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Instruction Manual
s
D5138
Part: D301687X012
March, 2011
ControlWave Radio-Ready
Installation Guide
For field installation of radios in:
ControlWave Corrector
ControlWave EFM
ControlWave ExpressPAC
ControlWave GFC
ControlWave GFC Plus
ControlWave
Remote Automa ti on Solution
www.EmersonProcess.com/Remote
Page 2
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 Emerson Process
Management, Remote Automation Solutions division (RAS) for further information.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
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, fail-safe valves, relief valves, emergency shutoffs, emergency switches,
etc. If additional information is required, the purchaser is advised to contact RAS.
RETURNED EQUIPMENT WARNING
When returning any equipment to RAS for repairs or evaluation, please note the following: The
party sending such materials is responsible to ensure that the materials returned to RAS 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 RAS and save RAS harmless from
any liability or damage which RAS 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 gr ounded 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 for proper care and handling of ESD-sensitive components.
Remote Automation Solutions
A Division of Emerson Process Management
1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
Page 3
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 essential to your operation. Emerson offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at various locations. By participating in our training, your personnel
can learn how to install, calibrate, configure, program and maintain your Emerson products
and realize the full potential of your system.
For information or to enroll in any class, go to http://www.EmersonProcess.com/Remote
click on “Educational Services” or contact our training department in Watertown at (860)
945-2200.
and
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Introduction
ControlWave Radio-Ready Installation Guide (D5138)
You can order certain ControlWave-series devices with a radio preinstalled at the factory, or as “radio-ready” in which you can install a
radio in the field. These ControlWave units are:
ControlWave Corrector
ControlWave EFM
ControlWave ExpressPAC
ControlWave GFC
ControlWave GFC Plus
Radio-ready units contain all hardware necessary to field install the
radio except the radio itself, and the radio installation hardware such as
screws, nuts, and washers. Radio-ready units include either an internal
RF radio cable with bulk head antenna connector, or an internal RF
radio cable that mates to an optional polyphaser (surge impulse
suppressor).
Radio Associated Installation
MDS 4710A Remote Data
Transceiver (Radio)
MDS 4710B Data
Transceiver (Radio)
Radios ship from the factory with all necessary installation hardware for
mounting on the radio mounting bracket or radio mounting plate.
Table 1 shows the supported radios and the installation hardware
included.
Table 1. Radios Supported
Refer to these Figures
Hardware
four (4) 6-32 x 5/16
mounting screws
power cable
radio interface cable
four (4) 6-32 x 5/16
mounting screws
power cable
radio interface cable
Figure 1. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram - MDS
Radios (Models 4710A, 4710B, 9710A,
9710B & 9810)
Figure 2. ControlWave GFC Plus - Radio
Installation/Mounting Diagram - MDS
Radios Models 4710A, 4710B, 9710A,
9710B & 9810
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 1. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram - MDS
Radios (Models 4710A, 4710B, 9710A,
9710B & 9810)
Figure 2. ControlWave GFC Plus - Radio
Installation/Mounting Diagram - MDS
Radios Models 4710A, 4710B, 9710A,
Issued Mar-2011 1
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ControlWave Radio-Ready Installation Guide (D5138)
Radio Associated Installation
MDS 9710A Remote Data
Transceiver (Radio)
MDS 9710B Data
Transceiver (Radio)
MDS 9810 Spread
Spectrum Data Transceiver
(Radio)
MDS entraNET 900
Extended Range IP
Networking Transceiver
Hardware
four (4) 6-32 x 5/16
mounting screws
power cable
radio interface cable
four (4) 6-32 x 5/16
mounting screws
power cable
radio interface cable
four (4) 6-32 x 5/16
mounting screws
power cable
radio interface cable
four (4) 6-32 x 5/16
mounting screws
power cable
Refer to these Figures
9710B & 9810
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 1. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram - MDS
Radios (Models 4710A, 4710B, 9710A,
9710B & 9810)
Figure 2. ControlWave GFC Plus - Radio
Installation/Mounting Diagram - MDS
Radios Models 4710A, 4710B, 9710A,
9710B & 9810
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 1. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram - MDS
Radios (Models 4710A, 4710B, 9710A,
9710B & 9810)
Figure 2. ControlWave GFC Plus - Radio
Installation/Mounting Diagram - MDS
Radios Models 4710A, 4710B, 9710A,
9710B & 9810
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 1. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram - MDS
Radios (Models 4710A, 4710B, 9710A,
9710B & 9810)
Figure 2. ControlWave GFC Plus - Radio
Installation/Mounting Diagram - MDS
Radios Models 4710A, 4710B, 9710A,
9710B & 9810
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 5. ControlWave Corrector / GFC
Radio Installation/Mounting Diagram -
MDS entraNET 900 Radio
2 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
Radio Associated Installation
MDS iNET 900 Ethernet
Radio
MDS Transnet 900 Spread
Spectrum Data Transceiver
FreeWave Radio Spread
Spectrum Data Transceiver
Model FGRM-501X005
Hardware
radio interface cable
four (4) 6-32 x 5/16
mounting screws
power cable
radio interface cable
four (4) 6-32 x 5/16
mounting screws
four (4) #6 flat 5/16 O.D.
washers
four (4) 6-32 hex nuts
power cable
radio interface cable
eight (8) 6-32 x 5/16 pan
head screws
four (4) 6-32 x 0.500 F/F
standoffs
four (4) 6-32 x 5/16
countersunk screws
radio interface cable
Refer to these Figures
Figure 6. ControlWave GFC Plus Radio
Installation/Mounting Diagram - MDS
entraNET 900 Radio (Serial Remote &
Ethernet Remote Radios)
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 7. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram - MDS
Radios MDS entraNET900 Access Point
Radio & MDS iNET 900 Radios
Figure 9. ControlWave GFC Plus Radio
Installation/Mounting Diagram - MDS
iNET 900 Radios
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 3. ControlWave Corrector
/Expres
Installation/Mounting Diagram - MDS
Transnet Radio
sPAC / GFC Radio
Figure 4. ControlWave GFC Plus - Radio
Installation/Mounting Diagram - MDS
Transnet Radio
Figure 16. ControlWave EFM Radio
Installation - Mounting Diagram
Figure 17. ControlWave EFM - Radio
Mounting Bracket - Radio Installation
Diagram
Figure 10. ControlWave Corrector /
ExpressPAC / GFC Radio
Installation/Mounting Diagram – FreeWave
Radio
Figure 11. ControlWave EFM /
ExpressPAC / GFC Plus - Radio
Installation/Mounting Diagram – FreeWave
Radio
Figure 18. Cable Diagram for FreeWave
Radio to COM2 (TB3) Intf. & Radio Power
Figure 19. PC Connected to FreeWave
Radio) - (Part Number VASC2009DC)
Issued Mar-2011 3
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ControlWave Radio-Ready Installation Guide (D5138)
Installation
Radios supplied by Emerson for use in the ControlWave Corrector,
WARNING
ControlWave ExpressPAC, ControlWave GFC, and ControlWave GFC
Plus are approved for use in Class I, Division 2, Groups C, and D
hazardous locations. Radios supplied by Emerson for use in the
ControlWave EFM are approved for use in Class I, Division 2, Groups A,
B, C, and D hazardous locations. Radios may also be used in non-
hazardous locations. The installer must be familiar with hazardous
location installation guidelines before installation or maintenance is
undertaken. Do no begin radio installation or service unless the area is
known to be non-hazardous.
Only the radios listed in Table 1 may be used in Class I, Division 2,
hazardous locations! Use of other radios in these locations is prohibited.
Avoid operating equipment during an electrical storm. An impulse
suppressor may save equipment from danger, but should not be
considered as being safe for personnel.
Follow all cautions and warnings in the manual for your ControlWave
controller/flow computer.
Installation Steps
1. Open the front cover of the ControlWave device. Refer to Table 1
to reference the figure(s) that apply for your ControlWave device.
2. Remove the radio mounting plate/bracket. To do this, loosen the
pan head screws that secure it to the battery mounting bracket (or in
the case of the GFC Plus or EFM that secure it to the fabrication
panel). Slide the radio mounting plate/bracket upward until you can
remove it.
3. Using the mounting hardware provided with the radio, mount and
secure the radio to the radio mounting plate/bracket you removed in
Step 2.
4. Re-install the radio mounting plate/bracket (now with the radio
attached) that you removed in Step 2 by sliding it in and tightening
the screws.
5. Connect the radio’s RF cable to the radio. Connect the other end of
the radio’s internal RF cable to a polyphaser or an RF bulk
head/antenna interface connector. (See Figure 12, Figure 13,
Figure 14, or Figure 15, as appropriate.)
6. Connect the user-supplied antenna cable to either the polyphaser or
bulk head antenna cable connector jack on the bottom of the
ControlWave device.
7. Plug the radio interface cable into the radio’s communication port.
Plug the other end of this cable into COM2 of the CPU/System
Controller board assembly (or EFM CPU module). For non-EFM
units, in the case of the FreeWave radio, the interface cable
supplies power to the radio from CPU connector TB1 as follows:
4 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
OTTO
TB1-5 = Aux. Power Out+ (Red), TB1-6 = GND (Black).
8. For MDS radios, remove the MDS radio’s power connector from
the radio, and connect the unterminated ends of the MDS power
cable to the MDS power connector (Red = Pos., and Black =
GND). Plug the end of the MDS radio power cable that you just
dressed into the MDS radio. For ControlWave GFC, GFC Plus,
Corrector, or EPAC, connect the other end of the MDS radio power
cable to connector TB1’s AUX PWR terminals on the CPU/System
Controller board (Red = TB1-5, Black = TB1-6). For ControlWave
EFM, connect the other end of the MDS radio power cable to
connector TB3 on the Power Distribution board.
9. After testing the unit, secure the door.
FRONT VIEW (Mounted)
MDS Radios
Models:
4710A, 4710B,
9710A, 9710B
& 9810
RIGHT
SIDE VIEW
(Mounted)
+
B
M VIEW
Figure 1. ControlWave Corrector / ExpressPAC / GFC Radio Installation/Mounting Diagram - MDS
Radios (Models 4710A, 4710B, 9710A, 9710B & 9810)
Issued Mar-2011 5
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 2. ControlWave GFC Plus - Radio Installation/Mounting Diagram - MDS Radios Models
4710A, 4710B, 9710A, 9710B & 9810
6 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
)
FRONT VIEW (Mounted
+
LEFT
SIDE VIEW
RIGHT
SIDE VIEW
(Mounted)
MDS Transnet
TOP VIEW
Figure 3. ControlWave Corrector /ExpressPAC / GFC Radio Installation/Mounting Diagram - MDS
Transnet Radio
Issued Mar-2011 7
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 4. ControlWave GFC Plus - Radio Installation/Mounting Diagram - MDS Transnet Radio
8 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
)
W
W
FRONT VIEW (Mounted
+
LEFT
SIDE VIEW
RIGHT
SIDE VIE
(Mounted)
MDS NET 900entra
TOP VIE
Figure 5. ControlWave Corrector / GFC Radio Installation/Mounting Diagram - MDS entraNET 900
Radio
Issued Mar-2011 9
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 6. ControlWave GFC Plus Radio Installation/Mounting Diagram - MDS entraNET 900 Radio
(Serial Remote & Ethernet Remote Radios)
10 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
FRONT VIEW (Mounted)
+
LEFT
SIDE VIEW
BOTTOM VIEW
MDS NET 900entra
Access Point Radio
RIGHT
SIDE VIEW
(Mounted)
MDS iNET 900 Radios
FRONT VIEW (Mounted)
Figure 7. ControlWave Corrector / ExpressPAC / GFC Radio Installation/Mounting Diagram - MDS
Radios MDS entraNET900 Access Point Radio & MDS iNET 900 Radios
Issued Mar-2011 11
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 8. ControlWave GFC Plus Radio Installation/Mounting Diagram - MDS entraNET 900 Radio
(Access Point Radio)
12 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 9. ControlWave GFC Plus Radio Installation/Mounting Diagram - MDS iNET 900 Radios
Issued Mar-2011 13
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ControlWave Radio-Ready Installation Guide (D5138)
)
FRONT VIEW (Mounted
FreeWave
RIGHT
SIDE VIEW
(Mounted)
TOP VIEW
Figure 10. ControlWave Corrector / ExpressPAC / GFC Radio Installation/Mounting Diagram –
FreeWave Radio
14 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 11. ControlWave EFM / ExpressPAC / GFC Plus - Radio Installation/Mounting Diagram –
FreeWave Radio
Issued Mar-2011 15
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 12. Partial View – ControlWave GFC, EPAC, with/without Polyphaser
Figure 13. Partial View - ControlWave GFC Plus with/without Polyphaser
16 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 14. Partial View - ControlWave Corrector with/without Polyphaser
Figure 15. Partial View - ControlWave EFM with/without Polyphaser Installed
Issued Mar-2011 17
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ControlWave Radio-Ready Installation Guide (D5138)
A
FRONT VIEW
A
Models:
4710A, 4710B,
9710A, 9710B & 9810
T wo Screws that Secure the Radio
Mounting Bracket to the Fabrication Panel.
BB
+
C
+
A
C
A
B
Serial Remote &
Ethernet Remote
Radios
C
SIDE VIEW
RIGHT SIDE VIEW
B
MDS NET 900entra
RIGHT SIDE VIEW
CC
MDS NET 900entra
Access Point Radio
B
+
D
E
Location of Mounting Hardware
that Secures the Radio to the
Radio Mounting Bracket.
& MDS iNET 900 Radios
D
D
E
E
RIGHT SIDE VIEW
D
MDS Transnet
RIGHT SIDE VIEW
E
E
FreeWave
= MDS Models 4710A, 4710B, 9710A, 9710B & 9810
B = MDS entraNET 900 Serial Remote & Ethernet Remote
C = MDS entraNET 900 Access Point & MDS iNET 900
D = MDS TRANSNET
E = FreeWave
D
Figure 16. ControlWave EFM Radio Installation - Mounting Diagram
18 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 17. ControlWave EFM - Radio Mounting Bracket - Radio Installation Diagram
Additional FreeWave Information
The FreeWave Spread Spectrum Data Transceiver Model FGRM501X005 User Manual contains in-depth details on modem parameters,
operation, installation, tuning transceiver performance, and more.
Copies of the FreeWave Spread Spectrum Data Transceiver Model
FGRM-501X005 User Manual can be obtained from FreeWave
Technologies, Inc. (electronically) by contacting their Technical
Support Group.
FreeWave Tech. Support can be reached at 303-444-3862 or at
www.freewave.com.
Issued Mar-2011 19
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ControlWave Radio-Ready Installation Guide (D5138)
Follow the “Tuning Transceiver Performance” section of the FreeWave
Technologies, Inc. FreeWave Spread Spectrum Data Transceiver Model
FGRM-501X005 User Manual to configure the radio.
Note:
Start HyperTerminal on your PC then invoke the setup program
by connecting the radio to the PC. Set the parameters for that
terminal to those of Table 2, and put the radio into setup mode.
To connect to the PC requires a special RS-232 cable with a 9pin female D-type connector on the PC end and a 10-pin female
MTA-100 connector assembly on the radio end. You can
construct a cable as illustrated in Figure 18. The setup program
is invoked by shorting MTA-100 connector pins 4 (GND) and 2
(MENU) together.
Table 2. FreeWave Setup Menu Terminal Settings
Baud Rate
Data Rate
Parity
Stop Bits
Parity Check
Carrier Detect
Parameter Setting
19,200
8
None
1
None/Off
None/Off
Figure 18. Cable Diagram for FreeWave Radio to COM2 (TB3) Intf. & Radio Power
20 Issued Mar-2011
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ControlWave Radio-Ready Installation Guide (D5138)
Figure 19. PC Connected to FreeWave Radio) - (Part Number VASC2009DC)
Issued Mar-2011 21
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Instruction Manual
D5138
ControlWave Radio-Ready Installation Guide
March, 2011
Emerson Process Management
Remote Automation Solutions
1100 Buckingham Street
Waterto
wn, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Remote
Emerson Process Management
Remote Automation Solutions
6338 Viscount Rd.
Mississauga, Ont
Canada
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Remote
Emerso
n Process Management SA de CV
Calle 10 #145
Col. San Pedro de los Pinos
01180 Mexico, D.F.
Mexico
T +52 (55) 5809-5300
F +52 (55) 2614-8663
www.EmersonProcess.com/Remote
Emerso
n Process Management, Ltd.
Remote Automation Solutions
Blackpole Road
W
orcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969
www.EmersonProcess.com/Remote
Emerso
n Process Management AP Pte Ltd.
Remote Automation Solutions Division
1 Pandan Crescent
Singapore 128461
Phone: +65-6770-8584
Fax: +65-6891-7841
www.EmersonProcess.com/Remote
. L4V 1H3
NOTICE
“Remote Automation Solutions (“RAS”), division of Emerson Process
Management shall not be liable for technical or editorial errors in this manual
or omissions from this manual. RAS MAKES NO WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THIS MANUAL AND, IN NO EVENT SHALL RAS BE LIABLE
FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL
DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION,
LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS
INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND
POWER, AND CLAIMS OF THIRD PARTIES.
Bristol, Inc., Bristol Babcock Lt
Computer Division are wholly owned subsidiaries of Emerson Electric Co.
doing business as Remote Automation Solutions (“RAS”), a division of
Emerson Process Management. FloBoss, ROCLINK, Bristol, Bristol
Babcock, ControlWave, TeleFlow and Helicoid are trademarks of RAS. AMS,
PlantWeb and the PlantWeb logo are marks of Emerson Electric Co. The
Emerson logo is a trademark and service mark of the Emerson Electric Co.
All other trademarks are property of their respective owners.
The contents of this publication are presented for informational purposes
only. While every effort has been made to ensure informational accuracy,
they are not to be construed as warranties or guarantees, express or implied,
regarding the products or services described herein or their use or
applicability. RAS reserves the right to modify or improve the designs or
specifications of such products at any time without notice. All sales are
governed by RAS’ terms and conditions which are available upon request.
© 2011 Remote Automation Solutions, division of Emerson Process
Management. All rights reserved.
d, Bristol Canada, BBI SA de CV and the Flow
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