Emerson Process Management Controlwave Efm 4710A Users Manual Bristol Electronic Flow Meter (EFM) (CI ControlWaveEFM)

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Instruction Manual
CI-ControlWave EFM
Oct., 2006

ControlWave EFM
(Electronic Flow Meter)

www.EmersonProcess.com/Bristol

ControlWave EFM

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 (860) 945-2200

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.

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.

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.

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.

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.

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.

REMEDIES
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.

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.

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 (860) 945-3875. 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 brepair@bristolbabcock.com. A Bristol Repair Dept.
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 (860) 945-2442. A Bristol Repair Department 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.

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_

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

Line No.____________

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)

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:

Part II

E-Mail:

Please complete Parts II & III for each unit returned

Model No./Part No.

Description

Range/Calibration

S/N

Reason for return :
1.

Failure

Upgrade

Verify Operation

Other

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:

What is the Firmware revision? _____________________

Standalone

RS-485

Ethernet

Other:______________

Modem (PLM (2W or 4W) or SNW)

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:

repaired

returned

replaced

scrapped?

C. If product is deemed not repairable would you like your product:

returned

replaced

scrapped?

D. If Bristol is unable to verify the discrepancy, would you like the product:

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: _________________________ phone_____________________
Special Requests: ____________________________________________________________________________________
____________________________________________________________________________________________________
Ship prepaid to:
Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442
Fax: 860-945-3875
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
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 6856200.

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:
(860) 945-2200
(860) 945-2213 (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 (860) 945-8604.
For technical questions about ControlWave call (860) 945-2394 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865
or e-mail: scada@bristolbabcock.com

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: bsupport@bristolbabcock.com
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 (407) 629-9463 or (407) 629-9464.
You can e-mail the Communication Technology Group at:
orlandoRFgroup@bristolbabcock.com

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 (860) 945-2343 for course
information, enrollment, pricing, and scheduling.

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
INSTALLATION FORWARD
NOTE for all ControlWave EFM 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 EFM.
• Instructors who must become familiar with and teach Field Engineers/Technicians on
the installation, operation and repair of ControlWave EFM.
• Field Engineers/Technicians who must install and service the ControlWave EFM.
Installation of the ControlWave EFM electronic flow meter is provided in two formats as
follows:
Section 2 - Installation & Operation provides a detailed overview of the installation and
operation of the ControlWave EFM. Section 2 provides all the information required for
instructors who are training individuals unfamiliar with the ControlWave EFM. It is also
intended to support anyone who needs to learn how to install and operate the
ControlWave EFM for the first time.
Appendix C - Hardware Installation Guide is intended for individuals who are already
familiar with the ControlWave EFM but need the configuration information in a concise
format. Field Engineers/Technicians who have previously installed one or more
ControlWave EFM electronic flow meters will find the necessary installation information
logically sequenced for their convenience.
NOTE:
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. Bristol’s WINDIAG program
provides menu driven diagnostics that have been designed to assist a technician
or Process Engineer in troubleshooting the various ControlWave EFM circuits. A
brief overview is provided in Section 3.5 of this manual. For more detailed
descriptions of ControlWave EFM Windows Diagnostics than those provided
herein, see Document D4041A – Chapters 1 and 7B.

CI-ControlWave EFM - Installation Forward

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #
Section 1 - ControlWave EFM INTRODUCTION

1.1
1.2
1.3
1.3.1
1.3.2
1.3.2.1
1.3.2.2
1.3.2.3
1.3.2.4
1.3.2.5
1.3.3
1.3.3.1
1.3.3.2
1.3.3.3
1.3.3.4
1.3.3.5
1.3.4
1.3.5
1.3.6
1.3.6.1
1.3.6.2
1.3.6.3
1.3.6.4
1.3.7
1.3.8
1.3.9
1.3.10
1.3.11
1.3.12
1.3.13
1.3.14
1.3.15
1.4
1.5
1.5.1
1.5.2
1.5.2.1
1.5.2.2
1.5.2.3
1.5.2.3.1
1.5.2.3.2
1.5.2.4
1.5.3
1.5.3.1

GENERAL DESCRIPTION ........................................................................................... 1-1
ControlWave PROGRAMMING ENVIRONMENT .................................................... 1-5
PHYSICAL DESCRIPTION........................................................................................... 1-7
Enclosure......................................................................................................................... 1-8
CPU Module .................................................................................................................... 1-8
CPU Module Connectors .............................................................................................. 1-10
CPU Memory................................................................................................................. 1-10
CPU Module Configuration Jumpers .......................................................................... 1-11
CPU Module Configuration Switches.......................................................................... 1-11
CPU Module LEDs ....................................................................................................... 1-12
System Controller Module (SCM)................................................................................ 1-12
SCM Mode Switch......................................................................................................... 1-13
SCM Board Fuse........................................................................................................... 1-13
SCM Board Connectors ................................................................................................ 1-14
SCM Jumpers ............................................................................................................... 1-14
SCM LEDs..................................................................................................................... 1-14
ControlWave EFM Backplanes.................................................................................. 1-14
ControlWave EFM Base Assembly Chassis.............................................................. 1-15
ControlWave EFM I/O Modules ................................................................................ 1-16
Non-isolated Analog I/O & Analog Input Modules ..................................................... 1-17
Non-isolated Digital Input/Output Module................................................................. 1-17
Non-isolated High Speed Counter Input Module........................................................ 1-17
Non-isolated Mixed Input/Output Module .................................................................. 1-17
ControlWave EFM Expansion Communications Modules ....................................... 1-17
Internal Mounting Brackets ........................................................................................ 1-18
Multivariable Transducer ............................................................................................ 1-19
Power Distribution Board ............................................................................................ 1-19
Digital to Relay I/O Option .......................................................................................... 1-19
21V Power Supply Option ............................................................................................ 1-20
Power System................................................................................................................ 1-20
RTD Probe ..................................................................................................................... 1-21
External Radio/Modem................................................................................................. 1-21
FIELD WIRING............................................................................................................ 1-21
FUNCTIONS................................................................................................................. 1-21
Data Acquisition ........................................................................................................... 1-22
Flow and Volume Calculations .................................................................................... 1-22
Flow Rate and Flow Time Calculations (AGA3) ......................................................... 1-23
Flow Rate Calculations and Flow Time Accumulations (AGA7) ............................... 1-23
Extension Calculation and Analog Averaging ............................................................ 1-23
Energy Calculation ....................................................................................................... 1-23
Volume and Energy Integration .................................................................................. 1-23
Downstream Pressure Tap........................................................................................... 1-23
Archives......................................................................................................................... 1-24
Hourly Historical Data Log.......................................................................................... 1-24

CI-ControlWave EFM

Contents / 0 - 1

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #

Section 1 - ControlWave EFM INTRODUCTION (Continued)
1.5.3.2
1.5.3.3
1.5.3.4
1.5.4
1.5.5
1.5.5.1
1.5.6
1.5.6.1
1.5.6.2
1.5.6.3
1.5.7

Daily Historical Data Log ............................................................................................ 1-24
Periodic Historical Data Log ........................................................................................ 1-25
Alarm and Event Storage............................................................................................. 1-25
LCD Display.................................................................................................................. 1-25
Communications ........................................................................................................... 1-26
BSAP Message Support................................................................................................ 1-27
Discrete and Analog I/O EFM Functionality .............................................................. 1-27
Flow Rate Control - DDC (jog control) using PID....................................................... 1-27
Pulse Output for External Totalizer or Sampler ........................................................ 1-28
Nominations.................................................................................................................. 1-28
Self Test & Diagnostics ................................................................................................ 1-28
Section 1A - PRODUCT FEATURES & OVERVIEW

1A.1
1A.1.1
1A.1.2
1A.2
1A.2.1
1A.2.2
1A.2.3
1A.3
1A.3.1
1A.3.2
1A.3.3
1A.3.3.1
1A.3.3.2
1A.3.4
1A.3.5
1A.4
1A.4.1
1A.4.1.1
1A.4.1.2
1A.4.1.3

PRODUCT OVERVIEW .............................................................................................. 1A-1
Hardware Features...................................................................................................... 1A-1
Firmware and Software Features............................................................................... 1A-1
PRODUCT FAMILY COMPATIBILITY .................................................................... 1A-2
Open Standards for Programming, Network Config. and Communication ............. 1A-2
ControlWave Designer with ACCOL III................................................................... 1A-2
ACCOL III.................................................................................................................... 1A-2
STANDARD APPLICATION PROGRAM.................................................................. 1A-3
OpenBSI - Simply Creative......................................................................................... 1A-3
OpenBSI Utilities ........................................................................................................ 1A-4
Real-time ActiveX Controls......................................................................................... 1A-4
ActiveX Controls .......................................................................................................... 1A-5
Required Software ....................................................................................................... 1A-5
Historical Data Collection ........................................................................................... 1A-5
OPC Server .................................................................................................................. 1A-5
ControlWave OPEN NETWORK CONNECTIVITY................................................ 1A-6
Communication Protocols............................................................................................ 1A-6
BSAP Protocol.............................................................................................................. 1A-6
Modbus Protocol........................................................................................................... 1A-7
Generic Serial Interface .............................................................................................. 1A-7
Section 2 - INSTALLATION & OPERATION

2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
0 - 2 / Contents

INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1
SITE LOCATION CONSIDERATIONS........................................................................ 2-4
Temperature & Humidity Limits .................................................................................. 2-4
Vibration Limits ............................................................................................................. 2-4
ControlWave EFM INSTALLATION/CONFIGURATION ........................................ 2-4
Mounting the ControlWave EFM Enclosure .............................................................. 2-8
CI-ControlWave EFM

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #

Section 2 - INSTALLATION & OPERATION (Continued)
2.3.1.1
2.3.1.2
2.3.1.3
2.3.2
2.3.3
2.3.3.1
2.3.3.2
2.3.3.3
2.3.3.4
2.3.3.5
2.3.3.6
2.3.4
2.3.4.1
2.3.4.2
2.3.4.3
2.3.4.4
2.3.4.4.1
2.3.4.5
2.3.4.5.1
2.3.4.6
2.3.4.6.1
2.3.4.7
2.3.4.7.1
2.3.5
2.3.6
2.3.7
2.3.7.1
2.3.8
2.3.9
2.3.9.1
2.3.9.2
2.3.9.3
2.3.9.3.1
2.3.9.3.2
2.3.9.4
2.3.9.5
2.3.10
2.3.11
2.4
2.4.1
2.4.2
2.4.2.1
2.4.2.2

Connection to the Multivariable Transducer (MVT) .................................................. 2-10
Process Pipeline Connection (Meter Runs without Cathodic Protection) ................. 2-11
Process Pipeline Connection (Meter Runs with Cathodic Protection)....................... 2-11
System Controller Module (SCM) Configuration........................................................ 2-13
CPU Module & ECOM Module Configuration ............................................................ 2-14
CPU Module Switch Configuration ............................................................................. 2-14
Communication Ports ................................................................................................... 2-16
RS-232 & RS-485 Interfaces ........................................................................................ 2-17
Piggy-back Spread Spectrum Modem (Radio) Port .................................................... 2-22
Piggy-back 56K PSTN Modem Port............................................................................. 2-23
Radio Ready and External (Case Mounted) Modem or Radio.................................... 2-27
I/O Module Installation & Wiring................................................................................ 2-27
Installation of I/O Modules .......................................................................................... 2-27
I/O Wire Connections.................................................................................................... 2-30
Shielding and Grounding ............................................................................................. 2-30
Non-isolated Digital Input/Output Module................................................................. 2-30
Digital Input/Output Configurations .......................................................................... 2-30
Non-isolated Analog Input/Output & Analog Input Modules .................................... 2-31
Analog Input/Output Configurations .......................................................................... 2-33
Non-isolated High Speed Counter Input Module........................................................ 2-33
High Speed Counter Configurations............................................................................ 2-35
Non-isolated Mixed I/O Module ................................................................................... 2-35
Mixed I/O Module Configuration ................................................................................. 2-37
RTD Wiring ................................................................................................................... 2-38
21V Power Supply Option ............................................................................................ 2-39
Digital to Relay I/O Board Option ............................................................................... 2-40
Digital to Relay I/O Board Jumper Settings ............................................................... 2-40
Connection to a Model 3808 Transmitter.................................................................... 2-42
Power Wiring & Distribution ....................................................................................... 2-44
Bulk Power Supply Current Requirements ................................................................ 2-45
Power Wiring ................................................................................................................ 2-46
Mounting an Optional Solar Panel .............................................................................. 2-47
Swivel (Directional Facing) .......................................................................................... 2-47
Tilt Angle....................................................................................................................... 2-48
Installing the Rechargeable Battery and Solar Panel Harness................................. 2-48
ControlWave EFM System Grounding...................................................................... 2-49
Operation of the Lithium Backup Coin-cell Battery .................................................. 2-49
Installation of a Bezel Assembly.................................................................................. 2-50
OPERATIONAL DETAILS .......................................................................................... 2-51
Downloading the Application Load.............................................................................. 2-51
Upgrading ControlWave EFM Firmware ................................................................. 2-51
Using LocalView to Upgrade ControlWave EFM Firmware ................................... 2-52
Using Hyperterminal to Upgrade ControlWave EFM Firmware............................ 2-55

CI-ControlWave EFM

Contents / 0 - 3

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #

Section 2 - INSTALLATION & OPERATION (Continued)
2.4.2.3
2.4.3
2.4.4
2.4.5
2.4.5.1

Remote Upgrade of ControlWave EFM Firmware ................................................... 2-58
Operation of the Mode Switch...................................................................................... 2-59
Soft Switch Configuration and Communication Ports ............................................... 2-59
Optional Display/Keypad Assemblies.......................................................................... 2-60
Operation of the Dual-button Display/Keypad Assembly .......................................... 2-62
Section 3 - SERVICE

3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.2.11
3.3
3.3.1
3.3.2
3.3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.5.1
3.5.1.1
3.5.1.2
3.6
3.7

SERVICE INTRODUCTION ........................................................................................ 3-1
COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1
Accessing Modules For Testing...................................................................................... 3-1
Removal/Replacement of the Bezel Assembly............................................................... 3-2
Removal/Replacement of the CPU Module ................................................................... 3-2
Removal/Replacement of the System Controller Module ............................................. 3-2
Removal/Replacement of an I/O Module ....................................................................... 3-2
Removal/Replacement of an Expansion Comm. Module .............................................. 3-3
Removal/Replacement of a Rechargeable Lead-acid Battery....................................... 3-3
Removal/Replacement of a Power Distribution Board ................................................. 3-4
Removal/Replacement of a 21V Power Supply Board .................................................. 3-5
Removal/Replacement of a Digital to Relay I/O Board................................................. 3-5
Removal/Replacement of an External Radio/Modem ................................................... 3-5
TROUBLESHOOTING TIPS......................................................................................... 3-5
System Controller Module (SCM) Voltage Checks ....................................................... 3-5
LED Checks .................................................................................................................... 3-6
Wiring/Signal Checks ................................................................................................... 3-10
GENERAL SERVICE NOTES ..................................................................................... 3-10
Extent of Field Repairs................................................................................................. 3-11
Disconnecting RAM Battery ........................................................................................ 3-11
Maintaining Backup Files............................................................................................ 3-11
WINDIAG DIAGNOSTICS .......................................................................................... 3-11
Diagnostics Using WINDIAG ...................................................................................... 3-14
Communications Diagnostic Port Loop-back Test ...................................................... 3-14
Serial Comm. Port Eternal Loop-back Test Procedure .............................................. 3-14
CORE UPDUMP........................................................................................................... 3-16
CALIBRATION CHECKS............................................................................................ 3-16
Section 4 - SPECIFICATIONS

4.1
4.2
4.3
4.3.1
4.3.2
0 - 4 / Contents

CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1
COMMUNICATION PORTS ......................................................................................... 4-1
SYSTEM CONTROLLER MODULE ............................................................................ 4-2
Input Power Specs. ......................................................................................................... 4-2
Power Supply Sequencer Specs. .................................................................................... 4-3
CI-ControlWave EFM

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #
Section 4 - SPECIFICATIONS (Continued)

4.3.3
4.3.4
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.5
4.6
4.7
4.8

Power Supply External Power Monitor Specs. ............................................................ 4-3
System Controller Module Connectors.......................................................................... 4-3
INPUT/OUTPUT MODULE SPECIFICATIONS......................................................... 4-4
Non-isolated Analog Input/Output Module................................................................... 4-4
Non-isolated Digital Input/Output Module................................................................... 4-5
Non-isolated High Speed Counter Input Module.......................................................... 4-6
Non-isolated Mixed Input/Output Module .................................................................... 4-6
DIGITAL TO RELAY I/O BOARD SPECIFICATION ................................................. 4-9
21V POWER SUPPLY BOARD SPECIFICATIONS .................................................... 4-9
ENVIRONMENTAL SPECIFICATIONS.................................................................... 4-10
DIMENSIONS .............................................................................................................. 4-10

APPENDICES/SUPPLEMENTAL INSTRUCTION
Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A
Reserved ............................................................................................................Appendix B
HARDWARE INSTALLATION GUIDE..........................................................Appendix C
ECOM MODULE RADIO/MODEM INSTALLATION GUIDE .................... Appendix D
DISPLAY/KEYPAD ASSEMBLY GUIDE.......................................................Appendix E
Using ControlWave EFM WebBSI Web Pages ............................................. Appendix F
RADIO READY INSTALLATION GUIDE .................................................... Appendix G
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 BBI Controllers........................................D4041A
ControlWaveMICRO Quick Setup Guide ............................................................. D5124
Open BSI Utilities Manual ...................................................................................... D5081
Getting Started with ControlWave Designer.......................................................... D5085
Web_BSI Manual ...................................................................................................... D5087
ControlWave Designer Reference Manual .............................................................. D5088
ControlWave Designer Programmer’s Handbook ................................................... D5125
TechView User’s Guide............................................................................................. D5131
ControlWave Loop Power Supply Product Installation Guide........ PIP-ControlWaveLS

REFERENCED OEM MANUALS
Expansion Comm. Module Piggy-back Modem/Radio OEM Manuals
MDS Transnet Radio wired to Polyphaser - Spread Spectrum Data Transceiver
MDS document MDS 05-3946A01, Rev. A April, 2003 (PDF = 3946A-TNET_OEM-web.pdf)
CI-ControlWave EFM

Contents / 0 - 5

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #

REFERENCED OEM MANUALS (Continued)
Expansion Comm. Module Piggy-back Modem/Radio OEM Manuals (Continued)
Internal FreeWave Radio (wired to Polyphaser) - Spread Spectrum Data Transceiver
FreeWave Spread Spectrum Wireless Data Transceiver User Manual - V5.0R (model FGR09CSU)
Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the
latest copy of the user manual.
MultiTech Systems wired to Surge Suppressor - Modem Module MT3334SMI & MT5634SMI
MultiTech Systems Developer Guide PN S000181C, version C 6/24/02 (PDF = S000181C.pdf)

External Modem/Radio OEM Manuals
MDS Transnet 900 - Spread Spectrum Data Transceiver
MDS TransNET 900 Spread Spectrum Data Transceiver Installation & Operation Guide – MDS Doc.
MDS 05-2708A01, Rev. C, Feb., 2004 (PDF = 2708C-TransNET-web.pdf) for MDS TransNet 900
MDS 4710A – Remote Data Transceiver (Radio)
MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver Installation and Operation Guide
– MDS Doc. 05-3305A01, Rev. B, Sept. 2000
(PDF = 3305B-710AC.pdf) for model MDS 4710A
MDS 4710B – Data Transceiver (Radio)
MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev.
E, Sept. 2000
(PDF = 3316E-x710B.pdf) for model MDS 4710B
MDS 9810 – Spread Spectrum Data Transceiver (Radio)
MDS 9810/24810 900 MHz/2.4GHz Spread Spectrum Transceivers Installation and Operation Guide
– MDS Doc. 05-3301A01, Rev. B, April 2000
(PDF = 3301B-x810.pdf) for model MDS 9810
MDS 9710A Remote Data Transceiver (Radio)
MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver – MDS Doc. 05-3305A01, Rev. B,
Sept. 2000
(Installation & Operation) (PDF = 3305B-710AC.pdf) for model MDS 9710A
MDS 9710B Data Transceiver (Radio)
MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev.
E, Sept. 2000
(PDF = 3316E-x710B.pdf) for model MDS 9710B

0 - 6 / Contents

CI-ControlWave EFM

ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION

TITLE

PAGE #

REFERENCED OEM MANUALS (Continued)
External Modem/Radio OEM Manuals (Continued)
MDS iNET 900 Ethernet Radio
MDS iNET 900 Wireless IP/Ethernet Transceiver – User Guide = MDS 05-2806A01, Rev. D, Aug.
2003
(PDF = 2806D-iNET_User-web.pdf) for iNET 900 Ethernet Radio
Center Insert (Installation Reference Chart) = (PDF = 2873D-iNET_Center_Sheet.pdf)
MDS iNET 900 Wireless IP/Ethernet Transceiver – Installation Guide = MDS 05-2873A01, Rev. D,
Aug. 2003
(PDF = 2873D-iNET-Install_web.pdf) for iNET 900 Ethernet Radio
MDS entraNET Extended Range IP Networking Transceivers
MDS entraNET Extended Range IP Networking Transceivers – System Guide = MDS 05-4055A01,
Rev. A, Oct. 2003
(Installation & Operation) (PDF = 4055A-entraNET-web.pdf) for MDS entraNET 900 System
FreeWave Radio - Spread Spectrum Data Transceiver Model FGRM-501X005
Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the
latest copy of the user manual.

CI-ControlWave EFM

Contents / 0 - 7

Section 1
ControlWave EFM INTRODUCTION
1.1 GENERAL DESCRIPTION
ControlWave EFM electronic flow meters measure differential pressure, static pressure
and temperature for a single run and compute flow for both volume and energy. In addition
to operation in an unprotected outdoor environment, the ControlWave EFC electronic flow
meter provides the following key features.
•
•
•
•
•
•
•

•
•
•
•
•
•
•
•
•
•

ARM processor provides exceptional performance and low power consumption
Wide operating temperature range: (-40 to +70°C) (-40 to 158°F)
CPU, SCM & I/O Modules provide LED status Indicators
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
Integral Multivariable Transducer (MVT) with “smart” performance
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
Three serial communications ports (Two RS-232 & One RS-485)
Four line alphanumeric display (with dual-button Keypad or 25-button Keypad)
User choice of I/O Modules (AI/AO, AI, DI/DO, HSC and Mixed I/O)
RTD input
Nonincendive Class I, Div. 2, Groups C & D Hazardous Locations (see Appendix A)
RTD input
Optional Expansion Comm. Modules with/without built-in modem and/or radio
Chassis Slots 3 and 4 support Expansion Comm. Modules or I/O Modules or one of each
Optional Display/Keypad System
Mixed I/O Modules provide cost effective I/O for small RTU applications

ControlWave EFC electronic flow meters are furnished in a NEMA 3X rated Hoffman®
Enclosure. The flow computer hardware is comprised of a Backplane Board (mounted in a
Housing), a System Controller Module and a CPU Module. Optional Expansion
Communication Modules may reside in Slots 3 and 4 of the Housing in lieu of I/O Modules.
The CPU Module utilizes Sharp’s LH7A400 System-on-Chip Advanced RISC Machine
(ARM) microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC)
Core. In addition to the microprocessor and control logic, the CPU Board includes two RS232 communication ports, one RS-485 Communication port, 2MB of battery backed Static
RAM (SRAM), 512kB Boot/Downloader FLASH, 8MB simultaneous read/write FLASH, and
an I/O Bus Connector.
All system modules plug into the Backplane Board (4-Slot or 8-Slot). Each I/O Module
provides the circuitry and field interface hardware necessary to interconnect the assigned
field I/O circuits. Non-isolated power is generated and regulated by the System Controller
Module (SCM) that provides +3.3Vdc for all logic and bulk power for I/O field circuits from
either a bulk 6Vdc or bulk 12Vdc source. +1.8Vdc, used by the ARM microprocessor, is
CI-ControlWave EFM

Introduction / 1-1

generated on the CPU Module (derived from the regulated 3.3Vdc logic power). In addition
to Idle and Watchdog LEDs, there are six status LEDs located on the SCM that will display
run time status information.

Figure 1-1 - ControlWave EFM Enclosure
(with 25-Button Display/Keypad Assembly)(Shown with Circular Local Port)
1-2 / Introduction

CI-ControlWave EFM

Figure 1-2A - 4-Slot ControlWave EFM (Internal View)
Component Identification Diagram (Shown with D-Type Local Port)
CI-ControlWave EFM

Introduction / 1-3

Figure 1-2B - 8-Slot ControlWave EFM (Internal View)
Component Identification Diagram (Shown with Circular Local Port)
1-4 / Introduction

CI-ControlWave EFM

Figure 1-3 - 8/4-Slot ControlWave EFM (Electronic Flow Meter) Base Assemblies
(The 4-Slot Chassis is shown with ECM Modules in Slots 3 & 4)

1.2 ControlWave PROGRAMMING ENVIRONMENT
The ControlWave programming environment uses industry-standard tools and protocols to
provide a flexible, adaptable approach for various process control applications in the water
treatment, wastewater treatment, and industrial automation business.
CI-ControlWave EFM

Introduction / 1-5

ControlWave EFM 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 EFM 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.
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.

Figure 1-4 - ControlWave - Control Strategy Software Diagram
•

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

1-6 / Introduction

CI-ControlWave EFM

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 EFM 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 ControlWave EFM.

• Flash Configuration Utility – Parameters such as the BSAP local address, IP address, etc. are set using the Flash Configuration Utility, accessible via Open BSI
LocalView or NetView. The ControlWave EFM ships with a standard Flash Configuration Profile (FCP) file, with default configuration parameters already set.

1.3 PHYSICAL DESCRIPTION
ControlWave EFM electronic flow meters are comprised of the following major components:
•
•
•
•
•
•
•

Enclosure with Local Communications Port (RS-232) and LCD Display (Section 1.3.1)
CPU Module (Section 1.3.2)
System Controller Module (Section 1.3.3)
Backplane (Section 1.3.4)
Base Assembly (Chassis) (Section 1.3.5)
Up to two I/O Modules (Section 1.3.6) or two Expansion Communication Modules (see
Section 1.3.7) - (or one of either, one of each, or none)
Internal Mounting Brackets (Section 1.3.8)

ControlWave EFMs can be factory configured with the following options:
•
•
•
•
•
•

•

Multivariable Transducer (Section 1.3.9)
Power Distribution Board (Section 1.3.10)
Digital to Relay I/O Board (Section 1.3.11)
21V Power Supply Board (Section 1.3.12)
Power System - Solar Panel (30W) & 33AH Lead-acid Battery (with Battery Charger/Power Manager Board (Section 1.3.13)
RTD Probe (Section 1.3.14)
External Radio/Modem (Section 1.3.15)

CI-ControlWave EFM

Introduction / 1-7

1.3.1 Enclosure
ControlWave EFMs are housed in a standard Hoffman® Enclosure. External dimensions
(excluding added hardware and Cover Latches) are approximately 14.56” high, by 12.97”
wide, by 8.31” deep. When present, the Multivariable Transducer adds 2.89” to the height of
the unit. The enclosure consists of two pieces, the body and the Instrument Front Cover. A
continuous gasket seals the unit when the Instrument Front Cover is closed. A hinge on the
left side (facing the front of the unit) is formed by molded channels on the Instrument Front
Cover and the body that capture a stainless steel pin. Two latches on the enclosure’s right
side secure the Instrument Front Cover when it is closed.
A weatherproof communication connector, either a 9-Pin male D-Type connector or a a
circular 3-pin connector, (the Local Port) is mounted to the bottom of the enclosure and
connected internally to RS-232 Comm. Port 1 provides connection for a local
communications device, typically a PC. Communications rate is configurable 300 to 115.2
KB (115.2 KB - default).
Enclosures are provided with either a 2-button 4 X 20 LCD display or a 4 X 20 LCD display
supported by a 25-button keypad. In normal operation, the display stays off after the unit
has been configured and placed into service. The operator may activate the display at any
time by pressing the appropriate front panel button.

1.3.2 CPU Module
The CPU Module houses the CPU Board. This multilayer board provides ControlWave
MICRO EFM CPU, I/O monitor/control, memory and communication functions. ControlWave MICRO EFM CPU Modules operate over an extended temperature range with longterm product reliability.
ControlWave EFM CPU Boards are based on Sharp’s LH7A400 System-on-Chip ARM
microprocessor with 32-bit ARM9TDMI RISC Core. The CPU operates at 1.8V with a
system clock speed of 33 MHz. The Microcontroller is packaged in a 256-pin Plastic Ball
Grid Array. In addition to the microprocessor and control logic, the CPU Board includes two
RS-232 and one RS-485 communication ports, 2MB of battery backed Static RAM (SRAM),
512kB Boot/Downloader FLASH, 8MB simultaneous read/write FLASH and an I/O Bus
Connector.
CPU Modules are provided backup power via a piggyback mounted Battery Backup board
equipped with 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 JP1 on the Battery Backup Bd. is installed.
If the 3.3Vdc that powers the unit goes out of specification, a supervisory circuit on the
Battery Backup Board switches the battery voltage to the VBAT3.3 hardware signal (used
by the CPU’s SRAM and RTC). This supervisory circuit also generates a BATTERYGOOD
signal when the battery voltage is above 2.2V.
The system SRAM is specified to have a standby current of 20:A maximum for each part
(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.
A supervisory circuit is used to switch to battery power when VCC falls out of specification.
For maximum shelf life, the battery may be isolated from the circuit by removing the
1-8 / Introduction

CI-ControlWave EFM

Backup Battery Jumper JP1 (on the Battery Backup Board) 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).

Figure 1-5 – ControlWave EFM CPU Module
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, 512K x 32, with Battery Back-up
8MB simultaneous read/write FLASH, TSOP sites
Two 9 wire PC2 compatible (RS-232) serial communications ports with modem control
pins and one 5 wire RS-485 Comm. port
I/O Bus Interface capable of driving up to 14 I/O Modules
Spread Spectrum clock for lower EMI
Two Status LEDs per Comm. Port
8-Position general-purpose switch bank plus a 4-Position recovery switch bank
Coin cell socket accepts a 3.0V, 300mA-hr lithium battery

CI-ControlWave EFM

Introduction / 1-9

1.3.2.1 CPU Module Connectors
The CPU Modules contain up to seven connectors that function as follows (see Table 1-1):
Table 1-1 - CPU Board Connector Summary
Ref.
P1
P2
P3
J2
J3
J4
J5

# Pins
76-Pin
36-pin
44-pin
10-Pin
9-pin
9-pin
9-pin

Function
Factory Debug
Card Edge Backplane I/O Bus Intf.
Card Edge Backplane SCM Intf.
PLD JTAG Header
COM1 9-pin male D-sub (RS-232)
COM2 9-pin male D-sub (RS-232)
COM3 9-pin male D-sub (RS-485)

Notes
Not user accessible
see Figure 2-9
see Figure 2-8
Not user accessible
see Figure 2-11 & Table 2-3 or 4-2
see Figure 2-11 & Table 2-3 or 4-2
see Figure 2-11 & Table 2-3 or 4-2

CPU Module Comm. Port Connectors J3, J4 and J5
The CPU Module supports up to two external 9-pin RS-232 serial communication ports
(COM1 and COM2) and an external 9-pin RS-485 serial communication port (COM3).
COM1 and COM2 and COM3 utilize standard 9-pin male D-sub connectors. RS-232 ports
are protected with LCDA12C devices to ±4KV ESD. RS-485 port COM3 is protected with
LCDA12C and LCDA05 devices to ±4KV ESD.
CPU Module I/OB Connector P2
CPU Module I/O Bus connector P2 provides a 36-pin interface between slot #2 (P3) of the
Backplane PCB and the CPU Module. Separate data, address and control buffers provide
access to the I/O bus which in turn provides up to 14 slots of memory mapped I/O Modules.
The CPU Module interface to the I/O Modules is through a set of buffers and transceivers
that are capable of driving up to fourteen I/O Modules.
CPU Module/System Controller Module Interface Connector (P3)
CPU Module/System Controller Module Interface connector (P3) provides a 44-pin interface
between slot #2 (P2) of the Backplane PCB and the CPU Module. The SCM provides:
-

a wide input range Vin to 3.3V DC to DC Converter
1200 Millisecond good power detection
Vin out of Spec. detection
LED Status indication

1.3.2.2 CPU Memory
Boot/downloader FLASH
Boot/download code is contained in a single 512Kbytes uniform sector FLASH IC. This
device resides on the local bus, operates at 3.3V and is configured for 8-bit access. 4Position DIP-Switch SW1’s position 3 allows start-up menu options to be displayed or bootup from system FLASH. If SW1-3 is closed when a reset occurs, the boot-up code will cause
a recovery menu to be sent out the COM1 serial port to a terminal program running on an
external host computer. Note: Recovery Mode will also be initiated if SCM Switch SW1
positions 1 and 2 are both set OPEN (Right) or CLOSED (Left) when a reset occurs.
FLASH Memory
The base version of the CPU Module has 8Mbytes of 3.3V, simultaneous read/write (DL)
FLASH memory. Each CPU Board contains two 48-pin TSOP sites that will each accept 4
or 8 Mbytes of 3.3V, (DL) FLASH IC, for a total of 4 or 8 Mbytes of memory. FLASH
1-10 / Introduction

CI-ControlWave EFM

memory is 32-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 two 512K x 16 asynchronous SRAMs that are configured as a 512K x 32-bit
array. 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 44-pin TSOPs.
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 32-bit accesses and is connected to the GP bus.
1.3.2.3 CPU Module Configuration Jumpers
ControlWave EFM CPU Modules are provided with three User Configuration Jumpers
that function as follows:
• JP1 - Battery Backup Disable Jumper - On the Battery Backup Board - When JP1 is
removed, the CPU Module backup battery is disabled.
• JP4 - Status LEDs Disable Jumper - When JP4 is removed, the Status LEDs and the Idle
LED on the System Controller Module (SCM) are disabled.
• JP7 - Comm. port Status LEDs Disable Jumper - When JP7 is removed the CPU Comm.
Port Status LEDs are disabled.
1.3.2.4 CPU Module Configuration Switches
Three user configurable DIP-Switches are provided on the CPU Board; eight-bit DIPSwitch SW2 is provided for user configuration settings while four-bit DIP-Switch SW1
provides forced recovery functions. Eight-bit DIP-Switch SW3 provides loopback,
termination control, and receiver bias settings for the RS-485 port (COM3).
Table 1-2 - Assignment of CPU Bd. Switch SW2 - User Configurations
Switch
SW2-1
SW2-2
SW2-3
SW2-4

Function
Watchdog Enable
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6

SW2-5

SRAM Control

SW2-6

System Firmware
Load Control *

SW2-8

Enable WINDIAG

Setting
ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches or 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 via Mode Switch (SW1) on SCM
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 = Don’t allow WINDIAG to run test
OFF = Disable boot project and allow WINDIAG to run test

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

CI-ControlWave EFM

Introduction / 1-11

Table 1-3 - Assignment of CPU Bd. Switch SW1
Force Recovery Mode
Switch

Function

SW1-3

Force Recovery Mode

Setting
ON = Force recovery mode (via CW Console)
OFF = Recovery mode disabled

Table 1-4 - Assignment of CPU Module Switch SW3
COM3 - Loopback & Termination Control
Switch
SW3-1
SW3-2
SW3-3
SW3-4
SW3-7
SW3-8

RS-485 Function
TX+ to RX+ Loopback
TX- to RX- Loopback
100 Ohm RX+ Termination
100 Ohm RX- Termination
RX+ Bias (End Node)
RX- Bias (End Node)

Setting
ON - Only for Diagnostics
ON - Only for Diagnostics
ON - End Nodes Only
ON - End Nodes Only
ON - End Nodes Only
ON - End Nodes Only

1.3.2.5 CPU Module LEDs
ControlWave EFM CPU Modules have six (6) LEDs on the CPU Board. Units equipped
with an optional Ethernet Port have two (2) additional LEDs (situated on the Ethernet RJ45 connector). Table 1-5 provides CPU Module LED assignments. An ON LED indicates an
associated transmit (TX) or receive (RX) activity.
Table 1-5 - Assignment of CPU Module LEDs
LED Ref.
C1
C1
C2
C2
C3
C3

LED Function
TX COM1
RX COM1
TX COM2
RX COM2
TX COM3
RX COM3

1.3.3 System Controller Module (SCM)
The System Controller Module (SCM) plugs into the system’s Backplane Board slot #1
(Connector P1 - a 44-pin female non-keyed header). The front of the SCM contains two
pluggable terminal blocks for external, input power (TB1) and RTD (TB2 - future) connections. An RJ-45 connector provides the interface to a remote Display/Keypad Assembly. Two
red LEDs, visible through the front panel, 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, it should be ON most of the
time. When the Idle LED is OFF, it indicates that the CPU has no free time, and may be
overloaded). Six status LEDs provide run time status codes.
SCMs contain a DC to DC power supply that generates a +3.3Vdc supply for the entire unit,
i.e., the CPU and various I/O Modules that plug into the Backplane Board. Also contained
on the SCM is the sequencer circuit that monitors the external power supply as well as the
logic supplies (3.3Vdc and 1.8Vdc on the CPU Board). The sequencer circuit has a
reset/early power fail warning controller that is utilized by the CPU Board to generate a
master reset (MRESET) to the rest of the system and to generate a power fail interrupt to
the CPU.
1-12 / Introduction

CI-ControlWave EFM

The power supply operates from +4.5/+4.9 to +16Vdc or +9.6/10.3 to +16Vdc with the
nominal input supply configuration (+6V or +12V) user configured via on-board jumpers. A
supervisory circuit monitors the incoming power and the supply voltages. The isolated
supplies are shut down when the incoming voltage drops below +4.5V for a +6V system or
+9.6V, for a +12V system.
An external battery monitor is composed of an Analog to Digital Converter (ADC) and
interface circuitry.

WATCHDOG LED

JP5, JP6, JP7, JP8 & JP9
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

(Red)

CR27
IDLE LED
(Red)

CR26
CR25
CR24

Staus LEDs
(Red)

JP6
JP7
1
1

JP5
JP8
1

JP9
1

SW1 = Mode Switch

J2
Display Intf.
Connector

J2
RJ-45

TB1
Input Power
Connector

TB2
RTD Interface
Connector
P2
MVT Interface
Connector

(+4.5/4.9Vdc to +16.0Vdc for +6V supply)

TB1-1 +VIN (+9.6/10.3Vdc to +16.0Vdc for +12V supply)
TB1-2 -VIN (Supply Ground)
TB1-3 Chassis Ground (CHASSIS)

JP1 - Factory Configured
(Not Shown)

JP7 - 1.2V Reference Source Current Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP5 - Power Fail Trip Point Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP8 - Supply Shutdown Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP6 - Supply Shutdown Trip Point Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP9- Power Fail Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

Figure 1-6 - ControlWave EFM System Controller Module

CI-ControlWave EFM

Introduction / 1-13

1.3.3.1 SCM Mode Switch
SCM Module’s Mode Switch (SW1), is a 2-position piano type DIP-Switch that is utilized for
recovery mode and core updump operations (see Sections 2.4.3 and 3.6)
1.3.3.2 SCM Board Fuse
The SCM is fused to protect the entire system. 5x20mm Slow Blow Fuse F1 is rated at 1A.
1.3.3.3 SCM Board Connectors
Connectors TB1, TB2, J1, J2 and P2 function as described below.
SCM Bd. Terminal Block Connector TB1
TB1 provides 3 input connections for bulk power:
TB1-1 = +VIN (+4.5/4.9 to +16.0V dc for +6Vdc supply)
(+9.6/10.3V to +16V dc for +12Vdc supply)
TB1-2 = -VIN (Supply Ground - PSGND)
TB1-3 = Chassis Ground - CHASSIS ( )
SCM Bd. Terminal Block Connector TB2
TB2 provides 3 connections for a 100-ohm platinum bulb (DIN 43760 curve) RTD:
TB2-1 = RTD + (Sense or Excitation)
TB2-2 = RTD + (Sense or Excitation)
TB2-3 = RTD – (Return)
SCM Bd. Connector P2
P2 is an 8-pin non-keyed male in-line connector that mates with the Multivariable
Transducers (MVT) Interface Cable’s female connector.
SCM Bd. Connector P1
P1 is a 44-pin non-keyed male card-edge connector that mates with Backplane connector P1
(slot #1) and interfaces Power, Ground, Status and Control signals to the system.
SCM Bd. Connector J2
RJ-45 Connector J2 provides an interface to a remote Display/Keypad Assembly.
1.3.3.4 SCM Jumpers
ControlWave EFM SCM Modules are provided with six User Configuration Jumpers (see
Figure 1-6 for jumper functionality).
1.3.3.5 SCM LEDs
In addition to WATCHDOG and IDLE LEDs, the SCM contains six status LEDs, which are
driven by a status register on the CPU Module. These LEDs are visible through the front
panel and provide run time status codes (see Section 2.4.2 or Section 3.3.2).

1-14 / Introduction

CI-ControlWave EFM

1.3.4 ControlWave EFM Backplanes
4-Slot or 8-Slot ControlWave EFM Backplanes provide for the electrical interconnection of
the System Controller Module (SCM), CPU Module, Expansion Communication Modules
(ECOMs) and/or I/O Modules. One or two Expansion Comm. Modules may be substituted
for I/O Modules in Backplane slots 3 & 4. Backplane module slot connections that support
Expansion Comm. Modules (slots 3 & 4) or I/O Modules (slots 3 through 8) are implemented
via 36-pin female Headers.
The main complement of signals on the Backplane, implement an I/O bus for data transfer
between the CPU and I/O Modules. Note: I/O Modules are Non Interrupt Capable.
+3.3Vdc and GND from the SCM are connected to the CPU. All I/O Module slot positions
receive +3.3Vdc and GND. Additionally, the SCM supplies switched field power
(FIELDVOUT) to all I/O Module slots. The power supply sequencer circuit (within the
SCM) provides POWERGOOD, POWERFAIL, VIN100M and PFDLYCLK signals to the
CPU thus providing properly timed early warning of low input or supply voltages followed
by a CPU reset to support the WARM START CPU function.

Figure 1-7 - Backplane Board Diagram

1.3.5 ControlWave EFM Base Assembly Chassis
A Gold Irridite Aluminum Chassis supports the ControlWave EFM Backplane PCBs and
the modules that comprise the system (see Figs. 1-3 & 4-3). Dimensions are provided in
Section 4 of this manual (see Figures 4-3 and 4-4 for 4-Slot and 8-Slot Chassis,
respectively).
CI-ControlWave EFM

Introduction / 1-15

The unit’s Base Assembly Chassis is mounted to the Fabrication Panel inside the Hoffman
Enclosure. ControlWave EFM Chassis’ contain a Ground Lug that accommodates up to a
#4 AWG Ground Wire. Grounding the unit is accomplished by connecting a ground wire
between the Ground Lug and a known good Earth Ground.

1.3.6 ControlWave EFM I/O Modules
Five unique I/O Modules are available factory configured for either local or remote field
device wiring termination. I/O Modules provide Configuration Jumpers that accommodate
individual field I/O user configuration. Terminations are pluggable and accept a maximum
wire size of 14 gauge. All I/O have surge protection that meets C37.90-1978 and IEC 801-5
specifications. Each I/O Module is connected to the ControlWave EFM Back-plane via a
36-pin male card-edge connector. With the exception of the Mixed Input/Output Module, all
I/O Modules are provided with two 10-point Terminal Block Assemblies (for local
termination) or two 14-pin Mass Termination Headers (for remote termination). Mixed I/O
Modules are provided with two 10-point Terminal Block Assemblies (for local termination).
A brief overview of each I/O Module type is provided below. Specifications are covered in
Section 4.4.

Figure 1-8 - Two ControlWave EFM I/O Modules (with Bezel)
1-16 / Introduction

CI-ControlWave EFM

1.3.6.1 Non-isolated Analog I/O & Analog Input Modules (also see Section 2.3.4.5)
ControlWave EFM AI/O Modules provide 6 Analog Inputs and optionally 2 Analog
Outputs. All Analog Inputs are externally sourced, single-ended and individually Jumper
configurable for either 4-20mA or 1-5Vdc. Analog Outputs are externally sourced and are
individually Jumper configurable for 4-20 mA or 1-5 Vdc. 30Vdc Transorbs provide surge
suppression between each signal and ground. Analog Input Modules are identical to AI/O
Modules but have a depopulated AO section.
1.3.6.2 Non-isolated Digital Input/Output Module (also see Section 2.3.4.4)
ControlWave EFM DI/O Modules provide 12 Digital Inputs and 4 Digital Outputs. All
Digital Inputs support dry contact inputs internally sourced from the 3.3 Vdc supply and a
jumper selectable input current range of 60 uA (for low power applications) or 2 mA (for inplant noise immunity). 15 millisecond input filtering protects against contact bounce.
Digital Outputs have a 30 Vdc operating range and are driven by Open Drain FETs that
provide 100 mA (max) at 30Vdc. DI/O Modules support optional Status Indication with an
LED per I/O point. 31Vdc Transorbs provide surge suppression between each signal and
ground.
1.3.6.3 Non-isolated High Speed Counter Input Module (also see Section 2.3.4.6)
High Speed Counter Input (HSCI) Modules provide a total of 4 internally sourced inputs
that provide 2mA or 200uA (low power) input signals. Signal conditioning is provided by a
debounce circuit for a relay contact input source, followed by a one-shot pulse circuit that
generates a 65usec ±10% pulse. The signal conditioning circuitry also provides 20 microsecond filtering. All Input circuits have surge suppression. HSC inputs can be individually
configured for dry contact or externally generated signal inputs. HSCI Modules are
provided with thirteen (13) user Configuration Jumpers that accommodate LED
enable/disable functionality, individual HSC input debounce enable/disable and individual
HSC 200uA or 2mA source for field connections.
1.3.6.4 Non-isolated Mixed Input/Output Module (also see Section 2.3.4.7)
Non-isolated Mixed I/O Modules provide a total of 6 individually field configurable Digital
Inputs/Outputs, 4 Analog Inputs, 2 High Speed Counter Inputs and 1 optional Analog
Output. All I/O circuitry is similar to those utilized on the I/O Modules discussed in sections
1.3.6.1 through 1.3.6.3.

1.3.7 ControlWave EFM Expansion Communications Modules
Expansion Comm. Modules provide two additional serial communications ports and optionally the choice of a piggy-backed dial-line modem or piggy-backed 900 MHz Spread
Spectrum radio (or both). Both serial communication ports support speeds of up to 115.2
KB. The top Comm. port (labeled C1) supports RS-232 operation while the second one
(labeled C2) supports RS-485 operation. The RS-485 Port can optionally be ordered with
isolation to 500Vdc. Up to two Exp. Comm. modules may be installed (backplane slots 3 and
4).

CI-ControlWave EFM

Introduction / 1-17

Figure 1-9 - ControlWave EFM Communications Module

1.3.8 Internal Mounting Brackets
Internal mounting brackets that support the various system components, such as the
Battery, ControlWave EFM Base Assembly, etc., are mounted on the ‘Fabrication Panel,’
which in turn is secured to the inner rear wall of the enclosure. An External radio or
1-18 / Introduction

CI-ControlWave EFM

modem will mount via a Radio/Modem Mounting Bracket (beneath the Battery Mounting
Bracket on units equipped with a 4-Slot Chassis)..

1.3.9 Multivariable Transducer
The Multivariable Transducer (MVT) pressure assembly is connected to the process
manifold either directly or by 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 Multivariable Transducer extends into the bottom of the enclosure, with the
body of the transducer outside the enclosure. The MVT cable connector is factory mated
with System Controller Module connector P2.

1.3.10 Power Distribution Board
When an external power source is used to provide bulk power to the unit, power is routed to
various optional items through a Power Distribution Board. In this case, options such as
the 21V Power Supply, Digital to Relay I/O Board or an external radio or modem, will
require the use of the Power Distribution Board. Power Distribution Boards, Digital to
Relay I/O Boards and the 21V Power Supply Boards are mounted to the inside of the
enclosure in question using a Snap Track and Dual PCB Mounting Bracket.

Figure 1-10 - Power Distribution Board
1.3.11 Digital to Relay I/O Option
The Digital To Relay I/O Board (see Figure 1-11) converts one or two Discrete Output
Signals from open drain MOSFET levels to Form C relay output signal using Solid State
Relay (SSR) logic.
Each Discrete Output can be converted to Form C relay output signals which can be
configured for opposite or identical conditions, i.e., both Normally Open (NO) or Normally
Closed (NC) or one Normally Open with the other normally Closed.

CI-ControlWave EFM

Introduction / 1-19

Figure 1-11 - Digital To Relay I/O Board

1.3.12 21V Power Supply Option
The 21V Power Supply is a continuous mode boost switching type power supply. It is based
upon a low power, low noise circuit that produces 21 Volts from a 12V input. Power
shutdown is not an option with this unit since it employs a Boost circuit; therefore, the 21V
Power Supply must be powered continuously.

Figure 1-12 - 21V Power Supply Board
The 21V Power Supply is mainly used in conjunction with Temperature and Pressure
Transmitters which require a higher than +12V but lower than 21.4V (± .8V) input supply
to operate.

1.3.13 Power System
Power may be provided by a rechargeable 12V, 33AH Lead Acid Battery used in conjunction
with either a 30 Watt or 40 Watt Solar Panel or power may be externally supplied.
1-20 / Introduction

CI-ControlWave EFM

Solar panels mount to a 2" pipe and can be swiveled for optimum alignment with the sun
and their tilt angle is adjustable for maximum performance to accommodate the latitude of
the installation site. Solar panel wires enter the unit through a liquid tight conduit fitting
on the bottom of the enclosure. Internally the solar panel wires connect directly to the
rechargeable battery - PWR (red wire) and GND (black wire) terminals.

1.3.14 RTD Probe
SCM Connector TB2 provides connection to a 100-ohm platinum bulb (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.

1.3.15 External Radio/Modem
In addition to or in lieu of an internal modem/radio an external modem or spread spectrum
radio may be factory installed within the enclosure. A listing of modem and radios is
provided in the Table Of Contents under the topic REFERENCED OEM MANUALS.

1.4 FIELD WIRING
ControlWave EFM electronic flow meters support connection to external field devices
through its field wiring terminals on the System Controller Module and the various I/O
Modules. In some cases a Power Distribution Board is provided and it may be connected to
an external DC Power Supply or Source (such as a Solar Panel, user supplied - nominally 6
or 12Vdc battery) or a user supplied 4.5 to 16Vdc power supply. Connections to the
following types of external devices may be made:
•
•
•
•
•

RTD
Analog Inputs (AIs)
Digital Inputs (DIs)
Digital Outputs (DOs)
Relays

•
•
•
•

Pulse Inputs (HSCs)
Analog Outputs (AOs)
Battery/Power Supply/Solar Panel
Communications (RS-232 and RS-485)

1.5 FUNCTIONS
ControlWave EFM can come with or without a base application program that satisfies API
21.1 requirements for a meter station using up to four 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 four-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

CI-ControlWave EFM

Introduction / 1-21

•
•
•
•
•
•

AGA7 with selectable AGA8 Gross or AGA8 Detail
Auto Adjust AGA7/NX-19
Auto Adjust 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 EFM 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
Flow calculations
Data archives
Audit trail archives
Local display
Communications
Control outputs
Status inputs
Self test and diagnostics

(see Section 1.5.1)
(see Section 1.5.2)
(see Section 1.5.3)
(see Section 1.5.3.4)
(see Section 1.5.4)
(see Section 1.5.5)
(see Section 1.5.6)
(see Section 1.5.6)
(see Section 1.5.7)

1.5.1 Data Acquisition
The process inputs used by the ControlWave EFM 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 EFM System Controller Module (SCM). The inputs may
also be derived 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 EFM application program allows
any combination of inputs to be selected, for up to four runs of measurement.
Regardless of the operating mode or the calculation interval, the ControlWave EFM
acquires samples as follows:
a.
b.
c.
d.

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

1.5.2 Flow and Volume Calculations
The ControlWave EFM 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,

1-22 / Introduction

CI-ControlWave EFM

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.
1.5.2.3.1 Energy Calculation
The ControlWave EFM 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 conditions by the
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)
CI-ControlWave EFM

Introduction / 1-23

or an external 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.

1.5.3 Archives
The ControlWave EFM 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 EFM 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 EFM 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 EFM 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 2minute 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 EFM FLASH memory.
The following items are stored in the Hourly Data Log:
•
•
•
•
•
•
•
•
•
•

Corrected Volume
Uncorrected Volume
Accumulated Energy
Average Static Pressure
Average Temperature
Average Differential Pressure
Average Specific Gravity
Average Heating Value
Flow Time
Uncorrected Count

Each log entry also contains the date and time. The ControlWave EFM has a Hourly
Historical Log for each of four runs.
1.5.3.2 Daily Historical Data Log
The Daily Data Log holds one record for every contract day. The contract hour may be
changed by the user. The daily log holds 62 entries; this ensures that the previous calendar
month of daily data is always resident in ControlWave EFM FLASH memory.
1-24 / Introduction

CI-ControlWave EFM

The following items are stored in the Daily Data Log.
•
•
•
•
•
•
•
•
•
•

Each log entry also contains the date and time. The ControlWave EFM has a Daily
Historical Log for each of four runs.
1.5.3.3 Periodic Historical Data Log
The periodic data log holds one record for every log interval. Log interval is 15 minutes. The
Periodic Historical Data Log holds 1440 records, or four days of 15 minute data.
The following items are stored in the Periodic Historical Data Log:
•
•
•
•

Flowing Differential Pressure
Flowing Static Pressure
Flowing Temperature
Frequency

Each log entry also contains the date and time. The ControlWave EFM has a Periodic
Historical Data Log for each of four runs.
1.5.3.4 Alarm and Event Storage
The ControlWave EFM keeps an Audit Trail Buffer capable of storing the most recent 500
Alarms and the most recent 500 Events. Internally, these buffers are maintained
separately to prevent recurring alarms from overwriting configuration audit data.
Externally, they are reported to the user as a single entity. Both operate in a circular
fashion with new entries overwriting the oldest entry when the buffer is full.
The following circumstances cause an entry to be made in the Audit Trail Buffer:
•
•
•
•

Any operator change to a ControlWave EFM configuration variable
Any change in the state of a ControlWave EFM alarm signal
A system restart
Certain other system events

1.5.4 LCD Display
In normal operation, the display stays off after the unit is configured and placed in service.
The operator may activate the display at any time by pressing the front panel button.
When activated, the display scrolls through a list of current values. The list defaults to an
appropriate set of values.

CI-ControlWave EFM

Introduction / 1-25

1.5.5 Communications
A ControlWave EFM can be configured as a Master or Slave node on either a MODBUS
network or a BSAP network. Up to three communication ports are contained on the
ControlWave EFM CPU Module and are designated as follows:
CPU Module:

COM1 - Port 1:
COM2 - Port 2:
COM3 - Port 3:

CPU Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J4, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J5, PC/AT 9-Pin Male D-Sub - RS-485 - Configured by SW3

A ControlWave EFM can support up to two optional Expansion Communications Modules,
which can reside in slots 3 and 4 (ONLY), in lieu of I/O Modules. Each Expansion
Communications Module contains two serial communications ports (one RS-232 and one
RS-485), an optional built-in spread spectrum modem (radio) and an optional built-in 56KB
PL/PSTN modem that are designated as follows:
Expansion Communications Modules:
COM4, COM5, COM6 & COM7 on first ECOM Bd., assigned to Base Chassis Slot #3
COM8, COM9, COM10 and COM11 on second ECOM Bd., assigned to Base Chassis Slot #4
COM4/8 - Port 1: ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - Both RS-232
COM5/9 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - Both RS-485 - Configured by
SW1 on ECOM Board
COM6/10 - Port 3: ECOM Bd. Piggy-back Radio Module (FreeWave or MDS TransNet
Spread Spectrum Modem) Antenna connector provided
COM7/11 - Port 4: ECOM Bd. Piggy-back Modem Module (Multitech 56KB PL/PSTN
Modem) RJ-11 connector provided
Note: These RS-485 Ports are optionally available with 500Vdc isolation.
Communication Ports COM1, COM2, COM3, COM4, COM5, COM8 and COM9 support
serial asynchronous operation. Communication Ports COM1, COM2, COM4 and COM5
support RS-232 while COM3, COM5 and COM9 support RS-485 operation. Communication
Ports COM4/8, COM5/9, COM6/10 and COM7/11 reside on optional Expansion
Communications Modules (ECOM1/2). ECOM1 must reside in Base Chassis Backplane Slot
#3 while ECOM2 must reside in Base Chassis Backplane Slot #4. ECOM Modules have one
RS-232 Port and one RS-485 Port. Additionally, an ECOM Module may optionally contain a
56Kbaud PSTN Modem and/or a Spread Spectrum Modem (Radio). Any non-Ethernet
communication ports can be configured for local communications, i.e., connected to a PC
loaded with ControlWave Designer and OpenBSI software.
RS-232 Ports
An RS-232 interface supports Point to Point, half-duplex and full-duplex communications
(20 feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWave EFM utilize MODBUS or BSAP protocol, while full-duplex is supported by
the Point to Point (PPP) protocol. ControlWave EFM RS-232 ports utilize the “null
modem” cable (Figure 2-12A) to interconnect with other devices such as a PC, printer,
another ControlWave EFM or other ControlWave series unit when the ControlWave
EFM is communicating using the full-duplex PPP protocol.
RS-485 Ports
ControlWave EFM can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Essentially, the master and the first
1-26 / Introduction

CI-ControlWave EFM

slave transmit and receive data on opposite lines; all slaves (from the first to the "nth") are
paralleled (daisy chained) across the same lines. The master node should be wired to one
end of the RS-485 cable run. A 24-gauge paired conductor cable, such as Belden 9843
should be used. Note: Only half-duplex RS-485 networks are supported.
From the factory COM1 defaults to 115.2 kbd using the BSAP Protocol. The remaining
serial communication ports, i.e., COM2 through COM5 default as follows:
COM2 – BSAP Slave @ 9600 Baud
COM3 – BSAP Master @ 9600 Baud (for use with Bristol Babcock 3808 MVT Transmitters)
*COM4 – MODBUS Master @ 9600 Baud (for use with Daniel 2251 Chromatograph)
*COM5 – MODBUS Master @ 9600 Baud (for use with Rosemount Transmitters)
* COM4 and COM5 are situated on an optional Expansion Comm. Module.
1.5.5.1 BSAP Message Support
The ControlWave EFM supports the same subset of BSAP messages as the other
ControlWave products.

1.5.6 Discrete and Analog I/O EFM Functionality
ControlWave EFM electronic flow meters may be equipped with a variety of I/O Modules
(see Sections 1.3.6 through 1.3.6.4). While using the standard application program, inputs
and outputs required for measurement and control are mapped to the application using the
configuration Web pages. Analog Alarm limits for variables required by the standard
application program are defined via the configuration Web pages. Discrete Input alarms
associated with the standard application program can be enabled or disabled on a per point
basis via the configuration Web pages. Control algorithms (flow control, sampler control,
odorant control, etc.) are selected via the configuration Web pages.
1.5.6.1 Flow Rate Control - DDC (jog control) using PID
When the user configures the ControlWave EFM to perform flow rate control, the two
digital output signals are wired to the Open and Close inputs of a controller. The
ControlWave EFM uses a Proportional/Integral/Derivative (PID) algorithm to cause the
measured rate of flow to match a user-entered setpoint. When the flow rate is below the
setpoint, the Open output is pulsed. When the flow rate is above the setpoint, the Close
output is pulsed. The PID equation calculates the duration of the Open or Close pulse. The
minimum pulse duration is 1.0 seconds. The user changeable parameters are:
•
•
•
•
•
•
•
•

Flow Setpoint in MSCFH
Deadband in % of setpoint
Proportional Gain
Integral Time in repeats/minute
Derivative Time in seconds
Valve Travel Time (full close to full open)
Process Control Limiting
Pressure Override Limits

The flow control algorithm runs once per second.

CI-ControlWave EFM

Introduction / 1-27

1.5.6.2 Pulse Output for External Totalizer or Sampler
When the ControlWave EFM is configured to provide a pulse output based on volume, the
operator provides a control volume and pulse duration. After each calculation cycle, an
internal volume accumulator is compared to the control volume. If the accumulator exceeds
the control volume then a pulse is output and the accumulator is reduced by the volume
represented by the pulse. The pulse output may be used to drive an external totalizer,
odorizer, gas sampler, or similar device.
1.5.6.3 Nominations
The nomination function allows a user to establish a time period over which an
accumulation count of volume or energy that is delivered during the period is monitored
and compared to a configured ‘nomination' value. When the nomination value is reached,
the system will perform an action (such as opening or closing a valve). Prior to nomination
being reached, the volume/energy will be compared to a configured alarm level and an
alarm will be generated when the volume/energy reaches or exceeds the defined (specified)
level.

1.5.7 Self Test & Diagnostics
The ControlWave EFM periodically runs a series of diagnostics to verify the operational
status of various system components. The tests include transducer parameters, main and
backup battery voltages, software sanity checks, and other indications of system health. An
appropriate alarm is generated if any test fails.
Bristol, Inc’s. WINDIAG program provides menu driven diagnostics that have been
designed to assist a technician or Process Engineer in troubleshooting the various
ControlWave EFM Modules (see Document D4041A).

1-28 / Introduction

CI-ControlWave EFM

Section 1A
PRODUCT FEATURES & OVERVIEW
1A.1 PRODUCT OVERVIEW
ControlWave® products have been designed and integrated as a highly adaptable, high
performance Distributed Open Controller family with exceptional networking capability
that provides a complete Process Automation Management Solution. ControlWave EFM
electronic flow meters have been designed with an emphasis on providing high performance
with low power consumption, scalability and modularity. ControlWave EFM Base
Housings support up to 2 I/O or 6 I/O Modules (4-Slot and 8-Slot Housings respectively).
ControlWave EFM electronic flow meters have been designed as an ideal platform for
remote site automation, measurement and data management within the oil & gas industry.
ControlWave EFM units are extremely effective in Flow Computer, Process Controller or
Remote Terminal Unit capacities as follows:
•

API 21.1 EFM/Flow Computer application

ControlWave EFM units offer a cost effective and competitive match to all industry meters
used in Electronic Flow Measurement and Flow Computer installations.
-

•

For orifice and other differential meters, ControlWave EFM has been designed to
integrate a DP/P/T, smart Multivariable Transducer with excellent per-formance over
the full range of operating pressure and temperature conditions.
For linear meters, such as turbine and ultrasonic meters, ControlWave EFM doesn’t
overlook the importance of pressure and temperature corrections and utilizes smart
P/T circuitry to provide high accuracy over the full range of operating conditions.
Process Controller or Remote Terminal Unit (RTU) applications

Process Controller and RTU applications don’t suffer performance limitations of flow
computers with expanded hardware. User configurable I/O Modules provide AI/O, DI/O and
HSC functionality. Up to two Expansion Communication Modules (2 RS-232 & 1 RS-485
Port, each) can be added to a ControlWave EFM.

1A.1.1 Hardware Features
•
•
•
•
•
•

Wide operating temperature range (-40 to 70°C)
Nonincendive Class I, Div. 2 Hazardous Location approval & CE approval
ARM Processor provides exceptional performance and low power consumption
Standard three serial communication ports (Two RS-232 & One RS-485)
Optional serial communication port expansion with built-in modem and radio options
Mixed I/O Cards provide cost effective I/O for small RTU applications

1A.1.2 Firmware and Software Features
•
•

Standard application load for up to four run, API 21.1 EFM operation
Additional application loads (e.g. well automation with plunger lift control) are also
available

CI-ControlWave EFM

Product Features & Overview / 1A-1

•
•
•
•

Full user programming environment, ControlWave Designer with ACCOL III, is
available for modification of existing loads as well as creation of custom loads
Full suite of function blocks for flow calculations, audit trail, historical archive/data
management, communication, and process control is included.
File management, including video images
Fully supported by a complete HMI and network communication software suite: Bristol
Babcock’s OpenBSI

1A.2 PRODUCT FAMILY COMPATIBILITY
Not only is ControlWave EFM scalable, it is also compatible with Bristol Babcock’s
ControlWave family. ControlWave EFM is fully software-compatible with the original
ControlWave, which provides greater I/O capacity.
1A.2.1 Open Standards for Programming, Network Config. and Communication
Only ControlWave brings the perfect combination of industry standards to minimize
learning, engineering and implementation costs.
By adhering to such industry standards as Ethernet, TCP/IP, Microsoft Windows®,
COM/DCOM, FTP, OLE and ActiveX, ControlWave is able to achieve the highest degree of
openness in control system architecture and bring the optimal process efficiency and
productivity needed to ensure a successful system implementation.

1A.2.2 ControlWave Designer with ACCOL III
To minimize your engineering and development time, we have adopted the international
standard for PLC programming, IEC 61131-3. ControlWave Designer is a fully IEC 611313 compliant programming environment for the ControlWave family of products.
ControlWave Designer includes all five IEC 61131-3 process languages for batch,
continuous and discrete control. Function Block Diagram, Structured Text Sequential
Function Chart, Ladder Logic Diagram and Instruction List.
ControlWave Designer includes an extensive library of more than 200 basic IEC 61131-3
functions and function blocks common to many IEC 61131-3 based products. These include:
•
•
•
•
•

Flip-flops, Counters & Timers
Ladder diagram functions – coils and contacts, etc.
Numerical, Arithmetic & Boolean functions – Sine, Cosine, Add, Sub, Square Root, And,
Or, etc.
Selection & Comparison – Min, Max, Greater than, Equal, Less than, etc.
Type conversions – Integer to Real, Boolean to Word, etc.

1A.2.3 ACCOL III
In addition to the basic functions and function blocks, ControlWave Designer brings the
benefit of over twenty years of SCADA and plant control experience in Bristol Babcock’s
ACCOL III function block library. ACCOL III includes over sixty function blocks valuable
for use in oil & gas, water & waste and process measurement & control applications.
Further, ACCOL III is designed to take full advantage of the significant features offered by
ControlWave.

1A-2 / Product Features & Overview

CI-ControlWave EFM

Briefly, this library includes function blocks for:
•
•
•
•
•

Average, Compare, Totalize
Scheduling & Sequencing
PID & Lead/Lag
AGA gas flow and liquids calculations
File handling

In addition, ControlWave ensures data integrity, in the event of a communication
interruption, by storing critical time-stamped alarm and historical data in the controller
memory. This data is then securely retrieved when communication is restored.

1A.3 STANDARD APPLICATION PROGRAM
ControlWave EFM can come with or without a base, application program that satisfies
API 21.1 requirements for a meter station using up to four meter runs. Using ControlWave
Designer, the user can readily modify this load to add or subtract functions, increase the
number of runs, etc.
Overview of the base, application load:
•
•
•
•
•

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 four-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
• 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

1A.3.1 OpenBSI - Simply Creative
OpenBSI (Open Bristol System Interface) is a set of network setup, communication
diagnostic, and data viewing utilities that provide access to both ControlWave and
Network 3000 controllers and RTUs. OpenBSI is the only product available in the industry
to bring such unique functionality and ease of use to the network level. At the core is the
communication interface, written as a Windows communication server API through which
CI-ControlWave EFM

Product Features & Overview / 1A-3

other client applications communicate with the Bristol networks. OpenBSI supports both
serial BSAP protocol and Ethernet Internet Protocol communication to ControlWave and
Network 3000 RTUs and controllers.

1A.3.2 OpenBSI Utilities
Above this communication layer are a group of applications known as OpenBSI Utilities.
These client utilities communicate through the server to collect and manage data gathered
from the network, generate files based on collected historical data, collect alarms, and
monitor and control OpenBSI communications.
•
•
•
•
•
•
•
•

Communication engine for PC applications
Supports ControlWave and Network 3000 serial and IP protocols
RS 232, Dial-line, cellular, radio, CDPD, satellite, and Ethernet connections
Provides on-line download & signal variable changes
Allows network configuration through NetView
PC and Network communication diagnostics
OPC Server for interfacing to most HMI software
Harvester collects historical data on request or scheduled basis

NetView is the basic configuration and application interface for all network operations.
NetView uses a tree structure for network graphical display in the Windows Explorer style.
Network nodes can be added on-line by simply dragging the node Icon into the tree. This
invokes a configuration Wizard simplifying network setup. Through the NetView Wizard,
the necessary network parameters are entered for node and IP address, alarm and message
routing, and network communication media. Once configured, selecting any node allows
direct access to the common OpenBSI utilities to reprogram, download a new application to
the node, review communication statistics, view real-time data through DataViewer, and
edit controller/RTU properties.
Local Configuration Wizard allows local communication with any attached ControlWave controller or RTU to download system flashware upgrades, configure cold download
parameters, and configure IP and soft-switch parameters.
DataView is an on-line utility used to collect and display several types of process data,
including signal values, data array values, signal lists, and audit trail information.
Operators have the ability to alter signal values. Multiple DataView windows may be open
simultaneously.

1A.3.3 Real-time ActiveX Controls
One of the many benefits OpenBSI brings to you is our use of open standards such as
ActiveX Controls. ActiveX is another of the Microsoft standards, which allow plug and play
with any ActiveX container, using Microsoft ActiveX container technology such as Visual
Basic, HTML web pages, and Microsoft Excel.
The set of available ActiveX Controls provides the basic functions necessary to communicate and collect data from ControlWaves.

1A-4 / Product Features & Overview

CI-ControlWave EFM

1A.3.3.1 ActiveX Controls
•
•
•
•
•

Security - 56-bit encryption - allows the user to sign on to the RTU
Signal Value - displays signal values in various formats
Comm. Statistics - works with a standard page that displays the RTU’s communication
statistics
Configuration Info - works with a standard page that displays and allows the user to
change RTU Configuration information
Historical - Collect and view historical archive and audit files

The IP compliant ControlWave opens the door for owner controlled access via web pages.
Any generic web page builder can be employed to create user defined pages to access
ControlWave. The web pages are populated with these pre-configured ActiveX controls and
are stored at the PC.
1A.3.3.2 Required Software
Microsoft Internet Explorer
Bristol Babcock ActiveX controls
OpenBSI LocalView or NetView

1A.3.4 Historical Data Collection
High Historical Data Integrity
The ControlWave Historical Data Collection system offers exceptional historical data
integrity by providing time-stamped historical data storage in ControlWave flash memory.
The historical data is collected, through OpenBSI, on a scheduled or demand basis and
converted to .CSV and ODBC compliant file formats for use in spreadsheets and reports. If
data is missed due to a communication failure, it is collected when the communication is
reestablished and the PC historical database is back-filled with the missing data. This
distributed historical database architecture provides the greatest data reliability and
integrity during communication or PC failure.
Another important historical feature is the Audit storage and collection system. The Audit
Trail is a file stored in ControlWave flash memory containing significant events and timestamped alarms. The alarms stored in the Audit system provide a historical archive in
addition to the real-time alarm reporting system.
This file is also collected through OpenBSI and presented as a text file in the PC. This
functionality is extremely useful in providing an event trail during communication or PC
downtime or other system problem.
•
•
•
•

Archive Collection – collection and storage to disk of the ControlWave archive data
Audit Collection - collection and storage to disk of the ControlWave audit data.
Exports data files to third party, CSV & ODBC applications
DDE compliant for use with other popular Windows applications

1A.3.5 OPC Server
With industry demand for open standards, ControlWave answers the call by embracing
technologies that open the door for maximizing your efficiency and productivity. The OPC
standard was developed by the OPC Foundation comprised of hardware and software
suppliers from the process control community. OPC allows the engineer to select best in
CI-ControlWave EFM

Product Features & Overview / 1A-5

class hardware and software with confidence in their interoperability. Our OpenBSI OPC
Server was among the first to comply with the OPC Foundation alarm and event server
specification.
•
•
•
•
•
•
•
•
•
•
•

OPC Data Access 1.0a & 2.0 compatible
Windows NT, 2000 & XP
Compatible with both ControlWave and Network 3000 systems
32 bit multi-threading, multi-processor design
Automatic database builder
Integrated real-time data monitor
Supports OPC Browse interface
Supports both serial communications and IP Ethernet connections
Supports COM/DCOM & OLE Automation
Primary and Background polling scheme
OPC Alarm & Event Server support

1A.4 ControlWave OPEN NETWORK CONNECTIVITY
By embracing the open system network technologies available through TCP/IP, Ethernet,
OPC, and Microsoft DNA, as well as pseudo standards such as Modbus and Open Modbus,
ControlWave can provide a total Process Automation Management Solution for in-plant
LAN based networks and Wide Area Network SCADA systems.
With the exceptional connectivity provided by the ControlWave network, access to realtime data and operating conditions, historical data, maintenance and performance data are
all available to the global network. ControlWave provides the needed information to the
plant floor technician, operator, engineer, supervisor and corporate management, even
external customers.

1A.4.1 Communication Protocols
Like all Bristol Babcock products, ControlWave supports BSAP (Bristol Standard Asynchronous Protocol), Modbus, DF1, DNP 3 (serial) and serial ASCII as standard functions.
These protocols are implemented in Flashware so no additional hardware is required to use
any one or a combination of all protocols.
1A.4.1.1 BSAP Protocol
BSAP - All Bristol Babcock Network 3000 and ControlWave RTU and controller products
support BSAP protocol. BSAP is widely accepted as providing exceptional data integrity
and greatly simplifies communication between controllers. BSAP is provided with
interfaces for Master/Slave, vertical networks and Client/Server, horizontal networks. In
either case, variable lists are created in each controller that are easily passed from server to
client or slave to master.
BSAP meets the definition of an industry-standard, open architecture protocol because if
conforms to ISO standards 2629, 1745 and 2111, it is not proprietary in that Bristol
Babcock does not charge a license fee and makes the protocol and documentation available
to anyone.
While BSAP is an open protocol, the added functionality of the messages provide much
more capability than is found other networks.
1A-6 / Product Features & Overview

CI-ControlWave EFM

•
•
•
•
•
•
•

Global time-synchronization
Time-stamped Alarm reporting
Historical archive data transfer
Audit file transfer
On-line program editing
Diagnostics
Communication statistics

1A.4.1.2 Modbus Protocol
Modbus - Modbus is often considered a de-facto standard protocol because broad usage as
either the primary or a secondary offering in many measurement and control related
products. Even with its common use, Modbus protocol actually has many variations.
Consider Modbus RTU and Modbus ASCII, Master & Slave, Serial and TCP/IP Open
Modbus. In addition there are consideration regarding supported function codes, floating
point values and byte order. Bristol Babcock supports the following:
•
•
•
•
•

Modbus serial and TCP/IP Open Modbus (Ethernet)
Master and Slave
Modbus RTU and ASCII
Modes 1 - 7, 8, 15 & 16
Integer and IEEE 4 byte floating point

1A.4.1.3 Generic Serial Interface
The Generic Serial Interface is a user programmable Master and Slave protocol used to
send and receive messages typically with third party serial ASCII devices. This protocol can
be used to interface with such devices and message boards, card readers and many
measurement devices.

CI-ControlWave EFM

Product Features & Overview / 1A-7

BLANK PAGE

Section 2
INSTALLATION & OPERATION
2.1 INSTALLATION IN HAZARDOUS AREAS
Each ControlWave EFM electronic flow meter is furnished in a housing designed to meet
the NEMA Type 3 specifications and to operate in a Class I, Division 2, Groups C & D
environment with a nonincendive rating (see Appendix A).

Figure 2-1A - 4-Slot ControlWave EFM
(Shown with MDS - Transnet Radio & D-Type Local Port)
CI-ControlWave EFM

Installation & Operation / 2-1

Figure 2-1B - 8-Slot ControlWave EFM
(Shown with MDS - Transnet Radio & Circular Local Port)
2-2 / Installation & Operation

CI-ControlWave EFM

Each ControlWave EFM Base Assembly (4/8-Slot) is housed in an open-faced Gold Irridite
coated Aluminum Chassis assembly. Keyed cutouts in rear wall of the ControlWave EFM
Base Assembly are provided for Wall or Panel mounting arrangements. The ControlWave
EFM Base Assembly is mounted to the Fabricated Panel on the inner rear wall of the
Hoffman Enclosure and is comprised of the following components:
•
•
•

Built-in Card Guides accommodate installation/removal and vertical mounting of all
Modules
Built-in Chassis Ground Lug (on bottom of unit)
Backplane PCB provides seating and electrical interface for all Modules

Figure 2-2 – 8/4-Slot ControlWave EFM Base Assemblies - (The 4-Slot Chassis is
shown with ECOMs in Slots 3 & 4)
CI-ControlWave EFM

Installation & Operation / 2-3

ControlWave EFM Modules that comprise the system are housed in a base assembly
consisting of an open faced Gold Irridite coated Aluminum Chassis equipped with either a
4-Slot or 8-Slot Backplane. Dimensional drawings of the Base Assemblies are provided at
the end of Chapter 4.

2.2 SITE LOCATION CONSIDERATIONS
Check all clearances when choosing an installation site. Make sure that the ControlWave
EFM Instrument Front Cover (hinged on the left side) can be opened for wiring and service.
Make sure that the LCD/Keypad is visible and accessible to the on-site operator. There
should also be clearance for the optional Solar Panel (if required). The enclosed unit
measures 14.55” in height by 13” in width by 6.875” in depth. The Multivariable
Transducer adds 2.8” to the height of the unit.
Information on mounting the ControlWave EFM assembly at an installation site is
provided in Section 2.3.1 Mounting the ControlWave EFM Enclosure.

2.2.1 Temperature & Humidity Limits
ControlWave EFM electronic flow computers have been designed to operate over a -40°F
to +158°F (-40°C to +70°C) temperature range (with storage at up to +185°F (+85°C)) and a
0% to 95% Relative Humidity range. Make sure that the ambient temperature and
humidity at the measuring site remains within these limits. Operation beyond these ranges
could cause output errors and erratic performance. Prolonged operation under extreme
conditions could also result in failure of the unit.

2.2.2 Vibration Limits
Check the mounted enclosure, panel or equipment rack for mechanical vibrations. Make
sure that the ControlWave EFM is not exposed to a level of vibration that ex-ceeds those
given in the specifications. ControlWave EFM vibration limits are 1g for 10 - 150 Hz & .5g
for 150 - 2000 Hz.

2.3 ControlWave EFM INSTALLATION/CONIGURATION
ControlWave EFM electronic flow computers are shipped from the factory with all
components (wired and mounted) except for the unit’s Solar Panel and Battery (if provided);
these items are shipped separately.

Overview of Configuration
An overview of the seven main configuration steps are provided herein.
Step 1. Hardware Configuration
This involves unpacking the ControlWave EFM hardware, mounting the enclosure, wiring
I/O terminations, connecting any permanent communication cables, making proper ground
connections, connecting a communication cable to a PC workstation and setting switches.
To install and configure the ControlWave EFM, follow Hard-ware configuration steps 1
through 11 below:

2-4 / Installation & Operation

CI-ControlWave EFM

1. Remove the unit from its carton and install it at the assigned work site (see Section
2.3.1). Dimensions are provided in Section 4.6 of this manual.
2. Remove the SCM Module and after configuring its jumpers, install it into ControlWave EFM Base Assembly, chassis slot 1, i.e., the first slot from the left end of the
Base Assembly Chassis (see Section 2.3.2).
3. Remove the CPU Module. Make sure that the Lithium Backup Battery has been
enabled, i.e., Backup Battery Board Jumper JP1 should be installed (on its jumper
posts). After configuring the CPU Module’s DIP-Switches (see Section 2.3.3) install it
into ControlWave EFM Base Assembly, chassis slot 2, i.e., the second slot from the
left end of the Base Assembly Chassis.
4. Configure/Connect appropriate communication port(s) (see Section 2.3.3.2). Connect
COMM. Port 1 or 2 of the ControlWave EFM (depending on CPU Switch SW1
settings - see Section 2.3.3.1) to a Communication Port of a PC (typically PC COMM.
Port 1). Note: Also see Section 2.4.4.
5. Install I/O wiring to each I/O Module (see Section 2.3.4). Install a communications
cable to a Model 3808 Transmitter if required (see Section 2.3.8).
6. Install a ground wire between the Enclosure’s Ground Lug and a known good Earth
Ground (see Section 2.3.9.5).
7. Install the Bezel so that the I/O Modules are covered (see Section 2.3.11).
8. If required, install the RTD Probe (see Section 2.3.5).
9. Install the Rechargeable Lead Acid Battery and Solar Panel (if provided) (see
Sections (2.3.9.3 & 2.3.9.4).
10. Connect DC Power wiring to the ControlWave EFM SCM (see Sections 2.3.9.1 &
2.3.9.2).
11. Apply power to the ControlWave EFM. Now continue with Steps 2 through 7 below
(and Section 2.4.1) and the ControlWave EFM will be ready for on line operation.
Step 2. Software Installation on the PC Workstation
ControlWave Designer software will have to be installed on the PC if the ControlWave
EFM is to be utilized in an application other than that supported by the standard load.
This is accomplished by installing the ControlWave Designer Package from the Open
BSI CD ROM.
You must install the Open BSI Network Edition. For information on minimum system
requirements and more details of the installation, see the installation procedure in Chapter
2 of the Open BSI Utilities Manual (document # D5081).
If you have an older version of ControlWave Designer already installed:
Beginning with ControlWave Designer Version 3.3, the copy protection key (dongle) is
NOT required. Prior to installing ControlWave Designer 3.3 or newer, you MUST remove
the hardware dongle from the parallel port of your PC workstation. Otherwise, when you
subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will
limit the available system resources.
IMPORTANT:
When you start ControlWave Designer, you will be reminded to register the
software. Unregistered software can only be used for a maximum of 30 days. For
more information on the registration process, see Chapter 2 of the Open BSI
Utilities Manual (document # D5081).

CI-ControlWave EFM

Installation & Operation / 2-5

Step 3. Establish Communications using either LocalView or NetView, and Run
the Flash Configuration Utility
Communications must be established with the ControlWave EFM using either LocalView
or NetView.
The ControlWave EFM ships from the factory with a default Flash configuration. Most
users will need to edit this configuration to set the BSAP local address (IP address if using
PPP), user accounts, and port parameters. This can be done in one of two ways:
•

Either open the supplied Flash Configuration Profile (FCP) file and modify it, directly in
the Flash Configuration Utility, or in a text editor,

•

Or retrieve existing Flash Parameters directly from the unit, and edit them in the Flash
Configuration Utility.

Detailed information on the Flash Configuration Utility, and LocalView is included in
Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in
Chapter 6 of that same manual.
Step 4. Modification of the Application-Specific Control Strategy (OPTIONAL)
ControlWave EFM electronic flow meters are shipped with the EFM program already
loaded. However, you can create your own application-specific control strategy using
ControlWave Designer. This involves opening a new project using the ‘CWMicro’ template,
defining I/O points using the I/O Configurator, and creating a program using one or more of
the five supported IEC 61131 languages (FBD, ST, SFC, LD, or IL). Some of these
languages are text based, others are graphical diagrams. The choice is up to you, depending
upon your particular application.
The ControlWave MICRO Quick Setup Guide (document # D5124) includes a simple LD
example. Additional examples are included in the manual, Getting Started with
ControlWave Designer (document # D5085). More detailed information about
ControlWave Designer and IEC 61131 is included in the ControlWave Designer Reference
Manual (document # D5088).
The ACCOL3 Firmware Library, which is automatically accessible through the template
referenced above, includes a series of function blocks which perform a variety of process
control and communication functions. These can be included within your program to perform various duties including PID control, alarming, calculations, etc. Detailed information
about each function block is included in the ControlWave Designer on-line help files.
On the variables declaration page(s) in ControlWave Designer, you will need to mark any
variable you want to make accessible to external programs, such as Open BSI’s DataView
utility, as “PDD”. Similarly, any variables which should be collected into a database, or
exported using the OLE for Process Control (OPC) Server must be marked as “OPC.”
Variables marked as OPC can be built into a text file by the OpenBSI Signal Extractor.
The text file can then be used in the creation of a database for human machine interface
(HMI) software such as OpenEnterprise or Iconics’ Genesis. These HMI software packages
require that the "Datatype conversion enable" option be selected when generating the
file using Signal Extractor. Information about the OpenBSI Signal Extractor is included in
Chapter 12 of the Open BSI Utilities Manual (document # D5081).

2-6 / Installation & Operation

CI-ControlWave EFM

Once the program has been created, it is assigned to an executable task. The entire project
is then saved and compiled.
NOTE: From this point on, the order of steps may be varied, somewhat,
depending upon the requirements of the user's application.
NOTE: If you modify the standard EFM program, you may need to modify the
standard web pages associated with it. (See Step 5, below).
Step 5. Use Standard Web Pages Provided to Select Options in the Standard
Control Strategy
The ControlWave EFM has a standard set of web pages for configuration purposes (stored
on a PC) that lets you enter parameters, and configuration options for the standard EFC
program (see Step 4, above). If you modify the standard EFM program, you may need to
modify the standard web pages. If you create your own application program (instead of
using the standard one), you may create your own web pages using Bristol ActiveX controls
discussed in the Web_BSI Manual (document # D5087).
You can use whichever HTML creation package you want to create the pages, however, all
ControlWave EFM related web pages (whether standard or user-created) must be viewed
within Microsoft® Internet Explorer. Web pages are stored on a PC workstation.
Step 6. Create an Open BSI Network Containing the ControlWave EFM, or ADD
the ControlWave EFM to an Existing Open BSI Network
In order for the ControlWave EFM unit to function as part of a Bristol Babcock network, it
is necessary to include it in the Bristol Babcock network.
If no Bristol network exists:
You need to run Open BSI’s NetView software on the PC workstation in order to define
a Bristol network. A series of software wizards are used to define a Network Host PC, a
network, and the RTUs (controllers) assigned to the network. Finally, communication
lines must be specified which handle the address assigned to the Control-Wave EFM.
Chapters 3 and 4 of the Open BSI Utilities Manual (document # D5081) include ‘quick
start’ examples for performing these steps. More detailed information is included in the
NetView chapter (Chapter 6) of D5081.
If a Bristol network already exists:
You will need to add the ControlWave EFM to the existing network using Net-View’s
RTU Wizard. Chapter 6 of the Open BSI Utilities Manual (document # D5081) includes
different sub-sections depending upon whether you are adding the unit to a BSAP
network, or an IP network.
Step 7. If applicable, download new or modified control strategy (OPTIONAL)
If you modified the standard EFM program, or substituted your own program, compile and
download the new or modified program into the unit, using either ControlWave Designer, or
the Open BSI 1131 Downloader. In this case, you download the control strategy into the
BOOT project area of FLASH memory; this ensures that if the ControlWave EFM is reset,
or if there has been a failure of the backup battery, the control strategy can be restarted
from the beginning, i.e. from the BOOT project in FLASH memory. To download the project,
see Section 2.4.1.
CI-ControlWave EFM

Installation & Operation / 2-7

2.3.1 Mounting the ControlWave EFM Enclosure
When mounting one of these units, it is to be positioned in accordance with the following
restrictions:
-

The unit is to be positioned vertically with the Multivariable Transducer (MVT) at its
base and is to be mounted to a wall or a vertical 2” pipe (clamed at the rear of the unit
via two clamps and four bolts). If used, the 2” pipe is to be anchored in cement (deep
enough to conform to local building codes associated with frost considerations). The
basic unit measures 14.55” in height by 13” in width by 6.875” in depth. A Multivariable Transducer adds 2.8” to the unit’s height. See Figures 2-3 and 2-4.

(1)
(3)
(5)
(7)
(8)

1” NPT Conduit Hub
RTD Cable Assembly or Sealing Plug
5” Liquid Tight Conduit Fitting or Plug
Solderless Ground Lug
Multivariable Transducer

(2) Local Port D-Type Jack
Male D-Type Jack or
Circular Female Jack
(4) Battery Ventilation Assembly
(6) Ant. Cable Fitting, Polyphaser,
or Plug

Figure 2-3 - ControlWave EFM Bottom View
-

The Multivariable Transducer (MVT) is bolted to a process manifold which in-turn is
connected to the main (meter run) directly or via two pipes (see Figures 2-5 - 2-7).
The unit must be positioned so that the front of the assembly is visible and the unit is
accessible for service, i.e., installing an option or replacement of the Lithium Battery,
or installation/removal of any ControlWave EFM Module.
Make certain that the LCD Display/Keypad is accessible and visible to the on-site
operator.

2-8 / Installation & Operation

CI-ControlWave EFM

There should be clearance for the optional Solar Panel (if required) (the Solar Panel
may be mounted to the same 2” pipe that secures the unit.
Power wiring should not be installed until the unit has been mounted and grounded at
a designated work site.
I/O wiring, external power wiring, 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.

Figure 2-4 - Side View of ControlWave EFM Mounted to a 2” Pipe
CI-ControlWave EFM

Installation & Operation / 2-9

2.3.1.1 Connection to the Multivariable Transducer (MVT)
One Multivariable Transducer (MVT) is provided with each ControlWave EFM and is
secured to the bottom of the enclosure. Figure 2-5 details MVT process flange and optional
manifold block connector mounting dimensions.
The MVT provides connection ports on the process flange as the standard arrangement.
Optional manifold blocks may also be specified. Both arrangements are described as
follows:
Standard Process Flange: Two process flanges containing the connection ports are assembled to the transmitter. Port designations (L and H) are stamped on the body of the
flanges. Ports accept 1/4-18 NPT pipe connections on 2-1/8 in. centers for connection to
orifice taps or a standard three-valve manifold. These process flange connections are
illustrated at the top of Figure 2-5.
The two process flange assemblies are held in place by four bolts and nuts. When the bolts
are removed, the flanges can be repositioned so that the connections can emanate from the
front, rear or bottom of the transmitter. Care should be taken not to damage the sensor
module assembly during this procedure. Once the flange has been positioned, the bolts
should be tightened in an alternating sequence to about 20-30 foot-pounds of torque.

Figure 2-5 - Process Flange and Optional Manifold Block Connectors
2-10 / Installation & Operation

CI-ControlWave EFM

Optional Process Manifold Blocks: Process manifold blocks may be installed on the
transmitter to permit the use of connector assemblies having different connection centers.
The manifold blocks, which are oval in appearance, mate with the transmitter's process
flange. The blocks may be installed in several positions to achieve different connection
centers as shown in Figure 2-5.
MVT Interface Cable. An interface, connected to the top of the MVT, is factory connected to
Connector P2 near the bottom of the System Controller Module. This cable is keyed to
simplify installation.
2.3.1.2 Process Pipeline Connection (Meter Runs without Cathodic Protection)
ControlWave EFMs may be mounted directly on the pipeline or remotely on a vertical
stand-alone two-inch pipe or a wall. The Earth Ground Cable is to run between the
ControlWave EFM’s Ground Lug and Earth Ground (Rod or Bed) even though the
ControlWave EFM’s Multivariable Transducer (MVT) may be grounded to the pipeline. If
any pressure transmitters or pulse transducers are remotely mounted, connect their chassis
grounds to the pipeline or earth ground.
2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.

Transducer to Manifold
Dielectric Isolation Kit
Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Bottom Washers (4)
Mounting Bolts (4)

AWG 4 Ground Wire
Ground Rod or System

Figure 2-6 - ControlWave EFM
Direct Mount Installation with Cathodic Protection
Note: Direct Mount installation of a unit, without Cathodic protection, is similar
to that of Figure 2-6 except it doesn’t utilize the Transducer to Manifold
Dielectric Isolation Kit.
2.3.1.3 Process Pipeline Connection (Meter Runs with Cathodic Protection)
Dielectric isolators are available from Bristol Babcock and are always recommended as an
added measure in isolating the ControlWave EFM from the pipeline even though the
enclosure does provide some galvanic isolation from the pipeline and should not be affected
CI-ControlWave EFM

Installation & Operation / 2-11

by cathodic protection or other EMF on the pipeline. ControlWave EFMs may be mounted
directly on the pipeline (see Figure 2-6) or remotely on a vertical stand-alone two-inch pipe
(see Figure 2-7). It is recommended that isolation fitting always be used in remotely
mounted meter systems. An isolation fittings or gasket should be installed between the
following connections:
•
•
•

all conductive tubing that runs between the pipeline and mounting valve manifold
and/or the units Multivariable Transducer (MVT)
all conductive connections or tubing runs between the ControlWave EFM electronic
flow meter and a turbine meter, pulse transducer, or any other I/O device that is
mounted on the pipeline
any Temperature Transducer, Pressure Transmitter, etc. and their mount/interface to
the pipeline.

Transducer to Manifold
Dielectric Isolation Kit
Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
AWG 4 Ground Wire

Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)

Isolating
Fittings

Bottom Washers (4)
Mounting Bolts (4)

2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.

Clamp(s)
Ground Rod or System

Figure 2-7 - ControlWave EFM Remote Installation
(with Cathodic Protection)
Note: Remote installation of a unit, without Cathodic protection, is similar to that
of Figure 2-7 except it doesn’t utilize the Transducer to Manifold Dielectric
Isolation Kit.
Mount the ControlWave EFM’s enclosure on a stand-alone vertical 2-inch pipe or on a
wall. The ground conductor connects between the ControlWave EFM’s Chassis Ground
Lug and a known good earth ground. Connect the cases of Temperature Transducers,
Pressure Transmitters, etc., to the known good earth ground. If the mounting 2-inch pipe
(when used) is in continuity with the pipeline it will have to be electrically isolated from the
ControlWave EFM. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22
EU 3140. This black tubing will easily slip over the 2-inch pipe and then after uniform
2-12 / Installation & Operation

CI-ControlWave EFM

heating (e.g., with a rose-bud torch) it electrically insulates and increases the strength of
the pipe stand. See Bristol Specification Summary F1670SS-0a for information on PGI
Direct Mount Systems and Manifolds.

2.3.2 System Controller Module (SCM) Configuration
System Controller Module’ (SCM) configuration jumpers must be set to configure bulk
power (+6Vdc or +12Vdc nominally) and to enable or disable the Power Good LED (see
Figure 2-8). The SCM is installed in Backplane slot #1 (see Figure 2-2). Slot #1 is the first
slot, counting left to right, and provides 44-pin female interface connector P1.

WATCHDOG LED

JP5, JP6, JP7, JP8 & JP9
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

(Red)

CR27
IDLE LED
(Red)

CR26
CR25
CR24

Staus LEDs
(Red)

JP6
JP7
1
1

JP5
JP8
1

JP9
1

SW1 = Mode Switch

J2
Display Intf.
Connector

J2
RJ-45

TB1
Input Power
Connector

TB2
RTD Interface
Connector
P2
MVT Interface
Connector

(+4.5/4.9Vdc to +16.0Vdc for +6V supply)

TB1-1 +VIN (+9.6/10.3Vdc to +16.0Vdc for +12V supply)
TB1-2 -VIN (Supply Ground)
TB1-3 Chassis Ground (CHASSIS)

JP1 - Factory Configured
(Not Shown)

JP7 - 1.2V Reference Source Current Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP5 - Power Fail Trip Point Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP8 - Supply Shutdown Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP6 - Supply Shutdown Trip Point Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

JP9- Power Fail Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

Figure 2-8 - System Controller Module Component Identification Diagram
CI-ControlWave EFM

Installation & Operation / 2-13

For safety reasons and to prevent accidental damage to a user supplied external bulk DC
Power Supply, it is recommended that pluggable Terminal Block connector TB1 be disconnected from the SCM until the entire unit has been wired, and hardware configured.
Sections 2.3.9.1 & 2.3.9.2 provide details on DC Power Connector TB1 wiring.
Table 2-1 - System Controller Module Switch SW1 – User Configurations
Switch
SW1-1/2

Function
Recovery/Local
Mode

Setting - (ON = Factory Default)
Both Open/Closed = Recovery Mode
SW1-1 Open (right) & SW1-2 Closed (left) = Local Mode

Note: Only SCM Switch SW1 settings listed in this table have been tested.

2.3.3 CPU Module & ECOM Module Configuration
To configure the CPU Module, Jumpers must be set (see Figure 2-9), DIP-Switches must be
set (see Section 2.3.3.1) and Communication Ports must be wired (see Sections 2.3.3.2
through 2.3.3.3). The CPU Module resides in Base Chassis Backplane Slot #2 (see Figure 22). Backplane Slot #2 provides 44-pin female interface connector P2 on the bottom and 36pin female interface connector P3 on the top.
2.3.3.1 CPU Module Switch Configuration
ControlWave EFM CPU Module DIP-Switches must be set for the desired performance
options. Tables 2-2, 2-3 and 2-6 provide an overview of switch settings.
SW2-1 set OFF will disable the system from entering a watchdog state when a crash or
system hangup occurs. Setting SW2-1 OFF prevents the system from automatically
restarting.
SW2-2 set OFF prevents changing the Soft Switches, other configurations and FLASH files,
i.e., these items are locked. To change Soft Switch, configuration and FLASH files SW2-2
must be set to the ON position (see Section 2.4.4).
Table 2-2 - CPU Bd. Switch SW2 - User Configurations
Note: Except for SW2-4, ON = Factory Default
Switch

Function

SW2-1

Watchdog Enable

SW2-2
SW2-3
SW2-4
SW2-5

Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
SRAM Control

SW2-7

System Firmware
Load Control *
N/A

SW2-8

Enable WINDIAG

SW2-6

Setting - (ON = Factory Default)
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 Mode Switch (SW1) on SCM
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)

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

2-14 / Installation & Operation

CI-ControlWave EFM

SW2-3 set OFF forces the use of Soft Switches as set per factory default (see Section 2.4.4).
For use of user defined Soft Switches, SW2-3 must be set to the ON position. Note: If both
SW2-3 and SW2-8 are set OFF (closed), all communication ports will be set to 9600 bps
operation (8-bits, no parity, 1 stop bit, BSAP Protocol).
SW2-4 set OFF and used in conjunction with the SCM Mode switch will cause the
ControlWave EFM to perform a Core Updump (see Section 3.6).
SW2-6 set ON will enable the user to perform a remote download of System Firmware (see
Section 2.4.2.3).
SW2-5 set OFF forces the ControlWave EFM to reinitialize SRAM when the unit recovers
from a low power or power outage condition. When set ON, the contents of SRAM will be
retained and utilized when the system restarts. Note: If the Battery is removed from
the CPU Module (CPU removed) CPU should not be installed (and power applied)
before one minute has passed unless SW2-5 on the CPU has been set OFF.
SW2-8 set OFF prevents the ‘Boot Project’ from running and places the unit into diagnostic
mode. SW2-8 must be set OFF to run the WINDIAG program resident on the local PC (see
Section 3.5). When SW2-8 has been set ON, diagnostics is disabled. SW2-8 must be set to
the ON position for normal system operation, i.e. for the Boot project to run. Note: If both
SW2-3 and SW2-8 are set OFF (closed), all communication ports will be set to 9600 bps
operation (8-bits, no parity, 1 stop bit, BSAP Protocol).
Table 2-6 in Section 2.3.3.3 provides CPU Switch SW3 (COM3) and ECOM Switch SW1
COM5/9 RS-485 communication port settings.

Figure 2-9 - CPU Module Component Identification Diagram
CI-ControlWave EFM

Installation & Operation / 2-15

Table 2-3 - CPU Bd. Switch SW1 - Force Recovery Mode/Battery Enable
Switch

Function

Setting - (OFF = Factory Default)
ON = Force recovery mode (via CW Console)
SW1-3
Force Recovery Mode
OFF = Recovery mode disabled
Note: SW1-1, SW1-2 and SW1-4 are not used.

2.3.3.2 Communication Ports
A ControlWave EFM can be configured as a Master or Slave node on either a MODBUS
network or a BSAP network. A variety of communication schemes are available. One
optional 56K Modem and one optional Spread Spectrum Modem can be piggy-back mounted
on Expansion Communications Modules (or the Modem can be on one ECOM Module while
the radio is on the other). In lieu of an internal radio (Spread Spectrum Modem), an
external radio can be mounted on a radio mounting bracket within the enclosure.

Figure 2-10 - ECOM Module Component Identification Diagram

2-16 / Installation & Operation

CI-ControlWave EFM

Up to three communication ports are contained on the ControlWave EFM CPU Module
and are designated as follows:
CPU Module:
COM1 - Port 1: CPU Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232 - connected to Local Port
COM2 - Port 2: CPU Bd. J4, PC/AT 9-Pin Male D-Sub - RS-232 - supports External Radio
COM3 - Port 3: CPU Bd. J5, PC/AT 9-Pin Male D-Sub - RS-485 - Configured by SW3
The ControlWave EFM can support up to two optional Expansion Communications
Modules, which can reside in slots 3 and 4 (ONLY), in lieu of I/O Modules. Each Expansion
Communications Module contains two serial communications ports (one RS-232 and one
RS-485), and may contain an optional built-in spread spectrum modem (radio) and/or an
optional built-in 56KB PL/PSTN modem that are designated as follows:
Expansion Communications Module:
COM4, COM5, COM6 & COM7 on first ECOM Bd., assigned to Base Chassis Slot #3
COM8, COM9, COM10 and COM11 on second ECOM Bd., assigned to Base Chassis Slot #4
COM4/8 - Port 1: ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - Both RS-232
COM5/9 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - Both RS-485 - Configured by
SW1 on ECOM Board
COM6/10 - Port 3: ECOM Bd. Piggy-back Radio Module (FreeWave or MDS TransNet
Spread Spectrum Modem) Antenna connector provided
COM7/11 - Port 4: ECOM Bd. Piggy-back Modem Module (MultiTech 56KB PL/PSTN
Modem) RJ-11 connector provided
Note: These RS-485 Ports are optionally available with 500Vdc isolation.
COM1 is also available as the Local Port. This accomplished by either a 9-pin D-Type male
connector or a circular 3-pin female connector. The Local Port is situated on the bottom of
the instrument.
Communication Ports COM1, COM2, COM3, COM4, COM5, COM8 and COM9 support
serial asynchronous operation. Communication Ports COM1, COM2, COM4 and COM5
support RS-232 while COM3, COM5 and COM9 support RS-485 operation. Com-munication
Ports COM4/8, COM5/9, COM6/10 and COM7/11 reside on optional Expansion
Communications Modules (ECOM1/2). ECOM1 must reside in Base Chassis Backplane Slot
#3 while ECOM2 must reside in Base Chassis Backplane Slot #4. ECOM Modules have one
RS-232 Port and one RS-485 Port. Additionally, an ECOM Module may optionally contain a
56Kbaud PSTN Modem and/or a Spread Spectrum Modem (Radio). Any non-Ethernet
communication ports can be configured for local communications, i.e., connected to a PC
loaded with ControlWave Designer and OpenBSI software.
The connections for the 9-pin, RS-232/485 interface are shown in Figure 2-11, while the
corresponding pin labels are provided in Table 2-4A.
2.3.3.3 RS-232 & RS-485 Interfaces
ControlWave EFM RS-232 & RS-485 communications connectors are summarized below:
CPU Module:
COM1 - Port 1:
COM2 - Port 2:
COM3 - Port 3:

CPU Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J4, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J5, PC/AT 9-Pin Male D-Sub - RS-485

CI-ControlWave EFM

Installation & Operation / 2-17

Expansion Communications Module 1: Resides in Base Chassis Backplane Slot #3
COM4 - Port 1: ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - RS-232
COM5 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - RS-485
Expansion Communications Module 2: Resides in Base Chassis Backplane Slot #4
COM8 - Port 1:
ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - RS-232
COM9 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - RS-485
RS-232 Ports
An RS-232 interface supports Point to Point, half-duplex and full-duplex communications
(20 feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWave EFM utilize MODBUS or BSAP protocol, while full-duplex is supported by
the Point to Point (PPP) protocol. ControlWave EFM RS-232 ports utilize the “null
modem” cable (Figure 2-12A) to interconnect with other devices such as a PC, printer,
another ControlWave EFM or ControlWave series unit (other than CW_10/30/35) when
the ControlWave EFM is communicating using the full-duplex PPP protocol. The halfduplex cable shown in Figure 2-12A is utilized when the ControlWave EFM is connected
to another ControlWave EFM or ControlWave series unit (other than CW_10/30/35). If
communicating with a Bristol series 3305, 3310, 3330, 3335 or CW_10/30/35 RTU/DPC,
one of the cables shown in Figure 2-12B must be used. Refer to Figure 2-12C to connect a
ControlWave EFM serial RS-232 port to either an external modem or external radio.
When interfacing to Port COM3 of a ControlWave unit, or to COM5 or COM6 of a
ControlWaveEXP, the cable of Figure 2-12D must be used along with the one of Figure 212A or 2-12B.
Illustrations of the Local Communication Port cable connections (Typically Comm. Port 1)
are provided in Figures 2-13A and 2-13B. An illustration of the CPU Module’s male 9-pin
D-type connectors is provided in Figure 2-11. Table 2-4A provides the connector pin
assignments for ports COM1, COM2, COM3 and expansion communications ports COM4/5
& COM8/9. Table 2-4B provides pin assignments associated with the circular Local Port.
Note: The following facts regarding ControlWave EFM RS-232 serial communication
ports should be observed when constructing communications cables:
•
•
•
•
•
•
•
•

DCD must be high to transmit (except when dialing a modem)
Each RS-232 transceiver has one active receiver while in powerdown mode (disabled);
the DCD signal is connected to the active receiver.
CTS must be high to transmit.
When port is set for full-duplex operation - RTS is always ON.
DTR is always high (when port is active); DTR enables RS-232 Transceivers.
When port is set for half-duplex operation - CTS must go low after RTS goes low.
All RS-232 Ports support RTS, DTR, CTS, DCD and DSR control signals.
All RS-232 Port I/O signals are protected by LCDA12C surge protectors to ±4KV ESD.

Figure 2-11 - Male DB9 9-Pin Connector Associated with COM1/2/3/4/5/8/9

2-18 / Installation & Operation

CI-ControlWave EFM

Figure 2-12 - Communication Port RS-232 Cable Wiring Diagram
CI-ControlWave EFM

Installation & Operation / 2-19

Table 2-4A - RS-232 Ports (1/2/4/8) and RS-485 Ports (3/5/9) Pin Assignments
Pin Signal
Description:
Signal
#
RS-232
RS-232 Signals
RS-485
1
DCD
Data Carrier Detect Input
2
RXD
Receive Data Input
RXD3
TXD
Transmit Data Output
TXD4
DTR
Data Terminal Ready Output
TXD+
5
GND
Signal/Power Ground
GND/ISOGND*
6
DSR
Data Set Ready Input
RXD+
7
RTS
Request To Send Output
8
CTS
Clear To Send Input
* ISOGND on Isolated RS-485 Ports Only! Note: Pin-9 not used

Description:
RS-485 Signals
N/A
Receive Data - Input
Transmit Data - Output
Transmit Data + Output
Ground/Isolated Ground
Receive Data + Input
N/A
N/A

Table 2-4B - RS-232 Port (COM1) Connector Pin Assignments
(COM1 Connectors, i.e., Circular Local Port & D-Type ‘C1’ on CPU)
COM1 Signal
Description:
Pin # RS-232
RS-232 Signals
1
DCD
Data Carrier Detect Input
2
RXD
Receive Data Input
3
TXD
Transmit Data Output
4
DTR
Data Terminal Ready Output
5
GND
Power Ground
6
DSR
Data Set Ready Input
7*
RTS
Request To Send Output
8*
CTS
Clear To Send Input
* = RTS connected to CTS

Wire
Color
Green
White
Red
Brown
Black

Local Port
RS-232 Pin #
1
7
2
4
6

ControlWave EFM

5 = GND
4 = DTR
8 = CTS

3 = TXD
7 = RTS
2 = RXD
6 = DSR
1 = DCD

To P2 Pin-5
To P2 Pin-6
To P2 Pin-2
To P2 Pin-1
To P2 Pin-3
To P2 Pin-4
To P2 Pin-7

9-Pin Female
“D” Connector

(Looking into
Wire Terminal Side
of
Cable Connectors)
or
vice
versa

1 = DCD
6 = DSR
2 = RXD
7 = RTS
3 = TXD
8 = CTS
4 = DTR
5 = GND

9-Pin Female
“D” Connector

Figure 2-13A - PC Connected to ControlWave EFM via D-Type Local Port
(Use Null Modem Cable - Bristol Part Number 392843-01-3)

2-20 / Installation & Operation

CI-ControlWave EFM

Figure 2-13B - PC Connected to ControlWave EFM via Circular Local Port
Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable
RS-485 Ports
ControlWave EFM can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for
network communications, Table 2-5 provides the appropriate connections for wiring the
master, 1st slave, and nth slave. Essentially, the master and the first slave transmit and
receive data on opposite lines; all slaves (from the first to the "nth") are paralleled (daisy
chained) across the same lines. The master node should be wired to one end of the RS-485
cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used. Note:
Only half-duplex RS-485 networks are supported.
Receiver biasing and termination as well as 2-wire or 4-wire selection are enabled by eightposition DIP-Switches situated on the CPU Module and Expansion Communications
Modules (ECOM) as follows: COM3: CPU Module Switch SW3, COM5: ECOM1 Switch
SW1, and COM9: ECOM2 Switch SW1. An illustration of the CPU Module’s male 9-pin Dtype connectors is provided in Figure 2-11. Table 2-4A provides the connector pin
assignments for CPU port COM3, ECOM1 port COM5 & ECOM2 port COM9. Table 2-6
provides the RS-485 termination and loopback control Switch Settings for the RS-485 Ports.
To ensure that the “Receive Data” lines are in a proper state during inactive transmission
periods, certain bias voltage levels must be maintained at the master and most distant
slave units (end nodes). These end nodes also require the insertion of 100-Ohm terminating
resistors to properly balance the network. Secondary Communication Board switches must
be configured at each node to establish proper network performance. This is accomplished
CI-ControlWave EFM

Installation & Operation / 2-21

by configuring CPU Bd. Switch SW3 and/or ECOM Switch SW1 (COM6/COM9) so that the
100-Ohm termination resistors and biasing networks are installed at the end nodes and are
removed at all other nodes on the network (see Table 2-6).
Table 2-5 - RS-485 Network Connections
(see Table 2-4A ControlWave EFM RS-485 Port Pin # Assignments)
From
Master
TXD+
TXDRXD+
RXDGND/ISOGND*

To 1st
Slave
RXD+
RXDTXD+
TXDGND/ISOGND*

To nth
Slave
RXD+
RXDTXD+
TXDGND/ISOGND*

* ISOGND with Isolated RS-485 Ports Only!
Note: Pins 1, 2, 3, 4 & 9 of BBI Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485 Comm.
Ports are assigned as follows: 1 = TXD+, 2 = TXD-, 3 = RXD+, 4 = RXD- & 9 = ISOGND.

Table 2-6 - CPU Bd. Switch SW3 for COM3 & ECOM Bd. Switch SW1 for COM5/9
Loopback & Termination Control
SWITCH
#
1
2
3
4
5
6
(see note 2)

7
8

RS-485 Function
Switch ON
TX+ to RX+ Loopback
TX- to RX- Loopback
100 Ohm RX+ Termination
100 Ohm RX- Termination
N/A
Slew Rate
ISO485 ONLY
RX+ Bias (End Node)
RX- Bias (End Node)

Note 1: Closed = Switch set ON

Setting
ON - for Half Duplex Network or Diagnostics
ON - for Half Duplex Network or Diagnostics
ON - End Nodes Only
ON - End Nodes Only
N/A
ON - Slow Rate Enabled
OFF - Fast Rate Enabled
ON - End Nodes Only
ON - End Nodes Only

Note 2: Switch SW3 (COM3) = N/A

2.3.3.4 Piggy-back Spread Spectrum Modem (Radio) Port (see Appendix D)
An optional Spread Spectrum Modem (Radio) is available on each Expansion Communications Module (mounted piggy-back) and is assigned port status as follows: COM6 for
ECOM1 and COM10 for ECOM2. There are two unique radios offered. These radios will
only communicate with their own brand of radio, i.e., FreeWave radios are not compatible
with MDS radios. DTE/DCE serial data can be clocked into (transmit) or out of (receive) the
radio at a rate up to 115.2kHz.
These radios are supplied in kit form with all the hardware required for user installation
onto an Expansion Communications Module. Figure 2-14 shows both versions of radios
mounted on the Expansion Comm. Module. Radios are user installed onto the ECOM
Module (see Figure 2-14) and their associated Ports are setup during installation in the
Ports Page of the Flash Configuration Utility. The Flash Configuration Utility is accessed
via NetView or LocalView.
FreeWave® Spread Spectrum Wireless Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
Microwave Data System Inc. MDS TransNET OEM™ Spread Spectrum Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
2-22 / Installation & Operation

CI-ControlWave EFM

Installation steps 1 through 3 below support user installation and configuration of a Spread
Spectrum Modem.
1. Mount the radio (Spread Spectrum Modem) onto the Expansion Comm. Module. Remove
the nut and washer from the internal coaxial RF cable supplied with the ECOM Module.
Remove the plug from the front of the ECOM Cover and insert the in-ternal coaxial RF
cable’s SMA connector (straight end with flat area on top) through the rear of the
ECOM Cover. Install the washer and nut to secure the internal coaxial RF cable to the
front of the ECOM Cover. Install the other end of the internal coaxial RF cable to the
radio’s RF antenna connector. Install the Expansion Comm. Module into Slot 3 or 4 of a
base ControlWave EFM unit.
2. Install the user supplied coaxial RF cable between the ECOM cover’s SMA connector
(installed in step 1) and the remote antenna. Note: A Polyphaser may be placed between
the antenna and the radio’s SMA connector via two user supplied RF cables.
3. For FreeWave Radio: Follow the Tuning Transceiver Performance” section of the
FreeWave Technologies Inc. FreeWave Spread Spectrum Wireless Data Transceiver
User Manual to configure the radio.
For MDS Radio: Refer to section 3.3 “Initial Power-Up & Configuration” within the
MDS TransNet OEM Integration Guide and if necessary for more information on
connecting a PC terminal and preparing it for use, refer to section 9.0
“PROGRAMMING REFERENCE.”
Note:
To invoke the setup program, connect the radio (via ECOM1 port COM4 or
ECOM2 port COM8) to a terminal program (such as HyperTerminal) via a null
modem cable (see Figures 2-12, 2-13A & 2-13B), put the radio into setup mode
and set the parameters for the terminal to those of Table 2-7. The setup
program is invoked by connecting Pins 1 and 2 of ECOM Bd. Jumper Post JP2.
Table 2-7 - Radio Setup Menu Terminal Settings
PARAMETERS
Baud Rate
Data Rate
Parity
Stop Bits
Parity Check
Carrier Detect
Flow Control

SETTINGS
19,200
8
None
1
None/Off
None/Off
Xon/Xoff

2.3.3.5 Piggy-back 56K PSTN Modem Port (see Appendix D)
An optional 56K PSTN Hayes type Modem can be mounted piggy-back on each Expansion
Communications Module and is assigned port status as follows: COM7 for ECOM1 and
COM11 for ECOM2. The Model MT5634SMI Modem module is manufactured by MultiTech
System and can be user configured for PSTN operation. DTE/DCE serial data can be
clocked into (transmit) or out of (receive) the modem at a rate up to 115.2kHz.

CI-ControlWave EFM

Installation & Operation / 2-23

Figure 2-14 - Expansion Comm. Module Radio/Modem Installation Diagram

2-24 / Installation & Operation

CI-ControlWave EFM

Modems are supplied in kit form with all the hardware required for user installation onto
an Expansion Communications Module. Figure 2-14 shows the modem mounted on the
Expansion Comm. Module.
Modems are user installed onto the ECOM Module (see Figure 2-14) and their associated
Ports are setup during installation in the Ports Page of the Flash Configuration Utility. The
Flash Configuration Utility is accessed via NetView or LocalView. A Terminal Emulation
program such as HyperTerminal is used to profile the modem via AT commands. Users
typically use AT commands only when checking the modem’s active or stored profile or
when reconfiguring a modem, e.g., to turn auto answer on or off, etc.
MultiTech Modems are pre-configured using the following 7 steps prior to being shipped.
• Enable modem setup by setting ECOM Board jumper JP2 to 2-3.
• Connect via HyperTerminal (Parameters = 9600, 8, N, 1, None) to ECOM port C1 using
the null modem cable (see Figure 2-12A or 2-13).
• Send Factory Default = AT&F0
• Disable Flow Control = AT&K0
• Set Baud using AT Command: AT$SB9600, or whatever baud rate you require.
• Write to Memory. = AT&W
• Disable setup mode. Park JP2 (no connection)
Note:
The modem can be reconfigured via AT commands using a terminal program
(such as HyperTerminal). Connect Pins 2 and 3 of ECOM Bd. Jumper Post JP2 via
a Suitcase Jumper. Connect the modem (via ECOM1 port COM4 or ECOM2 port
COM8) to the PC via a null modem cable (see Figure 2-12A).
Publicly Switched Telephone Network (PSTN) Hookup
A PSTN using a master and three remote Process Automation Controllers (each equipped
with a PSTN modem) is shown in Figure 2-15. A connection to the PSTN is made using a
cable having standard telephone connectors at each end. One end of the cable plugs into the
ECOM’s RJ11 connector jack while the other end plugs into a telephone company RJ11 wall
jack. The telephone company provides the necessary subscriber loops at its central system
along with the phone numbers for each destination.
Warning
Only one modem should be connected to each drop. If an attempt is made to parallel two or
more modems across a single drop, an impedance mismatch will occur and the quality of the
signal will be adversely affected. Modems will not provide reliable communications under
these conditions.
An application consisting of a single master and a single remote requires only one of the
remote connections shown in Figure 2-15.
The 56K PSTN Modem is FCC-approved for use with public telephone lines. Before placing
a modem in operation, the following items should be checked to insure that all FCC
requirements are met:
•

Connections to party line service is subject to state tariffs.

•

Connection to telephone company provided coin service (central office implemented
systems) is prohibited.
The equipment compliance information is summarized as follows:

•

CI-ControlWave EFM

Installation & Operation / 2-25

Complies with Part 68 FCC Rules.
Contains device with FCC Registration Number: AU7-USA-25814-M5-E
Ringer Equivalence Number (REN): 0.3B
Note: The sum of all the RENs on your telephone lines should be less than five in
order to assure proper service from the telephone company. In some cases, a
sum of five may not be usable on a given line.
•

Any direct connections to PSTN lines must be made through standard plugs and
jacks as specified in the FCC rules. The PSTN line connector plugs into J1 on the
modem. Notify your telephone company that the jack (connector) required for your
device is one of the following: Note: The Jack provided on the Modem (J1) is a 6-Pin
TLECO RJ-11. The connections to the modem are Pin 3 PSTN-Tip, and Pin 4 PSTNRing.
USOC: RJ11C or USOC: RJ11W

•

After the telephone company has installed the above jack, connect the modem to
your equipment by inserting the appropriate equipment interface cable (plugs) into
the modem jack and the wall jack.

Figure 2-15 - Field Connections for ControlWave EFM on Basic PSTN
2-26 / Installation & Operation

CI-ControlWave EFM

Figure 2-16 - Wiring for Phone Cord Connector
2.3.3.6 Radio Ready and External (Case Mounted) Modem or Radio
A wide selection of modems and radios are offered. The ControlWave EFM is factory
shipped with a user selected radio or modem installed within the enclosure (beneath the
Battery Mounting Bracket) or as a radio ready unit, i.e., ready for field installation of a
Bristol supplied radio. The installer must ensure that the remote antenna (associated with
a case mounted radio) is properly installed and connected.
Information on operating and configuring a BBI supplied radio or modem is contained in
documentation authored by the unit’s manufacturer. A list of reference manuals is provided
in the Table of Contents under the topic REFERENCED OEM MANUAS.

2.3.4 I/O Module Installation & Wiring
ControlWave EFM Base Assembly chassis’ are available with a Backplane Assembly that
supports up to 2 or 6 I/O Modules (for 4-Slot and 8-Slot base units, respectively). I/O
Modules may reside in Slots 3 through 4 of the 4-Slot base unit and Slots 3 through 8 of the
8-Slot base unit.. In lieu of an I/O Module, an Optional Expansion Communications
Modules may reside in either Slots 3 or 4 (or both) of a ControlWave EFM Base Assembly.
Figure 2-17 shows ControlWave EFM Backplane Slot assignments.
2.3.4.1 Installation of I/O Modules
If installing one or more I/O Modules into an already operational unit, the unit must be
taken off-line. Processes associated with the ControlWave EFM in question must be shut
down, switched over manually or handled by another controller. Module installation and
removal may not be performed while the unit is powered. Additionally, the application load
in ControlWave Designer must be configured to accept any new I/O Module(s) and then
the new application load must be downloaded before the new I/O Module(s) can become
operational. Hardware configuration should take place with power disconnected until the
entire unit has been physically installed, configured and wired.
Perform steps 1 through 6 below for each I/O Module. I/O Modules are provided with a
removable Cover. The I/O Module Cover snaps on or off to provide access to the unit’s I/O
connectors.
1. Remove the I/O Module and associated I/O Module Cover from the shipping carton.
2. I/O Modules are available that support local terminations (field wiring connected
directly to the I/O Module’s removable Terminal Blocks). When installing wiring in
conjunction with I/O Modules, install the field wiring between the I/O Module’s
CI-ControlWave EFM

Installation & Operation / 2-27

removable Terminal Block connectors and field devices (see Figure 2-18). Use AWG
14 or smaller wire, (consult with the field device manufacturer for recommendations). Leave some slack and plan for wire routing, identification, maintenance, etc. The bundled wires are to be routed in/out through the bottom of the I/O
Module Assembly between the Terminal Block Assembly and the Terminal Housing
Assembly. All I/O wiring should be routed in/out of the enclosure through 1” NPT
Conduit Hub.
Non-Isolated I/O Module wiring information is provided in the following sections:
Section 2.3.4.4 =
Section 2.3.4.5 =
Section 2.3.4.6 =
Section 2.3.4.7 =

Digital I/O Module (12 DI & 4 DO)
Analog I/O Module (6 AI & 2 AO) and Analog Input Module (6 AI)
High Speed Counter Module (4 HSC)
Mixed I/O Module (6 DI/DO, 4AI, 2 HSC & 1 optional AO

Note: The ControlWave Loop Power Supply can be used to provide
regulated and isolated 24Vdc field power for externally powered
non-isolated I/O see PIP-ControlWaveLS).
3. Align the I/O Module with the assigned I/O Slot and install the unit into the
Chassis. Make sure that the I/O Module Cover snaps into the applicable notches in
the Chassis Assembly.
4. Plug the Local Cable Assemblies onto the appropriate I/O Module connectors.
5. When two I/O Modules have been installed into the Chassis (with field wiring), a
Bezel Assembly should be installed to cover, protect and dress the unit.

Figure 2-17 - ControlWave EFM Slot Assignments
2-28 / Installation & Operation

CI-ControlWave EFM

6. Using a PC equipped with ‘ControlWave Designer’ and ‘OpenBSI’ software, configure the ControlWave EFM to accept the new I/O Module (and any other modules
that have been added or removed) and then download the application load into the
ControlWave EFM CPU’s System FLASH and/or SDRAM (see Section 2.4.1). For
new installations, this step can be skipped until the unit has been wired and power
applied.

Figure 2-18 - I/O Module (Local Termination) Wire Routing
CI-ControlWave EFM

Installation & Operation / 2-29

2.3.4.2 I/O Wire Connections
ControlWave EFM electronic flow computers utilize compression-type terminals that
accommodate up to #14 AWG wire. A connection is made by inserting the wire’s bared end
(1/4” max) into the clamp beneath the screw and securing the screw. The wire should be
inserted fully so that no bare wires are exposed to cause shorts. If using standard wire, tin
the bare end with solder to prevent flattening and improve conductivity.
Allow some slack in the wires when making terminal connections. The slack makes the
connections more manageable and minimizes mechanical strain on the terminal blocks.
2.3.4.3 Shielding and Grounding
The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize
signal errors caused by electromagnetic interference (EMI), radio frequency interference
(RFI) and transients. When using shielded cable, all shields should only be grounded at one
point in the appropriate system. This is necessary to prevent circulating ground current
loops that can cause signal errors.
2.3.4.4 Non-isolated Digital Input/Output Module (see Figure 2-19)
ControlWave EFM non-isolated Digital Input/Output Modules contain field interface
circuitry for up to 12 Digital Inputs and 4 Digital Outputs. Surge Suppression and signal
conditioning is provided for each DI. DO circuits consist of an open drain MOSFETs and
Surge Suppression. The DI filter time is 15 milliseconds. DI/O Modules con-sists of a Digital
Input/Output PCB with two 10-point Terminal Block Assemblies (for local termination), 14
Configuration Jumpers, an LED Board with 16 Status LEDs (one for each point) and a
Cover Assembly. The DI/O Board mates with the Backplane PCB via a 36-pin gold plated
card edge connector.
DI/O Modules provide internally sourced DI operation for Dry Contacts pulled internally to
3.3Vdc when the field input is open. Each DI is protected with a surge suppressor. DI
filtering is 15 milliseconds. The four DOs are composed of open drain MOSFETs and surge
suppressors. The DOs sink current to system ground of the DI/O Board.
2.3.4.4.1 Digital Input/Output Configurations
Digital Input/Output Modules provide 12 individually field configurable DIs and 4 nonconfigurable externally powered DOs. Each DI may be individually set to provide either a
2mA or 60uA source current via Configuration Jumpers W1 through W12. Open drain
MOSFETs associated with each DO provide up 100mA each @ 30Vdc to an externally
powered device. DI/O Module Configuration Jumpers W1 through W14 must be set per
Table 2-8. Field wiring assignments are provided in Figure 2-19.
Table 2-8 - Non-Isolated DI/O Module Jumper Assignments
Jumper
W1 - W12

Purpose
Configures DI1 through
DI12 (respectively)

W13

LED Enable

W14

Program Serial EEPROM

2-30 / Installation & Operation

Notes
Pins 1-2 installed = 2mA Source Current
Pins 2-3 installed = 60uA Source Current
Pins 1-2 installed = Enables LEDs Manually
Pins 2-3 installed = Enable LEDs via
software
Factory Use ONLY

CI-ControlWave EFM

Figure 2-19 - Non-Isolated DI/O Module Configuration Diagram
2.3.4.5 Non-isolated Analog Input/Output & Analog Input Modules (see Figure 2-20)
Analog Input/Output Modules support six 4-20mA or 1-5 Vdc single ended analog inputs
and optionally, two independently configurable 4-20mA or 1-5 Vdc analog outputs. AI/O
Modules consists of an Analog Input/Output PCB with two 10-point Terminal Block
Assemblies (for local termination), 12 Configuration Jumpers and a Cover Assembly. The
AI/O Board mates with the Backplane PCB via a 36-pin gold plated card edge connector.
Analog Input Modules are identical to AI/O Modules but have a depopulated AO section.
CI-ControlWave EFM

Installation & Operation / 2-31

Each AI signal is channeled through signal conditioning circuitry (that provides a 2 Hertz
low pass filter), a transorb for surge suppression, multiplexer, and an A to D Converter
(ADC).

Figure 2-20 - Non-isolated AI/O & AI Module Configuration Diagram
2-32 / Installation & Operation

CI-ControlWave EFM

The Analog Output circuit consists of a 12-bit resolution Digital to Analog Converter (DAC),
a V to I circuit, and a V to V circuit. The 12-bit DAC dives the V to I circuitry. A scaling
circuit within the V to I circuit drives the V to V circuitry. V to I and V to V circuitry are
powered by an external power source.
A CPLD generates the control signals for the ADC, multiplexer, EEPROM, Bus Interface
and E2PROM that contains the calibration data.
2.3.4.5.1 Analog Input/Output Configurations
AI/O and AI Modules are provided with Configuration Jumpers that accommodate
configuration of each of the six Analog Inputs. Analog Input can be individually configured
for 1-5V or 4-20mA operation. Field wiring assignments are provided in Figure 2-20.
Note:
Cable shields associated with AI wiring should be connected to the ControlWave EFM’s
Chassis Ground. Multiple shield terminations will require a user supplied copper ground
bus. This ground bus must be connected to the ControlWave EFM’s Chassis Ground Lug
(using up to a #4 AWG wire size) and must accommodate a connection to a known good
Earth Ground (in lieu of a direct connection from the Ground Lug) and to all AI cable
shields. Shield wires should use an appropriate Terminal Lug and should be secured to
the copper bus via industry rugged hardware (screw/bolt, lockwasher and nuts).

Analog Input/Output Modules are provided with two Analog Outputs that are individually
jumper configurable for 1-5V or 4-20mA AO operation. The maximum external load that
can be connected to the 4-20mA output is 250 ohms (with an external 11V power source) or
650 ohms (with an external 24V power Source). The maximum external load current for the
1-5V output is 5mA (with an external 11 to 30 V power source). AO operation requires an
11 to 30Vdc power source connected to the VEXT terminal of the AI/O Module.
Table 2-9 - Analog Input/Output/Analog Input Module Jumper Assignments
Jumper
JP1 - JP6

Purpose
Configures AI1 through
AI6 (respectively)
AO1 Field Output

Notes
Pins 1-2 installed = 4-20 mA AI
Pins 2-3 installed = 1-5V AI
JP7
Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5V AO
JP8
AO2 Field Output
Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5V AO
JP9
AO1 Output Status
Pins 1-2 installed = 1-5V AO
Pins 2-3 installed = 4-20 mA AO
JP10
AO2 Output Status
Pins 1-2 installed = 1-5V AO
Pins 2-3 installed = 4-20 mA AO
J1
Configure ISP Connector Factory Use ONLY
W1
Program Serial EEPROM Factory Use ONLY
* Note: JP7 & JP9 Operation Must Match, i.e., both set for 1-5V or 4-20mA
JP8 & JP10 Operation Must Match, i.e., both set for 1-5V or 4-20mA

2.3.4.6 Non-isolated High Speed Counter Input Module (see Figure 2-21)
Non-isolated High Speed Counter Input (HSC) Modules provide a total of 4 inputs provided
with surge suppression bandwidth limiting and 20 microsecond (50kHz) filtering. HSC
Module inputs may be individually field configured with contact debounce circuitry enabled
or disabled and for 2mA or 200uA (low power) operation. When debounce circuitry is
enabled, spurious pulses caused by relay contact bounce are reduced with filters. HSC
CI-ControlWave EFM

Installation & Operation / 2-33

Modules consists of a High Speed Counter PCB with two 10-point Terminal Block
Assemblies (for local termination), 14 Configuration Jumpers, an LED Board with 4 Status
LEDs (one for each point) and a Cover Assembly. The HSC Board mates with the
Backplane PCB via a 36-pin gold plated card edge connector.

Figure 2-21 - Non Isolated HSC Module Configuration Diagram
High Speed Counter Input Modules contain conditioning circuitry consisting of a debounce
circuitry followed by a one shot pulse circuit that generates a 65 microsecond ±10% pulse
and limits the maximum frequency of an input signal to 15kHz. Field inputs can be driven
2-34 / Installation & Operation

CI-ControlWave EFM

signals, or relay contacts. A serial EEPROM contains HSC Board serialization data. Each
input of the HSCI Module is configured as a 16-bit high-speed counter.
2.3.4.6.1 High Speed Counter Configurations
HSC Modules provide a total of 4 HSC inputs with surge protection. HSC Module Configuration Jumpers W1 through W14 must be set per Table 2-10.
Table 2-10 - Non Isolated High Speed Counter Module Jumper Assignments
Jumper
W1 - W4
W5
W6

Purpose
Configures HSC1 through
HSC4 (respectively)
Program Serial EEPROM
LED Enable/Disable

W7 & W8

HSC1 Current Control

W9 & W10

HSC2 Current Control

W11 & W12

HSC3 Current Control

W13 & W14

HSC4 Current Control

Notes
Pins 1-2 installed = Enables HSC Debounce
Pins 2-3 installed = Disabled HSC Debounce
Factory Use ONLY
Pins 1-2 installed = Enables LEDs Manually
Pins 2-3 installed = Enable LEDs via software
Pins 1-2 installed = for additional 2mA load
Pins 2-3 installed = 200uA Source no 2mA load
Pins 1-2 installed = for additional 2mA load
Pins 2-3 installed = 200uA Source no 2mA load
Pins 1-2 installed = for additional 2mA load
Pins 2-3 installed = 200uA Source no 2mA load
Pins 1-2 installed = for additional 2mA load
Pins 2-3 installed = 200uA Source no 2mA load

Field wiring assignments are provided in Figure 2-21.
2.3.4.7 Non-isolated Mixed I/O Module (see Figures 2-22 & 2-23)
Non-isolated Mixed I/O Modules provide a total of 6 individually field configurable Digital
Inputs/Outputs, 4 Analog Inputs, 2 High Speed Counter Inputs and 1 optional Analog
Output. I/O circuitry is similar to those utilized on the I/O Modules discussed in sections
2.3.4.4 through 2.3.4.6.
Surge Suppression and signal conditioning is provided for each DI. DO circuits consist of an
open drain MOSFETs and Surge Suppression. Mixed I/O Modules provide internally
sourced DI operation for Dry Contacts pulled internally to 3.3Vdc when the field input is
open. Each DI is protected with a surge suppressor. DI filtering is 15 milliseconds. DOs are
composed of open drain MOSFETs and surge suppressors.
Mixed I/O Module AIs are independently configurable for 4-20mA or 1-5 Vdc single ended
operation. Each AI signal is channeled through signal conditioning circuitry (that provides
a 2 Hertz low pass filter), a transorb for surge suppression, multiplexer, and an A-to-D
Converter (ADC).
Non-isolated Mixed I/O Modules support a total of 2 HSC inputs provided with surge
suppression, bandwidth limiting and 20 microsecond (50kHz) filtering. HSC inputs may be
individually field configured with contact debounce circuitry enabled or disabled and for
2mA or 200uA (low power) operation. HSCs are supported by signal conditioning circuitry
consisting of a debounce circuit followed by a one shot pulse circuit that generates a 65
microsecond ±10% pulse and limits the maximum frequency of an input signal to 15kHz.
Field inputs can be driven signals, or relay contacts. Each input of the HSCI Module is
configured as a 16-bit high-speed counter.

CI-ControlWave EFM

Installation & Operation / 2-35

Figure 2-22 - Mixed I/O Module Wiring Diagram
Mixed I/O Modules optionally support one externally powered (VEXT = 11 to 30Vdc) analog
output. AO Circuitry consists of a 12-bit resolution Digital to Analog Converter (DAC), a V
to I circuit, and a V to V circuit. The 12-bit DAC drives the V to I circuitry. A scaling circuit
within the V to I circuit drives the V to V circuitry. V to I and V to V circuitry are powered
by an external power source.

2-36 / Installation & Operation

CI-ControlWave EFM

Figure 2-23 - Non Isolated Mixed I/O Module Configuration Diagram
2.3.4.7.1 Mixed I/O Module Configurations
Mixed I/O Module Configuration Jumpers W1 through W28 must be set per Table 2-11.
Table 2-11 - Non Isolated Mixed I/O Module Jumper Assignments
Jumper
W1*
W2

Purpose
Configures optional AO for
Voltage or Current Output
Configures optional AO for
Voltage or Current Output

W5 & W6

HSC1 Current Control

W7 & W8

HSC2 Current Control

W9 & W10
W11 - W16
W17 - W22

Configures HSC1 and HSC2
Debounce (respectively)
Configures DI1 through DI6
Current (respectively)
DI/O1 through DI/O6 Point
Selection (respectively)

CI-ControlWave EFM

Notes
Pins 1-2 installed = AO set for Current Output
Pins 2-3 installed = AO set for Voltage Output
Pins 1-2 installed = AO set for Voltage Output
Pins 2-3 installed = AO set for Current Output
Pins 1-2 installed = for additional 2mA load
Pins 2-3 installed = 200uA Source no 2mA load
Pins 1-2 installed = for additional 2mA load
Pins 2-3 installed = 200uA Source no 2mA load
Pins 1-2 installed = Enables HSC Debounce
Pins 2-3 installed = Disabled HSC Debounce
Pins 1-2 installed = 2mA Source Current
Pins 2-3 installed = 60uA Source Current
Pins 1-2 installed = Digital Input Operation
Pins 2-3 installed = Digital Output Operation
Installation & Operation / 2-37

Table 2-11 - Non Isolated Mixed I/O Module Jumper Assignments (Continued)
Jumper
W23 - W26
W27

Purpose
Configures AI1 through AI4
(respectively)
AO Voltage Selection
Set W27 Pins 2-3
ALWAYS

Notes
Pins 1-2 installed = 4-20mA AI (250 ohm resistor
in)
Pins 2-3 installed = 1-5V AI
Pins 1-2 installed = N/A
Pins 2-3 installed = External Field Voltage (TB2-9)

Pins 1-2 installed = HSC Circuit Enable (Powered)
Pins 2-3 installed = HSC Circuit Disabled
* = W1 located on optional AO Daughter Board
W28

HSC Circuitry Enable

2.3.5 RTD Wiring
A 3-wire RTD may be provided with the ControlWave EFM. Connector TB2 on the System
Controller Module accommodates a removable three-wire Terminal Block (similar to TB1).
This connector accommodates a 100-ohm platinum bulb using the DIN 43760 curve.
ControlWave EFM’s utilize the common three-wire configuration. In this configuration,
the Return lead connects to RTD- and the two junction leads (Sense and Excitation),
connect to RTD+ and RTD EXC. Connection between the RTD and System Controller
Module is wired as follows:
Table 2-12 - RTD Connections to System Controller Connector TB2
TB2 Pin
1
2
3

Signal
RTD EXC
RTD+
RTD-

Function
Excitation
Sense
Return

Never ground the RTD Cable Shield at both ends or allow it to come in contact with metallic or conductive conduit as multiple ground paths could result and cause RTD input errors.

Figure 2-24 - 3-Wire RTD Temperature Input Wiring
To install the RTD Probe, screw the Fitting Body into the thermowell with a 7/8”open-end
wrench. While applying pressure against the sheath to force the Tip of the RTD Probe into
the bottom of the thermowell (so that the Probe Tip is in contact with the thermowell),
tighten the Nut (9/16” open-end wrench) against the 7/8” Fitting Body (see Figure 2-25).

2-38 / Installation & Operation

CI-ControlWave EFM

Figure 2-25 - RTD Probe Installation/Removal Diagram

2.3.6 21V Power Supply Option
21V Power Supplies are mainly used in conjunction with Temperature and Pressure
Transmitters which require a higher than +12V but lower than +21.4V (±.8V) input supply
to operate (such as Series 3508 Transmitters).

Figure 2-26 - 21V Power Supply Board
21V Power Supply Boards contain two terminal blocks that accommodate power connections between the ControlWave EFM and remote transmitters. TB1 is a three-position
terminal block that provides input power connection from the Power Distribution Board.
Four-position Terminal Block (TB2) provides +21V power and ground to external devices
such as Series 3508 Transmitters.
CI-ControlWave EFM

Installation & Operation / 2-39

Table 2-13 - 21V Power Supply Board Terminal Designations
21VPS
TB#
TB1-1
TB1-2
TB1-3
TB2-1
TB2-2
TB2-3
TB2-4

21VPS
TB NAME
+12VIN
12VGND
CHASSISGND
+21V
21VGND
+21V
21VGND

CONNECTION
to PDB.
TB3-1
TB3-2
N/A
N/A
N/A
N/A
N/A

CONNECTION
to XMTR.
N/A
N/A
N/A
XMTR1+
XMTR1XMTR2+
XMTR2-

2.3.7 Digital to Relay I/O Board Option
Digital to Relay I/O Boards except up to two discrete input signals from an open drain
MOSFET device and convert them to Form C relay output signals using Solid State Relay
(SSR) logic. The minimum current load will be 100mA. Figure 2-27 provides a component
view of the Digital to Relay I/O Board.
Each ControlWave EFM Discrete Output is converted to a Form C relay output signal
which can be configured for opposite or identical state conditions, i.e., both Normally Open
(NO) or Normally Closed (NC) or one Normally open with the other Normally Closed.

Figure 2-27 - Digital to Relay I/O Board
2.3.7.1 Digital to Relay I/O Board Jumper Settings
The Digital To Relay I/O Board contains ten (10) Jumpers which allow the user to configure
contacts for Normally Open/Normally Closed states. Contacts associated with each of the
Form C Relays may be configured for identical or opposite states. Note: Jumper Pairs
W3/W5, W4/W6, W7/W9 and W8/W10 must be set in opposite states.
2-40 / Installation & Operation

CI-ControlWave EFM

The commons associated with each form C Relay (R0COM and R1COM) have the option of
being tied to the ControlWave EFM Power Ground or to a floating Ground. Jumper W1 is
associated with Outputs R0A and R0B and W2 is associated with outputs R1A and R1B.
When Jumper W1 is installed the common (C) associated with Outputs R0A and R0B is tied
to ControlWave EFM Power ground; when Jumper W1 is not installed, the common will
be floating. When Jumper W2 is installed the common (C) associated with Outputs R1A and
R1B is tied ControlWave EFM Power ground; when Jumper W2 is not installed, the
common will be floating.
Table 2-14 - Jumper Settings versus Form C Relay Output States
JUMPERS
W3/W5
IN/OUT
OUT/IN

R0A
STATE
NO
NC

JUMPERS
W4/46
IN/OUT
OUT/IN

R0B
STATE
NO
NC

JUMPERS
W7/W9
IN/OUT
OUT/IN

R1A
STATE
NO
NC

JUMPERS
W7/W9
IN/OUT
OUT/IN

R1B
STATE
NO
NC

Table 2-13 provides the relationship between Jumper settings and Form C Relay Outputs.
Table 2-15 - Digital To Relay I/O Board Connections to J1/P1
J1 Pin

Signal

Function

Wiring Connections

1
2
3
4
5
6
7
8

R1B
R1A
R1COM
CHASSIS GND
R0COM
ROB
ROA
-

Relay 1 Output B
Relay 1 Output A
Relay 1 Common
Chassis Ground
Relay 0 Common
Relay 0 Output B
Relay 0 Output A
-

POWER GND

Power Ground

POWER - DC

Power - 6/12 Vdc

DOUT0

Discrete Output 0

DOUT1

Discrete Output 1

To Field
To Field
To Field (See W2)
CWMICRO Chassis Gnd. Lug
To Field (See W1 - Section 1.1.1)
To Field
To Field
Pwr. Dist. Bd.
TB4 Pin 2 (Black Wire)
Pwr. Dist. Bd.
TB4 Pin 1 (Red Wire)
DI/O Module TB2-5 - TB2-8 or
Mixed I/O Module TB1-1 - TB1-6 (Yellow Wire)
DI/O Module TB2-6 - TB2-8 or
Mixed I/O Module TB1-2 - TB1-6 (Orange
Wire)

The DI/DO Module and the Mixed I/O Module provide independently firmware controlled
open drain outputs, which can be used for control or signaling functions (DI/DO Modules
provide up to four DO while the Mixed I/O Module provides up to 6 DO). Each output is
wired to the source terminal of an N Channel MOSFET capable of switching up to 16 Volts
at up to 100mA. When closed, the FET shorts the output to ground with resistance of .5
Ohms or less. These outputs are protected by 16V Transorbs. Since these outputs are not
isolated, caution must be exercised to ensure that the load current does not affect operation
of the ControlWave EFM or related devices.
Two of these outputs may be wired to field circuitry via the Digital to Relay I/O Board
option (see Figure 2-28). Table 2-15 provides the wiring connections for the DI/O Module or
the Mixed I/O Module and the Digital to Relay I/O Board.

CI-ControlWave EFM

Installation & Operation / 2-41

Figure 2-28 - Digital to Relay I/O Board Wiring Diagram

2.3.8 Connection to a Model 3808 Transmitter
A Model 3808 Transmitter (Digital) can be interfaced to a ControlWave EFM via either
an RS-232 or an RS-485 communication scheme. Communication schemes and cable
lengths are determined the type of communication port utilized. In general RS-232
communications are utilized when the Model 3808 Transmitter is situated within 25 feet of
the ControlWave EFM, i.e., for local communications. Communications can be achieved
with transmitters up to 4000 feet away (remote communications) via the RS-485 scheme.

Figure 2-29 - Model 3808 Transmitter to ControlWave EFM
RS-232 Comm. Cable

2-42 / Installation & Operation

CI-ControlWave EFM

Note: For Loopback & Termination Control:
Use SW3 on CPU Module to configure COM3.
Use SW1 on ECOM Module to configure COM5 or COM9.

Figure 2-30 - Model 3808 Transmitter to ControlWave EFM
RS-485 Comm. Cable

Figure 2-31 - ControlWave EFM to 3808s - RS-485 Network Diagram

CI-ControlWave EFM

Installation & Operation / 2-43

Figures 2-29 and 2-30 detail the RS-232 and RS-485 wiring connections required between
the ControlWave EFM and the Model 3808 Transmitter.
Up to eight (8) Model 3808 Transmitters can be connected to a ControlWave EFM via a
half duplex RS-485 Network. An illustration of this network is provided in Figure 2-31.

2.3.9 Power Wiring & Distribution
Power may be provided from a rechargeable 12V lead-acid battery (used in conjunction with
a 30W Solar Panel (with a built-in Regulator) or a user supplied external bulk dc power
supply (4.5 to 16Vdc). A Power Distribution Board is required if the unit is equipped with
an external radio/modem, or 21Vdc Power Supply Board, or Digital to Relay I/O Board (or
any combination of them) and bulk power is supplied from an external bulk dc source.

Figure 2-32 - Pwr. Distribution Bd. and Other Options - Snap Track Mounting
ControlWave EFM Terminal Blocks utilize compression-type terminals that accommodate
up to #14 AWG wire. A connection is made by inserting the wire’s bared end (1/4” max) into
the clamp adjacent to the screw and then securing the screw. The wire should be inserted
fully so that no bare wires are exposed to cause shorts. If using standard wire, tin the bare
end with solder to prevent flattening and improve conductivity. Allow some slack in the
wires when making connections. The slack makes the connections more manageable and
helps to minimize mechanical strain on the terminal blocks.

2-44 / Installation & Operation

CI-ControlWave EFM

Power Distribution Boards are provided with six (6) Terminal Connector Blocks that
function as follows:
TB1 - Primary Power Input: (three-conductor) (from user supplied bulk power source)
TB1-1 = Power+ (Pos. input)
TB1-2 = Power– (Neg. input)
TB1-3 = Chassis (GND)
TB2 - Main Power Output 1: (two-conductor) (to SCM Power Connector TB1)
TB2-1 = PWR1+ to TB1-1 on SCM (+VIN)
TB2-2 = PWR1– to TB1-2 on SCM (–VIN)
TB3 - Main Power Output 2: (two-conductor) (to 21V PS Board Connector TB1)
TB3-1 = PWR2+ to TB1-1 on 21VPS (+VIN)
TB3-2 = PWR2– to TB1-2 on 21VPS (GND)
TB4 - Fused Power Output 1: (two-conductor) (to Digital to Relay I/O Board Connector J1)
TB4-1 = FPWR1+ to J1-10 on D-to-R I/O Bd. (PWR+)
TB4-2 = FPWR1– to J1-9 on D-to-R I/O Bd. (PWR GND)
TB5 - Fused Power Output 2: (two-conductor) (to External Modem/Radio Pwr. Connector)
TB5-1 = FPWR2+ to Radio/Modem Power+
TB5-2 = FPWR2– to Radio/Modem Power– (PWR GND)
TB6 - Fused Power Output 3: (two-conductor) (optional use - similar to TB5)
TB6-1 = FPWR3+ to Radio/Modem Power+
TB6-2 = FPWR3– to Radio/Modem Power– (PWR GND)
Note: F1 is rated at 1.5A and protects the Solar Panel Regulator Circuitry. Fuse
F3 is rated at .5A and protects Fused Power Output 1. F1 and F3 are provided for
Class I, Div. 1 Hazardous Location use Only.

Figure 2-33 - Power Distribution Board
2.3.9.1 Bulk Power Supply Current Requirements
ControlWave EFM electronic flow meters are equipped with a System Controller Module
that accepts either 6Vdc or 12Vdc Bulk Power input. The maximum current required for a
particular ControlWave EFM can be estimated as follows:
CI-ControlWave EFM

Installation & Operation / 2-45

Bulk +6/12Vdc Supply Current = CPU* + Sum of all ECOM Modules, I/O Modules, optional
Boards & Optional External Modem/Radio

This summation will accommodate steady state current draw. Table 2-16 provides detailed
steady state power current requirements for each ControlWave EFM Base Assembly
module. Note: In the case of an external modem/radio, the unit’s manufacturer provides
power consumption specifications. Power requirements for the optional Digital to Relay I/O
Board, 21V Power Supply Board and the Battery Charger/Power Manager Board are
provided in Sections 4.5, 4.6 and 4.7 (respectively) of this manual.
Table 2-16 - ControlWave EFM Base Assembly Power Requirements
COMPONENTS
BULK 12Vdc Supply
CPU* = CPU + SCM + Backplane 8.6mA
Non-Isolated AI/O Module
2.8mA + (47.2mA - VEXT)
Non-Isolated DI/O Module
12mA
Non-Isolated HSC Module
5mA
Non-Isolated Mixed I/O Module
16.67mA + (24.3mA - VEXT)
(with optional AO Board)
ECOM Module
22mA
(without Modem/Radio)
ECOM Module
56mA
(with MultiTech Modem)
ECOM Module
277mA
(with MDS Radio)
ECOM Module
311mA
(with Modem & MDS Radio)
ECOM Module
272mA
(with FreeWave Radio)
ECOM Module
306mA
(with Modem & FreeWave Radio)
Note: Current consumption provided in Table 2-15 is
Electronic Flow Computer application load.

BULK 6Vdc Supply
14mA
5.6mA + (47.2mA - VEXT)
24mA
10mA
34mA + (24.3mA - VEXT)
45mA
112mA
555mA
622mA
545mA
612mA
based on the standard

2.3.9.2 Power Wiring
DC Power is interconnected to the System Controller Module (SCM) on Connector TB1. One
Bulk DC supply can be connected to the ControlWave EFM SCM. The Bulk DC supply
(nominally +6Vdc or +12Vdc) connected to TB1-1 (+VIN on SCM) is converted, regulated
and filtered by the SCM to produce +3.3Vdc. This SCM circuit is fused at 1A. The operating
range of the SCM is +4.5/4.9Vdc to +16.0Vdc (nominal +6Vdc input source) or +9.6/10.3Vdc
to +16.0Vdc (nominal +12Vdc input source).
SCM Connector TB1 provides 3 input connections for bulk power as follows:
TB1-1 = (+VIN) (+4.5/4.9V to +16V dc for +6V bulk) (+9.6/10.3V to +16V dc for +12V bulk)
TB1-2 = (-VIN) (Supply Ground)
TB1-3 = Chassis Ground - CHASSIS

Figure 2-34 - SCM (TB1) Typical Wiring Scheme
2-46 / Installation & Operation

CI-ControlWave EFM

2.3.9.3 Mounting an Optional Solar Panel
Solar Panels (used to charge the rechargeable lead acid batteries) are to be mounted to a 2”
to 2-3/8” pipe as illustrated in Figure 2-35. Muffler (Pipe) Clamps, utilized for this purpose,
are secured via four 1/4-20 nuts and washers.

A
A

B
B

D
C

Note 2: Item D slots
accommodate Tilt
Angle Adjustment.

NOTE 1: To Attach item C to item D:
Slide two bolts (A) through the top and bottom
Solar Panel (Centered) Channel Holes. Affix item
C to item D via 2 sets of item A hardware as
follows: Flat Washer, Lock Washer & Hex Nut
(Max. Torque = 120 Inch-Pounds).

A
B
A

Adjustable
Tilt Angle

A
E

Vertical
Pole

A - 6 places consists of
the following hardware:
A

5/16-18 x .75 Hex Hd. Bolt
5/16 Flat Washer
5/16 Spring Lock Washer
5/16-18 Hex Nut

B - 2 places:
A

2-3/8 U-Clamp Assembly

C - Adjustable Angle Bracket
(Attaches to Solar Panel)
D - Pole Mounting Bracket
E - 30 or 40 Watt Solar Panel

Figure 2-35 - 30/40 Watt Solar Panel Mounting Diagram
2.3.9.3.1 Swivel (Directional Facing)
Solar Panels used in the Northern Hemisphere should face due south (not magnetic south)
while those used in the southern hemisphere should face due north (not magnetic north).
CI-ControlWave EFM

Installation & Operation / 2-47

2.3.9.3.2 Tilt Angle
30/40 Watt Solar Panel Systems (see Figure 2-35) have adjustable tilt angles. Table 2-17
shows the angle (from horizontal) at which the Solar Panel should be installed in order to
maximize annual energy output. At most latitudes, performance can be improved by less of
an angle during the summer and more of an angle during the winter.
Table 2-17 - Solar Panel Tilt Angle for 40 Watt & 30 Watt Solar Panels
LATITUDE
0-4°
5-20°
21-45°
46-65°
66-75°

INSTALLATION ANGLE
10° from Horizontal
Add 5° to the Local Latitude
Add 10° to the Local Latitude
Add 15° to the Local Latitude
80° from Horizontal

2.3.9.4 Installing the Rechargeable Battery and Solar Panel Harness
The Rechargeable Sealed Lead-acid Battery must be removed from its shipping carton and
installed on its mounting bracket within the enclosure as illustrated in Figure 2-36.

Figure 2-36 - Enclosure with Sealed Lead-acid Battery Installed
2-48 / Installation & Operation

CI-ControlWave EFM

1. Remove connector TB1 from the System Control Module (SCM) and remove the
Battery/Power Harness from the Battery Charger/Power Manager Board.
2. Remove the Lead-acid Battery from its shipping carton.
3. Install the Lead-acid Battery (on end) as illustrated in Figure 2-36. Note: Make sure
the Lead-acid Battery is fully charged before installing it.
4. Route Solar Panel Power Wiring Harness into the enclosure through the Solar Power
Conduit Fitting (see Item 5 of Figure 2-3).
5. Connect the Solar Panel Harness to the internal Battery (Red = Pos. & Black = Neg.).
6. Secure the Battery via the Battery Clamp.
7. When you are ready to apply power, connect the Battery Power Harness to either the
Power Distribution Board (if present) or to TB1 on the SCM.
2.3.9.5 ControlWave EFM System Grounding
ControlWave EFM Enclosures are provided with a Ground Lug that accommodates up to a
#4 AWG wire size. A ground wire must be run between the Enclosure’s Ground Lug (see
Figure 2-3) and a known good Earth Ground. As an extra added precaution, it is
recommended that a #14 AWG wire be run from SCM Power Connector TB1-3 (Chassis
Ground) to the same known good Earth Ground. The following considerations are provided
for the installation of ControlWave EFM system grounds (see S1400CW):
• Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is recommended
that stranded copper wire is used and that the length should be as short as possible.
• This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
• The wire ends should be tinned with solder prior to insertion into the Chassis Ground
Lug. Note: Use a high wattage Soldering Iron.
• The ground wire should be run such that any routing bend in the cable has a minimum
radius of 12-inches below ground and 8-inches above ground.
2.3.10 Operation of the Lithium Backup Coin-cell Battery
CPU Modules have a Coin-cell Socket (S1) that accommodates a 3.0V, 300 mA-hr lithium
coin cell. A supervisory circuit on the CPU is used to switch to battery power when the
regulated 3.3Vdc VCC falls out of specification. The CPU switches the battery voltage to the
VBAT3.3 hardware signal, which provides backup power for the real-time clock (RTC) and
the system SRAM on the CPU Module.
The system SRAM has a standby current draw of 20uA maximum for each part. For a unit
containing 2MB of SRAM, a worst-case current draw of 42uA allows a battery life of
approximately 7142 hours.
Jumper JP1 on the Battery Backup Board must be installed to enable the battery. For
maximum shelf life, the battery may be isolated from the circuit by removing Jumper JP1.
JP1’s suitcase jumper can be stored on either of its pins.
CPU Modules are shipped with the Lithium backup battery installed. To remove the
backup battery, pry up the Battery Securing Tab on the Coin-cell Battery Socket and then
remove the battery using a pair of tweezers or needle-nose pliers. Install the replacement
battery. Note: This step will not be required until units have been in operation for an extended period of time (normally many years) as the battery life is approximately 7142 hours
of backup service. (Power is drawn from the battery when the unit looses power).

CI-ControlWave EFM

Installation & Operation / 2-49

NOTE:
If the Battery or is removed when power is off the contents of SRAM (on the CPU
Module) will not be retained. Once a Battery has been removed, don’t install a
replacement Battery for at least one minute unless SW2-5 on the CPU has been
set OFF.

2.3.11 Installation of a Bezel Assembly (see Figure 2-2 & 2-37)
Bezel Assemblies provide a protective cover and wire routing for any two ControlWave
EFM I/O Modules. One Bezel Assembly will cover Slots 3 & 4 (when equipped with I/O
Modules) and will provide the following functions:
• It can be removed to access the two I/O Modules.
• Bundled wires and cables are routed downward between the Modules and the Bezel.
• The Bezel is functional and its appearance is contiguous with the I/O Modules.
Bezel Assemblies are provided when two I/O Modules are ordered and should be installed
whenever the unit is operational (except during service). The Bezel is secured to the Covers
of two I/O Modules via four built-in latches (hooks). To remove the Bezel assembly, gently
grasp its sides and pull up and then away from the Chassis.
Installation of the Bezel Assembly requires that its latches be aligned with their mating
notches on the associated left and right I/O Module Covers. Once the Bezel has been
properly aligned with the notches on the I/O Module Covers, simply press in and then
downward to set it into place.

Figure 2-37 - Bezel Assembly
2-50 / Installation & Operation

CI-ControlWave EFM

2.4 OPERATIONAL DETAILS
ControlWave EFM electronic flow computers are shipped from the factory with firmware
that allows the unit to be configured in conjunction with an IEC 61131, application
program. This section provides information as follows:
-

Steps required to download the application load and place the unit into ‘Run’ mode.
Steps required to download system firmware.
Operation of the SCM Module’s Mode Switch
Soft Switch Configurations and Communication Ports

Operational details on ControlWave EFM LEDs, the SCM’s Status LEDs and use of the
BBI WINDIAG program for fault isolation are provided in Chapter 3.

2.4.1 Downloading the Application Load
Any ControlWave EFM must have a configured application load before it can be placed into
operation. For units not shipped with the ‘Standard Load,’ this will require connection of the
ControlWave EFM to a PC running Windows NT (4.0 or higher), Windows 2000 or Windows
XP Professional and equipped with ControlWave Designer software & OpenBSI software.
Configuration of the application load must be performed by an individual familiar with the
various programming tools. The following software user documentation is referenced:
Getting Started with ControlWave Designer Manual - D5085
ControlWave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Web_BSI Manual - D5087
An application load download can be initiated, i.e., from ControlWave Designer, or from the
OpenBSI 1131 Downloader for ControlWave EFM Nodes.
1. Make sure that the System Controller Module’s Mode Switch (SW1) is set in ‘Local Mode,’
i.e., SW1-1 set to the OPEN (Right) position and SW1-2 set to the CLOSED (Left)
position.
Note: From the factory, COM1 defaults to 115.2 Kbaud (RS-232) using the Internet
Point to Point Protocol (PPP). Don’t connect COM1 to a PC unless the PC’s
RS-232 port in question has been configured for PPP.

2. Once the ControlWave EFM project has been defined, communications and
configuration parameters have been set, perform the download according to either
‘ControlWave Designer’ (see D5088 - chapter 11) or ‘The Open BSI 1131 Downloader’
(see D5081 - Chapter 7).
3. After the download has been completed leave the System Controller Module’s Mode
Switch (SW1) in the ‘Local Mode’ position.

2.4.2 Upgrading ControlWave EFM Firmware
The ControlWave EFM CPU ships from the factory with system firmware already
installed. If an upgrade of the system firmware is required, use one of the procedures below
to download the new or replacement firmware from the PC.

CI-ControlWave EFM

Installation & Operation / 2-51

Upgrade of system firmware via LocalView FLASH Mode requires OpenBSI 5.1 (or newer).
If you have an older version of OpenBSI, FLASH upgrades are to be performed via
HyperTerminal. You will need a binary (*.BIN) system firmware file, and that file should
be defined in the Flash Master File (FLASH.MST). A sample Flash Master File is shown,
below:
cwe0420.bin

where cwe is the product code and 0420 is the release #

Upgrade of an unattended ControlWave EFM can be accomplished from a remote PC. This
capability is introduced in Section 2.4.2.3.
2.4.2.1 Using LocalView to Upgrade ControlWave EFM Firmware
NOTE
Your ControlWave EFM must be set to Recovery Mode ENABLE (ON) prior to performing
the FLASH upgrade, then set to Recovery Mode DISABLE (OFF) after the upgrade. On
ControlWave EFMs this is accomplished via the System Controller’s Mode Switch SW1.
Set both switches to the OPEN (Right) or CLOSED (Left) positions for Recovery Mode.
After setting the System Controller’s Switch SW1 for Recovery Mode, turn power OFF
and then ON again.

A null modem cable (see Figure 2-12) must be connected to COM1 of the ControlWave
EFM and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this
purpose must be set to run at 115.2 Kbaud. ControlWave EFM CPU Switch SW1, position,
3 must be set ON.
Start LocalView, Choose FLASH, Enter A Name, Click on [Create]
Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView. The
New View Mode dialog box will appear:

Figure 2-38 - Local View - New View Mode Menu
"Mode"
Choose 'Flash' for the mode.
"Name"
Enter a name for the View Mode File in the "Name" field.
"Location"
If you want to store the View Mode File in a directory other than that shown in the
"Location" field, enter the new location there, or use the [Browse] push button to find
the directory.
2-52 / Installation & Operation

CI-ControlWave EFM

When the "Mode", "Name", and "Location" have been specified, click on the [Create] push
button to activate the Communication Setup Wizard.
Step 1 - Communication Setup
Choose the communication port you want in the What port would you like to use: field.
Click on the [Next] pushbutton to activate the next wizard.

Figure 2-39 - Communication Setup: Step 1 Menu
Step 2 - Flash RTU Setup
In the Flash RTU Setup Wizard, you need not set the RTU type or local address, since these
are unused in this mode. Click on the [Next] push button to activate the Flash Data Setup
Wizard.

Figure 2-40 - Flash RTU Setup Menu
CI-ControlWave EFM

Installation & Operation / 2-53

Step 3 - Flash Data Setup
Complete the following fields in the Flash Data Setup Wizard:
"Please enter the name of the binary file to Flash"
To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file
on your hard disk containing the firmware.
Click on [Finish] to install the specified BIN file in FLASH memory at the RTU.

Figure 2-41 - Flash Data Setup Menu

Figure 2-42 - Local View Downloading System Firmware Menu
2-54 / Installation & Operation

CI-ControlWave EFM

Once the Flash download has begun, you will NOT be allowed to shut down LocalView,
unless you cancel the download, or it has been completed.
The progress of the Flash download will be displayed in the window. Any mismatch in file
versions, or if the type of .BIN file does not match the type of RTU, the download will be
aborted.
Once the download has completed, disable Recovery Mode by setting System Controller
Module switch SW1 as follows: SW1-1 set OPEN (Right) and SW1-2 set CLOSED
(Left).Switch Power OFF and then ON again.
2.4.2.2 Using HyperTerminal to Upgrade ControlWave EFM Firmware
A null modem cable (see Figure 2-12) must be connected to COM1 of the ControlWave
EFM and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this
purpose must be set to run at 115.2 Kbaud. ControlWave EFM CPU Switch SW1, position,
3 must be set to the ON position or the System Controller Module Mode Switch SW1 must
initially be set as follows: SW1-1 set OPEN (Right) and SW1-2 set to CLOSED (Left).
1. If not already running, apply power to the associated PC.
2. Start the HyperTerminal program on the PC. Note: HyperTerminal is a Windows 95 (or
newer) application utility program. If using HyperTerminal for the first time, set the
communications properties (for the PC Port being utilized) via the Properties Menu as
follows: Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop bits: = 1, and Flow
control: = None and then click OK.
3. Set the System Controller Module’s Mode Switch (SW1) for ‘Recovery Mode,’ i.e., both
switches in the OPEN (Right) or CLOSED (Left).position or set CPU Module Switch
SW1-3 ON.
4. Apply power to the ControlWave. The resident BIOS will initialize and test the
hardware, this process is referred to as POST (Power On Self Test).
Unless there is a problem status code 10 (LED #5 ON) will be posted to the SCM’s
Status LEDs. Detection of a fault during POST will be posted on the Status LEDs.
When the Power On Self Test has completed, a system status code will be posted to the
SCM’s Status LEDs (see Table 2-18 and Figure 2-47).
From the HyperTerminal Recovery Mode menu (Figure 2-43), press the ‘F’ key to enter
FLASH download. A message will be displayed warning that the FLASH is about to be
erased; press the ‘Y’ key at the prompt. The screen will display dots as the flash devices are
being erased; this could take a few minutes.
5. When the FLASH is ready for download the letter C will be displayed on the screen. In
the HyperTerminal command bar click on Transfer and then Send File…(see Figure 244). In the Send File Dialog Box (see Figure 2-45), select “1KXmodem” for the protocol,
enter the filename of the appropriate .bin file in the format “CWExxxxx.bin” (where
xxxxx varies from release to release). Click on the Send button to start the download
(see Figure 2-45). When the HyperTerminal Recovery Mode Menu of Figure 2-43
appears, the download has completed.

CI-ControlWave EFM

Installation & Operation / 2-55

6. Close the HyperTerminal program. The null modem cable connected between the
ControlWave EFM and the PC can be removed if desired.
7. Set the System Controller Module’s Mode Switch (SW1) for ‘Local Mode,’ i.e., SW1-1 in the
OPEN (Right) position and SW1-2 in the CLOSED (Left) position. Switch Power OFF
and then ON again. If CPU Module Switch SW1 was set for Recovery Mode, set SW1-3
OFF.

Figure 2-43 - HyperTerminal Recovery Mode Menu

Figure 2-44 - HyperTerminal FLASH Download Menu
(Ready to Download) - (Transfer/Send File Selected)

2-56 / Installation & Operation

CI-ControlWave EFM

Once the ControlWave EFM running its application load, status codes are posted to the
six Status LEDs on the PSSM. These Status LED (Hex) Codes are listed in Table 2-15 (see
Figure 2-47.

Figure 2-45 - HyperTerminal Flash Download
(Send File Dialog Box - Enter Filename)

Figure 2-46 - HyperTerminal FLASH Download (Download in Process)
CI-ControlWave EFM

Installation & Operation / 2-57

Table 2-18 - System Status LED Codes on System Controller Module
Status
In Hex
00
01
03
04
05
07
08
09
0A
0B
10
11
12
20
28
30
38
3B
3E
3F

LED

0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1

0
0
0
0
0
0
0
0
0
0
1
1
1
0
0
1
1
1
1
1

0
0
0
0
0
0
1
1
1
1
0
0
0
0
1
0
1
1
1
1

0
0
0
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
1
1

0
0
1
0
0
1
0
0
1
1
0
0
1
0
0
0
0
1
1
1

0
1
1
0
1
1
0
1
0
1
0
1
0
0
0
0
0
1
0
1

Indication
Definition
Application Running
Unit in Diagnostic Mode
Unit Running Diagnostics
Flash XSUM Error
Error Initializing Application Device
Flash Programming Error
Using Factory Defaults (flashed at start)
Battery Failure Detected (flashed at startup)
Currently Loading the Boot Project
System Initialization in Progress
Waiting in Recovery Mode
Error Testing SDRAM
Error Testing SRAM
Application Loaded
Stopped at a Break Point
No Application Loaded
Running with Break Points
Waiting for Power-down (after NMI)
Waiting for Updump to be Performed
Unit Crashed (Watchdog Disabled)

Figure 2-47 - SCM Status LED Hexi-decimal Codes
(See Table 2-18 for Definitions)
2.4.2.3 Remote Upgrade of ControlWave EFM Firmware
It is possible to download system firmware into an unattended remote ControlWave EFM.
This function can only be accomplished if CPU Board Switch SW2-6 (associated with the
unit in question) is set in the ON position (factory default). The procedure for performing a
remote download of system firmware is discussed in Appendix J of the Open BSI Utilities
Manual (document D5081). Note: Remote Upgrade of ControlWave EFM Firmware
requires Boot PROM version 4.7 or higher and System PROM version 4.7 or
higher.
2-58 / Installation & Operation

CI-ControlWave EFM

2.4.3 Operation of the Mode Switch
The System Controller’s Mode Switch (SW1) is a two position piano type DIP-Switch that
functions as follows:
Both switches set to the OPEN (Right) or CLOSED (Left) positions = Recovery Mode.
Recovery Mode is used for either a firmware upgrade (see Section 2.4.2) or a core updump
(see Section 3.6).
SW1-1 set to the OPEN (Right) position and SW1-2 set to the CLOSED (Left) position =
Local Mode. Local Mode should be selected for normal running operations.

2.4.4 Soft Switch Configuration and Communication Ports
Firmware defined soft switches that control many default settings for various system
operating parameters such as BSAP Local Address, EBSAP Group Number, four (4) communication port parameters, etc., can be viewed and, if desired, changed via ‘Configuration
Web Pages’ in Microsoft Internet Explorer via the Flash Configuration Utility. When
connecting the ControlWave EFM to the PC (local or network) for the first time you should
be aware of the communication port default parameter settings provided below (see Figures
2-8 through 2-13B). Note: Communication port factory defaults can be enabled anytime by
setting CPU Board Switch SW2-3 to the OFF position.
COM1: From the factory, RS-232 Communications Port COM1 defaults to 115.2 kbd (RS-232)
using the Internet Point to Point Protocol (PPP). Note: By setting CPU Switch SW2-8
OFF, the boot project will be prevented from running and the unit will be placed
into diagnostic mode. To test COM1 using the WINDIAG program, it must not
otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG
program. Connection to a PC requires the use of an RS-232 “Null Modem” cable (see
Figure 2-12).
COM2: From the factory, RS-232 Communications Port COM2 on the CPU Board defaults
to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol
operation. To test COM2 using the WINDIAG program, it must not otherwise be in
use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program.
COM3: RS-485 Communications Port COM3 on the CPU Board defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM3 using the WINDIAG program, it must not otherwise be in use. Note: CPU
Switch SW2-8 must be set OFF to run the WINDIAG program. In lieu of the use of
an RS-232 Port, an RS-485 cable (see Tables 2-4A & 2-5) can be connected between
COM3 and the PC’s RS-485 Port.
COM4: From the factory, RS-232 Communications Port COM4 on the first optional
Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop
bit, BSAP/ControlWave Designer protocol operation. To test COM4 using the
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must
be set OFF to run the WINDIAG program. When required, an RS-232 “Null Modem”
cable be connected between COM4 and the PC (typically COM1) (see Figure 2-12).
COM5: RS-485 Communications Port COM5 on the first optional Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ControlWave Designer protocol operation. To test COM5 using the
CI-ControlWave EFM

Installation & Operation / 2-59

WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must
be set OFF to run the WINDIAG program. In lieu of the use of an RS-232 Port, an
RS-485 cable (see Tables 2-4A & 2-5) can be connected between COM5 and the PC’s
RS-485 Port.
COM8: From the factory, RS-232 Communications Port COM8 on the second optional
Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop
bit, BSAP/ControlWave Designer protocol operation. To test COM8 using the
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must
be set OFF to run the WINDIAG program. When required, an RS-232 “Null Modem”
cable be connected between COM8 and the PC (typically COM1) (see Figure 2-12).
COM9 RS-485 Communications Port COM9 on the second optional Expansion
Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ControlWave Designer protocol operation. To test COM9 using the WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be
set OFF to run the WINDIAG program. In lieu of the use of an RS-232 Port, an RS485 cable (see Tables 2-4A & 2-5) can be connected between COM9 and the PC’s
RS-485 Port.

2.4.5 Optional Display/Keypad Assemblies
Two Display/Keypad Assemblies are offered; one with a dual-button Keypad (see Figure 248) and one with a 25-button Keypad (see Figure 2-49). Both Display/Keypad Assemblies
utilize identical 4 x 20 LCD Displays. Each Display/Keypad Assembly employs a unique
microcontroller based Display/Keypad Interface Assembly that drive the 4 x 20 LCD
Display and interfaces the Keypad. Interface to the ControlWave EFM is made via a cable
equipped with RJ-45 plugs. This cable connects to the RJ-45 Display Interface Jack (J2) on
the System Controller Module and the RJ-45 Jack (J1) on the Display/Keypad Assembly. A
potentiometer is provided on the Display/Keypad Sub-assembly to set the contrast of the
LCD Display.
Figure 2-48 provides mounting hardware information for the Dual-button Display/Keypad
Assembly. Operation of the Dual-button Display/Keypad Assembly is discussed in section
2.4.5.1.
Figure 2-49 provides mounting hardware information for the 25-button Display/Keypad
Assembly. Information on configuring the ‘Display Function Block’ (required to configure
the Display associated with the 25-button Display/Keypad Assembly) is provided in
ControlWave Designer’s On-Line Help.
Note: Operation of the 25-button Display/Keypad Assembly is discussed in Appendix E.

2-60 / Installation & Operation

CI-ControlWave EFM

Figure 2-48 - Dual-Button Display/Keypad Assembly Installation Drawing

CI-ControlWave EFM

Installation & Operation / 2-61

Figure 2-49 - 25-Button Display/Keypad Assembly Installation Drawing
2.4.5.1 Operation of the Dual-button Display/Keypad Assembly
The Display will have a timeout of 20 minutes. If there has been no keypad activity for this
time the display will “logout,” i.e., the display will be turned off and scrolling stopped until
a key press occurs. When a key press occurs after a timeout the display will return to the
opening screen.
2-62 / Installation & Operation

CI-ControlWave EFM

If a shorter timeout of the display is needed for power savings, another timeout may be
implemented. The processor connected to the display will control the timeout. When the
timeout occurs the display will be blanked, but communications between the ARM and
display processor will still occur. The display processor will ignore posting the messages to
the screen when in the low power mode. When a key is pressed the display processor will
return to displaying information to the display.
Displays are organized into screens as follows:
Opening Screen:

User defined strings

List Selection Screen:

List Name
List Number

The List Selection screen is entered from the main opening screen by pressing the right
arrow. Once here the operator can select which list is to be viewed. The operator can
traverse though different list numbers by pressing the down arrow key. When the list to be
scrolled is shown on the display, pressing the right arrow key will bring the operator to the
Display Element screen.
Display Element Screen:

Variable Name
Variable Name

The Display Element screen is entered from the list selection screen by pressing the right
arrow. Once here the operator can view the variables in the list. Once entered the first
element of the list is displayed and then next element will be displayed after the scroll
timeout occurs. The scrolling will continue displaying the next element in the list and then
wrapping around to the beginning of the list. The down arrow key will toggle the display
through hold and scroll mode. Pressing the right arrow key will bring the operator to the
list selection screen.
Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode.
In Automatic Mode a set of screens (based on the application load) are displayed. The
application programmer provides strings for the opening screen. From there the firmware is
responsible for displaying the screens and responding to key presses. Screens are fixed and
start off with an opening screen, which displays user information passed into the function
block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled
has been selected, the user can scroll through the list by pressing the down arrow key. List
elements will be displayed automatically, scrolling at a predetermined rate (determined by
iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing
the right arrow key again will cause the list to start scrolling again.
The essence of Automatic Mode is that the user can supply inputs into the function that
will determine which list can be displayed, but cannot change the menu or display. The
user is allowed to select a list and to start/stop scrolling.

CI-ControlWave EFM

Installation & Operation / 2-63

Manual Mode
In Manual Mode the programmer is responsible for creating each screen and displaying the
next desired screen, based on key inputs. The programmer has access to all lines of the
display and can provide any string that he/she desires to display. Special formats that must
be adhered to that allow the programmer to display what they want on the screen are
provided in the description of iaScrnSruct in the ACCOL 3 Display function block within
ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode
does not support reading Keypad keypresses. Note: Manual Mode operation requires
ControlWave Firmware 4.50 or newer.

2-64 / Installation & Operation

CI-ControlWave EFM

Section 3
SERVICE
3.1 SERVICE INTRODUCTION
This section provides general, diagnostic and test information for the ControlWave EFM.
The service procedures described herein will require the following equipment:
1. PC with null modem interface cable & Bristol’s WINDIAG Software
2. Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 3-9)
3. Loop-back plug, 9-pin female D-Sub (for RS-485) (see Figure 3-10)
The following test equipment can be used to test the Power Supply/Sequencer Module:
1. DMM (Digital Multimeter): 5-1/2 digit resolution
2. Variable DC Supply: Variable to 30Vdc @ 2.5A (with vernier adjustment)
When ControlWave EFM electronic flow meters are serviced on site, it is recommended
that any associated processes be closed down or placed under manual control. This
precaution will prevent any processes from accidentally running out of control when tests
are conducted.

Warning
Harmful electrical potentials may still be present at the field wiring terminals
even though the ControlWave EFM’s power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or perform any
wiring operations until all the associated supply sources are turned off and/or
disconnected.

Warning
Always turn off the any external supply sources used for externally powered
I/O circuits, before changing any modules.

3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES
This section provides information on accessing ControlWave EFM modules for testing, as
well as removal/replacement procedures.

3.2.1 Accessing Modules For Testing
Testing and replacement of ControlWave EFM modules should only be per-formed by
technically qualified persons. Familiarity with the disassembly and test procedures
described in this manual are required before starting. Any damage to the ControlWave
EFM resulting from improper handling or incorrect service procedures will not be covered
under the product warranty agreement. If these procedures cannot be performed properly,
the unit should be returned to Bristol (with prior authorization from Bristol Inc.) for factory
evaluation and repairs.
CI-ControlWave EFM

Service / 3-1

3.2.2 Removal/Replacement of the Bezel Assembly
Before I/O Modules can be removed, the Bezel Assembly, which covers them, must be
removed.
1. Grasp the sides of the Bezel Assembly and gently lift it up and then pull it out and
off its associated I/O Module Covers.
2. To replace the Bezel Assembly, first align the latches (left and right, top and bottom)
with the associated I/O Module Cover notches. Press the Bezel in so that its latches
can be captured by the notches, and slide it downward until it seats and is secured.

3.2.3 Removal/Replacement of the CPU Module
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Disconnect any CPU Module Communication Cables, making sure they are identified so they can be returned to their assigned Comm. Ports.
3. Press down on the Cover’s built-in top latch (with one hand) and up on the Cover’s
built-in bottom latch (with the other hand).
4. Carefully slide the CPU Module out of the front of the Housing. If binding occurs,
gently rock the module up and down to free it.
5. To replace a CPU Module, power must be off. Carefully align the CPU Module with
ControlWave EFM Slot 2 and insert the unit into the Housing. When the assembly
is fully seated, its cover should be latched to the Housing.
6. Replace any Comm. Cables and then apply power and test the unit.

3.2.4 Removal/Replacement of the System Controller Module
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Unplug the SCM’s modular connectors.
3. Press down on the Cover’s built-in top latch (with one hand) and up on the Cover’s
built-in bottom latch (with the other hand).
4. Carefully slide the SCM Module out of the front of the Housing. If binding occurs,
gently rock the module up and down to free it.
5. To replace the SCM Module, power must be off. Carefully align the SCM Module
with ControlWave EFM Slot 1 and insert the unit into the Housings. When the
assembly is fully seated, its cover should be latched to the Housing.
6. Replace Power and Watchdog cables and then apply power and test the unit.

3.2.5 Removal/Replacement of an I/O Module
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Remove the applicable Bezel Assembly (see Section 3.2.2).
3. Unplug local termination cable headers from I/O Module connectors TB1 and TB2 or
remote termination cables headers from connectors P3 and P4 and set the cables
aside. Make sure these cables are identified so they can be returned to their
assigned connectors.

3-2 / Service

CI-ControlWave EFM

4. Press down on the Cover’s built-in top latch (with one hand) and up on the Cover’s
built-in bottom latch (with the other hand).
5. Carefully slide the I/O Module out of the front of the Housing. If binding occurs,
gently rock the I/O Module up and down to free it.
6. To replace an I/O Module, power must be off. Carefully align the I/O Module with
the applicable I/O Slot and insert the unit into the Housing. When the assembly is
fully seated, its cover should be latched to the Housing.
7. Connect local termination cables to I/O Module connectors TB1 and TB2 or remote
termination cables to I/O Module connectors P3 and P4.
8. Apply power and test the unit.

3.2.6 Removal/Replacement of an Expansion Comm. Module
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Disconnect any Expansion Comm. Module Communication Cables, making sure they
are identified so they can be returned to their assigned Comm. Ports.
3. Press down on the Cover’s built-in top latch (with one hand) and up on the Cover’s
built-in bottom latch (with the other hand).
4. Carefully slide the Expansion Comm. Module out of the front of the Housing. If
binding occurs, gently rock the module up and down to free it.
5. To replace a Expansion Comm. Module, power must be off. Carefully align the Expansion Comm. Module with ControlWave EFM Slot 3 or 4 (as required) and insert
the unit into the Housing. When the assembly is fully seated, its cover should be
latched to the Housing.
6. Replace any Comm. Cables and then apply power and test the unit.

3.2.7 Removal/Replacement of a Rechargeable Lead-acid Battery
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Disconnect the power cables from the battery terminals (remove screw and nut on
each terminal).
3. Loosen the two 11/32” nuts on the ends of the Battery Clamp. Lift the Battery
Clamp and rotate it rearward.
4. Carefully lift up and remove the Rechargeable Lead-acid Battery.
5. To replace the Rechargeable Lead-acid Battery, align the unit such that the negative
battery terminal is oriented to the top and right as illustrated in Figure 3-1 and
place the battery into the Battery Mounting Bracket (Battery Clamp must be in the
released position. Note: Make sure the Lead-acid Battery is fully charged
before installing it.
6. Raise the Battery Clamp and rotate it forward until it can be lowered to secure the
Rechargeable Lead-acid Battery. Tighten the two 11/32” nuts on the ends of the
Battery Clamp.
7. Replace the power cables to the battery terminals (black/NEG, Red/POS).
8. Apply power (replace SCM Power Connector - TB1) and test the unit.

CI-ControlWave EFM

Service / 3-3

Figure 3-1 - Sealed Lead-acid Battery Mounting Diagram

3.2.8 Removal/Replacement of a Power Distribution Board
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Unplug wiring harnesses from Power Distribution Board connectors TB1 through
TB6 (make sure cables are identified for proper replacement).
3. Slide the Power Distribution Board toward the front of the unit and remove it from
its Snap Track Holder.
4. To replace a Power Distribution Board, slide it into its Snap Track Holder. Replace
wiring harness connectors TB1 through TB6.
5. Apply power (replace SCM Power Connector - TB1) and test the unit.
3-4 / Service

CI-ControlWave EFM

3.2.9 Removal/Replacement of a 21V Power Supply Board
1. If the ControlWave EFM is running, place any critical control processes under
manual control (as required).
2. Unplug wiring harnesses from 21V Power Supply Board connectors TB1 and TB2.
3. Slide the 21V Power Supply Board toward the front of the unit and remove it from
its Snap Track Holder.
4. To replace a 21V Power Supply Board, slide it into its Snap Track Holder. Replace
wiring harness connectors TB1 and TB2.
5. Apply power (if necessary) and test the unit.

3.2.10 Removal/Replacement of a Digital to Relay I/O Board
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Unplug wiring harnesses from Digital to Relay I/O Board connector J1.
3. Slide the Digital to Relay I/O Board toward the front of the unit and remove it from
its Snap Track Holder.
4. To replace a Digital to Relay I/O Board, slide it into its Snap Track Holder. Replace
wiring harness connector J1/P1.
5. Apply power (replace SCM Power Connector - TB1) and test the unit.

3.2.11 Removal/Replacement of an External Radio/Modem
1. If the ControlWave EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power to the System
Controller Module (SCM).
2. Remove the Sealed Lead-acid Battery (if present) (see Section 3.2.7).
3. Disconnect (unplug) all connectors (power and interface) from the Radio/Modem.
4. Remove the mounting screws from the bottom (inside) of the Battery Mounting
Bracket and remove the Radio/Modem (with Mounting Plate if present).
5. Replace the Radio/Modem in the reverse order from which it was removed.
6. Apply power (replace SCM Power Connector - TB1) and test the unit.

3.3 TROUBLESHOOTING TIPS
3.3.1 System Controller Module (SCM) Voltage Checks
One bulk power source can be connected to the SCM. SCM connector TB1 provides 3 input
terminal connections for bulk power (see Figure 3-2):
TB1-1 = (+VIN) (+4.5/4.9V to +16V dc for +6V supply) (+9.6/10.3V to +16V dc for +12V supply)
TB1-2 = (-VIN) (Supply Ground)
TB1-3 = Chassis Ground - CHASSIS (;)

Bulk supply voltages can be checked at TB1 using a voltmeter or multimeter. SCM’s are
factory configured for use with a nominal 6Vdc or 12Vdc bulk power supply. The maximum
and minimum input power switch-points can be tested with the use of a Variable dc Power
Supply connected between TB1-1 (+) and TB1-2 (-). By increasing the input voltage
(starting at less than +4.5Vdc or less than +9.6Vdc) for +6V or +12V units respectively, you
can determine the point at which the unit will turn on, i.e., the point at which the green
PWRGOOD LED on the SCM comes ON (Vt+). By decreasing the input voltage (starting at
CI-ControlWave EFM

Service / 3-5

+16Vdc), you can determine the point at which the unit turns off, i.e., the point at which the
PWRGOOD LED on the SCM goes OFF (Vt-). If the value of the bulk power supply’s +6Vdc
or +12Vdc output approaches the value of Vt+ or Vt- it should be replaced by a power
supply with the correct +6V or +12V output.

WATCHDOG LED
(Red)

CR27

JP5, JP6, JP7, JP8 & JP9
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

IDLE LED
(Red)

Staus LEDs
(Red)

CR26
CR25
CR24

JP6
JP7
1
1

JP5
JP8
1

JP9
1

SW1 = Mode Switch

J2
Display Intf.
Connector
TB1
Input Power
Connector

J2
RJ-45

TB2
RTD Interface
Connector
P2
MVT Interface
Connector

(+4.5/4.9Vdc to +16.0Vdc for +6V supply)

TB1-1 +VIN (+9.6/10.3Vdc to +16.0Vdc for +12V supply)
TB1-2 -VIN (Supply Ground)
TB1-3 Chassis Ground (CHASSIS)

Figure 3-2 - System Controller Module’s Component & LED Designations

3.3.2 LED Checks
All ControlWave EFM Modules contain light emitting diodes (LEDs) that provide
operational and diagnostic functions. A brief synopsis of the individual module LEDs is
provided as follows:
SCM:
CPUM:
ECOM1:
ECOM2:
AI/OM:
DI/OM:
HSCM:
MI/OM:

1 IDLE LED, 1 Watchdog LED, & 6 System Status LEDs
2 LEDs per Comm. Port = 6
2 LEDs per Comm. Port = 8
2 LEDs per Comm. Port = 8
None
1 LED per DI x 12 = 12 DI LEDs, 1 LED per DO x 4 = 4 DO LEDs
1 LED per HSC x 4 = 4 HSC LEDs
None

3-6 / Service

CI-ControlWave EFM

ControlWave EFM LED designations are provided in Table 3-1.
Table 3-1 - LED Assignment
LED
Name

Module
SCM *
SCM *
SCM
CPUM
CPUM
CPUM
CPUM
CPUM
CPUM
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2

IDLE
WD
6 STATUS
C1 RX (Comm 1)
C1 TX (Comm 1)
C2 RX (Comm 2)
C2 TX (Comm 2)
C3 RX (Comm 3)
C3 TX (Comm 3)
C1 RX (Comm 4)
C1 TX (Comm 4)
C2 RX (Comm 5)
C2 TX (Comm 5)
Radio RX (Comm 6)
Radio TX (Comm 6)
Modem RX (Comm 7)
Modem TX (Comm 7)
C1 RX (Comm 8)
C1 TX (Comm 8)
C2 RX (Comm 9)
C2 TX (Comm 9)
Radio RX (Comm 10)
Radio TX (Comm 10)
Modem RX (Comm 11)
Modem TX (Comm 11)
Input (12 LEDs)
DI/OM
(1 Per Point)
Output (4 LEDs)
DI/OM
(1 Per Point)
INPUT (4 LEDs)
HSCM
(1 Per Point)
* = see Figure 3-2

LED
Color
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red

Function
ON = Idle
ON = Watchdog Condition - OFF = Normal
See Table 3-2 & Figure 3-2
ON = RX Activity (Top-Left - see Fig. 3-4)
ON = TX Activity (Top-Right -see Fig. 3-4)
ON = RX Activity (Middle-Left - see Fig. 3-4)
ON = TX Activity (Middle-Right -see Fig. 3-4)
ON = RX Activity (Bottom-Left - see Fig. 3-4)
ON = TX Activity (Bottom-Right -see Fig. 3-4)
ON = RX Activity (Top-Left - see Fig. 3-6)
ON = TX Activity (Top-Right -see Fig. 3-6)
ON = RX Activity (2nd from Top-Left - see Fig. 3-6)
ON = TX Activity (2nd from Top-Right -see Fig. 3-6)
ON = RX Activity (3rd from Top-Left - see Fig. 3-6)
ON = TX Activity (3rd from Top-Right -see Fig. 3-6)
ON = RX Activity (Bottom-Left - see Fig. 3-6)
ON = TX Activity (Bottom-Right -see Fig. 3-6)
ON = RX Activity (Top-Left - see Fig. 3-6)
ON = TX Activity (Top-Right -see Fig. 3-6)
ON = RX Activity (2nd from Top-Left - see Fig. 3-6)
ON = TX Activity (2nd from Top-Right -see Fig. 3-6)
ON = RX Activity (3rd from Top-Left - see Fig. 3-6)
ON = TX Activity (3rd from Top-Right -see Fig. 3-6)
ON = RX Activity (Bottom-Left - see Fig. 3-6)
ON = TX Activity (Bottom-Right -see Fig. 3-6)
LED ON = Input is present
LED OFF = Input is not present (see Fig. 3-5)

Red

LED ON = Output is ON (see Fig. 3-5)

Red

LED ON = Input activity on input is present
LED OFF = No activity on input (see Fig. 3-5)

Table 3-2 - System Status LED Codes on System Controller Module
Status
(Hex)
00
01
03
04
05
07
08
09
0A
0B
10

LED
6
0
0
0
0
0
0
0
0
0
0
0

LED
5
0
0
0
0
0
0
0
0
0
0
1

CI-ControlWave EFM

LED
4
0
0
0
0
0
0
1
1
1
1
0

LED
3
0
0
0
1
1
1
0
0
0
0
0

LED
2
0
0
1
0
0
1
0
0
1
1
0

LED
1
0
1
1
0
1
1
0
1
0
1
0

Service / 3-7

Table 3-2 - System Status LED Codes on System Controller Module (Continued)
Status
(Hex)
11
12
20
28
30
38
3B
3E
3F

LED
6
0
0
1
1
1
1
1
1
1

LED
5
1
1
0
0
1
1
1
1
1

LED
4
0
0
0
1
0
1
1
1
1

LED
3
0
0
0
0
0
0
0
1
1

LED
2
0
1
0
0
0
0
1
1
1

LED
1
1
0
0
0
0
0
1
0
1

Indication
Definition
Error Testing SDRAM
Error Testing SRAM
Application Loaded
Stopped at a Break Point
No Application Loaded
Running with Break Points
Waiting for Power-down (after NMI)
Waiting for Updump to be Performed
Unit Crashed (Watchdog Disabled)

* = Flashed at startup

Figure 3-3 - System Controller Module Status LED Hexi-decimal Codes
(See Table 3-2 for Definitions)

3-8 / Service

CI-ControlWave EFM

Figure 3-4 - CPU Module Communication Connector and LED Designations

Figure 3-5 - ControlWave EFM Plus I/O Module LED Designations

CI-ControlWave EFM

Service / 3-9

Figure 3-6 - Expansion Comm. Module - Comm. Connector and LED Designations

3.3.3 Wiring/Signal Checks
Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check
wiring for continuity, shorts & opens. Check I/O signals at their respective Terminal Blocks
(see Table 3-3).
Table 3-3 - I/O Field Wiring - Terminal Block Reference List
I/O Subsystem
Digital I/O
Analog I/O
HSC Inputs
Mixed I/O

Figures
2-19
2-20
2-21
2-22

Notes
See Section 2.3.4.4
See Section 2.3.4.5
See Section 2.3.4.6
See Section 2.3.4.7

3.4 GENERAL SERVICE NOTES
Certain questions or situations frequently arise when servicing the ControlWave EFM.
Some items of interest are provided in Sections 3.4.1 through 3.4.4.

3-10 / Service

CI-ControlWave EFM

3.4.1 Extent of Field Repairs
Field repairs to a ControlWave EFM are strictly limited to the replacement of complete
modules. Component replacement on a ControlWave EFM Module constitutes tampering
and will violate the warranty. Defective ControlWave EFM Housings or Modules must be
returned to Bristol Inc. for authorized service.

3.4.2 Disconnecting RAM Battery
The ControlWave EFM’s Lithium RAM battery cannot be replaced while power is on.
Once the RAM battery has been replaced, the unit will still execute its FLASH-based
application load (Boot Project) upon power-up, but all of the current process data will have
been lost. Upon power-up, the unit will act as though it had just been booted and it will
revert back to the initial values specified in its application load. The battery may be
disabled by removing CPU Module Battery Backup Board Jumper, JP1.

3.4.3 Maintaining Backup Files
It is essential to maintain a backup disk of each application load file to guard against an
accidental loss of process configuration data. Without a backup record, it will be necessary
to reconfigure the entire application load; that can be a very time consuming procedure.
Always play it safe and keep backup copies of your operating system loads. A copy of the
application load can be loaded into ControlWave EFM FLASH memory and/or saved to a
PC’s Hard Drive as a ZIP file.

3.5 WINDIAG DIAGNOSTICS
Bristol’s WINDIAG Software is a diagnostic tool used for testing ControlWave EFM I/O
Modules, CPU memory, communications ports, etc., for proper performance.
The
ControlWave EFM must be communicating with a PC equipped with the WINDIAG
program. CPU Module configuration switch SW2-8 must be set to the OFF (Closed) position
to enable diagnostics. Communication between the ControlWave EFM (with/without
application loaded) and the PC can be made via a Local or Network Port with the following
restrictions:
•
•
•

CPU Board Switch SW2-8 must be OFF to run the WINDIAG program. Setting SW2-8
OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic
mode.
Any ControlWave EFM communication port can be connected to the PC (PEI) provided
their port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to
9600 bps operation).
Setting CPU Board Switches SW2-3 and SW2-8 OFF prevents the ‘Boot Project’ from
running, places the unit into diagnostic mode and forces communication ports COM1,
COM2, COM3, COM4, COM5, COM8 and COM9 to operate at 9600 baud.

COM1: From the factory, RS-232 Communications Port COM1 defaults to 115.2 kbd (RS232) using the Internet Point to Point Protocol (PPP). Note: Port COM1 will be
configured for RS-232 operation (at 9600 baud) by setting CPU Switches SW2-3
and SW2-8 OFF. This will prevent the boot project from running and places the
unit into diagnostic mode. To test COM1 using the WINDIAG program, it must not
otherwise be in use and CPU Switch SW2-8 must be set OFF. Connection to a PC
requires the use of an RS-232 “Null Modem” cable (see Figure 2-12).
CI-ControlWave EFM

Service / 3-11

COM2: From the factory, RS-232 Communications Port COM2 on the CPU Board defaults
to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol
operation. To test COM2 using the WINDIAG program, it must not otherwise be in
use and CPU Switch SW2-8 must be set OFF.
COM3: RS-485 Communications Port COM3 on the CPU Board defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM3 using the WINDIAG program, it must not otherwise be in use and CPU
Switch SW2-8 must be set OFF. In lieu of the use of an RS-232 Port, an RS-485
cable (see Tables 2-3 & 2-5) can be connected between COM3 and the PC’s RS-485
Port.
COM4: From the factory, RS-232 Communications Port COM4 on the first optional
Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop
bit, BSAP/ControlWave Designer protocol operation. To test COM4 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW2-8 must
be set OFF. When required, an RS-232 “Null Modem” cable be connected between
COM4 and the PC (typically COM1) (see Figure 2-12).
COM5: RS-485 Communications Port COM5 on the first optional Expansion
Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ControlWave Designer protocol operation. To test COM5 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW2-8 must
be set OFF. In lieu of the use of an RS-232 Port, an RS-485 cable (see Tables 2-3 &
2-4) can be connected between COM5 and the PC’s RS-485 Port.
COM8: From the factory, RS-232 Communications Port COM8 on the second optional
Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop
bit, BSAP/ControlWave Designer protocol operation. To test COM8 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW2-8 must
be set OFF. When required, an RS-232 “Null Modem” cable be connected between
COM8 and the PC (typically COM1) (see Figure 2-12).
COM9 RS-485 Communications Port COM9 on the second optional Expansion
Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ControlWave Designer protocol operation. To test COM9 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW2-8 must
be set OFF. In lieu of the use of an RS-232 Port, an RS-485 cable (see Tables 2-3 &
2-4) can be connected between COM9 and the PC’s RS-485 Port.
To use the WINDIAG program place any critical process (associated with the ControlWave EFM unit in question) under manual control. WINDIAG cannot be run while the
ControlWave EFM application is running. Set the CPU Modules Switch SW2-8 to the OFF
position. Perform steps 1 through 6 below.
1. Start the OpenBSI NetView Program. A menu similar to Figure 3-7 will appear.
2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI Tools,
then select Utilities Programs and then select Diagnostics.
3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 3-8 will
appear.

3-12 / Service

CI-ControlWave EFM

Figure 3-7 - Netview Startup Menu - Example with Multiple Networks

Figure 3-8 - WINDIAG Main Diagnostics Menu
CI-ControlWave EFM

Service / 3-13

4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG
will perform the diagnostics and display pass/fail results.
5. After all diagnostic testing has been performed, exit the WINDIAG program and then
exit the Netview Program if there aren’t any other ControlWave EFM units to be
tested.
When you close the Netview program you will be prompted as to whether or not you
want to close the OpenBSI program; select Yes.
6. Set the ControlWave EFM CPU Switch SW2-8 to the ON (Open) position. The
ControlWave EFM should resume normal operation.

3.5.1 Diagnostics Using WINDIAG
All ControlWave EFM Modules except the System Controller Module can be tested using
the WINDIAG program. From WINDIAG’s Main Diagnostics Menu (see Figure 3-8) the
following diagnostic tests can be performed:
CPU & Peripherals Diagnostic:
PROM/RAM Diagnostic:
Communications Diagnostic:
Analog Output Diagnostic:
Analog Input Diagnostic:
Discrete I/O Diagnostic:
High Speed Counter Diagnostic:

Checks the CPU Module (except for RAM & PROM).
Checks the CPU’s RAM and PROM hardware.
Checks Comm. Ports 1, 2, 3, 4, 5, 8 and 9 - The External
loop-back tests require the use of a loop-back plug.
Checks AOs on AI/O & Mixed I/O Modules.
Checks AIs on AI/O & Mixed I/O Modules.
Checks DIs or DOs on DI/O & Mixed I/O Modules.
Checks HSCs on HSC & Mixed I/O Modules.

3.5.1.1 Communications Diagnostic Port Loop-back Test
WINDIAG’s Communications Diagnostic Menu (see Figure 3-11) provides for selection of
the communication port to be tested. Depending on the type of network (RS-232 or RS-485)
and the port in question, a special loop-back plug is required as follows:
Ports 1, 2, 4 & 8 - RS-232 use a 9-pin female D-type loop-back plug (see Fig. 3-9).
Ports 3, 5 & 9 - RS-485 use a 9-pin female D-type loop-back plug (see Fig. 3-10).
This group of tests verifies the correct operation of the Communication Interface. COM1,
COM2, COM3, COM4, COM5, COM8 and COM9 can be tested with this diagnostic. The
ControlWave EFM communication port that is connected to the PC (local or network and
used for running these tests) can’t be tested until diagnostics has been established via one
of the other ports, i.e., to test all ControlWave EFM communication ports (via WINDIAG),
communications with the PC will have to be established twice (each time via a different
port). It should be noted that the ControlWave EFM communication port that is connected
to the PC (RS-232, RS-485 or Ethernet) must be good for WINDIAG to run the
Communications Diagnostics
3.5.1.2 Serial Comm. Port External Loop-back Test Procedure
Connect an external loop-back plug to the CPU Port to be tested, i.e., J3 of CPU for COM1,
J4 of CPU for COM2 2, J5 of CPU for COM3, J1 of ECOM1 for COM4, J2 of ECOM1 for
COM5, J1 of ECOM2 for COM8 or J2 of ECOM2 for COM9 (see Figures 3-9 through 3-11).

3-14 / Service

CI-ControlWave EFM

Figure 3-9 - RS-232 Loop-back Plugs

Figure 3-10 - RS-485 Loop-back Plugs

Figure 3-11 - WINDIAG’s Communications Diagnostic Menu
1. Type "1," "2," "3," or "4" for the port to test.
2. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5.
CI-ControlWave EFM

Service / 3-15

3. Click on RUN button next to External loop-back.

Test responses:
a) Success - All sections of test passed
b) Failure - TXD RXD Failure or CTS RTS Failure
Execution time < 5 sec.

3.6 CORE UPDUMP
In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for
evaluation by Bristol Inc. engineers. This upload is referred to as a ‘Core Updump.’ A Core
Updump may be required if the ControlWave EFM electronic flow meter repeatedly enters
a ‘Watchdog State’ thus ill effecting system operation. A Watchdog State is entered when
the system crashes, i.e., a CPU timeout occurs due to improper software operation, a
firmware glitch, etc. In some cases the Watchdog State may reoccur but may not be
logically reproduced.
‘Crash Blocks’ (a function of firmware provided for watchdog troubleshooting) are stored in
CPU RAM. The user can view and save the ‘Crash Blocks’ by viewing the Crash Block
Statistic Web Page (see Chapter 4 of the Open BSI Technician’s Toolkit - D5087). Crash
Block files should be forwarded to Bristol Inc. for evaluation. If additional information is
required to evaluate the condition, a Core Updump may be requested by Bristol. Once the
file generated by the Core Updump has been forwarded to Bristol it will be evaluated and
the results will be provided to the user.
Follow the five steps below to perform a Core Updump.
1. Set CPU Module Switch SW2-1 OFF (Disable Watchdog Timer). If SW2-4 is ON, set it to
OFF (Enable Core Updump). Note: The factory default setting for SW2-4 is OFF.
2. Wait for the error condition (typically 3F on SCM Status LEDs).
3. Connect ControlWave EFM Comm. Port 1 to a PC using a Null Modem Cable (see
Figures 2-12 and 2-13).
4. Set the System Controller’s Mode Switch (SW1) so that both switches are in the OPEN
(Right) position or the CLOSED (Left) position.
5. Start the PC’s HyperTerminal Program (at 115.2kbaud) and generate a file using the
1KX-Modem protocol. Save the resulting Core Updump in a file to be forwarded to
Bristol, Inc. for evaluation.
By setting CPU Module Switches SW2-1 OFF and SW2-4 OFF prior to the failure of a
ControlWave EFM, it will not recover but will wait for the Core Updump to be taken. Once
the Core Updump has completed, set the ControlWave EFM CPU Module’s switch SW2-1
ON (Watchdog Enabled) and SW2-4 OFF (Core Updump Enabled) and the SCM’s Mode
Switch positions SW1-1 OPEN (right) and SW1-2 CLOSED (Left), i.e., for Local Mode, if
required, and then power cycle the unit to recover and start running again.

3.7 CALIBRATION CHECKS
Calibration of the MVT and the RTD are performed using OpenBSI’s TechView Program
(see document # D5131 – TechView User’s Guide).
3-16 / Service

CI-ControlWave EFM

Section 4
SPECIFICATIONS
4.1 CPU, MEMORY & PROGRAM INTERFACE
Processor:

Sharp’s LH7A400 32-bit
ARM9TDMI RISC Core

System-on-Chip

with

32-bit

Memory:

8 Mbytes of simultaneous read/write FLASH
2 Mbyte of on-board SRAM
512 Kbytes FLASH Boot/Downloader

Real Time Clock:

A Semtech SH3000 support IC provides a full BCD clock
calender with programmable periodic/wakeup interrupt and
a programmable clock generator with adjustable spectrum
spreading.

Connectors:

(see Table 4-1 and referenced Tables)
Table 4-1 - CPU Board Connector Summary

Ref.
P1
P2
P3
J3
J4
J5
J2

# Pins
76-pin
36-pin
44-pin
9-pin
9-pin
9-pin
10-pin

Function
Factory Debug Connector
IOBUS Connector
SCM Connector
COM1 (RS-232) 9-pin male D-sub
COM2 (RS-232) 9-pin male D-sub
COM3 RJ-45 (RS-485)
PLD JTAG Header

Notes

see Figure 4-1 & Table 4-2
see Figure 4-1 & Table 4-2
see Figure 4-1 & Table 4-2
Not user accessible

4.2 COMMUNICATION PORTS
Connector/Port:

J3 - 9-Pin D-Type
J4 - 9-Pin D-Type
J5 - 9-Pin D-Type
J1 - 9-Pin D-Type
J2 - 9-Pin D-Type

- COM1 (RS-232) (on CPU Bd.)
- COM2 (RS-232) (on CPU Bd.)
- COM3 (RS-485) (on CPU Bd.)
- COM4 (RS-232) (on ECOM1 Bd.)
- COM5 (RS-485) (on ECOM1 Bd.)
- COM6 Radio (on ECOM1 Bd.)*
J8 - 6-Pin RJ-45 - COM7 PSTN Modem (on ECOM1 Bd.)*
J1 - 9-Pin D-Type - COM8 (RS-232) (on ECOM2 Bd.)
J2 - 9-Pin D-Type - COM9 (RS-485) (on ECOM2 Bd.)
- COM10 Radio (on ECOM2 Bd.)*
J8 - 6-Pin RJ-45 - COM11 PSTN Modem (on ECOM2)*
Note: * = available as an option

Baud Rate:

300 to 115Kbps for RS-232 or RS-485
Up to 56Kbps for Modem
Bottom of Enclosure (one or the other)
9-Pin D-Type - COM1 (RS-232)
3-Pin Circular - COM1 (RS-232)

CI-ControlWave EFM

Specifications / 4-1

Table 4-2 - RS-232 Ports (COM1/2/4/8 and RS-485 Ports COM3//5/9
Connector Pin Assignments
Pin
#
1
2
3
4
5
6
7
8
9

Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS

Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Signal/Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
N/A

Signal
RS-485
RXDTXDTXD+
ISOGND
RXD+

Description:
RS-485 Signals
N/A
Receive Data - Input
Transmit Data - Output
Transmit Data + Output
Isolated Ground
Receive Data + Input
N/A
N/A
N/A

Figure 4-1 - DB9 9-Pin Connector
Associated with COM1, COM2, COM3, COM4, COM5, COM8 & COM9

4.3 SYSTEM CONTROLLER MODULE
4.3.1 Input Power Specs.
Note: Voltages are dc unless otherwise specified.
Operating Range:

+4.5/4.9V to +16.0V (+6V Input Supply) (Shutdown occurs
at +4.72/4.33V nominal)
+9.6/10.3V to +16.0V (+12V Input Supply) (Shutdown
occurs at +10.29/9.56V nominal)

Output Voltages:

+3.3Vdc ±1%

Output Current:

1A Max. @ 3.3Vdc

Output Ripple P/P:

+3.3V Output: 10mV

Input Current:

With Supply Loading of 3.3V @ 1.0A
Vin @ +6V - Iin Max. TBDA
Vin @ +12V - Iin Max. TBDA

Fusing:

1A Slow Blow 5x20mm Fuse

Electrical Isolation:

None

Surge Suppression:

16V Transorb to DGND and Chassis
Meets ANSI/IEEE C37.90-1978

Terminations:

Pluggable, maximum wire size is 16 gauge

4-2 / Specifications

CI-ControlWave EFM

Shutdown:

+6V System:
Max. ON Switchpoint = 4.90V
Min. OFF Switchpoint = 4.33V
+12V System:
Max. ON Switchpoint = 10.3V
Min. OFF Switchpoint = 9.28V

4.3.2 Power Supply Sequencer Specs.
Signals Monitored:

Input Power

Sequencer Switchpoints:

+3.3V Max. ON Switchpoint = +3.15V
+3.3V Min. OFF Switchpoint = +3.00V
+1.8V Max. ON Switchpoint = +1.72V
+1.8V Min. OFF Switchpoint = +1.64V

Sequencer Output Signals: PFDLYCLK Timing on power down 2msec after POWERFAIL
VIN100M timing on power Up 1200msec delay for Good
Power
POWERGOOD incoming power, 3.3V & 1.8V in Spec.

4.3.3 Power Supply External Power Monitor Specs.
Input Signal:

Input power after fuse, before Diode

Input Range:

0Vdc to 16Vdc

Resolution:

17 Bit

Accuracy:

Uncalibrated: ±3% @ +25°C (+77°F)
Uncalibrated: ±4% over -40 to +85°C (-6.2 to +185°F)
Calibrated: ±0.1% @ +25°C (+77°F)
Calibrated: ±1.1% over -40 to +85°C (-6.2 to +185°F)

4.3.4 System Controller Module Connectors (see Figure 4-2, Tables 4-3 & 4-4)
Table 4-3 - System Controller Module Connector Summary
Ref.
P1
P2
TB1
TB2
J2

# Pins
44-pin
8-pin
3-pin
3-pin
8-pin

Function
Backplane Connector
MVT Interface Connector
Input Power Term. Block (see Table 4-4)
RTD Intf. Connector (see Section 2.3.5)
Display/Keypad Intf. Connector (RJ-45)

Table 4-4 - System Controller Module Input Power Terminal Block Assignments
TERM. #
TB1-1
TB1-2
TB1-3
CI-ControlWave EFM

NAME
+VIN
-VIN
CHASSIS

FUNCTION
+6Vdc or +12Vdc (nominal) Input
Supply Common
Chassis Ground
Specifications / 4-3

Figure 4-2 - SCM - TB1 (Power Connector)

4.4 INPUT/OUTPUT MODULE SPECIFICATIONS
4.4.1 Non-isolated Analog Input/Output Module
Non-isolated Analog Inputs
Number of Inputs:

6 Single Ended Inputs (1-5V or 4-20Ma) individually
jumper configurable

Input Type:

(Externally Powered) Voltage Input: 1-5 Vdc
(Externally Powered) Current Loop: 4-20mA

Input Impedance:

1 Meg ohm for 1-5V inputs
250 ohm for 4-20mA inputs

Non-isolated Analog Outputs
Number of Outputs:
4-20mA Output
Compliance:
1-5V Output:

2 AOs (1-5V or 4-20Ma) individually jumper configurable
250 ohm load with 11V External Power Source
650 ohm load with 24V External Power Source
5mA maximum output current into external load with
external voltage range of 11 to 30 Vdc

General AI/AO Module Specs.
Accuracy:

Analog Input
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
Analog Output
Current Output:
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -20ºC to +70ºC (-4ºF to 158ºF)
0.3% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
Voltage Output Compliance (Iloadmax = 5mA):
(see Note1 & Note2)
0.1% of Span + X @ +25ºC (+77ºF)
0.2% of Span + X @ -20ºC to +70ºC (-4ºF to +158ºF)
0.3% of Span + X @ -40ºC to +70ºC (-40ºF to 158ºF)
where X = [(2.5 ohms x Iload)/4.4V x 100]
Note1: Does not include error due to inductors

4-4 / Specifications

CI-ControlWave EFM

Note2: 2.5 ohm uncompensated series resistance with
Inductors

Terminations:

Pluggable - Max. wire size is 14 gauge

Data Transfer:

8 Bit Wide bus access

4.4.2 Non-isolated Digital Input/Output Module
Non-isolated Digital Inputs
Number of Inputs:

12 DI individually jumper configurable for 2mA or 60uA
Internally Sourced (Dry Contact) operation

Input Filtering:

15 milliseconds

Input Current:

Jumper configured for 2mA or 60uA nominal

‘0’ State Voltage:

below 1.5V

‘1’ State Voltage:

above 1.5V

Bus Access:

Eight Bits Wide

Electrical Isolation:

None

Surge Suppression:

31V Transorb between signal and ground
Meets ANSI/IEEE C37.90-1978

Status Indication:

12 LEDs (one per point)

Non-isolated Digital Outputs
Number of Outputs:

4 DO

Output Configuration:

Open Drain (Externally Powered)

Maximum Load Current:

100mA @ 31Vdc

Bus Access:

Eight Bits Wide

Electrical Isolation:

None

Surge Suppression:

31V Transorb between signal and ground
Meets ANSI/IEEE C37.90-1978

General DI/DO Module Specs.
Power Consumption:

CI-ControlWave EFM

Status LEDs Disabled
1.3mA @ 3.3Vdc: 12DIs OFF, CLK stopped
2.1mA @ 3.3Vdc: 12DIs ON @ 66uA, CLK stopped
25.3 @ 3.3Vdc: 12DIs ON @ 2mA, CLK stopped
3.6mA @ 3.3Vdc: 12DIs OFF, CLK active
Specifications / 4-5

4.4mA @ 3.3Vdc: 12 DIs ON @ 66uA, CLK active
27.6mA @ 3.3Vdc: 12 DIs ON @ 2mA, CLK active

Status LEDs Enabled
All DIs and DOs OFF: 33uA
All DIs and DOs ON: add 32mA
Terminations:

Pluggable, max wire size is 14 gauge for local terminations Two 14-pin mass termination headers are provided for
remote terminations

4.4.3 Non-isolated High Speed Counter Input Module
Number of Inputs:

4 HSC Inputs per Module

Input Configuration:

Internally Sourced Dry Contact, individually Jumper
selectable Debounce Circuitry and individually Jumper
selectable input current of 200uA or 2mA

Input Frequency:

10kHz Max.

Input filtering:

20 microseconds

Signal Conditioning:

Debounce circuit for contact closures and bandwidth
limiting

‘1’ State Voltage:
‘0’ State Voltage:

below 1.5V
above 1.5V

Bus Access:

Eight Bits Wide

Electrical isolation:

None

Surge Suppression:

31V Transorb between signal and ground
Meets ANSI/IEEE C37.90-1978

Terminations:

Pluggable, max wire size is 14 gauge for local terminations Two 14-pin mass termination headers are provided for
remote terminations

Status Indication:

4 LEDs (one per point)

Power Consumption:

3.9mA IOCLK stopped (All Inputs OFF)
6.8mA IOCLK running (All Inputs OFF)
Additional Current per Input
200uA or 2MA per HSCSET or HSCRST Input (ON State)
2mA per ON LED
33uA for LED circuitry

4.4.4 Non-isolated Mixed Input/Output Module
Number of I/Os:

4-6 / Specifications

6 jumper configurable DI/DOs per Module
4 Analog Inputs per Module
CI-ControlWave EFM

2 High Speed Counter Inputs per Module
1 Analog Output (optional) per Module
Terminations:

Pluggable - Max. wire size is 14 gauge

Power Consumption:

5mA Base Current @ 3.3V

Non-isolated Mixed I/O Module Digital Inputs/Outputs
Number of Points:

Up to 6 individually jumper configurable DI/O

Input Current:

Individually Jumper selectable input current of 60uA or
2mA

Input Configuration:

Internally Sourced Dry Contact

Input Filtering:

30 milliseconds

‘0’ State Voltage:

below 1.5V

‘1’ State Voltage:

above 1.5V

Bus Access:

Eight Bits Wide

Surge Suppression:

31V Transorb between signal and ground
Meets ANSI/IEEE C37.90-1978

Status Indication:

None

Output Configuration:

Open Drain (Externally Powered)

Max. DO Load Current:

100mA @ 31Vdc

Electrical Isolation:

None

Power Consumption:

Add: 66uA or 2mA for Each ON DI (Jumper Selectable per
Point)

Non-isolated Mixed I/O Module Analog Inputs
Number of Inputs:

4 Single Ended Inputs (1-5V or 4-20Ma) individually
jumper configurable

Input Type:

(Externally Powered) Voltage Input: 1-5 Vdc
(Externally Powered) Current Loop: 4-20mA
1 Meg ohm for 1-5V inputs
250 ohm for 4-20mA inputs

Input Impedance:
Accuracy:

0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)

Conversion Time:

20 microseconds

CI-ControlWave EFM

Specifications / 4-7

Power Consumption:

2.5mA + 1.145mA @ 4.66US/Channel Period, CLK active
180uA, CLK stopped

Non-isolated Mixed I/O Module Analog Output
Number of Outputs:
4-20mA Output
Compliance:

1 AO (1-5V or 4-20Ma) jumper configurable
250 ohm load with 11V External Power Source
650 ohm load with 24V External Power Source

1-5V Output:

5mA maximum output current into external load with
external voltage range of 11 to 30 Vdc

Accuracy:

Current Output:
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -20ºC to +70ºC (-4ºF to 158ºF)
0.3% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
Voltage Output Compliance (Iloadmax = 5mA):
(see Note1 & Note2)
0.1% of Span + X @ +25ºC (+77ºF)
0.2% of Span + X @ -20ºC to +70ºC (-4ºF to +158ºF)
0.3% of Span + X @ -40ºC to +70ºC (-40ºF to 158ºF)
where X = [(2.5 ohms x Iload)/4.4V x 100]
Note1: Does not include error due to inductors
Note2: 2.5 ohm uncompensated series resistance with
Inductors

Power Consumption:

System Power - 5.0mA from 3.3V source
External Power V to I (AO at 20mA each) - 24.3mA
External Power V to I (AO at 5V @ 0mA) – 4.2mA
External Power V to I (AO at 5V @ 5mA) - 9.2mA

Non-isolated Mixed I/O Module High Speed Counter Inputs
Number of Inputs:

2 HSC Inputs per Module

Input Configuration:

Internally Sourced Dry Contact, individually Jumper
selectable Debounce Circuitry and individually Jumper
selectable input current of 180uA or 2.2mA. HSC Circuitry
can be Jumper Enable/Disabled to save power

Input Frequency:

10kHz Max.

Input filtering:

20 microseconds

Signal Conditioning:

Debounce circuit for contact closures and bandwidth
limiting

‘1’ State Voltage:
‘0’ State Voltage:

below 1.5V
above 1.5V

Bus Access:

Eight Bits Wide

4-8 / Specifications

CI-ControlWave EFM

Electrical isolation:

None

Surge Suppression:

31V Transorb between signal and ground
Meets ANSI/IEEE C37.90-1978

Status Indication:

None

Power Consumption:

200uA or 2mA per HSCSET or HSCRST Input (ON State)
(Jumper Selectable per Point)
(Clock Power Disabled - Subtract 1.1mA @ 3.3V)

4.5 DIGITAL TO RELAY I/O BOARD SPECIFICATIONS
Digital to Relay I/O Board General Specs.
Terminations:

Pluggable - Max. wire size is 14 gauge

Digital to Relay I/O Board Input Requirements
Power Source Range:

3 to 15 Vdc

SSR Input Impedance:

400 Ohms

MOSFET Sink Current:

Max. = 20mA (both SSRs in Normally Closed mode)

Digital to Relay I/O Board Output Requirements
Contact Ratings:

3 to 60 Vdc

Maximum Current:

3 Amps at 25°C (77°F) or 1.5 Amps at 70°C (158°F)

Maximum ON State:

1.2Vdc

Minimum Current Load:

100mA

4.6 21V POWER SUPPLY BOARD SPECIFICATIONS
21V Power Supply Board General Specs.
Terminations:
ESD Susceptibility:

Pluggable - Max. wire size is 14 gauge
Field connected circuits meet the requirements of IEC 8012 for withstand capability up to 10KV.

EMI Compatibility:

Designed to coexist within a shielded enclosure with the
ControlWave EFM electronics. EMI radiation is insignificant and susceptibility is comparable or superior to
associated electronics.

Transient Susceptibility:

Field connected circuits meet the requirements of
ANSI/IEEEC37.90-1998 (Formerly IEEE 472) for surge
withstand capability.

CI-ControlWave EFM

Specifications / 4-9

Vibration:

1g for 10Hz to 500Hz per PMC-31-1 (without damage or
impairment)

21V Power Supply Board Performance Specifications
Input Voltage (Vin):

10.8V to 16V (dc)

Input Current (Iin):

100mA (Typ. @ 12V & 50mA load)
140mA (Max. over Temp. Range @ 50mA load)

Output Voltage (Vout):

21.4Vdc ±0.8V

Output Current (Iout):

50mA (Max.)

Ripple/Noise:

20mV (Max. P-to-P)

Efficiency:

88% (Typ.)

Fuses:

F1 = 500mA (Slow Blow): Protects host power source from
failures within the 21V Pwr.
Supply Bd.
F2 = 350mA(Fast Blow): Protects 21V Pwr. Supply Bd.
circuitry from short circuits on
an output.

4.7 ENVIRONMENTAL SPECIFICATIONS
-40 to +158 °F (-40 to +70 °C)
-40 to +158 °F (-40 to +70 °C)

Temperature:

Operating:
Storage:

Relative Humidity:

0-95% Non-condensing

Vibration:

2g for 10 - 150 Hz
1g for 150 - 2000 Hz

RFI Susceptibility:

In conformity with the following standards:
IEC 1000-4-3 (Level 2): 3V/meter - 80MHz to 1000MHz

ESD:

Field connected circuits meet the requirements of IEC
1000-4-2 for ESD withstand capability up to 4KV

4.8 DIMENSIONS
4-Slot Base Chassis:

see Figure 4-3

8-Slot Base Chassis:

see Figure 4-4

NEMA 3X Enclosure

see Figure 4-5

4-10 / Specifications

CI-ControlWave EFM

Figure 4-3 - 4-Slot ControlWave EFM
Base Chassis Assembly Dimensions

CI-ControlWave EFM

Specifications / 4-11

Figure 4-4 - 8-Slot ControlWave EFM
Base Chassis Assembly Dimensions

4-12 / Specifications

CI-ControlWave EFM

Figure 4-5 - ControlWave EFM NEMA 3X Enclosure Dimensions

CI-ControlWave EFM

Specifications / 4-13

BLANK PAGE

ControlWave EFM
Special Instructions for Class I, Division 2 Hazardous Locations
1.

6.
7.
8.
9.
10.
11.

12.

13.

Bristol, Inc.’s ControlWave EFM Electronic Flow Meter is listed by Underwriters Laboratories (UL) as
nonincendive and is suitable for use in Class I, Division 2, Group C and D hazardous locations or
nonhazardous locations only. Read this document carefully before installing a nonincendive
ControlWave EFM Electronic Flow Meter. Refer to the ControlWave EFMs Electronic Flow Meter
User's Manual for general information. In the event of a conflict between the ControlWave EFM
Electronic Flow Meter User's Manual and this document, always follow the instructions in this document.
The ControlWave EFM Electronic Flow Meter includes both nonincendive and unrated field circuits.
Unless a circuit is specifically identified in this document as nonincendive, the circuit is unrated. Unrated
circuits must be wired using Div. 2 wiring methods as specified in article 501-4(b) of the National
Electrical Code (NEC), NFPA 70 for installations in the United States, or as specified in Section 18-152 of
the Canadian Electrical Code for installation in Canada.
The local communications port terminates in a D-Type connector on the bottom of the ControlWave
EFM Electronic Flow Meter enclosure. The wiring on this connector is unrated. No connections may be
made to this port unless the user ensures that the area is known to be nonhazardous. Connections to this
port are temporary, and must be short in duration to ensure that flammable concentrations do not
accumulate while it is in use.
The optional power system (solar panel and battery) approved for use with the nonincendive ControlWave EFM Electronic Flow Meter are described in the Model Specification. The connection to the solar
panel is approved as a nonincendive circuit so that Division 2 wiring methods are not required. The
nominal panel voltage must match the nominal battery voltage (12V).
WARNING: EXPLOSION HAZARD - Do Not disconnect Solar Power from the Battery or any
other power connections within the ControlWave EFM Enclosure (including con-nectors TB1
through TB6 on the Power Distribution Board, connector TB1 on the System Controller
Module, any power connections to optional items such as radio, modem, Digital to Relay I/O
Board, 21V Power Supply Board, or cabling to the Display/Keypad unless the area is known to
be nonhazardous.
WARNING: EXPLOSION HAZARD - Substitution of major components may impair suitability
for use in Class I, Division 2 environments.
WARNING: EXPLOSION HAZARD - The area must be known to be nonhazardous before
servicing/replacing the unit and before installing or removing I/O wiring.
WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless power has been
disconnected and the area is known to be nonhazardous.
An RTD is normally supplied with the ControlWave EFM. Connection to the RTD is approved as a
nonincendive circuit, so that Division 2 wiring methods are not required.
Signal connectors available for customer wiring are listed in Table A1. I/O Connections are unrated and
must be wired using Div. 2 wiring methods.
The UL listed nonincendive ControlWave EFM may include radio/modem communications (listed on
Model Spec.) that is used in conjunction with a 30W Solar Panel and 12V, 33AH Lead Acid Battery
System. Connection to the radio or modem is approved as a nonincendive circuit, so that Division 2 wiring
methods are not required.
The UL Listed nonincendive ControlWave EFM may include a Digital To Relay I/O Board (option). No
field wiring connections/removals should be made at the Digital To Relay I/O Board unless the area is
known to be nonhazardous. Digital To Relay I/O Board I/O circuitry is unrated and must be wired using
Div. 2 wiring methods.
The UL Listed nonincendive ControlWave EFM may include a 21V Power Supply Board (option). No
field wiring connections/removals should be made at the 21V Power Supply Board unless the area is
known to be nonhazardous. 21V Power Supply Board Transmitter Interface circuitry is unrated and must
be wired using Div. 2 wiring methods.

Table A1 -Module/Board Connector Customer Wiring Connectors
Module/Item

Connector

CPU Module

J3 - COM1, 9-pin Male D-sub

CPU Module

J4 - COM2, 9-pin Male D-sub
RS-232
J5 - COM3, 9-pin Male D-sub
RS-485

SCM Module
SCM Module

J2 - Display Intf. RJ-45 Female
P2 - MVT Intf.

10/06/2006

Wiring Notes

Factory Connected to Local Comm. Port. Refer
to ¶ 3 of this document.
Remote Comm. Port: For Radio or external
Network Comm. Refer to Model Spec. and ¶ 10
of this document. When used for Network
Comm., use Div. 2 wiring methods. If COM2 is
used in conjunction with a radio/modem refer
to 11 of this document.
Factory Wired - *
Factory Wired - *

Appendix A, Document CI-ControlWave EFM

Page 1 of 2

ControlWave EFM
Special Instructions for Class I, Division 2 Hazardous Locations
Table A1 -Module/Board Connector Customer Wiring Connectors (Continued)
Module/Item

Connector

SCM Module
SCM Module
Exp. Comm Module 1

TB1 - Input Power
TB2 - RTD Interface
J4 - COM4, 9-pin Male D-sub
RS-232
J5 - COM5, 9-pin Male D-sub
RS-485

Exp. Comm Module 1
Exp. Comm Module 2

J8 - COM7, RJ11 Female
J4 - COM8, 9-pin Male D-sub
RS-232
J5 - COM9, 9-pin Male D-sub
RS-485

Exp. Comm Module 2

J8 - COM11, RJ11 Female

Analog I/O Module

TB1/TB2 - 10-pin Term. Blocks

Digital I/O Module

TB1/TB2 - 10-pin Term. Blocks

HSC Input Module

TB1/TB2 - 10-pin Term. Blocks

Mixed I/O Module

TB1/TB2 - 10-pin Term. Blocks

Digital To Relay I/O Bd.

J1 10-pin In-line Connector

Power Distribution Bd.
(see ¶ 5 - this document)

TB1 - 3-pin Term Block
TB2 - 2-pin Term Block
TB3 - 2-pin Term Block
TB4 - 2-pin Term Block
TB5 - 2-pin Term Block
TB6 - 2-pin Term Block
TB1 - 3-pin Term Block
TB2 - 4-pin Term Block

21V Power Supply Bd.
(see ¶ 5 & 13 of
this document)
Enclosure Bottom

Local Port Circular Connector

Wiring Notes

Typically Factory Wired - *
Field Wired - Refer to ¶ 9 of this document.
Remote Comm. Port: For Radio or external
Network Comm. Refer to Model Spec. and ¶ 10
of this document. When used for Network
Comm., use Div. 2 wiring methods. If COM4 is
used in conjunction with a radio/modem refer
to 11 of this document.
Modular connection to Phone Co. equipment.
Remote Comm. Port: For Radio or external
Network Comm. Refer to Model Spec. and ¶ 10
of this document. When used for Network
Comm., use Div. 2 wiring methods. If COM8 is
used in conjunction with a radio/modem refer
to 11 of this Document.
Modular connection to Phone Co. equipment.
Refer to ¶ 6, 7, 8 & 11of this document.
Field I/O wiring connectors are unrated; use
Div. 2 wiring methods. *
Field I/O wiring connectors are unrated; use
Div. 2 wiring methods. *
Field Input wiring connectors are unrated;
use Div. 2 wiring methods. *
Field I/O wiring connectors are unrated; use
Div. 2 wiring methods. *
Field I/O wiring connector is unrated, use Div.
2 wiring methods. Refer to ¶ 12 of this
document. *
Primary Power Input - User wired *
Main Power Out 1 - Factory wired *
Main Power Out 2 - Factory wired *
Fused Power Out 1 - Factory wired *
Fused Power Out 2 - Factory wired *
Fused Power Out 3 - Factory wired *
12V Power Input - Factory wired *
21V Transmitter Power -Field Wired
TB2 is unrated, use Div. 2 wiring methods.
Local Comm. Port - Factory Wired. Refer to ¶
3 of this document. *

Note: * = These wires should only be installed/removed when the item (PCB) in question is
installed/removed or when checking wiring continuity. The area must be known to be
nonhazardous before servicing/replacing the unit and before installing or removing PCBs,
Connectors or individual I/O or Power wires. Refer to ¶ 6, 7 & 8 of this document. All input
power and I/O wiring must be performed 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.

10/06/2006

Appendix A, Document CI-ControlWave EFM

Page 2 of 2

Appendix C
HARDWARE INSTALLATION GUIDE
Hardware Configuration
There are seven (7) main steps required to configure a ControlWave EFM. This appendix
provides an overview of these steps with an emphasis on the installation and configuration
of the hardware. This appendix is intended for users who have already installed at least one
ControlWave EFM.
Step 1. Hardware Configuration
This involves unpacking the ControlWave EFM hardware, mounting the chassis, installing I/O modules, wiring I/O terminations, making proper ground connections, connecting a
communication cable to the PC workstation and setting switches. To install and configure
the ControlWave EFM, follow Hardware Configuration steps 1 through 11 below:
1. Remove the unit from its carton and install it at the assigned work site (see Section
2.3.1). Dimensions are provided in Section 4.6 of this manual.

Figure C-1A - ControlWave EFM - Base Assembly Chassis
SCM & CPUM Installed in Slots #1 & #2 (Respectively)
CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-1

Figure C-1B - 8-Slot ControlWave EFM (Internal View)
SCM & CPUM Installed in Slots #1 & #2 (Respectively) of Base Assembly
C-2 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Step 1. Hardware Configuration (Continued)
2. Remove the System Controller Module (SCM) and after configuring its configuration
jumpers, install it in chassis slot 1, i.e., the first slot from the left end of the Base
Assembly Chassis (see Section 2.3.2).

WATCHDOG LED
(Red)

CR27

JP5, JP6, JP7, JP8 & JP9
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System

IDLE LED
(Red)

Staus LEDs
(Red)

CR26
CR25
CR24

JP6
JP7
1
1

JP5
JP8
1

JP9
1

SW1 = Mode Switch

J2
Display Intf.
Connector

J2
RJ-45

TB1
Input Power
Connector

TB2
RTD Interface
Connector
P2
MVT Interface
Connector

Bulk Supply #1 Pos. Term.
Bulk Supply #1 Neg. Term.
Chassis Ground

(+4.5/4.9Vdc to +16.0Vdc for +6V supply)

TB1-1 +VIN (+9.6/10.3Vdc to +16.0Vdc for +12V supply)
TB1-2 -VIN (Supply Ground)
TB1-3 Chassis Ground (CHASSIS)

1 +VIN

-VIN
3 CHASSIS

Figure C-2 - SCM Component Identification and TB1 Wiring Diagram
3. Remove the CPU Module. Make sure that the Lithium Backup Battery has been
enabled, i.e., Backup Battery Board Jumper JP1 should be installed (on its jumper
posts). After configuring the CPU Module’s DIP-Switches (see Section 2.3.3), install it
into ControlWave EFM Base Assembly, chassis slot 2, i.e., the second slot from the left
end of the Base Assembly Chassis. Tables C-1, C-2 and C-3 provide an overview of
switch settings (see Tables C-1, C-2, C-3 and Figure C-3).
CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-3

Table C-1 - CPU Bd. Switch SW1 - Force Recovery Mode/Battery Enable
Switch

Function
Setting - (OFF = Factory Default)
Force Recovery
ON = Force recovery mode (via CW Console)
SW1-3
Mode
OFF = Recovery mode disabled
Note: SCM Switch SW1 can also be used for Force Recovery Mode operation

Table C-2 - CPU Bd. Switch SW2 - User Configurations
Note: Except for SW2-4, ON = Factory Default
Switch

Function

Setting - (ON = Factory Default)
ON = Watchdog circuit is enabled
SW2-1
Watchdog Enable
OFF = Watchdog circuit is disabled
Lock/Unlock
ON = Write to Soft Switches and FLASH files
SW2-2
Soft Switches
OFF = Soft Switches, configurations and FLASH files are locked
Use/Ignore
ON = Use Soft Switches (configured in FLASH)
SW2-3
Soft Switches
OFF = Ignore Soft Switch Configuration and use factory defaults
Core Updump
ON = Core Updump Disabled
SW2-4
See Section 3.6
OFF = Core Updump via Mode Switch (SW1) on SCM
ON = Retain values in SRAM during restarts
SW2-5
SRAM Control
OFF = Force system to reinitialize SRAM
System Firmware ON = Enable remote download of System Firmware
SW2-6
Load Control *
OFF = Disable remote download of System Firmware
Enable
ON = Normal Operation (don’t allow WINDIAG to run test)
SW2-8
WINDIAG
OFF = Disable boot project (allow WINDIAG to run test)
* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher

Table C-3 provides CPU Switch SW3 (COM3) and ECOM Switch SW1 COM5/9 RS-485
communication port settings.
Table C-3 - CPU Bd. Switch SW3 for COM3 & ECOM Bd. Switch SW1 for COM5/9
Loopback & Termination Control
Switch
RS-485 Function
#
Switch ON
1
TX+ to RX+ Loopback
2
TX- to RX- Loopback
3
100 Ohm RX+ Termination
4
100 Ohm RX- Termination
5
N/A
6
Slow Slew Rate
(see note
ISO485 ONLY
2)
7
RX+ Bias (End Node)
8
RX- Bias (End Node)
Note 1: Closed = Switch set ON
Note 2: Switch SW3 (COM3) = N/A

Setting
ON - Only for Diagnostics
ON - Only for Diagnostics
ON - End Nodes Only
ON - End Nodes Only
ON - Slew Rate Enabled
ON - Slow Rate Enabled
OFF - Fast Rate Enabled
ON - End Nodes Only
ON - End Nodes Only

Step 1. Hardware Configuration (Continued)
4. Configure/Connect appropriate communication port(s) (see Sections 2.3.3.2). Connect
COMM. Port 1 or 2 of the ControlWave EFM (depending on CPU Switch SW1 settings
- see Tables C-2 & C-3) to a Communication Port of a PC (typically PC COMM. Port 1).
Note: Also see Section 2.4.4.

C-4 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

A ControlWave EFM can be configured as a Master or Slave node on either a
MODBUS network or a BSAP network. Up to three communication ports are contained
on the ControlWave EFM CPU Module and are designated as follows:
CPU Module:
COM1 - Port 1:
COM2 - Port 2:
COM3 - Port 3:

CPU Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J4, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J5, PC/AT 9-Pin Male D-Sub - RS-485 - Supported by SW3

Figure C-3 - CPU Module Component Identification Drawing
CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-5

Expansion Communications Module:
COM4, COM5, COM6 & COM7 on 1st ECOM Bd., - assigned to Base Housing Slot #3
COM8, COM9, COM10 and COM11 on 2nd ECOM Bd., assigned to Base Housing Slot #4
COM4/8 - Port 1: ECOM Bd. J1, PC/AT 9-Pin Male D-Sub - Both RS-232
COM5/9 - Port 2: ECOM Bd. J2, PC/AT 9-Pin Male D-Sub - Both RS-485
COM6/10 - Port 3: ECOM Bd. Piggy-back Radio Module (FreeWave or MDS TransNet
Spread Spectrum Modem) Antenna connector provided (Optional)
COM7/11 - Port 4: ECOM Bd. Piggy-back Modem Module (Multitech 56KB PL/PSTN
Modem) RJ-11 connector provided (Optional)
Communication Ports COM1, COM2, COM3, COM4, COM5, COM8 and COM9 support
serial asynchronous operation. Communication Ports COM1, COM2, COM4 and COM5
support RS-232 while COM3, COM5 and COM9 support RS-485 operation. Communication Ports COM4/8, COM5/9, COM6/10 and COM7/11 reside on optional
Expansion Communications Modules (ECOM1/2). ECOM1 must reside in Base Chassis
Backplane Slot #3 while ECOM2 must reside in Base Chassis Backplane Slot #4. ECOM
Modules have one RS-232 Port and one RS-485 Port. Additionally, an ECOM Module
may optionally contain a 56Kbaud PSTN Modem and/or a Spread Spectrum Modem
(Radio). Any communication port can be configured for local communications, i.e.,
connected to a PC loaded with ControlWave Designer and OpenBSI software. The pin
labels for the 9-pin, RS-232/485 interface are provided in Table C-4.
Table C-4 - RS-232 Ports COM1/2/4/8 and RS-485 Ports COM3/5/9
Connector Pin Assignments
Pin Signal
Description:
#
RS-232
RS-232 Signals
1
DCD
Data Carrier Detect Input
2
RXD
Receive Data Input
3
TXD
Transmit Data Output
4
DTR
Data Terminal Ready Output
5
GND
Signal/Power Ground
6
DSR
Data Set Ready Input
7
RTS
Request To Send Output
8
CTS
Clear To Send Input
9
N/A
* ISOGND on Isolated RS-485 Ports Only!

Signal
RS-485
RXDTXDTXD+
GND/ISOGND*
RXD+

Description:
RS-485 Signals
N/A
Receive Data - Input
Transmit Data - Output
Transmit Data + Output
Ground/Isolated Ground*
Receive Data + Input
N/A
N/A
N/A

Remove any Expansion Communication Module and configure its Jumpers as required
(see Figures C-4A & C-4B). Install each Expansion Comm. Modules into the appropriate
ControlWave EFM Base Housing Communication I/O Slot. Expansion Comm. Modules
may reside in ControlWave EFM Base Housing Slots #3 and #4 ONLY (1st ECOM
resides in Slot #3, 2nd ECOM resides in Slot #4). Expansion Comm. Modules may not
reside in Expansion Housings.
Spread Spectrum Modem Port
An optional Spread Spectrum Modem (Radio) is available on each Expansion Communications Module (mounted piggy-back) and is assigned port status as follows: COM6 for
ECOM1 and COM10 for ECOM2. There are two unique radios offered. These radios will
only communicate with their own brand of radio, i.e., FreeWave radios are not compatible
with MDS radios. DTE/DCE serial data can be clocked into (transmit) or out of (receive) the
radio at a rate up to 115.2kHz.

C-6 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Radios are user installed onto the ECOM Module (see Figure C-4A) and their associated
Ports are setup during installation in the Ports Page of the Flash Configuration Utility. The
Flash Configuration Utility is accessed via NetView or LocalView.
FreeWave® Spread Spectrum Wireless Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).

Figure C-4A - ECOM Module Component Identification Diagram #1
CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-7

Figure C-4B - ECOM Module Component Identification Diagram #2
Microwave Data System Inc. MDS TransNET OEM™ Spread Spectrum Data Transceiver:
Operates in the 902 to 928 MHz range (20 miles).
Installation steps below support user installation and configuration of a Spread Spectrum
Modem.
•

Mount the radio (Spread Spectrum Modem) onto the Expansion Comm. Module. Remove
the nut and washer from the internal coaxial RF cable supplied with the ECOM Module.
Remove the plug from the front of the ECOM Cover and insert the in-ternal coaxial RF
cable’s SMA connector (straight end with flat area on top) through the rear of the
ECOM Cover. Install the washer and nut to secure the internal coaxial RF cable to the
front of the ECOM Cover. Install the other end of the internal coaxial RF cable to the
radio’s RF antenna connector. Install the Expansion Comm. Module into Slot 3 or 4 of a
base ControlWave EFM. Install the user supplied coaxial RF cable between the ECOM
Cover’s SMA connector and the remote antenna.

C-8 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Figure C-5 - Communication Port RS-232 Cable Wiring Diagram
CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-9

•

For FreeWave Radio:
Follow the Tuning Transceiver Performance” section of the FreeWave Technologies Inc.
FreeWave Spread Spectrum Wireless Data Transceiver User Manual to configure the
radio.
For MDS Radio:
Refer to section 3.3 “Initial Power-Up & Configuration” within the MDS TransNet OEM
Integration Guide and if necessary for more information on connecting a PC terminal
and preparing it for use, refer to section 9.0 “PROGRAMMING REFERENCE.”
Note:
To invoke the setup program, connect the radio (via ECOM1 port COM4 or
ECOM2 port COM8) to a terminal program (such as HyperTerminal) via a null
modem cable (see Figure C-5A), put the radio into setup mode and set the
parameters for the terminal to those of Table C-5 below. The setup program is
invoked by connecting Pins 2 and 3 of ECOM Bd. Jumper Post JP2 via a
Suitcase Jumper.
Table C-5 - Radio Setup Menu Terminal Settings
PARAMETERS
Baud Rate
Data Rate
Parity
Stop Bits
Parity Check
Carrier Detect
Flow Control

SETTINGS
19,200
8
None
1
None/Off
None/Off
Xon/Xoff

56K PSTN Modem Port
An optional 56K PSTN Hayes type Modem can be mounted piggy-back on each Expansion
Communications Module and is assigned port status as follows: COM7 for ECOM1 and
COM11 for ECOM2. The Model MT5634SMI Modem module is manufactured by MultiTech
System and can be user configured for PSTN operation. DTE/DCE serial data can be
clocked into (transmit) or out of (receive) the modem at a rate up to 115.2kHz.
Modems are supplied in kit form with all the hardware required for user installation onto
an Expansion Communications Module. Figure C-4 shows the modem mounted on the
Expansion Comm. Module. Modems are user installed onto the ECOM Module and their
associated Ports are setup during installation in the Ports Page of the Flash Configuration
Utility. The Flash Configuration Utility is accessed via NetView or LocalView.
A Terminal Emulation program such as HyperTerminal is used to profile the modem via AT
commands. Users typically use AT commands only when checking the modem’s active or
stored profile or when reconfiguring a modem, e.g., to turn auto answer on or off, etc.
Step 1. Hardware Configuration (Continued)
5. Remove and configure each I/O Module for its intended application. After configuration,
install them into the ControlWave EFM Base Assembly Chassis. I/O Modules may
reside in a ControlWave EFM Chassis as follows:

C-10 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Base Housings - Slots 3 & 4 (in lieu of Expansion Comm. Modules) & Slots 5 through 8
Expansion Housings - Any Slot
Install I/O wiring to each I/O Module (see Figures C-6 through C-10). Install a
communications cable between the ControlWave EFM and a Model 3808 Transmitter
(Network of Transmitters) if required (see Figures C-11 & C-12).

Figure C-6 - Non-Isolated DI/O Module Configuration Diagram

CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-11

Figure C-7 - Non-isolated AI/O Module Configuration Diagram
C-12 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Figure C-8 - Non Isolated HSC Module Configuration Diagram
Step 1. Hardware Configuration (Continued)
6. Install a ground wire between the Chassis Ground Lug and a known good Earth Ground
(also see Supplement Guide S1400CW).
ControlWave EFM Housings are provided with a Ground Lug that accommodates up to
a #4 AWG wire size. A ground wire must be run between the Chassis Ground Lug and a
known good Earth Ground. The cases of the various ControlWave EFM Modules are
CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-13

connected to Chassis Ground when they have been installed and secured via their two
Captured Panel Fasteners. As an extra added precaution, it is recommended that a #14
AWG wire be run from SCM Power Connector TB1-3 (Chassis Ground) to the same
known good Earth Ground. The following considerations are provided for the
installation of ControlWave EFM system grounds.

Figure C-9 - Non-isolated Mixed I/O Module Configuration Diagram

C-14 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Figure C-10 - Non-isolated Mixed I/O Module Wiring Diagram
(see Figure C-9 for Mixed I/O Module Configuration Diagram)
•

Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is
recommended that stranded copper wire is used and that the length should be as
short as possible.

•

This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).

CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-15

•

The wire ends should be tinned with solder prior to insertion into the Chassis
Ground Lug. Note: Use a high wattage Soldering Iron.

•

The ground wire should be run such that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above ground

Step 1. Hardware Configuration (Continued)
7. Install the Bezel/Bezels so that the I/O Modules are covered.
8. Install RTD (wiring and Probe) (see Section 2.3.5 of this manual).
9. Install the Rechargeable Lead Acid Battery and Solar Panel (if provided) (see Sections
2.3.9.3 and 2.3.9.4.
10. Connect DC Power wiring to the ControlWave EFM’s SCM Module (see Section 2.3.9,
2.3.9.1 and 2.3.9.2 and Figure C-2).
SCM Connector TB1 provides 3 input connections for bulk power as follows:
TB1-1 =
TB1-2 =
TB1-3 =

(+VIN) (+4.5/4.9V to +16.0V dc for +6V) (+9.6/10.3V to +16.0V dc for +12V)
(-VIN) (Supply Ground)
Chassis Ground - CHASSIS (;)

11. Apply power to the ControlWave EFM. Continue with Steps 2 through 6 below and
Section 2.4.1, and the ControlWave EFM will be ready for on line operation.

Figure C-11
Model 3808 Transmitter to ControlWave EFM Comm. Cables

C-16 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Figure C-12 - ControlWaveEFM to 3808s - RS-485 Network Diagram
Step 2. Software Installation on the PC Workstation
ControlWave Designer software will have to be installed on the PC if the ControlWave
EFM is to be utilized in an application other than that supported by the standard load.
This is accomplished by installing the ControlWave Designer Package from the Open
BSI CD ROM.
You must install the Open BSI Network Edition. For information on minimum system
requirements and more details of the installation, see the installation procedure in Chapter
2 of the Open BSI Utilities Manual (document # D5081).
If you have an older version of ControlWave Designer already installed:
Beginning with ControlWave Designer Version 3.3, the copy protection key (dongle) is
NOT required. Prior to installing ControlWave Designer 3.3 or newer, you MUST remove
the hardware dongle from the parallel port of your PC workstation. Otherwise, when you
subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will
limit the available system resources.
IMPORTANT:
When you start ControlWave Designer, you will be reminded to register the
software. Unregistered software can only be used for a maximum of 30 days. For
more information on the registration process, see Chapter 2 of the Open BSI
Utilities Manual (document# D5081).

CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-17

Either open the supplied Flash Configuration Profile (FCP) file and modify it, directly in
the Flash Configuration Utility, or in a text editor,

•

Or retrieve existing Flash Parameters directly from the unit, and edit them in the Flash
Configuration Utility.

Detailed information on the Flash Configuration Utility and LocalView is included in
Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in
Chapter 6 of that same manual.
Step 4. Modification of the Application-Specific Control Strategy (OPTIONAL)
ControlWave EFM electronic flow meters are shipped with the EFM program already
loaded. However, you can create your own application-specific control strategy using
ControlWave Designer. This involves opening a new project using the ‘CWMicro’ template,
defining I/O points using the I/O Configurator, and creating a program using one or more of
the five supported IEC 61131 languages (FBD, ST, SFC, LD, or IL). Some of these
languages are text based, others are graphical diagrams. The choice is up to you, depending
upon your particular application.
The ControlWave MICRO Quick Setup Guide (document # D5124) includes a simple LD
example. Additional examples are included in the manual, Getting Started with
ControlWave Designer (document # D5085). More detailed information about
ControlWave Designer and IEC 61131 is included in the ControlWave Designer Reference
Manual (document # D5088).
The ACCOL3 Firmware Library, which is automatically accessible through the template
referenced above, includes a series of function blocks which perform a variety of process
control and communication functions. These can be included within your program to perform various duties including PID control, alarming, calculations, etc. Detailed information
about each function block is included in the ControlWave Designer on-line help files.
On the variables declaration page(s) in ControlWave Designer, you will need to mark any
variable you want to make accessible to external programs, such as Open BSI’s DataView
utility, as “PDD”. Similarly, any variables which should be collected into a database, or
exported using the OLE for Process Control (OPC) Server must be marked as “OPC.”
Variables marked as OPC can be built into a text file by the OpenBSI Signal Extractor.
The text file can then be used in the creation of a database for human machine interface
(HMI) software such as OpenEnterprise or Iconics’ Genesis. These HMI software packages
require that the "Datatype conversion enable" option be selected when generating the
file using Signal Extractor. Information about the OpenBSI Signal Extractor is included in
Chapter 12 of the Open BSI Utilities Manual (document # D5081).

C-18 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Once the program has been created, it is assigned to an executable task. The entire project
is then saved and compiled.
NOTE: From this point on, the order of steps may be varied, somewhat,
depending upon the requirements of the user's application. If you modify the
standard EFM program, you may need to modify the standard web pages
associated with it. (See Step 5, below).
Step 5. Use Standard Web Pages Provided to Select Options in the Standard
Control Strategy
The ControlWave EFM has a standard set of web pages for configuration purposes (stored
on a PC) that let you enter parameters, and configuration options for the standard EFC
program (see Step 4, above). If you modify the standard EFM program, you may need to
modify the standard web pages. If you create your own application program (instead of
using the standard one), you may create your own web pages using Bristol ActiveX controls
discussed in the Web_BSI Manual (document # D5087).
You can use whichever HTML creation package you want to create the pages, however, all
ControlWave EFM related web pages (whether standard or user-created) must be viewed
within Microsoft® Internet Explorer. Web pages are stored on a PC workstation.
Step 6. Create an Open BSI Network Containing the ControlWave EFM, or ADD
the ControlWave EFM to an Existing Open BSI Network
In order for the ControlWave EFM unit to function as part of a Bristol network, it is
necessary to include it in the Bristol network.
If no Bristol network exists:
You need to run Open BSI’s NetView software on the PC workstation in order to define
a Bristol network. A series of software wizards are used to define a Network Host PC, a
network, and the RTUs (controllers) assigned to the network. Finally, communication
lines must be specified which handle the address assigned to the ControlWave EFM.
Chapters 3 and 4 of the Open BSI Utilities Manual (document # D5081) include ‘quick
start’ examples for performing these steps. More detailed information is included in the
NetView chapter (Chapter 6) of D5081.
If a Bristol network already exists:
You will need to add the ControlWave EFM to the existing network using Net-View’s
RTU Wizard. Chapter 6 of the Open BSI Utilities Manual (document # D5081) includes
different sub-sections depending upon whether you are adding the unit to a BSAP
network, or an IP network.
Step 7. If applicable, download new or modified control strategy (OPTIONAL)
If you modified the standard EFM program, or substituted your own program, compile and
download the new or modified program into the unit, using either ControlWave Designer, or
the Open BSI 1131 Downloader. In this case, you download the control strategy into the
BOOT project area of FLASH memory; this ensures that if the ControlWave EFM is reset,
or if there has been a failure of the backup battery, the control strategy can be restarted
from the beginning, i.e. from the BOOT project in FLASH memory. To download the project,
see Downloading the Application Load.

CI-ControlWave EFM

Appendix C - Hardware Installation Guide / C-19

Downloading the Application Load
Any ControlWave EFM must have a configured application load before it can be placed into
operation. For units not shipped with the ‘Standard Load,’ this will require connection of the
ControlWave EFM to a PC running Windows NT (4.0 or higher), Windows 2000 or Windows
XP Professional and equipped with ControlWave Designer software & OpenBSI software.
Configuration of the application load must be performed by an individual familiar with the
various programming tools. The following software user documentation is referenced:
Getting Started with ControlWave Designer Manual - D5085
ControlWave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Web_BSI Manual - D5087
An application load download can be initiated, i.e., from ControlWave Designer, or from the
OpenBSI 1131 Downloader for ControlWave EFM Nodes.
1. Make sure that the System Controller Module’s Mode Switch (SW1) is set in ‘Local Mode,’
i.e., SW1-1 set to the OPEN (Right) position and SW1-2 set to the CLOSED (Left)
position.
Note: From the factory, COM1 defaults to 115.2 kbd (RS-232) using the Internet Point to Point Protocol (PPP). Don’t connect COM1 to a PC unless
the PC’s RS-232 port in question has been configured for PPP.
2. Once the ControlWave EFM project has been defined, communications and configuration parameters have been set, perform the download according to either
‘ControlWave Designer’ (see D5088 - chapter 11) or ‘The Open BSI 1131 Downloader’
(see D5081 - Chapter 7).
3. After the download has been completed leave the System Controller Module’s Mode
Switch (SW1) in the ‘Local Mode’ position.

LED Checks
All ControlWave EFM Modules contain light emitting diodes (LEDs) that provide
operational and diagnostic functions. ControlWave EFM LED designations and functions
are provided in Table C-6. A brief synopsis of the individual module LEDs is provided as
follows:
SCM:
CPUM:
ECOM1:
ECOM2:
AI/OM:
DI/O:
HSC:
MI/OM:

C-20 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Table C-6 - LED Assignments
Module

LED
Name

SCM *
SCM *
SCM
CPUM
CPUM
CPUM
CPUM
CPUM
CPUM
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM1
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2
ECOM2

CI-ControlWave EFM

LED
Color
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red
Red

Function
ON = Idle
ON = Watchdog Condition - OFF = Normal
See Figure C-13
ON = RX Activity (Top-Left - see Fig C-3)
ON = TX Activity (Top-Right -see Fig C-3)
ON = RX Activity (Middle-Left - see Fig C-3)
ON = TX Activity (Middle-Right -see Fig C-3)
ON = RX Activity (Bottom-Left - see Fig C-3)
ON = TX Activity (Bottom-Right -see Fig C-3)
ON = RX Activity (Top-Left - see Fig C-4)
ON = TX Activity (Top-Right -see Fig C-4)
ON = RX Activity (2nd from Top-Left - see Fig C-4)
ON = TX Activity (2nd from Top-Right -see Fig C-4)
ON = RX Activity (3rd from Top-Left - see Fig C-4)
ON = TX Activity (3rd from Top-Right -see Fig C-4)
ON = RX Activity (Bottom-Left - see Fig C-4)
ON = TX Activity (Bottom-Right -see Fig C-4)
ON = RX Activity (Top-Left - see Fig C-4)
ON = TX Activity (Top-Right -see Fig C-4)
ON = RX Activity (2nd from Top-Left - see Fig C-4)
ON = TX Activity (2nd from Top-Right -see Fig C-4)
ON = RX Activity (3rd from Top-Left - see Fig C-4)
ON = TX Activity (3rd from Top-Right -see Fig C-4)
ON = RX Activity (Bottom-Left - see Fig C-4)
ON = TX Activity (Bottom-Right -see Fig C-4)
LED ON = Input is present
LED OFF = Input is not present (see Fig C-6)

Red

LED ON = Output is ON (see Fig C-6)

Red

LED ON = Input activity on input is present
LED OFF = No activity on input (see Fig C-8)

Appendix C - Hardware Installation Guide / C-21

Figure C-13 - SCM Status LED Hexi-decimal Codes

C-22 / Appendix C - Hardware Installation Guide

CI-ControlWave EFM

Appendix D
ECOM MODULE RADIO/MODEM
INSTALLATION GUIDE
D1.1 RADIO INSTALLATION & CONFIGURATION
D1.1.1 Installing an Internal FreeWave Radio (FGR09CSU)
FreeWave Radio Model GR09SCU is provided (for user installation) in a kit consisting of
the following components:
•
•
•
•
•

2-56 x .188” Pan Head Screw (Qty. 3) - Fig. D2 Reference = 1
2-56 x .250” F/F Standoff (Qty. 3) - Fig. D2 Reference = 2
2-56 x .250” Pan Head Screw (Qty. 3) - Fig. D2 Reference = 3
FreeWave Radio Cable (with Nut and Washer) - Fig. D2 Reference = 4
FreeWave Radio Module - Fig. D2 Reference = 5

To install a Model FGR09SCU Radio onto an Expansion Communication Module, perform
the following nine (9) steps:
1. Remove the Expansion Comm. Module from the unit in question (see Figure D1).
2. Grasp the Expansion Comm. Module with one hand. Squeeze both sides of the Cover
Panel (just below the unit’s top) and pull up and away to release the Cover Panel and
EMI Gasket from the PCB (see Figure D2). Note: If necessary, a small screwdriver can
be used to pry the Cover Panel from the PCB.

3. Install the three (3), F/F Standoffs (item2) to the rear of the FreeWave Radio via three
(3), 2-56 x .250” Pan Head Screws (item 3) (through the PCB).
4. Mount the FreeWave Radio to the Exp. Comm. Module making sure that the interface
connectors (J12 on Exp. Comm. Module) align. Secure the FreeWave Radio to the Exp.
Comm. Module via three (3), 2-56 x .188” Pan Head Screws (item 1).
5. Plug the radio end of the Antenna Cable (item 4) into the FreeWave Radio’s RF
Connector.
6. If installing an optional MultiTech Model MT5634SMI Modem, proceed to Section D2.1
prior to installing the Antenna Cable to the Cover Panel; if not, install the antenna end
of the Antenna Cable (item 4) through the EMI Gasket and Cover Panel. Secure the
Antenna Cable to the Cover Panel via the Antenna Cable’s washer and nut.
7. Remove Expansion Comm. Module Jumper JP1 and place it in storage, i.e., plugged
onto pin 1 or 2.
8. Snap the Cover Panel onto the Expansion Comm. Module PCB and insert the ECOM
Module into the appropriate Backplane Slot, i.e., Slot 3 or 4.
9. Apply power and test the unit.

CI-CW MICRO/CW EFM

Appendix D - Radio/Modem Installation Guide / D-1

Figure D1 – Expansion Comm. Module Component Identification Diagram

D1.1.2 Configuring the FreeWave Radio (FGR09CSU)
To configure a Model FGR09SCU Radio (installed on an Expansion Communication
Module), perform the following eight (8) steps:
1. If required, remove the Exp. Comm. Module from the unit in question (see Figure. D1).
2. Place the radio into configuration ode by setting Expansion Comm. Module Jumper JP2
onto pins 1 and 2. This will enable configuration of the radio through Comm. Port 4 for
radio on Comm. Port 6 (ECOM1) or through COMM. Port 8 for radio on Comm. Port 10
(ECOM2).
3. Connect a Full Duplex ControlWave Null Modem Cable (see Figure D3) between a PC
and Comm. Port 4 (ECOM1) to configure radio on COMM. Port 6 (ECOM1) or Comm.
Port 8 (ECOM2) to configure radio on COMM. Port 10 (ECOM2).
D-2 / Appendix D - Radio/Modem Installation Guide

CI-CW MICRO/CW EFM

Figure D2 - FreeWave Radio Installation Diagram
CI-CW MICRO/CW EFM

Appendix D - Radio/Modem Installation Guide / D-3

4. Open Hyperterminal on the PC and set the PC communication port settings as follows:
Bits per second:
Data bits:
Parity:
Stop bit:
Parity Check:
Carrier Detect:
Flow Control:

19200
8
None
1
None/Off
None/Off
Xon/Xoff

5. Cycle power to the ControlWave MICRO/ControlWave EFM. The FreeWave
configuration menu will appear in Hyperterminal.
6. In the configuration menu, set the radio as a multipoint slave. Go to the edit book and
type in the serial number of the Master Radio to which you want to communicate. Make
sure the Baud Rate matches that of the Master Radio. Once settings have been
implemented, press the Esc Key to exit the configuration menu.
7. Set Expansion Comm. Module Configuration Jumper JP2 into a storage position, i.e.,
parked (no connection).
8. Using Hyperterminal at the Master Radio, inter configuration mode and set the radio as
a multipoint master. Using the edit book (in configuration mode) make sure that no
serial number is set. Verify that the baud rate matches that of the Slave Radio.

PC
9-Pin Female
“D” Connector

CW u/CW EFM
9-Pin Female
“D” Connector

P2
5 = GND
4 = DTR

8 = CTS

3 = TXD
7 = RTS
2 = RXD
6 = DSR
1 = DCD

To P2 Pin-5
To P2 Pin-6

(Looking into
Wire Terminal Side
of
Cable Connectors)

To P2 Pin-2
To P2 Pin-1
To P2 Pin-3
To P2 Pin-4
To P2 Pin-7

or
vice
versa

1 = DCD
6 = DSR
2 = RXD
7 = RTS
3 = TXD
8 = CTS
4 = DTR
5 = GND

Figure D3 - (Internal Radio/Modem Configuration) BBI P/N 392843-01-3
Full-duplex Null Modem Cable Diagram

D1.1.3 Installing an Internal MDS Transnet OEM Radio
MDS Transnet OEM Radio is provided (for user installation) in a kit consisting of the
following components:
•
•
•
•
•
•

6-32 x .188” Pan Head Screw (Qty. 4) - Fig. D4 Reference = 1
6-32 x .313” F/F Standoff (Qty. 4) - Fig. D4 Reference = 2
6-32 x .250” Pan Head Screw (Qty. 4) - Fig. D4 Reference = 3
MDS Transnet Radio Cable (with Nut and Washer- Fig. D4 Reference = 4
Swaged Standoff (Qty 4) - Built into CPU/System Controller Bd. - Fig. D3 Reference = E
MDS Transnet Radio Module - Fig. D5 Reference = 5

D-4 / Appendix D - Radio/Modem Installation Guide

CI-CW MICRO/CW EFM

NOTE:
ECOM Module Comm. Ports
4/8 (RS-232)
are wired the same as
CPU Module Comm. Ports

OPTION
Populated
by
Order

If In Slot #3
Comm. Port
Assignments
If In Slot #4

1
J11

2
2
1
3

1
5
2
2

4/8

3
3
4

MDS Transnet Radio Kit Parts

6/10
Cover Panel

EMI Gasket

1 = 6-32 x .188” Pan Head Screw (Nylon) (Qty. 4)
2 = 6-32 x .313” F/F Standoff (Nylon) (Qty. 4)
3 = 6-32 x .250” Pan Head Screw (Qty. 4)
4 = MDS Transnet Radio Cable (with Nut and Washer)
5 = MDS Transnet Radio Module
Exp Comm. Module’s
MDS Transnet Radio
Connector J11

MDS
Transnet
Radio
module
3

JP2
1
1

JP1
JP4

Figure D4 - MDS Transnet OEM Radio Installation Diagram

CI-CW MICRO/CW EFM

Appendix D - Radio/Modem Installation Guide / D-5

To install a MDS Transnet OEM Radio onto an Expansion Comm. Module, perform the
following nine (9) steps (referring to Figure D-4):
1. Remove the Expansion Comm. Module from the unit in question (see Figure D1).
2. Grasp the Expansion Comm. Module with one hand. Squeeze both sides of the Cover
Panel (just below the unit’s top) and pull up and away to release the Cover Panel and
EMI Gasket from the PCB (see Figure D2). Note: If necessary, a small screwdriver can
be used to pry the Cover Panel from the PCB.

3. Install the four (4), F/F Standoffs (item2) to the rear of the MDS Transnet Radio via
four (4), 6-32 x .250” Pan Head Screws (item 3) (through the PCB).
4. Mount the MDS Transnet Radio to the Exp. Comm. Module making sure that the
interface connectors (J11 on Exp. Comm. Module) align. Secure the MDS Transnet Radio
to the Exp. Comm. Module via four (4), 6-32 x .188” Pan Head Screws (item 1).
5. Plug the radio end of the Antenna Cable (item 4) into the MDS Transnet Radio’s RF
Connector.
6. If installing an optional MultiTech Model MT5634SMI Modem, proceed to Section D2.1
prior to installing the Antenna Cable to the Cover Panel; if not, install the antenna end
of the Antenna Cable (item 4) through the EMI Gasket and Cover Panel. Secure the
Antenna Cable to the Cover Panel via the Antenna Cable’s washer and nut.
7. Make sure that Expansion Comm. Module Jumper JP1 is installed, i.e., plugged into the
jumper pins.
8. Snap the Cover Panel onto the Expansion Comm. Module PCB and insert the ECOM
Module into the appropriate Backplane Slot, i.e., Slot 3 or 4.
9. Apply power and test the unit.

D1.1.4 MDS Transnet OEM Radio Configuration Guidelines
To configure a MDS Transnet OEM Radio (installed on an Expansion Comm. Module),
perform the following seven (7) steps:
1. Place the radio into configuration mode by placing Expansion Comm. Module Jumper
JP2 onto pins 1 and 2. This will enable configuration of the radio through Comm. Port 4
for radio on Comm. Port 6 (ECOM1) or through COMM. Port 8 for radio on Comm. Port
10 (ECOM2).
2. Connect a Full Duplex ControlWave Null Modem Cable (see Figure D3) between a PC
and Comm. Port 4 (ECOM1) to configure radio on COMM. Port 6 (ECOM1) or Comm.
Port 8 (ECOM2) to configure radio on COMM. Port 10 (ECOM2).
3. Open HyperTerminal on the PC and set the PC communication port settings as follows:
Bits per second:
Data bits:
Parity:
Stop bit:

19200
8
None
1

D-6 / Appendix D - Radio/Modem Installation Guide

CI-CW MICRO/CW EFM

Parity Check:
Carrier Detect:
Flow Control:

None/Off
None/Off
Xon/Xoff

4. Cycle power to the ControlWave MICRO/ControlWave EFM. After hitting the escape
(Esc) key and then the carriage return twice (at approximately half second intervals),
the right arrow (>) will appear.
5. In the configuration menu, set the radio mode using either the MODE M (master) or
MODE R (remote) command. Note: There can be only one Master radio per
network. Go to the edit book and type in the serial number of the network’s Master
Radio. Set a unique Network Address (1 - 65000) using the ADDR command. Note: All
radios on the network must have the same Network Address. Make sure the Baud
Rate of any Remote Radio matches that of the Master Radio. Set the radio’s data
interface parameters (bps: 1200 – 114200 bps), Data Bits: (8). Parity (N), Stop bits: (1).
Once settings have been implemented, press the Esc Key to exit the configuration menu.
6. Set Expansion Comm. Module Configuration Jumper JP2 into a storage position, i.e.,
parked (no connection).
7. Apply power and test the unit.

D2.1 MODEM INSTALLATION & CONFIGURATION
D2.1.1 Installing an Internal MultiTech Modem (MT5634SMI)
MultiTech Modem Model MT5634SMI is provided (for user installation) in a kit consisting
of the following components:
•
•

Nylon Support Post
MultiTech Modem Module

To install a Model MT5634SMI Modem onto an Expansion Communication Module,
perform the following seven (7) steps:
1. Remove the Expansion Comm. Module from the unit in question (see Figure D1).
2. Unplug the Antenna Cable from the RF Connector on any installed Radio Module.
Grasp the Expansion Comm. Module with one hand. Squeeze both sides of the Cover
Panel (just below the unit’s top) and pull up and away to release the Cover Panel and
EMI Gasket from the PCB (see Figure D4). Note: If necessary, a small screwdriver can
be used to pry the Cover Panel from the PCB.

3. Install the Nylon Support Post onto the Expansion Comm. Module.
4. Mount the MultiTech Modem to the Exp. Comm. Module making sure that the interface
connectors (J6, J7, J9 & J10 on Exp. Comm. Module) align.
5. Plug the Antenna Cable(s) (if present - removed in Step 2) into the appropriate RF
Connector of an installed Radio Module(s).

CI-CW MICRO/CW EFM

Appendix D - Radio/Modem Installation Guide / D-7

Figure D5 - MultiTech Modem Installation Diagram
D-8 / Appendix D - Radio/Modem Installation Guide

CI-CW MICRO/CW EFM

6. Snap the Cover Panel onto the Expansion Comm. Module PCB and insert the ECOM
Module into the appropriate Backplane Slot, i.e., Slot 3 or 4.
7. Apply power and test the unit.

D2.1.2 Configuring the MultiTech Modem (MT5634SMI)
To configure a Model MT5634SMI Modem (installed on an Expansion Communication
Module), perform the following nine (9) steps:
1. If required, remove the Exp. Comm. Module from the unit in question (see Figure D1).
2. Place the modem into configuration mode by setting Expansion Comm. Module Jumper
JP2 onto pins 2 and 3. This will enable configuration of the modem through Comm. Port
4 for modem on ECOM1 or through COMM. Port 8 for modem on ECOM2.
3. Connect a Full Duplex ControlWave Null Modem Cable (see Figure D3) between a PC
and Comm. Port 4 (ECOM1) to configure modem on ECOM1 or Comm. Port 8 (ECOM2)
to configure modem on ECOM2.
4. Open Hyperterminal on the PC and set the PC communication port settings as follows:
Bits per second:
Data bits:
Parity:
Stop bit:
Flow Control:

9600
8
None
1
None

5. Send Factory Default = AT&F0.
6. Disable Flow Control = AT&K0.
7. Set baud rate using AT Command: AT$SB9600, or whatever baud rate you require.
8. Write to memory = AT&W.
9. Set Expansion Comm. Module Configuration Jumper JP2 into a storage position, i.e.,
parked (no connection).

CI-CW MICRO/CW EFM

Appendix D - Radio/Modem Installation Guide / D-9

BLANK PAGE

Instruction Manual
CI-ControlWave EFM & CI-ControlWave MICRO
Oct., 2006

ControlWave EFM & MICRO

ControlWave EFM/MICRO
DISPLAY/KEYPAD ASSEMBLY - GUIDE
Appendix E

www.EmersonProcess.com/Bristol

APPENDIX E

ControlWave MICRO/EFM
Display/Keypad Assembly Guide
TABLE OF CONTENTS
SECTION

TITLE

E1.1
E2.1
E2.1.1
E3.1
E4.1
E4.1.1
E4.1.2
E4.1.3
E4.1.3.1
E4.1.3.2
E4.1.4
E4.1.5
E4.1.6
E4.1.7
E5.1

OVERVIEW ................................................................................................................... E-1
DISPLAY FUNCTION BLOCK DESCRIPTION......................................................... E-2
DISPLAY Function Block Parameters ......................................................................... E-2
PREPARING THE ControlWave PROJECT................................................................ E-3
USING THE KEYPAD .................................................................................................. E-4
Scrolling.......................................................................................................................... E-5
Signing-On ..................................................................................................................... E-6
Using the Clock Functions ............................................................................................ E-7
Changing the Time ........................................................................................................ E-8
Changing the Date......................................................................................................... E-8
Choosing a Variable from the List Menu ..................................................................... E-8
Moving Through a Variable List................................................................................... E-9
Changing Variable Parameters .................................................................................... E-9
Signing-Off ................................................................................................................... E-12
KEYPAD IDENTIFICATION & INSTALLATION INFO......................................... E-13

CI-ControlWave MICRO/CW EFM

PAGE #

Appendix E – Display/Keypad Contents / 0 - 1

Appendix E
DISPLAY/KEYPAD ASSEMBLY GUIDE
E1.1 OVERVIEW
Bristol, Inc. Display/Keypad assemblies provide a built-in, local, user interface for the
ControlWave MICRO or the ControlWave EFM. These assemblies allow an operator or
engineer to view and modify variable values and associated status information, via an
ACCOL3 Function Block. Variables can include inputs, process variables, calculated
variables, constants, setpoints, tuning parameters and outputs used in a measurement or
control application. Status bits include alarm state, alarm acknowledge, control, manual,
and questionable data.
Setting up the Display/Keypad is a simple matter of configuring a Display Function Block
in the ControlWave Designer project.
The Display/Keypad is comprised of a four line by twenty character liquid crystal display,
with adjustable LCD Contrast, and a 25 button membrane key matrix. Each key has a
microswitch for positive tactile feedback. This means that as you firmly depress the keys,
you will feel it click as it engages. In the case of the ControlWave EFM, the
Display/Keypad is located in the Instrument Front Cover and is installed at the factory.

Figure 1 - Display/Keypad Assembly – 25 Button Keypad & 4 X 20 Display
CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-1

Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode.
Automatic Mode
In Automatic Mode a set of screens (based on the application load) are displayed. The
application programmer provides strings for the opening screen. From there the firmware is
responsible for displaying the screens and responding to key presses. Screens are fixed and
start off with an opening screen, which displays user information passed into the function
block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled
has been selected, the user can scroll through the list by pressing the down arrow key. List
elements will be displayed automatically, scrolling at a predetermined rate (determined by
iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing
the right arrow key again will cause the list to start scrolling again.
The essence of Automatic Mode is that the user can supply inputs into the function that
will determine which list can be displayed, but cannot change the menu or display. The
user is allowed to select a list and to start/stop scrolling.
Manual Mode
In Manual Mode the programmer is responsible for creating each screen and displaying the
next desired screen, based on key inputs. The programmer has access to all lines of the
display and can provide any string that he/she desires to display. Special formats that must
be adhered to that allow the programmer to display what they want on the screen are
provided in the description of iaScrnSruct in the ACCOL 3 Display function block within
ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode
does not support reading Keypad keypresses. Note: Manual Mode operation requires
ControlWave Firmware 4.50 or newer.
If you're setting up the keypad, follow the configuration instructions provided in Section E3
of this appendix.
If your keypad has already been set up, Section E4 will tell you how to use the keypad and
interpret the display.

E2.1 DISPLAY FUNCTION BLOCK DESCRIPTION
Keypad and display control/configuration are handled by the DISPLAY Function Block.
This function block allows an operator to view/change variable data or to be allowed to
scroll through lists of variable data based upon their login privileges.
In order for the keypad and display to operate, the ControlWave Designer project must
include a properly configured DISPLAY Function Block. Use ControlWave Designer to
configure this function block and assign the parameters according to the four steps covered
in Section 3.

E2.1.1 DISPLAY Function Block Parameters
Referring to Figure 2, various DISPLAY Function Block Parameters are available. For
information on configuring the Display Function Block, please reference on-line help in
ControlWave Designer.

E-2 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

Figure 2 - ACCOL3 DISPLAY Function Block Parameters

E3.1 PREPARING THE ControlWave PROJECT
In order for the keypad and display to operate, the ControlWave Designer project must
include a properly configured Display Function Block. Once the Keypad is operating, a user
who has signed on with a password can scroll through the names of variable lists and
choose a list to read or change. Use Up Arrow and Down Arrow keys to select the Username
and use the numeric keys to enter your password. The steps that follow describe how to
configure this function block.

Step 1: Creating the Identifier Display
The Identifier Display is the first display to appear when the Display Function Block is
initialized and begins to execute. This display will look similar to Figure 3. Each of the first
three lines of the display contains the text value of a string variable. These string variables
are created utilizing iaScrnStruct parameters of the Display Function Block (See Figure 2)
and your computer keyboard. Since this is the first display that the user will see, you may
want the display to contain general information such as the node name of the controller or
the process that the controller is monitoring.
The bottom line on the display is called the legend line. It shows which function keys are
currently active and their purpose. Function keys are those keys on the Keypad that are
marked ([F1] through [F4]). Function key assignments are preconfigured and cannot be
changed. Using function keys is described in Section 4, Using the Keypad.
The legend line in Figure 3 shows that the user has two choices: to Log-in (using [F1]) or
scroll (using [F2]).

CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-3

Figure 3 - Creating the Identifier Message

Step 2: Defining a Scroll List
Once the keypad is operating properly, you can automatically scroll through a list of
variables created via DISPLAY Function Block Parameters iiList2Scroll and iiListMode.
Scrolling can be done without entering a password. The variables in the list are displayed
one at a time and in the same order in which they were entered in the variable list.
Later, we'll discuss other variable lists that can be accessed with the keypad. To distinguish
this list from others, let's call this variable list the Scroll List.
Enter the number of a variable list to be scrolled. This variable list becomes the Scroll List.
The Scroll List can contain different types of variables (that is, logical, analog and string).
You can create a specific scroll variable list or use any list in the ControlWave Project.
Each variable in the Scroll List will be displayed for the number of seconds defined by the
iiScrollTime parameter. If you don't specify a time for this parameter, the hold time will be
two seconds. If you signed-on and then started scrolling you will be signed-off in 20 minutes
if no keys are pressed. If you don’t want to automatically stop scrolling after 20 minutes,
sign-off (INIT key) before starting scrolling.

Step 3: Assigning Passwords
A valid RTU username/password combination must be entered to go beyond the initial
displays. Passwords can be any combination of numbers up to 16 digits in length, from
0000000000000000 to 9999999999999999. If none are specified, the default values are
system for User-name and 666666 for Password (read/write access).

Step 4: Status Information
Enter a variable name on the odiStatus terminal.
See On Line Help in ControlWave Designer for Status Values.
The next section describes how to use the Keypad to access variable information.

E4.1 USING THE KEYPAD
The Identifier Display is the starting point from which you can go to other displays. It
shows an identification message and the words Login and Scroll at the bottom of the screen
(see Note 1). The identification message may contain the name of the controller, the plant
equipment it is monitoring, or the variables you can expect to see when you use this
display.
E-4 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

Note 1 : If your display shows something else, press the [F4] key until you see the words
Login and Scroll on the bottom line.
If your screen is blank, turn the brightness screw clockwise. This screw is located to
the left of the Keypad (looking at the rear of the 25-Button Display/Keypad Assembly (see Figure 17). If no letters appear, the controller has not been programmed properly to operate the keypad.
The words Login and Scroll at the bottom of the screen are on the legend line. It tells you
which function keys (that is, key [F1] through [F4]) are active and their purpose at that
time.
Up to four legends can appear on the legend line. The legend on the far left corresponds to
the function of the [F1] key. The assignment for the [F4] key is on the far right. Keys [F2]
and [F3] are described to the left and right of center. When no legend appears, that function
key is not active at that time. For example, in Figure 4 only [F1] and [F2] are active.

Figure 4 - The Identifier Display
From the Identifier Display, you have two choices. Pressing [F1] will allow you to sign-on if
you have a password. By pressing [F2] you can activate automatic scrolling through a list of
variables.

Figure 5 - Identifier Display Legends and Corresponding Keypad Alignment
for 25 Button Membrane Key Matrix Keypad System

E4.1.1 Scrolling
To begin automatic scrolling, press [F2] from the Identifier Display (Figure 4). Variable information will appear on the screen and remain there for 1 to 30 seconds (default = 2). The
CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-5

variable name appears on the first line. The variable value appears on the second line and
status information appears on the third line. An example is shown in Figure 6.
When all variables in the list have been displayed, they will be shown again in the same
order. This is called Single Variable Mode.
Pressing Mlti [F2] activates Multiple Variable Mode. Multiple Variable Mode displays up to
three (3) variables and their values on the screen simultaneously. Pressing Sngl [F2]
terminates Multiple Variable Mode and returns you to Single Variable Mode.

Figure 6 - Scrolling
Press HOLD [F1] to halt scrolling. Changing variable values will continue to be displayed.
Press GO [F1] to resume scrolling.
Press EXIT [F4] to return to the Identifier Display (Figure 4).

E4.1.2 Signing-On
To access the List Menu, you must first sign-on with a proper password. From the
Identifier Display (Figure 4), press [F1]. The screen will look like Figure 7A or 7C. If the
display looks like Figure 7C:
Someone else has already signed on. Go to the paragraph below that starts "Once you
have successfully signed on,…".
If the display looks like Figure 7A:
Select the Username (default = system) by using the Up and Down Arrow Keys. If the
Username system is displayed and no other Username is available (i.e., no others have
been assigned), press [ENTER].
Enter a password using the 0 to 9 keys. For security, asterisks will appear as you enter
the digits. If you make a mistake, press [F1] and try again (or use the delete key to
delete the previously pressed key action). The default password is 666666 (used when a
password is not known or no password has been assigned). After typing the password,
press [ENTER].
If your password is not recognized, the asterisks will be erased after you press
[ENTER]. Check your password and try again.
E-6 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

Figure 7 - Logging On
Once the correct password has been entered, the display will look like Figure 7C.
When the second line shows READ/WRITE, you can read and write variable parameters.
When it shows READ ONLY you cannot change variable parameters. You are only permitted to read variable information. If your display shows READ ONLY and you want to
change variable values, sign-off (press the [INIT] key) and log on with a username and
password that provides Read/Write privileges.
Once you have successfully signed on, the legend line will show that you have four options.
You can view and change the time and date of the local clock, access more variable lists,
Scroll, or return to the Identifier Display. Use function keys F1 through F4 to select the
next menu (F1 = Clock, F2 = Menu, F3 = Scroll list & F4 = Exit). Let's start by setting the
local clock.

E4.1.3 Using the Clock Functions
From the Logged-On Display (Figure 7C), press [F1]. The screen will show the present date
and time and will look like Figure 8. Follow the instructions below to change the time or
date. When you're finished, press [F4] to exit.
Today's date is shown in the first line in the format month/day/year.
The current time is shown in the form of hours:minutes:seconds.

CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-7

Figure 8 - Clock Display
E4.1.3.1 Changing the Time
From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third
line. Enter the new time there and press [ENTER]. Valid times range from 00:00:00 to
23:59:59. Invalid entries will be ignored. The display will be updated to show the new time.

Figure 9 - Time Set Display
If you make a mistake while entering the new time, use [DEL] to backspace and delete one
character at a time.
E4.1.3.2 Changing the Date
From the clock display (Figure 8, press [F1]. Slash marks (/) will appear on the third line.
Enter the new date there and press [ENTER].

Figure 10 - Date Set Display
If you make a mistake while entering the new date, use [DEL] to back space and delete one
character at a time. Press [F4] to return to the Logged-On Display (Figure 7C).

E4.1.4 Choosing a Variable List from the List Menu
The List Menu is another area where variable information can be seen. As explained earlier
in this section, your first opportunity to read variable information is by choosing the
E-8 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

SCROLL function from the Initial Display. The variable name and value are presented
from the Scroll List. This function is available to all users even without signing-on.
The List Menu will show other groups of variable which you can choose to read. This information will be more detailed than the Scroll List.
To get to the List Menu, choose MENU (press [F2]) from the Logged-On Display (Figure
7C).

Figure 11 - Using the List Menu Display
The first variable list number in the menu will appear on the second line.
Press PREV (F1) and NEXT (F2) to see the other variable lists that are available in the List
Menu. You can also use the Up and Down Arrow Keys to scroll through the various lists. To
move directly to a list, enter the list number, then press [ENTER].

E4.1.5 Moving Through a Variable List
After READ (F1) or WRITE (F2) has been pressed, the display will show the first variable
in the list. An example is shown in Figure 12. Each time NEXT (F2) is pressed; the display
will show the next variable in the list. PREV (F1) will show the previous variable. You can
also use the Up and Down Arrow Keys to move through a list.
Automatic wraparound occurs in either direction. When you reach the end of the list, [F1]
will display the first variable again. At the top of the list, [F2] will display the last variable.

E4.1.6 Changing Variable Parameters
From Figure 11, you can change variable parameters by pressing F2 [Write]. Then follow
the directions summarized below (see Note 2).
Note 2: If your display does not contain the legend Write in the legend line, your password
will only allow you to read variables. If you want to change variable values at this
time, you must first log-off and then log-on using the correct password. See your
Systems Engineer for the correct password.

CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-9

Before making any changes, first check the signal inhibit status field (See Figure 12). When
the display shows ME (manual enable) you can change variable parameters. When it shows
MI (manual inhibit), you cannot alter the parameters of this variable. If the field indicates
MI, press the OPER I/E key to change it to ME.
To change an analog value:
Press CHNG (F3) to clear the third line. Use the number keys 0 through 9 to enter the
new value. The minus sign and period are also permitted. Press [ENTER].
If you make a mistake, press CHNG (F3) and enter the number again or use the [DEL]
key to erase a character.
Another way to enter new values is by using the arrow up and arrow down keys (located
below the [F3] key and left of the [INIT] key). These keys will raise and lower the value
by 1% of the displayed amount.
To change the status of a logical variable:
Press CHNG (F3), then use either the down and up arrow keys or the [0/OFF] and
[1/ON] keys to change the state of a logical variable. If the [0/OFF] and [1/ON] keys are
used, you must also press [ENTER].

Figure 12 - Interpreting Variable Information
To acknowledge an alarm:
Press [ALM ACK].
To change the alarm enable/inhibit status for alarm variables:
Press [ALM I/E] key. (Note: This will only inhibit alarm reporting, and not alarm level
detection.)

E-10 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

Notes for Figure 12
1. Variable Name (Example 1: @GV.FLOW_RATE) (Example 2: @GV.TOTAL_FLOW_RATE)
2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be
shown as asterisks.
Analog values are displayed in floating point format, for example, 0.0125, 99.627, and 1287.66.
When the value cannot be shown in floating point format, scientific format is used
(1.287668E+10 or 1.25E-02 for example).
3. Questionable Data Status - for analog variables, column 1 will be clear if the status is valid. It
will display a question mark if the status is questionable.
4. Variable Inhibit Status
CE (Control Enable) means this variable can be updated by the ControlWave project.
CI (Control Inhibit) means the variable cannot be updated by the ControlWave project.
ME (Manual Enable) means the variable can be changed manually.
MI (Manual Inhibit) means the variable cannot be changed manually.
5. Alarm Enable (for alarm variables only)
AE - variable is alarm enabled (changes will be reported).
AI - variable is alarm inhibited (changes will not be reported).
6. Alarm State
For Analog Variables:
HH - high-high alarm
HI
- high alarm
LO - low alarm
LL - low-low alarm

For Logical Variables:
TA - true alarm
FA - false alarm
CA - change-of-state alarm

! - alarm is unacknowledged
7

Multiple Signal Display
In Read Mode, pressing MULT (F3) will display the variable name extension, value, and units
for three variables at one time. These variables include the variable displayed when NEXT (F2)
was pressed and the next two variables in the list. Press SNGL [F3] to return to viewing one
variable at a time (see Figure 12A).

Figure 12A - Example of MULT Display in READ Mode

CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-11

Notes for Figure 12 (Continued)
Variables are shown below as they would appear in SNGL mode.
1) String
SITE_NAME
WEST SUNBURY PUMP STATION
CE ME
2) Analog
TOTAL_FLOW_RATE
1260.578
CE MI
3) Logical
FLOW_ALARM
OFF
CE MI AE NA

E4.1.7 Signing-Off
Once you have logged-on, use the [INIT] key at any time to log-off. When this key has been
pressed, the screen will look like Figure 13. Press Yes (F1) to sign-off. You are signed-off
when the Identifier Display (Figure 3C) appears.
If you do not want to log-off, press Exit (F4) to leave the Log-Off Display.
Once you are signed-on an automatic sign-off will occur if 20 minutes has elapsed since the
last key was pressed.

Figure 13 - Log-Off Display

E-12 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

E5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO.

5.50

5.50
3.25

3.13
.19

1.13

.313

.31
TYP

1.25

.75
2.750

.43

7.38

.06
2.13
2.00

.25
MAX
TYP.

.25
1.25

4.19

.06

6.500
.50
.75

.190
.170
4.69

7.38

3.625
.937

Figure 14 – 25 Button Display/Keypad Assembly Installation Drawing

CI-CW MICRO/CW EFM

Appendix E - Display/Keypad / E-13

Figure 15 - 25 Button Keypad
Table 1 - 25 Button Keypad Keys
KEY
F1, F2, F3,
F4
INIT
0 to 9, -, •
Δ
∇
ALM I/E
ALM ACK
A/M
OPER I/E
DEL
ENTER

FUNCTION
Function keys will take on a variety of different functions depending on the
situation. The function of these keys is listed on the legend line (bottom line) of the
display.
The INIT key is used to terminate the keyboard session and sign-off.
These keys are used to change the value of analog variables in the
CONFIGURATION mode. The 0/OFF and 1/ON keys are used to change the state
of logical variables.
Each press of this key will raise an analog variable value by 1% of the displayed
value or turn a logical variable ON.
Each press of this key will lower an analog variable value by 1% of the displayed
value or turn a logical variable OFF.
Use this key to enable or inhibit alarm variables.
Use this key to acknowledge alarms.
Toggle between AUTO (CE) and MANUAL (CI) with this key.
Toggle between manual inhibit (MI) and enable (ME) with this key.
Use this backspace key to erase digits that have been entered on the keypad.
This key is used to enter new data from the display into the controller, e.g.,
password or variable values.

E-14 / Appendix E - Display/5x5Keypad

CI-CW MICRO/CW EFM

Instruction Manual
CI-ControlWave EFM
Oct., 2006

Using ControlWave EFM
WebBSI Web Pages
Appendix F

www.EmersonProcess.com/Bristol

ControlWave EFM

BLANK PAGE

APPENDIX F

ControlWave EFM
Using ControlWave EFM
WebBSI Web Pages
TABLE OF CONTENTS
SECTION

TITLE

F.1
F.1.1
F.2
F.2.1
F.3
F.4
F.4.1
F.4.1.1
F.4.1.2
F.4.2
F.4.3
F.5
F.5.1
F.5.2
F.5.2.1
F.5.2.2
F.5.3
F.5.4
F.5.4.1
F.5.4.1.1
F.5.4.1.2
F.5.4.1.3
F.5.4.1.4
F.5.4.1.5
F.5.5
F.5.5.1
F.5.5.2
F.5.5.3
F.5.5.4
F.5.6
F.5.6.1
F.5.6.2
F.5.7
F.5.7.1
F.5.7.2
F.5.7.3
F.5.7.4
F.5.7.5
F.5.7.6
F.5.7.7
F.6
F.6.1
F.6.1.1
F.6.1.2

GENERAL OVERVIEW .................................................................................................F-1
Viewing WebBSI .............................................................................................................F-1
INSTALLING WebBSI SOFTWARE & ControlWave EFM Web Pages .....................F-1
Communication Connections .........................................................................................F-2
WebBSI PROGRAM STARTUP.....................................................................................F-3
SECURITY CATEGORY FUNCTIONS ........................................................................F-3
Signing On/Off ................................................................................................................F-4
Selecting a Node and Signing ON..................................................................................F-4
Signing Off from the Node .............................................................................................F-4
Locating Nodes................................................................................................................F-4
Contacts...........................................................................................................................F-5
STATION CATEGORY FUNCTIONS...........................................................................F-5
Station Summary............................................................................................................F-5
Sampler and Odorizer Configuration ............................................................................F-6
Sampler Configuration ...................................................................................................F-6
Odorizer Configuration...................................................................................................F-6
Mechanical Counter Configuration ...............................................................................F-7
Nomination......................................................................................................................F-8
Nomination Operation....................................................................................................F-9
Enabling the Nomination Function ...............................................................................F-9
Beginning a Nomination Period...................................................................................F-11
Ending a Nomination Period........................................................................................F-12
Changing the Nomination Target................................................................................F-12
Manually Starting/Ending a Nomination Period........................................................F-12
Flow Control & Valve Control......................................................................................F-12
Nomination....................................................................................................................F-12
Flow Control..................................................................................................................F-12
Pressure Override (set one or both to enable override) ..............................................F-14
Valve Control ................................................................................................................F-14
Run Switching...............................................................................................................F-15
Common Properties ......................................................................................................F-15
Run1/2/3/4 Properties ...................................................................................................F-15
Radio Control ................................................................................................................F-17
Radio Control Mode ......................................................................................................F-18
Common Properties ......................................................................................................F-18
Radio Sensing Mode .....................................................................................................F-18
Hourly Mode..................................................................................................................F-18
Daily Mode ....................................................................................................................F-19
Day Light Mode ............................................................................................................F-19
Statistic .........................................................................................................................F-19
METER RUN CATEGORY FUNCTIONS ..................................................................F-19
Meter Run Overview ....................................................................................................F-19
AGA3 - Orifice Meter....................................................................................................F-20
AGA7 Frequency Meter................................................................................................F-22

CI-ControlWave EFM

PAGE #

Appendix F - Using ControlWave EFM WebBSI Web Pages / 0 - 1

APPENDIX F

ControlWave EFM
Using ControlWave EFM
WebBSI Web Pages
TABLE OF CONTENTS
SECTION

TITLE

F.6.2
F.6.2.1
F.6.2.2
F.6.2.3
F.6.2.4
F.6.3
F.6.3.1
F.6.3.1.1
F.6.3.1.2
F.6.3.1.3
F.6.3.2
F.6.4
F.7
F.7.1
F.7.2
F.7.3
F.7.4
F.7.5
F.8
F.8.1
F.8.2
F.8.3
F.8.4
F.9
F.10

Meter Run I/O Configuration.......................................................................................F-23
Differential Pressure, Static Pressure and Temperature Inputs ..............................F-23
Frequency Input ...........................................................................................................F-25
Heating Value Input.....................................................................................................F-25
Alarm Configuration (Accessed via Meter Run I/O Configuration)...........................F-27
Flow Equations .............................................................................................................F-27
Orifice Flow Equation Setup........................................................................................F-27
Differential Measurement............................................................................................F-27
1985 AGA3 Equation Configuration............................................................................F-28
1992 AGA3 Equation Configuration............................................................................F-29
Frequency Flow Equation Setup..................................................................................F-31
Supercompressibility Setup .........................................................................................F-32
CHROMATOGRAPH CATEGORY FUNCTIONS......................................................F-34
Communication Settings ..............................................................................................F-35
Stream Assignment and Setup ....................................................................................F-35
Analysis Data................................................................................................................F-35
Gas Components ...........................................................................................................F-35
Chromatograph Component Range Setup ..................................................................F-35
LOGS CATEGORY FUNCTIONS ...............................................................................F-36
Meter Run Archive Files ..............................................................................................F-37
Meter Run Audit Trial..................................................................................................F-38
View Signal List............................................................................................................F-38
Archive File Collection .................................................................................................F-39
LOAD/SAVE CATEGORY FUNCTION ......................................................................F-40
SPECIAL FUNCTIONS ...............................................................................................F-41

CI-ControlWave EFM

PAGE #

Appendix F - Using ControlWave EFM WebBSI Web Pages / 0 - 2

Appendix F

Using ControlWave EFM
WebBSI Web Pages
F.1 GENERAL OVERVIEW
The ControlWave EFM is configured and monitored using WebBSI Web pages developed
specifically for the standard application program. The Web pages are stored and displayed
on a personal computer (PC), and use either OpenBSI Network edition or Local edition to
interface to the ControlWave EFM. Web pages provide:
* Sign-on to the ControlWave EFM (CW EFM)
* Invoke menus to configure the CW EFM for operation
* Read current gas flow and total information
* Set the CW EFM Date and Time
* Change the CW EFM network address
* Collect & Display the Daily, Hourly, Periodic, & Audit Logs

F.1.1 Viewing WebBSI
WebBSI is best viewed under these conditions:
• The Internet Explorer window be maximized or be viewed full-screen.
• The resolution of the monitor be at least 800x600 or above (preferably 1024x768 or above).
• The color depth can be at least 16 bit high color or above (preferably 24 bit true color or
above).
• The text size of Internet Explorer be "Medium" or smaller (preferably "Medium").
• JavaScript and ActiveX Controls be enabled in Internet Explorer.
Pop-up Help windows for WebBSI Web pages can be accessed by clicking the Help button
on the left side of WebBSI Web pages. The help windows must be closed in order to open
another.
On pages that contain tables of controls:
• A white background on a control means that it is read/write.
• A beige background on a control means that it is read only.
NOTE: Web pages may appear slightly different than those displayed herein!

F.2 INSTALLING WebBSI SOFTWARE & ControlWave EFM Web
Pages
The WebBSI software requires a PC (computer) running either OpenBSI Network Edition
or OpenBSI Local Edition, with the WebBSI ActiveX controls installed and registered on
the PC (see appropriate document for details).
ControlWave EFM Web pages will be installed in the following directory as the default:
C:\OpenBSI\CWEFM\ and the default startup page will be CW_MICRO_EFM.htm

CI-ControlWave EFM

Appendix F / F-1

PC/Laptop
Computer

ControlWave EFM

Figure F-1 - ControlWave EFM
Connected to PC via the Local Communications Cable

F.2.1 Communication Connections
The ControlWave EFM communicates with the PC through the Local Port as shown in
Figures F-1 through 2B. The Local Port has been provided specifically for installation,
startup and on-site configuration and data collection.
For ControlWave EFM’s equipped with a D-type Local Port, local communications between
the ControlWave EFM and the PC is provided over a standard ControlWave null-modem
cable (see Figure F-2A). Units equipped with the circular 3-pin Local Port utilize a special
cable as illustrated in Figure F-2B.
ControlWave EFM

5 = GND
4 = DTR
8 = CTS

3 = TXD
7 = RTS
2 = RXD
6 = DSR
1 = DCD

9-Pin Female
“D” Connector

To P2 Pin-5
To P2 Pin-6
To P2 Pin-2
To P2 Pin-1
To P2 Pin-3
To P2 Pin-4
To P2 Pin-7

(Looking into
Wire Terminal Side
of
Cable Connectors)
or
vice
versa

1 = DCD
6 = DSR
2 = RXD
7 = RTS
3 = TXD
8 = CTS
4 = DTR
5 = GND

9-Pin Female
“D” Connector

Figure F-2A - ControlWave EFM (with D-type Local Port)
Null Modem Cable (Bristol P/N 392843-01-3) Connection Diagram
F-2 / Appendix F

CI-ControlWave EFM

Figure F-2B - PC Connected to ControlWave EFM (via Circular Local Port)
Bristol Cable Part Number 395402-01-8 = 10 Foot Comm. Cable
Bristol Cable Part Number 395402-02-6 = 25 Foot Comm. Cable

F.3 WebBSI PROGRAM STARTUP
Ensure that the Local Communications Cable connections (at both the ControlWave EFM
& the PC) are secure.
If the WebBSI Web pages for the ControlWave EFM have been assigned as the default
Web pages for a node in OpenBSI, they can be invoked either from OpenBSI by right
clicking on the appropriate RTU and selecting RTU -> WebPage Access. Web pages are also
accessible by selecting Start -> Programs-> OpenBSI Tools-> WebPage Access -> CW EFC
Pages.
Six Category Functions are provided as follows:
Section F.4 (Security)
Section F.5 (Station)
Section F.6 (Meter Run)

Section F.7 (Chromatograph) Section F.10 (Special Functions)
Section F.8 (Logs)
Section F.9 (Load/Save)

F.4 SECURITY CATEGORY FUNCTIONS
Three Web pages are accessible from the Security category section of WebBSI.
• Sign On/Off
• Locate Nodes

(Section F.4.1)
(Section F.4.2)

CI-ControlWave EFM

• Contacts

(Section F.4.3)

Appendix F / F-3

F.4.1 Signing On/Off
When the WebBSI Web pages for the ControlWave EFM are first accessed, the SIGN
On/Off Web page is displayed. A user must select the RTU Name from the drop down
menu. If using OpenBSI Network Edition, this drop down menu will include all nodes
available on the network. If using OpenBSI Local Edition, only the default node (RTU) will
be available.

Figure F-3 - Sign On/Off Web Page

F.4.1.1 Selecting a Node and Signing On
The user must choose the Node they want to sign-on to from the RTU Name list box. The
user must enter the Username and Password. The user must then click on the Sign On
button. If the sign-on attempt is successful, the message Access Granted will appear (in
green text) within the message area. Failure messages appear in red text and informational
messages appear in black text.

F.4.1.2 Signing Off from the Node
To sign off from a Node, the user must click on the [Sign Off] push button. If the sign-off
attempt is successful, the message “Sign Off Successful” will appear in green (failures are
in red).
Note: For Security Maintenance functions refer to CW MICRO Quick Setup Guide – D5124
– Part 2 – Configuring User Accounts & Privileges.

F.4.2 Locating Nodes
The user may identify which node(s) they would like to communicate with by using the
Locator page. The Nodes can be identified either by loading a proxy file, or by loading Open
BSI information. In either case, they will be displayed as icons in a tree on the left side of
the page.
F-4 / Appendix F

CI-ControlWave EFM

The Node Locator Web page is accessible by clicking on the Security category button and
choosing the Locate Nodes drop-down menu selection.

Figure F-4 - Locate Nodes Web Page

F.4.3 Contacts
A list of Bristol Inc. offices is provided under the topic Contacts.
The Contacts Page is accessible by clicking on the Security category button and choosing
the Contacts drop-down menu selection.

F.5 STATION CATEGORY FUNCTIONS
The standard application program for the ControlWave EFM allows the user to configure
a station with up to four meter runs. Users must configure Station parameters from the
Station Configuration category section of WebBSI. Seven Web Pages are accessible from
the Station Configuration category section of WebBSI.
•
•
•
•
•
•
•

Station Summary
Sampler & Odorizer
Mechanical Counter
Nominations
Flow Control
Run Switching
Radio Control

(Section F.5.1)
(Section F.5.2)
(Section F.5.3)
(Section F.5.4)
(Section F.5.5)
(Section F.5.6)
(Section F.5.7)

F.5.1 Station Summary
Station Summary Web Pages display corrected and uncorrected flow rates and volumes
for the station and each run. Corrected Volumes, Uncorrected Volumes and Accumulated
Energy totals are displayed for the previous hour and previous day.
CI-ControlWave EFM

Appendix F / F-5

Figure F-5 - Station Summary Web Page

F.5.2 Sampler and Odorizer Configuration
See section F.5.2.1 for Sampler Configuration or F.5.2.2 for Odorizer Configuration.

F.5.2.1 Sampler Configuration
The user may enable or disable the Sampler by using the Enable/Disable button. If
enabled, the Sampler will operate at a frequency set by the Pulse Frequency setpoint (in
cubic feet). Users must select which Digital Output (DO) Point will be used. A running
count of samples taken will be displayed. Users may reset this count by pressing the Reset
Count button.

F.5.2.2 Odorizer Configuration
Users may enable or disable the Odorizer by using the Enable/Disable button. The user
also selects the Output Mode, i.e., Analog Output or Digital Output. If the Analog Output
Mode is selected, Analog Point ID 1 is assigned. If the Digital Output Mode is selected, the
Digital Output Point to be used is selected via the DO Point ID field.
When the Analog Output Mode is selected, the user must set the Scale Factor. The Scale
Factor is a ratio of the amount of odorant to be injected per cubic foot of gas. Users must
know the maximum output of the Odorizer and calculate the ratio accordingly.
F-6 / Appendix F

CI-ControlWave EFM

When the Digital Output Mode is used, the user must enter the frequency of the pulses per
volume through the meter (in cubic feet).

Figure F-6 - Sampler & Odorizer Configuration Web Page

F.5.3 Mechanical Counter Configuration
The Mechanical Counter Configuration section of the Sampler & Mechanical
Counter Configuration Web Page is used to simulate a mechanical counter. An
Enable/Disable button is used to activate/deactivate this function. Synchronization of the
ControlWave EFM Counter with an external Mechanical Counter is achieved via the
Initial Count field. Determination of the volume of gas per pulse is performed utilizing the
Pulse Frequency field. Current Count is the actual number of pulses received by the unit.
Users must select which HSC Input will be used with the Mechanical Counter.

Figure F-7 - Mechanical Counter Configuration Web Page
CI-ControlWave EFM

Appendix F / F-7

F.5.4 Nomination

Figure F-8 - Nomination Web Page

Users configure the nominations control from the Nomination WebPage. Nominations
functionally provide the user with the ability to set the ControlWave EFM to allocate
precise amounts of gas flow during specific time periods. These periods are called
“nomination periods.” A nomination may be set for any duration of time (not to exceed one
month). The volume to be delivered (nominated) during a nomination period is the target.
Targets may be specified in terms of volume or energy. Users set a nomination period by
keying in the desired day of the month and hour to begin the period and the desired day of
the month and hour to end the period. The daily nomination feature is used if the user
desires the same start/stop times every day. A unit programmed with a daily nomination,
will ignore the programmed start and end day numbers and will perform the nomination in
question at the same time once per day.
The delivery of the nominated quantity (volume or energy during the nomination period)
may be performed via one of the two unique schemes listed below.
Valve Control
The Valve Control method overrides PID flow control and allows the valve to be
independently controlled, thus permitting full flow of gas through the meter in order to

F-8 / Appendix F

CI-ControlWave EFM

arrive at the target (volume or energy) as quickly as possible without regard to the
programmed end time.
Flow Control
The Flow Control method internally enables the PID flow control algorithm in order to hit
the target volume/energy at exactly the programmed end time.
The user programs the ControlWave EFM t(via the ‘Stop Mode’ button) to either close the
valve upon reaching the target or leave it in its last position.

F.5.4.1 Nomination Operation
See sections F.5.4.1.1 through F.5.4.1.5.
F.5.4.1.1 Enabling the Nomination Function
The nomination function runs once per calculation cycle after the volume and energy
accumulations have been updated by the ControlWave EFM. To setup and enable this
feature follow the steps below.
1. Setup of the nominations feature depends on the desired control mode selection, i.e., the
Fast approach mode or PID mode. Fast approach mode is the default mode for
nominations. If the desired control mode is the Fast approach mode, proceed to step 2;
however, if the desired control mode selection is the PID mode, you must first program
all the PID tuning parameters such as gain and integral. Note: DON’T enable the PID
flow control algorithm or the ControlWave EFM will automatically disable nomination.
When properly configured the ControlWave EFM will automatically enable the PID
flow control algorithm during nomination periods.
2. Select the Nomination Web Page (Figure F-8) via the Nomination button under the
Station Category Function (see Figure F-5 or F-9).
A description of the menu entries (Figure F-8) used to implement the nomination function follows:
NOMINATION CONTROL – In addition to the Time, this section of the Nomination
Web Page provides the following eight areas for nomination setup/selection:
Main function
The Main function selection is used to enable/disable the nomination function. If this
signal is set to the disable state, nomination will not occur.
Quantity units
The Quantity units selection is used to set the target units as MCF or MMBTU.
Control mode
Control mode provides for the selection of either the Valve Control or Flow Control
modes of nomination operation.
Status
The Status signal is an output of the nominations algorithm that indicates whether
there is currently a nominations period in progress. The user may change the state of

CI-ControlWave EFM

Appendix F / F-9

this signal to end an in progress nomination immediately, or to start the next period
immediately (see Manually Starting/Ending a Nomination Period).
Stop Mode
The Stop mode selection allows the user to automatically have the valve closed, i.e.,
shut-in on stop mode, or left in the last position upon reaching the target (or
programmed end period).
Daily Only Mode
When Daily mode is enabled, only the programmed start and end hours are used by the
ControlWave EFM; the Start/Stop days are ignored, i.e., nomination begins and ends
within a 24 hour period every day.
Alarm at a level of %
The Alarm at a level of % setting can be configured as percentage of Volume (MCF) or
Energy (MMBTU). This feature allows the ControlWave EFM to provide an alarm
(logical nomination alarm) or indication to an operator or computer that a specified
amount of target has been reached. The number entered (1 to 100) sets the percentage
at which the logical nomination alarm will occur. The status of this setting, i.e., whether
or not a nomination alarm has occurred, can be determined via the Alarm Status signal
(see Figure F-9).
Alarm Status
When the amount specified in ‘Alarm at a Level of (%)’ is reached, the value of the
signal will be set true.
CURRENT NOMINATION PERIOD - This section allows the operator to view the
following information associated with a nomination which is currently in progress:
Start: day/hour
The actual time and day of the month when the current nomination period started is
displayed. This may be the programmed time or the time at which an operator manually
started a period.
Stop: day/hour
The programmed end time and day of the month at which the current nomination
period will end. If using the Fast approach mode, the period may end sooner, i.e., when
the target is reached. If using the daily nomination feature, the stop date (day) will
show 0 to indicate that only the hour matters.
Target value (x 1000)
The Target value provides the value of Volume/Energy to be delivered during this
period.
Amount Delivered (x 1000)
The Amount Delivered reading provides the actual amount of volume/energy delivered
so far during this period.
Percent elapsed time
This signal shows the percentage of time which has elapsed for the current nomination
period, e.g., 4 hours into a 100 hour nomination period would cause this value to be 4.0.

F-10 / Appendix F

CI-ControlWave EFM

Percent Delivered
This signal provides the percentage of target delivered to this point in the current
nomination period.
NEXT NOMINATION PERIOD - This section allows the operator to set/view the
following parameters associated with the next nomination which is to be programmed
(has been programmed): Note: New entries must be made prior to the ending of the
current nomination period.
Start: day/hour
The actual start day of the month (1-31) and start hour (0-23) when the next nomination
period is to start is displayed or entered. The start day is ignored if the daily nomination
feature is enabled.
Stop: day/hour
The actual stop day of the month (1-31) and stop hour (1-23) when the next nomination
period is to end is displayed or entered. The stop day is ignored if the daily nomination
feature is enabled.
Target Value (x 1000)
The Target value provides (is used to set) the value of Volume/Energy to be delivered
during the next nomination period.
LAST NOMINATION PERIOD - This section allows the operator to view information
associated with the last nomination period which was completed. Information displayed
remains valid until the next time a nomination period ends (when the information is upgraded to reflect the new "last" nomination period. Start and end times stored here
indicate the actual time that the nomination period ended, which is not necessarily the
programmed time (because of the time required to close/open valves or complete other
actions). The days are valid even if the daily nomination mode is active.
3. Program all the configuration items for the NEXT Nomination Period such as start
and stop times and target value.
4. Set the desired parameters for NOMINATION CONTROL such as Quantity units,
Control mode, Stop mode, Daily only mode and Alarm at a level of and then set the Main
function signal to the Enable State.
5. If a radio is to be used in conjunction with a "logical nomination alarm," access the
Radio Control Configuration Web Page (see Figure F-12) via the Radio Control button.
See Section F.5.6 to configure the radio for logical nomination alarms.
F.5.4.1.2 Beginning a Nomination Period
When no nomination period is in progress, the ControlWave EFM compares the NEXT
start date and time to the current time. If the date and time match (or time only for the
daily nomination mode), a new period is begun. The current time is copied into the
CURRENT START signals, and the next target is copied into the current target. The accumulators for the current period are zeroed and the current stop time is set to the next
start time. If the PID mode is selected, a new flow setpoint is calculated and stored in the
setpoint signal. The PID setpoint is recalculated every 15 minutes and whenever any
parameter is changed.

CI-ControlWave EFM

Appendix F / F-11

F.5.4.1.3 Ending a Nomination Period
If shut-in on stop mode is in use, the current period will end when the target accumulation
is reached. At this time, the ControlWave EFM attempts to close the control valve. If PID
control is being used, the setpoint is set to 0.0, the current cycle will ramp down
accordingly. When the flow rate reaches 0.0, the current cycle accumulations and the actual
end time are copied into the LAST signals. If the valve fails to close, the volume will
continue to accumulate until the programmed end time. If the shut-in on stop mode is not
in use, the nomination period continues until the programmed end time.
F.5.4.1.4 Changing the Nomination Target
To change the target of the next period, the user should change the NEXT TARGET signal.
F.5.4.1.5 Manually Starting/Ending a Nomination Period
When a Nomination Period is not in progress, the user can immediately begin the NEXT
period by setting the Status signal to the ON state. The current start time will reflect the
time that the user started the cycle. The target and stop times used will be those of the
NEXT period. The user may immediately end a nomination period which is in progress by
setting the Status signal to the OFF state. The current time will be stored as the LAST stop
time.

F.5.5 Flow Control & Valve Control
The Flow Control & Valve Control Web Page (Figure F-9) is accessible via the Flow
Control button. The PID Controller is utilized in the ControlWave EFM for Flow Rate
Control. Sections F.5.5.1 through F.5.5.4 provide information on the four major functions
accessible from the Flow Control & Valve Control Web Page (see Figure F-9).

F.5.5.1 Nomination
Function
The Nominations Function provides for enabling/disabling the nominations feature (see
Section F.5.3). If this signal is set to the disable state, no nomination will be performed.
Status
The Status signal is an output of the nominations algorithm that indicates whether there is
currently a nominations period in progress. The user may change the state of this signal to
end an in progress nomination immediately, or to start the next period immediately (see
Manually Starting/Ending a Nomination Period in Section F.5.3).

F.5.5.2 Flow Control
Enable
Pressing the button to the right of Enable will allow the operator to toggle between PID
Flow Control Enabled and Disabled. It is recommended that GAIN, INTEGRAL and
DERIVATIVE adjustments be checked before turning a controller ON.
Warning
Do not enable PID Flow Control without first checking the external process control
loop. The initial values displayed on the PID Menu may drive some critical
processes beyond the extremes of safe limits. This could result in fire, explosion,
F-12 / Appendix F

CI-ControlWave EFM

property damage, and injury to persons. When setting the WebBSI Web Page
parameters, make sure the associated process is observed and protected.

Figure F-9 - Flow Control & Valve Control Web Page
Setpoint (x1000)
This field contains the operating point at which the flow rate is to be controlled. Set-point
units are MSCFH with a default setting of 1000 MSCF per Hour. To change the Setpoint
value, right click on the field and select Change Signal Value.
Gain
Gain controls the amount of output change resulting from a change of the measured
variable. The default value of 1.00 is typically used as a starting point; final gain is usually
less. To change the Gain value, right click on the field and select Change Signal Value.
Integral
Integral determines the time it will take the PID to correct an error in the measured
variable. The number of times the output is adjusted in a given time period is specified in
seconds. An entry of 60 seconds can be used as a starting point; this would provide one (1)
repeat per minute. To change the Integral value, right click on the field and select Change
Signal Value.
Derivative
Derivative compensates for a rapidly changing measured variable. The time is specified in
seconds (SECS) and most applications will use a setting of zero (0). To change the
Derivative value, right click on the field and select Change Signal Value.
Deadband
Deadband provides a means of specifying a 'window' in which the variable does not affect
the output. This entry is in percent (%) of the SETPOINT signal. As an example, a 5% entry
would mean that the controller output must exceed the present setpoint by 5% before the
output is changed. To change the Deadband value, right click on the field and select Change
Signal Value.
CI-ControlWave EFM

Appendix F / F-13

Max Flow Rate (x1000)
Max Flow Rate represents the maximum flow rate allowed. If the number entered in the
Setpoint field exceeds the Max Flow Rate value, the Max Flow Rate value will be used. To
change the Max Flow Rate (x1000) value, right click on the field and select Change Signal
Value.
Valve Travel Time
Valve Travel Time is the amount of time it takes a Control Valve to go from being fully
open to fully closed (or visa-versa). The default value is 30 Seconds. To change the Valve
Travel Time value, right click on the field and select Change Signal Value.
Current Data Flow Rate (x1000)
The Flow Rate value is Read Only data; it is the present calculated flow rate per hour.

F.5.5.3 Pressure Override (set one or both to enable override)
When the PID controller is active in flow-control mode, it will adjust a pressure valve to
maintain the established flow rate setpoint. Pressure override is used in situations where
full line pressure should not be applied to the downstream equipment or in circumstances
where a minimum pressure must be maintained.
Maximum & Minimum
A Maximum and Minimum pressure can be configured which set the PID controller to
switch to pressure control mode whenever the line pressure attempts to go outside the
defined limits. The pressure override mode becomes active when either or both limits are
set to a non-zero value.
Pressure Tap Location Relative to the Control Valve
The Pressure Tap location is specified as either upstream UPSTRM or downstream
DNSTRM with respect to the control valve. The action of the override controller depends on
the configured Tap location. When the pressure tap is configured as Downstream of the
control valve, pressure will rise as the valve opens to increase the flow rate. Increasing
demand will cause the valve to open more. Should conditions occur that cause the pressure
to exceed the maximum pressure limit, the override will take control and close the valve to
maintain the configured maximum pressure. Should the valve attempt to close and reduce
pressure below the configured maximum pressure, the override will take control to
maintain the minimum pressure. When the pressure tap is configured as Upstream, the
action is reversed, i.e., when the maximum pressure is exceeded the valve will open to lower
the pressure. When the minimum pressure is exceeded the valve will be closed.
Users are cautioned to test the regular override controller actions to verify correct valve
movement for all expected conditions.

F.5.5.4 Valve Control
A user may select the Valve Control type, i.e., Analog Output or Raise/Lower control via the
Digital Outputs. If the operator selects Analog Output control, Analog Output 1 will be
used by default. Current Data will show the value of the Analog Output in percent (4mA =
0%, 20mA = 100%).
Users may set the valves Output Control into either Manual or Automatic (Auto). When
Manual Mode has been selected, the current value of the Analog Output will be frozen.
Users may change the Manual Analog Output value, by right clicking on the field and
F-14 / Appendix F

CI-ControlWave EFM

entering a new value. When the mode is changed back to Automatic, the valve control
starts from the last Manual value entered for Bumpless transfer.
If the user selects Raise Lower Mode, the DO associated with raising the valve must be
selected and a separate DO must be selected for lowering the valve. When the Raise Lower
Mode is being used, the Current Data section will display if the Raise DO is Off’ or Raising
and it will display the Lower DO state, i.e., Off or Lowering.
In the Manual Control mode, users may select whether to Raise or Lower the valve by using
the Manual Raise or Manual Lower Output buttons. If the valve is raising and the operator
pushes the Manual Lower Output button, the Raise Output will be automatically set to Off.
If the valve is lowering and the Manual Raise Output button, is pressed, the Lower DO
will automatically be set Off.
When switching back and forth between the Automatic and Manual Modes, both Raise and
Lower DOs will be set to Off.

F.5.6 Run Switching
Sections F.5.6.1 and F.5.6.2 provide information on run switching properties (see Figure F10). Enable/Disable Run Switching via a button to the right of Run Switching.

F.5.6.1 Common Properties
Current Rank shows how many runs are required to be open. Maximum Rank is selected by
the user (from 2 to 4). Process Variable (PV) Selection can be Differential Pressure,
Frequency or Flow Rate. The Transition Time is the amount of time required to allow run
switching to access (opening or closing a run). Valve Settle Time is the amount of time
allowed after the Transition Time for the process variable (PV) to settle, before allowing
another run switching action to occur.

F.5.6.2 Run1/2/3/4 Properties
When a run is in Manual Mode (selected by the Run Auto/Manual button), the valve may
be opened or closed by right clicking on the field to the right of the Current Valve Command
and toggling the valve. When a run is in Auto Mode and Run Switching is enabled, the
valve is controlled by the run switching logic. If the Target Rank of a run is 1, the valve will
always be open. The Call Next Run Setpoint (SP) is the value if the process variable (DP,
Frequency or Flow Rate) that will cause the next run to open. The process variable for
calling runs is the PV from the run selected as Target Rank 1. If the run with Target Rank
1 is open, and the run with Target Rank 2 is not open when the PV for Target Rank 1
exceeds the Call Next Run SP, the Target Rank 2 will be opened. Likewise, if the PV for
Target Rank 2 drops below the Call Prev Run SP, the highest ranked run that is open will
be closed.
Call Next Deadband is the amount of time that the PV has to be greater than the Call Next
Run SP value before the next run will be opened.
Call Previous Deadband is the amount of time that the PV has to be less then the Call Prev
Run SP value before the lowest rank run will be closed.
Valve Control DO Point is the digital output point used for valve control.

CI-ControlWave EFM

Appendix F / F-15

Figure F-10 - Run Switching Web Page
F-16 / Appendix F

CI-ControlWave EFM

F.5.7 Radio Control
The Radio Control Configuration Web Page is accessible for users by selecting Radio
Control.

Figure F-11 - Radio Control Web Page
CI-ControlWave EFM

Appendix F / F-17

F.5.7.1 Radio Control Mode
Enable/Disable Radio Control via a control button to the right of Radio Control Mode.

F.5.7.2 Common Properties
Local Address
Local Address of the ControlWave EFM is set via the RTU Configuration Parameters
Page in NETVIEW or LOCAL VIEW.
Group Number
Group Address of the ControlWave EFM. This is set via the RTU Con-figuration
Parameters Page in NETVIEW or LOCAL VIEW.
Activate Radio on Local Port Active
When using any of the radio port scheduling modes (Radio Sensing, Hourly, Daily or
Daylight) Port 2 (the Radio Port) is inactive unless communications are scheduled.
However, by enabling the Activate Radio on Local Port Active mode, Port 1 (the Local Port)
can be used to control the state of Port 2. By plugging a cable into Port 1, Port 2 will
automatically be activated.

F.5.7.3 Radio Sensing Mode
Radio sensing allows a user to activate the radio for very short time intervals (specified in
milliseconds under Listen Time Out) every so many milliseconds (specified in seconds
under Listen Interval) to 'sense' a valid BSAP message on the radio's carrier frequency. If a
message is not detected, the radio is deactivated. If a message is detected, the radio is left
activated until it responds, after which it remains ON for another listen time interval. If no
more valid messages are detected, the radio returns to 'sense' mode. This mode allows the
system to use as little energy as possible to detect traffic throughout the day. Energy usage
depends on the activation time and activation rate (INTERVAL). Assuming a 1 watt radio
then a 200 millisecond listening period every 5 seconds is equivalent to .04 watts. Users can
configure the Interval and Rate (Listening period) to suit their energy needs. Radio Sensing
occurs between the START HOUR and END HOUR specified by the operator.

F.5.7.4 Hourly Mode
Start Time Offset Into Hour Seconds
Start Time Offset Into Hour Seconds specifies a user supplied offset which is used when
computing the radio On Time. Start Time Offset is a factor used to calculate the On Time.
Poll Time Per Node Seconds
Poll Time Per Node Seconds sets the duration of time (seconds) allocated for communications per node. Poll Time Per Node time is also used to calculate the On Time.
Poll Time Per Group Seconds
Poll Time Per Group Seconds sets the duration of time (seconds) allocated for communications per group. Poll Time Per Group time is also used to calculate the On Time.
Listen Time Seconds
Listen Time Seconds is the amount of time (in seconds) that the radio will be enabled for (at
the scheduled time, i.e., the enabled time before it will shut off due to the lack of communications.
F-18 / Appendix F

CI-ControlWave EFM

Re-Calculate Next On Time
If the user makes any changes to the items that affect the On Time, it must re-calculate the
Next On Time using this button.
Next On Time Hour/Minute/Second
When the Radio Control Mode is selected for Hourly, Daily or Daylight, these values
represent the next time that the radio will be turned on.
Turn Off Delay Seconds
Turn Off Delay Seconds is the amount of time (in seconds) that the radio will remain
enabled after successful communications have been established and completed. The radio
will remain active for the time period specified at the Turn Off Delay.

F.5.7.5 Daily Mode
Daily Mode Hour Offset
When the Daily Mode is selected, the radio will be turned on once during the day. The Daily
Mode Hour Offset determines which hour (0 - 23) that the radio will be turned on. On Time
Minutes and On Time Seconds are calculated.

F.5.7.6 Day Light Mode
A user may want to conserve battery autonomy by using the radios only during day light
hours. This is accomplished by selecting Daylight as the Radio Control Mode. Users select
the start of day light using the Day Light Mode Start Hour and Day Light Mode Start
Minute fields. Users select the end of day light using the Day Light Mode End Hour and
Day Light Mode End Minute field.

F.5.7.7 Statistic
Current/Previous Hour Radio On Time
Current/Previous Day Radio On Time
Current/Previous Month Radio On Time

F.6 METER RUN CATEGORY FUNCTIONS
Up to six WebBSI Web Pages are accessible under the Meter Run Category Section of
WebBSI; these include:
• Overview
• I/O Configuration

(Section F.6.1)
(Section F.6.2)

• Frequency Equation
• Compressibility Setup

(Section F.6.3)
(Section F.6.4)

The Web Page of Figure F.13 will appear when either the ‘Overview’ or ‘Flow Equation’ one
category has been selected, if a Meter Run Type (Differential or Linear) has not been
configured.

F.6.1 Meter Run Overview
See section F.6.1.1 for AGA3 Orifice Meters or F.6.1.2 for AGA7 Frequency Meters.

CI-ControlWave EFM

Appendix F / F-19

Figure F-12 - Meter Run Type Configuration WebPage

F.6.1.1 AGA3 - Orifice Meter
If the meter is configured as an Orifice Meter the following Read Only items are displayed:
Pipe Diameter & Orifice Diameter – To change these items, select Flow Equation from
the left side menu section.

Figure F-13A - Meter Run Overview (1985 AGA3 – Orifice Meter) Web Page

F-20 / Appendix F

CI-ControlWave EFM

Figure F-13B - Meter Run Overview (1992 AGA3 – Orifice Meter) Web Page
DP (Differential Pressure), SP (Static Pressure) and T (Temperature) – Live Values
from the Transmitters being used for calculation (selected via the I/O Configuration Page).
Active Flow Calculation – (AGA3I (1992) or AGA3 (1985) – To change an item, select
Flow Equation from the left side menu section.
Current Heating Value – The instantaneous value is provided.
Flow Rate (x1000) – The instantaneous value is provided.
Accumulated Volume and Accumulated Energy ‘Read Only’ fields are provided for the
Current Hour and Current Day:
Accumulated Volume, Accumulated Energy, Avg. Static Pressure, Avg. Temperature, Avg.
Diff. Pressure, Avg. Specific Gravity, Avg. Heating Value and Flow Time ‘Read Only’ fields
are provided for the Previous Hour and Previous Day:
The following five fields accommodate user changes:
Meter ID – a string signal identifying the meter run (default is ‘Run n,’) (n = the Run #).
Contract Hour – The user enters the Contract Hour for the start of the current day here.
Current Heating Value (Units) – The user may select the Heating Value units from a
drop down menu; default units are BTU/Ft3.
Flow Rate (Units) – The user may select the Flow Rate units from a drop down menu;
default units are Ft3/Hour.
Energy Rate (x1000000) – The user may select the Energy Rate - Energy Units from a
drop down menu; default units are BTU. The user may select the Energy Rate - Rate Units
from a drop down menu; default units are HOUR.
CI-ControlWave EFM

Appendix F / F-21

Reset Meter Run’s Measurement Type – This button (bottom of menu) allows the user
to reset the meter run’s measurement type (if a mistatke hass occurred during
configuration).

F.6.1.2 AGA7 Frequency Meter
If the meter is configured as a Linear Meter, following Read Only items are displayed:
Active Flow Calculation – Always AGA7
Corrected Flow Rate – Instantaneous Value
Uncorrected Flow Rate – Instantaneous Value
Current Heating Value – Instantaneous Value
Energy Value – Instantaneous Value
The following information is displayed for the Current Hour and Current Day:
Corrected Volume
Uncorrected Volume
Accumulated Energy
The following information is displayed for the Previous Hour and Previous Day:
Corrected Volume
Uncorrected Volume
Accumulated Energy
Average Static Pressure
Average Temperature
Average Specific Gravity
Average Heating Value
Flow Time

Figure F-14 - Meter Run Overview (AGA7 - Frequency Meter) Web Page
F-22 / Appendix F

CI-ControlWave EFM

There are five fields that allow the user to make changes:
Contract Hour – Users enter the Contract Hour for the start of the Contract Day here.
Current Heating Value (Units) – The user may select the Heating Value units from a
drop down menu; default units are BTU/Ft3.
Flow Rate (Units) – The user may select the Flow Rate units from a drop down menu;
default units are Ft3/Hour.
Energy Rate (x1000000) – The user may select the Energy Rate - Energy Units from a
drop down menu; default units are BTU. The user may select the Energy Rate - Rate Units
from a drop down menu; default units are HOUR.
Reset Meter Run’s Measurement Type - This button (bottom of menu) allows the user
to reset the meter run’s measurement type (if a mistake has occurred during configuration).

F.6.2 Meter Run I/O Configuration
Retrieving Configuration Please Wait will initially be posted on the WebBSI Web Page
when I/O Configuration has been selected followed by the Meter Run I/O Configuration
Web Page (see Figure F-15).
The Meter Run I/O Configuration Web Page provides the mechanism for assigning the
source for the inputs to the meter run calculations. From this page, the user would assign
specific transmitters and meters to a meter run. The user may select from analog
transmitters connected to I/O points, or from Smart Transmitters using BSAP or MODBUS
connected via an RS-485 serial port. In addition, the user would select the source of the
heating value, whether it is from a chromatograph and analog inputs or manually entered.

F.6.2.1 Differential Pressure, Static Pressure and Temperature Inputs
To select the source for pressure, differential pressure, and temperature, the user selects
‘Source,’ ‘Point ID’ and either the ‘BSAP Address,’ or ‘MODBUS Address.’
Analog Input is used when a transmitter is connected to the ControlWave GFC via a 420mA or 1-5Vdc signal. The user must then select the Point ID on the I/O board to which
the transmitter is physically connected. In addition, the zero and span settings and the
engineering units must be assigned by clicking the ‘Zeros & Spans’ link.
Wet End is used when the internal transmitter is used. No other configuration is required.
‘BSAP’ is selected when an external Bristol Babcock Smart Transmitter (either the
TeleTrans or the MVT) is used via RS-485 communications. The only configuration required
is to assign the BSAP address (1-127) of the BBI Smart Transmitter connected to the RS485 port.
‘MODBUS’ is selected when an external Smart Transmitter is used via RS-485
communications. The MODBUS interface supports the register list of the Rosemount 3095
smart multivariable transmitter. No additional configuration is required. Note: This functionality is only available when the Expansion Communications Module is used.

CI-ControlWave EFM

Appendix F / F-23

If a Zeros & Spans Button is pressed an Analog Input Configuration Web Pge Menu will
appear (see Figure F16A). Zero, Span and Units can be configured for analog inputs 1
through 3. The Analog Input Configuration Web Page also allows the user to enable/disable
the Damping function.

Figure F-15 - Meter Run I/O Configuration Web Page
F-24 / Appendix F

CI-ControlWave EFM

F.6.2.2 Frequency Input
The frequency input must be brought into one of the two high-speed counter (HSC) inputs
on the I/O board. Users select the two I/O points to which the typical turbine, PD, or
ultrasonic meter is connected. However; if using an Invensys Auto-Adjust Turbo-Meter,
both HSC inputs are used to select the Auto-Adjust Algorithm. To select the Auto-Adjust
Algorithm, the user will toggle the push button under Source fromr High Speed Counter to
Auto Adjust Module. In this case, the user selects which point will be used for the Main
Rotor and which point will be used for the Sense Rotor.
Further configuration of the Auto-Adjust Turbine Meter is performed via the Auto-Adjust
Configuration Page. (For a description of the items on the Auto-Adjust Configuration Page,
see the ACCOL3 Function Block Help Documentation).
If the user selects the Auto-Adjust Configuration button the Auto-Adjust Configuration for
Run # Web Page will appear (see Figure F-16B). This page provides Calibration Data,
Configuration Data and Calculated Factors.

Figure F-16A - Analog Input Configuration Web Page
(Accessed from Meter Run I/O Configuration Web Page)

F.6.2.3 Heating Value Input
The user has four options for the source of the heating value, Manual Entry,
Chromatograph, AGA5 or Analog Input.
Manual Entry is selected when the heating value will be directly entered. This value may
be entered via the Meter Run I/O Configuration Web Page, or may be written to a signal
externally.
Chromatograph is selected when the heating value is read directly from the chromatograph
via the MODBUS interface.
CI-ControlWave EFM

Appendix F / F-25

AGA5 is selected when the component mole % values are fed into the AGA5 equation.
Source of the component mole % values is determined by settings made on the
Chromatograph Setup Page.

Figure F-16B - Auto-Adjust Configuration for Run# Web Page
(Accessed from Meter Run I/O Configuration Web Page)
F-26 / Appendix F

CI-ControlWave EFM

F.6.2.4 Alarm Configuration (Accessed via Meter Run I/O Configuration)

Figure F-17 - Alarm Configuration Web Page
(Accessed from Meter Run I/O Configuration Web Page)
Enable/Disable - the alarm function on a per point basis.
Units and Current Value - are read from the I/O source.
Alarm Limit - are set via the appropriate alarm limit point.
Deadband - dead bands represent a range just below the high limits or just above the low
limits in which the alarm variable remains in an alarm state, despite the fact that its value
no longer exceeds the alarm limit. Should the alarm variable rapidly fluctuate above and
below the alarm limit (without the use of dead band settings), the system will be flooded
with alarm messages.

F.6.3 Flow Equations
When the user pushes the Flow Equation button (on the left side of the menu) the Flow
Equation Setup Web Page that is appropriate for the meter type will appear. If the meter
type has not been configured, the screen shown for Figure F-12 will appear. A user must
then select the Meter Run Type to be used.

F.6.3.1 Orifice Flow Equation Setup
F.6.3.1.1 Differential Measurement

If the user configures the meter as a Differential Measurement type, the Flow
Equation defaults to the AGA3 (1985) equation. Users may change to the AGA3
CI-ControlWave EFM

Appendix F / F-27

(1992) equation by toggling the push button labeled Click Here to select AGA3I
(1992).
F.6.3.1.2 1985 AGA3 Equation Configuration
The user must configure the inputs to the equation.
Pressure Tap – The user must select Pressure Tap type and location. The type is defined
Flange or Tap and the location is defined as Upstream or Downstream. Pressure Tap is
selected as follows:
1
2
3
4

DOWNSTREAM FLANGE
UPSTRERAM FLANGE
DOWNSTREAM TAPS
UPSTREAM TAPS

Figure F-18A - (1985 AGA3) Orifice Flow Equation Setup Web Page
Low Flow Cut Off - When the differential pressure drops below the low flow cut off value,
the flow rate will be set to zero. Default units are “inches of water.”
Orifice Diameter - Orifice diameter is entered here. Default units are “inches.”
Pipe Diameter - Diameter of the pipe is entered here. Default units are “inches.”
Orifice Constant - K (AGA3 1985) - Orifice constant is entered here.
Adjust Press. - Users enter Average Barometric Pressure here.
Diff. Pressure - Actual value of Differential Pressure (Inches H2O) are displayed here.
Static Pressure - Actual value of Static Pressure (psig) are displayed here.
Temperature - Actual value of Temperature (Deg. F) are displayed here.
Specific Gravity - Specific Gravity of the gas being measured is displayed here.
F-28 / Appendix F

CI-ControlWave EFM

FPV - Supercompressibility Factor (FPV) is displayed here.
Base Temperature - Required or Contract Base Temperature is entered here (Deg. F).
Base Pressure - Required or Contract Base Pressure is entered here (psig).
The following outputs from the AGA3 calculation are displayed:
MSCF/H - Flow rate in thousands of standard cubic feet per hour
Low Flow Cut Off - Cutoff (if the DP drops below the low flow cut off value) or OK
C Prime - Orifice Flow Constant
Fb - Basic Orifice Factor
Fr - Reynolds Number Factor
Y - Expansion Factor
Fpb - Pressure Base Factor
Ftb - Temperature Base Factor
Ftf - Flowing Temperature Facture
Fg - Specific Gravity Factor
Extension - Square Feet of the Product of Differential Pressure and Static Pressure
F.6.3.1.3 1992 AGA3 Equation Configuration
The user must configure the inputs to the equation.
Pressure Tap - The user mat toggle between pressure tap settings Flange/Upstrm and
Flange/Dnstrm.
Low Flow Cut Off - When the differential pressure drops below the low flow cut off value,
the flow rate will be set to zero. Default units are inches of water (H2O).
Orifice Diameter - Orifice diameter is entered here. Default units are inches.
Pipe Diameter - Diameter of the pipe is entered here. Default units are inches.
Orifice Temp. Coefficient - Orifice coefficient of thermal expansion is entered here
(Inches per Inch-degree F).
Pipe Temp. Coefficient - Pipe coefficient of thermal expansion is entered here (Inches per
Inch-degree F).
Isentropic Exponent - Gas Isentropic Exponent is entered here. This should not be
changed unless the Gas Isentropic Exponent is known to be other than the 1.3 value given
in the 1992 American Gas Association (AGA3) Report.

CI-ControlWave EFM

Appendix F / F-29

Figure F-18B - (1992 AGA3) Orifice Flow Equation Setup Web Page
Adjust Press. - Users enter Average Barometric Pressure here (psia).
Diff. Press. - Actual value in use is displayed here.
Static Pressure - Actual value in use is displayed here.
Temperature - Actual value in use is displayed here.
Spec. Gravity - Specific Gravity of the gas being measured is displayed here.
Z Flowing - Flowing compressibility Factor, Zf, generated from the AGA8 calculation
referenced to upstream conditions.
Z Base - Base compressibility Factor from the AGA8 Gross calculation.
Base Temperature - Required and Contract Base Temperate is entered here (Deg. F).
Base Pressure - Required or Contract Base Pressure is entered here (psia). The following
outputs from the AGA3 calculation are displayed:
MSCF/H - Flow rate in thousands of standard cubic feet per hour
Low Flow Cut Off - Cutoff (if the DP drops below the low flow cut off value) or OK
C Prime - Orifice Flow Constant
Fn - Numeric Conversion factor which includes Ev (the velocity of approach factor)
CD - Orifice Coefficient of Discharge

F-30 / Appendix F

CI-ControlWave EFM

Y - Expansion Factor
Fpb - Pressure Base Factor
Ftb - Temperature Base Factor
Ftf - Flowing Temperature Facture
Fpv - Supercompressibility Factor
Fm - Additional Correction Factor
Extension - Square Root of the product of Diff. Pressure and Static Pressure (
Reynolds Number - Computed Pipe Reynolds Number

)

BCF - Base Correction (Zb/Zf)

F.6.3.2 Frequency Flow Equation Setup
If the user configures a meter as a linear meter, the AGA7 Calculation page appears (see
Figure F-19).

Figure F-19 - Frequency Flow Equation Setup Web Page
CI-ControlWave EFM

Appendix F / F-31

Density Switch - Users may select whether a density meter or Gravitometer is used as an
input to the equation.
Gravitometer Press. Switch - Users may save the default value for Pressure or Volume
entered in the Gravitometer Press. Used field.
Gravitometer Temp. Switch - Users may use the default temperature value of the value
entered in the Gravitometer Temp. Used field.
Specific Gravity - Specific Gravity of the gas being measured is displayed here.
FPV - Supercompressibility Factor is displayed here.
K Factor Units - Users may select whether the factor is in units of CuFt/Count or
Counts/CuFt.
K Factor - Actual Gas Volume represented per count is entered here. The relationship is
controlled by the K Factor Units switch. If the K Factor Units switch is set to CuFt/Count,
and each pulse from the meter represents 100 cubic feet, the K Factor is entered as 100. If
the K Factor Units switch is set to Counts/CuFt and each pulse from the meter represents
100 cubic feet, the K Factor is entered as 1/100 or 0.01.
Frequency Input - The frequency from the meter (Hz) is displayed here.
Frequency Input Max - If the frequency input exceeds the Frequency Input Max value,
the Frequency Input Max value is used in the flow equation.
Static Pressure - Actual values in use for the calculation
Temperature - Actual values in use for the calculation
Pressure Adjustment - Average Barometric Pressure (psia)
Base Pressure - Required or Contract base pressure (psia)
Base Temperature - Required or Contract base temperature (Deg. F)
Calibration Factor - Sometimes referred to as Meter Factor, this is an adjustment factor
issued by the meter manufacturer to account for known meter adjustments. The default 1,
i.e., no adjustments required.
MSCF/H - Flow rate in thousands of standard cubic feet per hour.
MSCF/H (Max) - The maximum flow value allowed through the meter at the maximum
frequency input.

F.6.4 Supercompressibility Setup
When the 1985 AGA3 calculation is selected, the Supercompressibility (Fpv) value is
calculated using the NX-19 equations. When the 1992 AGA3 calculation is used the Flowing
(Zf) and Base (Zb) compressibility factors are calculated using either the AGA8 Detail or
AGA8 Gross module. The AGA8 Gross module provides either (G, C, N) or (HV, G, C)
modes.
F-32 / Appendix F

CI-ControlWave EFM

If the Base Pressure or Base Temperature differ from Standard conditions (14.73 psia, 60
ºF) and the 1992 AGA3 calculation is in use, an AGA8 Detail or AGA8 Gross module will be
executed to calculate standard compressibility Zs for the defined gas composition. The
calculation of Zs will be done once per minute or whenever a related gas constant changes.
Users may select which Supercompressibility equation to use on a per run basis. The user
will click on the appropriate button to select the calculation equation to be used. The
selected compressibility calculation will be shown.

Figure F-20 - Supercompressibility Configuration Web Page
When using the AGA8 Gross Calculation, the user must select the Gross Mode1 or the
Gross Mode2 calculation. The user may change the Base Pressure and the Base
Temperature for this screen.
Flowing Static Pressure, Flowing Temperature, BTU and Specific Gravity in use are
displayed on this page.
Values of the gas components used to calculate the Supercompressibility are displayed
along with the FPV, Zflowing and ZBase values calculated by the Supercompressibility
equation in use.
CI-ControlWave EFM

Appendix F / F-33

F.7 CHROMATOGRAPH CATEGORY FUNCTIONS
The standard application program is configured for communicating with a Daniel 2251 Gas
Chromatograph, via a serial MODBUS interface. Users will configure the Chromatograph
interface from the “Chromatograph Setup” Web Page (Figure F-21).

Figure F-21 - Chromatograph Setup Web Page
F-34 / Appendix F

CI-ControlWave EFM

F.7.1 Communication Settings
Mode – Enabled/Disabled - When this signal is ENABLED, a chromatograph is present,
and gas component data is provided by the chromatograph interface. When this signal is
DISABLED, the fixed values for the gas component data are used.
Common Fixed Data - When COMMON is selected fixed chromatograph values for all runs
will come from the Stream 1 fixed values. When INDIVIDUAL is selected, fixed
chromatograph values will come from the individual stream assigned to each run.
Port Number - When a chromatograph is present, this is the port number on the ControlWave EFM that the chromatograph is connected to. The Default Port in the load is Port 4.
Note: This functionality requires that an Expansion Communications Module is
installed.
MODBUS Address - When a chromatograph is present, this is the MODBUS Address (1246) of the chromatograph.

F.7.2 Stream Assignment and Setup
The Daniel 2251 can provide gas properties for up to 4 individual streams. The standard
application program allows the user to assign any stream to any meter run (up to four
streams and four runs). Each meter run may be assigned to the same stream, or each may
be assigned to a different stream.
In the event of a chromatograph failure, the user may assign either fixed values to use for
each gas component, or the last good values retrieved from the chromatograph. This mode
is selectable on a per stream basis.

F.7.3 Analysis Data
The Raw values of BTU and Specific Gravity from the Chromatograph will be displayed for
each stream. Fixed values for BTU and Specific Gravity may be entered for each stream.

F.7.4 Gas Components
The Raw value of each gas component from the chromatograph will be displayed for each
stream. Fixed values for each gas component may be entered for each stream

F.7.5 Chromatograph Component Range Setup
Values of BTU, Specific Gravity and each gas component of each stream are compared to
user configured (high and low) allowable limits. These limits are set from the
Chromatograph Component Range Setup Web Page, accessible from the Chromatograph
Setup Web Page. If a component is found to be outside the user defined limits, the value
will be clamped at the closest configured limit.
It also checks the sum of the components; if the sum is outside the configurable limits, a
Boolean signal is set indicating so. If any component or the total is out of range, either fixed
or last values will be used.

CI-ControlWave EFM

Appendix F / F-35

Figure F-22 - Chromatograph Component Range Setup Web Page

F.8 LOGS CATEGORY FUNCTIONS
Two WebBSI Web Pages are accessible under the Logs Category Section of WebBSI; these
are:
•
•
•
•

View Archives
View Audit Trail
View Signal List
Archive File Collection

F-36 / Appendix F

(Section F.8.1)
(Section F.8.2)
(Section F.8.3)
(Section F.8.4)
CI-ControlWave EFM

F.8.1 Meter Run Archive Files
When View Archive has been selected, the Meter Run Archive Files WebBSI Web Page
will be displayed (see Figure F-23). Meter Run Archive Files Web Pages provide three
types of archive files, i.e., Hourly, Daily & 15 Minute for each of the four runs.

Figure F-23 - Meter Run Archive File Web Page (Hourly Archive Shown)
Meter Run Archive File Web page pushbuttons allow the user to Collect Data, Save
Parameters, Search Criteria, select Floating Point Format and show File Definition. Users
can select one of the following Archive Collection Parameters: File Number To Collect,
Select from oldest record or Freeze Date/Time. Users can select the archive file, (Hourly,
Daily or 15 Minutes) for the run in question by entering a number from 1 to 12 in the field
adjacent to File Number:
Meter
Run

Run ID

1
2
3
4

Run 1
Run 2
Run 3
Run 4

Hourly
Archive
Number
1
4
7
10

Daily
Archive
Number
2
5
8
11

15 Minute
Archive
Number
3
6
9
12

The Web page opens by default configured to view Archive 1 (R1_HOURLY). To view
another archive, the user will enter the desired archive number in the File Number: field
and then press the Collect Data button.
To save the collected archive data, the user would press the Save Parameters button. A
Save Parameters dialog box will appear which will allow the user to select the file name to
save the data as, and select the folder to save the data in. After selecting the file Name and
Path (each box) and checking Save Archive Data, the file will be saved by clicking OK on
the Save Parameters Dialog. The file saved is a binary file. To view the file, the user may
use the Data File Conversion Utility or the UOI Dump Utility (UOIDMP.exe).

CI-ControlWave EFM

Appendix F / F-37

By clicking on the Floating Point Format button, the user may change the way Analog
Values are displayed. By clicking on the File Definition button, the user can view how the
archive file is configured.
Additionally, the Meter Run Archive Web page provides the number of Fields Collected
and Records Collected under the Stats field.

F.8.2 Meter Run Audit Trail
The ControlWave EFM keeps an Audit Trail Buffer capable of storing the most recent 500
Alarms and the most recent 500 Events. Internally, these buffers are maintained
separately to prevent recurring alarms from overwriting configuration audit data.
Externally, they are reported to the user as a single entity. Both operate in a circular
fashion with new entries overwriting the oldest entry when the buffer is full.
When View Audit Trail is selected, the Meter Run Audit Trail Web Page (see Figure
F.24) will be displayed. Meter Run Audit Trail Web page buttons allow the user to
Collect Data, Save Parameters, Search Criteria, and Show Statistics. Additionally, the
Meter Run Audit Trial Web page posts the Total # of Records Collected near the top right
side of the page. When the page is initially opened, only the 24 most recent records are
gathered. To view more records, the user may scroll down using the Vertical Scroll Bars.

Figure F-24 - Meter Run Audit Trail Web Page (Both Alarms & Events Selected)

F.8.3 View Signal List
Signal List Information:

Number - List Number to be viewed
Start Index - List Element to start collecting

Collect List:
Floating Point Format:
F-38 / Appendix F

Max Signals to Collect – Number of Signals to collect
Starts list collection
Select this button to change the appearance of Floating Point
Values
CI-ControlWave EFM

Figure F-25 - Signal List Web Page

F.8.4 Archive File Collection
When Collection is selected, an Archive File Collection Web Page (see Figure F.26) will be
displayed. Log Break Configuration buttons are provided on the Archive File Collection
Web Page to enable/disable log breaks for configuration changes and Gas Chromatograph
operation and configuration. Log Breaks are ‘Disabled’ by default.

Figure F-26 - Archive File Collection Web Page
CI-ControlWave EFM

Appendix F / F-39

F.9 LOAD/SAVE CATEGORY FUNCTION
One WebBSI Web page is accessible under the Load/Save Category Section of WebBSI; this
is called the Meter Run Save/Load Configuration Web page (see Figure F.27).
This page allows a user to save configuration parameters from a ControlWave EFM or
load a saved configuration down to a ControlWave EFM. The page opens from defaults
and the information displayed is retrieved from the following file:
(C:\OpenBSI\WebEFM\Config\DefaultMEFM.RCP).
The information displayed is returned from this file. If a user has made changes to the
configuration of the unit, upgrade of the values can be changed by clicking on Load from
RTU. The values in the configuration now reflect the actual configuration of the unit.

Figure F-27 - Meter Run Save/Load Configuration Web Page
Users may save their configuration to a file. First the user should select the file where the
configuration should be save. This is done by clicking on Browse, and selecting an existing
file, or by typing in a new file name to save the configuration. After the file has been
selected, the date is saved by clicking on Write to File.
F-40 / Appendix F

CI-ControlWave EFM

A user may download a previously saved configuration to the ControlWave EFM. Users
would select the file to download to the unit by clicking on the Browse button to locate it. A
user would then click on Load from File. This will update the recipe with the information
from the file. To load the configuration to the ControlWave EFM, the user would click on
Write to RTU. By defaults the RCP files are stored in the following folder:
(C:\OpenBSI\WebEFM\Config).
The RCP file can be edited with a text editor such as WordPad. Users may save a
configuration from one meter, use a text editor to change the configuration parameters for a
different meter and read the configuration from the file, and download the modified
configuration to a new meter.
Users may modify the value of a signal from the Meter Run Save/Load Configuration
page. A user would highlight the signal that needs to be modified and then click on the
Modify Signal button. A dialog box will open with the Signal Name and Value. Users may
either enter the new value for String Signals and Analog Signals or select the new value
from the drop down menu (for logical signals). To write the change down to the
ControlWave EFM, the user must click on Write to RTU. To ensure a saved configuration,
the user must click on Write to File.
Typical Steps:
1. Open Page – Values from DefaultMEFM,RCP are shown. If there is another configuration that the user would like to use, skip to Step 7.
2. Update Values with actual settings by clicking on Load from RTU.
3. Review settings and make modifications as required using the Modify Signal button.
4. Click on Write to RTU.
5. Select the file to save the configuration to by clicking on Browse. Find an existing file to
update or enter the name of a new file to create.
6. Click on Write to File. - FINISHED
7. Select another file to use by clicking on Browse and the desired .RCP file.
8. Click on Load from File. - Return to Step 2.

F.10 SPECIAL FUNCTIONS
A special Sync Date & Time web page (see Figure F-28) is accessible from the Special
Functions Category Section of WebBSI.

CI-ControlWave EFM

Appendix F / F-41

Figure F-28 - Sync Date & Time Web Page Display

F-42 / Appendix F

CI-ControlWave EFM

Instruction Manual
CI-ControlWave EFM
Oct., 2006

ControlWave EFM

ControlWave EFM RADIO READY
INSTALLATION GUIDE (P/N 721700-01-2)
Appendix G

www.EmersonProcess.com/Bristol

APPENDIX G

ControlWave EFM
Radio Ready Installation Guide
TABLE OF CONTENTS
SECTION

TITLE

G1.1
G2.1
G2.1.1
G2.2

GENERAL INTRODUCTION....................................................................................... G-1
RADIO INSTALLATION .............................................................................................. G-2
Installation of a Radio into a Radio Ready ControlWave EFM .................................. G-2
ADDITIONAL FreeWave INFORMATION ................................................................. G-5

CI-ControlWave EFM

PAGE #

Appendix G - Radio Ready Installation Guide Contents / 0 - 1

Appendix G
RADIO READY INSTALLATION GUIDE
G1.1 GENERAL INTRODUCTION
ControlWave EFM Electronic Flow Meters may be ordered "Radio Equipped," or “Radio
Ready.” Radio Ready units contain all hardware required to field install a Bristol provided
radio except the radio and radio installation hardware (such as screws, nuts and washers.
Radio Ready units will 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 Suppresser).
Radios are shipped with all necessary installation hardware and are to be secured to the
factory installed Radio Mounting Bracket which in turn mounts to the ControlWave EFM
Fabrication Panel.
ControlWave EFM Electronic Flow Meters may be equipped with one of the external
radios listed below or may be shipped with the hardware necessary to install one of these
radios at a future date. The term “external radio,” refers to those radios that mount on a
Radio Mounting Bracket instead of piggy-back on an Expansion Comm. Module.
MDS 4710A – Remote Data Transceiver (Radio)
MDS 4710B – Data Transceiver (Radio)
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 Transceivers
MDS iNET 900 Ethernet Radio
MDS Transnet 900 - Spread Spectrum Data Transceiver
FreeWave Radio - Spread Spectrum Data Transceiver Model FGRM-501X005

Radios are shipped with the following additional hardware:
MDS 4710A/B, MDS 9710A/B & MDS 9810 models are provided with four (4) 6-32 x 5/16
Pan Head Screws and a Power Connector.
MDS entraNET 900 Serial Remote and Ethernet Remote models are provided with four (4)
6-32 x 5/16 Pan Head Screws and a Power Connector.
MDS entraNET 900 Access Point and MDS iNET 900 (Remote Serial Gateway, Remote
Ethernet Bridge or Access Point/Remote Dual Gateway) models are provided with four (4)
6-32 x 5/16 Pan Head Screws and a Power Connector.
MDS TRANSNET radios are provided with four (4) 6-32 x 7/16 Pan Head Screws, four (4)
#6 Flat 5/16 O.D. Washers and four (4) 6-32 Hex Nuts and a Power Connector.
FreeWave radios are provided with eight (8) 6-32 x 5/16 Pan Head Screws and four (4) 6-32
x .500 F/F Standoffs.

CI-ControlWave EFM

Appendix G - Radio Ready Installation Guide / G-1

G2.1 RADIO INSTALLATION
DANGER
Radios provided by Bristol, Inc. for use in the ControlWave EFM
Electronic Flow Meters are approved for use in Class I, Division 2, Groups
A, B, C & D hazardous locations. Radios may also be used in nonhazardous locations. The installer must be familiar with hazardous
location installation guidelines before installation or maintenance is
undertaken. Do not begin radio installation or service to the ControlWave
EFM unless the area is known to be non-hazardous.
NOTE
Only the external radios listed on page 1 of this document may be used in
Class I, Division 2, Groups A, B, C & D hazardous locations! Use of other
external radios in Class I, Division 2, Groups A, B, C & D hazardous
locations is not allowed!
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.
G2.1.1 Installation of a Radio into a Radio Ready ControlWave EFM
Radio Ready ControlWave EFM Electronic Flow Meters contain all the hard-ware
required (except the radio and securing hardware) to accommodate installation and
operation of the radio option.
1. Open the Instrument Front Cover.
2. Remove the Radio Mounting Bracket by removing the two 10-32 x 3/8 Pan Head Screws
that secure it to the Fabrication Panel.
3. Using the mounting hardware provided with the radio, mount and secure the radio to
the Radio Mounting Bracket removed in step 2 (see Figures 1 & 2).
4. Re-install the Radio Mounting Bracket to the Fabrication Panel using the two 10-32 x
3/8 Pan Head Screws that were removed in step 2.
5. Connect the radio’s RF cable to the radio. The other end of the radio’s internal RF cable
should already be installed onto either a Polyphaser or a RF Bulk Head/Antenna
Interface connector.
6. Connect the user supplied antenna cable to either the Polyphaser or Bulk Head antenna
cable connector jack on the bottom of the ControlWave EFM (see Figure 3).

G-2 / Radio Ready Installation Guide

CI-ControlWave EFM

Figure 1 - Radio Installation - Mounting Diagram
CI-ControlWave EFM

Appendix G - Radio Ready Installation Guide / G-3

Figure 2 - Radio Mounting Bracket - Radio Installation Diagram
7. Plug the Radio Interface Cable into the radio’s Comm. Port. The other end of this cable
should already be installed into Comm. Port 2. of the CPU Module. In the case of the
FreeWave Radio, power is also supplied via the Interface Cable.
8. Remove the MDS Radio’s Power Connector from the MDS Radio in question and connect the unterminated ends of the MDS Power Cable (shipped loose with the
ControlWave EFM) to the MDS Power Connector (Red = Pos. and Black = GND) (see
Figure 1). Plug the end of the MDS Radio Power Cable that you just dressed into the
MDS Radio. Plug the other end of the MDS Radio Power Cable into connector TB3 of
the Power Distribution Board (see Figure 4).
9. After testing the unit, close and secure the Door.

G-4 / Radio Ready Installation Guide

CI-ControlWave EFM

Figure 3 - Partial View - ControlWave EFM
with/without Polyphaser Installed

G2.2 ADDITIONAL FreeWave INFORMATION
The FreeWave Spread Spectrum Data Transceiver Model FGRM-501X005 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.
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:
The setup program is invoked by connecting the radio to any PC
equipped with a terminal program (such as HyperTerminal), setting the parameters for that terminal to those of Table 1, and
putting the radio into setup mode.
Connection to the PC requires a special RS-232 cable with a 9-pin
Female D-Type connector on the PC side and a 10-pin Female
MTA-100 Connector assembly on the radio side. A cable can be
constructed as illustrated in Figure 4. The terminal program must
be running before invoking the setup program. The setup
program is invoked by shorting MTA-100 Connector pins 4 (GND)
and 2 (MENU) together.

CI-ControlWave EFM

Appendix G - Radio Ready Installation Guide / G-5

Table 1 - Setup Menu Terminal Settings
PARAMETER
Baud Rate
Data Rate
Parity
Stop Bits
Parity Check
Carrier Detect

SETTING
19,200
8
None
1
None/Off
None/Off

Figure 4 - Cable Diagram for Radio to PC Interface

G-6 / Radio Ready Installation Guide

CI-ControlWave EFM

ControlWave EFM
Material Safety Data Sheets
A Material Safety Data Sheet is provided herein to comply with OSHA’s Hazard Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific
requirements.
Material Safety Data Sheets are provided in the order listed in Table Z-1 below.
TABLE Z-1
MSDS for ControlWave EFM Instruction Manual
(CI-ControlWave EFM
Manufacturer
DURACELL

General Description
3V Lithium Manganese
Dioxide Battery

Part Number
DL 2450

Bristol Babcock Part Number = 395620-01-5
Manufacturer

General Description
12V - 33AH/20 Hr.
B.B. Battery
Sealed Lead-acid
Co., Ltd.
Battery
Bristol Babcock Part Number = 395407-03-6

01/31/05

Part Number
BP33-12

Appendix Z - CI-ControlWave EFM

MSDS

BLANK PAGE

Gillette
Environment
Health and Safety

37 A Street
Needham, MA 02492
Tel 781.292.8151
Page 1 of 4

MATERIAL SAFETY DATA SHEET
NAME:

DURACELL LITHIUM MANGANESE DIOXIDE COIN BATTERIES
Effective Date: 8/8/03
Not applicable

CAS NO:

Rev:

A. — IDENTIFICATION
%
65-75

Manganese Dioxide (1313-13-9)
Propylene Carbonate (108-32-7)
Lithium (7439-93-2)
Graphite, synthetic (7440-44-0)
1,2-Dimethoxyethane (110-71-4)
Lithium Perchlorate (7791-03-9)

Formula: Mixture

Mixture

Molecular Weight:

10-15
5-10

Synonyms:

Lithium Manganese Dioxide Coin Cells:
3V-DL2016; DL2025; DL2430; DL2450;
DL2032; DL1616; DL1620

5-10
1-10

<1.5

B. — PHYSICAL DATA
NA

Boiling Point
°F
NA

°C

Melting Point
°F
NA

°C

Specific Gravity (H2O=1)

Vapor Density (air=1)

Evaporation
(

=1)

Ether
NA

Freezing Point
°F
NA

Vapor Pressure @

°F

Saturation in Air
(by volume@

°C

mm Hg

Autoignition Temperature
°F

°F)

% Volatiles

Solubility in Water

Appearance/Color

Coin cells. Contents dark in color.

Flash Point and
Test Method(s)

1,2-Dimethoxyethane (Approximately 3-7% of contents): 42.8 °F, 6°C (Closed Cup)

Flammable Limits in Air
(% by volume)

Lower

°C

Upper

C. — REACTIVITY
Stability

stable

unstable

Polymerization

Conditions to Avoid

Do not heat, crush, disassemble, short circuit or
recharge.
Incompatible Materials

Contents incompatible with strong oxidizing agents.

may occur

will not occur

Conditions to Avoid

Not applicable
Hazardous Decomposition Products

Thermal degradation may produce hazardous fumes
of manganese and lithium; oxides of carbon and other
toxic by-products.

* IF MULTIPLE INGREDIENTS, INCLUDE CAS NUMBERS FOR EACH

NA=NOT AVAILABLE

Footnotes

Not applicable
GMEL#

2033.3

Page 2 of 4

D. — HEALTH HAZARD DATA
Occupational Exposure Limits PEL’s, TLV’s, etc.)

8-Hour TWAs: Manganese Dioxide (as Mn) - 5 mg/m3 (Ceiling) (OSHA); 0.2 mg/m3 (ACGIH/Gillette)
1,2-Dimethoxyethane - 0.15 ppm (Gillette)
Graphite (all kinds except fibrous) - 2 mg/m3 (synthetic, ACGIH); 15 mg/m3 (total, OSHA);
5 mg/m3 (respirable, OSHA)
These levels are not anticipated under normal consumer use conditions.
Warning Signals

Not applicable
Routes/Effects of Exposure

These chemicals and metals are contained in a sealed can. For consumer use, adequate hazard warnings are
included on both the package and on the battery. Potential for exposure should not exist unless the battery
leaks, is exposed to high temperature, is accidentally swallowed or is mechanically, physically, or electrically
abused.
1. Inhalation

Not anticipated. Respiratory (and eye) irritation may occur if fumes are released due to heat or
an abundance of leaking batteries.

2. Ingestion

An initial x-ray should be obtained promptly to determine battery location. Batteries lodged in
the esophagus should be removed immediately since leakage, burns and perforation can occur
as soon as 4-6 hours after ingestion. Irritation to the internal/external mouth areas may occur
following exposure to a leaking battery.

3. Skin

a. Contact

Irritation may occur following exposure to a leaking battery.
b. Absorption

Not anticipated.
4. Eye Contact

Irritation may occur following exposure to a leaking battery.

5. Other

Not applicable

E. — ENVIRONMENTAL IMPACT
1. Applicable Regulations All ingredients listed in TSCA inventory.
2. DOT Hazard Class 3. DOT Shipping Name -

Not applicable
Not applicable

While lithium batteries are regulated by IATA and ICAO, the type of lithium batteries offered for sale by DURACELL are
considered non-hazardous per provision A45 of the IATA Dangerous Goods Regulations and provision A45 of the ICAO
Technical Instructions For The Safe Transport Of Dangerous Goods By Air. Per section A45 of the IATA and ICAO
regulations, properly marked, labeled and packaged DURACELL consumer lithium batteries, which are of the solid cathode
type, with less than 1g lithium per cell and less than 2g lithium per battery, are exempt from further regulation. When these
batteries are separated to prevent short circuits and properly packaged in strong packaging (except when installed in electronic
devices), they are acceptable for air transport as airfreight without any other restrictions. In addition, when installed in
equipment or when no more than 24 cells or 12 batteries meeting the A45 provision are shipped, they are not subject to
special packaging, marking, labeling or shipping documentation requirements. Thus, these batteries are not considered
hazardous under the current regulations and are acceptable for air transport.
Environmental Effects

These batteries pass the U. S. EPA's Toxicity Characteristic Leaching Procedure and therefore, maybe
disposed of with normal waste.
GMEL#

2033.3

Page 3 of 4

F. — EXPOSURE CONTROL METHODS
Engineering Controls

General ventilation under normal use conditions.

Eye Protection

None under normal use conditions. Wear safety glasses when handling leaking batteries.
Skin Protection

None under normal use conditions. Use butyl gloves when handling leaking batteries.
Respiratory Protection

None under normal use conditions.

Other

Keep batteries away from small children.

G. — WORK PRACTICES
Handling and Storage

Store at room temperature. Avoid mechanical or electrical abuse. DO NOT short or install incorrectly.
Batteries may explode, pyrolize or vent if disassembled, crushed, recharged or exposed to high temperatures.
Install batteries in accordance with equipment instructions. Replace all batteries in equipment at the same
time. Do not carry batteries loose in pocket or bag.

Normal Clean Up

Not applicable

Waste Disposal Methods

No special precautions are required for small quantities. Large quantities of open batteries should be treated
as hazardous waste. Dispose of in accordance with federal, state and local regulations. Do not incinerate,
since batteries may explode at excessive temperatures.

GMEL#

2033.3

Page 4 of 4

H. — EMERGENCY PROCEDURES
Steps to be taken if material is released to the environment or spilled in the work area

Evacuate the area and allow vapors to dissipate. Increase ventilation. Avoid eye or skin contact. DO NOT
inhale vapors. Clean-up personnel should wear appropriate protective gear. Remove spilled liquid with
absorbent and contain for disposal.
Fire and Explosion Hazard

Extinguishing Media

Batteries may burst and release hazardous decomposition products when As for surrounding area. Dry
exposed to a fire situation. See Sec. C.
chemical, alcohol foam, water or
carbon dioxide. For incipient
fires, carbon dioxide extinguishers
are more effective than water.
Firefighting Procedures

Cool fire-exposed batteries and adjacent structures with water spray from a distance. Use self-contained
breathing apparatus and full protective gear.
I. — FIRST AID AND MEDICAL EMERGENCY PROCEDURES
Eyes

Not anticipated. If battery is leaking and material contacts eyes, flush with copious amounts of clear, tepid
water for 30 minutes. Contact physician at once.
Skin

Not anticipated. If battery is leaking, irrigate exposed skin with copious amounts of clear, tepid water for a
least 15 minutes. If irritation, injury or pain persists, consult a physician.
Inhalation

Not anticipated. Respiratory (and eye) irritation may occur if fumes are released due to heat or an abundance
of leaking batteries. Remove to fresh air. Contact physician if irritation persists.
Ingestion

Consult a physician. Published reports recommend removal from the esophagus be done endoscopically
(under direct visualization). Batteries beyond the esophagus need not be retrieved unless there are signs of
injury to the GI tract or a large diameter battery fails to pass the pylorus. If asymptomatic, follow-up x-rays
are necessary only to confirm passage of larger batteries. Confirmation by stool inspection is preferable
under most circumstances. If mouth area irritation/burning has occurred, rinse the mouth and surrounding
area with clear, tepid water for at least 15 minutes.
Notes to Physician

1) For information on treatment, telephone (202)-625-3333 collect.
2) Potential leakage of less than 50 milligrams of propylene carbonate (CAS #108-32-1) and
dimethoxyethane (CAS #110-71-4).
3) Dimethoxyethane readily evaporates.
4) Under certain misuse conditions and by abusively opening the battery, exposed lithium can react with
water or moisture in the air causing potential thermal burns or fire hazard.
Replaces # 1461
The information contained in the Material Safety Data Sheet is based on data considered to be accurate, however, no warranty is
expressed or implied regarding the accuracy of the data or the results to be obtained from the use thereof.
MSDS-4 (8/95)

GMEL#

2033.3

MATERIAL SAFETY DATA SHEET
SECTION 1: PRODUCT AND MANUFACTACTURER
Product name: Sealed maintenance-free lead acid batteries
Manufacturer: B.B. Battery Co., Ltd.
Address: Chengdong Trial Area, Huanggang, Raoping, Guangdong, P.R.China 515700
Tel: +86-768-7601001 or +86-768-7601002
Fax: +86-768-7601469
US Office: B&B Battery USA, Inc.
Address: 6415 Randolph Street, Commerce, CA 90040
Tel: 323-278-1900
Fax: 323-278-1268

SECTION 2: HAZARDOUS COMPONENTS
COMPONENTS

%WEIGHT TLV

LD50 ORAL

LC50 INHALATION LC50 CONTACT

Lead (Pb, PbO2, PbSO4)

About 70% N/A

(500) mg/Kg

N/A

Sulfuric Acid

About 20% 1 mg/m3

(2.140) mg/Kg N/A

N/A

Fiberglass Separator

About 5%

N/A

ABS or PP

About 5%

N/A

SECTION 3: PHYSICAL DATA
COMPONENTS

DENSITY MELTING POINT

SOLLUBILITY
(H2O)

ODOR

APPEARANCE

Lead

11.34

327.4°C (Boiling)

None

Sliver-Gray Metal

Lead Sulfate

6.2

1070°C (Boiling)

40 mg/l (15°C)

None

White Powder

Lead Dioxide

9.4

290°C (Boiling)

None

Brown Powder

Sulfuric Acid

About 1.3 About 114°C (Boiling)

100%

Acidic

Clear Colorless Liquid

Fiberglass Sep.

N/A

Slight

Toxic

White Fibrous Glass

ABS or PP

N/A

None

No Odor

Solid

SECTION 4: PROTECTION
EXPOSURE

PROTECTION

COMMENTS

SKIN

Rubber gloves, Apron, Safety shoes Protective equipment must be worn if battery is cracked
or otherwise damaged.

RESPIRATORY Respirator (for lead)

A respirator should be worn during reclaim operations if
the TLV exceeded.

EYES

Safety goggles, Face Shield

SECTION 5: FLAMMABILITY DATA
COMPONENTS

FLASHPOINT

EXPLOSIVE LIMITS

Lead

None

Sulfuric Acid

None

Hydrogen

259*

4% - 74.2%

COMMENTS

Sealed batteries can emit hydrogen only if over
charged (float voltage> 2.4 VPC). The gas enters
the air through the vent caps. To avoid the chance
of a fire or explosion, keep sparks and other
sources of ignition away from the battery.
Extinguishing Media: Dry chemical, foam, CO2

Fiberglass Sep.

N/A

Toxic vapors may be released.
In case of fire: wear self-contained breathing
apparatus.

478 Polystyrene

None

N/A

Temperatures over 300 °C (572°F) may release
combustible gases. In case of fire: wear positive
pressure self-contained breathing apparatus.

SECTION 6: REACTIVITY DATA
COMPONENT

Lead/lead compounds

STABILITY

Stable

INCOMPATIBILITY

Potassium, carbides, sulfides, peroxides, phosphorus, sulfurs.

DECOMPOSITION PRODUCTS Oxides of lead and sulfur.
CONDITIONS TO AVOID

High temperature, Sparks and other sources of ignition.

COMPONENT

Sulfuric Acid

STABILITY

Stable at all temperatures

POLYMERIZATION

Will not polymerize

INCOMPATIBILITY

Reactive metals, strong bases, most organic compounds

DECOMPOSITION PRODUCTS Sulfuric dioxide, trioxide, hydrogen sulfide, hydrogen
CONDITIONS TO AVOID

Prohibit smoking, sparks, etc. from battery charging area. Avoid mixing acid
with other chemicals.

SECTION 7: CONTROL MEASURES
1. Store lead/acid batteries with adequate ventilation. Room ventilation is required for batteries utilized for
standby power generation. Never recharge batteries in an unventilated, enclosed space.
2. Do not remove vent caps. Follow shipping and handling instructions that are applicable to the battery type. To
avoid damage to terminals and seals, do not double-stack industrial batteries.
STEPS TO TAKE IN CASE OF LEAKS OR SPILLS
If sulfuric acid is spilled from a battery, neutralize the acid with sodium bicarbonate (baking soda), sodium
carbon (soda ash), or calcium oxide (lime).
Flush the area with water discard to the sewage systems. Do not allow unneutralized acid into the sewage
system.
WASTE DISPOSAL METHOD:
Neutralized acid may be flushed down the sewer. Spent batteries must be treated as hazardous waste and
disposed of according to local state, and federal regulations. A copy of this material safety data must be supplied
to any scrap dealer or secondary smelter with battery.
ELECTRICAL SAFETY
Due to the battery’s low internal resistance and high power density. High levels of short circuit can be developed
across the battery terminals. Do not rest tools or cables on the battery. Use insulated tools only.
Follow all installation instruction and diagrams when installing or maintaining battery systems.

SECTION 8: HEALTH HAZARD DATA
LEAD: The toxic effects of lead are accumulative and slow to appear. It affects the kidneys, reproductive, and
central nervous system.
The symptoms of lead overexposure are anemia, vomiting, headache, stomach pain (lead colic), dizziness, loss
of appetite, and muscle and joint pain. Exposure to lead from a battery most often occurs during lead reclaim
operations through the breathing or ingestion of lead dusts and fumes.
THIS DATA MUST BE PASSED TO ANY SCRAP OR SMELTER WHEN A BATTERY IS RESOLD.
SULFURIC ACID: Sulfuric acid is a strong corrosive. Contact with acid can cause severe burns on the skin and in
the eyes. Ingestion of sulfuric acid will cause GI tract burns. Acid can be release if the battery case is damaged or
if the vents are tampered with.
FIBERGLASS SEPARATOR: Fibrous glass is an irritant of the upper respiratory tract, skin and eyes. For
exposure up to 10F/CC use MSA Comfort with type H filter. Above 10F/CC up to 50F/CC use Ultra-Twin with type
H filter.

NTP or OSHA does not consider this product carcinogenic.

SECTION 9: SULFURIC ACID PRECAUTIONS
INHALATION: Acid mist form formation process may cause respiratory irritation, remove from exposure and
apply oxygen if breathing is difficult.
SKIN CONTACT: Acid may cause irritation, burns or ulceration. Flush with plenty of soap and water, remove
contaminated clothing, and see physician if contact area is large or if blisters form.
EYE CONTACT: Acid may cause severe irritation, burns, cornea damage and blindness. Call physician
immediately and flush with water until physician arrives.
INGESTION: Acid may cause irritation of mouth, throat, esophagus and stomach. Call physician. If patient is
conscious, flush mouth with water, have the patient drink milk or sodium bicarbonate solution.

DO NOT GIVE ANYTHING TO AN UNCONSCIOUS PERSON.

SECTION 10: TRANSPORTATION REGULATIONS
We hereby certify that all B.B. Battery Maintenance Free Rechargeable Sealed Lead Acid batteries conform to
the UN2800 classification as “ Batteries, wet, Non- Spillable, and electric storage” as a result of passing the
Vibration and Pressure Differential Test described in DOT [49 CFR 173.159(d) and IATA/ICAO [Special Provision
A67].
B.B. Batteries having met the related conditions are EXEMPT from hazardous goods regulations for the purpose
of transportation by DOT, and IATA/ICAO, and therefore are unrestricted for transportation by any means. For all
modes of transportation, each battery outer package is labeled "NON-SPILLABLE".

Supplement Guide - S1400CW

Issue: 04/05

SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING

A Guide for the Protection of
Site Equipment & Personnel
In the Installation of
ControlWave
Process Automation Controllers

Bristol Babcock

NOTICE
Copyright Notice
The information in this document is subject to change without notice. Every effort has been
made to supply complete and accurate information. However, Bristol Babcock assumes no
responsibility for any errors that may appear in this document.

Request for Additional Instructions
Additional copies of instruction manuals may be ordered from the address below per
attention of the Sales Order Processing Department. List the instruction book numbers or
give complete model number, serial or software version number. Furnish a return address
that includes the name of the person who will receive the material. Billing for extra copies
will be according to current pricing schedules.
ControlWave® is a re registered trademark of Bristol Babcock. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their
respective companies, or trademark holders.
Copyright (c) 2005 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of
this manual may be reproduced in any form without the express written permission of
Bristol Babcock.

Supplement Guide S1400CW
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION

TITLE

PAGE #
Section 1 - INTRODUCTION

1.1
1.2

GENERAL INTRODUCTION ....................................................................................... 1-1
MAJOR TOPICS ............................................................................................................. 1-1

Section 2 - PROTECTION
2.1
2.1.1
2.2
2.2.1
2.2.2
2.3

PROTECTING INSTRUMENT SYSTEMS................................................................... 2-1
Quality Is Conformance To Requirements.................................................................... 2-1
PROTECTING EQUIPMENT & PERSONNEL ........................................................... 2-1
Considerations For The Protection of Personnel .......................................................... 2-2
Considerations For The Protection of Equipment ........................................................ 2-2
OTHER SITE SAFETY CONSIDERATIONS............................................................... 2-3

Section 3 - GROUNDING & ISOLATION
3.1
3.2
3.3
3.3.1
3.3.1.1
3.3.1.2
3.3.1.3
3.3.2
3.3.3
3.4
3.4.1
3.4.2

POWER & GROUND SYSTEMS................................................................................... 3-1
IMPORTANCE OF GOOD GROUNDS......................................................................... 3-1
EARTH GROUND CONNECTIONS............................................................................. 3-1
Establishing a Good Earth Ground. .............................................................................. 3-1
Soil Conditions ................................................................................................................ 3-2
Soil Types ........................................................................................................................ 3-2
Dry, Sandy or Rocky Soil................................................................................................ 3-4
Ground Wire Considerations. ........................................................................................ 3-5
Other Grounding Considerations. ................................................................................. 3-6
ISOLATING EQUIPMENT FROM THE PIPELINE ................................................... 3-7
Meter Runs Without Cathodic Protection..................................................................... 3-7
Meter Runs With Cathodic Protection .......................................................................... 3-7

Section 4 - LIGHTNING ARRESTERS & SURGE PROTECTORS
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.2

STROKES & STRIKES .................................................................................................. 4-1
Chance of Being Struck by Lightning. .......................................................................... 4-1
Antenna Caution ............................................................................................................ 4-3
Ground Propagation ....................................................................................................... 4-5
Tying it all Together....................................................................................................... 4-5
Impulse Protection Summary ........................................................................................ 4-5
USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS................................ 4-6

Section 5 - WIRING TECHNIQUES
5.1
5.2
5.2.1

OVERVIEW ....................................................................................................................5-1
INSTRUMENT WIRING. .............................................................................................. 5-1
Common Returns ............................................................................................................5-1

Supplement S1400CW

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Table Of Contents

Supplement Guide S1400CW
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION

TITLE

PAGE #

Section 5 - WIRING TECHNIQUES (Continued)
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10

Use of Twisted Shielded Pair Wiring (with Overall Insulation).................................. 5-2
Grounding of Cable Shields. .......................................................................................... 5-3
Use of Known Good Earth Grounds .............................................................................. 5-3
Earth Ground Wires ....................................................................................................... 5-3
Working Neatly & Professionally .................................................................................. 5-3
High Power Conductors and Signal Wiring .................................................................. 5-4
Use of Proper Wire Size ................................................................................................. 5-4
Lightning Arresters & Surge Protectors ....................................................................... 5-4
Secure Wiring Connections ............................................................................................ 5-5

REFERENCE DOCUMENTS
1.
2.
3.
4.
5.
6.
7.

IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std
142-1982
IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise inputs to Controllers
from External Sources - IEE Std 518-1982
Lightning Strike Protect; Roy B. Carpenter, Jr. & Mark N. Drabkin, Ph.D.; Lightning Eliminators &
Consultant, Inc., 6687 Arapahoe Road, Boulder Colorado
Lightning Protection Manual for Rural Electric Systems, NRECA Research Project 82-5, Washington DC,
1983
Grounding for the Control of EMI; Hugh W. Denny; Don White Consultants, Inc., 1983, 1st Edition
Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam
Street, Shreveport, Louisiana 71151
TeleFlow Modem Grounding Kit 621495-01-8 Installation Instructions - PIP-3530MGKI; Bristol Babcock,
Watertown, CT 06795

Supplement S1400CW

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Table Of Contents

Section 1 - Overview
1.1 INTRODUCTION
This document provides information pertaining to the installation of ControlWave
systems; more specifically, information covering reasons, theory and techniques for
protecting your personnel and equipment from electrical damage. Your instrument system
affects the quality of service provided by your company and many aspects of its operational
safety. Loss of instruments means lost production and profits as well as increased expenses.
Information contained in this document is for educational purposes. Bristol Babcock makes
no warranties or guarantees on the effectiveness or the safety of techniques described herein.
Where the safety of installations and personnel is concerned, refer to the National Electrical
Code Rules and rules of local regulatory agencies.

1.2 MAJOR TOPICS
Topics are covered in seven sections designed to pinpoint major areas of concern for the
protection of site equipment and personnel. The following overview is provided for each of
the major sections.
·

Section 2 - Protection
This section provides the reasons for protecting instrument systems. An overview of the
definition of quality and what we are trying to accomplish in the protection of site
installations and how to satisfy the defined requirements is presented. Additionally,
this section provides considerations for the protection of personnel and equipment.

Section 3 - Grounding & Isolation
Information pertaining to what constitutes a good earth ground, how to test and
establish such grounds, as well as when and how to connect equipment to earth grounds
is provided

Section 4 - Lightning Arresters & Surge Protectors
Some interesting information dealing with Lightning strikes and strokes is presented in
technical and statistical form along with a discussion of how to determine the likelihood
of a lightning strike. Protecting equipment and personnel during the installation of
radios and antenna is discussed in a review of the dangers to equipment and personnel
when working with antennas. Reasons for the use of lightning arresters and surge
protectors are presented along with overviews of how each device protects site
equipment.

Section 5 - Wiring Techniques
Installation of Power and “Measurement & Control” wiring is discussed. Information on
obscure problems, circulating ground and power loops, bad relays, etc. is presented.
Good wire preparation and connection techniques along with problems to avoid are
discussed. This sections list the ten rules of instrument wiring.

Section 1 - Overview

Page 1-1

S1400CW

Section 2 - Protection
2.1 PROTECTING INSTRUMENT SYSTEMS
Electrical instrumentation is susceptible to damage from a variety of natural and man
made phenomena. In addition to wind, rain and fire, the most common types of system and
equipment damaging phenomena are lightning, power faults, communication surges &
noise and other electrical interference’s caused by devices such as radios, welders,
switching gear, automobiles, etc. Additionally there are problems induced by geophysical
electrical potential & noise plus things that are often beyond our wildest imagination.
2.1.1 Quality Is Conformance To Requirements
A quality instrumentation system is one that works reliably, safely and as purported by the
equipment manufacturer (and in some cases by the system integrator) as a result of good
equipment design and well defined and followed installation practices. If we except the
general definition of quality to be, “quality is conformance to requirements,” we must also
except the premise that a condition of “quality” can’t exist where requirements for such an
end have not been evolved. In other words, you can’t have quality unless you have
requirements that have been followed. By understanding the requirements for a safe, sound
and reliable instrumentation system, and by following good installation practices (as
associated with the personnel and equipment in question), the operational integrity of the
equipment and system will be enhanced.
Understanding what is required to properly install BBI equipment in various environments, safely, and in accordance with good grounding, isolating and equipment
protection practices goes a long way toward maintaining a system which is healthy to the
owner and customer alike. Properly installed equipment is easier to maintain and operate,
and is more efficient and as such more profitable to our customers. Following good installation practices will minimize injury, equipment failure and the customer frustrations
that accompany failing and poorly operating equipment (of even the finest design). Additionally, personnel involved in the installation of a piece of equipment add to or subtract
from the reliability of a system by a degree which is commensurate with their technical
prowess, i.e., their understanding of the equipment, site conditions and the requirements
for a quality installation.

2.2 PROTECTING EQUIPMENT & PERSONNEL
ControlWave installations must be performed in accordance with National Electrical Code
Rules, electrical rules set by local regulatory agencies, and depending on the customer
environment (gas, water, etc), other national, state and local agencies such as the American
Water Works Association (AWWA). Additionally, installation at various customer sites may
be performed in conjunction with a “safety manager” or utility personnel with HAZMAT
(hazardous material) training on materials present (or potentially present) as required by
OSHA, the customer, etc.

Section 2 - Protection

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2.2.1 Considerations For The Protection of Personnel
Always evaluate the site environment as if your life depended on it. Make sure that you
understand the physical nature of the location where you will be working. Table 2-1
provides a general guideline for evaluating an installation site.
Table 2-1 - Installation Site Safety Evaluation Guide
#
1
2
3
4
5
6
7
8
9

Guide
Indoor or outdoor – Dress Appropriately
If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees,
spiders, snakes, etc.)
If indoor or outdoor – determine if there are any pieces of dangerous equipment or any
processes which might be a risk to your safety
If in a tunnel, bunker, etc. watch out for a build up of toxic or flammable gases. Make
sure the air is good. Watch out for local varmint (bees, spiders, snakes, etc.)
Hazardous or Non-Hazardous Environment – Wear appropriate safety equipment and
perform all necessary safety measures.
Before installing any equipment or power or ground wiring, make sure that there are no
lethal (life threatening) voltages between the site where the instrument will be installed
and other equipment, pipes, cabinets, etc. or to earth itself.
Never assume that adjacent or peripheral equipment has been properly installed and
grounded. Determine if this equipment and the ControlWave unit in question can be
touched simultaneously without hazard to personnel and/or equipment?
Before embarking to remote locations where there are few or no human inhabitants ask a
few simple questions like, should I bring water, food, hygienic materials, first aid kit, etc?
Be Prepared!
Observe the work habits of those around you – for your own safety!

Some of the items that a service person should consider before ever going on site can be
ascertained by simply asking questions of the appropriate individual. Obviously other
safety considerations can only be established at the installation site.

2.2.2 Considerations For The Protection of Equipment
Always evaluate the site installation/service environment and equipment. Understand the
various physical interfaces you will be dealing with such as equipment mounting and
supporting, ControlWave analog and digital circuits, power circuits, communication
circuits and various electrical grounds. Table 2-2 provides a general guideline for
evaluating the equipment protection requirements of an installation site.
Table 2-2 - Equipment Protection Site Safety Evaluation Guide
#
1
2
3
4
5

Guide
Environment - Class I, Division 2 - Nonincendive
Environment - Class I, Division 1 - Intrinsically Safe
Other - Safe or unrated area
Earth Ground - Established by mechanical/electrical or
(both) or not at all.
Is the area prone to lightning strikes?
Are there surge suppressors installed or to be installed?
Are there overhead or underground power or communication cables in the immediate area?

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Reference Section
See Appendix A of CI Manual
See Appendix B of CI Manual
See Section 3
See Section 4
See Section 4
See Section 2.3

Section 2 - Protection

Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued)
#
6
7
8
9

2.3

Guide
Is there an antenna in the immediate area?
How close is other equipment? Can someone safely touch this
equipment and a ControlWave simultaneously?
Determine equipment ground requirements. How will the
ControlWave and its related wiring be grounded? Consider Earth
Ground, Circuit Ground, Conduit Ground, Site Grounds!
Are there any obviously faulty or questionable power or ground
circuits?

Reference Section
See Section 4.1.2
See Section 2.3
See Section 3
See Section 2.3

OTHER SITE SAFETY CONSIDERATIONS

Overhead or underground power or communication cables must be identified prior to
installing a new unit. Accidentally cutting, shorting or simply just contacting power,
ground, communication or process control I/O wiring can have potentially devastating
effects on site equipment, the process system and or personnel.
Don’t assume that it is safe to touch adjacent equipment, machinery, pipes, cabinets or even
the earth itself. Adjacent equipment may not have been properly wired or grounded, may be
defective or may have one or more loose system grounds. Measure between the case of a
questionable piece of equipment and its earth ground for voltage. If a voltage is present,
something is wrong.
AC powered equipment with a conductive case should have the case grounded. If you don’t
see a chassis ground wire, don’t assume that it is safe to touch this equipment. If you notice
that equipment has been grounded to pipes, conduit, structural steel, etc., you should be
leery. Note: AWWA’s policy on grounding of electric circuits on water pipes states,
“The American Water Works Association (AWWA) opposes the grounding of
electrical systems to pipe systems conveying water to the customer’s premises….”
Be sure that the voltage between any two points in the instrument system is less than the
stand-off voltage. Exceeding the stand-off voltage will cause damage to the instrument and
will cause the instrument to fail.

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S1400CW

Section 3 - Grounding & Isolation
3.1 POWER & GROUND SYSTEMS
ControlWaves utilize DC power systems. AC power supplies are not provided with ControlWave units. ControlWave, ControlWave MICRO, ControlWave EFM/GFC/EFC,
ControlWaveRED, ControlWaveREDIO and ControlWave I/O Expansion Racks are
provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing
a connection to Earth Ground. In the case of the ControlWaveLP, a Chassis Ground
termination terminal (TB2, Pin-3), that accepts up to a #14 AWG size wire, is provided on
the unit’s Power Supply/Sequencer Board.

3.2 IMPORTANCE OF GOOD GROUNDS
ControlWave units (see above) are utilized in instrument and control systems that must
operate continually and within their stated accuracy over long periods of time with
minimum attention. Failures resulting from an improperly grounded system can become
costly in terms of lost time and disrupted processes. A properly grounded system will help
prevent electrical shock hazards resulting from contact with live metal surfaces, provide
additional protection of equipment from lightning strikes and power surges, minimize the
effects of electrical noise and power transients, and reduce signal errors caused by ground
wiring loops. Conversely, an improperly grounded system may exhibit a host of problems
that appear to have no relation-ship to grounding. It is essential that the reader (service
technician) have a good under-standing of this subject to prevent needless troubleshooting
procedures.
WARNING
This device must be installed in accordance with the National
Electrical Code (NEC) ANSI/NEPA-70. Installation in hazardous
locations must also comply with Article 500 of the code. For
information on the usage of ControlWave units in Class I, Division 2,
Groups C & D Hazardous and Nonhazardous locations, see appendix A
of the applicable Customer Instruction (CI) manual. For information
on the usage of ControlWave units in Class I, Division 1, Groups C &
D Hazardous locations, see appendix B of the applicable Customer
Instruction (CI) manual.

3.3 EARTH GROUND CONNECTIONS
To properly ground a ControlWave unit, the units Chassis Ground (post or terminal) must
ultimately be connected to a known good Earth Ground. Observe recommendations
provided in topics Establishing a Good Earth Ground and Ground Wire Considerations.

3.3.1 Establishing a Good Earth Ground
A common misconception of a ground is that it consists of nothing more than a metal pipe
driven into the soil. While such a ground may function for some applications, it will often

Section 3 - Grounding & Isolation

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S1400CW

not be suitable for a complex system of sophisticated electronic equipment. Conditions such
as soil type, composition and moisture will all have a bearing on ground reliability.
A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into
conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG
solid copper wire should be used for the ground wire. The end of the wire should be clean,
free of any coating and fastened to the rod with a clamp. This ground connection should be
covered or coated to protect it from the weather and the environment.

Figure 3-1 - Basic Ground Rod Installation
3.3.1.1 Soil Conditions
Before installing a ground rod, the soil type and moisture content should be analyzed.
Ideally, the soil should be moist and moderately packed throughout to the depth of the
ground rod. However, some soils will exhibit less than ideal conditions and will require
extra attention.
Soil types can be placed into two general categories with respect to establishing and
maintaining a good earth ground, i.e., ‘Good Soil’ and ‘Poor Soil.’
To be a good conductor, soil must contain some moisture and free ions (from salts in the
soil). In very rainy areas, the salts may be washed out of the soil. In very sandy or arid area
the soil may be to dry and/or salt free to a good conductor. If salt is lacking add rock salt
(NaCl); if the soil is dry add calcium chloride (CaCl2).
3.3.1.2 Soil Types:

Good
Damp Loam
Salty Soil or Sand
Farm Land

Poor
Back Fill
Dry Soil
Sand Washed by a Lot of Rain
Dry Sand (Desert)
Rocky Soil

Ground Beds must always be tested for conductivity prior to being placed into service. A
brief description of ground bed testing in ‘Good Soil’ and ‘Poor Soil’ is provided herein.
Details on this test are described in the National Electrical Code Handbook. Once a reliable
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Section 3 - Grounding & Isolation

ground has been established, it should be tested on a regular basis to preserve system
integrity.

Figure 3-2 - Basic Ground Bed Soil Test Setup

Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods
Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5
ohms, the ground is good. The lower the resistance, the better the earth ground. If the
Section 3 - Grounding & Isolation

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S1400CW

Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is
indicated, one or more additional ground rods connected 10 feet from the main ground rod
should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x
¼-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the
Biddle Instrument Co. (now owned by AVO International). Other devices that
may be used to test ground resistance are “Viboground”; Associated Research,
Inc., “Groundmeter”; Industrial Instruments, Inc., and “Ground-ohmer”; Herman
H. Sticht Co., Inc.
If the Megger still reads more than 10 ohms, mix a generous amount of cooking salt, ice
cream salt or rock salt with water and then pour about 2.5 to 5 gallons of this solution
around each rod (including the test rods). Wait 15 minutes and re-test the soil. If the test
fails, the soil is poor and a ‘Poor Soil Ground Bed’ will have to be constructed.
Figure 3-4 shows a typical Poor Soil Ground Bed Electrode. A Poor Soil Ground Bed will
typically consists of four or more 10-foot long electrodes stacked vertically and separated by
earth. Figure 3-5 shows the construction of a Poor Soil Ground Bed. For some poor soil
sites, the ground bed will be constructed of many layers of ‘Capacitive Couplings’ as
illustrated. In extremely poor soil sites one or more 3’ by 3’ copper plates (12 gauge or 1/16”
thick) will have to be buried in place of the electrodes.

Figure 3-4 - Ground Electrode Construction for Poor Soil Conditions
3.3.1.3 Dry, Sandy or Rocky Soil
Very dry soil will not provide enough free ions for good conductance and a single ground rod
will not be effective. A buried counterpoise or copper screen is recommended for these
situations. It will be necessary to keep the soil moist through regular applications of water.
Sandy soil, either wet or dry, may have had its soluble salts leached out by rain water,
thereby reducing conductivity of the ground. High currents from lightning strikes could also
melt sand and cause glass to form around the ground rod, rendering it ineffective. A buried
counterpoise or copper screen is preferred for these installations along with regular
applications of salt water.
Rocky soil can pose many grounding problems. A counterpoise or copper plate will probably
be required. Constructing a trench at the grounding site and mixing the fill with a
hygroscopic salt such as calcium chloride may help for a time. Soaking the trench with
water on a regular basis will maintain conductivity.
Units with phone modems require the use of a lightning arrester. The lightning arrester
must be situated at the point where the communication line enters the building.

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Section 3 - Grounding & Isolation

Figure 3-5 - Poor Soil Ground Bed Construction Diagram

3.3.2 Ground Wire Considerations
ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveRED, ControlWave REDIO & ControlWave I/O Expansion Rack
ControlWave Chassis are provided with a Ground Lug that accommodates up to a #4 AWG
wire size. A ground wire must be run between the Chassis Ground Lug and a known good
Earth Ground. The cases of the various ControlWave Modules are connected to Chassis
Ground when they have been installed and secured via their two Captured Panel
Fasteners. As an extra added precaution, it is recommended that a #14 AWG wire be run
from PSSM Power Connector TB2-5 (Chassis Ground) (PSSM Connector TB1-3 for
ControlWave MICRO unit) (SCM Connector TB1-3 for ControlWave EFM) to the same
known good Earth Ground.
ControlWaveLP Process Automation Controller
A #14 AWG ground wire must be run from the ControlWaveLP’s PSSB Terminal TB2-3
(Chassis Ground) to a known good Earth Ground. In lieu of a direct connection to Earth
Section 3 - Grounding & Isolation

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S1400CW

Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a
conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground
Bus. The panel, lug or bus in turn must be connected to a known good Earth Ground via a
#4 AWG wire.
General Considerations
The following considerations are provided for the installation of ControlWave system
grounds:
i Size of ground wire (running to Earth Ground should be #4 AWG. It is recommended
that stranded copper wire is used for this application and that the length should be as
short as possible.
i This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
i The wire ends should be tinned with solder prior to installation.
i The ground wire should be run such that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above ground.
The units Earth Ground Cable should be clamped to an exposed Ground Rod or to an AWG
0000 stranded copper Ground Cable that in turn should be connected to either an Earth
Ground Rod or Earth Ground Bed. Both ends of the units Earth Ground Cable must be free
of any coating such as paint or insulated covering as well as any oxidation. The connecting
point of the Ground Rod or AWG 0000 Ground Cable must also be free of any coating and
free of oxidation. Once the ground connection has been established (at either the Ground
Rod or Ground Cable) it should be covered or coated to protect it from the environment.

3.3.3 Other Grounding Considerations

Figure 3-6 - Grounding of Phone Line
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Section 3 - Grounding & Isolation

For applications employing equipment that communicates over telephone lines, a lightning
arrester Must Be provided. For indoor equipment the lightning arrester must be installed
at the point where the communication line enters the building as shown in Figure 3-6. The
ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.
Gas lines also require special grounding considerations. If a gas meter run includes a
thermocouple or RTD sensor installed in a thermowell, the well (not the sensor) must be
connected to a gas discharge-type lightning arrester as shown in Figure 3-7. A copper braid,
brazed to the thermal well, is dressed into a smooth curve and connected to the arrester as
shown. The curve is necessary to minimize arcing caused by lightning strikes or high static
surges. The path from the lightning arrester to the ground bed should also be smooth and
free from sharp bends for the same reason.

Figure 3-7 - Grounding of Thermometer Well in Gas Line

3.4 ISOLATING EQUIPMENT FROM THE PIPELINE
3.4.1 Meter Runs Without Cathodic Protection
ControlWave EFM/GFC/XFC’s may be mounted directly on the pipeline or remotely on a
vertical stand-alone two-inch pipe (see Figure 3-8). The Earth Ground Cable is to run
between the ControlWave EFM/GFC/XFC’s Ground Lug and Earth Ground (Rod or Bed)
even though the ControlWave EFM/GFC/XFC’s Multivariable Transducer may be
Section 3 - Grounding & Isolation

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S1400CW

grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely
mounted, connect their chassis grounds to the pipeline or earth ground.

Figure 3-8 - ControlWave EFM (Installation is similar to GFC/XFC)
Remote Installation without Cathodic Protection

3.4.2 Meter Runs With Cathodic Protection
Dielectric isolators are available from Bristol Babcock and are always recommended as an
added measure in isolating the ControlWave EFM/GFC/XFC from the pipeline even
though the ControlWave EFM/GFC/XFC does provide 500V galvanic isolation from the
pipeline and should not be affected by cathodic protection or other EMF on the pipeline.
ControlWave EFM/GFC/XFC may be mounted directly on the pipeline (see Figure 3-9) or
remotely on a vertical stand-alone two-inch stand-pipe (see Figure 3-10). It is recommended
that isolation fitting always be used in remotely mounted meter systems. An isolation
fittings or gasket should be installed between the following connections:
S1400CW

Page 3-8

Section 3 - Grounding & Isolation

•
•
•

all conductive tubing that runs between the pipeline and mounting valve manifold
and/or the units multivariable pressure transducer
all conductive connections or tubing runs between the ControlWave EFM/GFC and
turbine meter, pulse transducer, or any input other device that is mounted on the
pipeline
any Temperature Transducer, Pressure Transmitter, etc. and their mount/interface to
the pipeline

Figure 3-9 - ControlWave EFM (Installation is similar to EFM/GFC/XFC)
Direct Mount Installation (with Cathodic Protection)
The ground conductor connects between the ControlWave EFM/GFC/XFC’s Ground Lug
and a known good earth ground. Connect the cases of Temperature Transducers, Pressure
Transmitters, etc., to the known good earth ground. If the mounting 2-inch pipe is in
continuity with the pipeline it will have to be electrically isolated from the ControlWave
EFM/GFC/XFC. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU
3140. This black tubing will easily slip over the 2-inch pipe and then after uniform heating
(e.g., with a rose-bud torch) it electrically insulates and increases the strength of the pipe
stand.

Section 3 - Grounding & Isolation

Page 3-9

S1400CW

See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems
and Manifolds.

Figure 3-10 – ControlWave EFM (Installation is similar to GFC/XFC)
Remote Installation (with Cathodic Protection)

S1400CW

Page 3-10

Section 3 - Grounding & Isolation

Section 4 - Lightning Arresters & Surge Protectors
4.1 STROKES & STRIKES
Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay
to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will
average 18 KA for the first impulse and about half of that for the second and third
impulses. Three strokes (impulses) is the average per lightning strike. The number of
visible flashes that may be seen is not necessarily the number of electrical strokes.
A lightning strike acts like a constant current source. Once ionization occurs, the air
becomes a luminous conductive plasma reaching up to 60,000° F. The resistance of a struck
object is of little consequence except for the power dissipation on the object (I2 x R). Fifty
percent of all lightning strikes will have a first impulse of at least 18 KA, ten percent will
exceed the 60 KA level, and only about one percent will exceed 120 KA.

4.1.1 Chance of Being Struck by Lightning
The map of Figure 4-1 shows the average annual number of thunderstorm days
(Isokeraunic level) for the various regions within the continental U.S.A. This map is not
representative of the severity of the storm or the number of lightning strikes since it does
not take into account more than one lightning strike in a thunderstorm day. The
Isokeraunic or Isoceraunic number provides a meteorological indication of the frequency of
thunderstorm activity; the higher the Isokeraunic number the greater the lightning strike
activity for a given area. These levels vary across the world from a low of 1 to a high of 300.
Within the United States the Isokeraunic level varies from a low of 1 to a high of 100.

Figure 4-1 - Average Thunderstorm Days of the Year (for Continental USA)
Section 4 - Lightning & Surge

Page 4-1

S1400CW

Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the
United States there is an average of 30 thunderstorm days per year. Any given storm may
produce from one to several strokes. Data on the subject indicates that for an average area
within the United States there can be eight to eleven strokes to each square mile per year.
The risk of stroke activity is increased for various areas such central Florida where up to 38
strokes to each square mile per year are likely to occur.
To determine the probability of a given structure (tower, building, etc.) (within your
location) being struck, perform the following computation:
1. Using the map of Figure 4-1 (or a comparable meteorological map for your local), find
the Isokeraunic level (I) for your area. Then using Chart 1, find “A” for your area.
2. Refer to Figure 4-1 to find the latitude. Then using Chart 2, find “B” for your latitude
(Lat.°).
3. Multiply “A” x “B” to get “C”.
4. To calculate the number of lightning strikes per year that are likely to strike a given
object (tower, mast, etc.), use the equation that follows (where “C” was calculated in
step 3 and “H” is equal to the height of the object.
Strikes Per Year = (“C” x H2) ÷ (.57 x 106 )
Chart 1
I
5
10
20
30
40
50
60
70
80
90
100

“A”
8
26
85
169
275
402
548
712
893
1069
1306

Chart 2
LAT.°
25
30
35
40
45

“B”
.170
.200
.236
.280
.325

Note for these charts:
I = Thunderstorm Days Per Year (Isokeraunic Number)
A = Stroke activity for associated Isokeraunic Area
B = Height/Stroke coefficient for associated latitude

For Example: On Long Island, New York (Isokeraunic number 20), Chart 1 gives “A” to
equal 85. The latitude is approximately 40°. Referring to Chart 2, “B” is found to be equal to
.28. “C” for this example is equal to 23.80. Using the equation for strikes per year, it is
determined that a 100-foot tower has .4 chances per year of being struck by lightning.
Assuming that no other structures are nearby, the tower will more than likely be struck by
lightning at least once in three years.
Note: The Isokeraunic activity numbers connoted as I, “A” and “B” in Charts 1 and 2 above
are provided for the continental United States. Isokeraunic data for various countries
is available from various federal or state Civil Engineering or Meterorelogical
organizations. This information is typically available from manufacturers of lightning
strike protection equipment (such as Lightning Arresters).
Since ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP and ControlWaveEXP units are dc operated systems that are isolated from AC
grids, they are typically immune to lightning strikes to power lines or power equipment
(except for inductive flashover due to close installation proximity). However, once a radio or
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Section 4 - Lightning & Surge

modem has been interfaced to a ControlWave, ControlWave MICRO, ControlWave
EFM/GFC/XFC, ControlWaveLP, or ControlWaveEXP the possibility of damage due to a
lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower
must be considered. It is recommended that the additional lightning protection
considerations listed below be followed for units installed in areas with a high possibility or
history of stroke activity.
Units interfaced to a modem: In series with the phone line (as far away as possible
from the equipment) - for indoor installations the lightning arrester should typically be
located at the point where the line enters the structure.
Units interfaced to a radio: Mount antenna discharge unit (lightning arrester) as
close as possible to where the lead in wire enters the structure. See Antenna Caution
below.

4.1.2 Antenna Caution
Each year hundreds of people are killed, mutilated, or receive severe permanent injuries
when attempting to install or remove an antenna or antenna lead. In many cases, the
victim was aware of the danger of electrocution but failed to take adequate steps to avoid
the hazard. For your safety, and for proper installation maintenance, please read and
follow the safety precautions that follow - they may save your life.
i When installing or servicing an antenna:
DO NOT use a metal ladder. DO NOT step onto or touch an antenna mast while power
is applied to an associated radio unless the radio is a low power (low current) type.
DO NOT work on a wet or windy day, especially during a thunderstorm or when there is
lightning or thunder in your area. Dress properly; shoes with rubber soles and heels,
rubber gloves, long sleeve shirt or jacket.
i The safe distance from power lines should be at least twice the height of the antenna
and mast combination.
i Antenna Grounding per National Electrical Code Instructions:
A. Use AWG 10 or 8 aluminum or AWG 1 copper-clad steel or bronze wire, or larger as
ground wires for both the mast and lead-in. Securely clamp the wire to the bottom of
the mast.
B. Secure lead-in wire from antenna to antenna discharge (lightning arrester) unit and
the mast ground wire to the structure (building, shed, etc.) with stand-off insulators
spaced from 4 feet (1.22 meters) to 6 feet (1.83 meters) apart.
C. Mount antenna discharge unit as close as possible to where the lead-in wire enters
the structure.
D. The hole drilled through the wall for the lead-in wire should be just large enough to
accommodate the cable. Before drilling this hole, make sure there are no wires or
pipes, etc. in the wall.
E. Push the cable through the hole and form a rain drip loop close to where the wire
enters the exterior of the structure.
F. Caulk around the lead-in wire (where it enters the structure) to keep out drafts.
G. Install lightning arresters (antenna discharge units). The grounding conductor
should be run in as straight a line as practicable from the antenna mast and/or the
antenna discharge units to grounding electrode(s).
H. Only connect the antenna cable to the radio after the mast has been properly
grounded and the lead-in cable has been properly connected to lightning arresters
which in turn have each been properly connected to a known good earth ground.
Section 4 - Lightning & Surge

Page 4-3

S1400CW

Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram
For all systems it is best to have all communication equipment input/output grounds tied
together. In the case of ControlWave units, this is accomplished via the unit’s Chassis
Ground (Typically at a ground lug, ground bus or ground plate). However additional
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Section 4 - Lightning & Surge

communication equipment lightning arresters and surge suppressors should be tied to the
same system ground. System ground consists of the tower leg grounds utility ground and
bulkhead-equipment ground-stakes that are tied together via bare copper wire.

4.1.3 Ground Propagation
As in any medium, a dynamic pulse, like R.F., will take time to propagate. This propagation
time will cause a differential step voltage to exist in time between any two ground rods that
are of different radial distances from the strike. With a ground rod tied to a struck tower,
the impulse will propagate its step voltage outwardly from this rod in ever-expanding
circles, like a pebble thrown into a pond. If the equipment house has a separate ground rod
and the power company and/or telephone company grounds are also separate, the dynamic
step voltage will cause currents to flow to equalize these separate ground voltages. Then if
the coax cable (associated with a radio) is the only path linking the equipment chassis with
the tower ground, the surge can destroy circuitry.

4.1.4 Tying it all Together
To prevent this disaster from occurring, a grounding system must be formed which
interconnects all grounds together. This will equalize and distribute the surge charge to all
grounds, and at the same time, it will make for a lower surge impedance ground system.
This interconnection can be done as a grid, where each ground has a separate line to each
other ground, or by using a “rat Race” ring which forms a closed loop (not necessarily a
perfect circle) which surrounds the equipment house completely.
By making this interconnection, it will be necessary to use proper I/O protectors for the
equipment. Of course, these should be a requirement regardless of whether this grounding
technique is used. I/O protectors are used for power lines (even those these don’t feed into a
ControlWave unit), telephone lines, and also to minimize EMI pick-up from a strike.
Ideally it is best to place all I/O protectors on a common panel that has a low inductance
path to the ground system. The ControlWave units would then have a single ground point
from its Chassis Ground Terminal/Ground Lug to this panel. In lieu of this, the
ControlWave unit in question should be tied to a ground rod that in turn is connected to
the Earth/System Ground created for the site.
Your protected equipment connected to a common single ground system, will now be just
like a bird sitting on a high tension wire. When lightning strikes, even with a 50 ohm surge
impedance ground system, the entire system consisting of equipment, ground system,
building, etc., will all rise together to the one million volt peak level (for example) and will
all decay back down together. So long as there is no voltage differential (taken care of by
protectors and ground interconnections, there will be no current flow through the
equipment and therefore no resulting equipment damage.

4.1.5 Impulse Protection Summary
i
i
i
i

Use more than one ground rod.
Place multi-ground stakes more than their length apart.
Tie Power, Telco, Tower, Bulkhead and equipment ground together.
Make all ground interconnect runs that are above ground with minimum radius
bends of eight inches and run them away from other conductors and use large solid
wire or a solid strap.

Section 4 - Lightning & Surge

Page 4-5

S1400CW

i Watch out for dissimilar metals connections and coat accordingly.
i Use bare wire radials together where possible with ground stakes to reduce ground
system impedance.
i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground
system.
i Ground the Coaxial Cable Shield (or use an impulse suppressor) at the bottom of the
tower just above the tower leg ground connection.

4.2 USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS
Units equipped with radios or modems use lightning arresters and surge protectors to
protect equipment from lightning strikes, power surges and from damaging currents that
have been induced onto communication lines.
The first line of defense is the Lightning Arrester. These devices typically use gas discharge
bulbs that can shunt high currents and voltages to earth ground when they fire. The high
current, high voltage gas discharge bulb has a relatively slow response time and only fire
when their gas has been ionized by high voltage.
The second line of defense is the Surge Protector, which is made of solid state devices, fires
very quickly and conducts low voltages and currents to ground. Surge protectors are built
into BBI 9600 bps modems.
Lightning Arresters are applied to circuits as follows:
i Equipment or circuits that can be exposed to lightning strikes, falling power lines,
high ground currents caused by power system faults, by operational problems on
electric railways, etc.
i Equipment installed in dry, windy areas, such as the Great Plains and the
Southwest Desert in the United States. Wind and wind blown dust can cause high
voltages (static) to appear on overhead wires, fences, and metal buildings.
Note: Lightning Arresters may explode if lightning strike is very close. Mount
lightning arresters where flying parts won't cause injury to equipment or
personnel.

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Page 4-6

Section 4 - Lightning & Surge

Section 5 - Wiring Techniques
5.1 OVERVIEW
This section provides information pertaining to good wiring practices. Installation of Power
and “Measurement & Control” wiring is discussed. Information on obscure problems,
circulating ground and power loops, bad relays, etc. is presented. Good wire preparation
and connection techniques along with problems to avoid are discussed.

5.2 INSTRUMENT WIRING
Each of the rules listed below is briefly discussed; the emphasis herein is placed on the
avoidance of problems as well as equipment safety.
Rule 1 - Never utilize common returns.
Rule 2 - Use twisted shielded pairs (with overall insulation) on all Signal/Control circuits.
Rule 3 - Ground cable shields at one end only.
Rule 4 - Use known good earth grounds (Rod, Bed, System) and test them periodically,
Rule 5 - Earth connections must utilize smoothly dressed large wire.
Rule 6 - Perform all work neatly and professionally.
Rule 7 - Route high power conductors away from signal wiring according to NEC Rules.
Rule 8 - Use appropriately sized wires as required by the load.
Rule 9 - Use lightning arresters and surge protectors.
Rule 10 - Make sure all wiring connections are secure.

5.2.1 Common Returns
Use of common returns on I/O wiring is one of the most common causes of obscure and
difficult to troubleshoot control signal problems. Since all wires and connections have
distributed resistance, inductance and capacitance, the chances of a achieving a balanced
system when common returns are present is very remote. Balanced systems (or circuits) are
only achieved when all currents and voltages developed in association with each of the
common returns are equal. In a balanced system (or circuit) there are no noise or
measurment errors introduced due to by “sneak circuits.”
The illustration of Figure 5-1 shows the difference between testing an I/O circuit that is
discrete and has no sneak circuits and one that utilizes common returns. Common sense
tells us that it is tough to mix up connections to a twisted shielded pair (with overall vinyl
covering) to every end device. Do yourself a favor; to make start up easier, DON’T USE
COMMON RETURNS!

Section 5 - Wiring Techniques

Page 5-1

S1400CW

Figure 5-1 - Field Wired Circuits With & Without A Common Return

5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation)
For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly
recommended. This type of cable provides discrete insulation for each of the wires and an
additional overall insulated covering that provides greater E.M.I. immunity and protection
to the shield as well.

S1400CW

Page 5-2

Section 5 - Wiring Techniques

5.2.3 Grounding of Cable Shields
DO NOT connect the cable shield to more than one ground point; it should only be grounded
at one end. Cable shields that are grounded at more than one point or at both ends may
have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O
signals. This will occur when the ground systems associated with multipoint connections to
a cable shield have a high resistance or impedance between them and a ground induced
voltage is developed (for what ever reason, i.e., man made error or nature produced
phenomena).

5.2.4 Use of Known Good Earth Grounds
ControlWave units should only have one connection to earth ground. For ControlWave
and ControlWave MICRO Process Automation Controllers, ControlWave MICRO,
ControlWave EFM Electronic Flow Meters, ControlWave GFC/XFC Gas Flow Computers
and ControlWave I/O Expansion Racks, this connection is provided via the Ground Lug
that is situated on the bottom of the unit. ControlWaveLPs require the installation of a
ground lug, ground bus or ground plate/panel. Since ControlWave units are DC-based
systems, grounding does not take into account AC power grounding considerations. Earth
grounding the unit is absolutely necessary when the unit is equipped with a radio or
modem. Additionally these units should be connected to earth ground when they are
installed in areas that have frequent lightning strikes or are located near or used in
conjunction with equipment that is likely to be struck by lightning or if struck by lightning
may cause equipment or associated system failure. Earth Grounds must be tested and must
be known to be good before connecting the ControlWave. Earth grounds must be
periodically tested and maintained (see Section 4).

5.2.5 Earth Ground Wires
Earth connections must utilize smoothly dressed large wire. Use AWG 3 or 4 stranded
copper wire with as short a length as possible. Exercise care when trimming the insulation
from the wire ends. Twists the strands tightly, trim off any frizzes and tin the ends with
solder. The earth ground wire should be clamped or brazed to the Ground Bed Conductor
(that is typically a standard AWG 0000 copper cable. The earth ground wire should be run
such that any routing bend in the cable is a minimum 8-inch radius above ground or a
minimum 12-inch radius below ground.

5.2.6 Working Neatly & Professionally
Take pride in your work and observe all site and maintenance safety precautions. After
properly trimming the stranded pair wire ends, twist them in the same direction as their
manufacturer did and then tin them with solder. Install the tinned wire end into it’s
connector and then secure the associated connector’s clamping screw. Remember to check
these connections for tightness from time to time. If solid copper wire is used (in
conjunction with the DC Power System or for Earth Ground) make sure that the conductor
is not nicked when trimming off the insulation. Nicked conductors are potential disasters
waiting to happen. Neatly trim shields and whenever possible, coat them to protect them
and prevent shorts and water entry.

Section 5 - Wiring Techniques

Page 5-3

S1400CW

Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to
being costly.

5.2.7 High Power Conductors and Signal Wiring
When routing wires, keep high power conductors away from signal conductors. Space wires
appropriately to vent high voltage inductance. Refer to the National Electrical Code
Handbook for regulatory and technical requirements.

5.2.8 Use of Proper Wire Size
ControlWaves utilize compression-type terminals that accommodate up to #14 AWG gauge
wire. A connection is made by inserting the bared end (1/4 inch max.) into the clamp
beneath the screw and securing the screw.
Allow some slack in the wires when making terminal connections. Slack makes the
connections more manageable and minimizes mechanical strain on the PCB connectors.
Provide external strain relief (utilizing Tie Wrap, etc.) to prevent the loose of slack at the
ControlWave.
Be careful to use wire that is appropriately sized for the load. Refer to equipment
manufacturer’s Specs. and the National Electrical Code Handbook for information on wire
size and wire resistance. After installing the field wiring, test each load to determine if the
correct voltage or current is present at the load. If you know the resistance of the field wires
(Circular Mills x Length) you should be able to calculate the load voltage. Conversely, if you
know the minimum load voltage and current, you should be able to derive the maximum
voltage loss that is allowable due to line resistance and then the correct wire size.
Referring to Figure 5-2, a relay that is picked by 100 mA, with a loop supply voltage of 24V
and a total line resistance of 20 ohms, the load voltage (voltage across the relay) should be:
VL = VS - (VC + VC) where VC + VC = (RC + RC) I
22 = 24 - 2
where 2V
= (20 Ω) x 0.1 A

Figure 5-2 - Calculating Load Voltage due to Line Resistance

5.2.9 Lightning Arresters & Surge Protectors
Use lightning arresters in association with any radio or modem equipped unit. BBI 9600
bps modems are equipped with surge protection circuitry. Lightning arresters or Antenna
S1400CW

Page 5-4

Section 5 - Wiring Techniques

Discharge Units should be placed on the base of the antenna and at the point where the
antenna lead (typically coax) enters the site equipment building. When a modem is used, a
lightning arrester should be placed at the point where the phone line enters the site
equipment building. If you use a modem (manufactured by other than BBI) it is
recommended that you also install a surge suppressors or lightning arrester on the phone
line as close to the modem as possible. Any unit interfaced to a radio or modem must be
connected to a known good earth ground.

5.2.10 Secure Wiring Connections
Make sure that all wiring connections are secure. In time wires that were once round will
become flattened due to the pressure applied by screw compression type terminals and site
vibrations. After a while these compression screws have a tendency to become loose. Part of
a good maintenance routine should be to check and tighten all screws associated with
wiring terminal connections. Avoid nicking the wire(s) when stripping insulation.
Remember, nicked conductors will lead to future problems. Also remember to provide some
cabling slack and strain relief.
If installing stranded or braided wiring that has not been tinned, be sure to tightly twist
the end (in the same direction as manufactured) and then trim off any frizzed wires.

Section 5 - Wiring Techniques

Page 5-5

S1400CW

BLANK PAGE

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DOCUMENT NUMBER: S1400CW
TITLE: ControlWaveTM SITE CONSIDERATIONS For EQUIPMENT INSTALLATION,
GROUNDING & WIRING
ISSUE DATE: APR., 2005
COMMENT/COMPLAINT:
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Mail this page to:
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Attn: Technical Publications Group, Dept. 315

Bristol Babcock
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Fax: +1 (860) 945-2213
Website: www.bristolbabcock.com

U.S.A. Locations:
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Phone: +1 (860) 945-2381
Fax: +1 (860) 945-2525
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Helicoid Instruments
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Phone: +1 (860) 945-2218
Fax: +1 (860) 945-2213
jmcgrail@bristolbabcock.com

Gulf Coast Region
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Western Region
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Southeast Region
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SouthwestUS@bristolbabcock.com

WesternUS@bristolbabcock.com

SoutheastUS@bristolbabcock.com

Central Region
Bristol Babcock Inc.
300 North Coit Road
Suite 1300
Richardson, TX 75080
Phone: +1 (972) 238-8935
Fax: +1 (972) 238-8198
dallas@bristolbabcock.com

Rocky Mountain Region
Bristol Babcock Inc.
906 San Juan Blvd., Suite A
Farmington, NM 87401
Phone: +1 (505) 320-5046
Fax: +1 (505) 327-3273

Communications
Technology Group
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Suite 1016
Altamonte Springs, FL 32701
Phone: +1 (407) 629-9464
Fax: +1 (407) 629-2106

NewMexUS@bristolbabcock.com

orlandoRFgroup@bristolbabcock.com

International Affiliates:
Canada
Bristol Babcock, Canada
234 Attwell Drive
Toronto, Ont. M9W 5B3
Canada
PH: 416-675-3820
FAX: 416-674-5129
info@bristolbabcock.ca

Mexico
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
PH: (52-55)-52-81-81-12
FAX: (52-55)-52-81-81-09
Mexico@bristolbabcock.com

United Kingdom
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
enquiries@bristol-babcock.com

Asia Pacific
Bristol Babcock, Inc.
PO Box 1987
Bunbury, Western Australia
6231
PH: +61 (0) 8 9791 3654
FAX: +61 (0) 8 9791 3173
dtrench@bdsa.com.au
Victoria, Australia
PH: +61 (0) 3 9384 2171
FAX: +61 (0) 3 8660 2501

Calgary Office
Bristol Babcock, Canada
3812 Edmonton Trail N.E.
Calgary, Alberta T2E 5T6
Canada
PH: 403-265-4808
FAX: 403-233-2914
janetl@bristolbabcock.ca

RC Rev: 05-Feb-04

Villahermosa Office
BBI, S.A. de C.V.
Av. Plomo No.2
Bodega No. 1 - Ciudad
Industrial
Villahermosa, Tabasco 86010
Mexico
PH: 52-993-353-3142
FAX: 52-993-353-3145
bbivsa@prodigy.net.mx

Middle East
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
enquiries@bristol-babcock.com

ESDS Manual
S14006
4/15/92

CARE AND HANDLING
OF
PC BOARDS
AND
ESD-SENSITIVE
COMPONENTS

BRISTOL BABCOCK

BLANK PAGE

ESDS Manual
S14006
4/15/92

TABLE OF CONTENTS
PAGE
TOOLS AND MATERIALS REQUIRED

ESD-SENSITIVE COMPONENT HANDLING PROCEDURE

Introduction

General Rules

Protecting ESD-Sensitive Components

Static-Safe Field Procedure

Cleaning and Lubricating

Completion

TOOLS AND MATERIALS REQUIRED
1.

Tools
Anti-Static Field kit. It is recommended that an anti-static field kit be kept on any
site where solid-state printed circuit boards and other ESD-sensitive components are handled. These kits are designed to remove any existing static charge
and to prevent the build-up of a static charge that could damage a PC board or
ESD-sensitive components. The typical anti-static field kit consists of the
following components:
1.

A work surface (10mm conductive plastic sheet with a female snap
fastener in one corner for ground cord attachment).

A 15-foot long ground cord for grounding the work surface.

Wrist strap (available in two sizes, large and small, for proper fit and
comfort) with a female snap fastener for ground cord attachment.

A coiled ground cord with a practical extension length of 10 feet for
attachment to the wrist strap.

Toothbrush (any standard one will do)

ESDS Manual
#S14006
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Materials
●

Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent)

●

Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent)

●

Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent)

ESD-SENSITIVE COMPONENT HANDLING PROCEDURE
1.

Introduction
Microelectronic devices such as PC boards, chips and other components are electrostatic-sensitive. Electrostatic discharge (ESD) of as few as 110 volts can damage or
disrupt the functioning of such devices. Imagine the damage possible from the 35,000
volts (or more) that you can generate on a dry winter day by simply walking across a
carpet. In fact, you can generate as much as 6,000 volts just working at a bench.
There are two kinds of damage that can be caused by the static charge. The more
severe kind results in complete failure of the PC board or component. This kind of
damage is relatively simple, although often expensive, to remedy by replacing the
affected item(s). The second kind of damage results in a degradation or weakening
which does not result in an outright failure of the component. This kind of damage is
difficult to detect and often results in faulty performance, intermittent failures, and
service calls.
Minimize the risk of ESD-sensitive component damage by preventing static build-up and
by promptly removing any existing charge. Grounding is effective, if the carrier of the
static charge is conductive such as a human body. To protect components from
nonconductive carriers of static charges such as plastic boxes, place the component
in static-shielding bags.
This manual contains general rules to be followed while handling ESD-sensitive
components. Use of the anti-static field kit to properly ground the human body as well
as the work surface is also discussed.

ESDS Manual
S14006
4/15/92

Table 1
Typical Electrostatic Voltages
Electrostatic Voltages
Means of Static
Generation
Walking across carpet
Walking over vinyl floor
Worker at bench
Vinyl envelopes for work instructions
Poly bag picked up from bench
Work chair padded with poly foam

10-20 Percent
Relative Humidity
35,000
12,000
6,000
7,000
20,000
18,000

65-90 Percent
Relative Humidity
1,500
250
100
600
1,200
1,500

General Rules
(1)

ESD-sensitive components shall only be removed from their static-shielding
bags by a person who is properly grounded.

(2)

When taken out of their static-shielding bags, ESD-sensitive components shall
never be placed over, or on, a surface which has not been properly grounded.

(3)

ESD-sensitive components shall be handled in such a way that the body does
not come in contact with the conductor paths and board components. Handle
ESD-sensitive components in such a way that they will not suffer damage from
physical abuse or from electric shock.

(4)

EPROMS/PROMS shall be kept in anti-static tubes until they are ready to use
and shall be removed only by a person who is properly grounded.

(5)

When inserting and removing EPROMS/PROMS from PC boards, use a chip
removal tool similar to the one shown in the figure following. Remember, all work
should be performed on a properly grounded surface by a properly-grounded
person.

ESDS Manual
#S14006
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Typical Chip Removal Tool

(6)

It is important to note when inserting EPROMS/PROMS, that the index notch on
the PROM must be matched with the index notch on the socket. Before pushing
the chip into the socket, make sure all the pins are aligned with the respective
socket-holes. Take special care not to crush any of the pins as this could destroy
the chip.

(7)

Power the system down before removing or inserting comb connectors/plugs or
removing and reinstalling PC boards or ESD-sensitive components from card
files or mounting hardware. Follow the power-down procedure applicable to the
system being serviced.

(8)

Handle all defective boards or components with the same care as new components. This helps eliminate damage caused by mishandling. Do not strip used PC
boards for parts. Ship defective boards promptly to Bristol Babcock in a staticshielding bag placed inside static-shielding foam and a box to avoid damage
during shipment.

ESDS Manual
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4/15/92

CAUTION
Don't place ESD-sensitive components and paperwork in the same bag.
The static caused by sliding the paper into the bag could develop a charge and
damage the component(s).
(9)

Include a note, which describes the malfunction, in a separate bag along with each
component being shipped. The repair facility will service the component and
promptly return it to the field.

Protecting ESD-Sensitive Components
(1)

As stated previously, it is recommended that an electrically-conductive anti-static
field kit be kept on any site where ESD-sensitive components are handled. A
recommended ESD-protective workplace arrangement is shown on page 7. The
anti-static safety kit serves to protect the equipment as well as the worker. As a safety
feature, a resistor (usually of the one-megohm, 1/2-watt, current-limiting type) has
been installed in the molded caps of the wrist strap cord and the ground cord. This
resistor limits current should a worker accidently come in contact with a power
source. Do not remove the molded caps from grounded cords. If a cord is damaged,
replace it immediately.

(2)

Be sure to position the work surface so that it does not touch grounded conductive
objects. The protective resistor is there to limit the current which can flow through
the strap. When the work surface touches a grounded conductive object, a short is
created which draws the current flow and defeats the purpose of the current-limiting
resistor.

(3)

Check resistivity of wrist strap periodically using a commercially-available system
tester similar to the one shown in the figure below:

ESDS Manual
#S14006
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Note: If a system checker is not available, use an ohmmeter connected to the cable
ends to measure its resistance. The ohmmeter reading should be 1 megohm +/15%. Be sure that the calibration date of the ohmmeter has not expired. If the
ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a
new one.

Static-safe Field Procedure

(1)

On reaching the work location, unfold and lay out the work surface on a convenient
surface (table or floor). Omit this step if the table or floor has a built-in ESD-safe work
surface.

(2)

Attach the ground cord to the work surface via the snap fasteners and attach the
other end of the ground cord to a reliable ground using an alligator clip.

(3)

Note which boards or components are to be inserted or replaced.

(4)

Power-down the system following the recommended power-down procedure.

(5)

Slip on a known-good wristband, which should fit snugly; an extremely loose fit is not
desirable.

(6)

Snap the ground cord to the wristband. Attach the other end of the ground cord to
a reliable ground using the alligator clip.

ESDS Manual
S14006
4/15/92

(7)

The components can now be handled following the general rules as described
in the instruction manual for the component.

(8)

Place the component in a static-shielding bag before the ground cord is
disconnected. This assures protection from electrostatic charge in case the work
surface is located beyond the reach of the extended ground cord.

C
D

✰R

B
R

EARTH GROUND

FLOOR

BUILDING

LEGEND

- Chair with ground (optional)

- ESD protective floor mat (optional)

- Wrist strap

- ESD protective trays, etc.

- Ionizer

- Other electrical equipment

- Workbench with ESD protective table top
✰ NOTE: ALL RESISTORS 1M Ω +/-10% 1/2W

ESDS Manual
#S14006
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(9)

If a component is to undergo on-site testing, it may be safely placed on the
grounded work surface for that purpose.

(10)

After all component work is accomplished, remove the wrist straps and ground
wire and place in the pouch of the work surface for future use.

Cleaning And Lubricating
The following procedure should be performed periodically for all PC boards and
when a PC board is being replaced.

CAUTION
Many PC board connectors are covered with a very fine gold-plate.
Do not use any abrasive cleaning substance or object such as a pencil eraser to
clean connectors.
Use only the approved cleaner/lubricants specified in the procedure following.

WARNING
Aerosol cans and products are extremely combustible.
Contact with a live circuit, or extreme heat can cause an
explosion.
Turn OFF all power and find an isolated, and ventilated
area to use any aerosol products specified in this procedure.

(1)

Turn the main line power OFF. Blow or vacuum out the component. This should
remove potential sources of dust or dirt contamination during the remainder of
this procedure.

ESDS Manual
S14006
4/15/92

(2)

Clean PC board connectors as follows:
a.

Review the static-safe field procedure detailed earlier.

Following the ESD-sensitive component handling procedures, remove
the connectors from the boards and remove the PC boards from their
holders.

Use cleaner to remove excessive dust build-up from comb connectors
and other connectors. This cleaner is especially useful for removing dust.

Liberally spray all PC board contacts with Inhibitor. The inhibitor:
●

Provides a long lasting lubricant and leaves a protective film to
guard against corrosion

●

Improves performance and reliability

●

Extends the life of the contacts

●

Is nonconductive, and is safe for use on most plastics

Clean the comb contacts using a lint-free wiping cloth.

Lightly mist all comb contacts again with Inhibitor.

NOTE: Do not use so much Inhibitor that it drips.
g.

(3)

Repeat the above procedure for the other PC boards from the device.

Cleaning PC edge connectors
a.

Use cleaner to remove excessive dust build-up from connectors. This
cleaner is especially useful for removing dust.

Liberally spray the outboard connector with Inhibitor.

Lightly brush the outboard connector with a soft, non-metallic, bristle
brush such as a toothbrush.

ESDS Manual
#S14006
4/15/92

Spray the connector liberally to flush out any contaminants.

Remove any excess spray by shaking the connector or wiping with either
a toothbrush, or a lint-free wiping cloth.

Completion
(1)

Replace any parts that were removed.

(2)

Make sure that the component cover is secure.

(3)

Return the system to normal operation.

(4)

Check that the component operates normally.

BLANK PAGE

ControlWave EFM (Electronic Flow Meter)

Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09
www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969
www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955
www.EmersonProcess.com/Bristol

Customer Instruction Manual
CI-ControlWave EFM
Oct., 2006

The information in this document is subject to change without notice. Every effort has
been made to supply complete and accurate information. However, Bristol, Inc.
assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your
local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software
delivered herewith. The Customer shall inspect and test such software and other
materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and
fitness for a particular purpose, concerning the software and other materials delivered
herewith.
TeleFlow™ is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service
mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in
this document are for information only, and belong to their respective companies, or
trademark holders.
Copyright (c) 2006, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part
of this manual may be reproduced in any form without the express written permission of
Bristol Inc.

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Emerson Process Management Controlwave Efm 4710A Users Manual Bristol Electronic Flow Meter (EFM) (CI ControlWaveEFM)

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