Emerson Process Management 3808 manual

www.EmersonProcess.com/Remote Instruction Manual CI-ControlWave Express Feb., 2009 Bristol Control Wave Ex p ress Bristol ControlWave Express (Remote Terminal Unit) Remo te Au toma tio n So lution s Click here to return to Table of Contents[...]

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING! Be sure that these instruction s are carefully read and und erstood before any operation is attempted. Improper use of this device in some ap plications may result in damage or injury. The user is urged to keep this book filed in a convenient location for futu re refe rence. These instructions may not c[...]

WARRANTY A. Remote Automation Solutions (RAS) warrants th at goods described herein and manufactured by RAS a re free from defects in material and workmanship for one year from the date of shipm ent unless otherwise agreed to by RAS in writing. B. RAS warrants that goods repai red by it pursuant to the warranty are free fro m defects in material an[...]

How to return material for Repair or Exchange Before a product can be returned to Remote Automation So lutions (RAS) for repa ir, upgrade, exchange, or to verify proper operation, Form (GBU 13.01) must be co mpleted in order to obtain a RA (Return Authorization ) number and thus ensure an optimal lead time. Co mpleting the form is very important si[...]

Remote Automation Solutions (RAS) Repair Authorization Form (on-line completion) ( Providing this information will permit Bristol, also doi ng business as Remote Auto mation Solutions (RAS) to effectively and efficiently process y our return. Completion is required to receiv e optimal lead time. Lack of information may result in increased lead time[...]

Emerson Process Management Training GET THE MOST FROM YOUR EMERSON 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 essentia l to your op[...]

CI-ControlW ave Express - Installation Forward CI-ControlWave Express Control Wave Express Remote Terminal Unit INSTALLATION FORWARD NOTE for all Control Wave Express Installers: READ THIS SECTION FIRST! This manual has been designed for the following audience: • Customer Site Engineers, who must plan for the installation and implementation of th[...]

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CI-ControlWave Express Contents / 0 - 1 CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - Control Wave Express INTRODUCTION 1.1 GENERAL DESCRIPTION ........................................................................................... 1-1 1.2 ControlWave PROGRAMMING ENVIRONMENT [...]

0 - 2 / Contents CI-ControlWave Express CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 2 - ControlWave Express INSTALLATION & OPERATION (Continued) 2.3.3.2 Communication Ports .................................................................................................. . 2-10[...]

CI-ControlWave Express Contents / 0 - 3 CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 3 - ControlWave Express SERVICE 3.1 SERVICE INTRODUCTION ........................................................................................ 3-1 3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES ...[...]

0 - 4 / Contents CI-ControlWave Express CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # APPENDICES/SUPPLEMENTAL INSTRUCTION (Continued) Sources for Obtaining Material Sa fety Data Sheets ..................................... Appendix Z Site Considerations for Equipment In stallation, Grounding[...]

CI-ControlWave Express Introduction / 1-1 Section 1 Control Wave Express INTRODUCTION 1.1 GENERAL DESCRIPTION ControlWave Express remote terminal units (R TU) have been designed to perform as the ideal platform for remote site automation, measurement and data management in process control and manufacturing. ControlWave Expr ess RTUs measure tempera[...]

1-2 / Introduction CI-ControlWave Express microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC) is the core of the CPU/System Controller Board. In addition to the microprocessor and control logic, the CPU/System Controller Board incl udes two fixed RS-232 Communication Ports (COM1 & COM2), 1 configurable (RS-232/RS-485) Co[...]

CI-ControlWave Express Introduction / 1-3 1.2 ControlWave PROGRAMMING ENVIRONMENT The ControlWave programming environment uses industry-standard tools and protocols to provide a flexible, adaptable approach for vari ous process control applications in the water treatment, wastewater treatment, and industrial automation business. Figure 1-2 - Contro[...]

1-4 / Introduction CI-ControlWave Express • ControlWave Designer programming package offers se veral different methods for generating and debugging con trol strategy programs including function blocks, ladder logic, structured languages, etc. The result ing programs are fully compatible with IEC 61131-3 standards. Various communication methods as[...]

CI-ControlWave Express Introduction / 1-5 will remain on. When interfaced to a keypad, the operator may activate the display at any time by pressing the appropriate front panel button. 1.3.2 CPU/System Controller Board The multilayer CPU/System Controller Board provides ControlWave Express CPU, I/O monitor/control, memory and communication function[...]

1-6 / Introduction CI-ControlWave Express S1 1 2 34 12 3 4 56 7 8 1 1 2 2 3 4 5 6 RJ-45 RJ-45 W3: 1-2 = Battery Enabled 2-3 = Battery Disabled W2: 1-2 = COM2 CTS from Port W5: 1-2 = 12/24V P ower Supply Shut-down Hysterisis Shut-down Hysterisis 2-3 = 6V Power Supply W6: 1-2 = 12V Power Supply Shut-down Shut-down 2-3 = 6/24V Power Supply 2-3 = CO M2[...]

CI-ControlWave Express Introduction / 1-7 A supervisory circuit is used to switch to batte ry power when VCC falls out of specification. For maximum shelf life, the battery may be is olated from the circuit by removing the Backup Battery Jumper W3 from position 1 to 2 and then storing it in position 2 to 3. If the real-time clock looses its battery[...]

1-8 / Introduction CI-ControlWave Express Table 1-1 - CPU/System Controller Board Connector Summary (Continued) Ref. # Pins Function Notes TB1 6-pin Solar Panel, Battery/Power Supply & Aux Out, Main Power Connector See Section 2.3.9 TB2 2-pin Secondary battery input TB3 8-pin Term. Block (COM2 - RS -232) See Table 2-3A or 4-2 TB4 5-pin Term. Bl[...]

CI-ControlWave Express Introduction / 1-9 • TB1-4 - Ground (GND) • TB1-5 - Auxiliary Power Out+: for an external radio/modem * • TB1-6 - Ground (GND) • TB2-1 - Secondary battery input • TB2-2 - Ground (GND) Note: * = Not available on units equipped with an Ethernet Port. Power may be provided by a user supplied re chargeable 6/12V Lead Ac[...]

1-10 / Introduction CI-ControlWave Express 1.3.2.3 CPU/System Controller Board Configuration Jumpers ControlWave Express CPU/System Contro ller Board are provided with 12 User Configuration Jumpers that function as follows: • W1 - COM1 CTS Use Selection 1 to 2 = COM1 CTS Source is from Device 2 to 3 = COM1 RTS to CTS Loopback • W2 - COM2 CTS Us[...]

CI-ControlWave Express Introduction / 1-11 • W17 - Input Power Selection (Controls Sola r Power Shunt Reg.) N/A for +24Vdc CPUs 1 to 2 = 6V Power 2 to 3 = 12V Power • W18 - COM1 Connector Selection 1 to 2 = Connector J4 (D connector) is active 2 to 3 = Alternate connector J11 is active 1.3.2.4 CPU/System Controller Board Configuration Switches [...]

1-12 / Introduction CI-ControlWave Express Table 1-4 - CPU/System Controller Bd. Switch SW3 Assignments RS-485 Loopback & Termination Control (COM3) Switch RS-485 Function Switch ON Setting SW3-1 TX+ to RX+ Loopback/2-Wire ON – 2-Wire Operation or Loopback Enabled OFF – 4-Wire Operation & Loopback Disabled SW3-2 TX − to RX − Loopbac[...]

CI-ControlWave Express Introduction / 1-13 • Two Non-Isolated Internally-Sourced High Speed Counter Inputs (or DI operation supported) • Three Non-Isolated Single-Ended 1-5V or 4 to 20mA Analog Inputs (Optional) • One Non-Isolated Externally-Powered 1-5V or 4 to 20mA Analog Output (Optional) 1.3.3.1 Process I/O Board Configuration Jumpers and[...]

1-14 / Introduction CI-ControlWave Express Figure 1-4 - ControlWave Express Process I/O Board Click here to return to Table of Contents[...]

CI-ControlWave Express Introduction / 1-15 1.3.3.2 Process I/O Board Connectors Process I/O Boards are equipped with up to si x (6) I/O interface connectors that function as follows (see Table 1-5): Table 1-5 - Process I/O Board Connector Summary Ref. # Pins Function Notes P1 20-Pin Bd. Power and I/O Bus In tf. to CPU/System Controller Bd. TB2 6-Pi[...]

1-16 / Introduction CI-ControlWave Express power is applied to the field device (controlle d via jumper JP4) and can be supplied by the system battery or an external power source. Ea ch AI channel can be individually configured for 4 to 20mA or 1-5V operation (via JP5 for AI1, JP6 for AI2 and JP7 for AI3). AIs are supplied with a two hertz low pass[...]

CI-ControlWave Express Introduction / 1-17 • Uses pre-configured web pages for user re adings, configuration and maintenance. Web pages can be modified and new pages configur ed to work with a modified application load • Resides on a BSAP SCADA network • Provides audit trail and archives • Allows the user to select engineerin g units, inclu[...]

1-18 / Introduction CI-ControlWave Express RS-232 or RS-485 operation. Any serial comm unication port can be configured for local communications, i.e., connected to a PC load ed with ControlWave Designer and OpenBSI software. RS-232 Ports An RS-232 interface supports Point-to-Point , half-duplex and full-duplex communications (20 feet maximum, usin[...]

CI-ControlWave Express Installation & Operation / 2-1 Section 2 Control Wave Express INSTALLATION & OPERATION 2.1 INSTALLATION IN HAZARDOUS AREAS Each ControlWave Express RTU is furnished in an enclosure/chassis that accommodates mounting to a Panel or a DIN-Rail and have been designed to operate in a protected Class I, Division 2, Groups C[...]

2-2 / Installation & Operation CI-ControlWave Express Chassis. Two Thumb Screws can be loosened to facilitate removal of the Card Edge Cover, and thus accommodating all instrument fi eld wiring. Information on mounting the ControlWave Express assembly is provided in Section 2.3.1 Mounting the ControlWave Express. 2.2.1 Temperature & Humidit[...]

CI-ControlWave Express Installation & Operation / 2-3 5. Install I/O wiring to the Process I/O Boar d and to the CPU/System Controller Board if Pulse Inputs are present (see Section 2.3.4). Install a communications cable to a Model 3808 Transmitter if required (see Section 2.3.6). 6. Install a ground wire between the Enclos ure and a known good[...]

2-4 / Installation & Operation CI-ControlWave Express Detailed information on the Flash Configurat ion Utility, and LocalView is included in Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in Chapter 6 of that same manual. TechView is described in the TechView User’s Guide (document# D5131). Step 4. Create [...]

CI-ControlWave Express Installation & Operation / 2-5 You can use whichever HTML creation package yo u want to create the pages, however, all ControlWave Express related web pages (whether standard or user-created) must be viewed within Microsoft® Internet Explorer. The web pa ges may reside either on a PC workstation, or they can be downloade[...]

2-6 / Installation & Operation CI-ControlWave Express Figure 2-2 - ControlWave Express Dimensions - Power wiring should not be installed until the unit has been mounted and grounded at a designated work site. - I/O wiring, external power wiring, local comm. port, and network (RS-232 and RS-485) comm. port cabling enter the unit though a slot on[...]

CI-ControlWave Express Installation & Operation / 2-7 2.3.2 Process I/O Board Configuration I/O Board jumpers and Switch SW1 must be se t to configure field I/O (see Figure 2-3). Figure 2-3 - Process I/O Board Component Identification Diagram Click here to return to Table of Contents[...]

2-8 / Installation & Operation CI-ControlWave Express 2.3.3 CPU/System Controller Board Configuration To configure the CPU/System Controller Board, Jumpers must be set (see Figure 2-4), DIP- Switches must be set (see Section 2.3.3.1) and Communication Ports must be wired (see Sections 2.3.3.2 through 2.3.3.3). For safety reasons and to prevent [...]

CI-ControlWave Express Installation & Operation / 2-9 S1 1 2 3 4 12 34 56 7 8 1 1 2 2 3 4 5 6 RJ-45 RJ-45 W3: 1-2 = Ba ttery Enabled 2-3 = Battery Disabled W2: 1-2 = COM2 CTS from Port W5: 1-2 = 12/24V Power Supply Shut-d ow n Hyster i sis Shut-down Hysterisis 2-3 = 6V Power Supply W6: 1-2 = 12V Power Supply Shut-down Shut-down 2-3 = 6/24V Powe[...]

2-10 / Installation & Operation CI-ControlWave Express SW2-5 set OFF forces the ControlWave Ex p r e s s to reinitialize SRAM when the unit recovers from a low power or power outage condition. When set ON, the contents of SRAM will be retained and utilized when the system restarts. Note: If the Battery is removed from the CPU Module (CPU remove[...]

CI-ControlWave Express Installation & Operation / 2-11 Figure 2-5 - Communication Ports – CPU Board RS-232 Cable Wiring Diagram Click here to return to Table of Contents[...]

2-12 / Installation & Operation CI-ControlWave Express Diagrams of RS-232/485 interfaces and connectors are shown in Figures 2-4 and 2-5 Hardware connector pin wiring assignments ar e provided in Tables 2-3A through 2-3C. 2.3.3.3 RS-232 & RS-485 Interfaces ControlWave Express RS-232 & RS-485 communi cation schemes are discussed herein. [...]

CI-ControlWave Express Installation & Operation / 2-13 Table 2-3B - RS-232 Port (COM1) Alternate Connector (COM1 Connector J11) Pin # Signal RS-232 Description: RS-232 Signals 1 GND Power Ground 2 RXD Receive Data Input 3 TXD Transmit Data Output NOTE: Choice of COM1 connectors (J4 or J11) det ermined by jum per W18. 2.2.3.3.2 RS-485 Ports Cont[...]

2-14 / Installation & Operation CI-ControlWave Express Table 2-4 - RS-485 Network Connections (see Table 2-3C ControlWave Express RS-485 Port Pin # Assignments) From Master To 1st Slave To nth Slave TXD+ RXD+ RXD+ TXD − RXD − RXD − RXD+ TXD+ TXD+ RXD − TXD − TXD − GND/ISOGND* GND/ISOGND* GND/ISOGND* * ISOGND with Isolated RS-485 Por[...]

CI-ControlWave Express Installation & Operation / 2-15 18 Looking into recept acle Figure 2-6 - RJ-45 Connector (Ethernet Port) J1 on CPU/System Controller Board Figure 2-7 - Point-to-Point 10/100Base-T Ethernet Cable Figure 2-8 - Standard 10/100Base-T Ethernet Cable (CPU/System Controller Board to Hub) Table 2-6 - Ethernet 10/100Base-T Pin Ass[...]

2-16 / Installation & Operation CI-ControlWave Express 2.3.4 I/O Wiring ControlWave Express RTUs are provided with ca rd edge terminal blocks that accommodate field wiring. Wiring is routed into the encl osure/chassis through a slot in the removable card edge cover. 2.3.4.1 I/O Wire Connections ControlWave Express RTUs utilize terminal blocks e[...]

CI-ControlWave Express Installation & Operation / 2-17 Figure 2-9 – Process I/O Board Field I/O Wiring Diagrams Click here to return to Table of Contents[...]

2-18 / Installation & Operation CI-ControlWave Express 2.3.4.4 Dedicated Non-isolated Digital Outputs Process I/O Board Terminal Bl ock connector TB3 provides in terface to 2 dedicated non- isolated Digital Outputs (DOs) and two se lectable DI/Os. Digital Outputs have a 30V operating range and are driven by Open Dr ain MOSFETs that provide 400 [...]

CI-ControlWave Express Installation & Operation / 2-19 Note: Cable shields associated with AI wiring shou ld be connected to the ControlWave Express Chassis Ground. Multiple shield terminations will require a user supplied copper ground bus. This ground bus must be con nected to the ControlWave Express Chassis Ground (using up to a #4 AWG wire [...]

2-20 / Installation & Operation CI-ControlWave Express 2.3.4.8 Non-isolated High Speed Counter/Digital Inputs Process I/O Board Terminal Block connector TB4 provides the interface to two internally- sourced single-ended High Speed Counter/Digit al Inputs (HSC/DIs). All Input circuits have surge suppression and signal conditioning. HS C inputs a[...]

CI-ControlWave Express Installation & Operation / 2-21 2.3.5 RTD Wiring A 3-wire RTD may be provided with the Co ntrolWave Express (equipped with a 14MHz CPU/System Controller Board). Connector TB6 on the CPU/System Controller Board accommodates a removable three-wire Terminal Block (TB6). This connector accommodates a 100-ohm platinum bulb usi[...]

2-22 / Installation & Operation CI-ControlWave Express 2.3.6 Connection to a Model 3808 Transmitter A Model 3808 Transmitter (Digital) can be interf aced to a ControlWave Ex p re ss via an RS- 232 or an RS-485 communication scheme. Communication schemes and cable lengths determine the type of communication port ut ilized. In general RS-232 comm[...]

CI-ControlWave Express Installation & Operation / 2-23 Figure 2-15 - ControlWave Express to 3808s - RS-485 Network Diagram Figures 2-13 and 2-14 detail the RS-232 and RS-485 wiring connections required between the ControlWave Express and the Model 3808 Transmitter. Up to two Model 3808 Transmitters can be co nnected to a ControlWave Express via[...]

2-24 / Installation & Operation CI-ControlWave Express • TB1-1 - Solar Power In + (TB1-2 = GND ) (GND = − ) • TB1-5 - Auxiliary Power Out + - for Exte rnal Radio/Modem (TB1-6 = GND) (GND = − ) A secondary power input is available at connector TB2: • TB2-1 – Input • TB2-2 – Ground ControlWave Express Terminal Blocks utilize compr[...]

CI-ControlWave Express Installation & Operation / 2-25 2.3.7.2 Power Wiring One Bulk DC supply can be connected to the ControlWave E xp r es s CPU/System Controller Board. The Bulk DC supply (nominally +6Vd c, +12Vdc or +24Vdc) connected to TB1-3 (Power In +) and TB1-4 (GND -) is converted, regulated and filtered by the CPU/System Controller Bo[...]

2-26 / Installation & Operation CI-ControlWave Express 2.3.8 Operation of the Lithium Backup Coin-cell Battery CPU/System Controller Boards are equippe d with a Coin-cell Socket (S1) that accommodates a 3.0V, 300 mA-hr lithium coin cell. A supervisory circuit on the CPU/System Controller Board is used to switch to battery power when the regulat[...]

CI-ControlWave Express Installation & Operation / 2-27 familiar with the various programming tools. Th e following software user documentation is referenced: Getting Started with ControlWave Designer Manual - D5085 ControlWave Designer Reference Manual - D5088 Open BSI Utilities Manual - D5081 Web_BSI Manual - D5087 ControlWave Designer Program[...]

2-28 / Installation & Operation CI-ControlWave Express purpose must be set to run at 115.2 Kbaud . ControlWave Express CPU Switch SW1, position, 3 must be set ON. Start LocalView, Choose FLASH, Enter A Name, Click on [Create] Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView . The New View Mode dialog box will appe[...]

CI-ControlWave Express Installation & Operation / 2-29 Step 3 - Flash Data Setup Complete the following fields in the Flash Data Setup Wizard: "Please enter the name of the binary file to Flash" To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file on your hard disk containing the firmware. Click on [[...]

2-30 / Installation & Operation CI-ControlWave Express Figure 2-19 - Flash RTU Setup Menu Click here to return to Table of Contents[...]

CI-ControlWave Express Installation & Operation / 2-31 Figure 2-20 - Flash Data Setup Menu (Note: Substitute e1s xxxx bin or e3s xxxx for cwe04...) Figure 2-21 - Local View Downloading System Firmware Menu Click here to return to Table of Contents[...]

2-32 / Installation & Operation CI-ControlWave Express 2.4.2.2 Using HyperTerminal to Upgrade ControlWave Express Firmware A half-duplex null modem cable (see Figure 2- 5) must be connected to COM1 of the ControlWave Express and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this purpose must be set to run at 115.2 Kba[...]

CI-ControlWave Express Installation & Operation / 2-33 5. When the FLASH is ready for download the letter C will be displayed on the screen. In the HyperTerminal command bar click on Tr ansfer and then Send File (see Figure 2- 23). In the Send File Dialog Box (see Figure 2-24), select “1KXmodem” for the protocol, enter the filename of the a[...]

2-34 / Installation & Operation CI-ControlWave Express Figure 2-25 - HyperTerminal FLASH Download (Download in Process) (Note: Substitute e1s xxxx bin or e3s xxxx .bin for cwe04... ) Figure 2-26 - CPU/System Controller LEDs (See Figure 2-27 and Table 2-12 for Status LED Definitions) Click here to return to Table of Contents[...]

CI-ControlWave Express Installation & Operation / 2-35 Figure 2-27 - CPU/System Controller LED Board - LED Hexadecimal Codes (See Table 2-12 for Definitions) Table 2-12 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Display Board. LED 6 STA6 LED 5 STA5 LED 4 STA4 LED 3 STA3 LED 2 STA2 LED 1 STA1 Status In[...]

2-36 / Installation & Operation CI-ControlWave Express 2.4.2.3 Remote Upgrade of ControlWave Express Firmware It is possible to download system firmwa re into an unattended remote ControlWave Express. This function can only be accomp lished if CPU Board Switch SW2-6 (associated with the unit in question) is set in the ON position (factory defau[...]

CI-ControlWave Express Installation & Operation / 2-37 WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program. COM3: RS-232/RS-485 Communications Port COM3 on the CPU/System Controller Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol opera[...]

2-38 / Installation & Operation CI-ControlWave Express Figure 2-28 - LCD Display (Only) Assembly Installation Drawing 2.4.5.2 Operation of the Dual-button Display/Keypad Assembly The Display will have a timeout of 20 minutes. If there has been no keypad activity for this time the display will “logout,” i.e., the displa y will be turned off [...]

CI-ControlWave Express Installation & Operation / 2-39 Figure 2-29 - Dual-button Display/Keypad Assembly Installation Drawing Displays are organized into screens as follows: Opening Screen: User defined strings List Selection Screen: List Name List Number <Blank Line> <Blank Line> The List Selection screen is entered from the main o[...]

2-40 / Installation & Operation CI-ControlWave Express Figure 2-30 - 25-Button Display/Keypad Assembly Installation Drawing Display Element Screen: <Blank Line> <Blank Line> Variable Name Variable Name The Display Element screen is entered from th e list selection screen by pressing the right arrow. Once here the operator can view t[...]

CI-ControlWave Express Installation & Operation / 2-41 Automatic Mode In Automatic mode a set of screens (based on the application) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for displaying the screens and resp onding to key presses. Screens are fixed and start off w[...]

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CI-ControlWave Express Service / 3-1 Section 3 Control Wav e Express SERVICE 3.1 SERVICE INTRODUCTION This section provides general, diagnostic and test information for the ControlWave Express. The service procedures described herein will require the following equipment: 1. PC with null modem interface cable & Bristol WINDIAG Software 2. Loop-b[...]

3-2 / Service CI-ControlWave Express 3.2.2 Removal/Replacement of the CPU/System Controller Board & the Process I/O Board 1. Loosen the two Thumb Screws and remo ve the Removable Card Edge Cover. 2. If the ControlWave Express is running, pl ace any critical control processes under manual control and shut down the unit by disconnecting power to [...]

CI-ControlWave Express Service / 3-3 Bulk supply voltages can be checked at TB1 using a voltmeter or multimeter. CPU/System Controller Board Assemblies are factory configur ed for use with a nominal 6Vdc or 12Vdc bulk power supply. The maximum and minimum input power switch-points can be tested with the use of a Variable dc Power Supply connected b[...]

3-4 / Service CI-ControlWave Express Figure 3-1 - CPU/System Controller LED Board – Status LED Hexadecimal Codes (See Table 3-1 for Definitions) Table 3-1 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Display Board. LED 6 STA6 LED 5 STA5 LED 4 STA4 LED 3 STA3 LED 2 STA2 LED 1 STA1 Status In Hex LCD Disp. I[...]

CI-ControlWave Express Service / 3-5 1 1 0 0 0 0 30 NO APP No Application Loaded 1 1 1 0 0 0 38 BREAKP Running with Break Points 1 1 1 0 1 1 3B POWERD Waiting for Power-down (after NMI) 1 1 1 1 1 0 3E UPDUMP Waiting for Updump to be Performed 1 1 1 1 1 1 3F NOTRUN Unit Crashed (Watchdog Disabled) * = Flashed at startup 3.3.3 Wiring/Signal Checks Ch[...]

3-6 / Service CI-ControlWave Express S1 1 2 3 4 12 34 56 7 8 1 1 2 2 3 4 5 6 RJ-45 RJ-45 W3: 1-2 = Ba ttery Enabled 2-3 = Battery Disabled W2: 1-2 = COM2 CTS from Port W5: 1-2 = 12/24V Power Supply Shut-d ow n Hyster i sis Shut-down Hysterisis 2-3 = 6V Power Supply W6: 1-2 = 12V Power Supply Shut-down Shut-down 2-3 = 6/24V Power Supply 2-3 = COM2 C[...]

CI-ControlWave Express Service / 3-7 Figure 3-3 - Process I/O Board Component Identification Diagram Click here to return to Table of Contents[...]

3-8 / Service CI-ControlWave Express Figure 3-4 - Process I/O Board Field I/O Wiring Diagram Click here to return to Table of Contents[...]

CI-ControlWave Express Service / 3-9 Figure 3-5 - CPU/System Controller Board Field I/O Wiring Diagram 3.4.2 Disconnecting RAM Battery The ControlWave Express RTU Lithium RAM batte ry cannot be replaced while power is on. Once the RAM battery has been replaced, the unit will still execute its FLASH-based application (Boot Project) upon power-up, bu[...]

3-10 / Service CI-ControlWave Express • CPU/System Controller Board Switch SW 2-8 must be OFF to run the WINDIAG program. Setting SW2-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode. • Any ControlWave Express communication po rt can be connected to the PC provided their port speeds and configu[...]

CI-ControlWave Express Service / 3-11 Figure 3-6 – NetView - Example with Multiple Networks Figure 3-7 - WINDIAG Main Diagnostics Screen Click here to return to Table of Contents[...]

3-12 / Service CI-ControlWave Express 4. Select the module to be tested. Enter any pr ompted parameters (slot #, etc.). WINDIAG will perform the diagnostics and display pass/fail results. 5. After all diagnostic testing has been perfor med, exit WINDIAG program and then exit the NetView. When you close Netview, you will be prompted as to whether or[...]

CI-ControlWave Express Service / 3-13 Figure 3-8 - COM1 & COM2 RS-232 Loop-back Plug/Wires Figure 3-9 - COM3 RS-232 & RS-485 Loop-back Wires Note: RS-485 Loopback can be achieved via CPU Switches SW3-1 & SW3-2 set ON 3.5.1.2 Serial Comm. Port External Loop-back Test Procedure Connect an external loop-back plug or loop- back wires to the[...]

3-14 / Service CI-ControlWave Express Figure 3-10 - WINDIAG’s Communications Diagnostic Menu 3.6 CORE UPDUMP In some cases a copy of the contents of S RAM and SDRAM can be uploaded to a PC for evaluation by Emerson Remote Automation Solu tions division engineers. This upload is referred to as a ‘Core Updump.’ A Core Up dump may be required if[...]

CI-ControlWave Express Service / 3-15 1. Set CPU/System Controller Board Switch SW2-1 OFF (Disable Watchdog Timer). If Switch SW2-4 is ON, set it to OFF (Enable Core Updump). Note: The factory default setting for SW2-4 is OFF. 2. Wait for the error condition (typically 3F on CPU/System Controller Board Status LEDs or NOTRUN on optional LCD Display)[...]

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CI-ControlWave Express Specifications / 4- 1 Section 4 Control Wave Express SPECIFICATIONS 4.1 CPU, MEMORY & PROGRAM INTERFACE Processor: Sharp’s LH7A400 32-bit System-on-Chip with 32-bit ARM9TDMI RISC Core Memory: 8 Mbytes of simultaneous read/write FLASH 2 Mbyte of on-board SRAM 512 Kbytes FLASH Boot/Downloader Real Time Clock: A Semtech SH[...]

4-2 / Specifications CI-ControlWave Express 4.2.2 Power Supply Sequencer Specs. Signals Monitored: Input Power Sequencer Switchpoints: +3.3V Ma x. ON Switchpoint = +3.15V +3.3V Min. OFF Switchpoint = +3.00V +1.8V Max. ON Switchpoint = +1.72V +1.8V Min. OFF Switchpoint = +1.64V Sequencer Output Signals: PFDLYCLK Timi ng on power down 2msec after POW[...]

CI-ControlWave Express Specifications / 4- 3 Table 4-2 - RS-232 Ports (COM1 & 2) Connector Pin Assignments (J4 - COM1 & TB3 COM2) Located on CPU/System Controller Bd. Pin # Signal RS-232 Description: RS-232 Signals 1 DCD Data Carrier Detect Input 2 RXD Receive Data Input 3 TXD Transmit Data Output 4 DTR Data Terminal Ready Output 5 GND Sign[...]

4-4 / Specifications CI-ControlWave Express Table 4-3 - RS-232/485 Port (COM3) Connector TB4 Pin Assignments Pin # Signal RS-232 Description: RS-232 Signals Signal RS-485 Description: RS-485 Signals 1 - - RXD+ Receive Data + Input 2 RXD Receive Data Input- RXD − Receive Data − Input 3 TXD Transmit Data Output TXD − Transmit Data − Output 4 [...]

CI-ControlWave Express Specifications / 4- 5 Max. Input Frequency: 10 kHz Signal conditioning: 20 microsecond Filtering. Figure 4-5 - 4-Position Pulse In put Interface Terminal Block TB5 RTD Input Note: Only Available on 14MHz CPUs RTD Type: 100-ohm platinum bulb (using the DIN 43760 curve). Configuration: The common three-wire configuration is acc[...]

4-6 / Specifications CI-ControlWave Express Figure 4-7 - Process I/O Board Edge View (Connector Identification) Click here to return to Table of Contents[...]

CI-ControlWave Express Specifications / 4- 7 4.3.2 Non-isolated Digital Input/Output Circuitry Specs. Non-isolated Digital Inputs Number of Inputs: 4 Fixed, 2 Selectable DI - Internally Sourced (Dry Contact) operation Input Filtering: 15 milliseconds Input Current: Switch Selectable (SW1-3) DI1 through DI4 (SW1-3: ON = 2mA, OFF = 60uA) DI5 & DI[...]

4-8 / Specifications CI-ControlWave Express Input Impedance: 1 Meg ohm for 1-5V inputs 250 ohm for 4-20mA inputs Settling Time: 600 msec to within 0.1% of input signal Conversion Time: 20 usec Non-isolated Analog Outputs Number of Outputs: 1 AO (1-5V or 4- 20mA) individually jumper configurable 4-20mA Output Compliance: 250 ohm load with 11V Extern[...]

CI-ControlWave Express Specifications / 4- 9 Input Frequency: Individually switch-s electable high (10kHz Max), or low (300 Hz). SW1-1 (HSC1), SW1-2 (HSC2). Input filtering: 20 microseconds on high speed (HS) and 1 millisecond on low speed (LS). Signal Conditioning: Bandwidth limiting ON State Voltage: below 1.46V OFF State Voltage: above 1.90V Bus[...]

4-10 / Specifications CI-ControlWave Express Figure 4-8 - Control Wave Express Dimensions Click here to return to Table of Contents[...]

Control Wave Express Special Instructions for Class I, Division 2 Hazardous Locations 04/24/2006 Appendix A, Document CI-ControlWave Express Page 1 of 2 1. Bristol’s Control Wave Express RTU is listed by Underwriters Laboratories (UL) as nonincendive and (when installed in a NEMA 1 or better enclosure) is su itable for use in Class I, Division 2,[...]

Control Wave Express Special Instructions for Class I, Division 2 Hazardous Locations 04/24/2006 Appendix A, Document CI-ControlWave Express Page 2 of 2 Table A1 -Module/Board Connector Customer Wiring Connectors (Continued) Module/Item Connector Wiring Notes Process I/O Board TB2: 6-pin Term. Block DI Interface Discrete Input Field Wiring: Field I[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-1 Appendix C HARDWARE INSTALLATION GUIDE Hardware Configuration There are seven (7) main steps required to conf igure a ControlWave Express. This appendix provides an overview of these steps with an em phasis on the installation and configuration of the hardware. This appendix is i[...]

C-2 / Appendix C - Hardware Installation Guide CI-ControlWave Express S1 1 2 34 12 3 4 56 7 8 1 1 2 2 3 4 5 6 RJ-45 RJ-45 W3: 1-2 = Batt ery Enabled 2-3 = Battery Disabled W2: 1-2 = COM2 CTS from Por t W5: 1-2 = 12/2 4V Power Su pply Shut-down Hyste ris is Shut-down Hyst erisis 2-3 = 6V Power S up ply W6: 1-2 = 12 V Power Supp ly Shut-down Shut-dow[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-3 Figure C-3 – Process I/O Board Component Identification Diagram Click here to return to Table of Contents[...]

C-4 / Appendix C - Hardware Installation Guide CI-ControlWave Express Step 1. Hardware Configuration (Continued) 2. Remove the Process I/O Board and the CPU/ System Controller Board (as one assembly). Table C-1 - CPU/System Controller Bd. Switch SW1 Recovery Mode/Local Mode Control SWITCH Function Setting SW1-1/2 Recovery/Local Mode * Both ON or OF[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-5 Step 1. Hardware Configuration (Continued) 3. Make sure that the Lithium Backup Batte ry has been enabled, i.e., Backup Battery Jumper W3 on the CPU/System Controller Assembly should be installed on jumper posts 1-2). Configure the CPU/System Co ntroller Board DIP-Switches and Ju[...]

C-6 / Appendix C - Hardware Installation Guide CI-ControlWave Express COM6 of a ControlWaveEXP, the cable of Figure C-4D must be used along with the one of Figure C-4A or C-4B. Figure C-4 - Communication Port RS-232 Cable Wiring Diagram Click here to return to Table of Contents[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-7 Step 1. Hardware Configuration (Continued) Tables C-4A through C-4C provide the co nnector pin assignments for the Comm. Ports. Note: The following facts regarding Co ntrolWave Express RS-232 serial communication ports should be observ ed when constructing communications cables: [...]

C-8 / Appendix C - Hardware Installation Guide CI-ControlWave Express Step 1. Hardware Configuration (Continued) RS-485 Ports ControlWave Express RTUs can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for network communications, Table C-5 provides the appro[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-9 a one-to-one wiring configuration as show n in Figure C-7. Table C-6 provides the assignments and definitions of the 8-pin 10/100Base-T connector. It is possible to connect two nodes in a point- to-point configuration without the use of a Hub. However, the cable used must be conf[...]

C-10 / Appendix C - Hardware Installation Guide CI-ControlWave Express Step 1. Hardware Configuration (Continued) 5. Install I/O wiring to the Process I/O Board and CPU/System Controller Board (see Figures C-11 and C-12 and Section 2.3.4 if required). Install a communications cable between the ControlWave Express and a Model 3808 Transmitter (Netwo[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-11 Step 1. Hardware Configuration (Continued) Up to two (2) Model 3808 Transmitters can be connected to a ControlWave Express via a half duplex RS-485 Network. An illustration of this network is provided in Figure C- 10. Figure C-10 - ControlWave Express to 3808s - RS-485 Network D[...]

C-12 / Appendix C - Hardware Installation Guide CI-ControlWave Express Figure C-12 – Process I/O Board Field I/O Wiring Diagrams Click here to return to Table of Contents[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-13 Step 1. Hardware Configuration (Continued) 6. Install a ground wire between the Enclos ure/Chassis and a known good Earth Ground. ControlWave Express Enclosures are not prov ided with a Ground Lug. A ground wire (#4 AWG Max. wire size) must be run between the Enclosure/Chassis v[...]

C-14 / Appendix C - Hardware Installation Guide CI-ControlWave Express subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will limit the available system resources. IMPORTANT: When you start ControlWave Designer, you will be reminded to register the software. Unregistered software can only be used for a maximum of[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-15 On the variables declaration page(s) in Con trolWave Designer, you will need to mark any variable you want to make accessible to exter nal programs, such as Open BSI’s DataView utility, as “PDD” . Similarly, any variables which should be collected into a database, or expor[...]

C-16 / Appendix C - Hardware Installation Guide CI-ControlWave Express the ControlWave Express is reset, or if there has been a failure of the backup battery, the control strategy can be restarted from th e beginning, i.e. from the BOOT project in FLASH memory. Downloading the Application Any ControlWave Ex pr es s must have a configured ControlWav[...]

CI-ControlWave Express Appendix C - Hardware Installation Guide / C-17 IDLE (Red) - the CPU has free time at the end of its execution cycle and may be overloaded TX1, TX2, TX3 (Red) - transmit activity on COM1, COM2 & COM3 (respectively) RX1, RX2, RX3 (Red) - receive activity on COM1, COM2 & COM3 (respectively) Six Status LEDs (Red) - provi[...]

C-18 / Appendix C - Hardware Installation Guide CI-ControlWave Express (See Table C-7 for Definitions) Table C-7 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Board. LED 6 STA6 LED 5 STA5 LED 4 STA4 LED 3 STA3 LED 2 STA2 LED 1 STA1 Status In Hex LCD Disp. Indication Definition 0 0 0 0 0 0 00 Blank Applicatio[...]

www.EmersonProcess.com/Bristol Instruction Manual CI-ControlWave Express Oct., 2006 Control Wave Ex p ress ControlWave Express DISPLAY/KEYPAD ASSEMBLY - GUIDE Appendix E Click here to return to Table of Contents[...]

CI-ControlWave Express Appendix E – Display/Keypad Contents / 0 - 1 APPENDIX E Control Wave Express Display/Keypad Assembly Guide TABLE OF CONTENTS SECTION TITLE PAGE # E1.1 OVERVIEW ................................................................................................................ ... E-1 E2.1 DISPLAY FUNCTION BLOCK DESCRIPTION ....[...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 1 Appendix E DISPLAY/KEYPAD ASSEMBLY GUIDE E1.1 OVERVIEW Bristol Display/Keypad assemblies provide a built-in, local, user interface for the Control Wave Express These assemblies allow an operator or engineer to view and modify variable values and associated status information, via an ACCOL3 [...]

E - 2 / Appendix E - Display/5x5Keypad CI-ControlWave Express Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode . Automatic Mode In Automatic Mode a set of screens (based on the application load) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for disp[...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 3 Figure 2 - ACCOL3 DISPLAY Function Block Parameters E3.1 PREPARING THE ControlWave PROJECT In order for the keypad and display to oper ate, the ControlWave Designer project must include a properly configured Display Function Block. Once the Keypad is operating, a user who has signed on with[...]

E - 4 / Appendix E - Display/5x5Keypad CI-ControlWave Express Figure 3 - Creating the Identifier Message Step 2: Defining a Scroll List Once the Keypad is operating properly, yo u can automatically scroll through a list of variables created via DISPLAY Functi on Block Parameters iiList2Scroll and iiListMode . Scrolling can be done without entering [...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 5 Note 1 : If your display shows something else, press the [F4] key until you see the words Login and Scroll on the bottom line. If your screen is blank, turn the brightness screw clockwise. This screw is located to the left of the Keypad (looking at the rear of the 25-Button Display/Keypad A[...]

E - 6 / Appendix E - Display/5x5Keypad CI-ControlWave Express formation will appear on the screen and remain there for 1 to 30 seconds (default = 2). The variable name appears on the first line. The variable value appears on the second line and status information appears on the third line. An example is shown in Figure 6. When all variables in the [...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 7 If your password is not recognized, the asterisks will be erased after you press [ENTER]. Check your password and try again. Figure 7 - Logging On Once the correct password has been entered, the display will look like Figure 7C. When the second line shows READ/WRITE, you can read and write [...]

E - 8 / Appendix E - Display/5x5Keypad CI-ControlWave Express The current time is shown in the form of hours:minutes:seconds. Figure 8 - Clock Display E4.1.3.1 Changing the Time From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third line. Enter the new time there and press [ENTER]. Valid times range from 00:00:00 t[...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 9 E4.1.4 Choosing a Variable List from the List Menu The List Menu is another area where variable information can be seen. As explained earlier in this section, your first opportunity to read variable information is by choosing the SCROLL function from the Initial Display. The variable name a[...]

E - 10 / Appendix E - Display/5x5Keypad CI-ControlWave Express time, you must first log-off and then lo g-on using the correct password. See your Systems Engineer for the correct password. Before making any changes, first check the sig nal inhibit status field (See Figure 12). When the display shows ME (manual enable) you can change variable parame[...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 11 Notes for Figure 12 1. Variable Name (Example 1: @GV.FLOW_ RATE) (Example 2: @GV.TOTAL_FLOW_RATE) 2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be shown as asterisks. Analog values are displayed in floating poin t format, for example, 0[...]

E - 12 / Appendix E - Display/5x5Keypad CI-ControlWave Express 1) String SITE_NAME WEST SUNBURY PUMP STATION CE ME 2) Analog TOTAL_FLOW_RATE 1260.578 CE MI 3) Logical FLOW_ALARM OFF CE MI AE NA E4.1.7 Signing-Off Once you have logged-on, use the [INIT] key at any time to log-off. When this key has been pressed, the screen will look like Figure 13. [...]

CI-ControlWave Express Appendix E - Display/Keypad / E - 13 E5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO. Figure 14 - 25-Button Display/Keyp ad Assembly Installation Drawing Click here to return to Table of Contents[...]

E - 14 / Appendix E - Display/5x5Keypad CI-ControlWave Express Figure 15 - 25 Button Keypad Table 1 - 25 Button Keypad Keys KEY FUNCTION F1, F2, F3, F4 Function keys will take on a variety of different functions depending on the situation. The function of these keys is lis ted on the legend line (bottom line) of the display. INIT The INIT key is us[...]

02/4/09 Appendix Z - CI-ControlWave Express MSDS 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 Part Number DURACELL[...]

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SITE CONSIDERA TIONS For EQUIPMENT INST ALLA TION, GROUNDING & WIRING Bristol Babcock Supplement Guide - S1400CW Issue: 04/05 A Guide for the Protection of Site Equipment & P ersonnel In the Installation of ControlW ave Process Automation Controllers TM Click here to return to Table of Contents[...]

NOTICE Copyright Notice The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate inform ation. However, Bristol Babcock assumes no responsibility for any errors that may appear in this document. Request for Additional Instructions Additional copies of instruction manuals ma y b[...]

Supplement S1400CW Page 0-1 Table Of Co ntents Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # S ection 1 - IN T R ODUC T ION 1.1 G ENERAL INTRODUCTION ....................................................................................... 1-1 1.2 MAJO R TOPICS .[...]

Supplement S1400CW Page 0-2 Table Of Co ntents Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # S e ct i o n 5 - W IRING T ECHNIQUES (C o n t i nue d ) 5.2.2 U se of Tw isted Shielded Pair Wi ring (with Over all Insulation).................................. 5-2 5.[...]

Section 1 - O verview Page 1-1 S1400CW Section 1 - Overview 1.1 INTRODUCTION This document provides inf ormation pertaining to the instal lation of Control Wave systems; mor e specifically, information co vering rea sons, theory and techniques fo r protecting your personnel and equipment fr om electr ical da mage. Y our instrumen t sy stem affects [...]

Section 2 - Pro tectio n Page 2-1 S1400CW Section 2 - Protection 2.1 PROTECTING IN STRUMEN T SYSTEMS Electrical in stru mentation is susce ptible to damage from a variety o f natural and man made phenomena. In additi on to wind, rain and fire , the most common types of system and equipment damaging phenomena are lightning , p ower faults , communi [...]

S1400CW Page 2-2 Section 2 - Protec tion 2.2.1 Consideration s For T he Protection of Personnel Always evaluate the si te environm ent as if yo ur li fe depended on it. Mak e sure that you understand the physi cal nature of the location where you will be working . Table 2-1 provides a general guideline for ev aluating an installa tion si te. Table [...]

Section 2 - Pro tectio n Page 2-3 S1400CW Table 2-2 - Equipment Protect ion Site Safety Evaluation G uide (Continu ed) # Guide Reference Section 6 Is there an antenna i n the immediat e area? See S ection 4. 1.2 7 How close is other eq uipment? Can someone sa fely touch this equipment a nd a Control Wave simu ltaneou sly? See Secti on 2.3 8 Determi[...]

Section 3 - Grounding & Isola tion Page 3-1 S1400CW Section 3 - Grounding & Isolation 3.1 POWER & GROUND SYSTEMS Control Waves utilize DC power systems. AC po wer supplies are not provided with Con- trol Wave units. Control Wave, Control Wave MICRO , Contro l Wave EFM/GFC/EFC , Control Wave RED , Control Wave REDIO and Control Wave I/O [...]

S1400CW Page 3-2 Section 3 - Grounding & I solation not be suitable for a complex system of sophis ticated electronic equipment. Conditions such as soil type, composition and moisture will all have a bearing on ground reliabilit y. A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into conductive earth to a [...]

Section 3 - Grounding & Isola tion Page 3-3 S1400CW ground has been established, it should be tested on a regular basis to preser ve 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 Megg[...]

S1400CW Page 3-4 Section 3 - Grounding & I solation Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is indicated, one or more additional ground ro ds connected 10 feet from the main ground rod should be driven into the soil and inte rconnected via bare AWG 0000 copper wire and 1” x ¼-20 cable clamps as i[...]

Section 3 - Grounding & Isola tion Page 3-5 S1400CW Figure 3-5 - Poor Soil Ground Bed Construction Diagram 3.3.2 Ground Wire Considerations Control Wave, Cont rol Wave MICRO , Control Wave EFM/ GFC/XFC , Control- Wave RED , Control Wave REDIO & Control Wave I/O Expansion Rack Control Wave Chassis are provided with a Ground Lug that accommod[...]

S1400CW Page 3-6 Section 3 - Grounding & I solation Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a conductive mounting panel or plate, a user su pplied 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 Considera[...]

Section 3 - Grounding & Isola tion Page 3-7 S1400CW For applications employing equipment that co mmunicates over telephone lines, a lightning arrester Must B e provided. For indoor equipment the lig htning 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[...]

S1400CW Page 3-8 Section 3 - Grounding & I solation grounded to the pipeline. If any pressure tr ansmitters or pulse transducers are remotely mounted, connect their chassis grounds to the pipeline or earth ground. Figure 3-8 - Control Wave EFM (Installation is similar to GFC/XFC) Remote Installation without Cathodic Protection 3.4.2 Meter Runs [...]

Section 3 - Grounding & Isola tion Page 3-9 S1400CW • 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 Control Wave EFM/GFC and turbine meter, pulse transducer, or any input other device that is mounted [...]

S1400CW Page 3-10 Section 3 - G rounding & Isolation See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds. Figure 3-10 – Control Wave EFM (Installation is similar to GFC/XFC) Remote Installation (with Cathodic Protection) Click here to return to Table of Contents[...]

Section 4 - Lightning & Surge Page 4-1 S1400CW 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 impul[...]

S1400CW Page 4-2 Section 4 - Lightning & Surge Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the United States there is an average of 30 thund erstorm 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 th[...]

Section 4 - Lightning & Surge Page 4-3 S1400CW modem has been interfaced to a Control Wav e, Control Wave MICRO , Control Wave EFM/GFC/XFC , Cont rol Wave LP , or Control Wave EXP 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 t[...]

S1400CW Page 4-4 Section 4 - Lightning & Surge Figure 4-2 - Radio Antenna Field In stallation Site Grounding Diagram For all systems it is best to have all communi cation equipment input/output grounds tied together. In the case of Control Wave units, this is accomplished via the unit’s Chassis Ground (Typically at a ground lug, ground bus or[...]

Section 4 - Lightning & Surge Page 4-5 S1400CW 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 ar e tied together via bare copper wire. 4.1.3 Ground Propagation As in any medium, a [...]

S1400CW Page 4-6 Section 4 - Lightning & Surge i Watch out for dissimilar metals connections and coat acco rdingly. i Use bare wire radials together where possibl e with ground sta kes to reduce ground system impedance. i Use I/O protectors (Phone line, Radio) with a low inductance pat h to the ground system. i Ground the Coaxial Cable Shield ([...]

Section 5 - Wiring Techniques Page 5-1 S1400CW Section 5 - Wiring Techniques 5.1 OVERVIEW This section provides information pertaining to good wiring practices. Installation of Power and “Measurement & Control” wiring is di scussed. Information on obscure problems, circulating ground and power loops, bad relays , etc. is presented. Good wir[...]

S1400CW Page 5-2 Section 5 - Wiring Techniques 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 dis crete insulation for each of[...]

Section 5 - Wiring Techniques Page 5-3 S1400CW 5.2.3 Grounding of Cable Shields DO NOT connect the cable shield to more than on e ground point; it should only be grounded at one end. Cable shields that are grounded at more th an one point or at both ends may have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O [...]

S1400CW Page 5-4 Section 5 - Wiring Techniques Remember loose connections, bad connections, intermittent connections, corroded connec- tions, etc., are hard to find, waste time, create system problems and confusion in addition to being costly. 5.2.7 High Power Conducto rs and Signal Wiring When routing wires, keep high power conducto rs away from s[...]

Section 5 - Wiring Techniques Page 5-5 S1400CW 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 ([...]

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READER RESPONSE FORM Please help us make our documentation m ore us eful to you! If you have a complaint, a sug- gestion, or a correction regarding this manual, please tell us by m ailing this page with your comments. It' s the only way we know we're doi ng our job by giving you co rrect, complete, and useful documentation. DOCUMENT NUMBE[...]

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 Gulf Coast Region Bristol Babcock Inc. 2000 Governor's Circle Suite F Houston, TX 77092-8731 Phone: +1 (713) 685-6200 Fax: +1 (713) 681-7331 SouthwestUS@bristolbabcock.c[...]

ESDS Ma n ual S14006 4/15/92 CARE AND HANDLING OF PC B O ARDS AND E SD-SENSITIVE COMPONENTS BRISTOL BABCOCK Click here to return to Table of Contents[...]

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1 ESDS Manual S14006 4/15/92 T ABLE 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 T OOLS AND M A TERIALS REQUIRED 1. Tools Anti-Static Field kit.[...]

2 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 Mic[...]

3 ESDS Manual S14006 4/15/92 Table 1 Typical Electrostatic Voltages Electrostatic Voltages Means of Static 10-20 Percent 65-90 Percent Generation Relative Humidity Relative Humidity Walking across carpet 35,000 1,500 Walking over vinyl floor 12,000 250 Worker at bench 6,000 100 Vinyl envelopes for work instructions 7,000 600 Poly bag picked up from[...]

4 ESDS Manual #S14006 4/15/92 (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[...]

5 ESDS Manual S14006 4/15/92 CA UTION Don't place ESD-sensitive components and paperwork in the same bag. The static caused by sliding the paper into the bag could develop a charge and damage the component(s). (9) Include a note, which describes the malfunction, in a separate bag along with each component being shipped. The repair facility wil[...]

6 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 ne[...]

7 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 t[...]

8 ESDS Manual #S14006 4/15/92 (9) If a component is to undergo on-site testing, it may be safely placed on the grounded work surface for that purpose. (10) After all component work is accomplished, remove the wrist straps and ground wire and place in the pouch of the work surface for future use. 5. Cleaning And Lubricating The following procedure s[...]

9 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 [...]

10 ESDS Manual #S14006 4/15/92 d. Spray the connector liberally to flush out any contaminants. e. Remove any excess spray by shaking the connector or wiping with either a toothbrush, or a lint-free wiping cloth. 6. Completion (1) Replace any parts that were removed. (2) Make sure that the component cover is secure. (3 ) Return the system to normal [...]

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Customer Instruction Manual CI-ControlWave Express February, 2009 Bristol ControlWave Express (Remote Terminal Unit) NOTICE “Remote Automation Solutions (“RAS”), division of Emerson Process Management shall not be liabl e for technical or editorial errors in this manual or omissions from this manual. RAS MAKES NO WARRANTIES, EXPRESSED OR IMPL[...]