Instruction Manual CI-ControlWaveLP Oct., 2006 Low Power ControlWave Process Automation Controller www.EmersonProcess.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING! Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference. These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance.
WARRANTY A. Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing. B. Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer. C.
How to return material for Repair or Exchange Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Repair Dept. to effectively and efficiently process the repair order. You can easily obtain a RA number by: A. FAX Completing the form (GBU 13.
Bristol Inc. Repair Authorization Form (off-line completion) (Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.) Date___________________ RA #___________________SH_ Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
Bristol Training GET THE MOST FROM YOUR BRISTOL BABCOCK INSTRUMENT OR SYSTEM • Avoid Delays and problems in getting your system on-line • Minimize installation, start-up and maintenance costs. • Make the most effective use of our hardware and software. • Know your system. As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors.
A Few Words About Bristol Inc. For over 100 years, Bristol® has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other software except for ControlWave and OpenEnterprise products, call (860) 945-2286. For technical questions about Network 3000 hardware, call (860) 945-2502. You can e-mail the Application Support Group at: bsupport@bristolbabcock.com The Application Support Group maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.
CI-ControlWaveLP LOW POWER ControlWave PROCESS AUTOMATION CONTROLLER TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - INTRODUCTION 1.1 1.2 1.3 1.3.1 1.3.1.1 1.3.1.2 1.3.1.3 1.3.1.4 1.3.2 1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5 1.3.3 1.3.3.1 GENERAL DESCRIPTION .......................................................................................... 1-1 ControlWave PROGRAMMING ENVIRONMENT ...................................................... 1-2 PHYSICAL DESCRIPTION ..............................
CI-ControlWaveLP LOW POWER ControlWave PROCESS AUTOMATION CONTROLLER TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - INTRODUCTION (Continued) 1.3.3.2 1.3.3.3 1.3.3.4 1.3.4 1.4 FMI/OB Board Connectors........................................................................................ 1-19 FMI/OB Bd. Connector TB1 - Discrete Inputs ..................................................... 1-19 FMI/OB Bd. Connector TB2 - Discrete Outputs...................................................
CI-ControlWaveLP LOW POWER ControlWave PROCESS AUTOMATION CONTROLLER TABLE OF CONTENTS SECTION TITLE PAGE # Section 2 - INSTALLATION (Continued) 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.6.1 2.5 2.5.1 2.5.2 2.5.2.1 2.5.2.2 2.5.2.3 2.5.3 2.5.4 Signal Shielding and Grounding.................................................................................. 2-15 Discrete Inputs ............................................................................................................ 2-15 Discrete Outputs...
CI-ControlWaveLP LOW POWER ControlWave PROCESS AUTOMATION CONTROLLER TABLE OF CONTENTS SECTION TITLE PAGE # Section 4 - SPECIFICATIONS 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.4 4.5 4.5.1 4.5.2 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1 COMMUNICATION PORTS ........................................................................................ 4-4 FMI/OB BOARD INPUT/OUTPUT SPECIFICATIONS..............................................
Section 1 INTRODUCTION 1.1 GENERAL DESCRIPTION ControlWaveLP Remote Terminal Units are comprised of a three board set (CPU Board, Fixed Multifunction Input/Output Board & the Power Supply/Sequencer Board) that have been designed and integrated to provide high performance with low power consumption. The CPU Board employs the Ultra Low Power Intel 486SX microprocessor with core logic support provided by an R400EX System Controller IC.
Figure 1-2 - ControlWaveLP - Top View 1.2 ControlWave PROGRAMMING ENVIRONMENT The ControlWave programming environment uses industry-standard tools and protocols to provide a flexible, adaptable approach for various process control applications in the water treatment, wastewater treatment, and industrial automation business.
The ControlWave programming environment consists of a set of integrated software tools which allow a user to create, test, implement, and download complex control strategies for use with Bristol’s ControlWave Process Automation Controller.
• The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer, allows you to define process I/O modules in the ControlWave and configure the individual mapping of I/O points for digital and analog inputs and outputs. • The Bristol Firmware Library (Bbifsb) which is imported into ControlWave Designer, includes a series of Bristol Babcock specific function blocks.
Figure 1-4 - ControlWaveLP CPU Board Basic CPU components and features are summarized as follows: • 3.
• • • • • Halt system into low power mode Programmable Clock Divider FLASH Controller Integrated real-time clock (with battery backup) Complete set of PC functions 512 Kbytes FLASH BIOS, 29LV040, 8-bit 2 Mbytes SRAM, 3.3V, 512K x 8, 70 nS, soldered down 4 Mbytes FLASH RFA soldered down Five (5) 9-wire PC/AT compatible serial communication ports (COM1 through COM5). COM3 is DIP Switch configurable for RS-232 or RS-485 operation.
The BIOS is contained in a single 512 Kbyte boot-block FLASH IC (FBD). The FBD resides on the ISA bus and operates at 3.3V. It is configured for 8-bit access. Three Switches, SW2A, SW2B and SW2C are used in conjunction with the BIOS (see Section 1.3.1.3). The CPU Board contains provisions for 4MB of 3.3V, industrial temperature FLASH to be soldered onto the CPU card.
CPU Bd. Connectors J10 & J11 - PC/104 Bus (CPU Bd. To FMI/OB Bd.) Connections to the ISA bus are available on the PC/104 bus via CPU/FMI/OB Interface Connectors J10 and J11 (J10 of CPU mates with P7 of FMI/OB and J11 of CPU mates with P10 of FMI/OB) (see Table 4-4). ISA bus signals are provided by the RadiSys R400EX system controller. During non-ISA bus cycles, the R400EX places the ISA bus into a quiet mode to reduce overall power consumption.
Table 1-2 - CPU Board Default Jumper Settings (Continued) JUMPER JP3A - Expansion SRAM Relocation Jumper JP3B - DX4 Clock Multiply Select JP3C - Write Back / Write Thru Cache Select JP4A - ULP Disable Jumper Open ⌦ ⌦ ⌦ ⌦ Installed JP4B - ULP HLDA Jumper ⌦ JP4C - ULP SMIACT Jumper ⌦ Note: The following CPU Board Jumpers are currently unused: JP1A, JP2 & JP3A. CPU Bd. Jumper JP1B - On-board SRAM & RTC Battery Enable/Disable Jumper JP1B provides the on-board SRAM and RTC battery enable/disable function.
CPU Bd. Jumper JP4C - ULP SMIACT (see Table 1-5) Table 1-5 - Jumper JP4C - ULP SMIACT Jumper JP4C Open The SMIACT output from the 80486-ULP is isolated from the $CPU. ~SMIACT signal, allowing the DX4 socket to drive SMIACT. ULP SMIACT Jumper Installed ULP drives the $CPU.~SMIACT signal. Do not populate the DX4 socket. 1.3.1.3 CPU Board Switches The CPU Board contains three 8-bit DIP switches; SW1 is used to configure Comm.
CPU Bd. Momentary Switch SW3 - CPU Reset SW3 is a momentary switch that is used to reset the ControlWaveLP if it goes into a watchdog condition. CPU Bd. DIP Switch SW4 Eight-bit DIP Switch SW4 is provided for user configuration settings (see Table 1-8). Table 1-8 - Assignment of CPU Bd.
The power supply operates from 10.0 to 20V or 20.7 to 30V (dc). The nominal settings for the 12V supply are ON state above 10.45V, and OFF state below 10.0V. The nominal settings for the 24V supply are ON state above 22V, and OFF state below 20.7V. A power MOSFET is utilized to switch the input power to the power supply circuitry. A mechanical switch (SW1) will drive the gate of the MOSFET.
located on the isolated secondary side of the power transformer. The low level detection circuitry on the secondary side of the power supply monitors the +5V, +12V and -12V dc supplies. MC* and PFIN* are generated by the sequencer and drive the two optocouplers. These signals (MC* & PFIN*) are buffered on the secondary side and drive the Status LEDs located on the FMI/OB Board.
1.3.2.1 PSSB Switches SPDT Switch SW1 is used to connect the MOSFET power switch gate to PSGND when the ‘I’ side of the switch has been pressed to its actuated position. 1.3.2.2 PSSB Board Jumpers The PSSB Board contains the following Jumpers (situated on the bottom of the PCB): JP1 - Watchdog Relay JP2 - -12V JP3 - +12V JP4 - 50mA Load JP5 - +12V Seq. Monitor JP6 - -12V Seq.
1.3.3 The Fixed Multifunction Input/Output Board (see Figure 1-2) The Fixed Multifunction Input/Output Board (FMI/OB) is a multilayer board that measures approximately 8.5” wide by 11” long. FMI/OBs contain a PC/104 interface, four I/O modules, electrical isolation to field devices, surge suppression, pluggable terminations, and status LEDs for Discrete I/O, CPU, and communication functions.
full load). Output current is rated at 200mA maximum. Supply shutdown is Jumper selectable. The total power consumption (from 5Vdc) for the FMI/OB Board is 300mW maximum. 1.3.3.1 FMI/OB Board Fixed I/O Subsystem The FMI/OB Board contains the 4 fixed I/O subsystems. These are discussed below. FMI/OB Bd. Discrete Inputs Discrete Inputs feature optical isolation and surge suppression, the input range is 12 or 24 VAC or VDC ±10%. 1 millisecond or 30 millisecond DI filtering is offered and is factory configured.
There are 8 LEDs (CR49 - CR56), located adjacent to the DO Terminal Block (TB2). These LEDs (which can be disabled by a jumper) indicate the status of the logic state of the Discrete Outputs. DO Operation Summary Number of Points: Output Type: Max. Operating Voltage: Max.
Powered Current Loop Common Mode Range: Input Filtering: Channel Settling Time: Conversion Time: On board References: Surge Suppression: Terminations: Bus Access: 0V referenced to isolated common. When a field supply common is connected to the AI system the isolated common is connected to the field supply common. 300 milliseconds to 99.
Terminations: Status Indication: Meets ANSI/IEEE C37.90-1978 Pluggable (TB4), maximum wire size is 16 gauge 4 LEDs (one per point) (DS95 - DS98 1.3.3.2 FMI/OB Board Connectors The FMI/OB Board contains seventeen (17) connectors that function as follows (see Table 19): Table 1-9 - FMI/OB Board Connector Summary Ref.
FMI/OB Bd. Connectors TB5 - TB8 PC/104 I/O & P3 - P6 I/O Expansion Interface FMI/OB Cable Connectors P3, P4, P5 and P6 are provided to interface a PC/104 Expansion Board to Expansion I/O Terminal Blocks TB5 through TB8 respectively. Ribbon Cable(s) will be used to interconnect a PC\104 Expansion Board to P3, P4, P5 & P6. FMI/OB Bd.
Table 1-10 - FMI/OB Board Jumper Assignment (Continued) Jumper W20B W21A W21B W22A W22B W23A W23B W24A W24B W25A W25B W26A W26B W27A W27B W28 W29 W30 W31 W32 W33 W34 W35 W36 W37 W38 W39 W40 W41 JP2 JP3 JP4 JP5 Function Config. AI1 Config. AI2 Config. AI2 Config. AI3 Config. AI3 Config. AI4 Config. AI4 Config. AI5 Config. AI5 Config. AI6 Config. AI6 Config. AI7 Config. AI7 Config. AI8 Config. AI8 Power Power Status LEDs Comm. LEDs Config. HSC1 Config. HSC1 Config. HSC2 Config. HSC2 Config. HSC3 Config.
Table 1-11 - FMI/OB Board LED Assignment (Continued) Name CR43 CR44 CR45 CR46 CR47 CR48 CR49 CR50 CR51 CR52 CR53 CR54 Function DI10 DI11 DI12 DI13 DI14 DI15 DO8 DO1 DO2 DO3 DO7 DO6 Name CR114 CR115 CR116 CR117 CR118 CR120 CR121 CR122 CR134 CR135 CR136 - Function STATUS 2 STATUS 3 STATUS 4 STATUS 5 COM2_RX/COM2_TX COM3_RX/COM3_TX COM4_RX/COM4_TX COM5_RX/COM5_TX MCLED* PFINLED* COM1_RX/COM1_TX - 1.3.4 ControlWaveLP Mounting Plate ControlWaveLP mounting Plates are manufactured from .
Section 2 INSTALLATION 2.1 INSTALLATION IN HAZARDOUS AREAS The ControlWaveLP is not furnished in an enclosure. The three PCBs which comprise the system are assembled and mounted to an aluminum plate, which in turn, is ready for user supplied backplate mounting. Use in hazardous areas will require the selection of an appropriate enclosure that meets the NEMA Type 3X or 4X specification.
Figure 2-2 - ControlWaveLP Dimensions - Front View & Left Edge View 2.2 ControlWaveLP SITE CONSIDERATIONS Check all clearances when choosing an installation site. Make sure that the ControlWaveLP is accessible for wiring and service. Make sure that the LCD Display Panel and Keyboard (if present) are accessible to the on-site operator. The unit’s Mounting Plate measures 8.5” in width by 12.5” in length by .562” in height (see Figures 2-1 & 2-2).
- The rear of the ControlWaveLP’s Mounting Plate must mount to the selected enclosure’s backplate. - The unit must be positioned so that the front of the assembly (exposed side of MFI/OB Board) is visible and the unit is accessible for service, i.e., installation of an option or replacement of the RAM Battery, Fuse or a PCB. 2.2.1 Temperature & Humidity Limits The ControlWaveLP is designed to operate over a -40 to +158 °F (-40 to +70 °C) temperature range and a 0% to 95% Relative Humidity range.
Figure 2-3 - ControlWaveLP Grounding Diagram 2.3 ControlWaveLP INSTALLATION/CONIGURATION 2.3.1 Overview of Configuration An overview of the seven (7) steps required to configure a ControlWave Process Automation Controller are provided below. Step 1. Hardware Configuration This involves unpacking the ControlWaveLP, mounting the unit, wiring I/O terminations, making proper ground connections, connecting a communication cable to the PC workstation and setting switches.
9. Apply power to the ControlWaveLP by setting the Power Switch on the PSSB Board to the ‘I’ position. With the ControlWaveLP connected to a PC via an RS-232 Null Modem Cable (see Figure 2-8) download the configured application load (see Section 2.4.1). 10. After receiving the Application Load, the ControlWaveLP Process Automation Controller is ready for on line operation. Step 2.
After this initial configuration is completed, any subsequent changes to these parameters may be made in configuration web pages (see Chapter 4 of the Open BSI Technician’s Toolkit Manual document # D5087). Step 4. Create an Application-Specific Control Strategy in ControlWave Designer At this point, you can create your application-specific control strategy using ControlWave Designer.
Optionally, additional user-created web pages may be created to allow a customized human-machine interface. A series of ActiveX controls for data collection and configuration are provided on the Open BSI 2000 CD which can be included as part of these user-created web pages. For information on the ActiveX controls, see the Web_BSI Manual (document # D5087).
Table 2-1 - FMI/OB Board Jumper Assignment Jumper W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17 W18 W20A W20B W21A W21B W22A W22B W23A W23B W24A W24B W25A W25B W26A W26B W27A W27B W28 W29 W30 W31 W32 W33 W34 W35 W36 W37 W38 W39 W40 W41 JP2 JP3 JP4 JP5 Function Config. DI1 Config. DI2 Config. DI3 Config. DI4 Config. DI5 Config. DI6 Config. DI7 Config. DI8 Config. DI9 Config. DI10 Config. DI11 Config. DI12 Config. DI13 Config. DI14 Config. DI15 Config. DI16 DI LEDs DO LEDs Config. AI1 Config.
2.3.3 CPU Module Switch Configuration ControlWaveLP CPU Board DIP Switches must be set for the desired performance options. Tables 2-2 and 2-3 provide an overview of switch settings. Table 2-2 - CPU Bd.
Table 2-3 - CPU Bd. Switch SW2 Soft Switch, FLASH Write & Force Recovery Settings SWITCH SW2-A SW2-B Function Not Used Not Used SW2-C Force Recovery Control SW2-D FLASH Download Control Setting - (ON = Factory Default) N/A N/A ON = Force recovery mode (via CW Console) OFF = Recovery mode disabled ON = FLASH Download enabled OFF = FLASH Download disabled 2.3.
An illustration of the CPU Module’s male 9-pin D-type connectors is provided in Figure 2-4. Table 2-4 provides the connector pin assignments for ports 1 through 5.
Figure 2-4 - Male DB9 9-Pin Connector Associated with COM1 through COM5 Figure 2-5 - Communication Port RS-232 Cable Wiring Diagrams 2-12 / Installation CI-ControlWaveLP
Table 2-6 - CPU Bd. COM3 Port Configuration Switch SW1 Settings Switch SW1 Function SW1-1 SW1-2 Not used RS-232/485 Select SW1-3 TXD to RXD Loop-back SW1-4 TXD to RXD Loop-back SW1-5 SW1-6 RS-485 termination RS-485 termination SW1-7 /RTS to /CTS Loop-back SW1-8 /RTS to /CTS Loop-back Setting N/A ON = RS-232, OFF = RS-485 ON = Loop-back enabled OFF = Loop-back disabled ON = Loop-back enabled OFF = Loop-back disabled ON = Term., OFF = No Term. ON = Term., OFF = No Term.
Figure 2-7 - Point-to-Point 10Base-T Ethernet Cable The maximum length of one segment (CPU to Hub) is 100 meters (328 feet). The use of Category 5 shielded cable is recommended.
2.4 WIRING NOTES 4 Field Wiring Terminals are located on the FMI/OB Board (see Figure 2-1). Terminal Connections The ControlWaveLP uses compression-type terminals that accommodate up to #16 AWG wire. A connection is made by inserting the wire’s bared end into the clamp beneath the screw and securing the screw. The wire should be inserted fully so that no bare wires are exposed to cause shorts. If using standard wire, tin the bare end with solder to prevent flattening and improve conductivity.
Figure 2-9 - Discrete Input Terminal Block TB1 - LEDs & Configuration Jumpers Figure 2-10 - Discrete Input Wired for Isolated DI Operation Figure 2-11 - Discrete Input Wired for Dry Contact Operation 2-16 / Installation CI-ControlWaveLP
2.4.2 Discrete Outputs (see Figures 2-12 & 2-13) A total of 8 Discrete Outputs (DOs) with surge protection are provided for control or signaling functions. Each DO utilizes a Solid State Relay that is capable of switching up to 35 volts at up to 100mA. 38V MOVs are provided to protect each DO. Field connections for DO1 through DO8 are located at TB2 (see Table 2-9).
2.4.3 Analog Inputs (see Figures 2-14 through 2-17) The Analog Input module of the FMI/OB Board is designed to support eight (8) 1-5V or 420mA isolated inputs or 4-20mA loops powered from a field source. An isolated DC/DC converter powers the ADC, instrumentation amplifier and multiplexers. Optocouplers are used for the control circuitry. Figure 2-14 - Analog Input Terminal Block TB3 - & Configuration Jumpers The common mode range for the Analog Inputs is 38VDC.
Figure 2-15 - Analog Input (Isolated Voltage Source) Field Wiring (AI1 Shown) Figure 2-16 - Analog In (Isolated Current Source) Field Wiring (AI1 Shown) Table 2-10 - Analog Input Terminal Block TB3 Pin Assignments Block Label AI-B AI-A AI-B AI-A AI-B AI-A AI-B AI-A CI-ControlWaveLP Pin # (Label) 1 (1) 2 (1) 3 (S) 4 (S) 5 (2) 6 (2) 7 (3) 8 (3) Name AI1AI1+ Shield Shield AI2AI2+ AI3AI3+ Pin # (Label) 9 (S) 10 (S) 11 (4) 12 (4) 13 (5) 14 (5) 15 (S) 16 (S) Name Shield Shield AI4AI4+ AI5AI5+ Shield Shield
Figure 2-17 - Analog Input (Internal Current Source) Field Wiring (AI1 Shown) 2.4.4 High Speed Counter Inputs (see Figures 2-18 through 2-22) Figure 2-18 - HSC Input Terminal Block TB4 - LEDs & Configuration Jumpers The high speed counter circuitry consists of signal conditioning circuitry, 16 bit accumulators, and control circuitry. The signal condition circuitry includes optocouplers, debounce circuitry and bandwidth limit circuitry.
required to accumulate counts. The maximum input frequency is 10 kHz. The nominal input current for an input is 1 mA.
Figure 2-20 - Isolated HSCSET & HSCRESET Inputs (Debounce Enabled Field Wiring Figure 2-21 - Field Powered HSC (Open Collector Using Set Input) (Debounce Disabled) Field Wiring 2-22 / Installation CI-ControlWaveLP
Figure 2-22 - Isolated HSC (Using SET Input) (Debounce Disabled) Field Wiring 2.4.5 Watchdog Relay/MOSFET Switch Circuitry (see Figs. 2-23 & 2-24) Figure 2-23 - Watchdog Relay Field Wiring The Watchdog Relay (K1) or Watchdog MOSFET Switch (Q6) circuits on the Power Supply Sequencer Board (PSSB) can be used to drive an alarm, annunciation or control device. The Watchdog Relay or Watchdog MOSFET Switch will be off when the signals Master Clear (MC) or Watchdog B (WDOGB) are active.
Figure 2-24 - Watchdog MOSFET Switch Field Wiring 2.4.6 DC Power Configuration & Wiring The ControlWaveLP requires a DC power source within the range of +10.6 to +30 V. A DC to DC Converter on the Power Supply Sequencer Board (PSSB) generates isolated +5VDC, +12VDC & -12VDC. A sequencer circuit monitors the external supply and the +5V, +12V and -12V supplies, and an analog to digital converter (ADC) measures the external voltage. The power supply operates from 10.6 to 30 VDC.
2.4.6.1 Bulk Power Supply Current Requirements Maximum current requirements for a bulk +12Vdc or bulk +24Vdc power supply used to power a ControlWaveLP RTU can be determined by use of Table 2-13 or 2-14 respectively. These tables provide detailed steady state and loop power current requirements. Table 2-13 - Power Requirements for Bulk 12Vdc Power Supply COMPONENTS Base CWLP Unit Base CWLP Unit Base CWLP Unit Base CWLP Unit DIs DOs AIs(4-20mA) AIs(1-5V) HSCs PC/104 AO Mod. (4-20mA) PC/104 AO Mod.
Operational details on ControlWaveLP LEDs and use of the BBI WinDiag program for fault isolation are provided in Chapter 3. 2.5.1 Downloading The Application Load A ControlWaveLP RTU must receive its configured application load before it can be placed into operation. This will require connection of the ControlWaveLP unit to a PC running Windows NT (4.0 or higher), Windows 2000 or Windows XP Professional and equipped with ControlWave Designer software & OpenBSI software.
2.5.2.1 Using LocalView to Upgrade ControlWaveLP Firmware NOTE Your ControlWaveLP must be set to Recovery Mode ENABLE (ON) prior to performing the FLASH upgrade, then set to Recovery Mode DISABLE (OFF) after the upgrade. On the ControlWaveLP this is accomplished via CPU Switch SW2-C. Also set CPU Switch SW4-3 (OFF) to ignore soft switch configuration and use factory defaults; set SW4-3 (ON) after the upgrade.
"Would you like to use auto baud rate detection?" / "What baud rate would you like to use?" If you know which baud rate to use, answer no for auto baud detection, and specify the baud rate. If you do not know which baud rate to use, choose auto baud detection. [Advanced Parameters] See the ‘Advanced Communication Parameters Dialog Box’ section, later in this chapter for details on this.
Step 3 - Flash Data Setup Complete the fields in the Flash Data Setup Wizard (see Figure 2-28), as described, below: "Please enter the name of the binary file to Flash" To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file on your hard disk containing the firmware. Normally, the contents of the various available BIN files are described in a Flash Master File (see box at bottom of the dialog box).
"Location of Flash Master File" Specifies the location of the Flash Master File (FLASH.MST). The contents of the FLASH Master File will be displayed in the box at the bottom of the dialog box, and may be used to select binary files for FLASH downloading. (See above). If necessary, you can use the [Browse] push button to locate the FLASH Master File. Click on [Finish] to install the specified BIN file in FLASH memory at the RTU.
Figure 2-30 - Local View Advanced Communication Parameters Menu "Would you like to use RTS/CTS signals?" If your communication line uses Ready to Send (RTS) / Clear to Send (CTS) signals (not to be confused with ControlWave variables used for this purpose), click on 'Yes'. "Front Pad", "Back Pad" These fields specify the number of null characters to insert at the beginning (front) or ending (back) of a message.
A status of the POST progress is displayed on the FMI/OB Status LEDs. Unless there is a problem these codes will scroll at a fast rate and won’t be discernable. Successful completion is indicated by a binary value of 86 on the Status LEDs and with the cold start menu being displayed on the PC’s screen. Detection of a fault will be indicated by a binary code on the Status LEDs. Refer to Section 3.4.4 for POST Status Code definition.
Once the ControlWaveLP is running its application load, status codes posted to the FMI/OB Status LEDs have a different meaning than the Port 80 POST Status Codes (see Section 3.4.4 for POST Status Codes). The PORT 80 Running Status (Hex) Codes are listed in Table 2-15.
Figure 2-34 - HyperTerminal FLASH Download (Download in Process) Table 2-15 - PORT 80 - Running Status Codes Status LEDs Definition Notes 1 2 3 4 5 6 0 0 0 0 0 0 No application 0 0 0 0 0 1 Application Loaded 0 1 0 1 0 0 Currently Loading the Boot Project 1 1 0 1 0 0 System Initialization in Progress 0 0 0 1 0 1 Application Loaded -with BPT Break Point(s) Set 0 0 0 0 1 1 Application Running Display Blank 0 0 0 1 1 1 Running with BPT Break Point in Debug 0 1 1 0 0 0 Recovery Mode * SW2-C = ON 1 0 0 1 0 0 Batt
remote download of system firmware is discussed in Appendix J of the Open BSI Utilities Manual (document D5081). Note: Remote upgrade of ControlWaveLP Firmware requires Boot PROM version 4.7 or higher and System PROM version 4.7 or higher. 2.5.3 Operation of The Reset Switch The CPU Module’s Reset Switch is a momentary button that allows the operator to stop and restart the unit during maintenance routines as required. 2.5.
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Section 3 SERVICE 3.1 SERVICE INTRODUCTION This section provides general, diagnostic and test information for the ControlWaveLP Process Application Controller. The service procedures described herein will require the following equipment: 1. PC with null modem interface cable (see Figure 2-5A) 2. Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 3-12) 3.
Caution PC board components can be damaged by electrostatic discharges (ESD) during disassembly/reassembly and test procedures. Use grounded wrist straps and surface pads when working near or handling circuit boards. See attached instruction supplement S14006 for proper grounding and handling techniques. 3.1.2 Removal/Replacement of the PSSB Board 1. Place any critical control processes under manual control and shut down the ControlWaveLP. 2.
Figure 3-2 - ControlWaveLP - Top View CI-ControlWaveLP Service / 3-3
Figure 3-3 - Left Side View of ControlWaveLP 3.1.3 Removal/Replacement of the CPU Board and Lithium Battery 1. Perform steps 1 through 3 of section 3.1.2 (see Figures 3-1 & 3-2). 2. Remove the pluggable I/O Terminal Blocks from the FMI/OB’s card edge connectors. 3. Remove the four screws (A) (corners of FMI/OB) and the two screws (B) (near the center of the FMI/OB) that secure the FMI/OB Board to the Mounting Panel (see Figures 3-1, 3-2 and 3-3).
5. Carefully disconnect the CPU Board from the FMI/OB Board. 6. Loosen the two screws (C) that secure the PSSB Board to the FMI/OB (see Figures 3-1 & 3-2). 7. Carefully disconnect the PSSB Board (Connector P1) from FMI/OB Board (Connector P9). 8. To replace the FMI/OB Board follow steps 1 through 7 in reverse order, replacing rather than removing the item in question. 3.1.5 Analog Input Circuitry Calibration Full calibration requires the use of the WINDIAG program (see D4041A).
3.2 TROUBLESHOOTING TIPS 3.2.1 Power Supply/Sequencer Board (PSSB) Voltage Checks Bulk power (+10.6 to +30 Vdc) is supplied to PSSB board connector TB2 (TB2-1 = +Bulk value & TB2-2 = Ground). The PSSB Board provides +5V (VCC), -12V and +12V to the system via PSSB Board connector P1 (FMI/OB Board Connector P9). Figure 3-5 provides the measurement locations to test Bulk, VCC and system voltages. Check the supplies on the PSSB Board as follows: • • • • +5V (VCC Supply) - measure at TP6 (GND) & TP3 (+5V) = +4.
Table 3-1 - FMI/OB Board LED Assignment (Continued) Name Function CR40 CR41 CR42 CR43 CR44 CR45 CR46 CR47 CR48 CR49 CR50 CR51 CR52 CR53 CR54 DI8 DI16 DI9 DI10 DI11 DI12 DI13 DI14 DI15 DO8 DO1 DO2 DO3 DO7 DO6 On Operation Data High Data High Data High Data High Data High Data High Data High Data High Data High Data High Data High Data High Data High Data High Data High Name Function CR111 CR112 CR113 CR114 CR115 CR116 CR117 CR118 CR120 CR121 CR122 CR134 CR135 CR136 - IDLE WDOG STATUS 1 STATUS 2 STATU
Figure 3-7 - Discrete Output (DO) LED Assignments Figure 3-8 - High Speed Counter Input (HSC) LED Assignments 3-8 / Service ControlWaveLP
Figure 3-9 - FMI/OB Board Misc. Operation & Status LED Assignments 3.2.3 Wiring/Signal Checks Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check wiring for continuity, shorts & opens. Check I/O signals at their respective Terminal Blocks (see Table 3-2). Table 3-2 - Field I/O Wiring - Terminal Block Reference List I/O Subsystem Discrete Inputs Discrete Outputs Analog Inputs HSC Inputs Watchdog Ckt.
3.3 GENERAL NOTES Certain questions or situations frequently arise when servicing the BBI Controllers. Some items of interest are provided in Sections 3.3.1 through 3.3.3. 3.3.1 Extent of Field Repairs Field repairs to ControlWaveLP units are strictly limited to the replacement of complete PC boards and assemblies. Any repairs made down to the component replacement level will violate the warranty. Defective PC boards or assemblies must be returned to Bristol Babcock for authorized service. 3.3.
Table 3-3 - POST Status Codes (Continued) Hex Code 0A 0B 0C 0D 0E 0F 10 11 12 13 14 15 16 17 18 19 1A 1B 1C 20 21 22 23 24 25 26 27 28 29 2A 2B 2C 2D 2E 2F 30 31 32 33 34 35 36 37 38 39 3A 40 41 42 43 44 CI-ControlWaveLP Status LEDs 1 2 3 4 5 6 0 1 0 1 0 0 1 1 0 1 0 0 0 0 1 1 0 0 1 0 1 1 0 0 0 1 1 1 0 0 1 1 1 1 0 0 0 0 0 0 1 0 1 0 0 0 1 0 0 1 0 0 1 0 1 1 0 0 1 0 0 0 1 0 1 0 1 0 1 0 1 0 0 1 1 0 1 0 1 1 1 0 1 0 0 0 0 1 1 0 1 0 0 1 1 0 0 1 0 1 1 0 1 1 0 1 1 0 0 0 1 1 1 0 0 0 0 0 0 1 1 0 0 0 0 1 0 1 0 0 0 1 1
Table 3-3 - POST Status Codes (Continued) Hex Code 45 46 47 48 49 4A 4B 4C 4D 4E 4F 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 80 81 82 83 84 85 86 87 88 89 8A 8B 8C 8D 8E 8F 90 91 92 93 94 95 3-12 / Service Status LEDs 1 2 3 4 5 6 1 0 1 0 0 0 0 1 1 0 0 0 1 1 1 0 0 0 0 0 0 1 0 0 1 0 0 1 0 0 0 1 0 1 0 0 1 1 0 1 0 0 0 0 1 1 0 0 1 0 1 1 0 0 0 1 1 1 0 0 1 1 1 1 0 0 0 0 0 0 1 0 1 0 0 0 1 0 0 1 0 0 1 0 1 1 0 0 1 0 0 0 1 0 1 0 1 0 1 0 1 0 0 1 1 0 1 0 1 1 1 0 1 0 0 0 0 1 1 0 1 0 0 1 1 0 0 0 0 0 0 1 1 0
Table 3-3 - POST Status Codes (Continued) Hex Code 96 97 98 99 9A 9B 9C 9D 9E 9F A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 B0 B1 B2 B3 Status LEDs 1 2 3 4 5 6 0 1 1 0 1 0 1 1 1 0 1 0 0 0 0 1 1 0 1 0 0 1 1 0 0 1 0 1 1 0 1 1 0 1 1 0 0 0 1 1 1 0 1 0 1 1 1 0 0 1 1 1 1 0 1 1 1 1 1 0 0 0 0 0 0 1 1 0 0 0 0 1 0 1 0 0 0 1 1 1 0 0 0 1 0 0 1 0 0 1 1 0 1 0 0 1 0 1 1 0 0 1 1 1 1 0 0 1 0 0 0 1 0 1 1 0 0 1 0 1 0 0 0 0 1 1 1 0 0 0 1 1 0 1 0 0 1 1 1 1 0 0 1 1 Definition initialization before calling C800h.
This will prevent the boot project from running and places the unit into diagnostic mode. To test COM1 using the WINDIAG program, it must not otherwise be in use and CPU Switch SW4-8 must be set OFF. Connection to a PC requires the use of an RS-232 “Null Modem” cable (see Figure 2-5). COM2: From the factory, COM2 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
6. Set the ControlWaveLP CPU Switch SW4-8 to the ON position. Restart the ControlWaveLP to resume normal operation. Figure 3-10 - Netview Startup Menu - Example with Multiple Networks 3.4.1 Diagnostics Using WINDIAG All printed circuit boards except the Power Supply/Sequencer Board can be tested using the WINDIAG program.
Figure 3-11 - Partial View of WINDIAG Main Diagnostics Menu 3.4.1.1 Communications Diagnostic Port Loop-back Test WINDIAG’s Communications Diagnostic Menu (see Figure 3-13) provides for selection of the communication port to be tested (1 through 5). Depending on the type of network (RS232 or RS-485) and the port in question, a special loop-back plug is required as follows: Ports 1, 2, 4, & 5 use the 9-pin female D-type (RS-232) loop-back plug.
noted that the ControlWaveLP communication port that is connected to the PC (RS-232, or RS-485) must be good for WINDIAG to run the Communications Diagnostics.
3.4.1.2 COM 1, 2, 3, 4 & 5 External Loop-back Test Procedure 1. Connect an external loop-back plug to the CPU Port to be tested, i.e., J1 for Port 1, J2 for Port 2, J3 Port 3, or J4 for Port 4 and J5 for Port 5 (see Figures 3-12 and 3-13). 2. Type "1," "2," "3," "4" or "5" for the port to test. 3. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5. 4. Click on RUN button next to External loop-back.
Figure 3-15 - WINDIAG’s Ethernet Diagnostic Menu 3.4.1.3.1 Ethernet Port Loop-back Out Twisted Pair Test Procedure This test configures the Ethernet to transmit and receive via the twisted pair port. Test frames are transmitted and compared against received frames. 1.
4. When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jackplug and reconnect the Ethernet cable to both the ControlWaveLP port in question and the Ethernet Hub. 3.4.1.3.2 Ethernet Port Return Hardware Address Test Procedure 1. Set the ‘Number of Passes’ to “5” and type "1" for the ‘Ethernet Port to Test.’ 2. Click on the "RUN Return hardware address” test button.
Section 4 SPECIFICATIONS 4.1 CPU, MEMORY & PROGRAM INTERFACE Processor: 486SX-ULP, 25MHz Memory: 4Mbytes of system FLASH 2Mbtyes of on-board static RAM 512Kbytes Boot-Block FLASH BIOS. Real Time Clock: 14818A-compatible RTC and alarm with 114 bytes of battery-backed CMOS memory. Connectors: (see Table 4-1 and referenced Tables) Table 1-1 - CPU Board Connector Summary Ref.
Table 4-2 - Connectors J1 - J5 Pin Assignment Pin Signal Signal Description : Description: # RS-232 RS-485 RS-232 signals RS485 signals 1 DCD CTS+ Data Carrier Detect (Input) Clear to Send + Input 2 RXD RXDReceive Data (Input) Receive Data - Input 3 TXD TXDTransmit Data (Output) Transmit Data - Output 4 DTR TXD+ Data Terminal Ready (Output) Transmit Data + Output 5 GND GND Signal/Power Ground Signal/Power Ground 6 DSR RXD+ Data Set Ready (Input) Receive Data + Input 7 RTS RTSRequest to Send (Output) Request
Table 4-3 - Connector J9 - Memory Expansion Pin Assignment (Continued) PIN 32 33 34 35 SIGNAL GND ~WRLD ~WRHI ~ADSB DESCRIPTION Power Write Low Byte Write High Byte Address Strobe PIN 67 68 69 70 SIGNAL VCC VCC GND GND DESCRIPTION Power Power Power Power Figure 4-3 - PC/104 Connectors J10 & J11 (CPU Bd. To FMI/OB Bd. Interface) Table 4-4 - Connectors J10 & J11 (CPU to FMI/OB Interface) Pin Assignment J10 34x2, 0.100” (2.
Figure 4-4 Connectors J12 & J24 - PLD JTAG Headers Connector J13 - CPU JTAG Header Connectors J14 & J17 - Manufacturing Test Figure 4-5 - Connector J15 - Port 80 Table 4-5 - Connector J15 - Port 80 Pin Assignment Pin # 1 2 3 4 Signal VCC D0 D1 D2 Pin # 5 6 7 8 Signal D3 D4 D5 D6 Pin # 9 10 11 12 Signal D7 PWRGOOD IOW80# ATB.IOW# Pin # 13 14 - Signal GND N/C - 4.2 COMMUNICATION PORTS Compatibility: PS/2 (Asynchronous) Network Port: Port 1, 2.
4.3 FMI/OB BOARD INPUT/OUTPUT SPECIFICATIONS Table 4-6 - FMI/OB Board Connector Summary Ref.
Table 4-7 - FMI/OB Board - PC/104 Connector P1 Pin Assignment (Continued) Odd Row Pin # 55 57 59 61 63 J1/P1 Signal Name SA3 SA2 SA1 SA0 PCOM Even Row Pin # 56 58 60 62 64 J1/P1 Signal Name BALE VCC OSC PCOM PCOM Table 4-8 - FMI/OB Board - PC/104 Connector P2 Pin Assignment Odd Row Pin # 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 J2/P2 Signal Name PCOM SBHE* LA23 LA22 LA21 LA20 LA19 LA18 LA17 MEMR* MEMW* SD8 SD9 SD10 SD11 SD12 SD13 SD14 SD15 (KEY)2 Even Row Pin # 2 4 6 8 10 12 14 16 18 20
Table 4-9 - PSSB Connector J1 - FMI/OB Connector P9 Pin Identification (see Section 2.4.6) Pin # 1 3 5 7 9 11 13 15 17 19 J1/P9 Pin Name CHASSIS +5V (VCC) /BATADCCE +12V +5V (VCC) /PFIN /PFINLED /WDOGB GND PSGND Pin # 2 4 6 8 10 12 14 16 18 20 J1/P9 Pin Name GND /EXTBAT_DOUT /BATADCCLK -12V /MC /MCLED GND VCC GND +VIN 4.3.
4.3.2 Discrete Inputs Number of Inputs: 16 Input Voltage Range: 12V or 24V Input Filtering: 1 millisecond or 30 milliseconds Input Configuration: Contact Closure, externally sourced on a point by point basis - Jumper configurable Input Current: 2.
Status Indication: 8 LEDs (one per point) (CR49 - CR56) Bus Access: 16 Bits Wide Maximum Load: 100mAdc @ 35Vdc 4.3.4 High Speed Counter Number of Inputs: 4 Input Voltage Range: 12V or 24V Input Frequency: 10KHz Max. Input filtering: 20 microseconds Input configuration: Set/Reset inputs, contact closure, externally sourced on point by point basis with jumper configuration. Input current: 2.
RFI Susceptibility: In conformity with the following standards: ENV 50140 Radio-frequency electromagnetic field, Amplitude modulated ENV 50204 Radio-frequency electromagnetic field, Pulse modulated 4.5 POWER & SPECIFICATIONS 4.5.1 Input Power Specs. Operating Range: 10.0V to 30.0V (dc) (Shutdown occurs at 10.0V nominal) Output Voltages: Isolated +5V, +12V & -12V (dc) Output Current: +5V @ 1A (Max.) +12V @ 200mA (Max.) -12V @ 200mA (MaX.
Table 4-10 - PSSB Connectors TB1 & TB2 Pin Assignments (see Sections 2.4.5 & 2.4.6) Connector TB1-1 TB1-2 TB1-3 TB2-1 TB2-2 TB2-3 CI-ControlWaveLP Sig. Name WDNO WDSWITCHOUT WDCOM WDSWITCHIN WDNC V+ V- Description Watchdog Normally Open Watchdog Voltage Out Watchdog Common Watchdog Voltage In Watchdog Normally Closed +Vdc Input Power Supply Ground Chassis Ground Notes WD Relay Pwr. MOSFET WD Relay Pwr. MOSFET WD Relay + 10.
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Instruction Manual CI-ControlWaveLP Oct., 2006 ControlWave LP Low Power ControlWave PC/104 ANALOG OUTPUT MODULE Appendix 1 www.EmersonProcess.
Appendix 1 PC-104 ANALOG OUTPUT MODULE OPTION TABLE OF CONTENTS TITLE PAGE # DESCRIPTION............................................................................................................................................. 1 INSTALLING THE PC/104 AO MODULE OPTION................................................................................. 2 Installing a PC/104 AO Module ...................................................................................................................
PC/104 ANALOG OUTPUT MODULE OPTION DESCRIPTION PC/104 Analog Output (AO) Modules provide 4 Analog Output channels that can be independently configured for 1-5V or 4-20mA operation. Analog outputs are electrically isolated from the CPU power system. The PC/104 Analog Output Board measures 3.775” x 3.550” and is provided with a ribbon cable which provides AO interconnection between AO Board connector P3 and one of four FMI/OB Board connectors (P3, P4, P5 or P6).
INSTALLING THE PC/104 AO MODULE OPTION The first PC/104 AO Module is to be mounted directly above the FMI/OB Board as illustrated in Figure 3. Installing a PC/104 AO Module Follow steps 1 through 6 below to install the PC/104 AO Module. 1. Disconnect power from the ControlWaveLP (Shut down or place under manual control any critical processes prior to disconnecting power). 2.
Figure 2 - ControlWaveLP FMI/OB Board PC/104 Board Mounting Location Diagram CI-ControlWaveLP Appendix 1 Page 3 PC-104 AO Module Option
Figure 3 - PC/104 AO Board Mounted on ControlWaveLP FMI/OB Board CI-ControlWaveLP Appendix 1 Page 4 PC-104 AO Module Option
Jumper JP7 provides for selection of either a 6 MHz Oscillator or the 6 MHz System Clock as the clock source for the PC/104 AO Board. The 6 MHz System Clock should be used when it is desired to shut down or slow down the clock during low power periods, i.e., when the CPU has been placed into power down or low power mode.
Figure 4 - Analog Output Terminal Blocks and Configuration Jumpers CI-ControlWaveLP Appendix 1 Page 6 PC-104 AO Module Option
Figure 5 - Switch S1 PC/104 AO Board I/O Memory Map Address Settings Figure 6 - 1-5 Vdc Analog Output Field Wiring Diagram CI-ControlWaveLP Appendix 1 Page 7 PC-104 AO Module Option
Figure 7 - 4-20 mA Analog Output Field Wiring Diagram Table 2 - PC/104 AO Board Connector P3 and FMI/OB PC/104 Connectors Wiring Summary AO Bd.
Table 2 - PC/104 AO Board Connector P3 and FMI/OB PC/104 Connectors Wiring Summary (Continued) FMI/OB TB5/6/7/8 Assignment 23 24 25 26 27 28 29 30 31 32 - AO Bd.
AO Configuration: 1-5Vdc & 4-20mA (Individually Config’d.) Power Loop: 9 to 30 Vdc for 4-20mA AO 10 to 30 Vdc for 1-5Vdc AO Accuracy: .1% of Span @ +25° C .2% of Span @ -20° to +70° (C) .3% of Span @ -40° to +85° (C) Common Mode Voltage: 500 Vdc (with respect to Chassis) Surge Suppression: 16V Transorb across input to AO Ground. (Meets ANSI/IEEE C37.
ControlWaveLP Material Safety Data Sheets A Material Safety Data Sheet is provided herein to comply with OSHA’s Hazard Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific requirements. Material Safety Data Sheets are provided in the order listed in Table Z-1 below. TABLE Z-1 MSDS for ControlWaveLP Instruction Manual CI-ControlWaveLP Manufacturer DURACELL 9/02/01 General Description 3V Lithium Manganese Dioxide Battery Part Number DL 2450 (DURACELL INC.
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Gillette Environment Health and Safety 37 A Street Needham, MA 02492 Tel 781.292.8151 Page 1 of 4 MATERIAL SAFETY DATA SHEET NAME: DURACELL LITHIUM MANGANESE DIOXIDE COIN BATTERIES Effective Date: 8/8/03 Not applicable CAS NO: Rev: 3 A.
Page 2 of 4 D. — HEALTH HAZARD DATA Occupational Exposure Limits PEL’s, TLV’s, etc.) 8-Hour TWAs: Manganese Dioxide (as Mn) - 5 mg/m3 (Ceiling) (OSHA); 0.2 mg/m3 (ACGIH/Gillette) 1,2-Dimethoxyethane - 0.15 ppm (Gillette) Graphite (all kinds except fibrous) - 2 mg/m3 (synthetic, ACGIH); 15 mg/m3 (total, OSHA); 5 mg/m3 (respirable, OSHA) These levels are not anticipated under normal consumer use conditions.
Page 3 of 4 F. — EXPOSURE CONTROL METHODS Engineering Controls General ventilation under normal use conditions. Eye Protection None under normal use conditions. Wear safety glasses when handling leaking batteries. Skin Protection None under normal use conditions. Use butyl gloves when handling leaking batteries. Respiratory Protection None under normal use conditions. Other Keep batteries away from small children. G. — WORK PRACTICES Handling and Storage Store at room temperature.
Page 4 of 4 H. — EMERGENCY PROCEDURES Steps to be taken if material is released to the environment or spilled in the work area Evacuate the area and allow vapors to dissipate. Increase ventilation. Avoid eye or skin contact. DO NOT inhale vapors. Clean-up personnel should wear appropriate protective gear. Remove spilled liquid with absorbent and contain for disposal.
Supplement Guide - S1400CW Issue: 04/05 TM SITE CONSIDERATIONS For EQUIPMENT INSTALLATION, GROUNDING & WIRING A Guide for the Protection of Site Equipment & Personnel In the Installation of ControlWave Process Automation Controllers Bristol Babcock
NOTICE Copyright Notice The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol Babcock assumes no responsibility for any errors that may appear in this document. Request for Additional Instructions Additional copies of instruction manuals may be ordered from the address below per attention of the Sales Order Processing Department.
Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - INTRODUCTION 1.1 1.2 GENERAL INTRODUCTION ....................................................................................... 1-1 MAJOR TOPICS ............................................................................................................. 1-1 Section 2 - PROTECTION 2.1 2.1.1 2.2 2.2.1 2.2.2 2.3 PROTECTING INSTRUMENT SYSTEMS....................
Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # Section 5 - WIRING TECHNIQUES (Continued) 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10 Use of Twisted Shielded Pair Wiring (with Overall Insulation).................................. 5-2 Grounding of Cable Shields. .......................................................................................... 5-3 Use of Known Good Earth Grounds .........................
Section 1 - Overview 1.1 INTRODUCTION This document provides information pertaining to the installation of ControlWave systems; more specifically, information covering reasons, theory and techniques for protecting your personnel and equipment from electrical damage. Your instrument system affects the quality of service provided by your company and many aspects of its operational safety. Loss of instruments means lost production and profits as well as increased expenses.
Section 2 - Protection 2.1 PROTECTING INSTRUMENT SYSTEMS Electrical instrumentation is susceptible to damage from a variety of natural and man made phenomena. In addition to wind, rain and fire, the most common types of system and equipment damaging phenomena are lightning, power faults, communication surges & noise and other electrical interference’s caused by devices such as radios, welders, switching gear, automobiles, etc.
2.2.1 Considerations For The Protection of Personnel Always evaluate the site environment as if your life depended on it. Make sure that you understand the physical nature of the location where you will be working. Table 2-1 provides a general guideline for evaluating an installation site. Table 2-1 - Installation Site Safety Evaluation Guide # 1 2 3 4 5 6 7 8 9 Guide Indoor or outdoor – Dress Appropriately If outdoor, what kind of environment, terrain, etc.
Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued) # 6 7 8 9 2.3 Guide Is there an antenna in the immediate area? How close is other equipment? Can someone safely touch this equipment and a ControlWave simultaneously? Determine equipment ground requirements.
Section 3 - Grounding & Isolation 3.1 POWER & GROUND SYSTEMS ControlWaves utilize DC power systems. AC power supplies are not provided with ControlWave units. ControlWave, ControlWave MICRO, ControlWave EFM/GFC/EFC, ControlWaveRED, ControlWaveREDIO and ControlWave I/O Expansion Racks are provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing a connection to Earth Ground.
not be suitable for a complex system of sophisticated electronic equipment. Conditions such as soil type, composition and moisture will all have a bearing on ground reliability. A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG solid copper wire should be used for the ground wire. The end of the wire should be clean, free of any coating and fastened to the rod with a clamp.
ground has been established, it should be tested on a regular basis to preserve system integrity. Figure 3-2 - Basic Ground Bed Soil Test Setup Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5 ohms, the ground is good. The lower the resistance, the better the earth ground.
Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is indicated, one or more additional ground rods connected 10 feet from the main ground rod should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x ¼-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the Biddle Instrument Co. (now owned by AVO International). Other devices that may be used to test ground resistance are “Viboground”; Associated Research, Inc.
Figure 3-5 - Poor Soil Ground Bed Construction Diagram 3.3.2 Ground Wire Considerations ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveRED, ControlWave REDIO & ControlWave I/O Expansion Rack ControlWave Chassis are provided with a Ground Lug that accommodates up to a #4 AWG wire size. A ground wire must be run between the Chassis Ground Lug and a known good Earth Ground.
Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground Bus. The panel, lug or bus in turn must be connected to a known good Earth Ground via a #4 AWG wire. General Considerations The following considerations are provided for the installation of ControlWave system grounds: i Size of ground wire (running to Earth Ground should be #4 AWG.
For applications employing equipment that communicates over telephone lines, a lightning arrester Must Be provided. For indoor equipment the lightning arrester must be installed at the point where the communication line enters the building as shown in Figure 3-6. The ground terminal of this arrester must connect to a ground rod and/or a buried ground bed. Gas lines also require special grounding considerations.
grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely mounted, connect their chassis grounds to the pipeline or earth ground. Figure 3-8 - ControlWave EFM (Installation is similar to GFC/XFC) Remote Installation without Cathodic Protection 3.4.
• • • all conductive tubing that runs between the pipeline and mounting valve manifold and/or the units multivariable pressure transducer all conductive connections or tubing runs between the ControlWave EFM/GFC and turbine meter, pulse transducer, or any input other device that is mounted on the pipeline any Temperature Transducer, Pressure Transmitter, etc.
See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds.
Section 4 - Lightning Arresters & Surge Protectors 4.1 STROKES & STRIKES Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will average 18 KA for the first impulse and about half of that for the second and third impulses. Three strokes (impulses) is the average per lightning strike. The number of visible flashes that may be seen is not necessarily the number of electrical strokes.
Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the United States there is an average of 30 thunderstorm days per year. Any given storm may produce from one to several strokes. Data on the subject indicates that for an average area within the United States there can be eight to eleven strokes to each square mile per year.
modem has been interfaced to a ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP, or ControlWaveEXP the possibility of damage due to a lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower must be considered. It is recommended that the additional lightning protection considerations listed below be followed for units installed in areas with a high possibility or history of stroke activity.
Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram For all systems it is best to have all communication equipment input/output grounds tied together. In the case of ControlWave units, this is accomplished via the unit’s Chassis Ground (Typically at a ground lug, ground bus or ground plate).
communication equipment lightning arresters and surge suppressors should be tied to the same system ground. System ground consists of the tower leg grounds utility ground and bulkhead-equipment ground-stakes that are tied together via bare copper wire. 4.1.3 Ground Propagation As in any medium, a dynamic pulse, like R.F., will take time to propagate.
i Watch out for dissimilar metals connections and coat accordingly. i Use bare wire radials together where possible with ground stakes to reduce ground system impedance. i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground system. i Ground the Coaxial Cable Shield (or use an impulse suppressor) at the bottom of the tower just above the tower leg ground connection. 4.
Section 5 - Wiring Techniques 5.1 OVERVIEW This section provides information pertaining to good wiring practices. Installation of Power and “Measurement & Control” wiring is discussed. Information on obscure problems, circulating ground and power loops, bad relays, etc. is presented. Good wire preparation and connection techniques along with problems to avoid are discussed. 5.
Figure 5-1 - Field Wired Circuits With & Without A Common Return 5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation) For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly recommended. This type of cable provides discrete insulation for each of the wires and an additional overall insulated covering that provides greater E.M.I. immunity and protection to the shield as well.
5.2.3 Grounding of Cable Shields DO NOT connect the cable shield to more than one ground point; it should only be grounded at one end. Cable shields that are grounded at more than one point or at both ends may have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O signals.
Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to being costly. 5.2.7 High Power Conductors and Signal Wiring When routing wires, keep high power conductors away from signal conductors. Space wires appropriately to vent high voltage inductance. Refer to the National Electrical Code Handbook for regulatory and technical requirements. 5.2.
Discharge Units should be placed on the base of the antenna and at the point where the antenna lead (typically coax) enters the site equipment building. When a modem is used, a lightning arrester should be placed at the point where the phone line enters the site equipment building. If you use a modem (manufactured by other than BBI) it is recommended that you also install a surge suppressors or lightning arrester on the phone line as close to the modem as possible.
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Bristol Babcock 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2200 Fax: +1 (860) 945-2213 Website: www.bristolbabcock.com U.S.A. Locations: Northern Region Bristol Babcock Inc. 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2381 Fax: +1 (860) 945-2525 NorthernUS@bristolbabcock.com Helicoid Instruments 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2218 Fax: +1 (860) 945-2213 jmcgrail@bristolbabcock.com Gulf Coast Region Bristol Babcock Inc.
ESDS Manual S14006 4/15/92 CARE AND HANDLING OF PC BOARDS AND ESD-SENSITIVE COMPONENTS BRISTOL BABCOCK
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ESDS Manual S14006 4/15/92 TABLE OF CONTENTS PAGE TOOLS AND MATERIALS REQUIRED 1 ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 2 1. Introduction 2 2. General Rules 3 3. Protecting ESD-Sensitive Components 5 4. Static-Safe Field Procedure 6 5. Cleaning and Lubricating 8 6. Completion 10 TOOLS AND MATERIALS REQUIRED 1. Tools Anti-Static Field kit.
ESDS Manual #S14006 4/15/92 2. Materials ● Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent) ● Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent) ● Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent) ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 1. Introduction Microelectronic devices such as PC boards, chips and other components are electrostatic-sensitive. Electrostatic discharge (ESD) of as few as 110 volts can damage or disrupt the functioning of such devices.
ESDS Manual S14006 4/15/92 Table 1 Typical Electrostatic Voltages Electrostatic Voltages Means of Static Generation Walking across carpet Walking over vinyl floor Worker at bench Vinyl envelopes for work instructions Poly bag picked up from bench Work chair padded with poly foam 2.
ESDS Manual #S14006 4/15/92 Typical Chip Removal Tool 4 (6) It is important to note when inserting EPROMS/PROMS, that the index notch on the PROM must be matched with the index notch on the socket. Before pushing the chip into the socket, make sure all the pins are aligned with the respective socket-holes. Take special care not to crush any of the pins as this could destroy the chip.
ESDS Manual S14006 4/15/92 CAUTION Don't place ESD-sensitive components and paperwork in the same bag. The static caused by sliding the paper into the bag could develop a charge and damage the component(s). (9) 3. Include a note, which describes the malfunction, in a separate bag along with each component being shipped. The repair facility will service the component and promptly return it to the field.
ESDS Manual #S14006 4/15/92 Note: If a system checker is not available, use an ohmmeter connected to the cable ends to measure its resistance. The ohmmeter reading should be 1 megohm +/15%. Be sure that the calibration date of the ohmmeter has not expired. If the ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a new one. 4. Static-safe Field Procedure 6 (1) On reaching the work location, unfold and lay out the work surface on a convenient surface (table or floor).
ESDS Manual S14006 4/15/92 (7) The components can now be handled following the general rules as described in the instruction manual for the component. (8) Place the component in a static-shielding bag before the ground cord is disconnected. This assures protection from electrostatic charge in case the work surface is located beyond the reach of the extended ground cord.
ESDS Manual #S14006 4/15/92 5. (9) If a component is to undergo on-site testing, it may be safely placed on the grounded work surface for that purpose. (10) After all component work is accomplished, remove the wrist straps and ground wire and place in the pouch of the work surface for future use. Cleaning And Lubricating The following procedure should be performed periodically for all PC boards and when a PC board is being replaced.
ESDS Manual S14006 4/15/92 (2) Clean PC board connectors as follows: a. Review the static-safe field procedure detailed earlier. b. Following the ESD-sensitive component handling procedures, remove the connectors from the boards and remove the PC boards from their holders. c. Use cleaner to remove excessive dust build-up from comb connectors and other connectors. This cleaner is especially useful for removing dust. d. Liberally spray all PC board contacts with Inhibitor.
ESDS Manual #S14006 4/15/92 6. 10 d. Spray the connector liberally to flush out any contaminants. e. Remove any excess spray by shaking the connector or wiping with either a toothbrush, or a lint-free wiping cloth. Completion (1) Replace any parts that were removed. (2) Make sure that the component cover is secure. (3) Return the system to normal operation. (4) Check that the component operates normally.
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ControlWaveLP Low Power PAC Emerson Process Management Bristol, Inc. 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2262 Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol Emerson Electric Canada, Ltd. Bristol Canada 6338 Viscount Rd. Mississauga, Ont. L4V 1H3 Canada Phone: 905-362-0880 Fax: 905-362-0882 www.EmersonProcess.com/Bristol Emerson Process Management BBI, S.A. de C.V. Homero No. 1343, 3er Piso Col. Morales Polanco 11540 Mexico, D.F.
