1 AERROR Current Value 8 PID Control Output Value Setpoint DRC 1 SETPT Current Value 9 Battery Voltage AINE 1 EU Average Table 2 6 LPP Default History Points History Definition Point Type Type of Point Archiving 1 Input Pressure LPC 1 LPVAL Average 2 Number of Calls from District Regulator 1 DR
59. Rev 9 99 1 27 GB600 Series Instruction Manual This page intentionally left blank 1 28 Rev 9 99 GB600 Series Instruction Manual SECTION 2 USING THE GRIDBOSS CONTROLLER 2 1 SCOPE This section describes the GB601 and GB602 controllers of the GridBoss System focusing on how the controller works its various components connecting wiring and troubleshooting This section also describes the AC power supply used in line powered installations 2 2 SECTION CONTENTS This section contains the following information Information Section Page Number Scope 2 1 2 1 Product Functions 2 3 2 3 Adaptive Predictive Control 2 3 1 2 3 Load Profiles 2 3 1 1 2 5 ime of Day Profiles 2 3 1 3 2 9 District Regulator 2 3 2 2 10 District Regulator Alarms 2 3 2 1 2 1 Low Pressure Point 2 3 3 2 13 Low Pressure Point Alarms 2 3 3 1 2 14 Inputs and Outputs 2 3 4 2 15 History Points 2 3 5 2 17 Minute Historical Log 2 3 5 1 2 18 15 Minute Historical Log 2 3 5 2 2 18 Daily Historical Log 2 3 5 3 2 18 Event Log 2 3 5 5 2 19 Main Electronics Board Overview 2 4 1 2 21 Microprocessor and Memor 2 4 2 2 21 Liquid Crystal Displa 2 4 3 2 23 Rev 9 99 2 1 GB600 Series Instruction Manual Information Section Page Number ommunications Ports 2 4 4 2 23 Operator Interface Port 2 4 4 1 2 2 ost Port 2 4 4 2 2 24 Built In Discrete Output 2 4 5 2 25 RTD Input 2 4 6 2 25 Real Time Clock 2 4 7 5 i 2 2 Automatic Self Tests
60. TION During this procedure all power will be removed from the controller and devices powered by the controller Ensure that all connected input devices output devices and processes will remain in a safe state when power is removed from the controller and also when power is restored to the controller 4 14 Rev 9 99 GB600 Series Instruction Manual 10 11 12 13 Refer to Section 2 7 1 and perform the RAM Backup Procedure Remove the Power terminal block at P8 on the Main Electronics Board If the communications card is a modem card unplug the RJ11 phone jack cable from the communications card connector J2 Using a rocking motion gently disengage the two stand off connectors located at the bottom of the communications card Using a rocking motion gently disengage the stand off connector located at the top middle of the communications card Using a rocking motion gently disengage the connectors at P1 pull the card free from the Main Electronic Board at P3 To reinstall a communications card orient the card with the P1 connectors on the communications card mating with the connectors at P3 on the Main Electronics Board Plug the card into its mating connectors and gently press until the connectors firmly seat Using a rocking motion gently engage the three stand off connectors For a modem card connect the RJ11 phone jack cable to communications card connector J2 Reconnect power by plugging in t
61. Tag DI tefl 1 Status tty Scan Parid 1 fork OTM Type arin na lar i Standard igi i 4 IRRE sobled Latches O Disabled lisi Enab aras Advanced alure Select function of discrete inout On Ling COMI Figure 5 5 Pulse Input PI I used as a Discrete Input 5 5 3 Analog Inputs Analog inputs AIs monitor current loop and voltage input devices The I O Card analog inputs each consist of a 12 or 24 volt current source switch dependent and a multiplexed A D converter The power for the A D is from the isolated power supply The A D signal input range is from 1 to 5 volts with 12 bit resolution Current inputs of 4 to 20 milliamps can be used with the addition of a 250 ohm resistor across the input terminals In the GridBoss System an Analog Input Al can be used to communicate the position of the Kixcel to the GB601 DR Controller when an Analog Output AO is used to send the Setpoint to the Kixcel The AI is compared to the AO to ensure that the Kixcel is approximately within the Deadband The analog inputs provided on the I O Card are designated Point Number B2 B3 and B4 The terminals for connecting wiring are as follows T Current limited positive battery voltage for transmitter power Positive Input Negative Input Common The analog inputs have three field terminals per channel The T terminal provides power for loop powered devices at either 12 or 24 volts depending on the position of jumper W1 See Fig
62. The GridBoss controller provides terminations for a four wire 100 ohm platinum RTD with a DIN 43760 curve The RTD has an alpha equal to 0 00385 A three wire or two wire RTD probe can be used instead of a four wire probe however they may produce measurement errors due to signal loss on the wiring Wiring between the RTD probe and the controller must be shielded wire with the shield grounded only at one end to prevent ground loops If an RTD sensor is mounted remote from the controller enclosure the RTD wires should be protected either by a metal sheath or conduit connected to a liquid tight conduit fitting on the bottom of the enclosure Rev 9 99 2 39 GB600 Series Instruction Manual 4 Wire RTD 3 Wire RTD 2 Wire RTD 100009 100008 BOVOVY a T Prts O 7 PRTS O pal E RTS O i Red Red Jumper o lA DPIOS O jc _ P99000A999988 2 T RTD Sensor DOCO357A Figure 2 12 RTD Wiring Terminal Connections The RTD terminals on the Main Electronics Board are designated and defined as follows REF current source signal positive input signal negative input RET return common As shown in Figure 2 12 the connections at the RTD terminals
63. The panel must also be tilted at an angle from the horizontal dependent on the latitude to maximize the energy output The angles for different latitudes are normally included in the solar panel documentation At most latitudes the performance can be improved by less of an angle during the summer and more of an angle during the winter As a site may have additional power requirements for radios repeaters and other monitoring devices power supply and converter accessories may be used to minimize the number of separate power sources required for an installation Solar arrays are used to generate electrical power for the controller from solar radiation The size and number of solar panels required for a particular installation depends on several factors including the power consumption of all devices connected to the solar array and the geographic location of the installation Refer to Section 1 7 4 1 22 Rev 9 99 GB600 Series Instruction Manual 1 7 4 1 System Solar Panel Sizing To determine solar panel output requirements first determine the solar insolation for your geographic area The map in Figure 1 3 shows solar insolation in hours for the United States during winter months Call your local Fisher Representative for a map detailing your specific geographic area Insolation from map hours Next calculate the amount of current required from the solar array per day using the following equation Isp is the system current require
64. Unit MCU board to remove power 3 Disconnect the ribbon cable connected at P11 and any wiring that would restrict the panel from opening Push down on the detent see Figure 5 2 and open the swing out panel Rev 9 99 5 3 GB600 Series Instruction Manual 4 Mate the I O Card 20 pin position connector J2 with P5 on back of the main electronics board 5 After mating the connector press firmly to seat the board on the two compression stand offs Install the three 6 32 screws Close the swing out panel and reconnect the ribbon cable and any other wiring Affix the supplied label to the front of the swing out panel Begs CA A Plug in the Power terminal block at P8 to restore power to the controller 10 Refer to Section 2 7 3 After Installing Components When power is applied to the controller scanning of the 1 O Card is automatically activated Use the GRIDLINK Configuration Software to configure the I O points and the history database as desired for the new points Refer to the GRIDLINK Configuration Software User Manual Form A6074 2 D a m a Connecting O O E Screw ASA E a E O ae O B8 O S Elo E o O IE
65. accessed by opening the front door after removing the lock if installed and releasing the hasp on the right hand side The input terminal wiring is arranged on the lower edge of the Main Electronics Board Refer to Error Reference source not found The terminal designations are printed on the circuit board 1 14 Rev 9 99 GB600 Series Instruction Manual 1 6 MOUNTING AND INSTALLATION When choosing an installation site be sure to check all clearances Provide adequate clearance for the enclosure door to be opened for wiring and service The door is hinged on the left side The LCD display should be visible and accessible for the on site operator When using a solar panel with a controller there should be adequate clearance and view of the sun should not be obstructed Allow adequate clearance and an obstructed location for antennas when using radios The Pressure Module PM is factory mounted directly to the controller enclosure with four bolts See Section 3 for more information The Mounting section includes Mounting the GB600 Series Controller e Mounting a Radio Accessing the Battery Compartment Installing the Intrusion Switch 1 6 1 Mounting the GB600 Series Controller Mounting of the controller can be accomplished using either of the following methods Pipe mounted The enclosure provides top and bottom mounting flanges with holes for 2 inch pipe clamps U bolts and brackets supplied The 2 inch pipe can be m
66. al If there is no continuity replace the LPM With a digital multimeter check each of the input terminals for continuity to the ground lead If the test shows continuity to the ground lead replace the LPM A 7 SPECIFICATIONS Lightning Protection Module Specifications ELECTRICAL CASE Series Resistance 10 ohms from input to output each terminal DC Clamping Voltage 72 to 108 volts 100 V ms Impulse Clamping Voltage 500 volts maximum Clamping Release Voltage 52 volts minimum 10 KV microsecond Impulse Clamping Voltage 900 volts maximum Surge Life Module can withstand 300 surges of 10 to 1000 microseconds duration at 500 amps minimum Insulation Resistance 10 000 megohm minimum Capacitance 1 0 picofarad maximum 1 MHz each terminal SURGE WITHSTAND Meets surge requirements CCITT K17 K20 A 4 Material ABS polycarbonate thermoplastic Dimensions 0 65 in H by 0 84 in W by 1 58 in D 17 mm by 21 mm by 40 mm Length of Ground Wire 48 inches 1 2 m nominal ENVIRONMENTAL Operating Temperature 40 to 75 C 40 to 167 F Storage Temperature 60 to 100 C 76 to 212 F Operating Humidity To 95 relative non condensing WEIGHT 1 2 ounces 34 grams APPROVALS Approved by CSA for hazardous locations Class l Division 2 Groups A B C and D Rev 9 99 GB600 Series Instruction Manual GLOSSARY OF TERMS AGA American Gas Association AI Analog I
67. all the P1 jumper in the reset RST position To enact a reset power up the unit with the jumper installed 4 Apply power by plugging in the Power terminal block at P8 5 Remove the P1 jumper and install it in the normal NORM position 6 Refer to Section 2 7 3 and perform the After Installing Components The reset action loads the factory default values into all configurable parameters 2 7 3 After Installing Components After removing power to the controller and installing components as needed perform the following steps to start your controller and reconfigure your data CAUTION Ensure all input devices output devices and processes remain in a safe state upon restoring power 2 48 Rev 9 99 GB600 Series Instruction Manual CAUTION When installing units in a hazardous area make sure installation components selected are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non hazardous CAUTION To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Reconnect power to the controller by inserting the Power terminal plug into the P8 Power connector 2 Launch the GRIDLINK Configuration Software log in and connect to the controller 3 Verify that the configuration is correct If it is not continue by configuring the needed items If major portions or the entire configuration
68. also provides a means to switch external power to communication devices such as a radio to conserve power LEDs are provided for diagnostic functions The screw terminals and their functions are as follows Terminal Function RXD Receive data TXD Transmit data DTR Data Terminal Ready RTS Ready to Send DCD Data Carrier Detect GND Ground In Power input Out Switched power output 4 5 1 1 Switched Auxiliary Power Wiring Switched auxiliary power is used for radios that do not have a built in sleep mode to automatically shut the radio off Control of the radio power is set up by using the GRIDLINK software Radio Power Control function to achieve the required power cycling The switched method involves wiring the radio power through the EIA 232 communications card as shown in Figure 4 5 If the radio already has built in sleep mode or for some reason you do not need to cycle the auxiliary radio power wire it directly to the RADIO power terminals as described in Section 2 or to some other suitable source of power Rev 9 99 4 11 GB600 Series Instruction Manual xO cononananana RS232 la o Comm lt O ouuu oT Card 20 OLOUOrOUODO S99888 Switched Power to Radio P DP DOCO360A Figure 4 5 Wiring Switched Auxiliary Power 4
69. alue The average pressure must be within the set Setpoint Deadband or a message is sent to the DR The message sent to the DR includes the average input pressure and the calculated change in the Setpoint for the Inner Control Loop If the average LPP pressure is still out of the Deadband after the Deadband Time Delay has expired the LPP recalculates the change in the Inner Loop Setpoints and re transmits the average pressure and the calculated change in the Setpoint for the Inner Control Loop Each District Regulator can have a different gain so the LPP calculates a change in the Inner Loop Setpoint for each DR 2 8 Rev 9 99 GB600 Series Instruction Manual In Adaptive Mode the DR uses a time of day and temperature load profile to modify the Inner Loop Setpoint and also incorporates the LPP calculated change in Inner Loop Setpoint as detailed in the previous Outer Loop Mode description If the time of day profiles have been cleared then the DR creates the time of day profiles and uses the information to modify the Inner Loop Setpoint and continues to develop both profiles The DR temperature is stored in a temperature profile which modifies a temperature coefficient every minute In addition the temperature profile does not calculate a new coefficient when the Inner Loop output or Setpoint is against either limit A predicted adaptive value Temperature Profile and a current time of day value TOD Profile are added to the Inner Loop Setpoint
70. and periodic integrity checks the LPP Controller does not require extended communications once the load profiles are well established The load profiles generate a bias value that is added to the minimum system pressure value Setpoint determined by the user When the temperature is colder the bias is larger allowing increased pressure When the temperature is warmer the bias is smaller and less pressure is released The DR Controller can clear the time of day and temperature profiles and receive time of day profiles through the communications ports LOI or COM1 The DR Controller can also send load profiles through the communications port LOI or COM1 to a PC running GRIDLINK 2 3 1 2 Control Mode Levels The District Regulator controls the regulator outlet pressure by adjusting the output to the Kixcel in one of four control modes The four control modes that can be enabled are Off Control processing does not occur if Off is selected e Manual Mode Values in Manual Mode are manually manipulated and do not include information from either the DR or the LPP controller Inner Loop Mode Inner Loop tuning includes only information from the DR Controller Inner Loop and the Kixcel I P or servo valve Information from the Low Pressure Point is not included Outer Loop Mode Outer Loop tuning includes both information from the DR Inner Loop and the LPP Outer Loop Adaptive Mode Outer Loop with Adaptive Control
71. arate ground rod or grid system All grounding should terminate at a single point If the pipeline to earth impedance is greater than 25 ohms the controller installation should be electrically isolated and a ground rod or grid grounding system installed Rev 9 99 1 13 GB600 Series Instruction Manual The recommended cable for I O signal wiring is an insulated shielded twisted pair The twisted pair and the shielding minimize signal errors caused by EMI electromagnetic interference RFI radio frequency interference and transients A ground bar is provided for terminating shield wires and other connections that require earth ground A lug on the outside of the enclosure is provided to ground the enclosure Note that the ground bar should be directly wired to the ground lug rather than depending on the enclosure to make the connection between the ground bar and ground lug Refer to Section 2 for further details CAUTION Do not connect the earth ground to any wiring terminal on the Main Electronics Board 1 5 6 I O Wiring Requirements I O wiring requirements are site and application dependent Local state or NEC requirements determine the I O wiring installation methods Direct burial cable conduit and cable or overhead cables are options for I O wiring installations Section 2 contains detailed information on connecting T O wiring to the controller The Main Electronics Board containing the field wiring terminal connections is
72. ardous Remove power from the area at the nearest electrical power switch box CAUTION To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap CAUTION During this procedure all power will be removed from the controller and any devices powered by it Ensure that all connected input devices output devices and processes remain in a safe state when power is removed from the controller and also when power is restored Refer to Section 2 7 1 on page 2 45 for the Backup Procedure Before Removing Power Disconnect the Power input connector at P8 from the Main Electronics Board If a communications card is present remove it by carefully pulling or prying the card loose from the lower compression stand offs first the upper compression stand off next and finish by unplugging the card from its mating connector Disconnect wiring from the communi cations card as needed to clear the way for removing the Main Electronics Board Remove all wiring connected to the Main Electronics Board Remove the Main Electronics Board from the five compression stand offs securing the card and lift the board out of the case You may need to pry the board off the stand offs if you are unable to loosen the board by hand Install the new Main Electronics Board in the case Firmly press the board over the compression stand offs to secure the board to the case The co
73. ation of the analog inputs associated with the calculation static pressure and temperature The GRIDLINK Configuration Software is used to perform both initial calibration and re calibration 3 6 1 Al Calibration The AI Calibration pushbutton allows you to calibrate the Analog Input displayed in this screen Perform the following steps to calibrate an analog input CAUTION During calibration the controller will time out and disconnect if it is left idle for extended amounts of time Your calibration values will be lost and you will have to reconnect and begin calibration from the beginning 1 Press the AI Calibration pushbutton A dialog box displays as shown in Figure 3 7 and the analog input is automatically frozen at the value displayed in the dialog box AI Calibration Freeze Value 20 00000 Calibrate Figure 3 7 Al Calibration 2 If the input has been calibrated before you can verify the calibration this can also be done immediately after performing calibration Press the Verify pushbutton to proceed with verification of an input s calibration Refer to Figure 3 8 and to Section 3 3 3 for details Otherwise skip to Step 6 to begin calibration Rev 9 99 3 11 GB600 Series Instruction Manual Werify Calibration Point Analog input Dead Weight Tester Value 0 Live Reading O Figure 3 8 Verify AI Calibration 3 Enter the Dead Weight Tester Value This is the input desired for the test valu
74. average pressure at the low pressure point in the gas distribution system Inputs and Outputs used to measure and control the Setpoint Archival of data for up to 15 history points and other historical logs Memory logging of 240 alarms and 240 events Security with local and remote password protection Logic and sequencing control using a user defined FST program ff gt o Power cycling control for a radio through the DTR signal or power switch on the optional EIA 232 communications card Closed loop control PID capability 2 3 1 Adaptive Predictive Control The GridBoss System uses two types of GridBoss controllers GB601 District Regulator DR Controller GB602 Low Pressure Point LPP Controller NOTE Throughout the rest of Section 2 DR generally refers to the GB601 District Regulator Controller and LPP refers to the GB602 Low Pressure Point Controller The DR controller is located at the vault and the LPP controller is located downstream from the DR controllers at the low pressure point on the gas distribution system Refer to Figure 2 1 An LPP controller can support up to five DRs The GridBoss algorithm uses data gathered from the Low Pressure Point to automatically create historical load profiles at the District Regulator controllers Load profiles are based on ambient temperature and the time of day The District Regulator is automated with a Kixcel I P or servo valve The District Regulator Set
75. ay profiles already exist then the DR modifies them by averaging the LPP calculated change in Inner Loop Setpoint and the current time of day value The DR temperature is stored in a temperature profile which modifies a temperature coefficient every minute If the LPP communicates an equipment failure or fails to check in within a preset time interval maximum Check in Time with DRs the Outer Loop terminates and the Inner Loop Setpoint is set to the Setpoint Default value Both the DR and the LPP software maintain a 15 minute averaging of pressure The final control mode is the Adaptive Mode Outer Loop with Adaptive Control Mode In Adaptive Mode the DR uses a time of day and temperature load profile to modify the Inner Loop Setpoint and uses the LPP calculated change in Inner Loop Setpoint Adaptive Mode is defined as a cascade PID control of the District Regulator outlet pressure with the Setpoint calculated from a PID loop controlling the Low Pressure Point LPP biased by the time of day and temperature load profile adjustments The adaptive pattern is used to control the Inner Loop DR to Kixcel Setpoint Communications from the LPP override and update the adaptive control parameters All control features available in Outer Loop Mode are present in Adaptive Mode The LPP calculates the inlet pressure average over a minute and compares it to the Setpoint Deadband The Setpoint Deadband is the Low Press Setpoint plus or minus a user defined v
76. cnnnnnnnonnonononccnnnnnoros 1 9 1 17 2 42 Serial Communications Card cccccecseceeeeees 4 3 4 5 DETVO Val Ve E EE ougecndocevedes xathonseeel ARA 1 2 Site Requirements coooononccnonnnnononononccnonccnonacinnaninnncnn 1 11 Software iii 1 7 Software Watchd08 oocoooocccnonccconccnonanoncnnonanccnonacnnass 2 26 Solar Arrays Refer to Solar PanelS ooooononcnnnncccnnoocncnconcconrnnonnno 1 22 Solar Panels tds 1 9 1 11 Charge Connections ccoococonccconcnononncnonccnonacnonacinnnos 2 32 POWELD sisaciscacessescicvavccadevevsvcusesusectadseacevvsesedes 1 12 1 22 SIZING otitis 1 23 Specifications Lina 2 52 3 16 Communications Cards cccssccceeeseeeeeesneeeees 4 16 Dial Up Modem Communications Cards 4 17 Serial Communications Cards coococonccconcccnonccnoncnos 4 16 SRAM pee ido ates ini ates 1 5 Standby Mode c ccccooccconccconccononccononanonacononccnonccnanacnnnoss 2 26 Status 1 26 Startup and Operation oooocconcccnccnoncnononcnonccnnnonanccinness 1 26 Static Pressure css ete ei vies 1 4 3 2 3 9 Static Random Access Memory Rev 9 99 GB600 Series Instruction Manual SRAM cti alla 2 21 Surge Protection oi e aa 1 13 System Voltage sssrini isinisisi s 1 21 T Table 1 1 Power Consumption of the Controller and Powered Devices cceesesceeeeeseneeeeeeeeeesseeeeeeenees 1 20 Table 1 2 Solar Panel Sizing 1 24 Table 2 1 District Regulator Alarms 0 eee 2
77. cnnnnnoss 1 3 1 6 2 10 Alar Sirini iat na a aih 2 12 DRaa E E E TEO aca tesied 1 3 GBOOT deiren eie ET aiii 1 1 Inputs and Outputs ooooocnnoccnonccnonnncnnnnononcnnonacinnecos 2 15 DIVISION 2hari she T R A E A TRE 1 12 D ze M de yeninin e a a 2 27 DIR rin aerae E a A RNa 2 24 4 4 Duty Cy Cleveesssiccsssscastsovsasiasuisevessasis celiacos 1 20 1 21 E EJA 232 Communication Cards cocooccnonccnonccnonnncnnnnno 4 3 EIA 485 Communication Cards cocooocnonccnonccnonnncnnonnos 4 5 Electrical Isolation Lotion ena aai 1 13 Electromagnetic Interference ooooocnnoncccnnoocccnnnonnnnnnnns 1 14 ElectroMles intercooler ii besl 2 21 Electronics BOAard occccccnnnnncnonononannonannnoconononnnooo 1 5 2 1 EMail 1 14 2 30 EncloS UC cita 1 4 1 10 Environmental Requirements coooccnoccnonccconcncnnnnononcnnnnonanccnonccnnnenns 1 10 Event Loiu nat A 2 19 F Figure 1 1 GB600 Series Controller 0 0 ee 1 7 Figure 1 2 Intrusion Switch Mounting for GB600 Series Enclosures jsiic scat it ii 1 18 Figure 1 3 Solar Insolation in Hours for the United Stalls wissen E E ET 1 23 Figure 2 1 GridBoss Gas Distribution System 2 4 Figure 2 2 GridBoss System Setup ocoococonccconcncnnncnn 2 5 Figure 2 3 District Regulator 2 11 Figure 2 4 Main Electronics Board ceee 2 22 Figure 2 5 Earth Ground Connection eeee 2 30 Figure 2 6 Power Input Terminal Connector 2 31 Figure 2 7 Battery and Solar Pane
78. ctronics Board with its built in I O capabilities and LCD display It also has room for batteries a communications card I O card AC power supply battery charger and one radio with an optional mounting bracket The Main Electronics Board mounts on stand offs located on the front of the swing out panel The dimensions of the board are approximately 5 by 7 5 inches The majority of the components are surface mounted with only the front of the board used for components The Main Electronics Board provides built in I O capabilities an LCD display connections to an optional I O card and provisions for an optional communications card Screw terminals located on the Main Electronics Board provide terminations for input power an RTD input a discrete output DO radio communications RADIO Pressure Module P PD and operator interface LOI communications For more information on the Main Electronics Board refer to Section 2 The built in Liquid Crystal Display LCD provides the ability to look at data and configuration parameters while on site without using the local operator interface LOI and a personal computer PC The LCD display is factory mounted directly to the Main Electronics Board and visible through the window on the front panel Through this display you can view pre determined information stored in the controller Up to 16 configuration parameters can be configured for display The display automatically cycles through the configured l
79. d A short duty cycle conserves power for I O channels radios etc DVM Digital voltmeter Rev 9 99 G 1 GB600 Series Instruction Manual E EEPROM Electrically Erasable Programmable ROM a form of permanent memory EIA 232 Serial Communications Protocol using three or more signal lines intended for short distances EIA 422 Serial Communications Protocol using four signal lines EIA 485 Serial Communications Protocol requiring only two signal lines Can allow up to 32 devices to be connected together in a daisy chained fashion EMF Electro motive force EMI Electro magnetic interference ESD Electronic Static Discharge EU Engineering Units F Firmware Internal software that is factory loaded into a form of ROM In the ROC FloBoss or GridBoss controller the firmware supplies the software used for gathering input data con verting raw input data calculated values storing values and providing control signals Flash ROM A type of read only memory that can be electrically re programmed It is a form of permanent memory needs no backup power FM Factory Mutual FSK Frequency shift keyed FST Function Sequence Table a type of program that can be written by the user in a high level language designed by Fisher Controls G H GB601 District Regulator Controller Fisher Control s microprocessor based unit that provides remote pressure monitoring and control in a GridBoss system
80. d a single 8 bit external data bus The unit can address up to four megabytes of memory including high speed direct memory access The Main Electronics Board has 512 Kbytes of static random access memory SRAM for storing interrupt vectors Function Sequence Tables FST alarms events and history data The Main Electronics Board also has a 512 Kbyte flash memory chip for storing the operating system factory code and configuration parameters Rev 9 99 2 21 GB600 Series Instruction Manual 2 22 FACTORY TEST JACK COMMUNICATIONS CARD CONNECTION P3 ooo o 8 6 ta 6 0 a E O PROCESSOR 68LC302 CR6 CR7 gt AA SSSI BLK WHT RED DOCO331B Figure 2 4 Main Electronics Board Rev 9 99 GB600 Series Instruction Manual 2 4 3 Liquid Crystal Display A two line Liquid Crystal Display LCD panel is mounted on the Main Electronics Board The panel has automatic contrast adjustment due to temperature sensing and bias adjustment circuitry on the Main Electronics Board The LCD panel remains on at all times when the power applied is in the valid operating range of 8 to 15 volts The panel cycles its display through a configured list of parameter values Up to 16 parameter values can be configured The first displays show values for time and date operating voltages and battery condition The District Regulator LCD also displays the ambient Temperature District Regulator input pressure District Re
81. e should be adjusted just outside the range of the low and high limits Make the span adjustments to the position signal from the Kixcel A 4 mA input should return a 4 mA signal and a 20 mA signal should return a 20 mA signal Adjust the speed and the torque current limit potentiometers Measure the voltage to ensure that the unit is not pulling too much power The voltage is measured from the tab of the power amplifier on the TB3 side of the upper PC board and the accessible wire of R77 on the lower PC board The voltage should be less than 2 75 volts One end of R77 is soldered into the PC board close to the resistor The resistor is perpendicular to the PC board and the accessible wire is bent back over and parallel to the resistor to solder into the PC board The Deadband potentiometer is usually not adjusted unless there is an oscillation as seen by the on and off action seen in the Green and Yellow LEDs on the lower PC board 2 5 9 2 Kixcel Analog Output and Analog Input Wiring The Kixcel I P or servo valve receives a control signal such as an Analog Output from the GridBoss controller and converts the signal into an outlet pressure adjusting the Setpoint at the DR When an AO is used an Analog Input Al can be sent back to the controller to indicate the position of the Kixcel and to ensure that it is approximately within the monitor Deadband These signals are connected as shown in Figure 2 11 Make sure the scaling resistor is presen
82. e and due North not magnetic North in the Southern Hemisphere Make sure nothing blocks the sunlight from 9 00 AM to 4 00 PM Antennas equipped for radio communications must be located with an unobstructed signal path If possible locate antennas at the highest point on the site and avoid aiming antennas into storage tanks buildings or other tall structures Allow sufficient overhead clearance to raise the antenna To minimize interference with radio communications locate the controller away from electrical noise sources such as engines large electric motors and utility line transformers 4 Locate the controller away from heavy traffic areas to reduce the risk of being damaged by vehicles However provide adequate vehicle access to aid in monitoring and maintenance Rev 9 99 1 11 GB600 Series Instruction Manual 1 5 3 Compliance with Hazardous Area Standards The controller units have hazardous location approvals pending for Class I Division 2 Groups C and D exposures The Class Division and Group terms are defined as follows Class defines the general nature of the hazardous material in the surrounding atmosphere Class I is for locations where flammable gases or vapors may be present in the air in quantities sufficient to produce explosive or ignitable mixtures Division defines the probability of hazardous material being present in an ignitable concentration in the surrounding atmosphere Division 2 locations are presu
83. e and is the actual value expected by the test equipment being calibrated against For example when calibrating temperature for an RTD input enter the degrees value associated with the resistance set up in the decade box 4 Press the Log Verify pushbutton Repeat Steps 3 and 4 for each value to be verified 5 Press the Cancel pushbutton If calibration is needed proceed to Step 6 otherwise press the Done pushbutton 6 Press the Calibrate pushbutton Refer to Figure 3 7 and to Section 3 3 4 for details 7 Calibrate the zero value 0 of range for the Analog Input Enter the Dead Weight Tester Value in engineering units and press the Set Zero pushbutton Refer to Figure 3 9 Point Analog input Dead Weight Tester Value Og Live Reading d Figure 3 9 AI Set Zero 8 Calibrate the span value 100 of range for the Analog Input Enter the Dead Weight Tester Value in engineering units and press the Set Span pushbutton Refer to Figure 3 10 3 12 Rev 9 99 GB600 Series Instruction Manual Point Analog input Dead Weight Tester Value Live Reading 99 Figure 3 10 Al Set Span 9 If desired calibrate Midpoint 1 such as 25 of range for the Analog Input Enter the Dead Weight Tester Value in engineering units and press the Set Mid 1 pushbutton Refer to Figure 3 11 Otherwise use the Done pushbutton and proceed to Step 12 Set Hidpoint 1 Point Analog input Dead Weight Tester Value Live Reading Set
84. e built in termination block on the LPM A 5 CONNECTING THE LPM TO WIRING There is a one to one correspondence between the LPM terminals and the terminals of the I O channel being protected If you are connecting field wiring to the LPM refer to the I O wiring information in this instruction manual NOTE The LPM module provides sockets for a plug in range scaling resistor These sockets which are internally connected to the module s middle and right most screw terminals must be used when installing a range resistor The LPM module provides a ground wire for connection to the enclosure ground bar or ground lug The enclosure ground bar or ground lug must in turn be connected to a good earth ground Do not use the power system ground for this connection Rev 9 99 A 3 GB600 Series Instruction Manual A 6 TROUBLESHOOTING AND REPAIR The lightning protection modules function by shunting the high voltage transients through gas discharge tubes to the ground lead In the event of an I O signal failure verify the signal is not interrupted by the LPM Proceed to the troubleshooting and repair procedures for I O in previous sections of this manual Before removing an LPM make sure all devices and processes remain in a safe state Remove the LPM and disconnect the field wiring Remove any range resistors from the LPM With a digital multimeter verify continuity through each connector socket to the corresponding field wiring termin
85. e field 1 O from the processor The power converter produces enough current to support four current loops three Als and one AO plus the power to run the analog to digital A D and digital to analog D A converters as well as the discrete inputs The power converter can turn off under processor control to reduce the load in low battery conditions Note that the pulse inputs can be wired as controller powered pulse counters The pulse circuitry is optically coupled to isolate the processor board from the input signal The pulse inputs can also be configured as discrete inputs NOTE Points represented by A such as Analog Input point number A2 are associated with the main electronics board and Pressure Module Points represented by B such as Analog Input point number B2 are associated with the VO Card 5 4 I O CARD INSTALLATION The I O Card is installed on a swing out mounting panel in front of the battery compartment The I O Card mounts on two compression standoffs a mating connector and three 6 32 screws Refer to Figure 5 1 and Figure 5 2 CAUTION To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap CAUTION Always turn the power to the controller off before you attempt any type of wiring 1 Refer to Section 2 7 1 and perform the Backup Procedure 2 Unplug the Power terminal block at P8 on the Master Controller
86. e once a second it then stores one hour of minute averages to the Minute Historical Log 2 3 5 2 15 Minute Historical Log The GridBoss controller stores eight days of 15 minute averages of every history point parameter The controller has a total of 840 15 Minute Historical Logs The time stamp for periodic logging consists of the month day 15 minute period and minute The exception is for FST Second logging in which the time stamp consists of the day 15 minute minute and second The District Regulator parameters include ambient temperature regulator inlet pressure regulator outlet pressure output signal to the Kixcel position and battery voltage once a second The LPP parameters include the low pressure point value and battery voltage once a second The LPP stores eight days of 15 minute averages of the low pressure point value and battery voltage 2 3 5 3 Daily Historical Log The GridBoss controller has a total of 35 Daily Historical Logs for the LPP and DR history point parameters The controller logs 35 days of daily history for the LPP and DR parameters and 2 days of daily minimum and maximum values of their parameters The Daily Log is recorded at the configured Contract Hour every day The time stamp for Daily Historical logging consists of the month day hour and minute The exception is for FST Second logging in which the time stamp consists of the day hour minute and second Each history point has daily historical
87. e port also called the Local Operator Interface LOD port provides direct communications between the controller and the serial port of an operator interface device such as an IBM compatible computer The LOI also provides the ability for the DR controller and the LPP controller to communicate peer to peer The DR and LPP can communicate with each other and the personal computer using the same Local Operator Interface LOD port The LOI port of both the LPP and DR have an optional switch that allows you to connect locally without disconnecting the line of peer to peer communication Rev 9 99 2 23 GB600 Series Instruction Manual The interface allows you to access the GridBoss controller using the GRIDLINK Configuration Software for configuration and transfer of stored data The LOI terminal on the Main Electronics Board provides wiring access to a built in EI A 232 serial interface and is capable of up to a 19 2k baud rate The operator interface port supports only ROC protocol communications The LOI also supports the log on security feature of the controller if the Security on LOI is Enabled in GRIDLINK A cannon type waterproof connector on the bottom of the enclosure provides connection through a prefabricated cable available from Fisher for an operator interface device typically an IBM compatible personal computer PC running the GRIDLINK Configuration Software Inside the GridBoss enclosure the cannon type connector is wired to three
88. e to Kixcel I O Card and AO point number B1 or DO point numbers B5 B6 or I P or servo valve Built in DO A4 two are required for TDO functionality Position signal from the T O Card AI point number B2 B3 or B4 available only when AO Kixcel I P or servo valve is used for Setpoint change to Kixcel I P or servo valve Optional Intrusion Switch T O Card DI point number B7 B8 B9 or B10 All Pressure Monitor sensors are accurate to 1 of range and have a selectable operating range from 0 5 psig to 0 1000 psia depending on the installation The District Regulator has an Analog Output or a Timed Duration Output TDO connected to the Kixcel I P or servo valve When using an AO an AI can be sent back to the controller to indicate the position of the Kixcel I P or servo valve to ensure that it is approximately within the monitor Deadband The position verification is not available when using a TDO The TDO requires two DOs to open and close the Kixcel The LPP has inputs for the following Input Pressure Module Input Optional Intrusion Switch Input Table 2 4 lists all inputs the physical location and the point number associated with the I O Table 2 4 Low Pressure Point Inputs and Outputs Input or Output Input pressure Location Point Number AI point number A2 Optional Intrusion Switch T O Card DI point number B7 B8 B9 or B10 The Low Pressure
89. ector Figure 3 5 Pulse Input from Controller Powered Device 3 8 Rev 9 99 GB600 Series Instruction Manual 3 5 CONFIGURATION Use the GRIDLINK Configuration Software Version 1 0 or later to configure the distribution system inputs and outputs associated with the Sensor Module Refer to Section 2 3 2 concerning History Points 3 5 1 Configuring Inputs To configure parameters for the individual inputs associated with the Sensor Module and the pressure calculation use the GRIDLINK I O menu as described in Section 4 of the GRIDLINK user manual The inputs and their point numbers are The inlet pressure is configured at Analog Input point number Al DR and LPP The outlet pressure is configured at Analog Input point number A2 DR only The RTD temperature on the main electronics board is configured at Analog Input point number A3 DR only Points starting with A such as A2 are associated with the main electronics board and the Sensor Module Points starting with B are associated with the I O card optional on the GB602 The initial pressures are read from the defaults contained within the sensor The initial range of the static pressure depends upon the type of sensor installed The ranges can be changed through the calibration routines It is recommended that the turndown on the ranges not be greater than five 3 5 2 Metric Units The Sensor Module supports the conversion of values to Metric units I
90. er produce an equipment failure alarm the control loop goes to Manual Mode and the Kixcel moves to the Default Output position The fastest loop period for the PID loop is one second If the Default Output is less than zero then the output remains in its current position When using Discrete Outputs the output also remains in its current position The LPP does not communicate with that DR again until the value entered in the Error Time Delay for DRs field has been meet After the Error Time Delay period the LPP communicates with the DR to determine if it is in the Outer Loop Mode or Adaptive Mode The Error Time Delay for DRs should always be less than the Check in Time for DRs Time of day and temperature load profiles are not generated in Inner Loop Control Mode All alarms are enabled when in Inner Loop Mode Outer Loop Mode uses the LPP calculated change in the Inner Loop Setpoint Outer Loop Mode is defined with a cascade PID control of the regulator Outlet Pressure with the Setpoint calculated from a PID loop controlling the Low Pressure Point LPP In Outer Loop Mode the LPP verifies the average pressure against a user defined Setpoint and Deadband If the average pressure varies from the Setpoint by more than the Setpoint Deadband the LPP calculates the change in Inner Loop Setpoint fora DR The LPP sends the change in Inner Loop Setpoint and the average LPP pressure Avg Low Press Value to the DR when the LPP average pressure is out
91. erating Humidity 5 to 95 non condensing Vibration Meets SAMA PMC 31 1 Sec 5 3 Condition 3 ESD Susceptibility Meets IEC 801 2 as required by EN50082 2 EMI Susceptibility Meets IEC 801 4 as required by EN50082 2 RFI Susceptibility No effect on operation of unit when tested properly mounted and door closed as required by EN50082 2 Emissions Meets CISPR22 and FCC part 15 Class A 2 53 GB600 Series Instruction Manual GB601 DR and GB602 LPP Specifications DIMENSIONS ENCLOSURE Overall 16 56 in H by 13 80 in W by 7 25 in D Construction Powder coated 14 gauge carbon 420 mm by 350 mm by 184 mm Height includes steel with lockable hasp and gasketed doors top mounting flange and SM Coating is ANSI 61 gray polyurethane paint All Wall Mounting 2 81 in W by 13 80 in H 72 mm unpainted hardware is stainless steel Meets CSA by 350 mm between mounting hole 0 38 in Type 4 rating NEMA 4 equivalent diameter centers Wiring access Three 0 88 in holes punched in Pipestand Mounting Mounts on 2 inch pipe with bottom U bolt mounting kit supplied APPROVALS WEIGHT Approved as Model W40079 by CSA for hazardous 23 b 10 35 kg nominal including SM but exclu locations Class l Division 2 Groups A B C and D ding batteries not supplied Power supply is 1 8 lb FCC Class A computing device Sensor Module SM PULSE COUNTER INPUTS CONSTRUCTION Quantity and Type 2 Voltage Sense inpu
92. eries Instruction Manual Rig EEE eeeeEleeseseseseeseeeqeeeeeeeon 60 PHEEEEBBORE Oee0000000000000000 O Jt O NORM RST a P1 Mating O Connector Stand off Hole 7 s __ Ke 00 00 U6 m oo crt Communications o0 4g 380 Card oo o E E Acre 20 CR4 fe cRS ULI EO coo BEER E E TB2 TB3 E Stand off Hole SASTS e AS gg E Stand off Hole Aff m m TUUT CR6 CR7 PT2 PT3 C FLL PT1 al MV1 MV2 O P9 P10 CR P8 PAL papa 9000099090 TRTS O DOCO332B POWER CHI ERanio p p BAT Aja LOT D0 RTD G BLK WHT RED REF RET Figure 4 4 Communications Card Location 4 10 Rev 9 99 GB600 Series Instruction Manual 4 5 CONNECTING COMMUNICATIONS CARDS TO WIRING Signal wiring connections to the communications cards are made through the terminal block located on the serial communications cards or through the RJ11 TELCO connector supplied on the modem card 4 5 1 ElA 232 Communications Card Wiring The EIA 232 communications card provides for RS232 signals on the host port This communications card
93. erviceable parts on the communications cards If a card appears to be operating improperly verify that the card is set up according to the information contained in Section 4 9 Initial Installation and Setup If it still fails to operate properly the recommended repair procedure is to remove and replace the card The faulty card should be returned to your Fisher Representative for repair or replacement Follow the procedures below to help ensure data is not lost and equipment is not damaged during replacement of a communications card 4 6 1 Replacing a Communications Card If you are installing a communications card for the first time refer to Section 4 4 To remove and replace a communications card on an in service controller perform the following procedure Be sure to observe the cautions to avoid losing data and damaging equipment CAUTION When repairing units in a hazardous area ensure that the components selected are labeled for use in such areas Change components only in an area known to be non hazardous CAUTION There is a possibility of losing the controller configuration and historical data while performing the following procedure As a precaution save the current configuration and historical data to permanent memory as instructed in Section 2 7 1 Backup Procedure CAUTION Be sure to use proper electrostatic handling such as wearing a grounded wrist strap or components on the circuit cards may be damaged CAU
94. eserve capacity to allow for overnight discharge Space limitations cost and solar panel output are all factors that affect the actual amount of battery capacity available To determine the system capacity requirements multiply the system current load Isr on the batteries by the amount of reserve time required Compute Isr as described in the Section 1 7 3 Totaling Power Requirements The equation is as follows System Requirement Isr amps x Reserve hrs _ amp hrs Next determine the number of batteries required for the calculated power consumption 7 14 21 or 28 amp hour capacity Rev 9 99 1 25 GB600 Series Instruction Manual 1 8 STARTUP AND OPERATION Before starting the controller perform the following checks to ensure the unit is properly installed Make sure the enclosure has a good earth ground connected to the earth ground bus inside the enclosure Check the field wiring for proper installation Refer to Section 2 Make sure the input power has the correct polarity Make sure the input power is fused at the power source CAUTION It is important to check the input power polarity before turning on the power Incorrect polarity can damage the GB600 Series Controller CAUTION When installing equipment in a hazardous area ensure that all components are approved for use in such areas Check the product labels 1 8 1 Startup Apply power to the controller by plugging the input power termi
95. gulator Output Pressure and PID control Mode The Low Pressure Point LCD also displays the average pressure the calculated change in Inner Loop Setpoint for each DR and the PID control Mode of each DR 2 4 4 Communications Ports The GridBoss controller provides two communication ports Operator interface port LOI Port for communication from the LPP DR Host COM1 The DR and LPP controllers have the ability to communicate with each other and the Host on the same communications port or on separate communications ports If two communication ports are used the LOI is used for peer to peer communications between the DR and the LPP while COM1 is used for Host communications If only one communications port is used the LPP DR and Host all use COM1 The DR timestamps Last LPP Comm Time the last time the LPP communicated with it The DR only communicates with one LPP The DR receives a message from the LPP at the minimum of once every maximum Check In Time for DRs Each District Regulator has a DR Retry Count that the LPP uses when it does not receive a reply from the DR The LPP waits until the DR Retry Time has expired before re transmitting the last message After the allotted time of the value entered in the DR Retry Count the LPP generates the DR communications failure alarm and waits for the Error Time Delay for DRs before trying to communicate with that DR again 2 4 4 1 Operator Interface Port LOI The Operator Interfac
96. he GB601 mounts on the bottom of the enclosure RTD wires should be protected either by a metal sheath or by conduit connected to a liquid tight conduit fitting on the bottom of the enclosure if installed farther away from the controller The RTD wires connect directly to the four terminal RTD connector on the Main Electronics Board inside the enclosure Rev 9 99 1 5 GB600 Series Instruction Manual The I O Card provides additional inputs and outputs as required by the controllers The I O Card contains analog inputs Als an analog output AO discrete inputs DIs pulse inputs PIs and discrete outputs DOs A DI on the card can be connected to an intrusion switch in both the District Regulator and Low Pressure Point controllers Refer to Section 5 for details concerning the I O card The GB601 DR typically uses a Kixcel such as the Fisher Type 662 Kixcel An I P or servo valve can be used in place of a Kixcel An AO or pair of Discrete Outputs can be used to open and close the Kixcel The Kixcel is a motorized device that is coupled to the adjusting screw of a Pilot regulator which actually adjusts the Setpoint of the DR To supply the power required by the Kixcel the DR typically uses an AC power supply and battery charger The GB601 DR communicates with the GB602 LPP The GB601 also initiates and accepts communications with a Host The GB602 LPP often powered by AC power with battery backup provides power to its Pressure Module
97. he Power terminal connector at P8 on the Main Electronic Board Check the configuration data and FSTs and load or modify them as required Verify that the controller performs as required Perform the After Installing Components detailed in Section 2 73 If you changed the configuration save the configuration data to Flash ROM If you changed the configuration history database or FSTs save them to disk See Section 2 7 1 for more information Rev 9 99 GB600 Series Instruction Manual 4 7 COMMUNICATION CARDS SPECIFICATIONS The following subsections list the specifications for each communications card 4 7 1 Serial Card Specifications ElA 232D CARD POWER REQUIREMENTS Meets EIA 232 standard for single ended data 4 75 to 5 25 Vdc 0 03 W maximum supplied by transmission over distances of up to 50 feet 15 m processor board Data Rate Selectable from 1200 to 19 2k baud Format Asynchronous 7 or 8 bit software ENVIRONMENTAL selectable with full handshaking Operating Temperature 40 to 75 C 40 to Parity None odd or even 167 F software selectable Storage Temperature 50 to 85 C 58 to 185 F Operating Humidity To 95 relative non EIA 485 CARD condensing Meets EIA 485 standard for differential data transmission over distances of up to 4000 feet 1220 WEIGHT meters for multiple devices f 2 inal Data Rate Software selectable from 1200 to 19 2k De 02 1230 nomina baud Format Asynchron
98. he change in the Inner Loop Setpoints and re transmits the average pressure and the calculated change in the Setpoint for the Inner Control Loop Each District Regulator can have different gains so the LPP calculates a change in the Inner Loop Setpoint for each DR Rev 9 99 2 13 GB600 Series Instruction Manual The LPP communicates with the DR to read information from the DR and to write information from the LPP to the DR The LPP can initiate communications with up to five DRs The LPP initially communicates with the DRs to determine in which of the four PID control modes the units are configured The Low Pressure Point contacts the District Regulator when the average low pressure point value varies from the Setpoint by more than the defined Deadband an LPP transmitter failure or low battery occurs or at the specified user defined time interval Check In Time for DRs The Low Pressure Point can accept remote operational changes from the Host The LPP can also log an alarm and send an RBX message to the Host upon DR communications failure or a standard I O alarm The Low Pressure Point monitors the average pressure to a user defined Setpoint and Deadband When the average pressure travels outside of the Deadband the LPP places a call to the DR The LPP also calls the DR periodically to check settings and communications The LPP may use the Discrete Input DI on the optional I O card for the optional intrusion switch Other inp
99. he factory for repair 2 7 2 1 Warm Start This re initialization is performed by setting a parameter in the System Flags The re initialization includes the Tasks Database Communication Ports and I O This does not change the current configu ration of any parameters Refer to Figure 2 16 1 Launch the GRIDLINK Configuration Software 2 Select Flags from the System menu option 3 Set the Warm Start flag to Yes 4 Press F8 Save i brid I Hist A System Help l br 0 Qata Oy Me E Wa be mis Ware Start Ho Ll pee cd Cold Start IAE le fraie Clear Internal Config He foo ear Infernal Config Kemory p gap Write bo Internal Config Hemoru Ho it Disabled Write Status Complete Sei RIS High for JB sacs OpPort Ho 5 1 Coal i H Winda tog IFR anos U METEEN ed in Figure 2 16 GridBoss System Flags Alternately you can perform a warm start by removing power from the controller and then restoring it Make sure that jumper P1 on the Main Electronics Board is in the NORM position for a warm start to take place 2 46 Rev 9 99 GB600 Series Instruction Manual 2 7 2 2 Cold Start This re initialization is performed by setting a parameter in the System Flags called Cold Start Options The re initialization includes the Tasks Database Communication Ports Pressure Module I O and restoring the saved configuration if there is one It also includes the following based upon the value entered
100. he power P consumption values for transmit and receive from the radio manufacturer s literature then use the following equation to calculate the power consumption for a particular duty cycle Power Prx X Duty Cycle Prx 1 Duty Cycle Determine the power consumption for all radios that use power from the controller and enter the total calculated value in Table 1 1 1 7 3 Totaling Power Requirements To adequately meet the needs of the controller it is important to determine the total power consumption size of the solar panel and battery backup requirements accordingly For total controller power consumption add the device values in Table 1 1 Although Table 1 1 takes into account the power supplied by the controller to its connected devices be sure to add the power consumption in mW of any other devices used with the controller in the same power system but not accounted for in the table Convert the total value in mW to Watts by dividing it by 1000 mW 1000 Watts For selecting an adequate power supply use a safety factor SF of 1 25 to account for losses and other variables not factored into the power consumption calculations To incorporate the safety factor multiply the total power consumption P by 1 25 Psp P x 1 25 Watts To convert Psr to current consumption in amps Isr divide Psr by the system voltage V either 12 or 24 volts Isp Psp V AA Amps Rev 9 99 1 21 GB600 Series Instruct
101. he static line inlet pressure converts and reads static outlet pressure stores the values temporarily and communicates the values on demand to the GB602 The inputs are used to determine the pressure output at the DR The Sensor Module firmware has 128 Kbytes of program storage and 4 Kbytes of RAM storage for data The primary inputs used for pressure monitoring at the DR are static pressure and temperature The primary input used for pressure monitoring at the LPP is static pressure The inlet and outlet static pressure come from the Sensor Module SM and the temperature input is read using the RTD probe The inputs are read at the following rates Static pressure is sampled once per second Temperature is sampled and linearized once per second The RTD is internally re calibrated for every 5 C temperature change as sensed by enclosure battery temperature The Sensor Module measures static pressure by converting the applied pressure to electrical signals All readings from the sensor are made available to the Main Electronics Board via a factory installed ribbon cable see Figure 3 1 that plugs into the Main Electronics Board at P DP The readings from the Sensor Module are configured as two analog input points located at Analog Input Point Number A1 Inlet static pressure DR and LPP Analog Input Point Number A2 Outlet static pressure DR only Standard Al alarming is implemented If the sensor fails to communicate
102. her inputs included within the DR are diagnostic Analog Inputs and include battery voltage AI point number El input voltage AI point number E2 and board temperature AI point number E5 The DR samples the regulator inlet pressure regulator outlet pressure ambient temperature and the Kixcel output position if connected once per second The GB601 and Kixcel I P or servo valve acquire power from an AC power supply with charger and battery As an option an I P may be used in place of the Kixcel or servo valve to adjust the Setpoint of the District Regulator An I P is a device that receives the 4 20 mA current input signal and converts it to a pneumatic pressure output The Kixcel turns the adjusting screw adjusts compression of spring of the regulator to change the Setpoint An I P supplies a pressure to the spring case which proportionally changes the Setpoint 2 10 Rev 9 99 GB600 Series Instruction Manual The DR performs Inner Loop control of the District Regulator The PID control loop compares the outlet pressure of the District Regulator with a Setpoint and controls the outlet pressure via the Kixcel I P or servo valve The DR also builds the temperature and time of day load profiles while in Outer Loop Mode In Outer Loop Mode calls are accepted by the District Regulator from one LPP and the control message is used to adjust the Inner Loop Setpoint Temperature and time of day adaptation occurs in the background
103. hic location to ensure continuous reliable operation Refer to Section 1 7 4 Solar Powered Installations on page 1 22 and Section 1 7 5 Batteries on page 1 24 for information that can help you determine the solar panel and battery requirements to fit your installation 1 12 Rev 9 99 GB600 Series Instruction Manual 1 5 5 Grounding Installation Requirements Ground wiring requirements for line powered equipment are governed by the National Electrical Code NEC When the equipment uses line power the grounding system must terminate at the service disconnect All equipment grounding conductors must provide an uninterrupted electrical path to the service disconnect The National Electrical Code Article 250 83 1993 paragraph c defines the material and installation requirements for grounding electrodes The National Electrical Code Article 250 91 1993 paragraph a defines the material requirements for grounding electrode conductors The National Electrical Code Article 250 92 1993 paragraph a provides installation requirements for grounding electrode conductors The National Electrical Code Article 250 95 1993 defines the size requirements for equipment grounding conductors Proper grounding of the controller helps to reduce the effects of electrical noise on the unit s operation and protects against lightning Lightning protection is built in to the controller providing lightning protection for built in field wiring in
104. ic to the type of Kixcel I P or servo valve that you are installing 2 52 Rev 9 99 GB600 Series Instruction Manual GB601 DR and GB602 LPP Specifications PROCESSOR MEMORY Motorola 32 bit running at 14 7 MHz Program 512 Kbyte flash ROM electrically programmable for firmware and configuration Data 512 Kbyte SRAM super capacitor backed for up to 4 weeks Memory Reset A reset jumper enables a cold start initialization when used during power up TIME FUNCTIONS Clock Type 32 kHz crystal oscillator with regulated supply super capacitor backed Year Month Day and Hour Minute Second with Daylight Savings Time control Clock Accuracy 0 01 Watchdog Timer Hardware monitor expires after 1 second and resets the processor DIAGNOSTICS These conditions are monitored and alarmed SRAM validity operation PM and RTD point fail battery and charging voltages and enclosure internal temperature COMMUNICATIONS PORTS Operator Interface ElA 232 RS 232D format Software configured 1200 to 19 2K baud rate selectable Screw cap protected connector Host Serial or modem interface when optional communications card is installed POWER Battery Input 8 to 16 Vdc normally 10 8 Vdc to start up 0 2 W typical excluding power for discrete output load communications card and I O card if present Charging Input 14 to 22 Vdc Charge current internally limited to 1 0 amp Optional Power Supply 105
105. idpoint 2 ooonocccnonccconccconnncnnnss 3 14 Figure 3 13 AI Set Midpoint 3 0 0 0 eee eeeeeeeeeeeeeee 3 14 Figure 4 1 EIA 232 Serial Communications Card 4 3 Figure 4 2 ElA 485 Serial Communications Card 4 5 Figure 4 3 Dial up Modem Communications Card 4 7 Figure 4 4 Communications Card Location 4 10 Figure 4 5 Wiring Switched Auxiliary Power 4 12 Figure 5 1 Input Output Card ee eeeeeneeeeeees 5 2 Figure 5 2 I O Card Installation 0 0 00 eeeeeeeees 5 4 Figure 5 3 Discrete Input Wiring eee eeeeeeeee 5 6 Figure 5 4 Pulse Input Wiring oooooccnonccconcccnncncnancnn 5 7 Figure 5 5 Pulse Input PI 1 used as a Discrete Input 5 8 Figure 5 6 Current Signal on I O Card Analog Input 5 9 Figure 5 7 Voltage Signal on I O Card Analog Input 5 9 Figure 5 8 Discrete Outputs ooooonnonncnonccnonccconccionass 5 10 Figure 5 9 Analog Output Field Wiring for Current LOOP DEVICES viii oestenehten 5 11 Figure A 1 Lightning Protection Module A 2 Figure A 2 Lighting Protection Module Installation A 2 E 1 7 Flash Memory uc e Seek std 2 21 Flash ROM pee ula cido 1 5 A E ESA EEA N 2 20 FST User M n al pestoressas eean eioen tees 1 3 Fune Seeker terete sheet oa a estoa 2 3 G GB600 Series Specifications ito ot 2 53 GB601 Controller issie noero e io 1 1 GB602 Controller caminata 1 1 Grid Impedance nrnna ia a ana a 1 13 GridBoss System A ae e E EE ER 1 3 GRIDLINK C
106. ies Instruction Manual Table 2 2 Low Pressure Point Alarms Alarm Actions LPP pressure transmitter point Communicate failure to DRs fails LPP low battery voltage Communicate failure to DRs DR communications failure RBX message sent to Host if enabled If the DRs and Host are on the same communication port COM1 then the LPP communicates with the DRs first and then attempts to send an RBX message to the Host if enabled 2 3 4 Inputs and Outputs Although the GridBoss controllers have extensive input and output capabilities not all of the I O capabilities are required by the GridBoss System Only the I Os required by the GridBoss System are discussed in this manual The DR has inputs for the following Ambient temperature Input Inlet pressure Input Outlet pressure Input Setpoint change to Kixcel I P or servo valve Output Position signal from the Kixcel I P or servo valve Input o gt 1 Optional Intrusion Switch Input Table 2 3 lists all input and outputs the physical location and the point number associated with the I O Rev 9 99 2 15 GB600 Series Instruction Manual Table 2 3 District Regulator Inputs and Outputs Point Number Input or Output Location Input pressure PM AI point number A1 Output pressure PM AI point number A2 Ambient temperature RTD AI point number A3 Setpoint chang
107. in Figure 2 17 clear clear clear clear clear Figure 2 17 Cold Start Options 1 Launch the GRIDLINK Configuration Software 2 Perform the Backup Procedure in Section 2 7 1 3 Select Flags from the System menu option 4 Click the Cold Start flag Options Refer to Figure 2 16 5 Select the type of Cold Start you desire Select Restore config and clear all of above to reset all options 6 Click OK 7 Press F8 Save 2 7 2 3 Jumper Reset The Main Electronics Board has a jumper located at P1 in the upper right hand corner that can be used to perform a special type of cold start Refer to Figure 2 18 This jumper permits a power up reset to re establish a known operating point The includes reinitializing the Tasks Database Communication Ports Pressure Module and I O and restoring the factory default configuration This cold start does not include any of the clearing options available in a Cold Start performed by using GRIDLINK see Section 2 7 2 2 Rev 9 99 2 47 GB600 Series Instruction Manual CAUTION This type of reset restores the factory configuration defaults Any user entered configuration data will be lost therefore try to back up any required data before performing this reset P1 NORM RST a Figure 2 18 Reset Jumper Shown in Normal Position 1 Refer to Section 2 7 1 and perform the Backup Procedure 2 Disconnect the Power terminal block to remove power 3 Inst
108. ing an Analog Output AO or two Discrete Outputs DO An Analog Input AD can be used to receive the position signal of the Kixcel I P or servo valve Optionally a Discrete Input DI on the I O card can be used the for a tamper resistant intrusion switch Appendix Al describes the optional Lightning Protection Module LPM defines terms used in Fisher Controls documentation alphabetically lists the items contained in this manual along with their page numbers NOTE An I P or servo valve may be used in place of the Kixcel To ensure ease of readability Kixcel is used throughout this manual to represent all three devices 1 2 SECTION CONTENTS This section contains the following information Information Section Page Number anual Overview 1 1 1 nvironmental Requirements Site Requirements Accessing the Battery Compartment nstalling the Intrusion Switch 4 2 Rev 9 99 GB600 Series Instruction Manual Information Section Page Number Power Consumption Calculation otaling Power Requirements Solar Powered Installations Operation 1 3 ADDITIONAL INFORMATION The following manuals may be used to acquire additional information not found in this manual GRIDLINK Configuration Software User Manual Part Number D301131X012 Function Sequence Table FST User Manual Part Number D301058X012 ROC FloBoss Accessories Instruction Manual Part Number D301061X012 Type 662 Kixcel Remote Control Pilot Drive
109. ing the default Inner Loop Setpoint if it was in Outer Loop Mode or Outer Loop with Adaptive Mode LPP low battery RBX message sent to Host if enabled and change PID Control to Inner Loop Mode using the default Inner Loop Setpoint if it was in Outer Loop Mode or Outer Loop with Adaptive Mode LPP pressure transmitter RBX message sent to Host if enabled and change PID failure Control to Inner Loop Mode using the default Inner Loop Setpoint if it was in Outer Loop Mode or Outer Loop with Adaptive Mode 2 3 3 Low Pressure Point The Low Pressure Point is located downstream from the District Regulator The Low Pressure Point LPP GB602 uses the Pressure Module PM sensor to acquire the average pressure from the low pressure point in the gas distribution system The pressure is associated with Analog Input point number Al The LPP samples the pressure once per second while keeping a minute average of the pressure The LPP calculates the pressure average over a minute and compares it to the Setpoint Deadband The Setpoint Deadband is the Low Press Setpoint plus or minus a user defined value The average pressure must be within the Setpoint Deadband or a message is sent to the DR The message sent to the DR includes the average pressure and the calculated change in the Setpoint for the Inner Loop If the average LPP pressure is still out of the Deadband after the Deadband Time Delay has expired the LPP recalculates t
110. ioe ads 4 7 Automatic Self Tests cesiones enon 2 26 Auxiliary Output Power oooocooccnonccconcnononnonanccnonccinnecos 2 36 Auxiliary Radio PoWet ccessccceeseeeeeeeeeeeeeenees 4 11 B Backup Procedures ooooocooccconccnonccconcnononnonanccnnnacionacos 2 45 After Installing Components oooocccocccnonnnonncnonocannos 2 48 BAP rociado iio A E S E 2 31 Battista do lies t 1 24 Accessing the Compartment oooooconccnnocccnoncnoncc nnon 1 16 Requirements 05 534 cbsdeessebsieteitevstteindsPaahtees 1 25 Balde cintas sas 1 9 Capacity with Power Supply ccooccnnocccnonncnonccnnnns 2 34 AE enarrare o R feat oak cuve ts 1 9 2 32 2 34 Charo iis ocio tias ltd 1 9 A 055s ks bei vseicks nieun Ear EE E Euas 2 31 C Calibration si sis rin adds 2 44 Alacan Roa is 3 11 Rev 9 99 VO Channels ao o cercas lies 1 26 Pressure Module cccccccccccececesseseessenseeeeees 3 11 Cathodic ProtectiON oooooocoonooooocccconononnonnnnnnnrrrnnnnnnnnnns 1 13 E 2 32 Baile ocres E AE NTE 1 9 CHG EAA ete NEARE arde 2 31 Class ti shat n eE e EErEE AR NS 1 12 Clock Real Me A AE ASE 2 25 Cold ati dd tl eee 2 47 COM e tcc rnct heen a atone PRS 1 6 2 23 2 24 Comm Port Host actina eo ae e A 2 24 Operator Interface oooononccnoncnonncnonnnonnncnnancnnnnccnnne 2 23 Communication Ports occccnnnnnnnnnnnonononinnnanananononos 2 23 Communications COMMECIOIS occcccnncncnoocccnnnncnnnnnnnonanocnnnccnnnnnnnnnannonos 2 24 A E EE EAT
111. ion During the low power modes the PLL and oscillator are in various states of shutdown Two low power modes are supported Standby and Doze Standby This mode is used during periods of inactivity When the operating system cannot find a task to run the controller enters Standby mode Processor loading is calculated by using the amount of time spent in Standby mode This mode keeps the clocks running and communications active with baud clocks running A Periodic Interrupt Timer wakes up the controller and starts the normal operating mode 2 26 Rev 9 99 GB600 Series Instruction Manual Wake up from Standby occurs when the controller receives a Timed Alarmed interrupt from the Real Time Clock Signal from the Operator Interface port LOI 4 Signal from Connector P10 built in I O or I O card Signal Ring Indicator RI from a communications board COM1 Doze This mode is used if a low battery voltage is detected The battery voltage is compared to the low low alarm limit in the diagnostic analog input for the battery voltage This value defaults to 10 6 volts If the battery voltage is less than the low low alarm limit configured for Analog Input point E1 the unit 1 Sets the Real Time Clock alarm for 15 minutes from the present time if a charge voltage is greater than the battery voltage or for 55 minutes if the charge voltage is less than the battery voltage Writes the message Low Battery to
112. ion Manual 1 7 4 Solar Powered Installations Solar power allows installation of the GB602 LPP controller in locations where line power is not available The two important elements in a solar installation are solar panels and batteries Solar panels and batteries must be properly sized for the application and geographic location to ensure continuous reliable operation The 12 volt solar panel can be installed to provide charging power for the backup batteries The panel can be rated at 5 10 or 11 watts to correspond to the CSA rating of the controller and is sized depending upon the power requirements of the unit The solar panel is typically mounted to the same 2 inch pipe that supports the controller The solar panel wiring is brought into the controller enclosure through the pre punched holes in the bottom of the enclosure and is terminated at the charge CHG power terminals on the Main Electronics Board Fisher Controls does not offer solar panels for GridBoss controllers However a list of acceptable solar panels is provided below Refer to the manufacturer s literature for installation instructions The following solar panels are approved by CSA for use in Class I Division 2 locations Solarex MSX 5 4 5 watt e Solarex MSA 5 5 1 watt Solarex MSX 10 10 0 watt Uni Solar RM 1212 11 0 watt The panel must face due South not magnetic South in the Northern Hemisphere and due North not magnetic North in the Southern Hemisphere
113. ired to the I O Card s Discrete Input DI in the controller an On status is detected when the door is closed and an Off status when it is open The status of the switch can be configured to generate an alarm when the door to the enclosure is open NOTE An I O Card is required in order to use the Intrusion Switch The Intrusion Switch kit FSACC 1 ITS3 includes the items in the following list Refer to Section 2 for specifications on the intrusion switch Description Quantity Key Switch Assembly 1 1 Three feet of 22 AWG 2 conductor cable 1 Push On Terminals 2 Mounting Bracket 1 2 Key numbers are associated with Figure 1 2 Use the following steps to install the intrusion switch Refer to Figure 1 2 1 Inspect the Intrusion Switch kit and verify that all parts are present 2 Secure the Mounting Bracket using the ground bar and ground bar screw 3 Fasten the Intrusion Switch to the mounting bracket as shown in Figure 1 2 Place the hex nut lock washer and anti rotation washer in that order on the Intrusion Switch Assembly Place the Intrusion Switch Assembly through the Mounting Bracket Place the decorative nut on the Intrusion Switch Assembly Tighten the Intrusion Switch Assembly AD UB Wire the switch to a Discrete Input on the I O Card to monitor access activity and to provide logging and alarm capability Refer to Intrusion Switch Wiring in Section 2 5 Rev 9 99 1 17 GB600 Series
114. iring for Current Loop Devices Rev 9 99 5 11 GB600 Series Instruction Manual 5 6 1 O CARD LEDS Six LED indicators are located on the I O Card when a specific PI DI or DO is active then the corresponding LED lights LED CR2 Pulse Discrete Input 1 LED CR3 Pulse Discrete Input 2 LED CR4 Discrete Input 1 LED CRS Discrete Input 2 LED CR6 Discrete Output 1 LED CR9 Discrete Output 2 o o 5 7 TROUBLESHOOTING To troubleshoot an 1 O channel first check to see how the channel is configured using the GRIDLINK Configuration Software If the configuration looks correct then simulate an input within the range of the input or force an output to be produced by using GRIDLINK If an input channel is in question you may be able to use one of the outputs on the I O Card known to be in working order to simulate the needed input Likewise if an output channel is in question you may able to connect it to a working input channel and check the results There are no field repair or replacement parts associated with the I O Card If the card appears to be faulty return it to your Fisher Representative for repair or replacement 5 12 Rev 9 99 GB600 Series Instruction Manual 5 8 SPECIFICATIONS I O Card Specifications POWER Input 8 to 15 Vdc supplied by main processor card 78 mW typical excluding power for DO and AO load Al Loop 12 or 24 Vdc nominal 4 to 20 mA provided for trans
115. is internally re calibrated for every 5 C temperature change as sensed by enclosure battery temperature At the configured Contract Hour the values are stored to the Daily Historical Log and zeroed for the start of a new day 2 3 2 District Regulator The District Regulator computes load profiles based on ambient temperature and time of day to determine the predicted Setpoint of the regulator The RTD mounts on the GB601 enclosure and reads the ambient temperature The GB601 uses the Pressure Module PM sensor to acquire the inlet and outlet pressure from the District Regulator The inlet pressure is located at Analog Input point number Al The outlet pressure is located at Analog Input point number A2 All hardware has an ambient operating temperature of 40 to 150 F The GB601 DR Controller includes one I O expansion card The I O card is used to send a signal Setpoint to the Kixcel I P or servo valve which readjusts the outlet pressure at the regulator The signal to the Kixcel can be sent as an Analog Output AO or as a Timed Duration Output TDO in which case two Discrete Outputs DOs are used to open and close the regulator When using an AO an Analog Input Al can be used to send the approximate position signal of the Kixcel back to the GB601 to ensure that the Kixcel has moved to the correct position Refer to Figure 2 3 The DR may also use a Discrete Input DI on the I O card for the optional intrusion switch Ot
116. isecond Key Off Delay The maximum baud rate is 19 2k The EIA 485 communications card includes LED indicators that display the status of the RXD TXD and RTS control lines LED indicators are detailed in Table 4 2 P1 C 00 Mating Connector call O CR2 c3 ALAA A Eds gt BOS v2 HEHHE C4 ee CR4 CRS EO R3 D I D R4 B A GND PTR1 0Uu0d0 PTR2 GH Host Terminals COM1 TB1 DOC0275A Figure 4 2 EIA 485 Serial Communications Card Rev 9 99 4 5 GB600 Series Instruction Manual Table 4 2 EIA 485 Communications Cards LED Indicators LEDs STATUS AND ACTIVITY RTS The RTS ready to send LED lights when a signal from the processor specifies the GridBoss controller is ready to transmit RXD The RXD receive data LED blinks when the receive signal is being received from the communications card The LED is on for a space and off for a mark TXD The TXD transmit data LED blinks when transmit signal data is being received from the processor The LED is on for a space and off for a mark 4 3 3 Dial up Modem Communications Card The dial up modem communications card supports V 22 bis 2400 baud communications with auto answer auto dial features Refer t
117. ist of items displaying a new value approximately every three seconds A Motorola 32 bit CMOS microprocessor runs at 14 7 Mhz and has low power operating modes including inactivity and low battery conditions The controllers come standard with 512 KB of built in super capacitor backed static random access memory SRAM for storing data and history The controllers also have 512 KB of programmable read only memory flash ROM for storing operating system firmware applications firmware and configuration parameters The built in inputs and outputs I O consist of a port for a Pressure Module PM a 4 wire Resistance Temperature Detector RTD input interface and a discrete output Three diagnostic inputs are dedicated to monitoring input power battery voltage and enclosure battery temperature The Pressure Module PM uses a Hitachi 16 bit micro controller and calculates static pressure At the District Regulator the Pressure Module reads the inlet static line pressure and the outlet static pressure At the Low Pressure Point the Pressure Module reads the pressure downstream of the DR The Pressure Module communicates this information to the Main Electronics Board The sensor housing flange mounts with four bolts to the bottom of the enclosure The Pressure Module cable plugs directly into the Main Electronics Board at the P DP connector For more information on the Pressure Module refer to Section 3 The RTD temperature probe supplied on t
118. l Connections 2 33 Figure 2 8 AC Power Supply Wiring 2 35 Figure 2 9 AC Power Supply Connections 2 35 Figure 2 10 Auxiliary Power Terminals 2 36 Figure 2 11 Kixcel AO AI Wiring comooccconccnonncnonnns 2 39 Figure 2 12 RTD Wiring Terminal Connections 2 40 Figure 2 13 Discrete Output Terminal Wiring 2 41 Figure 2 14 Intrusion Switch Wiring 2 42 Figure 2 15 Operator Interface Wiring 2 43 Figure 2 16 GridBoss System Flags coooonnncccon 2 46 Figure 2 17 Cold Start Options 2 47 Figure 2 18 Reset Jumper Shown in Normal Pos ei aio 2 48 Figure 2 19 Open Configuration File o 2 50 Figure 2 20 Download Configuration ooocnnnccnnn 2 50 Figure 3 1 Sensor Module ooonococconccconccconcconnncnnnncono 3 3 Figure 3 2 Side Cut away View Showing Process COMMECHONS ere ae fas 3 5 1 2 Figure 3 3 Pulse Input from Field Powered Device 3 7 Figure 3 4 Pulse Input from Controller Powered DEVICE diante tdi A Ea 3 7 Figure 3 5 Pulse Input from Controller Powered DEVICE aii Mei eheredseastensgiateic ete stan lorca 3 8 Figure 3 6 System Information 3 10 Figure 3 7 Al Calibration 3 11 Figure 3 8 Verify Al Calibration oocconncnnnccnnncnonos 3 12 Figure 3 9 Al Set Zero noiai aeien 3 12 Figure 3 10 AI Set Span 3 13 Figure 3 11 AI Set Midpoint l ooonocnnncninccnoncninnccnnss 3 13 Figure 3 12 AI Set M
119. lar design of the controller makes it easy to change hardware configurations in the field The following procedures assume that this is a first time installation of a communications card in a controller and that the unit is currently not in service For units currently in service refer to the procedures in Section 4 14 Troubleshooting and Repair CAUTION When installing units in a hazardous area ensure that the components selected are labeled for use in such areas Change components only in an area known to be non hazardous CAUTION Be sure to use proper electrostatic handling such as wearing a grounded wrist strap or components on the circuit cards may be damaged 4 4 1 Installing Communications Cards All communications cards install into the controller in the same manner 1 2 Rev 9 99 Refer to Section 2 7 1 and perform the Backup Procedure Unplug the Power terminal block at P8 to remove power Plug the communications card connector into connector P3 on the Main Electronics Board Figure 4 4 shows the card location Gently press the connectors together until the card contacts a stand off Ensuring that the three stand off holes in the communications card line up with the compression stand offs on the Main Electronics Board firmly press the communications card onto the stand offs Plug in the Power terminal block at P8 to restore power Perform the After Installing Components in Section 2 7 3 GB600 S
120. ld PI e STAT if Y Rst R C Ss coms r 1 r 1 DOCO300C Figure 3 1 Sensor Module Front View 3 2 1 Analog Inputs The static line pressure readings from the Sensor Module are configured as two analog input points in the DR controller and one analog input in the LPP controller The pressure circuitry uses a 16 bit A D converter The 16 bit values are converted to 24 bit values 23 bits plus a sign bit for transmitting to the MCU The circuitry is designed to use as much range of the reference as possible The sensors measure up to 300 psig or 1000 psia depending on which was ordered The Als are located at Analog Input Point Number A1 Inlet static pressure DR only Analog Input Point Number A2 Outlet static pressure DR and LPP 3 2 2 Pulse Inputs Pulse Inputs PI are not used by the GridBoss System but are described in case you desire to use them for an alternative purpose The Sensor Module is capable of handling two channels points for pulse inputs Rev 9 99 3 3 GB600 Series Instruction Manual The pulse input circuitry is based upon a two stage Schmidt trigger inverter Also provided is a source voltage for open collector drain turbines and for dry contacts This source voltage is a nominal 12 volts open circuit it provides approximately one milliamp in shorted or closed co
121. lication while planning an installation The versatility of the GB600 Series controller allows it to be used in many types of installations For additional information concerning a specific installation contact your Fisher Representative For detailed wiring information refer to Section 2 The Installation Requirements section includes Environmental Requirements Site Requirements Compliance with Hazardous Area Standards Power Installation Requirements Grounding Installation Requirements I O Wiring Requirements NOTE The GB600 Series controller has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy If not installed and used in accordance with this instruction manual the controller may cause harmful interference to radio communications Operation of the equipment in a residential area is likely to cause harmful interference in which case you will be required to correct the interference at your own expense 1 5 1 Environmental Requirements The GridBoss controller case is classified as a NEMA 4 equivalent enclosure This provides the level of protection required to keep the units operating under a variety of weather conditions The contro
122. ller is designed to operate over a wide range of temperatures However in extreme climates it may be necessary to moderate the temperature in which the unit must operate 1 10 Rev 9 99 GB600 Series Instruction Manual The controller is designed to operate over a 40 to 75 C 40 to 167 F temperature range The LCD temperature range is 25 to 70 C 13 to 158 F When mounting the unit be aware of external devices that could have an effect on the operating temperature Operation beyond the recommended temperature range could cause errors and erratic performance Prolonged operation under extreme conditions could also result in failure of the unit Check the installation for mechanical vibration The controller units should not be exposed to levels of vibration that exceed 2g for 15 to 150 hertz and 1g for 150 to 2000 hertz 1 5 2 Site Requirements Careful consideration in locating the controller on the site can help prevent future operational problems The following items should be considered when choosing a location Local state and federal codes often place restrictions on monitoring locations and dictate site requirements Examples of these restrictions are distance from pipe flanges and hazardous area classifications Locate the controller to minimize the length of signal and power wiring When using solar powered controller units orient solar panels to face due South not magnetic South in the Northern Hemispher
123. log entries unless the history point is configured for FST controlled logging The District Regulator parameters include ambient temperature regulator inlet pressure regulator outlet pressure output signal to the Kixcel valve position and battery voltage once a second The LPP parameters include the low pressure point value and battery voltage once a second 2 18 Rev 9 99 GB600 Series Instruction Manual 2 3 5 4 Alarm Log The Alarm Log contains the change in the state of any alarm signal that has been enabled for alarms The system Alarm Log has the capacity to maintain and store up to 240 alarms in a circular log The Alarm Log has information fields which include time and date stamp alarm clear or set indicator and either the tag name of the point which was alarmed with the current value or a 14 character ASCII description In addition to providing functionality for appending new alarms to the log it allows host packages to request the index of the most recently logged alarm entry Alarm logging is available internally to the system to external host packages and to the FST Alarm Logs are not stored to the flash ROM during the GRIDLINK Save Configuration function The Alarm Log operates in a circular fashion with new entries overwriting the oldest entry when the buffer is full The Alarm Log provides an audit history trail of past operation and changes The Alarm Log is stored separately to prevent recurring alarms from o
124. losure can hold up to four sealed lead acid batteries see Section 1 7 5 for recom mended battery types The 12 volt batteries can be installed to give 7 14 21 or 28 amp hours of backup capacity or up to 21 amp hours of backup capacity when used with an AC power supply The batteries are mounted behind the electronics swing out circuit card panel and are retained by stand offs on the panel when the panel is secured Refer to Figure 2 7 The AC power supply battery charger mounts in place of one of the batteries The batteries are connected to a harness that allows the batteries to be changed without removing power from the unit Make sure that the black wires of the harness are connected to the negative terminals of the batteries and the red wires are connected to the positive terminals 2 5 5 Solar Panel Charge Connections The controller contains an internal battery charger circuit for charge control of the 12 volt batteries The charger monitors the battery voltage charge voltage and the battery temperature which is actually the board enclosure temperature Based on these three conditions a charge rate is determined and applied to the battery Refer to Figure 2 7 for the proper wiring connections NOTE The internal battery charger limits the current input to 1 amp which is approximately the output of a 22 watt solar panel Therefore a bigger solar panel must have its own regulator and be connected to the BAT and BAT terminals NOT
125. med to be hazardous only in an abnormal situation Group defines the hazardous material in the surrounding atmosphere Groups C and D are defined as follows Group C Atmosphere containing ethylene gases or vapors of equivalent hazards Group D Atmosphere containing propane gases or vapors of equivalent hazards For the controller to be approved for hazardous locations it must be installed according to the National Electrical Code NEC Article 501 CAUTION When installing units in a hazardous area make sure all installation components selected are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non hazardous 1 5 4 Power Installation Requirements The primary source of power for controller installations is line power Where power requirements are lower such as for GB602 controllers installations may use solar power Care must be taken to route line power away from hazardous areas sensitive monitoring devices and radio equipment Local and company codes generally provide guidelines for line power installations You must adhere rigorously to local and National Electrical Code NEC requirements for line power installations Solar power allows installation of the controller in locations where line power is not available The two important elements in a solar installation are solar panels and batteries Each must be properly sized for the application and geograp
126. ment Refer to Section 1 7 3 on page 1 21 Tarray Isr amps x 24 hrs Insolation hrs amps Finally the number of solar panels can be determined using the following equation Number of Panels Larray amps Ipane amps panel panels Figure 1 3 Solar Insolation in Hours for the United States Rev 9 99 1 23 GB600 Series Instruction Manual For example if Iarray equals 0 54 amps and Ipanei equals 0 29 amps for a 5 watt panel then the number of panels required equals 1 86 which would be rounded up to 2 panels connected in parallel Alterna tively the next larger solar panel can be used which in this case would be a 10 watt panel Table 1 2 gives Ipane Values for solar panels recommended by Fisher Controls NOTE The I pane value varies depending on the type of solar panel installed Refer to the vendor s specifications for the solar panel being used NOTE The current accepted by the controller is limited by its charging circuit to around 1 amp Therefore it is not practical to install a solar array that supplies signifi cantly more than 1 amp to the controller Table 1 2 Solar Panel Sizing Panel I panel 4 5 watt 0 27 amps S5watt 0 29 amps 10 watt 0 58 amps 11 watt 0 7 amps 22 watt 1 4 amps 1 7 5 Batteries Batteries are used to supplement both line powered and solar powered installations When used in line powered installations
127. mitter loop power from internal power converter Available at T terminal on each analog input channel FIELD I O ISOLATION 1000 Vde minimum DISCRETE INPUTS Quantity Type 2 contact sense discrete inputs Two additional Dis are available when pulse inputs are so configured see Pulse Inputs Terminals positive input COM negative input common Signal Current 0 5 to 3 5 mA in the active on state 0 to 0 2 mA in the inactive off state Isolation 2500 Vdc from processor Frequency 50 Hz maximum Sample Period 10 ms minimum Rev 9 99 PULSE INPUTS Quantity Type 2 sourced pulse counter inputs one medium speed and one high speed Both are also software configurable as discrete inputs Terminals positive input COM negative input common Isolation 2500 Vdc Frequency Medium speed input is 50 Hz maximum high speed input is 10 KHz maximum ANALOG INPUTS Quantity Type 3 single ended voltage sense analog inputs current loop if scaling resistor is used Terminals T loop power positive input negative input common Signal 1 to 5 Vdc software configurable 4 to 20 mA with 250Q resistor supplied installed across and terminals Accuracy 0 1 over 40 to 65 C 40 to 149 F range Isolation 2500 Vdc from processor Input Impedance One MQ Filter Double pole low pass Resolution 12 bits Conversion Time
128. mpression stand offs snap into place when the card is secured Install the communications card if one was removed in Step 3 Plug the Main Electronics Board Power wiring into socket P8 Refer to Section 2 7 3 After Installing Components 2 51 GB600 Series Instruction Manual 2 7 5 Pressure Module Replacement Damaged or faulty Pressure Module units must be returned to the factory for repair To maintain the approval rating of the controller this replacement procedure should be performed only by a certified agent 1 Refer to Section 2 7 1 on page 2 45 for the Backup Procedure Before Removing Power 2 Disconnect the Power input connector at P8 from the Main Electronics Board 3 Disconnect the P DP input terminal connector from the Main Electronics Board 4 Remove the two bolts holding the Pressure Module in place 5 Return the Pressure Module to your Fisher Representative 6 Position the new Pressure Module and install the four bolts to hold the new Pressure Module in place 7 Reconnect the P DP input terminal connector to the Main Electronics Board 8 Refer to Section 2 7 3 After Installing Components 2 8 SPECIFICATIONS Refer to the following pages for specifications of the GB600 Series Controllers the Sensor Module and the Intrusion Switch Refer to the Type 662 Kixcel Remote Control Pilot Drive Actuator Instruction Manual Form 5419 concerning Kixcel specifications or to the documentation specif
129. n Metric mode both the static pressure and the auxiliary pressure are in kPa To enter the Metric mode using GRIDLINK Configuration Software 1 Select the System menu 2 From the pull down menu select Information 3 On the system information display enable the Metric field 4 Press F8 Save to save the change to the GridBoss controller Refer to Figure 3 6 Rev 9 99 3 9 GB600 Series Instruction Manual File Grid I 0 Data Display History Utilities System Help System Information 1 of 1 Station Name GridBoss District Rg GridBoss Type DR Automatic Daylight oo Units payin sipe Set roup nable Contract Hour Disable Force End of Day Firmware Inf oy Revision Info F1 Update F6 Cancel F8 Save Enter_a 20 character station identifier On Line COM Figure 3 6 System Information The controller automatically adjusts the units ranges alarm limits and calibration factors of the static pressure auxiliary pressure RTD and enclosure battery temperature to the metric mode for the entire distribution system To return to US units enable the US field and save this change to the controller The controller adjusts the values to US units 3 10 Rev 9 99 GB600 Series Instruction Manual 3 6 CALIBRATION The calibration procedure is performed using the GRIDLINK Configuration Software which allows you to perform a 5 point minimum maximum and up to three intermediate points calibr
130. n the I O Card are located at Point Number B11 and B12 The pulse input at Point Number B11 can operate at up to 50 Hz with a maximum 50 duty cycle The pulse input at Point Number B12 can operate at up to 10 kHz with a maximum 50 duty cycle NOTE The Pulse Inputs located at Point Numbers B11 and B12 can also be used as Discrete Inputs at Point Numbers B9 and B10 respectively See Section 5 5 2 1 Using Pulse Inputs as Discrete Inputs on page 5 7 The PI channel has two field terminals One terminal is a positive source voltage the other is the signal return The terminals are designated as follows Positive Pulse Input Sourced COM Common To use the channel as a pulse input shown in Figure 5 4 connect the and field wires to terminals PI 1 or PI 2 and COM on the I O Card pulse input channel When the field device completes the circuit between and COM terminals the PI indicator LED on the termination board lights to show an active circuit and the optical circuitry is triggered producing a signal to the controller unit 5 6 Rev 9 99 GB600 Series Instruction Manual Pl GRIDBOSS POWERED i Vs PULSE DEVICE z COM A Sa c 1 B11 12 6 65K A Figure 5 4 Pulse Input Wiring 5 5 2 1 Using Pulse Inputs as Discrete Inputs The two PI channels can be configured as both pulse inputs see Section 5 5 2 both discrete inp
131. naconnnconnncnn 3 1 PrOCESSO Gi ia 1 5 Profiles nia iii 2 5 2 6 Public Switched Telephone Networks PSTN A TON 4 6 Pulse Inputs necios id 5 6 Used as Discrete Inputs ooonocccnonccnonccnoncconncnonannnno 5 7 WATLING ss costes ara a E oraaa EEE a ai 3 6 Wiring VO Card ainese eee eei A 5 6 R Radio Brackets scnis 1 8 Radio Frequency Interference ooooococnnooccnonccononncnnnno 1 14 Radio MOUNtIN8 oooccoccnonncconcnconanonnnnonnninonccnonaninncnness 1 16 Radio Power uiccoiisicin ios 4 11 Radio Power Cycling cooooccnonccnoncccononancconancnnnos 2 36 4 4 Radio Power Requirements oooconoocccnnoooccnononcnononncno 1 21 Radio Terminal Auxiliary Output Power ooooconocccnocccnonccnonccnnnnncnnnos 2 36 RAM verres teoei eo eE ree A E Ao aE EEOSE EERE ET 1 5 Backup Procedure ires ieee gi as 2 45 Real Time Clock eiee a ane e S 2 25 2 27 Rebooting See Resetting the GridBoss ocooccnonccconcccnocncnannno 2 45 Repaso fea ridad E 2 44 Replacing Communications Cards ooooonoccccnnoncncnnonncnnnnananon no 4 14 Report by Exception occooooccnonccocononccoonnncononnanncncnnnnns 2 24 Reset JUDE eiii 2 47 Resetting the GridBosS ooooooncccnocccoocccnonccnonacconacinnnss 2 45 EN 1 14 2 30 ROM Ela tai 1 5 RS232 Communication Card WI ia 4 11 RD ta ias 1 4 1 5 2 25 2 26 3 2 III naa 2 39 RS e ees 2 43 4 4 4 6 RADA al 4 4 4 6 4 8 S SOCUPILY oor eieh enine r Enni een 1 6 2 20 2 24 2 46 Intrusion SWitCh ooo
132. nal block into the connector labeled POWER located at the bottom left of the Main Electronics Board Refer to Error Reference source not found After the controller completes start up diagnostics RAM and other internal checks the LCD displays the date and time to indicate that the controller completed a valid reset sequence If the LCD does not come on refer to the Troubleshooting and Repair paragraphs in Section 2 for possible causes 1 8 2 Operation Once startup is successful it is necessary to configure the controller to meet the requirements of the application The GRIDLINK Configuration Software User Manual Form A6074 details the procedure for configuring the controller and calibrating the I O Once the controller is configured and calibrated it can be placed into operation CAUTION Local configuration or monitoring of the controller through its LOI port must be performed only in an area known to be non hazardous 1 26 Rev 9 99 GB600 Series Instruction Manual During operation the controller can be monitored to view or retrieve current and historical data either locally or remotely Local monitoring is accomplished either by viewing the LCD panel detailed in Section 2 3 3 or by using GRIDLINK on a PC connected through the LOI port Remote monitoring is performed through the Host port COM 1 of the controller using either GRIDLINK or Host software Refer to the GRIDLINK User Manual for more information on monitoring
133. nd is primarily used with cellular telephones Three cycling zones are provided but zones can be disabled as desired The RS 232 communications card provides the switching mechanism and is controlled by the DTR signal The Power Control function calculates which zone should be currently active In Second mode the Power Control begins in the ON state and continues with a full On Time and then goes to the OFF state for the full Off Time In Minute mode the Power Control determines if it should be ON or OFF and how much time it needs until it switches 2 20 Rev 9 99 GB600 Series Instruction Manual 2 4 PRODUCT ELECTRONICS This section describes the Main Electronics Board of the GridBoss controllers 2 4 1 Main Electronics Board Overview The Main Electronics Board components support the functionality of the GridBoss controllers Refer to Figure 2 4 The board provides 32 bit microprocessor Built in static RAM Flash ROM Liquid Crystal Display LCD display Communications card connector P3 for Host COM1 port Operator interface port LOI Built in Discrete Output DO Board temperature RTD and voltage monitor inputs Real time clock Battery backup power Automatic self tests eff 19 19 19 19 19 OH 2 Input power regulation 2 4 2 Microprocessor and Memory The GridBoss controller derives processing power from a 32 bit microprocessor The 32 bit CMOS microprocessor features dual 32 bit internal data buses an
134. ndicator displays after a power up sequence Normal Operation flashing green Communication Fail solid green for 20 seconds then alternating red processor reset and green Power Fail LED off If a failure is indicated check the P DP connector and restart the GridBoss controller Rev 9 99 3 15 GB600 Series Instruction Manual 3 8 SPECIFICATIONS 3 16 Rev 9 99 GB600 Series Instruction Manual SECTION 4 COMMUNICATIONS CARDS 4 1 SCOPE This section describes the communications cards used in the controllers of a GridBoss System Topics covered include Product Descriptions Initial Installation and Setup Connecting the Communications Cards to Wiring Troubleshooting and Repair Specifications ee 4 2 SECTION CONTENTS This section contains the following information Information Section Page Number 4 3 Product Descriptions 4 JTA 232 Serial Communications Card Radio Power Cycling Serial Card Specifications Dial up Modem Card Specifications Rev 9 99 4 1 GB600 Series Instruction Manual 4 3 PRODUCT DESCRIPTIONS The communications cards provide communications between the GridBoss controller and a host system such as GridManager or external devices The communications cards install directly onto the Main Electronics Board and activate the host port COM1 when installed COM1 is configured using the GRIDLINK Configuration Software The Distric
135. neral Informatio 4 Section 2 Using the GridBoss Controllers Section 3 The Pressure Module Section 4 Communications Cards Section 5 Input Output Card Appendix A Lightening Protection Module Glossar Glossary of Terms Index Topical Inde able of Contents lists each section and information contained in that section of the document describes this manual and mentions related manuals This section provides a summary of the controller hardware installation requirements mounting the controller units and power requirements provides information and specifications concerning the use of the GridBoss Controllers Topics covered include the Main Electronics Board wiring processes and troubleshooting The Main Electronics Board provides the pressure sensor input channel one built in discrete output channel a direct Resistance Temperature Detector RTD input an operator interface port and a Host communications port In addition Section 2 details the optional AC power supply and battery charger describes the Pressure Module PM which is used to measure the inlet and outlet pressures of the District Regulator DR and the line pressure at the Low Pressure Point LPP Section 4 provides information and specifications for the optional communications cards Rev 9 99 1 1 GB600 Series Instruction Manual provides information and specifications for the Input Output I O Card which changes the pressure us
136. ng those requiring calculations logic and sequencing control using Function Sequence Tables FSTs Rev 9 99 1 3 GB600 Series Instruction Manual The GB602 LPP Controller measures the average pressure at the Low Pressure Point downstream from the District Regulator The average line pressure at the Low Pressure Point and the required change in Setpoint for the District Regulator is relayed back to the GB601 when the LPP pressure goes out of range The primary input used for measurement at the LPP is static pressure The primary inputs used for measurement at the DR are static pressures and outside ambient temperature The static pressure inputs come from the attached Pressure Module PM and the temperature input comes from a built in Resistance Temperature Detector RTD probe The GRIDLINK configuration software allows you to set up the DR and LPP controllers while the Host software monitors both the District Regulator and the Low Pressure Point and provides remote access for changing the configuration and taking control of the system The GridBoss controllers have the following components and features Weather tight enclosures Main Electronics Boards Built in Liquid Crystal Displays LCD with two line alphanumeric viewing A 32 bit microprocessors with 512K of flash ROM and 512K of static memory storage Built in Inputs and Outputs 1 0 Built in Pressure Modules PM for sensing static pressure Built in Resistance Temperature
137. nnecting the Module to Wiring Troubleshooting and Repair Specifications o o A 2 SECTION CONTENTS This section contains the following information Information Section Page Number Scope A l A 1 Section Contents 2 E Product Description nitial Installation n 3 A roubleshooting and Repair Specifications A 3 PRODUCT DESCRIPTION In lightning prone areas it is recommended an LPM or some other device be used to protect the circuitry for each field input or output possible The LPM is designed to prevent damage to I O card circuitry by augmenting protection from high voltage transients that may occur in field wiring The LPMs plug into the Analog Input termination sockets located on the I O Card To provide protection for other I O channels on the I O Card on the main board or on the Sensor Module use a separate protective device Figure A 1 shows a front and side view of the module The LPM provides screw terminals for connecting to field wiring The LPM has sockets for plugging in a range scaling resistor The module also provides a ground wire for connection to the enclosure ground bar Rev 9 99 A 1 GB600 Series Instruction Manual BUILT IN FIELD WIRING TERMINATION BLOCK 1 0 WIRING CONNECT GREEN WIRE TO ENCLOSURE GROUND BAR OR GROUND LUG FRONT VIEW SIDE VIEW DOC0138A Figure A 1 Lightning Protection Module A
138. nput AO Analog Output Analog Analog data is represented by a continuous variable such as a electrical current signal AP Absolute Pressure APC Adaptive Predictive Control ASCII American National Standard Code for Information Interchange Built in I O I O channels that are fabricated into the ROC FloBoss and GridBoss controller they do not require a separate module Also called on board I O COM1 Port on the ROC364 FloBoss 500 series and GB600 series that may be used for host communications depending on the installed communications card On the FloBoss 407 this port is built in and dedicated to RS 232 serial communications Configuration Typically the software setup of a device such as a ROC FloBoss or GridBoss controller that can often be defined and changed by the user Can also mean the hardware assembly scheme CSA Canadian Standards Association DB Database dB Decibel A unit that gives the ratio of the magnitudes of two signals on a logarithmic scale DCD Carrier Detect communications signal DI Discrete Input Discrete Input or output that is non continuous typically representing two levels such as on off DO Discrete Output DMM Digital multimeter DP Differential Pressure DR District Regulator DTR Data Terminal Ready modem communications signal Duty Cycle Proportion of time during a cycle that a device is activate
139. nputs and outputs some of which are used for adaptive predictive control The I O Card provides these types of additional I O channels for the GridBoss controllers Two Discrete Inputs Pulse Inputs DIs PIs Three Analog Inputs Als Two Discrete Outputs DOs One Analog Output AO The I O Card uses a microprocessor for monitoring control and acquisition of data from external devices connected to the I O channels The information is then relayed to the controller Six LEDs provide a visual indication as to the state of the discrete inputs discrete outputs and pulse inputs refer to Section 5 6 I O Card LEDs on page 5 12 Compression CRI g 8 Standoff O a a O UI ea o Q a So ef RI cre pr o 3 f J gt m 00 Ra a o e oo l A m RS eng oo R6 a co a a O 235 LEDs oo m e o P2 o
140. ntact positions An external amplifier must be connected to the field terminations to provide gain for low level turbine signals The amplifier is powered by the source voltage terminals and the amplifier output is connected to the input signal The normal gain of the amplifier is 30 This allows 100 mV signals to be amplified to 3 volts above the 2 5 volt threshold The pulses accumulate in a 32 bit register that rolls over when the 25 bit is set Only 24 bits are sent to the FloBoss for updates The Sensor Module accepts the signals shapes and filters the signals and sends the signals to the MCU The pulse input connectors consist of a 5 pin removable terminal block with screw type compression connectors Sensor module pulse inputs are configured at Pulse Input Point A5 Pulse Input Point A6 3 2 3 Sensor Module Connection The connection between the Sensor Module and the main electronics board is achieved through a ribbon cable plugged in at the P DP connector Refer to Figure 3 1 In addition to all the signals a 5 volt power supply from the controller is made available to the Sensor Module through the P DP ribbon cable The voltage of this power follows the battery voltage of the unit This supply operates under very low currents with an efficiency of 60 to 90 percent depending upon the current draw 3 4 Rev 9 99 GB600 Series Instruction Manual 3 3 PROCESS CONNECTIONS The process inputs are the static press
141. ny patent Fisher Controls reserves the right without notice to alter or improve the designs or specifications of the products described herein i Rev 9 99 GB600 Series Instruction Manual Table of Contents Rev 9 99 iii GB600 Series Instruction Manual Table of Contents Continued iv Rev 9 99 GB600 Series Instruction Manual SECTION 1 GENERAL INFORMATION 1 1 MANUAL OVERVIEW This manual describes the controllers manufactured by Fisher Controls which are used in a GridBoss Pressure Control and Management System The GridBoss System consists specifically of the GB601 District Regulator DR Controller the GB602 Low Pressure Point LPP Controller the GRIDLINK configuration software and optionally the GridManager Host The GridBoss System controls the setpoint at the GB601 DR Controller through a Kixcel such as a Fisher Type 662 Kixcel An I P or servo valve may be used in place of the Kixcel The setpoint is predicted by the historical profile of the District Regulator outlet pressure versus the time of day and temperature The GB602 LPP Controller monitors the average pressure at a low pressure point downstream from the District Regulator The average pressure and change in setpoint for the regulator is relayed back to the District Regulator when the average pressure is out of range The Included in this manual are the following sections 4 Table of Contents Table of Contents 4 Section 1 Ge
142. o Figure 4 3 The modem card is FCC part 68 approved for use with public switched telephone networks PSTNs The FCC label on the card provides the FCC registration number and the ringer equivalent The modem card has automatic adaptive and fixed compromise equalization This is an optional modem communications card for the host port activates COM1 The dial up modem communications card s P1 connector plugs into the Main Electronics Board at P3 The defaults for the dial up modem communications card are 2400 baud rate 8 data bits 1 stop bit no parity 10 millisecond Key On Delay and 10 millisecond Key Off Delay On power up the modem must be set up for Auto Answer Periodic checks are made to ensure that the modem is still in Auto Answer or that it is not left off the hook after a certain period of non communication 4 6 Rev 9 99 GB600 Series Instruction Manual 10000000002 _ Mating Connector cr FBi c2 P J1 o m o U2 E y TEE BBB BB C3 FB4 TXD CR2F O FE LEDs CR3 AR A C4 c5 OH R4 CR4 PIRI PTR2 J2 A RJ11 Connector Figure 4 3 Dial up Modem Communications Card The modem card interfaces to two wire full duplex telephone lines using asynchrono
143. o O 86 S lt B SIs 99 a O P5 to J2 Mating 90 la Connector 38 a Sp Connecting pes O 3 Screw 189 c O 8 IQ i O O h D 82 O ps O B1 J Connecting D P8 RS P10 AM Screw P H pe oO i00000S9S908S A LI DOCO308B Detent Figure 5 2 I O Card Installation 5 4 Rev 9 99 GB600 Series Instruction Manual 5 5 I O WIRING The field terminals on the I O Card are connected as explained in the following sections 5 5 1 Discrete Inputs Discrete inputs DIs monitor the status of relays solid state switches or other two state devices DI functions support discrete latched input and discrete status input In the case of the GridBoss System a DI is used with the optional intrusion switch The I O Card discrete inputs acquire power from the 24 volt power supply An LED indicator is included for each point on the field side The signal from the field is coupled through an optical isolator providing 2500 Vdc isolation from the main electronics board The discrete inputs provided on the I O Card are located at DI point number B7 through point number B10 and are connected as follows Positive Discrete Input COM Common NOTE The Discrete Inputs located at Point Number B9 and Point Number B10 are obtained by using the two Pulse Inputs on the I O Card see Section 5 5 2 1 Using Pulse Inputs as Discrete Inputs on page 5 7 The discrete input operates by providing a voltage across
144. o bracket using the four 6 32 x 0 25 flat head screws supplied 3 Place the radio and bracket into the enclosure aligning the assembly over the two studs on the back panel of the enclosure and the screw next to the swing out panel 4 Slide the bracket to the right to engage the slots and tighten the screw 5 Route the radio antenna either to the right or to the left and then out the bottom of the controller enclosure 1 6 3 Accessing the Battery Compartment As many as four 7 amp hour batteries can be mounted inside the controller enclosure Refer to Section 1 7 5 Batteries on page 1 24 To access the battery compartment 1 Unscrew the two captive screws on the left side of the swing out mounting panel containing the main electronics board 2 Unplug the printed circuit cable going to the Pressure Module by pressing down on the connector tab and pulling straight out 3 Push down on the detent immediately below the Pressure Module connector and swing the mounting panel out You now have full access to the battery compartment Refer to Section 2 for information on battery wiring 1 16 Rev 9 99 GB600 Series Instruction Manual 1 6 4 Installing the Intrusion Switch The intrusion switch is a momentary contact switch used to detect whether the door to the enclosure is open or closed The switch which has a normally closed contact is designed to be mounted in the controller enclosure When the normally closed contacts are w
145. onfiguration Software eee 1 4 GRIDLINK User Manual ooooccnnnnocccnnoncncnnonnnncnnnnnnnnnno 1 3 Ground RO tea 1 13 Grounding Earth Ground Kerrain seuss oes eon tuth conte tes eren sina aanned 1 13 Ground With sso lek oe eed he aes 2 29 Wiring Requirement oocoocccnnononnncnnancnonccnnnananccnnne 1 13 Groups Cand Ds ects ac e 1 12 Rev 9 99 GB600 Series Instruction Manual H Hardware Watchdog ocooccnonccconccconcccnnnccnonccnonccnonacos 2 26 Hazardous Locations ccesesceceeeeeeeeeeeneeeeeenneeees 1 12 Historical Load Profiles ooooonoccccnooocccnooonccnononnnonono 2 5 History Lo Binaria 2 18 History Points oooooooccnoocccnononcncnononcncnonnnonononcnononnncnnnn 2 17 Holiday Load Profiles oooooccnnncnoncconccnonacccnonnccnnnnos 2 6 Host Communications occcoooncccnononcncnonnnnnnonnncononananonono 1 6 Host POr aa ade 2 23 2 24 WILD Ao cali Haas beso leo lcd ds do da 2 43 4 11 l WO ses Seine ee ee 1 5 VO Cardin 1 6 5 1 Descriptions Sbado 5 2 LEDS iia nic i Rebel tte 5 12 T O Expansion Card See VO Cardiaca da 2 10 T O Power Requirement cccooccconccconcnononnnnonccnonacinnacos 1 20 I O Wiring Requirement cooccconccnoncnonncnonanonccinnonancnos 1 14 rA E habe sib ah ceS ia teat Bese ahah A ee seed 1 2 Impedance Crd i a A ATEN 1 13 Indicator LED ida 3 15 Information NS AE 1 3 Inner Loop Mode coooooccoocccoccnonncconanonncconanccnonccnnnon 2 6 2 7 Input Calculation
146. orts If two communication ports are used the LOI is used for peer to peer communications between the DR and the LPP controller while COM1 is used for Host communications If only one communications port is used the LPP controller the DR controller and the Host all use COM1 User Level Security allows the system manager to set up individual user security with various levels of access to the individual GridBoss controllers Security can be different for the LOI port and the Host port The I O parameters pressure calculations power control security and FST programmability are configured and accessed using the GRIDLINK Configuration Software Refer to the GRIDLINK Configuration Software User Manual for details concerning software capabilities 1 6 Rev 9 99 GB600 Series Instruction Manual Mounting Flange Lockable Hasp 6 GridBoss Operator Interface Connector Pressure Dimensions are in inches Module REY Figure 1 1 GB600 Series Controller GB601 DR shown 1 4 1 Firmware The firmware contained in flash ROM on the electronics board determines much of the functionality of the GridBoss units such as 4 Memory logging of 240 alarms and 240 events Extensive archival of data into daily averages 15 minute averages and minute averages Power cycling control for a radio through the optional E A 232 communications card Memory logging of two time of day profiles with 1440 entries DR controller only Closed loop
147. ounted to another pipe with a pipe saddle or it can be cemented into the ground deep enough to support the weight and conform to local building codes Wall or panel mounted Fasten to the wall or panel using the mounting flanges on the enclosure Use 3 8 inch bolts through all four holes Mounting dimensions are given in Figure 1 1 The pressure inputs must be piped to the 4 18 NPT connections on the Pressure Module CAUTION Do not mount the controller with the Pressure Module supporting the entire weight of the unit Due to the weight of the unit with batteries and a radio the unit does not meet vibration requirements unless the enclosure is installed using its mounting flanges CAUTION The controller must be mounted vertically with the Pressure Module PM at its base Rev 9 99 1 15 GB600 Series Instruction Manual 1 6 2 Mounting a Radio One radio up to 2 25 inches high can be mounted inside the controller enclosure by using the optional radio bracket This bracket allows most radios to be secured in the compartment Fasten the radio to the bracket using one of the predrilled mounting patterns and the four 6 32 x 0 25 pan head screws supplied NOTE If you require two radios one for peer to peer and one for peer to host one of the radios must be mounted outside of the controller enclosure For an MDS radio 1 Remove the winged brackets supplied with the radio 2 Fasten the radio through the bottom of the radi
148. ous 7 or 8 bit software DIMENSIONS selectable 0 7 in H by 2 0 in W by 2 75 in L 18 by 51 by Parity None odd or even software selectable 70 mm LED INDICATORS APPROVALS Individual LEDs for RXD TXD and RTS signals Approved by CSA for hazardous locations Class ElA 232D card also has LEDs for DTR and DCD Division 2 Groups C and D 4 16 Rev 9 99 GB600 Series Instruction Manual 4 7 2 Dial up Modem Card Specifications POWER REQUIREMENTS OPERATION Mode Full duplex 2 wire for dial up PSTN Bell 212 4 75 to 5 25 Vdc 0 25 W maximum supplied by compatible processor board Data Rate 300 1200 or 2400 baud asynchronous software selectable ENVIRONMENTAL Parity None odd or even software selectable Format 7 or 8 bits including start stop and parity Operating Temperature 0 to 70 C 32 to 158F Storage Temperature 25 to 85 C 32 to 185 F software selectable Transmit Carrier Frequencies Originate 1200 Hz 0 1 Answer 2400 Hz 0 1 Receive Carrier Frequencies Originate 2400 Hz 7 Hz Answer 1200 Hz 7 Hz Telephone Line Impedance 600 ohm typical Operating Humidity To 95 relative non condensing DIMENSIONS 0 7 in H by 2 0 in W by 2 75 in L 18 mm by 51 mm by 70 mm RTS to Transmission Delay Configurable in 10 WEIGHT millisecond periods software selectable 1 3 oz 36 g Receiver Sensitivity Off to On threshold 33 dBm On to Off threshold
149. ower Terminal ccecsscceeeesteeeeeseeeees 2 29 DU os eect a eset eevee eal NEEE 3 6 O 2 31 Pressure Modulen n a E 3 6 Rad O a h 2 36 RS232 Communications Card cee eeeeeeeeeeeeeee 4 11 RUD 40 laicidad 2 39 Solar Panel Charge Connections oooonocccnoccnonncnnnos 2 32 Wire Gae erren a a ea aorar e tii 2 31 1 5 GB600 Series Instruction Manual If you have comments or questions regarding this manual please direct them to your Fisher Representative or contact FAS Technical Documentation c o Fisher Controls International Inc 1612 South 17th Avenue Marshalltown lowa 50158 FAX 515 754 3630 1 6 Rev 9 99
150. point is determined by the load profiles The GridBoss System uses adaptive predictive control to automate gas distribution regulators it manipulates the system pressures in order to deliver gas not only at the lowest possible pressure but also at an optimized and adequate pressure to the system The GridBoss algorithm predicts system requirements to improve system integrity and reduce the average system pressure Rev 9 99 2 3 GB600 Series Instruction Manual Pa Jo DR DRS JPR E LPP DR District Regulator LPP Low Pressure Point Figure 2 1 GridBoss Gas Distribution System The GridBoss algorithm tracks the time of day to predict the outlet pressure it also tracks the outside ambient air temperature to adapt the output pressure setting The GridBoss algorithm learns the corresponding bias points relative to temperature and time of day This learning period is typically 1 2 weeks for the time of day profile The DR and LPP controllers have a dedicated communications link and communicate with each other to confirm that the DR is keeping the LPP within the Setpoint Deadband The Kixcel I P or servo valve receives the signal Analog Output or Timed Duration Output from the controller and converts the signal into an outlet pressure adjusting the Setpoint at the DR When an AO is used an Analog Input AI can be relayed back to the GB601 DR Controller to indicate the position of the Kixcel and ensure that it is approximately wi
151. point of the District Regulator 2 3 1 3 Time of Day Profiles The Low Pressure Point change in Inner Loop Setpoint is stored in one of two time of day profiles with 1440 entries that represent each minute of the day A new value is stored at the current minute of the day by adding 1 of the new change in Inner Loop Setpoint to the existing value in the time of day profile The previous 15 minutes in the profile are changed to allow the District Regulator to ramp up or down to the new value If the Inner Loop Output or Setpoint is against either limit then the time of day profile performs a slow decay using 99 of the current time of day value This repositions the Inner Loop Output or Setpoint off the limit One time of day profile is for weekdays Monday Tuesday Wednesday Thursday and Friday and the other for weekends Saturday and Sunday and holidays You may specify up to 30 holiday dates month day and year Rev 9 99 2 9 GB600 Series Instruction Manual 2 3 1 4 Input Calculation After power up the Master Controller Unit MCU enters the normal operation mode and the inlet and outlet pressure values are read These values are stored for retrieval by the DR controller Next the temperature is read and compensation is applied if necessary The MCU enters a low power mode and waits for the next one second interrupt 4 Static pressure is sampled once per second Temperature is sampled and linearized once per second The RTD
152. procedure As a precaution save the current configuration and historical data to permanent memory as follows CAUTION When installing units in a hazardous area make sure installation components selected are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non hazardous CAUTION To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap Launch the GRIDLINK Configuration Software Select Collect GridBoss Data from the File menu Select All in the Collect GridBoss Data dialog box Enter a File Name and click OK Pa oe eS 2 7 2 Resetting the Controller If you are experiencing problems with the GridBoss Controller that appear to be software related try resetting the controller As described in the following paragraphs there are three ways to perform a reset Warm Start Cold Start Jumper Reset Rev 9 99 2 45 GB600 Series Instruction Manual For example if security was enabled on both communication ports of the controller the settings were saved to permanent memory and then the ID and or Passwords were lost communications with the controller will be locked out on both ports until a Jumper Reset is performed then the Host port could be used since its security is disabled by default If none of these methods seem to help the controller may need to be returned to t
153. puts and outputs A surge protection device installed at the service disconnect on line powered systems offers lightning and power surge protection for the installed equipment You may also consider a telephone surge protector for the dial up modem communications card Refer to Appendix A concerning the Lightning Protection Module LPM used with the AI on the T O card All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured with a ground system tester The grounding conductor should have a resistance of 1 ohm or less between the controller case ground lug and the earth ground rod or grid The grounding installation method for the controller depends on whether the pipeline has cathodic protection On pipelines with cathodic protection the controller must be electrically isolated from the pipeline Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the distribution system In this case the controller could be flange mounted or saddle clamp mounted directly on the distribution system and grounded with a ground rod or grid system On pipelines without cathodic protection the pipeline itself may provide an adequate earth ground and the controller could mount directly on the distribution system Using a ground system tester test to make sure the pipeline to earth impedance is less than 25 ohms If an adequate ground is provided by the pipeline do not install a sep
154. r is applied typically backed up by a lithium battery or supercapacitor T Z TDO Timed Discrete Output or Timed Duration Output TLP Type of point Logical or point number and Parameter number TXD Transmitted Data communications signal Rev 9 99 G 5 GB600 Series Instruction Manual This page intentionally left blank G 6 Rev 9 99 GB600 Series Instruction Manual TOPICAL INDEX Numerical 15 Minute Historical LO8 ocononcccnoccconancnanaccnnnonannnss 2 18 32 bit CMOS Microprocessor coooccconccconcnononccnanccnnnnnnnne 1 5 A AA nda dio E 4 8 AC Power Supply cccccooccccnnoncncnnncnccnnnannnonanacinanos 1 9 2 34 Accessing the Battery Compartment eee 1 16 ACCESSOLIES iein oenina eaa E T Ea ei 1 8 Accessories Instruction Manual 1 3 Adaptive Modes siniseen ara a RiR 2 6 2 8 Additional Informati0N conocccnocncnoncconnncnonanonnnccnnncnno 1 3 After Installing Components oocononcnonnconncnonanonccnnnnnos 2 48 AGA TO 3 1 AT Calibration oiea eea n Ea Aaa 3 11 Alarm LoS iren a a T R e 2 19 Ambient Temperature oocooooconooncncnnnnnnnnnnnnconancncnnnnnnoss 2 17 Analog Inputs velvet saosin 3 3 5 8 Calibrador ieee 2 44 3 11 I O Card Voltage Signal 5 9 Witing VO Cardona mis 5 8 Analog OuUtpUlS oooococnnoocccononancnnnonnnnnononcnnnonancncnnnnnnnos 5 11 Witing VO Caterina ca vi 5 11 ADEMAS iii albores 1 11 APEC G 1 APE ane n ea o 3 1 Approvals cereri e E E E a 1 12 AT Command ia
155. rd Circuitry on the Main Electronics Board monitors and regulates the charge based on battery voltage charging voltage and temperature The typical panels used are 12 volt panels with output ratings of 5 10 or 11 watts The panels are typically bracket mounted on a pole or pipe and the wiring is brought into the bottom of the GridBoss enclosure through a liquid tight fitting Due to power requirements solar panels are normally used only on the GB602 The intrusion switch acts as a tamper detector for the GridBoss controllers The intrusion switch is a momentary contact switch used to detect whether the door to the enclosure is open or closed The switch which has a normally closed contact is designed to be mounted in the GridBoss enclosure When the normally closed contacts are wired to a Discrete Input DI an On status is detected when the door is closed and an Off status when it is open The status of the switch can be configured to generate an alarm when the door to the enclosure is open An I O Card must be installed in order to use the intrusion switch Rev 9 99 1 9 GB600 Series Instruction Manual 1 5 INSTALLATION REQUIREMENTS This section provides generalized guidelines for successful installation and operation of the GridBoss controllers Planning helps to ensure a smooth installation Be sure to consider location ground conditions climate and site accessibility as well as the suitability of the controller app
156. side of the LPP Setpoint Deadband If the average LPP pressure is still out of the Setpoint Deadband value after the Deadband Time Delay for DRs has expired then the LPP recalculates the change in Inner Loop Setpoint and retransmits it and the average pressure to the DR The Inner Loop Setpoint has a Maximum Setpoint and Minimum Setpoint limit which the Setpoint cannot exceed Rev 9 99 2 7 GB600 Series Instruction Manual An LPP may communicate with up to five DRs and each DR may have different gains so the LPP calculates a change in Inner Loop Setpoint for each DR The LPP regularly communicates the average pressure and change in Inner Loop Setpoint to each DR after the Check in Time has expired if the average pressure has not varied from the Setpoint by more than the Deadband The Error Time Delay for DRs should always be less than the Check in Time for DRs The Check in Time has a maximum limit of 8 hours Communications are accepted by the District Regulator from one LPP and the control message is used to adjust the Inner Control Loop DR to Kixcel Setpoint Outer Loop Mode contains a default Inner Loop Setpoint for when alarm conditions occur that terminate the Outer Loop Mode If the Default Setpoint is less than zero then the Setpoint remains at its current value Temperature and time of day adaptation occurs in the background If the time of day profiles have been cleared then the DR creates the time of day profiles If the time of d
157. t Regulator DR Controller and Low Pressure Point LPP Controller have the ability to communicate with each other and the Host on the same communications port or on separate communications ports If two communication ports are used the LOI is used for peer to peer communications between the DR and LPP controllers while COM1 is used for Host communications If only one communications port is used the LPP controller DR controller and Host all use COM1 The DR controller timestamps Last LPP Comm Time the last time the LPP controller communicated with it The DR controller only communicates with one LPP An LPP controller can communicate with up to five DRs The following communications cards are available EIA 232 Serial Communications Card EIA 485 Serial Communications Card Dial up Modem Communications Card 4 2 Rev 9 99 GB600 Series Instruction Manual 4 3 1 ElA 232 Serial Communications Card The EJA 232 communications card meets all EIA 232 specifications for single ended RS 232 asynchronous data transmission over distances of up to 50 feet Refer to Figure 4 1 The EIA 232 communications card provides transmit receive and modem control signals Normally not all of the control signals are used for any single application This is one of the optional interface cards for the host port of the GridBoss controllers The EIA 232 communication card s P1 connector plugs into the Main Electronics Board at P3 and activates COM
158. t board directly below each terminal as shown in Figure 3 1 The pulse input PI terminals and their function are detailed in Table 3 1 The first pulse input is on the left and the second pulse input is located on the right CAUTION Always turn the power to the controller off before you attempt any type of wiring CAUTION To avoid circuit damage when working with the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap Table 3 1 PI Connections on the Sensor Module Terminal Pulse Input 1 Left Position DEVICE 1 The positive pulse input from the first device This is the first pulse input identified as PI point A5 when configuring SOURCE 1 S First source voltage for open collector drain or dry contacts COMMON COM Power supply and circuit common Terminal Pulse Input 2 Right Position COMMON COM Power supply and circuit common DEVICE 2 The positive pulse input from a second device This is the second pulse input identified as PI point A6 when configuring SOURCE 2 S Second source voltage for open collector drain or dry contacts The actual wiring connections for the pulse input counter depends on the application See the following figures for typical hook ups Note that the power for the pulse device in Figure 3 3 could come from any suitable source other than the controller itself The field device in Figure
159. t on the AI terminal block of the I O Card 2 38 Rev 9 99 GB600 Series Instruction Manual 2 o e H L oPh SIIS O E OIE N oen IS IS TYPE 662 KIXCEL o JO UPPER PC BOARD as Sis iy A O Boral O di Al oe al B6 O 3 TB1 E3 i STs 1 88 SIR ool rt 2 118 se 2 2 O S o 183 s 19 o E IS a 8 O j1 INC 6 e 21 1 2 vec MANY E O E dl LTS as AE S If Os o 6 o o DOCO3S5A e p z Pi 2 EA 7 R DOOP OIE_ OOWOASSSOGg i F gt 2 El Scaling e Resistor BATTERY f Figure 2 11 Kixcel AO AI Wiring 2 5 10 RTD Wiring The temperature for the GB601 is sensed by the factory attached Resistance Temperature Detector RTD probe this probe is factory wired to the RTD input terminals on the Main Electronics Board If you need to connect a 2 wire 3 wire or 4 wire RTD to the controller refer to the wiring connections shown in Figure 2 12 and described below
160. t to prevent creation of a ground loop circuit A ground loop circuit could cause erratic operation of the system The Main Electronics Board is electrically connected to the ground lug and the ground bar through the enclosure with stand offs No earth ground connections to the board are required however the enclosure must be grounded from the ground lug CAUTION Do not connect the earth ground to any terminal on the Main Electronics Board The recommended cable for I O signal wiring is an insulated shielded twisted pair The twisted pair and the shielding minimize signal errors caused by EMI electromagnetic interference RFI radio frequency interference and transients For line powered installations the grounding conductor must end at the service disconnect The grounding conductor can be wire or metallic conduit as long as the circuit provides a low impedance ground path 6 GridBass DOCO363A Figure 2 5 Earth Ground Connection 2 30 Rev 9 99 GB600 Series Instruction Manual 2 5 3 Connecting Main Power Wiring Overview It is important that good wiring practice be used when sizing routing and connecting power wiring All wiring must conform to state local and NEC codes The POWER terminal block can accommodate up to 14 AWG wire Input power is monitored by diagnostic Analog Input Point E2 Refer to Figure 2 6 P8 DOI POWER Up to 1
161. terminals and COM see Figure 5 3 which is derived from internal voltage source V When a field device such as a relay contact is connected across and COM the closing of the contacts completes the circuit which causes a flow of current between V and ground at terminal COM This current flow activates the LED and is sensed in the DI circuitry which in turn signals the controller electronics that the relay contacts have closed When the contacts open current flow is interrupted and the DI circuit signals the controller electronics that the relay contacts have opened CAUTION The discrete input is designed to operate only with non powered discrete devices such as dry relay contacts or isolated solid state switches Use of the DI channel with powered devices may cause improper operation or damage to occur Rev 9 99 5 5 GB600 Series Instruction Manual DI GRIDBOSS POWERED T Vs DISCRETE DEVICE 3 COM A S 1 B7 10 6 65K Figure 5 3 Discrete Input Wiring 5 5 2 Pulse Inputs Pulse Inputs are not required by the GridBoss System Pulse Inputs PIs are used for counting pulses from pulse generating devices The I O Card pulse input circuits are physically the same as the discrete inputs The pulse input after the isolation is routed to a pulse accumulator where the pulses are counted and accumulated The pulse inputs provided o
162. the batteries serve as backup in case of line power failure When used in solar installations they provide power for the controller when the solar panels are not generating sufficient output The standard battery configurations use a 12 volt sealed lead acid battery These configurations can provide 7 14 21 or 28 amp hour capacities The batteries are connected in parallel to achieve the current capacity The amount of battery capacity required for a particular installation depends upon the power requirements of the equipment and days of reserve autonomy desired 1 24 Rev 9 99 GB600 Series Instruction Manual Recommended 7 amp hour battery types up to four batteries for controller units are listed below If other batteries are used Fisher Controls recommends rechargeable sealed gel cell lead acid batteries Powersonic PS 1270 7 0 Amp Hour e Panasonic LCR12V7 2P 7 2 Amp Hour Yuasa NP7 12 7 0 Amp Hour 1 7 5 1 Determining Battery Requirements Battery requirement calculations are based on power consumption of the controller and all devices that will be powered by the batteries Battery reserve is the amount of time that the batteries can provide power without discharging below 20 percent of their total output capacity A minimum of two days of battery reserve is recommended for a line powered unit For solar powered units a minimum reserve of five days is recommended with ten days of reserve preferred Add 24 hours of r
163. the controller through an optional communications card which is plugged into the Main Electronics Board to provide COM1 Section 4 details the types of communications cards available for the GridBoss controller and how to make wiring connections to each type of card Rev 9 99 2 43 GB600 Series Instruction Manual 2 6 CALIBRATION Analog Input calibration routines support 5 point calibration with the three mid points calibrated in any order The low end or zero reading Set Zero is calibrated first followed by the high end or full scale reading Set Span The three mid points can be calibrated next if desired The diagnostic analog inputs battery voltage AI point number El input voltage AI point number E2 and board temperature AI point number E5 are not designed to be calibrated The inputs that are supported with the 5 point calibration are Inlet Line static pressure located at AI Point Number A1 LPP and DR Outlet Line static pressure located at AI Point Number A2 DR only Temperature located at AI Point Number A3 DR only The calibration procedure for these inputs is described in Section 3 If you have an optional I O card installed then the Analog Inputs supplied by the card can likewise be calibrated using the GRIDLINK Configuration Software NOTE Points represented by A are associated with the main electronics board and Pressure Module Points represented by B are associated
164. thin the monitor Deadband Refer to Figure 2 2 The Kixcel 1 P or servo valve is used to adjust the District Regulator Setpoint Using electronic control signals to switch the electric stepping motor on and off the Kixcel turns the pilot adjusting screw changing the spring compression to increase or decrease the output pressure The Kixcel provides smooth and highly accurate positioning with positive position lock when not in motion 24 Rev 9 99 GB600 Series Instruction Manual To Host To Host X M1 Q 2 re H y a Temperature f LOI GridBoss GridBoss DR LPP Outlet lt gt Input 1 0 Card AL AOorTDO E A Kixcel Pilot ae gt gt A Inlet Outlet Typical gt y gt S Distance SO gt gt District in Miles Low Pressure Point Regulator in System Figure 2 2 GridBoss System Setup NOTE An Analog Output is used to send the Setpoint to the Kixcel An Analog Input may be used to communicate the position of the Kixcel to the GB601 The Al is compared to the AO to ensure that the Kixcel is approximately within the monitor Deadband 2 3 1 1 Load Profiles The control approach requires a Low Pressure Point LPP monitor The algorithm uses data gathered from the LPP to automatically create load profiles at the DR controllers At startup the system operates in a closed loop feedback mode Initially there is a high
165. tor RTD sensor The terminals for the RTD wires are located at the bottom right of the Main Electronics Board and labeled RTD Refer to Figure 2 4 The RTD input is converted through a 16 bit RTD converter chip The District Regulator controller sets the outlet pressure based on the actual ambient temperature and the stored time of day profile During operation the RTD is read once per second The value from the RTD is linearized and then it is sent to processing as Analog Input AI Point Number A3 The AI routine converts this value to engineering units performs calibration corrections and checks alarming The board temperature is monitored by the RTD routine if the temperature has changed by roughly 5 C or 9 F the RTD circuitry is sent a command to recalibrate its reference Refer to Section 2 5 9 RTD Wiring on page 2 39 2 4 7 Real Time Clock The real time clock provides the controller with the time of day month year and day of the week The time chip automatically switches to backup power when the Main Electronics board loses primary input power Backup power for the real time clock is adequate for up to two weeks Rev 9 99 2 25 GB600 Series Instruction Manual 2 4 8 Automatic Self Tests The controller performs the following self tests on a periodic basis Battery low Battery high Software watchdog Hardware watchdog RTD automatic temperature compensation Charging voltage for the super capacitor
166. ts Housing is 316 SST with Poron gasket between Field Wiring Terminals S COM housing and controller enclosure Source Power Voltage is same as battery voltage current is 1 mA max PROCESS CONNECTIONS Range Inactive 0 to 1 4 Vdc active 2 1 Vdc 1 4 18 NPT female on 1 56 inch center located on minimum bottom surface PRESSURE INPUTS ENVIRONMENTAL Up to two pressure sensors selected from the Compensated 0 to 70 C 32 to 158 F ranges in the table below Note that all are gauge Operating 40 to 80 C 4 to 176 F pressure inputs except for the 0 1000 PSI sensor Storage 40 to 80 C 40 to 176 F Pressure Inputs Range Accuracy of Span Proof Pressure Burst Pressure 0 5 PSIG 0 0 35 bar 0 2 20 PSIG 75 PSIG 0 30 PSIG 0 2 069 bar 0 2 90 PSIG 150 PSIG 0 100 PSIG 0 6 895 bar 0 2 300 PSIG 1250 PSIG 0 300 PSIG 0 20 65 bar 0 2 600 PSIG 1250 PSIG 0 500 PSIG 0 34 473 bar 0 2 850 PSIG 1000 PSIG 0 1000 PSIA 0 68 95 bar 0 2 2000 PSIA 3000 PSIA Intrusion Switch Specifications Type SPST normally closed hermetically sealed Weight 1 oz 30 g nominal spring loaded plunger Switch with iwo terminals Approvals Approved by CSA for hazardous locations Maximum Contact Rating Resistive Load 100 mA at Class I Division 2 Groups A B C and D 100 Vdc 2 54 Rev 9 99 GB600 Series Instruction Manual SECTION 3 SENSOR MODULE 3 1 SCOPE This section
167. ure 5 1 the jumper is actually found on the non component side of the board Each channel has a current regulator in series with the T terminal to provide short circuit protection A 250 ohm scaling resistor is supplied for use between the and analog input terminals 5 8 Rev 9 99 GB600 Series Instruction Manual oe 99 The terminal is the positive signal input and the terminal is the signal common These terminals accept a voltage signal in the 1 to 5 volt range Since the terminal is internally connected to common the analog input channels function as single ended inputs only When wiring a 4 to 20 milliamp current signal leave the 250 ohm resistor installed between the and terminals Wire the current loop device lead to the T terminal and the device lead to the AI terminal Figure 5 6 shows the wiring for a typical current signal Al T Current Limit O V GRIDBOSS POWERED CURRENT LOOP DEVICE Aas T 12 24 VDC 22 mA max p SIGNAL 4 TO 20 mA 250 OHM Figure 5 6 Current Signal on I O Card Analog Input When connecting the analog input channel to a voltage device remove the 250 ohm resistor from the analog input terminal block Figure 5 7 shows typical wiring for a voltage signal analog input
168. ure connections which are located on the bottom of the Sensor Module housing Refer to Figure 3 2 The inlet pressure connection is made to the front tap labeled 1 and the outlet pressure connection is made to the rear tap labeled 2 The LPP only uses the front tap Both pressure connections are 14 18 NPT CAUTION Be sure to use a pipe thread compound suitable for stainless steel or galling may occur an Cm IEA 4 n Y imagines Y Ribbon Cable ES Inlet pae ee A Pressure naaa Figure 3 2 Side Cut away View Showing Process Connections Rev 9 99 3 5 GB600 Series Instruction Manual 3 4 WIRING THE SENSOR MODULE Pulse Inputs PI are not used by the GridBoss System but are described in case you desire to use them for an alternative purpose The only field wiring connections to the Sensor Module are for the two pulse input channels Like the standard field wiring the wiring terminals for these inputs are accessed by opening the door of the GridBoss enclosure The terminal designations S and COM are printed on the circui
169. us operation at data baud rates of 1200 and 2400 The card interfaces to a PSTN through an RJ11 jack located at the bottom of the communications card The modem can be controlled using industry standard AT command software A 40 character command line is provided for the AT command set which is compatible with EIA document TR302 2 88 08006 LED indicators on the card show the status of the RXD TXD AA and OH control lines Refer to Table 4 3 The modem card also provides RS 232 level output signals RXD and TXD for an analyzer Rev 9 99 4 7 GB600 Series Instruction Manual 4 8 Table 4 3 Modem Card LED Indicators LEDs STATUS AND ACTIVITY AA The AA is the automatic answer indicator LED light An incoming modem transmission lights this indicator OH The OH is the off hook indicator LED light A dial tone has been detected and the telephone line is in use by your modem when OH is lit RXD The RXD receive data LED blinks when the receive signal is being received from the communications card The LED is on for a space and off for a mark TXD The TXD transmit data LED blinks when transmit signal data is being received from the processor The LED is on for a space and off for a mark Rev 9 99 GB600 Series Instruction Manual 4 4 INITIAL INSTALLATION AND SETUP Communications card installation is normally performed at the factory when the GridBoss controller is ordered However the modu
170. ut signal increases SW7 down for Automatic operation SW8 up to leave the Kixcel position locked in place if the input signal is lost Connect the power supply to the Kixcel Rev 9 99 2 37 GB600 Series Instruction Manual Connect the 4 20 mA signal generator to the Kixcel input Ensure that the wiring is shielded at the source 8 Connect the meter to the 4 20 mA output of Kixcel 10 11 12 13 14 15 16 17 18 19 20 21 Pull Kixcel jumpers pin 1 and pin 2 located at TB2 and set the lower Setpoint potentiometer The signal to the Kixcel is 4 mA Apply a 20 mA signal to the Kixcel count the shaft turns and adjust the upper Setpoint potentiometer for the correct number of turns Apply a 4 mA signal to the Kixcel allow it to travel and then turn off the power Mount the Kixcel to the Pilot regulator Do not move the pressure adjustment on the regulator Connect the pilot to the air supply and monitor the output pressure Apply power to the Kixcel and send a 4 mA signal to the Kixcel Verify that the regulator is providing 0 pressure adjust the lower Setpoint potentiometer if necessary Apply a 20 mA signal to the Kixcel and measure the full scale pressure adjust the high Setpoint potentiometer if necessary Turn off the Kixcel power and reconnect the Kixcel jumpers pin 1 and pin 2 located at TB2 Apply power to the Kixcel and set the end of travel limit potentiometers LS1 and LS2 Thes
171. uts or one of each in either order As PIs the two channels are designated Point Number B11 and Point Number B12 As DIs the two channels are designated Point Number B9 and Point Number B10 The Point Number designation can be seen when using the GRIDLINK configuration software see Figure 5 5 in addition these point numbers appear on a label to the left of the terminals on the I O Card To use a Pulse Input as a Discrete Input 1 2 3 4 5 Ensure the I O Card is installed correctly Refer to Section 5 4 on page 5 3 Attach a PC to the LOI port on the controller and launch GRIDLINK In GRIDLINK Connect to the GridBoss controller Select DI from the I O menu Press F3 Next until you display B9 to use PI 1 as a DI or B10 to use PI 2 as a DI in the Point Number field Refer to Figure 5 5 Type a name in the Tag field and Configure the rest of the Discrete Input as detailed in the GRIDLINK Configuration Software User Manual Wire the channel for the Discrete Input the same as described in Section 5 5 1 NOTE There is no jumper or software switch to set to change a PI into a DI or back again Both software points such as B9 and B11 always exist for the same channel in this case PI 1 Just ensure that the PI or DI point is configured for the channel s intended use Rev 9 99 5 7 GB600 Series Instruction Manual ile eter ala bop nal ne Lilies 1 Tem elp OO iscrele A Au Point Humber 10
172. uts included with the LPP are diagnostic Analog Inputs and include battery voltage AI point number El input voltage AI point number E2 and board temperature AI point number E5 The LPP controller acquires power either from an AC power supply or from solar power 2 3 3 1 Low Pressure Point Alarms Besides standard alarms informing you of high or low alarm limits and the intrusion switch DI alarm alarms that occur automatically include LPP low battery voltage which is checked against the Low Battery Voltage Limit LPP pressure transmitter point fail which checks Point Fail High and Low Limits and checks for Point Fail alarms from the AI alarm code DR communications failure DR failed to reply to LPP communication RBX alarming for LPP low battery and LPP Pressure Point Fail must be set at individual I O points Us the Low and High alarms of the I O alarming for the Low and High pint Fail limits The LPP low battery voltage and LPP pressure transmitter point fail alarms that are sent from the LPP to the DR are not logged to the Alarm Log However these alarms can be sent by the DR to the Host if RBX alarming is enabled Alarms can also be enabled when the appropriate point number is enabled for alarming When enabled the LPP communications failure alarm can be sent to the Alarm Log When an LPP alarm occurs special actions are taken based upon what alarm is generated Refer to Table 2 2 2 14 Rev 9 99 GB600 Ser
173. verwriting configuration audit data 2 3 5 5 Event Log The Event Log contains changes to any parameter within the GridBoss controller made through the protocol The Event Log also contains other controller events such as power cycles cold starts and disk configuration downloads The system Event Log has the capacity to maintain and store up to 240 events in a circular log The Event Log has information fields which include point type parameter number time and date stamp point number if applicable the operator identification and either the previous and current parameter values or a 14 byte detail string in ASCII format In addition to providing functionality for appending new events to the log it allows host packages to request the index of the most recently logged event entry Event Logging is available internally to the system to external host packages and to the FST Event Logs are not stored to flash ROM when the Save Configuration function is issued in the GRIDLINK Configuration Software The Event Log operates in a circular fashion with new entries overwriting the oldest entry when the buffer is full The Event Log provides an audit trail history of past operation and changes The Event Log is stored separately to prevent recurring alarms from overwriting configuration audit data NOTE An event is not logged when the LPP communicates the change in Inner Loop Setpoint and Pressure Rev 9 99 2 19 GB600 Series Instruction
174. with the option I O card Refer to the GRIDLINK Configuration Software User Manual for additional information 2 7 TROUBLESHOOTING AND REPAIR Troubleshooting and repair procedures are designed to help you identify and replace the Main Electronics Board and communications cards Return faulty boards and cards to your Fisher Representative for repair or replacement To troubleshoot communications cards refer to Section 4 The following tools are required for troubleshooting IBM compatible personal computer GRIDLINK Configuration Software Battery powered digital multi meter Fluke 8060A or equivalent The GRIDLINK Configuration Software runs on the personal computer and is required for a majority of the troubleshooting performed on the controller Refer to the GRIDLINK Configuration Software User Manual for additional information 2 44 Rev 9 99 GB600 Series Instruction Manual 2 7 1 Backup Procedure Before Removing Power Use the following backup procedure when removing or adding controller components This procedure preserves the current controller configuration and data held in RAM Before removing power to the controller for repairs troubleshooting or enhancements perform this backup procedure The procedure assumes you are using Version 1 00 or later of the standard GRIDLINK Configuration Software CAUTION There is a possibility of losing the configuration and historical data while performing the following

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