s
ControlWave Corrector
Instruction Manual
Doc Number CI-ControlWave Corrector
Part Number D301382X012
November 2013
Remote Automa ti on Solution
www.EmersonProcess.com/Remote
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 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 Remote Automation
Solutions.
RETURNED EQUIPMENT WARNING
When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions 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 Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions 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.
ControlWave Corrector Instruction Manual
Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual ................................................................................................................. 1-2
1.2 Physical Description .................................................................................................................. 1-2
1.3 CPU/System Controller Board .................................................................................................. 1-3
1.4 Power Options ........................................................................................................................... 1-5
1.5 I/O Options ................................................................................................................................ 1-5
1.6 Software Tools .......................................................................................................................... 1-6
1.7 Overview of the Gas Flow Measurement Application ............................................................... 1-8
1.7.1 Data Acquisition – Static Pressure, Differential Pressure, Temperature Variables ...... 1-8
1.7.2 Flow and Volume Calculations ...................................................................................... 1-8
1.7.3 Flow Rate and Flow Time Calculations (AGA3)............................................................ 1-9
1.7.4 Flow Rate and Flow Time Calculations (AGA7)............................................................ 1-9
1.7.5 Extension Calculation and Analog Averaging ............................................................... 1-9
1.7.6 Energy Calculation ...................................................................................................... 1-10
1.7.7 Volume and Energy Integration .................................................................................. 1-10
1.7.8 Historical Data Storage (Audit Records/ Archive Files) .............................................. 1-10
1.7.9 Run Switching ............................................................................................................. 1-12
1.7.10 Sampler and Odorizer ................................................................................................. 1-12
1.7.11 Chromatograph Interface ............................................................................................ 1-12
1.7.12 Nominations ................................................................................................................ 1-13
Chapter 2 – Installation 2-1
2.1 Site Considerations ................................................................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ...................................................................... 2-3
2.2 Installation Overview ................................................................................................................. 2-4
2.3 Unpacking Components ............................................................................................................ 2-5
2.4 Mounting the ControlWave Corrector Assembly ....................................................................... 2-5
2.4.1 Configuring the TeleCounter Assembly ...................................................................... 2-13
2.4.2 Configuring the ISPROX Module (Option) .................................................................. 2-13
2.4.3 Connection to the Gage Pressure Transducer (GPT) ................................................ 2-14
2.4.4 Grounding the Housing ............................................................................................... 2-17
2.5 Configuring the CPU/System Controller Board ....................................................................... 2-18
2.5.1 Setting DIP Switches on the CPU/System Controller Board ...................................... 2-19
2.5.2 Setting Jumpers on the CPU/System Controller Board .............................................. 2-21
2.5.3 General Wiring Guidelines .......................................................................................... 2-22
2.5.4 Wiring Power to the CPU/System Controller Board .................................................... 2-23
2.5.5 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board ............. 2-25
2.5.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller
Board ......................................................................................................................... 2-30
2.5.7 Connections to the Ethernet Port on the CPU/System Controller Board .................... 2-32
2.6 Radio-Ready and Case Mounted Modem or Radio ................................................................ 2-33
2.7 Mounting the Solar Panel ........................................................................................................ 2-34
2.8 Optional Display/Keypads ....................................................................................................... 2-37
Chapter 3 – I/O Configuration and Wiring 3-1
3.1 I/O Options ................................................................................................................................ 3-1
3.2 Process I/O Board ..................................................................................................................... 3-2
3.2.1 Setting Jumpers on the Process I/O Board ................................................................... 3-2
3.2.2 Setting DIP Switches on the Process I/O Board ........................................................... 3-2
3.3 I/O Wiring .................................................................................................................... .............. 3-4
Issued Nov-2013 Contents iii
ControlWave Corrector Instruction Manual
3.3.1 Non‐Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board ................... 3-6
3.3.2 Non‐Isolated Discrete Outputs (DO) on TB3 of Process I/O Board.............................. 3-7
3.3.3 Non‐Isolated Analog Inputs (AI) on TB6 of Process I/O Board .................................... 3-8
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board .................................. 3-9
3.3.5 Non‐Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Bd .. 3-10
3.3.6 Non‐Isolated High Speed Counter/ Discrete Inputs on TB4 of Process I/O Board .... 3-13
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board ..... 3-14
3.3.8 Connections to a Bristol Model 3808 Transmitter ....................................................... 3-16
Chapter 4 – Operation 4-1
4.1 Powering Up/Powering Down the ControlWave Corrector ....................................................... 4-1
4.2 Communicating with the ControlWave Corrector ...................................................................... 4-2
4.2.1 Default Comm Port Settings ......................................................................................... 4-2
4.2.2 Changing Port Settings ................................................................................................. 4-3
4.2.3 Collecting Data from the ControlWave Corrector ......................................................... 4-3
4.3 Creating and Downloading an Application (ControlWave Project) ........................................... 4-3
4.4 Creating and Maintaining Backups ........................................................................................... 4-4
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-4
4.4.2 Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-6
4.4.3 Backing up Data ............................................................................................................ 4-7
Chapter 5 – Service and Troubleshooting 5-1
5.1 Upgrading Firmware .................................................................................................................. 5-2
5.2 Removing or Replacing Components ....................................................................................... 5-6
5.2.1 Accessing Modules for Testing ..................................................................................... 5-6
5.2.2 Removing/Replacing the CPU/System Controller Board and the Process I/O Board .. 5-6
5.2.3 Removing/Replacing the Primary Battery System ........................................................ 5-7
5.2.4 Removing/Replacing the Backup Battery ..................................................................... 5-8
5.2.5 Enabling / Disabling the Backup Battery ....................................................................... 5-9
5.2.6 Removing/Replacing the Case-Mounted Radio or Modem .......................................... 5-9
5.2.7 Removing/Replacing the GPT Transducer ................................................................. 5-10
5.2.8 Removing/Replacing the TeleCounter (Pulser) Assembly.......................................... 5-10
5.3 General Troubleshooting Procedures ..................................................................................... 5-11
5.3.1 Common Communication Configuration Problems ..................................................... 5-11
5.3.2 Checking LEDs ........................................................................................................... 5-12
5.3.3 Checking LCD Status Codes ...................................................................................... 5-12
5.3.4 Wiring/Signal Checks .................................................................................................. 5-12
5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-13
5.4.1 Available Diagnostics .................................................................................................. 5-14
5.5 Core Updump .......................................................................................................................... 5-17
5.6 Calibration Checks .................................................................................................................. 5-18
Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1
Index IND-1
iv Contents Issued Nov-2013
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Corrector. For information about the software used with the
ControlWave Corrector, refer to:
ControlWave Flow Measurement Applications Guide (D5137),
Getting Started with ControlWave Designer (D5085)
ControlWave Designer Programmer’s Handbook (D5125)
ControlWave Designer online help
This chapter provides an overview of the ControlWave Corrector and its
components and details the structure of this manual
In This Chapter
1.1 Scope of the Manual ........................................................................ 1-2
1.2 Physical Description ........................................................................ 1-2
1.3 CPU/System Controller Board ......................................................... 1-3
1.4 Power Options ................................................................................. 1-5
1.5 I/O Options ....................................................................................... 1-5
1.6 Software Tools ................................................................................. 1-6
1.7 Overview of the Gas Flow Measurement Application ...................... 1-8
ControlWave Corrector Instruction Manual
Features
The ControlWave Corrector is pre-programmed to meet API 21.1
requirements for a two-run metering station and measures static
pressure and temperature for both runs and computes corrected volume
(i.e., volume or base conditions), uncorrected volume and energy rates
and totals. Most metering stations use the integral gauge pressure
assembly for the first meter run and an external transmitter, such as the
Bristol 3808 MVT, for the second meter run. ControlWave Correctors
are appropriate to all applications for electronic meter correction,
including those that require monitoring of additional I/O points or
extension to two meters. ControlWave Correctors are designed to
operate in an unprotected outdoor environment.
The ControlWave Corrector has the following key features:
Exceptional performance and low power consumption through use
of the ARM microprocessor.
Very low power consumption to minimize costs of solar panel /
battery power systems.
Two CPU / System Controller board configurations (see Table 1-1.)
Integral gage pressure transducer (GPT) can be removed and
replaced independently of the top-end electronics.
Optional integrated TeleCounter (pulser) assembly mounts directly
to rotary positive displacement meters.
Three process I/O board configurations (see Table 1-2).
Revised Nov-2013 Introduction 1-1
ControlWave Corrector Instruction Manual
Two RS-232 and one RS-232/RS-485 asynchronous serial
communication ports.
Optional 10/100 MB Ethernet port
Optional Display/Keypad.
Wide operating temperature range:
Without lead acid battery: (–40 to +70C) (–40 to 158F)
With lead acid battery: (–20 to +60C) (–4 to 140F)
Battery backup for Static RAM (SRAM) and real-time clock.
Nonincendive Class I, Division 2 (Groups A, B, C and D)
Hazardous Location approvals when installed in a suitable enclosure
- see Appendix A.
Cost-effective for small RTU/process controller applications.
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Chapter 2
Installation
Chapter 3
I/O Configuration
Chapter 4
Operation
Chapter 5 Service and
Troubleshooting
1.2 Physical Description
The ControlWave Corrector includes the following major components:
Enclosure with a local communication port and LCD
display/keypad.
CPU/system controller board (SCB) mounts on edge within the
enclosure – See Section 1.3
Optional I/O – see Section1.5.
Internal mounting brackets and battery
Provides an overview of the hardware Corrector
general information about the ControlWave
Corrector and its application software.
Provides information on mounting the
ControlWave Corrector and setting CPU
jumpers and switches.
Provides general information on wiring the
process I/O points.
Provides information on day-to-day operation of
the ControlWave Corrector.
Provides information on service and
troubleshooting procedures.
Gage pressure transducer (GPT) – See Chapter 2
Optional RTD probe – See Chapter 3
Radio/modem options
TeleCounter (pulser) assembly – See Chapter 2
1-2 Introduction Revised Nov-2013
Enclosure
ControlWave Corrector Instruction Manual
The ControlWave Corrector enclosure is a standard NEMA 3R rated
fiberglass enclosure. The enclosure consists of the body and the front
cover. A continuous gasket seals the unit when you close the front
cover. Molded channels on the cover and the body which capture a
stainless steel pin form a hinge on the left side (facing the front of the
unit).
The enclosure includes a weatherproof connector (local port) mounted
to the bottom of the cover and connected internally to RS-232 COM
port 1.
The enclosure includes a display or display/keypad for an operator or
technician to view process values locally.
Internal Mounting
Brackets and Battery
Internal mounting brackets support the various system components,
such as the battery, CPU/System Controller and Process I/O boards,
and the radio/modem option. These components attach to the one piece
mounting bracket which is secured to the inner rear wall of the
enclosure. A factory-supplied radio or modem mounts inside the
enclosure in front of the battery on a battery cover/radio mounting
plate.
Radio/Modem Options
You can order the ControlWave Corrector with a factory-installed
modem or spread spectrum radio. The unit supports a variety of radios
and modems. Contact Emerson Remote Automation Solutions for more
information.
1.3 CPU/System Controller Board
The CPU (central processing unit) and System Controller Board (SCB)
contains the ControlWave Corrector CPU, I/O monitor/control,
memory, and communication functions.
The CPU/System Controller board includes:
Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core, with a
system clock speed of either 14 MHz or 33 MHz.
two RS-232 communication ports
one communication port configurable by jumpers as either RS-232
or RS-485
optional 10/100baseT Ethernet port (See Table 1-1)
2 MB of battery backed Static RAM (SRAM),
512KB boot/downloader FLASH,
8MB simultaneous read/write FLASH memory
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ControlWave Corrector Instruction Manual
Board Variations
The CPU/System Controller board has two basic variations: `
Table 1-1. CPU/System Controller board Variations
14MHz
ultra low
power
33MHz +12V or
CPU Backup Battery
CPU Memory
CPU Nominal
Input
Power
+6Vdc or
+12Vdc
+24Vdc
Note: Each of the variants shown in Table 1-1 may be ordered with or
without special gas calculation firmware.
The CPU/System Controller board has a coin cell socket that accepts a
3.0V, 300 mA-hr lithium battery. This 3.0V battery provides backup
power for the real-time clock and the system’s Static RAM (SRAM).
There are several different types of memory used by the CPU:
Ethernet
Port?
No Yes Yes Yes.
Yes No No Yes (same as
Solar
Regulator
?
Auxiliary
Power
Output?
RTD Input?
Connects to
100-ohm
platinum bulb.
Uses DIN
43760 curve.
ultra low
power)
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The ControlWave Corrector includes 8 MB of FLASH memory. The
FLASH memory holds the system firmware and the boot project.
Optionally FLASH memory also stores the zipped ControlWave project
(*.zwt), user files, and historical data (audit/archive files).The FLASH
does not support hardware write protection.
System Memory (SRAM)
The ControlWave Corrector has 2 MB of static random access memory
(SRAM). During power loss periods, SRAM enters data retention mode
(powered by a backup 3.0V lithium battery). Critical system information
that must be retained during power outages or when the system has been
disabled for maintenance is stored here. This includes the last states of
all I/O points, audit/archive historical data (if not stored in FLASH), the
values of any variables marked RETAIN, the values of any variables
1-4 Introduction Revised Nov-2013
1.4 Power Options
ControlWave Corrector Instruction Manual
assigned to the static memory area, and any pending alarm messages not
yet reported.
You can power the ControlWave Corrector by:
a factory-supplied 6V lithium battery
a factory-supplied 6V lithium battery pack (dual 6V lithium
batteries in parallel)
a factory-supplied 6V, 7AH lead acid battery – used with a 1W, 6V
solar panel system
a factory-supplied 6V, 7AH lead acid battery – used with a 5W, 6V
solar panel system
a factory-supplied 12V, 7AH lead acid battery – used with a 5W,
12V solar panel system
an external (user-supplied) power supply with either +5.4Vdc to
+16Vdc (nominal +6Vdc), +11.4Vdc to +16Vdc (nominal +12Vdc)
or +21.8Vdc to + 28.0Vdc (nominal +24Vdc)
If you connect solar panels to rechargeable battery systems to power the
ControlWave Corrector, there is a secondary power input you can use to
provide power if there is no power from the solar panel/battery system.
1.5 I/O Options
Type Pulse
Standard 2
Option 1 2 2 4 2 2
Option 2 2 2 4 2 2 3
Option 3 2 2 4 2 2 3 1
ControlWave Corrector comes with the following standard I/O:
2 Pulse Counter Inputs with a 1 second scan rate (can be configured
as discrete inputs (DI))
Optional I/O includes:
Resistance Temperature Device (RTD) probe
Gage Pressure Transducer (GPT)
Process I/O board. Three different versions of the optional process
I/O board are available. See Table 1-2.
Table 1-2. Process I/O Configurations
Counter
Inputs (PI) /
Discrete
Input (DI)
Discrete
Input /
Output
(DI/DO)
Discrete
Input (DI)
Discrete
Output
(DO)
High Speed
Counter
(HSC)
Analog
Input (AI)
Analog
Output
(AO)
Revised Nov-2013 Introduction 1-5
ControlWave Corrector Instruction Manual
1.6 Software Tools
The ControlWave programming environment consists of a set of
integrated software tools which allow you to create, test, implement,
and download complex control strategies for use with the ControlWave
Corrector. Figure 1-1 graphically presents the programming
environment.
Figure 1-1. ControlWave Programming Environment
The tools which make up the programming environment include:
ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave unit. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), and the ControlWave Designer
Programmer’s Handbook (document D5125).
The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O in the ControlWave and
configure the individual mapping of I/O points for discrete and
analog inputs and outputs. For information on the I/O Configurator
see the ControlWave Designer Programmer’s Handbook (document
D5125).
1-6 Introduction Revised Nov-2013
ControlWave Corrector Instruction Manual
The ACCOL3 Firmware Library, available within ControlWave
Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see the
online help within ControlWave Designer.
OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).
OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).
Communication
Protocols
A series of web page controls are available for retrieval of real-time
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. (See the
ControlWave Flow Measurement Applications Guide D5137)
Alternatively, developers can place the controls in third-party
ActiveX compatible containers such as Visual BASIC or
Microsoft® Excel. For information on the ActiveX controls, see the
Web_BSI Manual (document D5087).
User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).
Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).
In addition to the Bristol Synchronous/Asynchronous Protocol
(BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port with serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
Revised Nov-2013 Introduction 1-7
ControlWave Corrector Instruction Manual
1.7 Overview of the Gas Flow Measurement Application
Note: For detailed information on the gas flow measurement
application and web pages refer to the ControlWave Flow
Measurement Applications Guide (D5137).
You can purchase the ControlWave Corrector with a pre-programmed
flow measurement application already loaded.
The ControlWave standard gas flow measurement application collects
static pressure, differential pressure and temperature data and computes
flow, energy, and volume for a station.
A station typically refers to a single flow computer and all its
associated meter runs. Each meter run refers to measurement of natural
gas through a single pipeline.
1.7.1 Data Acquisition – Static Pressure, Differential Pressure, Temperature Variables
The application requires these process inputs for orifice measurement:
static pressure (SP) collected once per second
differential pressure (DP) collected once per second
flowing temperature (T) collected once per second
The application requires these process inputs for measurement using a
positive displacement (PD), turbine, or ultrasonic meter:
static pressure (SP) collected once per second
frequency input collected once per second
flowing temperature (T) collected once per second
The application also collects self-test and compensation variables at
intervals of four seconds or less.
Pressure data can come from any of the following sources:
Analog pressure transmitters connected to analog input points on a
process I/O module in the ControlWave flow computer.
Built-in gage pressure transducer.
External multivariable transmitters (Bristol or Rosemount) using
BSAP or Modbus communications through an RS-485
communication port.
1.7.2 Flow and Volume Calculations
Flow and volume calculations conform to American Petroleum Institute
(API) and American Gas Association (AGA) standards.
Supported flow calculations include:
AGA3-1985/NX-19
AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
AGA7/NX-19
1-8 Introduction Revised Nov-2013
ControlWave Corrector Instruction Manual
AGA7 with selectable AGA8 Gross or AGA8 Detail
Auto-adjust AGA7/NX-19
Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
The application performs a complete flow calculation using the process
variables every second. Each calculation includes instantaneous rate
according to API 14.3, compressibility according to AGA 8 Detail or
Gross method, and updates of all volumes, totals, and archive averages.
1.7.3 Flow Rate and Flow Time Calculations (AGA3)
For orifice flow measurement, the application compares the differential
pressure value to a low flow cutoff value every second. If the
differential pressure falls below the low 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 and temperature are used
as inputs to the flow equations. You can select API 14.3 (AGA3, 1992)
and AGA8 calculations, with compressibility calculations according to
AGA Report No. 8, 1992 (with 1993 errata). The application supports
both the detail method and the two gross methods of characterization
described in AGA 8. Users may also select the AGA3, 1995 and NX-19
flow equations to calculate the rate of flow.
1.7.4 Flow Rate and Flow Time Calculations (AGA7)
When using PD meters, turbine meters or ultrasonic meters, the
application calculates flow rate 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 application sets the
flow rate estimate to zero; however, volume calculations still
accumulate. The flow time recorded is the time for which the flow rate
is non-zero.
1.7.5 Extension Calculation and Analog Averaging
For orifice meters, the application calculates the flow extension 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, the application
reports the arithmetic averages of static pressure and temperature. This
allows you to monitor static pressure and temperature during shut-in
periods.
Revised Nov-2013 Introduction 1-9
ControlWave Corrector Instruction Manual
p
1.7.6 Energy Calculation
The application offers the option of using a fixed volumetric heating
value or calculating the energy content of the gas according to AGA
Report No. 5.
1.7.7 Volume and Energy Integration
The application integrates and accumulates volume and energy at the
end of every calculation cycle. The application calculates the volume
for a cycle by multiplying the calculated rate by the flow time for that
cycle. The application calculates the energy for a cycle by multiplying
the volume at base conditions by the heating value.
1.7.8 Historical Data Storage (Audit Records/ Archive Files)
The ControlWave supports two distinct types of historical data storage –
audit records and archive files.
Where feasible, both forms of archive data conform to the requirements
of the API Chapter 21. 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.
Audit Records
(Alarms and
Events)
The audit system maintains a history of alarms and certain events that
have an impact on the calculated and reported gas flow rates and
volumes.
The application stores the most recent 500 alarms and the most recent
500 events. As new alarms/events arrive, they overwrite the oldest
entries. Internally, the application stores alarms and events separately to
revent recurring alarms from overwriting configuration audit data
events. The application reports alarms and events in the same log.
The following circumstances generate an audit record:
Any operator change to a configuration variable
Any change in the state of an alarm variable
A system restart
Certain other system events
You can view audit records on-screen in the audit log.
See the Appendix K of the OpenBSI Utilities Manual (D5081) for help
on interpreting audit records.
1-10 Introduction Revised Nov-2013
ControlWave Corrector Instruction Manual
Archive Files
(Averages,
totals, and other
values)
Archive files store the value of process variables and other calculated
variables at specified intervals along with the date and time of each
entry. This includes flow rates, volumes and other calculated values.
When archive files fill up, new values overwrite the oldest entries in the
files.
The application displays archive file data in hourly, data, and periodic
logs you can view on screen.
Log Breaks
You can configure the application to support the "breaking" of a log
period when an operator-changes a parameter. When this occurs, the log
period in process closes out to make a log, and a new log begins.
Note: To prevent several very short logs from being created due to a
series of successive configuration changes, the application will
not create a log which contains less than 60 seconds (flowing or
otherwise) of data. Therefore if you enter 15 configuration
changes over a 2-minute period, the log will only breaks twice.
Hourly Historical Data Log
Each meter run maintains an hourly data log that 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
flash memory.
The hourly data log stores the following items:
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
Daily Historical Data Log
Each meter run maintains a daily data log that holds one record for
every contract gas day. You can change the contract hour if the contract
gas day starts at some time other than midnight. The daily log holds 62
entries; this ensures that the previous calendar month of daily data is
always resident in flash memory.
The daily data log stores the following items:
Revised Nov-2013 Introduction 1-11
ControlWave Corrector Instruction Manual
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
Periodic Historical Data Log
Each meter run maintains a periodic data log that holds one record for
every log interval. Each log interval is 15 minutes. The periodic
historical data log holds 1440 records, or four days of 15 minute data.
The periodic historical data log stores the following items:
flowing differential pressure
flowing static pressure
flowing temperature
frequency
1.7.9 Run Switching
If you use multiple meter runs in the application, you can configure run
switching. Run switching (also known as meter run staging or tube
switching) allows changes to the number of meter runs currently active
to meet the gas flow demand for the station.
1.7.10 Sampler and Odorizer
Samplers are external devices which measure the quality of the gas
stream.
Because natural gas is odorless and colorless, devices called odorizers
inject an additive to the gas stream that allows people to detect the
presence of natural gas in the event of a gas leak.
1.7.11 Chromatograph Interface
If you use a chromatograph to measure gas component information you
can integrate this into the application. You can also specify fixed gas
component percentages to use if the chromatograph fails.
1-12 Introduction Revised Nov-2013
1.7.12 Nominations
Nominations allow you to configure the ControlWave flow computer to
allocate precise amounts of gas flow during specific time periods, called
nomination periods.
ControlWave Corrector Instruction Manual
Revised Nov-2013 Introduction 1-13
This page is intentionally left blank
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
Corrector, considerations for installation, and instructions for setting
switches and jumpers.
In This Chapter
2.1 Site Considerations .......................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ............................. 2-3
2.2 Installation Overview ........................................................................ 2-4
2.3 Unpacking Components .................................................................. 2-5
2.4 Mounting the ControlWave Corrector Assembly ............................. 2-5
2.4.1 Configuring the TeleCounter Assembly ............................. 2-13
2.4.2 Configuring the ISPROX Module (Option) ......................... 2-13
2.4.3 Connection to the Gage Pressure Transducer (GPT) ....... 2-14
2.4.4 Grounding the Housing ...................................................... 2-17
2.5 Configuring the CPU/System Controller Board ............................. 2-18
2.5.1 Setting DIP Switches on the CPU/System Controller Bd ... 2-19
2.5.2 Setting Jumpers on the CPU/System Controller Board ..... 2-21
2.5.3 General Wiring Guidelines ................................................. 2-22
2.5.4 Wiring Power to the CPU/System Controller Board ........... 2-23
2.5.5 Connections to RS-232 Serial Port(s) on the CPU/System
2.5.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the
2.5.7 Connections to the Ethernet Port on the CPU/System Controller
2.6 Radio-Ready and Case Mounted Modem or Radio ...................... 2-33
2.7 Mounting the Solar Panel .............................................................. 2-34
2.8 Optional Display/Keypads.............................................................. 2-37
ControlWave Corrector Instruction Manual
Controller Board ................................................................ 2-25
CPU/System Controller Board .......................................... 2-30
Board ................................................................................ 2-32
2.1 Site Considerations
When choosing an installation site, check all clearances for the
enclosure, for the attached GPT, for the optional RTD probe, for the
TeleCounter assembly, and if applicable, for the solar panel. Ensure that
you can open the front cover of the ControlWave Corrector (hinged on
the left side) for wiring and service. Make sure the display/keypad is
accessible and visible.
See Figure 2-9 for a dimensional drawing of the NEMA 3R enclosure
with a GPT and TeleCounter. See Figure 2-10 for a dimensional
drawing of the NEMA 3R enclosure with a GPT and no TeleCounter.
The ControlWave Corrector is designed to operate in a Class I Division
2, Groups A, B, C & D environment with a nonincendive rating (see
Appendix A). The ControlWave Corrector can operate in an unprotected
outdoor environment.
Revised Nov-2013 Installation 2-1
ControlWave Corrector Instruction Manual
To ensure safe use of this product, please review and follow the
Caution
instructions in the following supplemental documentation:
Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
10
8
13
9
P1
P2
P3
11
P4
P5
3
2
1
NOTE: Units is equipped with Item 4 or 11, or Neither.NOTE: Units is equipped with Item 4 or 11, or Neither.
1.
1. One Piece/Battery Mounting Bracket
One Piece/Battery Mounting Bracket
2. CPU/System Controller Board
2.
CPU/System Controller Board
3. Local Comm. Port Connector & Cover
3.
Local Comm. Port Connector & Cover
4. Optional TeleCounter Assembly
4.
Optional TeleCounter Assembly
5. Optional Polyphaser
5.
Optional Polyphaser
6. Ground Lug
6.
Ground Lug
7. Optional External Radio
7.
Optional External Radio
(MDS - Transnet)
(MDS
8. Radio/Modem Mounting Bracket
8.
Radio/Modem Mounting Bracket
- Transnet)
9.
Optional Process I/O Board
9. Optional Process I/O Board
Optional Dual-Button Display/Keypad Ass’y.
10.
Optional Dual-Button Display/Keypad Ass’y.
10.
11. Optional ISProx Module
11.
Optional ISProx Module
12. 3/4” Conduit Fitting
12.
3/4” Conduit Fitting
13. Smart, Gage Pressure Sensor
13.
Smart, Gage Pressure Sensor
ONO
N
1
2
3
4
5
6
7
8
ONO
N
1
2
3
4
7
12
5
6
4
Figure 2-1. ControlWave Corrector (with MDS - Transnet Radio) (Internal View) Component
Identification Diagram
2-2 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Specifications
for Temperature,
Humidity and
Vibration
2.1.1 Class I, Div 2 Installation Considerations
See document 1665DS2c available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave Corrector.
Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave Corrector is
not exposed to a level of vibration that exceeds that provided in the
technical specifications.
Underwriters Laboratories (UL) lists the ControlWave Corrector as non-
incendive and suitable only for use in Class I, Division 2, Groups A, B,
C, and D hazardous locations and non-hazardous locations. Read this
chapter and Appendix A carefully before you install a ControlWave
Corrector in a hazardous location.
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 Group A, B, C and D environments.
When the ControlWave Corrector is situated in a hazardous location,
turn off power before servicing or replacing the unit and before
installing or removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
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ControlWave Corrector Instruction Manual
2.2 Installation Overview
Installing a ControlWave Corrector involves several general steps:
1. Unpacking, assembling, and configuring the hardware. This
includes:
a) Mounting the enclosure on site. (See Section 2.4)
b) Removing the CPU/System Controller board and optional
Process I/O board assembly so you can enable the backup
battery by setting jumper W3 on the CPU/System Controller
board to position 1 to 2. See Section 5.2.2 for instructions on
removing/replacing the board assembly, see Section 2.5.2 for
information on setting jumpers.
b) Setting other switches and jumpers on the CPU/System
Controller board (see Section 2.5.1 and Section 2.5.2) and on the
Process I/O board (see Section 3.2.1 and Section 3.2.2) and
placing both boards (as a single assembly) back into the chassis.
d) Connecting communication cables. (See Sections 2.5.5, 2.5.6,
and 2.5.7)
e) Wiring I/O. (See Section 3.3)
f) Connecting an external 3808 transmitter (see Section 3.3.8 if
required).
f) Installing a ground wire between the enclosure’s ground lug and
a known good Earth ground. (See Section 2.4.4)
h) Connecting the RTD probe (if required). (See Section 3.3.7)
g) Installing the solar panel (See Section 2.7) and rechargeable
battery (See Section 2.5.4 if applicable)
i) Wiring power to the unit. (See Section 2.5.4)
j) Turning on power. (See Section 4.1)
2. Installing PC-based software (TechView).
3. Establishing communications to perform calibration activities or
view data using the standard flow measurement application menus.
2-4 Installation Revised Nov-2013
Note: Steps 2 through 3 require that you install and use OpenBSI
TechView software to perform calibration and that you use the
standard menus. This manual focuses on hardware installation
and preparation. Software installation and configuration is
beyond the scope of this manual. Refer to the TechView User’s
Guide (D5131) and the ControlWave Flow Measurement
Applications Guide (D5137) for more information. If you are
not using the flow measurement application and plan to create
your own application, refer to the Getting Started with
ControlWave Designer Manual (D5085) and the ControlWave
Designer Programmer’s Handbook (D5125).
2.3 Unpacking Components
ControlWave Corrector Instruction Manual
Packaging
ControlWave Corrector units ship from the factory with all components
wired and mounted except for the unit’s solar panel and battery; these
items are shipped separately.
2.4 Mounting the ControlWave Corrector Assembly
You must position the ControlWave Corrector vertically. Units
equipped with the TeleCounter (Pulser) assembly mount directly to
a turbine meter. Units that do not have the optional TeleCounter
assembly can be mounted remotely to a panel or wall or to a vertical
2” pipe (clamped at the rear of the unit via two clamps and four
bolts – see Figure 2-4 and Figure 2-6). If used, the 2” pipe must be
anchored in cement (deep enough to conform to local building codes
associated with frost and support considerations).
See Figure 2-9 for a dimensional drawing of the NEMA 3R
enclosure with a GPT and TeleCounter. See Figure 2-10 for a
dimensional drawing of the NEMA 3R enclosure with a GPT and no
TeleCounter.
Position the unit so that the front of the unit is both visible and
accessible for service, i.e., installing an option or replacement of the
battery, or installation/removal of any ControlWave Corrector
module. Make sure the operator can see and access the
keypad/display.
You must allow clearance space for the optional Solar Panel (if
required).
The TeleCounter bolts to a turbine meter (via four nuts at the base of
the TeleCounter) (see Figure 2-2); the turbine meter, in-turn,
connects to the main (meter run). A gasket is required between the
TeleCounter assembly and the top of the turbine meter (see Figure
2-3). When mating the ControlWave Corrector to the turbine meter,
it is essential that the TeleCounter input shaft and the opening on the
turbine meter output shaft mate properly. Be careful not to damage
Revised Nov-2013 Installation 2-5
ControlWave Corrector Instruction Manual
the mating surfaces. Once the surfaces align, install and secure the
mounting washers and nuts. Be aware that the meter interface
(TeleCounter base plate) has an eight-bolt mounting pattern. The
bolt patterns allow the ControlWave Corrector to be mounted in two
positions that are 180° apart. The meter interface mounting hole
locations illustrated in Figure 2-3 accommodate the flow meters
listed in Table 2-1.
Table 2-1. Flow Meter Mounting Position
Manufacturer
American Meter, Root & Romet Forward mount A The base plate can be rotated in 90o
Rockwell Forward mount B The base plate can be rotated in 90 o
Rockwell Reverse mount C The base plate can be rotated in 90 o
Mounting
Position
Hole Pattern Notes
increments.
For reverse mounting, remove the base
plate screws (see Figure 2-3 hole
locations “D”) and rotate the base plate
o
.
180
increments.
increments.
Figure 2-2. ControlWave Corrector Mounted to Turbine Meter
2-6 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-3. ControlWave Corrector/Meter Interface Mounting Hole Pattern (Dimensions are in
Inches)
Power wiring should not be installed until the unit has been mounted
and grounded at a designated work site. External power wiring, RTD
cabling, local comm. port, antenna cable, and network (RS-232 and RS-
485) comm. port cabling enter the bottom of the unit though conduit or
special function fittings. I/O wiring is routed through the left side of the
unit (right when facing the front) via a .75” Conduit Fitting.
Revised Nov-2013 Installation 2-7
ControlWave Corrector Instruction Manual
(1) Local Port Connector (2) TeleCounter (Pulser) Holes
(3) RTD Cable Assembly or Sealing Plug (4) Battery Ventilation Assembly
(5) Solar Pwr. Cable, Ext. Pwr. Cable, or Plug (6) Ant. Cable, Polyphaser, or Plug
(7) Solderless Ground Lug (8) GP Transducer (1/4-18 NPT
(9) .75” Conduit Fitting Female)
Figure 2-4. ControlWave Corrector Bottom View
2-8 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-5. Side View of ControlWave Corrector (with TeleCounter)
Revised Nov-2013 Installation 2-9
ControlWave Corrector Instruction Manual
Figure 2-6. Side View of ControlWave Corrector (without TeleCounter)- (Pipe Mounted)
2-10 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-7. TeleCounter Assembly (1 to 1 Gear Ratio) Rotation Adjust Diagram
Revised Nov-2013 Installation 2-11
ControlWave Corrector Instruction Manual
Figure 2-8. TeleCounter Assembly (2 to 1 Gear Ratio) Rotation Adjust Diagram
2-12 Installation Revised Nov-2013
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