Instruction Manual Doc Number CI-ControlWave GFC Plus Part Number D301389X012 February 2013 ControlWave Gas Flow Computer Plus (GFC Plus) Remote Automation Solutions 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.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Contents Chapter 1 – Introduction 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1-1 Scope of the Manual .................................................................................................................1-2 Physical Description ..................................................................................................................1-2 CPU/System Controller Board .....................................................
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Chapter 3 – I/O Configuration and Wiring 3.1 3.2 3.3 3-1 I/O Options ................................................................................................................................ 3-1 Process I/O Board ..................................................................................................................... 3-2 3.2.1 Setting Jumpers on the Process I/O Board .................................
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Chapter 1 – Introduction This manual focuses on the hardware aspects of the ControlWave Gas Flow Computer (GFC Plus).
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 1.1 Scope of the Manual This manual contains the following chapters: Chapter 1 Introduction Provides an overview of the hardware and general information about the ControlWave GFC Plus and its application software. Chapter 2 Installation Provides information on mounting the ControlWave GFC Plus and setting CPU jumpers and switches.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 1-1. ControlWave GFC Plus Enclosure (MVT Equipped) with 25-Button Display/Keypad Assembly Enclosure The ControlWave GFC Plus enclosure is a standard NEMA 3R rated fiberglass enclosure. The enclosure consists of the body and the front cover. A continuous gasket seals the unit when you close the front cover. Two latches on the enclosure’s right side secure the cover.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Internal Mounting Internal mounting brackets support the various system components, Brackets and Battery such as the battery, CPU/System Controller and Process I/O boards, and the radio/modem option. These components attach to the one piece mounting bracket which is secured to the inner rear wall of the enclosure. A factory-supplied radio or modem mounts in front of the battery on a battery cover/radio mounting plate.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) CPU Backup Battery The CPU/System Controller board has a coin cell socket that accepts a 3.0V, 300 mA-hr lithium battery. This 3.0V battery provides backup power for the real-time clock and the system’s Static RAM (SRAM). CPU Memory There are several different types of memory used by the CPU: Boot/Downloader FLASH Boot/download code is contained in a single 512 Kbyte FLASH chip.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Internally mounted factory-supplied 12V, 33AH lead acid battery (UL approved) Externally mounted user supplied power (12Vdc bulk or regulated power) Externally mounted +12Vdc battery with lithium backup battery If you connect solar panels to rechargeable battery systems to power the ControlWave GFC Plus, there is a secondary power input you can use to provide power if there is no power from the solar panel/battery
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 1.6 Software Tools The ControlWave programming environment consists of a set of integrated software tools which allow you to create, test, implement, and download complex control strategies for use with the ControlWave GFC Plus. Figure 1-2 graphically presents the programming environment. Figure 1-2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) The ACCOL3 Firmware Library, available within ControlWave Designer, includes a series of ControlWave-specific function blocks. These pre-programmed function blocks let you accomplish various tasks common to most user applications including alarming, historical data storage, as well as process control algorithms such as PID control.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 1.7 Overview of the Gas Flow Measurement Application Note: For detailed information on the gas flow measurement application and web pages refer to the ControlWave Flow Measurement Applications Guide (D5137). You can purchase the ControlWave GFC Plus with a pre-programmed flow measurement application already loaded.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) AGA7/NX-19 AGA7 with selectable AGA8 Gross or AGA8 Detail Auto-adjust AGA7/NX-19 Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail The application performs a complete flow calculation using the process variables every second. Each calculation includes instantaneous rate according to API 14.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 1.7.6 Energy Calculation The application offers the option of using a fixed volumetric heating value or calculating the energy content of the gas according to AGA Report No. 5. 1.7.7 Volume and Energy Integration The application integrates and accumulates volume and energy at the end of every calculation cycle.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) The following circumstances generate an audit record: Any operator change to a configuration variable Any change in the state of an alarm variable A system restart Certain other system events You can view audit records on-screen in the audit log. See the Supplement to OpenBSI 5.8 Service Pack 1 documentation for help on interpreting audit records.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) gas day starts at some time other than midnight. The daily log holds 62 entries; this ensures that the previous calendar month of daily data is always resident in flash memory.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 1.7.13 Nominations Nominations allow you to configure the ControlWave flow computer to allocate precise amounts of gas flow during specific time periods, called nomination periods.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Chapter 2 – Installation This chapter discusses the physical configuration of the ControlWave GFC Plus, considerations for installation, and instructions for setting switches and jumpers. In This Chapter 2.1 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations .............................2-3 2.2 Installation Overview............
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) A). The ControlWave GFC Plus can operate in an unprotected outdoor environment. Caution To ensure safe use of this product, please review and follow the instructions in the following supplemental documentation: Supplement Guide - ControlWave Site Considerations for Equipment Installation, Grounding, and Wiring (S1400CW) ESDS Manual – Care and Handling of PC Boards and ESD Sensitive Components (S14006) Figure 2-1.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Specifications for Temperature, Humidity and Vibration See document 1660DS9b available on our website for detailed technical specifications for temperature, humidity, and vibration for the ControlWave GFC Plus. Ensure that the ambient temperature and humidity at the installation site remains within these specifications. Operation beyond the specified ranges could cause output errors and erratic performance.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.2 Installation Overview Installing a ControlWave GFC Plus involves several general steps: 1. Unpacking, assembling, and configuring the hardware. This includes: a) Mounting the enclosure on site. (See Section 2.2.2) b) Removing the CPU/System Controller board and optional Process I/O board assembly so you can enable the backup battery by setting jumper W3 on the CPU/System Controller board to position 1 to 2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) ControlWave Designer Manual (D5085) and the ControlWave Designer Programmer’s Handbook (D5125). 2.2.1 Unpacking Components Packaging ControlWave GFC Plus gas flow computers ship from the factory with all components wired and mounted except for the unit’s solar panel and battery; these items are shipped separately. 2.2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) (1) (3) (5) (7) 1” Conduit Fitting - I/O wires RTD Cable Assembly or Sealing Plug Solar Pwr. Cable, Ext. Pwr. Cable, or Plug Solderless Ground Lug (2) (4) (6) (8) Local Port Connector Battery Ventilation Assembly Ant. Cable, Polyphaser, or Plug Multivariable Transducer Figure 2-2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 2-3. Side View of ControlWave GFC Plus Mounted Only connect power wiring after the unit is mounted and properly grounded. I/O, power, and communication cabling enters the bottom of the unit through conduit or special function fittings.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 2-4.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.2.3 Grounding the Housing The ControlWave GFC Plus enclosure includes a ground lug. See Figure 2-2 to locate the ground lug. Once you have installed the unit, run a ground wire (#4 AWG max wire size) between the ground lug and a known good earth ground. Connect the cases of temperature transducers, pressure transmitters, and so on to the known good earth ground.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) The MVT provides connection ports on the process flange as the standard arrangement. Optional manifold blocks may also be specified. Arrangements are described as follows: Standard Process Flange for MVT – Two process flanges containing the connection ports are assembled to the differential transducer. Port designations (L and H) are stamped on the body between the flanges.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Optional Process Manifold Blocks – Process manifold blocks may be installed on the transducers to permit the use of connector assemblies having different connection centers. The manifold blocks, which are oval in appearance, mate with the tranducer’s process flange. The blocks may be installed in several positions to achieve different connection centers as shown in Figure 2-5.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Connect a ground conductor between the chassis ground lug and a known good Earth ground. Connect the cases of temperature transducers, pressure transmitters, etc. to the known good Earth ground. If the mounting 2-inch pipe (when used) is in continuity with the pipeline you may need to electrically isolate it from the unit. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU 3140.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Transducer to Manifold Dielectric Isolation Kit Multivariable Transducer (MVT) Dielectric Gasket & Flange Seals (2) AWG 4 Ground Wire Valve Block Manifold Top Washers (4) Dielectric Bolt Sleeves (4) Isolating Fittings Bottom Washers (4) Mounting Bolts (4) 2” Pipe-mounting Package Note: Mounting Pipe does not contact the Main Pipeline. Clamp(s) Ground Rod or System Figure 2-7.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.3 Configuring the CPU/System Controller Board The CPU/System Controller board is situated on the right side of the Process I/O board; the combined assembly mounts vertically on edge on the inner left side of the enclosure. To configure the CPU/System Controller board, you need to set some switches and jumpers. NOTE: Ultra Low Power CPU/System Controller Bds. don’t have an Ethernet Port. Solar Pwr. In and Aux.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.3.1 Setting DIP Switches on the CPU/System Controller Board Before you install the CPU/System Controller board, you must determine the settings for three banks of DIP switches. Refer to Figure 2-8 for the location of the DIP switch banks. Refer to Tables 2-1, 2-2, and 2-3 for an explanation of the DIP switch positions. Notes: Examine each bank of DIP switches carefully to note the switch direction for ON or OFF.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) SW2 Setting Function Mode defaults) Note: Setting both switch 3 and switch 8 to OFF (closed) sets all serial communication ports to 9600 bps operation. All serial communication ports must be set at 9600 bps before WINDIAG can perform communication tests. 4 Core Updump Causes the ControlWave GFC Plus to perform a core updump, provided you have set the SW1 switches to allow recovery mode.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Switch Setting Function Mode TX- to RX- Loopback / 2wire ON (2-wire operation or loopback enabled) 3 100 Ohm RX+ Termination ON (End nodes only) 4 100 Ohm RX- Termination ON (End nodes only) 5 N/A Not currently used 6 N/A Not currently used 7 RX+ Bias (End Nodes/Node) ON (4-wire = Both End nodes only; 2-wire= One end node only) 2 OFF (4-wire operation and loopback disabled) OFF = No bias RX- Bias (End
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) o 2-to-3 Installed = 6/24V power fail trip point W12: COM3 configuration selection: o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W13: COM3 configuration selection: o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W14: COM3 configuration selection: o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W15: COM3 configuration selection:
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.3.4 Wiring Power to the CPU/System Controller Board Caution At this time you can connect power wiring. However; for safety reasons and to prevent accidental damage to your bulk DC power supply, do not connect the pluggable terminal block connectors TB1 and TB2 to the CPU/System Controller board until after you install, wire, ground, and configure the entire unit. Follow the instructions in Section 2.3.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Terminal Block Unplug removable connector TB1 from the CPU/System Controller Connector TB1 board. We recommend you do not plug the connector back into the CPU until the unit is already installed in the housing. You can power the ControlWave GFC Plus using a bulk DC power supply using connections TB1-3 and TB1-4. Nominal input source operating ranges for the DC power supply are: +6Vdc (+5.4Vdc to +16.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Terminal Block The ControlWave GFC Plus includes an alternative power connecter, Connector TB2 TB2, to provide power if none is available at TB1. For example, you can connect a bulk DC power supply to TB2 to handle situations where the solar panel/battery system does not have sufficient power. TB2 connections are: TB2-1 = Power Input TB2-2 = Ground (GND) 2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) A A B B D C E Note 2: Item D slots accommodate Tilt Angle Adjustment. A A NOTE 1: To Attach item C to item D: Slide two bolts (A) through the top and bottom Solar Panel (Centered) Channel Holes. Affix item C to item D via 2 sets of item A hardware as follows: Flat Washer, Lock Washer & Hex Nut (Max. Torque = 120 Inch-Pounds).
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.5 Installing the Rechargeable Battery and Solar Panel Harness You must remove the rechargeable sealed lead-acid battery from its shipping carton and install it on its mounting bracket within the enclosure as illustrated in Figure 2-11. Figure 2-11. Enclosure with Sealed Lead-acid Battery Installed Revised Feb-2013 1. Remove connector TB1 from the CPU/System Control Board. 2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 5. Connect the solar panel harness to the CPU/System Controller Board (TB1-1 = +, TB1-2 = GND). 6. Secure the battery via the battery clamp and connect the battery power wires to the battery (Red = Pos., Black = Neg.). 7. When you are ready to apply power, plug connector TB1 into the CPU/System Controller Board. 2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) You mount the digital to relay I/O board (two maximum) to the inside of the enclosure using a Snap Track that is secured to a dual PCB mounting bracket. Figure 2-13. Digital to Relay I/O Board 2.8 ControlWave Loop Supply Option ControlWave loop supplies provide non-regulated 24Vdc power outputs that can be used to power field devices such as transmitters or nonisolated I/O circuits (see PIP-ControlWaveLS). Figure 2-14.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Like the power distribution board and the digital to relay I/O board, each ControlWave Loop Supply board mounts to the inside of the enclosure using a Snap Track that you secure to a dual PCB mounting bracket. 2.9 Communication Connections Communication is via the serial ports and optional Ethernet port. 2.9.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Notes: Cable part number 395402-01-8 = 10 foot communication cable. Cable part number 395402-02-6 = 25 foot communication cable. COM2 is intended for connections to modem/radio located on the battery cover/radio mounting plate. RS-232 COM Port Names and Connectors RS-232 COM ports use different connector types. Table 2-6.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Table 2-7.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 2-17. Full-duplex and Half-duplex Cable Use the half-duplex cable (shown in the bottom part of Figure 2-17) when connecting the ControlWave GFC Plus to another ControlWave series unit (again, with the exception of the CW_10/30/35). When communicating with a Network 3000 series RTU 3305, RTU 3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of the cables shown in Figure 2-18. Figure 2-18.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 2-19. Connection from a case-mounted Modem/Radio to COM2 of the ControlWave GFC Plus When interfacing to the COM3 port of a ControlWave, or the COM5 or COM6 port a ControlWaveEXP unit, use the cable presented in Figure 2-20 along with one of the cables shown in Figure 2-17 or Figure 2-18. Figure 2-20.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.9.2 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller Board You use jumpers W12 through W16 to configure COM3 of the ControlWave GFC Plus for either RS-232 or RS-485 operation. See Section 2.3.2 for information on these jumpers. Table 2-9.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Note: ControlWave GFC Plus supports only half-duplex RS-485 networks. Table 2-11.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.9.3 Connections to the Ethernet Port on the CPU/System Controller Board Caution The RJ45 Ethernet port is connector (J1) located on the CPU/System Controller board. The board also has one RJ45 port (J2) for the optional Display/Keypad. Never connect Ethernet to J2 (the Display/Keypad port) or damage will result. The 33MHz ControlWave GFC Plus can support one Ethernet port.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Pin Description 7 Not connected 8 Not connected Note: You can swap TX and RX at the hub. You can connect two nodes in a point-to-point configuration without using a hub. However, you must configure the cable so that the TX+/Data pins connect to the RX+/- Data pins (swapped) at the opposite ends of the cable (see Figure 2-23). Figure 2-23.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2.11 Optional Display/Keypads The ControlWave GFC Plus supports two optional display/keypads and a display without a keypad: A 2-button keypad (shown in the left of Figure 2-24) A 25-button keypad (shown in the right Figure 2-24) Display only (no keypad) – (see Figure 2-25) Figure 2-24. Optional 2-Button and 25-Button Keypads Figure 2-25.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) The Display without a keypad has a 2-line display with 10 characters on the first line, and 6 characters on the second line. This display shows variable values on line 1, and variable names on line 2. You connect the Display/Keypad or Display to the ControlWave GFC Plus using a cable, one end of which has an RJ-45 jack (connected into the RJ-45 equipped with two plugs.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Chapter 3 – I/O Configuration and Wiring This chapter discusses setting I/O configuration switches and jumpers and wiring I/O connections to the ControlWave GFC Plus. In This Chapter 3.1 3.2 3.3 I/O Options .......................................................................................3-1 Process I/O Board ...........................................................................3-2 3.2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.2 Process I/O Board ControlWave GFC Plus may include an optional Process I/O board. The Process I/O board stands vertically on edge against the inner left side of the enclosure and mounts to the CPU/System Controller board using six nylon mounting posts. To configure the Process I/O board, you need to set some switches and jumpers. See Figure 3-1 for the location of the switches and jumpers. 3.2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) SW1 Function SW1-3 DI/HSC source current SW1-4 AO configuration Mode OFF = 200μA ON = 2.2 mA OFF = current ON = voltage Figure 3-1.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Caution Power down the ControlWave GFC Plus before you perform I/O wiring. Shut down any processes the ControlWave GFC Plus may be managing (or switch them over manually or handle with another controller). Perform any hardware configuration (wiring, jumper configuration, and installation) only when the ControlWave GFC Plus is powered down.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 3-2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board Process I/O Board terminal block connector TB2 provides interface to four dedicated non-isolated discrete inputs DIs – DI1 through DI4. In addition, terminal block connector TB3 provides two additional points that can serve as either discrete inputs or discrete outputs (DI5 and DI6 when wired as inputs). Table 3-3.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O Board Process I/O Board terminal block connector TB3 provides interface to two dedicated non-isolated discrete outputs DOs – DO1 and DO2. In addition, terminal block connector TB3 provides two additional points that can serve as either discrete inputs or discrete outputs (DO3 and DO4 when wired as outputs). Table 3-4.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board Process I/O Board terminal block connector TB6 provides interface to three single-ended analog inputs (AIs). Table 3-5. Non-Isolated AI General Characteristics Type Analog Inputs (AI) Number Supported Characteristics 3 (on TB6) Jumper-selectable using JP5, JP6, and JP7 for either 4-20mA or 1-5V operation.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board Process I/O Board terminal block connector TB7 provides interface to a single analog output (AO). Table 3-6. Non-Isolated AO General Characteristics Type Analog Output (AO) Number Supported Characteristics 1 (on TB7) Supports either 4-20mA or 1-5V operation. Selection using jumper JP1 and switch SW14.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Board CPU/System Controller Board connector TB5 provides interface to two internally sourced open collector pulse counter/discrete inputs (Pulse1 and Pulse2) with a 1 second scan rate. Pulse counters act like high speed counters but cannot function with contact relays because they lack contact debounce circuitry. Table 3-7.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on TB4 of Process I/O Board Process I/O Board connector TB4 provides interface to two internally sourced single-ended high speed counter/discrete inputs (HSC1 and HSC2). Table 3-8.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board CPU/System Controller Board connector TB6 provides connection to a 3-wire 100 ohm platinum bulb RTD (using the DIN 43760 curve). Wire the RTD according to Table 3-9 and Figure 3-4 and Figure 3-5.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 3-5. RTD Probe Installation/Removal Diagram Software Configuration To use data from the RTD you must include a CWM_ECPU board in your ControlWave project using ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 3.3.8 Connections to a Bristol Model 3808 Transmitter You can connect a Bristol 3808 transmitter (digital) to the ControlWave GFC Plus through either an RS-232 or RS-485 port. Communication schemes and cable lengths determine the type of communication port you need to use. In general RS-232 communications require that you place the 3808 transmitter within 25 feet of the ControlWave GFC Plus (local communications).
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 3-7. 3808 Transmitter to ControlWave GFC Plus RS-485 Comm. Cable You can connect up to two 3808 transmitters to a ControlWave GFC Plus using a half-duplex RS-485 network. See Figure 3-8 for an illustration of this type of network. Figure 3-8.
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ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Chapter 4 – Operation This chapter provides general operational details for using the ControlWave GFC Plus. In This Chapter 4.1 4.2 4.3 4.4 WARNING Powering Up/Powering Down the ControlWave GFC Plus .............4-1 Communicating with the ControlWave GFC Plus............................4-2 4.2.1 Default Comm Port Settings .................................................4-2 4.2.2 Changing Port Settings ................
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Caution When you disconnect power from the ControlWave GFC Plus, your running control strategy is erased from SRAM, as is any process data not stored in retention mode.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 4.2.2 Changing Port Settings You change port settings (baud rate, port type, IP address, and so on) using the Flash Configuration utility. You must establish communications with the ControlWave deviceusing NetView, LocalView, or TechView before you can run the Flash Configuration utility. Note: For detailed information on using the Flash Configuration utility, see Chapter 5 of the OpenBSI Utilities Manual (D5081).
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 1. Connect a serial cable between your PC and COM1 of the ControlWave GFC Plus. 2. Define the ControlWave project in ControlWave Designer, and set communication and configuration parameters. 3. Download the project according to instructions in the Downloading section of the ControlWave Designer Programmer's Manual (D5125). 4.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 4-1. Saving a Backup of Your Project 2. In the “Save/Zip project as” dialog box, specify a project name in the File name field. In Figure 4-1 we chose the name mynewproj. 3. In the Save as type field, choose Zipped Project Files (*.zwt). 4. In the Zip Options area, select which additional files you want to include in the zwt file.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 7. Copy the resulting zwt file to backup media (CD-ROM, thumb drive, etc.) If you ever need to restore the project, just open the zwt file in ControlWave Designer, load libraries as needed, then compile the project and download it into the ControlWave. 4.4.2 Saving Flash Configuration Parameters (*.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Flash Configuration utility, and load the FCP file using the Read from FCP button, then choose the Write to RTU button. 4.4.3 Backing up Data You can back up certain types of data and restore it if needed. There are other types of data that you can only collect, but you cannot restore.
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ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave GFC Plus as well as some common maintenance procedures. In This Chapter 5.1 5.2 5.3 5.4 5.5 5.6 Equipment Upgrading Firmware ........................................................................5-2 Removing or Replacing Components ..............................................5-6 5.2.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Anti-seize compound (when replacing GPT/MVT) Note: When you service a ControlWave GFC Plus on site, we recommend that you close down (or place under manual control) any associated processes. This precaution prevents any processes from accidentally running out of control when you conduct tests.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) HyperTerminal HyperTerminal is a communications utility program included with Microsoft® Windows® XP. Notes: Revised Feb-2013 If you are using a version of OpenBSI older than 5.1, or do not have OpenBSI software, you can only perform a firmware upgrade using HyperTerminal. While HyperTerminal is included in Microsoft® Window® XP, some newer versions of Window® do not include it.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 5-1. HyperTerminal Mode Menu 7. When the FLASH is ready for download, HyperTerminal repeatedly displays the letter C on the screen. In the HyperTerminal menu bar click Transfer > Send File (see Figure 5-2). Figure 5-2. HyperTerminal (Ready to Download) 8. 5-4 In the Send File dialog box (see Figure 5-3), select 1KXmodem for the protocol, enter the filename of the appropriate .bin file in the format “E1Sxxxxx.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) xxxxx varies from release to release) and click Send to start the flash upgrade (see Figure 5-4). When you see the HyperTerminal Mode Menu again, it means the download has completed. 9. Exit HyperTerminal and power down the ControlWave GFC Plus. If desired, you can disconnect the null modem cable between the ControlWave GFC Plus and the PC. 10. Set switch SW1-3 to the OFF position (OFF = Recovery Mode Disabled). 11.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 5.2 Removing or Replacing Components This section provides information on accessing ControlWave GFC Plus components for testing, as well as removal/replacement procedures. Caution Field repairs to the ControlWave GFC Plus are strictly limited to the replacement of complete modules. Replacing board components constitutes tampering and violates the product warranty.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) board. Carefully unplug the boards from their interface connectors. Align the replacement boards with each other and press them together so that the interface connectors and mounting posts properly mate; then squeeze together so that the mounting post tabs capture the CPU/System Controller board. 7. To install the replacement boards, power must be off.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 5.2.4 Removing/Replacing the Backup Battery Note: The CPU/System Controller board draws power from the battery only if the board loses power. The system SRAM has a standby current draw of 20 μA maximum for each part plus 2 μA for the real time clock. For a ControlWave GFC Plus containing 2MB of SRAM, a worst-case current draw of 42 μA allows a battery life of approximately 9000 hours.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Removing / Replacing the Backup Battery 1. If the ControlWave GFC Plus is running, place any critical control processes under manual control. 2. Remove power from the ControlWave GFC Plus. 3. Remove the CPU/System Controller board assembly from the housing.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) reversing the steps from 7 to 3. 8. Apply power (re-connect TB1 and applicable TB2) and test the unit. 5.2.7 Removing/Replacing the MVT or GPT Transducer 1. If the ControlWave GFC Plus is running, place any critical control processes under manual control. 2. Open the cover and shut down the ControlWave GFC Plus by disconnecting the power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2). 3.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) utility. If this ControlWave is a BSAP slave node, and the range of addresses defined for the BSAP master port end of the communication line does not encompass the local BSAP address defined for this ControlWave, BSAP communications will not function. Incorrect EBSAP Group number – if you use expanded BSAP the EBSAP group number must be correct; if you are not using EBSAP, the group number must be 0.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) LCD Display INIT RECOV RAMERR STOP HALT NO APP BREAKP POWERD UPDUMP NOTRUN Indication Definition System Initialization in Progress Waiting in Recovery Mode Error Testing SRAM Application Loaded Stopped at a Break Point No Application Loaded Running with Break Points Waiting for Power-down (after NMI) Waiting for Updump to be Performed Unit Crashed (Watchdog Disabled) 5.3.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 5.4 WINDIAG Diagnostic Utility The ControlWave GFC Plus cannot execute your control strategy while it runs diagnostic routines; place any critical processes controlled by the ControlWave GFC Plus under manual control before starting this procedure. Caution WINDIAG is a software-based diagnostic tool you use to test the performance of I/O, CPU memory, communication ports, and other system components. .
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Figure 5-5. WINDIAG Main Diagnostics Menu 3. Select the component to be tested. See Section 5.4.1 for a description of the tests. Enter any prompted parameters (slot #, etc.). WINDIAG performs the diagnostics and displays pass/fail results. After performing all diagnostic testing, exit WINDIAG. 4. Set switches SW2-3 and SW2-8 on the CPU module to ON. The ControlWave GFC Plus should resume normal operation. 5.4.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Port Loop-back Test Option Tests COM2, and COM3. The External loop-back tests require the use of a loop-back plug. Discrete I/O Checks DIs and DOs on the Process I/O board. EEPROM Checks the EEPROM. Keyboard & Display Checks the optional display/keypad hardware. WINDIAG allows you to select the communication port to test.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Note: You can configure RS-485 loopback by setting CPU/System Controller board switches SW3-1 & SW3-2 ON. Port 3 - RS-485 use loop-back wires or CPU Switch SW3 (see Figure 5-7). These tests verify the correct operation of the communication ports. Note: You cannot test a communications port while you are using it. You can only test currently unused ports.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Note: The port you select must correlate to the port on which you placed the loop-back plug in step 1. 5. Select 115200 or ALL ASYNC as the baud rate (click to display all available rates). 6. Click RUN to start the test. At the completion of the test (which generally takes about 5 seconds), any failed results appear in the Status field to the right of the RUN button: For example: 7.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) both SW1-1 and SW1-2 to either the ON position or both to the OFF position.. 5. Start the PC’s HyperTerminal program (at 115.2 kbaud) and generate a receive using the 1KX-Modem protocol. Save the resulting core updump in a file so you can forward it later to the technical support group.
Special Appendix for ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Appendix A – ControlWave GFC Plus– Special Instructions for Class I, Division 2 Hazardous Locations 1. The ControlWave GFC Plus Gas Flow Computer is listed by Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups C and D hazardous locations or non-hazardous locations only.
Special Appendix for ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 7. The UL listed nonincendive ControlWave GFC Plus may include radio/modem communications (listed on the model specification) that is used in conjunction with a 5W, 12V, 7AH lead acid battery system. Connection to the radio or modem is approved as a nonincendive circuit, so that Division 2 wiring methods are not required.
Special Appendix for ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Module/Item Connector pulse input interface Wiring Notes connector is unrated, use Div. 2 wiring methods. * CPU/System Controller board TB6: 3-pin terminal block RTD interface Field wired: Refer to item 5 of this document. CPU/System Controller board J1: 8-pin RJ-45 jack 10/100Base-T Ethernet port 10/100Base-T Ethernet port jack for external connection to an Ethernet hub. Refer to model spec.
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ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Appendix Z – Sources for Obtaining Material Safety Data Sheets This device includes certain components or materials which may be hazardous if misused. For details on these hazards, please contact the manufacturer for the most recent material safety data sheet. Manufacturer General Description DURACELL http://www.duracell.com 3V lithium manganese dioxide battery Emerson Part Number 395620-01-5 P/N: DL 2450 B.B.
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ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Index A ACCOL3 Firmware Library ................................. 1-8 address default IP ........................................................ 4-2 Analog averaging .............................................. 1-10 Analog Inputs ...................................................... 3-8 Analog Output ..................................................... 3-9 E B Backup battery description ............................
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) 2-23. Point-to-Point Ethernet Cable ............. 2-34 2-24 Opt 2-Button and 25-Button Keypads .. 2-35 2-25 Display with No Keypad ....................... 2-35 3-1. Process I/O Board Component ID diag... 3-3 3-2. Process I/O Board Wiring diagrams........ 3-5 3-3. Pulse Input Wiring diagram ................... 3-10 3-4. 3-Wire RTD Temperature Input Wiring . 3-12 3-5. RTD Probe Installation/Removal diag ... 3-13 3-6.
ControlWave Gas Flow Computer (GFC Plus) Instruction Manual (CI-ControlWave GFC Plus) Pulse Counter/Discrete Inputs .......................... 3-10 R RAM Battery Disconnecting ............................................... 5-10 Recovery mode switches .................................. 2-15 Repair in field ...................................................... 5-6 Resistance Temperature Device (RTD) ........... 3-12 RS-232 Ports .................................................... 2-26 Cables ..............
ControlWave GFC Plus CI-ControlWave GFC Plus Instruction Manual February 2013 Headquarters: Emerson Process Management Remote Automation Solutions 6005 Rogerdale Road Houston, TX 77072 U.S.A. T +1 281 879 2699 | F +1 281 988 4445 www.EmersonProcess.com/Remote Europe: Emerson Process Management Remote Automation Solutions Unit 8, Waterfront Business Park Dudley Road, Brierly Hill Dudley UK DY5 1LX T +44 1384 487200 | F +44 1384 487258 www.EmersonProcess.
