Emerson ControlWave XFC User Manual

Instruction Manual

CI-ControlWave XFC
Oct., 2006

ControlWave XFC

(Explosion Proof Gas Flow Computer

ControlWave XFC

www.EmersonProcess.com/Bristol

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. Should problems arise that are not covered sufficiently in the text, the pur­chaser is advised to contact Bristol for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for
whatever reason, may leave an operating process without protection. Depending upon
the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment
or provide alternate means of protection such as alarm devices, output limiting, fail­safe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional
in-formation is required, the purchaser is advised to contact Bristol .

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note
the following: The party sending such materials is responsible to ensure that the
materials returned to Bristol are clean to safe levels, as such levels are defined and/or
determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Bristol and save Bristol harmless from any liability or
damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic in­struments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by
exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude
and duration of the ESD, this can result in erratic operation or complete failure of the
equipment. Read supplemental document S14006 at the back of this manual for
proper care and handling of ESD-sensitive components.

Bristol 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

A. Bristol warrants that goods described herein and manufactured by Bristol are free

from defects in material and workmanship for one year from the date of shipment
unless otherwise agreed to by Bristol in writing.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from

defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited

to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part

thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written

or oral warranties beyond those set forth herein.

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or

replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Water­town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incidental or consequential

damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.

REMEDIES

How to return material for Repair or Exchange

Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify
proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very
important since the information permits the Bristol Repair Dept. to effectively and
efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX
Completing the form (GBU 13.01) and faxing it to [phone]. A Bristol Repair

Dept. representative will return call (or other requested method) with a RA number.

B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)

and sending it via E-Mail to [e-mail]
representative will return E-Mail (or other requested method) with a RA number.

C. Mail
Mail the form (GBU 13.01) to

Bristol Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

A Bristol Repair Dept. representative will return call (or other requested method)

with a RA number.

D. Phone

Calling the Bristol Repair Department at [phone]. A Bristol Repair Depart-

ment representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in­cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.

. A Bristol Repair Dept.

Bristol Inc. Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required

to receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is

practice may be requested in the “Special Requests” section.

• Evaluate / Test / Verify Discrepancy

• Repair / Replace / etc. in accordance with this form

• Return to Customer

Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)
Bill to : Ship to:

Purchase Order: Contact Name:____________________________________
Phone: Fax: E-Mail:

Part II Please complete Parts II & III for each unit returned

Model No./Part No. Description

Please be aware of the Non warranty standard charge:

• There is a $100 minimum evaluation charge, which is

applied to the repair if applicable (√ in “returned”
B,C, or D of part III below)

Range/Calibration S/N
Reason for return

: Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________

3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due

to Bristol’s warranty clause, would you like the product:

repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,
would you like the product:

C. If product is deemed not repairable would you like your product:
D. If Bristol is unable to verify the discrepancy, would you like the product:

repaired returned replaced scrapped?

returned replaced scrapped?
returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact

that has the most knowledge of the problem is: ______________________________ phone_____________________

If we are unable to contact this person the backup person is: _________________________
Special Requests: ____________________________________________________________________________________

phone_____________________

____________________________________________________________________________________________________

Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: [phone] Fax: [phone] Form GBU 13.01 Rev. B 04/11/06

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

• Avoid Delays and problems in getting your system on-line

• Minimize installation, start-up and maintenance costs.

• Make the most effective use of our hardware and software.

• Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at three locations: Houston, Orlando and our Watertown, CT
headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol products and realize the full
potential of your system.

For information or to enroll in any class, contact our training department in Watertown at
[phone]. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

A Few Words About Bristol Inc.

For over 100 years, Bristol® has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Inc. instruments, controllers, and systems running year-in and
year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis­tance in using this product from the following sources:

Help Files / Release Notes

Many Bristol software products incorporate help screens. In addition, the software typically
includes a ‘read me’ release notes file detailing new features in the product, as well as other
information which was available too late for inclusion in the manual.

Contacting Bristol Inc. Directly

Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.

Our main phone numbers are:

[phone]
[phone] (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.

For technical questions about TeleFlow products call [phone].

For technical questions about ControlWave call [phone] or [phone].

For technical questions regarding Bristol’s OpenEnterprise product, call [phone]
or e-mail: [e-mail]

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call [phone].

For technical questions about Network 3000 hardware, call [phone].

You can e-mail the Application Support Group at: [e-mail]

The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at [phone] or [phone].

You can e-mail the Communication Technology Group at:

[e-mail]

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed on the rear cover of
this manual) or to your Bristol-authorized sales representative.

Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office
covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol’s Training Department offers a wide variety of courses in Bristol hardware and
software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at [phone] for course
information, enrollment, pricing, and scheduling.

CI-ControlWave XFC

ControlWave XFC

Explosion Proof Gas Flow Computer

INSTALLATION FORWARD

NOTE for all ControlWave XFC Installers:

READ THIS SECTION FIRST!

This manual has been designed for the following audience:

• Customer Site Engineers, who must plan for the installation and implementation of the

ControlWave XFC.

• Instructors who must become familiar with and teach Field Engineers/Technicians on

the installation, operation and repair of ControlWave XFC.

• Field Engineers/Technicians who must install and service the ControlWave XFC.

Installation instructions for the ControlWave XFC are provided in Section 2 of this
manual.

Section 2 - Installation & Operation

operation of the ControlWave XFC. Section 2 provides all the information required for
instructors who are training individuals unfamiliar with the ControlWave XFC. It is also
intended to support anyone who needs to learn how to install and operate the Control-
Wave XFC for the first time, or as a reference document for those who are already familiar
with the unit.

A Windows driven diagnostic tool referred to as WINDIAG is provided on the
OpenBSI Software CDROM. WINDIAG is documented in instruction manual
D4041A – Window Diagnostics for Bristol Controllers
provides menu driven diagnostics that have been designed to assist a technician
or Process Engineer in troubleshooting the various ControlWave XFC circuits. A
brief overview is provided in Section 3.5 of this manual. For more detailed
descriptions of ControlWave XFC Windows Diagnostics than those provided
herein, see Document D4041A – Chapters 1 and 7C.

provides a detailed overview of the installation and

NOTE:

. Bristol’s WINDIAG program

CI-ControlWave XFC - Installation Forward

BLANK PAGE

CI-ControlWave XFC

ControlWave XFC

Model 3820-EX - Explosion Proof Gas Flow Computer

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 - ControlWave XFC INTRODUCTION

1.1 GENERAL DESCRIPTION ........................................................................................... 1-1

1.2 ControlWave PROGRAMMING ENVIRONMENT ....................................................1-3

1.3 PHYSICAL DESCRIPTION........................................................................................... 1-5

1.3.1 Housing ........................................................................................................................... 1-5

1.3.2 ControlWave XFC Function Module.............................................................................. 1-6

1.3.3 CPU Board Assembly ..................................................................................................... 1-6

1.3.3.1 CPU Board Connector P2...............................................................................................1-8

1.3.3.2 CPU Memory................................................................................................................... 1-9

1.3.3.3 CPU Board Battery Enable Configuration Jumper...................................................... 1-9

1.3.3.4 CPU Board LEDs............................................................................................................ 1-9

1.3.3.5 CPU Board General Purpose Configuration Switche SW1 .......................................... 1-9

1.3.4 I/O Board Assembly...................................................................................................... 1-10

1.3.4.1 I/O Board Connectors ................................................................................................... 1-10

1.3.5 Terminal Plate .............................................................................................................. 1-11

1.3.5.1 Field I/O Wiring ............................................................................................................ 1-11

1.3.5.1.1 Non-isolated Analog I/O ...............................................................................................1-11

1.3.5.1.2 Non-isolated Digital I/O ...............................................................................................1-12

1.3.5.1.3 Non-isolated High Speed Counter Inputs ...................................................................1-12

1.3.5.1.4 Optional RTD Input Probe ........................................................................................... 1-13

1.3.5.2 Terminal Plate Input Power Connections................................................................... 1-13

1.3.5.3 Terminal Plate Communication Port Connections..................................................... 1-13

1.3.6 Multivariable or Gage Pressure Transducer............................................................... 1-13

1.3.7 RTD Probe..................................................................................................................... 1-13

1.4 FIELD WIRING............................................................................................................1-13

1.5 FUNCTIONS................................................................................................................. 1-14

1.5.1 Data Acquisition ........................................................................................................... 1-14

1.5.2 Flow and Volume Calculations ....................................................................................1-15

1.5.2.1 Flow Rate and Flow Time Calculations (AGA3) ......................................................... 1-15

1.5.2.2 Flow Rate Calculations and Flow Time Accumulations (AGA7) ............................... 1-15

1.5.2.3 Extension Calculation and Analog Averaging ............................................................ 1-15

1.5.2.3.1 Energy Calculation ....................................................................................................... 1-16

1.5.2.3.2 Volume and Energy Integration ..................................................................................1-16

1.5.2.4 Downstream Pressure Tap........................................................................................... 1-16

1.5.3 Archives.........................................................................................................................1-16

1.5.3.1 Hourly Historical Data Log.......................................................................................... 1-16

1.5.3.2 Daily Historical Data Log ............................................................................................1-17

1.5.3.3 Periodic Historical Data Log........................................................................................ 1-17

1.5.3.4 Alarm and Event Storage............................................................................................. 1-17

1.5.4 LCD Display..................................................................................................................1-18

1.5.5 Communications ........................................................................................................... 1-18

1.5.5.1 BSAP Message Support................................................................................................ 1-19

1.5.6 Discrete and Analog I/O XFC Functionality ............................................................... 1-19

1.5.6.1 Flow Rate Control - DDC (jog control) using PID....................................................... 1-19

1.5.6.2 Pulse Output for External Totalizer or Sampler ........................................................ 1-19

1.5.6.3 Nominations.................................................................................................................. 1-20

1.5.7 Self Test & Diagnostics ................................................................................................1-20

CI-ControlWave XFC Contents / 0 - 1

CI-ControlWave XFC

ControlWave XFC

Model 3820-EX - Explosion Proof Gas Flow Computer

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1A - PRODUCT FEATURES & OVERVIEW

1A.1 PRODUCT OVERVIEW.............................................................................................. 1A-1

1A.1.1 Hardware Features......................................................................................................1A-1

1A.1.2 Firmware and Software Features............................................................................... 1A-1

1A.2 PRODUCT FAMILY COMPATIBILITY .................................................................... 1A-2

1A.2.1 Open Standards for Programming, Network Config. and Communication ............. 1A-2

1A.2.2 ControlWave Designer with ACCOL III................................................................... 1A-2

1A.2.3 ACCOL III.................................................................................................................... 1A-2

1A.3 STANDARD APPLICATION PROGRAM.................................................................. 1A-3

1A.3.1 OpenBSI - Simply Creative......................................................................................... 1A-3

1A.3.2 OpenBSI Utilities ........................................................................................................ 1A-4

1A.3.3 Real-time ActiveX Controls......................................................................................... 1A-4

1A.3.3.1 ActiveX Controls .......................................................................................................... 1A-5

1A.3.3.2 Required Software ....................................................................................................... 1A-5

1A.3.4 Historical Data Collection ........................................................................................... 1A-5

1A.3.5 OPC Server .................................................................................................................. 1A-5

1A.4 ControlWave OPEN NETWORK CONNECTIVITY................................................ 1A-6

1A.4.1 Communication Protocols............................................................................................ 1A-6

1A.4.1.1 BSAP Protocol .............................................................................................................. 1A-6

1A.4.1.2 Modbus Protocol........................................................................................................... 1A-7

1A.4.1.3 Generic Serial Interface ..............................................................................................1A-7

Section 2 - INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1

2.2 SITE LOCATION CONSIDERATIONS........................................................................ 2-2

2.2.1 Temperature & Humidity Limits .................................................................................. 2-2

2.2.2 Vibration Limits ............................................................................................................. 2-2

2.3 ControlWave XFC INSTALLATION/CONFIGURATION ......................................... 2-2

2.3.1 Mounting the ControlWave XFC ................................................................................. 2-5

2.3.1.1 Connection to the Multivariable Transducer (MVT) .................................................... 2-9

2.3.1.2 Connection of the Gage4 Pressure Transducer (GPT)................................................ 2-10

2.3.1.3 Case Rotation................................................................................................................ 2-10

2.3.1.4 Process Pipeline Connection (Meter Runs without Cathodic Protection) ................. 2-10

2.3.1.5 Process Pipeline Connection (Meter Runs with Cathodic Protection)....................... 2-12

2.3.2 CPU Board Configuration ............................................................................................ 2-13

2.3.2.1 CPU Board Switch SW1 Configuration....................................................................... 2-13

2.3.2.2 Communication Ports................................................................................................... 2-15

2.3.2.3 RS-232 & RS-485 Interfaces ........................................................................................2-16

2.3.3 I/O Wiring......................................................................................................................2-18

2.3.3.1 I/O Wire Connections....................................................................................................2-18

2.3.3.2 Shielding and Grounding ............................................................................................. 2-19

2.3.3.3 Non-isolated Discrete Input/Output Connector Block J5........................................... 2-19

2.3.3.3.1 Discrete Input/Output Configurations ........................................................................2-19

2.3.3.4 Non-isolated Analog Input Connector Block J4.......................................................... 2-19

2.3.3.4.1 Analog Input Configurations ....................................................................................... 2-20

0 - 2 / Contents CI-ControlWave XFC

CI-ControlWave XFC

ControlWave XFC

Model 3820-EX - Explosion Proof Gas Flow Computer

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 2 - INSTALLATION & OPERATION (Continued)

2.3.3.5 Non-isolated Analog Output Connector Block J4 ....................................................... 2-20

2.3.3.5.1 Analog Output Configurations..................................................................................... 2-20

2.3.3.6 Non-isolated High Speed Counter Input Connector J5.............................................. 2-20

2.3.3.6.1 High Speed Counter Configurations............................................................................ 2-20

2.3.4 RTD Wiring ................................................................................................................... 2-21

2.3.4.1 Bendable RTD Installation .......................................................................................... 2-22

2.3.5 Connection to a Model 3808 Transmitter.................................................................... 2-23

2.3.6 Power Wiring & Distribution ....................................................................................... 2-24

2.3.6.1 Bulk Power Supply Current Requirements ................................................................ 2-25

2.3.6.2 Power Wiring ................................................................................................................ 2-25

2.3.6.3 ControlWave XFC System Grounding ...................................................................... 2-25

2.3.7 Operation of the Lithium Backup Coin-cell Battery .................................................. 2-25

2.4 OPERATIONAL DETAILS .......................................................................................... 2-26

2.4.1 Downloading the Application Load.............................................................................. 2-26

2.4.2 Upgrading ControlWave XFC Firmware .................................................................. 2-27

2.4.2.1 Using LocalView to Upgrade ControlWave XFC Firmware .................................... 2-27

2.4.2.2 Using Hyperterminal to Upgrade ControlWave XFC Firmware............................. 2-30

2.4.2.3 Remote Upgrade of ControlWave XFC Firmware ...................................................... 2-33

2.4.3 Operation of CPU Switch SW1 Mode Functions......................................................... 2-33

2.4.4 Soft Switch Configuration and Communication Ports ...............................................2-33

2.4.5 Display Assembly..........................................................................................................2-34

Section 3 - SERVICE

3.1 SERVICE INTRODUCTION ........................................................................................3-1

3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1

3.2.1 Accessing Components for Testing ................................................................................ 3-1

3.2.2 Removal/Replacement of the Function Module ............................................................ 3-2

3.2.3 Removal/Replacement of the MVT or GPT Transducer ............................................... 3-2

3.2.4 Removal/Replacement of the Lithium RAM Battery.................................................... 3-2

3.3 TROUBLESHOOTING TIPS......................................................................................... 3-4

3.3.1 Power Checks.................................................................................................................. 3-4

3.3.2 LCD Display System Status Codes................................................................................ 3-4

3.3.3 LED Checks .................................................................................................................... 3-4

3.3.4 Wiring/Signal Checks ..................................................................................................... 3-5

3.4 GENERAL SERVICE NOTES....................................................................................... 3-6

3.4.1 Extent of Field Repairs................................................................................................... 3-6

3.4.2 Maintaining Backup Files.............................................................................................. 3-6

3.5 WINDIAG DIAGNOSTICS ............................................................................................ 3-6

3.5.1 Diagnostics Using WINDIAG ........................................................................................ 3-9

3.5.1.1 Communications Diagnostic Port Loop-back Test........................................................ 3-9

3.5.1.2 Serial Comm. Port Eternal Loop-back Test Procedure ................................................ 3-9

3.6 CORE UPDUMP........................................................................................................... 3-11

3.7 CALIBRATION CHECKS............................................................................................ 3-11

CI-ControlWave XFC Contents / 0 - 3

CI-ControlWave XFC

ControlWave XFC

Model 3820-EX - Explosion Proof Gas Flow Computer

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 4 - SPECIFICATIONS

4.1 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1

4.2 COMMUNICATION PORTS ......................................................................................... 4-1

4.3 INPUT POWER SPECIFICATIONS ............................................................................ 4-2

4.4 I/O BOARD SPECIFICATIONS .................................................................................... 4-2

4.4.1 External Power Monitor Specs. ..................................................................................... 4-2

4.4.2 Power Supply Sequencer Specs. .................................................................................... 4-2

4.4.3 Non-isolated Digital Input/Output Circuitry Specs...................................................... 4-3

4.4.4 Non-isolated Analog Input/Output Circuitry Specs. ....................................................4-3

4.4.5 Non-isolated High Speed Counter Input Circuitry Specs. ...........................................4-4

4.4.6 Function Module Terminal Plate Connectors ............................................................... 4-4

4.5 TERMINAL PLATE SPECIFICATIONS ...................................................................... 4-4

4.6 ENVIRONMENTAL SPECIFICATIONS...................................................................... 4-5

4.7 DIMENSIONS ................................................................................................................ 4-5

APPENDICES/SUPPLEMENTAL INSTRUCTION

Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A

Special Instructions for Class I, Division 1 Hazardous Locations.................Appendix B

Using ControlWave XFC WebBSI Web Pages.............................................. Appendix F

MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z

Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW

Care and Handling of PC Boards and ESD-Sensitive Components .....................S14006

REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS

WINDIAG - Windows Diagnostics for Bristol Controllers ................................... D4041A

Open BSI Utilities Manual ...................................................................................... D5081

Getting Started with ControlWave Designer........................................................ D5085

Web_BSI Manual...................................................................................................... D5087

ControlWave Designer Reference Manual ............................................................ D5088

ControlWaveMICRO Quick Setup Guide ............................................................. D5124

ControlWave Designer Programmer’s Handbook................................................... D5125

TechView User’s Guide............................................................................................. D5131

0 - 4 / Contents CI-ControlWave XFC

Section 1

ControlWave XFC INTRODUCTION

1.1 GENERAL DESCRIPTION

Model 3820-EX - ControlWave XFC explosion proof gas flow computers have been

designed to perform as the ideal platform for direct mount oil/gas main automation,
measurement and data management in the oil and gas industry. ControlWave XFCs
measure differential pressure and static pressure and temperature for up to two runs and
compute flow for both volume and energy. In addition to operation in an unprotected
outdoor environment, the ControlWave XFC explosion proof gas flow computer provides
the following key features.

Model 3820-EX Hardware/Packaging Features:

• 32-bit ARM9 processor (LH7A400) provides exceptional performance and low power
consumption

• Wide operating temperature range: (-40 to +80°C) (-40 to 176°F)

• Two Board System Platform (CPU/Comm./Power Managemen

• Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,

300mA-hr lithium coin cell battery located on the CPU Module

• Very low power consumption - minimizes costs of solar panel/battery power systems

• Integral Multivariable Transducer (MVT) with “smart” performance (for DP or GP

measurement) or Gage Pressure Transducer (for GP measurement)

• Three serial communications ports (Two RS-232 & One RS-485)

• Integral 2-line LCD operates in a continuous cycle mode

• Optional I/O includes: 2 Digital Inputs (DI), 2 High Speed Counter Inputs (HSC), 4

Digital Outputs (DO), 3 Analog Inputs (AI) and 1 Analog Output (AO)

• RTD input

• Explosion Proof Class I, Division 1, Groups C & D Locations (see Appendix B) or

Nonincendive Class I, Division 2, Groups A, B, C and D Hazardous Locations (see
Appendix A)

• Readily integrates with Bristol Babcock model 2808 and 3808 MVT low power
transmitters for explosion proof installations

• Cost effective for small chart replacement or RTU/Process Controller applications

Model 3820-EX Firmware/Software Features

• Preprogrammed to meet API 21.1 requirements for a two-run metering station (with
networking via BSAP or Modbus)

• Functions as a Process Controller or Remote Terminal Unit (RTU)

• Standard Application Program supports the following Flow calculations:

• Calculates AGA3-1995/NX-19

• AGA3-1992 with selectable AGA8 Gross or AGA8 Detail

• 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

• Instromet Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail

• Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail

• WebBSI Web pages are preconfigured for all user operations

• Additional, standard application programs will be introduced on a continual basis

• Using our ControlWave Designer IEC 61131-3 Programming Environment, any user or

third party can modify the standard application or create a completely customized
program – full support from Bristol Babcock is available, every step of the way

t and I/O Board)

CI-ControlWave XFC Introduction / 1-1

• ControlWave XFCs are compatible with Bristol Babcock’s TeleFlow-series in software
and networking solutions for SCADA and EFM (Electronic Flow Meter) data
editing/management, and are similar in all operations.

ControlWave XFC explosion proof gas flow computers are furnished in an explosion proof
enclosure. In addition to the explosion proof case (enclosure), the gas flow computer
hardware is comprised of an internal Function Module and either a Multivariable
Transducer (MVT) or a Gage Pressure Transducer (GPT) that is mounted on the bottom of
the enclosure. The Function Module consists of a CPU Board, System Controller & I/O
Board, an LCD Display Module, a Terminal Plate Assembly, and mounting hardware.
Sharp’s LH7A400 System-on-Chip Advanced RISC Machine (ARM) microprocessor with 32­bit ARM9TDMI Reduced Instruction Set Computer (RISC) is the core of the CPU Board. In
addition to the microprocessor and control logic, the CPU Board includes 2MB of battery
backed Static RAM (SRAM), 512kB Boot/Downloader FLASH, 8MB simultaneous
read/write FLASH, SPI I/O Bus, Serial Real Time Clock, Display Interface, and three
Communication Ports [a 3-wire RS-232 Local Port (COM1), a 7-wire RS-232 Network Port
(COM2), and a 2-wire RS-485 Network Port (COM3)].

Figure 1-1 - 3820-EX - ControlWave XFC Models

1-2 / Introduction CI-ControlWave XFC

Figure 1-2 - ControlWave XFC (Isometric Views)

Component Identification Diagram (Shown with MVT)

The I/O Board contains I/O field interface circuitry and non-isolated power circuitry. Non­isolated power is generated and regulated by the I/O Board that provides +3.6Vdc for all
logic and bulk power for I/O field circuits from a bulk source of +6Vdc to +30Vdc.
Additionally, the I/O Board provides 3.3Vdc (logic power) to the CPU Board. +1.8Vdc, used
by the ARM microprocessor, is generated on the CPU Board (derived from the 3.3Vdc).

1.2 ControlWave PROGRAMMING ENVIRONMENT

ControlWave programming environment uses industry-standard tools and protocols to

provide a flexible, adaptable approach for various process control applications in the gas,
water treatment, wastewater treatment, and industrial automation business.

CI-ControlWave XFC Introduction / 1-3

ControlWave XFC units provide an ideal platform for remote site automation,
measurement, and data management in the oil and gas industry.

The control strategy file created and downloaded into the controller is referred to as a

ControlWave project. The ControlWave XFC ships from Bristol Babcock with a standard
ControlWave project, pre-configured for gas flow measurement, already loaded and ready

to run.

The ControlWave programming environment consists of a set of integrated software tools
which allow a user to modify the standard gas flow measurement project to fit the needs of
their own particular application, as well as to create, test, implement, and download a
different ControlWave project, if desired.

Figure 1-3 - ControlWave - Control Strategy Software Diagram

The tools that make up the programming environment are:

• ControlWave Designer load building package offers several different methods for

generating and debugging control strategy programs including function blocks, ladder
logic, structured languages, etc. The resulting process control load programs are fully
compatible with IEC 61131-3 standards. Various communication methods as offered,
including TCP/IP, serial links, as well as communication to Bristol Babcock’s Open BSI
software and networks

.

• The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,

allows you to define process I/O modules in the ControlWave and con-figure the
individual mapping of I/O points for digital and analog inputs and outputs.

• The ACCOL3 Firmware Library which is imported into ControlWave Designer,

includes a series of Bristol Babcock specific function blocks. These pre-programmed

1-4 / Introduction CI-ControlWave XFC

function blocks accomplish various tasks common to most user applications including
alarming, historical data storage, as well as process control algorithms such as PID
control.

• The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows

real-time data access to any OPC [Object Linking and Embedding (OLE) for Process
Control] compliant third-party software packages.

• A set of ControlWave XFC web pages is provided to set configuration parameters for

the standard gas flow measurement project, running in the unit. These web pages use
Bristol Babcock-specific ActiveX controls for retrieval of real-time data values and
communication statistics from the unit. The ActiveX controls are compatible with
Microsoft® Internet Explorer. Alternatively, developers can place the ActiveX controls
in third-party ActiveX compatible containers such as Visual BASIC or Microsoft® Excel.

• User-defined Web Pages – Users can place the same ActiveX controls into their own

web pages to provide a customized human-machine interface (HMI) to the Control-
Wave XFC.

• Flash Configuration Utility – Parameters such as the BSAP local address, IP ad-

dress, etc. are set using the Flash Configuration Utility, accessible via Open BSI
LocalView or NetView. The ControlWave XFC ships with a standard Flash Con­figuration Profile (FCP) file, with default configuration parameters already set.

1.3 PHYSICAL DESCRIPTION

ControlWave XFC gas flow computers are comprised of the following major components:

• Housing with LCD Display (Section 1.3.1)

• Function Module (Section 1.3.2)

• CPU Board Assembly (Section 1.3.3)

• I/O Board Assembly (Section 1.3.4)

• Terminal Plate (Section 1.3.5)

ControlWave XFCs can be factory configured with the following options:

• Multivariable Transducer (MVT) or Gage Pressure Transducer (GPT) (Section 1.3.6)

• RTD Probe (Section 1.3.7)

1.3.1 Housing

ControlWave XFCs are housed in an explosion proof enclosure (case) that is cast from 356

aluminum. External dimensions (are approximately 6.16” high, by 5.00” wide, by 6.19”
deep. When present, the Multivariable Transducer adds 3.02” while the Gage Pressure
Transducer adds 1.72” to the height of the unit. The housing consists of the main body and
two threaded covers, i.e., the Front/Display Cover and ther Rear/Wiring Cover.

The Front/Display Cover provides a viewing window for the LCD display. In normal
operation, the display remains running after the unit has been configured and placed into
service. Acess to the Terminal Plate is gained by removing the Rear/Wiiring Cover.

CI-ControlWave XFC Introduction / 1-5

1.3.2 ControlWave XFC Function Module

Internally the circuit boards are stood-off and mated to a Terminal Plate via an assembly
called the Function Module. The Function Module is secured to the inside of the
ControlWave XFC case via four scews. To replace a printed circuit board, the rear cover
must first be removed before removing the four screws that secure the Function Module.
Once the Function Module has been removed, the individual circuit boards are accessable
for removeal/replacement.

1.3.3 CPU Board Assembly

The multilayer CPU Board provides ControlWave XFC CPU, I/O monitor/control, memory
and communication functions. ControlWave XFC CPU Boards operate over an extended
temperature range with long-term product reliability.

ControlWave XFC CPU Boards are based on a 32-bit ARM9TDMI RISC Core Processor.
The CPU Board is specified to operate with a system clock speed of 14 MHz. The
Microcontroller is packaged in a 256-pin Plastic Ball Grid Array. In addition to the
microprocessor, memory and control logic, the CPU Board includes one fixed RS-232
communication Port (COM1), one 2-wire RS-232 communication port (Local Port) and a
two-wire RS-485 communication port (COM3). CPU Memory consists of 2MB of battery
backed Static RAM (SRAM), 512kB Boot/Downloader FLASH and 8MB simultaneous
read/write FLASH. Interface to field I/O is provided through an I/O Bus Connector.

CPU Boards are provided backup power via a coin cell socket that accepts a 3.0V, 300mA-hr
lithium battery. This 3.0V battery provides backup power for the real-time clock and the
system’s Static RAM (SRAM). Backup power is enabled when the Battery Backup Jumper
JP1 is installed.

If the 3.3Vdc that powers the unit goes out of specification (VCC-10%), a supervisory circuit
on the CPU is used to switch to battery power. For maximum shelf life, the battery may be
isolated from the circuit by removing the Backup Battery Jumper JP1 from position 1 to 2
and then storing it on either pin. If the Real-time clock looses its battery backup a
ControlWave Designer system variable bit (_QUEST_DATE) is set. This bit can be used to
post a message or alarm to the PC (see the ‘Systems Variables’ section of the ControlWave
Designer Programmer’s Handbook D5125).

The system SRAM is specified to have a standby current of 40:A maximum (plus 2uA for
the RTC). For a system containing 2MB of System SRAM, a worst-case current draw of
42:A allows a battery life of approximately 7142 hours.

LCD Interface hardware consists of a MSP430F436 micro controller and a contrast circuit
utilizing a small potentiometer (R43). The micro controller is responsible for the LCD
initialization sequence and control via commands from the SPI port.

+1.8Vdc, used by the ARM microprocessor, is generated on the CPU Module (derived from
the regulated 3.3Vdc logic power).

1-6 / Introduction CI-ControlWave XFC

REA

R

P2

1

2

BT1

Note: Connectors not shown are for Factory Use ONLY!

CR1

WD

IDLE

CR2

LCD

Contrast

R43

ON

123456

DIP

10

1
2
3
4
5
6
7
8
9

7
8910

SW1

JP1

Battery
Backup

General

Purpose

Switch

FRONT

Figure 1-4 - ControlWave XFC CPU

CI-ControlWave XFC Introduction / 1-7

Basic CPU components and features are summarized as follows:

• LH7A400 System-on-Chip 32-bit ARM9TDMI RISC Core microprocessor

• 512KB FLASH Boot/Downloader, 29LV040B, 90 nS, 8-bit access

• 2MB SRAM, 3.3V, 1024K x 16, 17nsec., with Battery Back-up

• 8MB simultaneous read/write FLASH, TSOP site

• 3 serial Comm. ports

• SPI I/O Bus Interface, three separate chip selects

• Spread Spectrum clock for lower EMI

• Serial Real Time Clock with battery backup

• 10-Position general-purpose switch bank

• Coin cell socket accepts a 3.0V, 300mA-hr lithium battery

• Display Module

1.3.3.1 CPU Board Connector P2

CPU Board connector P2 provides the interface to connector J7 on the XFC I/O Board (see
Table 1-1).

Table 1-1 - CPU Board Connector P2 - I/O Intf Signals (Pins 24 & 25 are not used)

I/O # Pins Signal Name Description

I/O 1 GND Power Ground

O 2 VCC1.8 1.8 Volt Power

I 3 VCC3 3.3 Volt Power

O 4 IORSTB#. I/O Reset

I 5 POWERGOOD Power Good
I 6 PFDLYCLK# PFDLYCLK#
I 7 PWRFAIL# PWRFAIL#I
I 8 VIN100M VIN100M

O 9 SPI_CK SPI Clock

I 10 SPI_MISO SPI Master In / Slave Out
O 11 SPI_MISI SPI Master Out / Slave In
O 12 SPI_IO_CS# SPI Chip Enable for I/O Board
O 13 232 TXD2 COM1

I 14 232 RXD2 COM1

I 15 232 DCD3 COM2

I 16 232 RXD3 COM2
O 17 232 RTS3 COM2
O 18 232 TXD3 COM2

I 19 232 CTS3 COM2
O 20 232 DTR3 COM2

I/O 21 TR+ 485 COM3
I/O 22 TR- 485 COM3

O 23 IO_CS# Spare Chip Select

I/O 26 GND Power Ground

CPU Board Serial Comm. Port Connectors (see Section 1.5.5)
The CPU Module supports up to three serial communication ports (COM1, COM2 &
COM3). COM1 provides a 3-wire half duplex RS-232 interface and is referenced on the
Terminal Plate as the Local Port. COM1 operates by sencing RS-232 levels on the TX or RX
terminals. COM2 provides a 7-wire RS-232 interface and supports half/full duplex
operation. When the ControlWave XFC has been configured for Auto DTR Mode, the DCD
signal must be high before COM2 becomes operational. COM3 supports RS-485

1-8 / Introduction CI-ControlWave XFC

communications via a 3-wire half duplex cable. All communication ports are Tranzorb
protected to ±15KV ESD.

1.3.3.2 CPU Memory

Boot/downloader FLASH

Boot/download code is contained in a single 512 Kbyte uniform sector FLASH IC. This
device resides on the local bus, operates at 3.3V and is configured for 8-bit access. 10­Position DIP-Switch (see Table 1-2) provides user configuration settings such as
enabling/disabling Recovery Mode, Core Updump, WINDIAG, etc. Note: Recovery Mode will

be initiated if CPU Switch SW1 positions 9 and 10 are both set ON or OFF when a reset
occurs.

FLASH Memory

The base version of the CPU Module has 8Mbytes of 3.3V, simultaneous read/write (DL)
FLASH memory. The CPU Board contains one 63-pin FBGA site that accepts an 8 Mbytes,

3.3V, (DL) FLASH IC. FLASH memory is 16-bits wide. System Firmware and the Boot
Project are stored here. No hardware write protection is provided for the FLASH array.

System Memory (SRAM)

The base version of the CPU Module has 2Mbytes of soldered-down static RAM, im­plemented with one 1M x 16 asynchronous SRAM that is configured as a 1M x 16-bit array.
All random access memory retained data is stored in SRAM. During power loss periods,
SRAM is placed into data retention mode (powered by a backup 3.0V lithium battery).
SRAMs operate at 3.3V and are packaged in 63-pin FBGA sites. Critical system information
that must be retained during power outages or when the system has been disabled for
maintenance is stored here. Data includes: Last states of all I/O, historical data, retain
variables and pending alarm messages not yet reported. The SRAM supports 16-bit
accesses.

1.3.3.3 CPU Board Battery Enable Configuration Jumper

ControlWave XFC CPU Board is provided with 1 User Configuration Jumper that

functions to enable/disable the backup lithium battery.

• JP1 - Battery Backup Jumper: Installed = Battery Enabled
Removed/Stored = Battery Disabled

1.3.3.4 CPU Board LEDS

Two red LEDs provide for the following status conditions when lit: WD indicates a
Watchdog condition has been detected. IDLE indicates that the CPU has free time at the
end of its execution cycle. Normally, IDLE should be ON for only 2 seconds every minute,
i.e., 2 out of 60 seconds, to save power. When the Idle LED is OFF continuously, it indicates
that the CPU has no free time, and may be overloaded.

1.3.3.5 CPU Board General Purpose Configuration Switch SW1

CPU/System Controller Board; Ten-position DIP-Switch SW1 is provided for user
configuration settings. Table 1-2 provides details on SW1 settings.

CI-ControlWave XFC Introduction / 1-9

Table 1-2 - ControlWave XFC CPU Board Switch SW1 Assignments

Note: Except for SW1-4, ON = Factory Default

SW# Function Setting - (ON = Factory Default)

SW1-1 Watchdog Enable

SW1-2

SW1-3

SW1-4

SW1-5 SRAM Control

SW1-6

SW1-7 N/A

SW1-8 Enable WINDIAG

SW1-9/10

* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher

Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches

Core Updump
See Section 3.6

System Firmware
Load Control *

Recovery/Local
Mode

ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory
defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via SW1-9 & SW1-10
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote download of System Firmware
OFF = Disable remote download of System Firmware

ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)
Both ON/OFF or SW1-9 ON & SW1-10 OFF =Recovery Mode
SW1-9 OFF & SW1-10 ON = Local Mode

1.3.4 I/O Board Assembly

The I/O Board assembly mounts against the Terminal Plate at the rear end of the Function
Module, i.e., the end furthest away from the the CPU Board. This board contains two
Microcontrollers that handles the following functions:

• Multivariable Transducer (MVT) or Gage Pressure Transducer (GPT) Interface

• Analog to Digital circuitry that monitors an external RTD and the unit’s power source

• Process I/O circuitry consisting of the following:

• Three 1-5V Analog Inputs (Optional)

• Two Discrete Inputs and Four Discrete (Sink) Outputs

• Two High Speed Counters

• One Analog Output (4 to 20mA) (Optional)

Input Power (J6) is run through a circuit that current limits the on board +V supply (for
AI’s and AO’s), and the field power for HSC devices.

The power supply operates from 6.0 to +30Vdc. A supervisory circuit monitors the incoming
power and the supply voltages. The supplies are shut down when the incoming voltage
drops to a level of +5.46Vdc (or less).

The I/O Board provides the interface hardware necessary to interconnect the assigned field
I/O circuits. Non-isolated power is generated and regulated by the I/O Board that provides
+3.6Vdc for all logic and bulk power for I/O field circuits and provides 3.3Vdc to the CPU
Board..

1.3.4.1 I/O Board Connectors

I/O Boards are equipped with 7 connectors that function as follows (see Table 1-3):

1-10 / Introduction CI-ControlWave XFC

Table 1-3 - I/O Board Connector Summary

Ref. # Pins Function Notes

J2 14-pin Comm. Port Interface To/From Term. Block J2 on Term. Plate
J3 3-pin RTD Interface. From Term Block J3 on Term. Plate
J4 11-pin AI/AO Interface To/From Term. Block J4 on Term Plate
J5 12-pin DI/DO/HSC Interface To/From Term. Block J5 on Term Plate
J6 2-pin Primary Power From Term. Block J6 on Term. Plate
J7 26-pin CPU/SPI/Power Interface To/From CPU Board Connector P2
P1 8-pin MVT or GPT Transducer Interface To/From MVT/GPT Transducer

J1

J8

1

J3

1

J5

J2

J4

P1

MVT/GPT

Intf.

J6

F1 = .375

Amp

J7

2

1

Figure 1-5 - ControlWave XFC I/O Board

Note: J1 and J8 are for Factory Use ONLY!

1.3.5 Terminal Plate

Input/Output, Communications, Input Power and RTD wiring are connected to the
Terminal Plate; accessed by removing the Rear/Wiring Cover.

1.3.5.1 Field I/O Wiring

Field I/O Wiring is supported by Connectors on the Terminal Plate Assembly as follows:

Non-isolated Analog Input/Output Connector J4 (Section 1.3.5.1.1)
Non-isolated Digital Input/Output Connector J5 (Section 1.3.5.1.2)
Non-isolated High Speed Counter Input Connector J5 (Section 1.3.5.1.3)
Optional RTD Input Connector J3 (Section 1.3.5.1.4)

1.3.5.1.1 Non-isolated Analog I/O (also see Sections 2.3.4.5 through 2.3.4.6.1)

Terninal Plate Term. Block connector J4 provides interface to three single ended Analog
Inputs and 1 Analog Output (respectively). Three field terminals (on J4) are assigned for

CI-ControlWave XFC Introduction / 1-11

each Analog Input. AI field power applied to each Analog Input can be supplied by an
external power source, or from a ControlWave XFC produced unregulated field power
supply (+V) [where +V ≈ Input Power - .6Vdc (and doesn’t exceed +15Vdc)]. Each Analog
Input support 1-5V operation.

AIs are supplied with a two hertz low pass filter and surge suppression (via 16Vdc
Transorbs).

Analog Output circuitry consists of a 16-bit resolution Digital to Analog Converter, and a V
to I circuit and provides a 4-20mA current sink.

D03

D01

D02

D04

P1

P2

G

G

DI1

DI2

G

G

RTD

+

+

J6

J5

POWER

+

+V

G

AO

NETWORK

DCD

DTR

CTS

RTS

AI3

+V

G

G

LOCAL

RXD

TXD

G

AI2

+V

G

RS485

RXD

TXD

TR+

TR-

+V

AI1

+V

J3

G

J2

J4

Figure 1-6 - ControlWave XFC Terminal Plate

1.3.5.1.2 Non-isolated Digital I/O (also see Section 2.3.4.4)

Terninal Plate, Term. Block connector J5 provides interface to 2 Digital Inputs and 4
Digital Outputs. All Digital Inputs support dry contact inputs that are pulled internally to

3.6 Vdc when the field input is open. Source current will be 60uA from the 3.6V supply. 15
millisecond input filtering protects against contact bounce.

Digital Outputs have a 30V operating range and are driven by Open Drain FETs that sink
400 mA (Max.) at 30Vdc. The maximum output frequency is 1 Hz. Transorbs provide surge
suppression between each signal and ground.

1.3.5.1.3 Non-isolated High Speed Counter Inputs (also see Sections 2.3.4.7)

Terninal Plate, Term. Block connector J5 also provides the interface to two externally
sourced single ended High Speed Counter Inputs (HSCI). Signal conditioning circuitry
provides 20 microsecond filtering. All Input circuits have surge suppression. HSC inputs
support externally generated, internally sourced input signals.

1-12 / Introduction CI-ControlWave XFC

High Speed Counter inputs are sourced from V+ with a source current of 200uA and a
maximum input frequency of 10kHz.

1.3.5.1.4 Optional RTD Input Probe (also see Section 2.3.6)

Terminal Plate, Term. Block connector J3
(using the DIN 43760 curve). The common three-wire configuration is accommodated. In
this configuration, the return lead connects to the RTD- terminal while the two junction
leads (Sense and Excitation) connect to the RTD+ terminals.

1.3.5.2 Terminal Plate Input Power Connections

A 2-position Terminal Block is provided on the Terminal Plate and accommodates input
power as follows:

• TB3 - External User supplied power (Battery or Regulated Power Supply) (6 to

+30Vdc).

1.3.5.3 Terminal Plate Communication Port Connections

Connections to two RS-232 and one RS-485 communication ports are provided via connector
J2 (see Section 2.3.2.2 and Section 2.3.2.3).

provides connection to a 100-ohm platinum bulb

1.3.6 Multivariable or Gage Pressure Transducer

The Multivariable Transducer (MVT) pressure assembly is connected to the process
manifold either directly or by tubing while the Gage Pressure Transducer (GPT) MUST
ONLY be connected via tubing. In the body of the transducer, metal diaphragms are
exposed to the gas. Solid-state strain gauge sensors in the neck of the transducer measure
the pressure applied to the diaphragms and produce proportional electrical signals.

The neck of the MVT/GPT Transducer extends into the bottom of the enclosure, with the
body of the transducer outside the enclosure. The MVT/GPT cable connector is factory
mated with I/O Board assembly connector P1.

1.3.7 RTD Probe

A 100-ohm platinum bulb (using the DIN 43760 curve) is optionally available. BBI supplied
RTDs are provided with three wires; the return lead connects to the RTD- terminal while
the two junction leads (Sense and Excitation) connect to the RTD+ terminals. RTDs
provided with a bendable conduit and a plastic bushing can only be used in Division 2
installations. Division I installations require the use of an RTD Connection Head used in
conjunction with conduit.

1.4 FIELD WIRING

ControlWave XFC explosion proof gas flow computers support connection to external field

devices through its field wiring terminals on the Function Module’s Terminal Plate.
Connections to the following types of external devices may be made:

• RTD • Digital Outputs (DOs)

• Analog Inputs (AIs) • Pulse Inputs (HSCs) • Communications (RS-232 & RS-485)

• Digital Inputs (DIs) • Analog Output (AO) • Relays

• Battery/Power Supply

CI-ControlWave XFC Introduction / 1-13

1.5 FUNCTIONS

ControlWave XFC can come with or without a base application program that satisfies API

21.1 requirements for a meter station using up to two meter runs. Using ControlWave
Designer, the user can readily modify this load to add or subtract functions, increase the
number of runs, etc. An overview of the base application load is provided below.

• Uses pre-configured web pages for user readings, configuration and maintenance. Web

pages can be modified and new pages configured to work with a modified application
load

• Application load is object oriented

• Standard configuration is a two-run station

• Each run can be orifice, turbine or ultrasonic meter type

• Flow calculations include the following:

• AGA3-1985/NX-19

• AGA3-1992 with selectable AGA8 Gross or AGA8 Detail

• 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

• Instromet Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail

• Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail

• Includes run switching

• Includes an auto-selector, PID flow/pressure control algorithm per run or per station

• Interfaces to a chromatograph and provides energy throughput as well as composition

information (requires the optional Expansion Communications Module)

• Resides on a BSAP SCADA network

• Supports samplers and odorizers

• Provides audit trail and archives

• Includes a nominations function

• Allows the user to select engineering units, including English and metric

The primary function of the ControlWave XFC is to measure the flow of natural gas in
accordance with API (American Petroleum Institute) and AGA (American Gas Association)
standards. Items below implement and supplement the primary function:

• Data acquisition (see Section 1.5.1)

• Flow calculations (see Section 1.5.2)

• Data archives (see Section 1.5.3)

• Audit trail archives (see Section 1.5.3.4)

• Local display (see Section 1.5.4)

• Communications (see Section 1.5.5)

• Control outputs (see Section 1.5.6)

• Status inputs (see Section 1.5.6)

• Self test and diagnostics (see Section 1.5.7)

1.5.1 Data Acquisition

The process inputs used by the ControlWave XFC are static pressure, differential
pressure, and temperature for orifice measurement, or static pressure, temperature, and
frequency input for positive displacement (PD), turbine, or ultrasonic meters. Static
pressure and differential pressure may be obtained from the Multivariable Transducer
connected to the ControlWave XFC I/O Board assembly. The inputs may also be derived

1-14 / Introduction CI-ControlWave XFC

from external smart Multivariable Transmitters using either the BSAP or MODBUS
protocols. Alternatively, the inputs may be obtained via the local I/O Modules using analog
transmitters. The standard ControlWave XFC application program allows various
combinations of inputs to be selected, for a two-run metering station.

Regardless of the operating mode or the calculation interval, the ControlWave XFC
acquires samples as follows:

a. Differential pressure once per second
b. Static pressure once per second
c. Flowing temperature once per second
d. All self-test and compensation values at intervals of 4 seconds or less

1.5.2 Flow and Volume Calculations

The ControlWave XFC performs a complete flow calculation using the process variables
every second. Each calculation includes instantaneous rate according to API 14.3,
compressibility according to AGA 8 Detail or Gross method, and updates of all volumes,
totals, and archive averages. The user can select AGA3/NX-19 (1985), AGA3/AGA8,
AGA7/NX-19 or AGA7/AGA8.

1.5.2.1 Flow Rate and Flow Time Calculations (AGA3)

For orifice flow measurement, the differential pressure value is compared to a flow cutoff
value every second. If the differential pressure is less than the flow cutoff value, flow is
considered to be zero for that second. Hourly and Daily flow time is defined to be the
number of seconds for which the differential pressure exceeded the cutoff value for the
period.

The values for static and differential pressure, temperature, and flow extensions are used
as inputs to the flow equations. Users may select API 14.3 (AGA3, 1992) and AGA8
calculations, with compressibility being calculated according to AGA Report No. 8, 1992
(with 1993 errata). Both the DETAIL method and the two GROSS methods of
characterization described in AGA8 are supported. Users may also select the AGA3, 1995
and NX-19 flow equations to calculate the rate of flow.

1.5.2.2 Flow Rate Calculations and Flow Time Accumulations (AGA7)

When using PD meters, turbine meters or ultrasonic meters, the flow rate is calculated by
applying the correction factor computed by the AGA7 calculations to the frequency of the
input pulses. When the frequency drops below 1 Hz, the flow rate estimate is set to zero;
however, volume calculations are still accumulated. The flow time recorded is the time for
which the flow rate is non-zero.

1.5.2.3 Extension Calculation and Analog Averaging

For orifice meters, a flow extension is calculated every second. The extension is the square
root of the product of the absolute upstream static pressure times the differential pressure.
This extension is used in the flow rate calculation. When there is no flow, arithmetic
averages of static pressure and temperature are reported. This allows monitoring of static
pressure and temperature during shut-in periods.

CI-ControlWave XFC Introduction / 1-15

1.5.2.3.1 Energy Calculation

The ControlWave XFC offers the option of using a fixed volumetric heating value or
calculating the energy content of the gas according to AGA Report No. 5.

1.5.2.3.2 Volume and Energy Integration

Volume and energy are each integrated and accumulated at the end of every calculation
cycle. The volume for a cycle is the calculated rate multiplied by the flow time for that cycle.
The energy for a cycle is calculated by multiplying the volume at BASE
heating value.

1.5.2.4 Downstream Pressure Tap

The multivariable transducer typically measures static pressure from an integral tap on the
upstream, high-pressure leg of the differential pressure connection. Static pressure can be
measured at the downstream pressure tap, with the measurement taken from the low-pres­sure side to the high-pressure side. In this installation, the differential signal from the
transducer is negative. If while using the integral smart Multivariable Transmitter (MVT),
the user selects the downstream tap location during MVT configuration, the MVT firmware
changes the sign of the differential pressure to provide a positive DP value.

conditions by the

1.5.3 Archives

The ControlWave XFC stores two distinct types of archive data. The first type is Audit
Trail data, which is a recording of the various events and alarms that have an impact on
the calculated and reported rates and volumes. The second type is historical data, which
includes records of rates and volumes and other signals over time. When an archive log
becomes full, new entries replace the oldest entries in the log.

Where feasible, both forms of archive data conform to the requirements of the API Chapter
21 (the Committee on Gas Measurement's GFC document). Specifically, the averages of the
process variables stored in the data archive are for flowing periods, appropriate to their
usage in the equations, and any gas-related parameter designated an event that is changed
by an operator either remotely or locally causes an entry in the audit log.

The ControlWave XFC supports the "breaking" of a log period when an operator-entered
parameter is changed. When this occurs, the log period in process is closed out, a log is
made, and a new log is begun. This feature is disabled by default and may be enabled by
the operator. Note: To prevent several very short logs from being created due to a series of

successive configuration changes, the ControlWave XFC will not create a log which
contains less than 60 seconds (flowing or otherwise) of data. Therefore if a user enters 15
configuration changes over a 2 minute period, the log will only be broken twice.

1.5.3.1 Hourly Historical Data Log

The Hourly Data Log holds one record for every contract hour. Hourly logs hold 840 entries
or 35 days; this ensures that the previous period of hourly data is always resident in
ControlWave XFC FLASH memory. The following items are stored in the Hourly Data
Log:

• Corrected Volume

• Uncorrected Volume

1-16 / Introduction CI-ControlWave XFC