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REMOTE TERMINAL UNITS

RTU 3305

Bristol Babcock
Instruction Manual CI-3305 - December, 2005
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.

TM
ACCOL is a trademark of Bristol Babcock. Other trademarks or copy-righted 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.
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 Babcock 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, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional information is required, the purchaser is advised to contact Bristol
Babcock.

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol Babcock for repairs or evaluation,


please note the following: The party sending such materials is responsible to ensure
that the materials returned to Bristol Babcock 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 Babcock and save Bristol Babcock
harmless from any liability or damage which Bristol Babcock 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 Babcock 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.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from
defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol are expressly limited
to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part
thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol’s consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER WAR-


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

F. No agent of Bristol is authorized to assume any liability for it or to make any written
or oral warranties beyond those set forth herein.

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 Water-
town 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 ar-
range to have a Bristol service person come to the site. The Service person’s
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

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


resulting from breach of any agreement relating to items included in this quotation
from use of the information herein or from the purchase or use by Buyer, its
employees 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 Babcock 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 Babcock 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 BBI 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 Babcock Web site
(www.bristolbabcock.com) and sending it via E-Mail to brepair@bristolbabcock.com.
A BBI 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 Babcock Inc.


Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

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

D. Phone
Calling the BBI Repair Department at (860) 945-2442. A BBI 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 in-
cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.
&VMWXSP &EFGSGO -RG 6ITEMV %YXLSVM^EXMSR *SVQ
(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to
receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is Please be aware of the Non warranty standard charge:
practice may be requested in the “Special Requests” section. • There is a $100 minimum evaluation charge, which is
• Evaluate / Test / Verify Discrepancy applied to the repair if applicable (√ in “returned”
• Repair / Replace / etc. in accordance with this form B,C, or D of part III below)
• Return to Customer
Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)

Bill to : Ship to:

Purchase Order: Contact Name:____________________________________


Phone: Fax: E-Mail:

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

Model No./Part No. Description


Range/Calibration S/N
Reason for return : Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)


2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________
3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due
to BBI’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 BBI 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 Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-3875

Form GBU 13.01 Rev. A


Bristol Babcock
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 Babcock 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 Babcock 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) 685-
6200.
BLANK PAGE
A Few Words About Bristol Babcock

For over 100 years, Bristol7 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 Babcock 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 assis-
tance in using this product from the following sources:

Help Files / Release Notes

Many Bristol Babcock 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 Babcock Directly

Bristol Babcock's world headquarters are 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 Babcock'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 Babcock hardware to radios, contact Bristol Babcock’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 Babcock 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 Babcock and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol Babcock’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-3305
MODEL 3305 REMOTE TERMINAL UNIT

TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 1 -INTRODUCTION

1.1 GENERAL INTRODUCTION........................................................................................ 1-1


1.2 PHYSICAL DESCRIPTION........................................................................................... 1-2
1.2.1 Backplane Board............................................................................................................. 1-2
1.2.2 Processor Memory Peripheral Power Supply Board (PMPP)....................................... 1-3
1.2.2.1 Configuration Jumpers................................................................................................... 1-5
1.2.2.2 Processor Memory Peripheral Power Supply Board Configuration Switch ................ 1-5
1.2.2.3 Processor Memory Peripheral Power Supply Board LED Indicators.......................... 1-6
1.2.2.4 Lithium Battery ............................................................................................................. 1-6
1.2.2.5 Communications Subsystem .......................................................................................... 1-7
1.2.2.6 Processor Memory Peripheral Power Supply Board Connectors ................................. 1-8
1.2.3 Multifunction Input/Output Board (MI/OB) ................................................................. 1-9
1.2.3.1 Discrete Input Circuitry ................................................................................................. 1-9
1.2.3.2 Discrete Output Circuitry .............................................................................................. 1-9
1.2.3.3 Analog Input Circuitry ................................................................................................. 1-11
1.2.3.4 Analog Output Circuitry .............................................................................................. 1-11
1.2.3.5 High Speed Counter Circuitry ..................................................................................... 1-11
1.2.3.6 Watchdog Relay Circuitry ............................................................................................ 1-11
1.2.3.7 Communications Ports ................................................................................................. 1-12
1.2.3.8 Multifunction I/O Board Terminal Blocks and Connectors........................................ 1-12
1.2.3.9 Multifunction I/O Board Jumpers & Switch SW1 ...................................................... 1-17
1.2.3.10 MI/OB LEDs ........................................................................................................................ 1-17
1.2.3.11 MI/OB On-Board Fuse F1................................................................................................... 1-18
1.3 OPTIONS ...................................................................................................................... 1-18
1.3.1 LCD Displays ............................................................................................................... 1-19
1.3.2 Network Communication Options .............................................................................. 1-21
1.3.2.1 Modems ........................................................................................................................ 1-21
1.3.2.2 BBI Transmitter Interface Board ............................................................................... 1-23
1.3.2.3 RS-485 Interface Board ................................................................................................ 1-23
1.3.2.4 Radio Delay Board ....................................................................................................... 1-25
1.3.2.5 BBI Network Interface Box (NIB) ............................................................................... 1-25
1.3.2.6 HART Device Interface Option .................................................................................... 1-25
1.3.3 Power Supplies.............................................................................................................. 1-25

Section 1A -APPLICATION SOFTWARE

1A.1 CATEGORIES OF APPLICATION SOFTWARE...................................................... 1A-1


1A.2 ACCOL TOOL SOFTWARE........................................................................................ 1A-1
1A.3 SUPERVISORY SOFTWARE ..................................................................................... 1A-3
1A.4 OPEN BSI UTILITIES SOFTWARE ......................................................................... 1A-3
1A.5 SYSTEM APPLICATIONS ......................................................................................... 1A-5
1A.5.1 Stand-Alone Unit ......................................................................................................... 1A-5
1A.5.2 Local Area Network (LAN).......................................................................................... 1A-5
1A.5.3 Wide Area Network (WAN)......................................................................................... 1A-7

3305 RTU Contents / 0 - 1


TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 2 - INSTALLATION

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


2.2 MOUNTING THE MODEL 3305 RTU.......................................................................... 2-2
2.2.1 Temperature & Humidity Limits .................................................................................. 2-2
2.2.2 Vibration Limits.............................................................................................................. 2-3
2.3 3305 RTU INSTALLATION/CONFIGURATION......................................................... 2-3
2.3.1 PMPP Board Jumper Configurable Options................................................................. 2-4
2.3.2 Soft switch Configuration .............................................................................................. 2-4
2.4 WIRING NOTES ............................................................................................................ 2-7
2.4.1 Discrete Inputs ............................................................................................................... 2-9
2.4.2 Discrete Outputs........................................................................................................... 2-10
2.4.3 Analog Inputs................................................................................................................ 2-12
2.4.4 Analog Outputs............................................................................................................. 2-13
2.4.5 High Speed Counter Circuitry ..................................................................................... 2-14
2.4.6 Watchdog Relay Circuitry ........................................................................................... 2-15
2.4.7 DC Power Configuration & Wiring ............................................................................. 2-15
2.4.8 Communication Ports .................................................................................................. 2-16
2.4.8.1 RS-485 Interface (Port D)............................................................................................. 2-16
2.4.8.2 RS-232 Interface (Ports B, C & D)............................................................................... 2-18
2.4.8.3 Port A RS-232 Interface ............................................................................................... 2-19
2.5 INSTALLING LCD OPTIONS..................................................................................... 2-19
2.5.1 Installing the 2 X 20 Local LCD Display Module ....................................................... 2-19
2.5.1.1 Installation of Local LCD Display (No Network Option Present) ............................. 2-19
2.5.1.2 Installation of Local LCD Display (Network Option Present)................................... 2-20
2.5.2 Installing the Remote LCD Display Module............................................................... 2-26
2.5.2.1 Installing the Remote 2 X 16 LCD Display Assembly................................................ 2-27
2.5.2.2 Installing the Remote 4 X 20 LCD Display/Keyboard Assembly............................... 2-28
2.6 INSTALLING A COMMUNICATION OPTION......................................................... 2-29

Section 3 - LIQUID CRYSTAL DISPLAYS

3.1 INTRODUCTION TO LCDs ......................................................................................... 3-1


3.1.1 2 X 16 LCD Display & Sensor Buttons.......................................................................... 3-1
3.1.2 4 X 20 LCD Display/Keyboard ....................................................................................... 3-2
3.2 PREPARING THE ACCOL LOAD ................................................................................ 3-2
3.2.1 ACCOL Module Terminals............................................................................................. 3-7
3.3 USING THE 4 X 20 DISPLAY/KEYBOARD .............................................................. 3-11
3.3.1 Display/Keyboard Scrolling ......................................................................................... 3-13
3.3.2 Signing-On With the Display/Keyboard...................................................................... 3-13
3.3.3 Clock Functions Via the Display/Keyboard ................................................................ 3-14
3.3.4 Choosing a Signal List from the List Menu via the Display/Keyboard..................... 3-15
3.3.5 Moving Through a Signal List via the Display/Keyboard.......................................... 3-16
3.3.6 Changing Signal Parameters via the Display/Keyboard ........................................... 3-16
3.3.7 Signing-Off via the Display/Keyboard......................................................................... 3-20
3.4 INTERPRETING ERROR MESSAGES ...................................................................... 3-20
3.5 2 X 16 LCD DISPLAY SCROLLING DETAILS......................................................... 3-22
3.5.1 Main 2 X 16 LCD Display ............................................................................................ 3-22
3.5.2 Other Lists Associated with the 2 X 16 LCD Display ................................................ 3-23
3.6 RESET & DIAGNOSTIC.............................................................................................. 3-26
3.6.1 Reset/Self-Test Diagnostics.......................................................................................... 3-26

0 - 2 / Contents 3305 RTU


TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 3 - LIQUID CRYSTAL DISPLAYS (Continued)

3.6.2 OFF-Line/ACCOL Diagnostics..................................................................................... 3-26

Section 4 - OPERATION

4.1 GEBERAL ....................................................................................................................... 4-1


4.2 PRELIMINARY CHECKS ............................................................................................. 4-1
4.3 STARTING THE RTU .................................................................................................... 4-2
4.3.1 Equipment Required ...................................................................................................... 4-2
4.3.2 General Setup Procedures ............................................................................................. 4-2
4.4 SHUTDOWN PROCEDURE.......................................................................................... 4-5
4.5 USING THE BBI SYSTEM CONFIG/FLASH DOWNLOADER PROGRAM............. 4-6
4.5.1 Downloading Standard System or Custom System Firmware .................................... 4-9
4.5.2 Download An ACCOL Load into FLASH Memory ..................................................... 4-10
4.5.3 Download An ACCOL Load into RAM ........................................................................ 4-10
4.5.4 Using BBI System/Flash Downloader Program Diagnostics..................................... 4-11

Section 5 - SERVICE

5.1 SERVICE INTRODUCTION ......................................................................................... 5-1


5.1.1 Accessing PC Boards For Testing .................................................................................. 5-1
5.1.2 Removal/Replacement of the PMPP Board ................................................................... 5-2
5.1.3 Removal/Replacement of the MI/OB Board .................................................................. 5-4
5.1.4 Removal/Replacement of the Backplane Board............................................................ 5-6
5.2 DIAGNOSTIC TEST PROCEDURES ........................................................................... 5-6
5.2.1 Self-Test Diagnostics (PMPP Board Status LEDs)....................................................... 5-6
5.2.2 Startup Diagnostics Using a Terminal Emulator....................................................... 5-10
5.3 DIAGNOSTIC PROGRAM (DIAG05.ACL) ................................................................. 5-11
5.3.1 Testing the 3305 RTU CPU Peripherals and Comm Ports ........................................ 5-12
5.3.2 Analog Input Circuitry Offset Calibration.................................................................. 5-13
5.3.3 Analog Output Circuitry Calibration .......................................................................... 5-14
5.3.4 Discrete Output & Discrete Input Tests ..................................................................... 5-14
5.3.5 High Speed Counter Tests ........................................................................................... 5-14
5.3.6 LCD Display & Display/Keyboard Tests ..................................................................... 5-16
5.4 POWER SUPPLY TESTS & TRIP POINT ADJUSTMENTS .................................... 5-16
5.4.1 Setting the Power Fail Trip Point ............................................................................... 5-16
5.4.2 Setting the Low Battery Voltage Detection Trip Points ............................................ 5-17
5.4.3 Power Checks................................................................................................................ 5-17
5.5 GENERAL NOTES....................................................................................................... 5-18
5.5.1 Extent of Field Repairs ................................................................................................ 5-18
5.5.2 Disconnecting RAM Battery ........................................................................................ 5-18
5.5.3 Maintaining Backup Files............................................................................................ 5-18

Section 6 - SPECIFICATIONS

6.1 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 6-1


6.2 COMMUNICATION PORTS ........................................................................................ 6-1
6.2.1 Communication Ports..................................................................................................... 6-1
6.2.2 Network Ports (B, C & D) .............................................................................................. 6-1
6.2.3 Customer Port (A)........................................................................................................... 6-2

3305 RTU Contents / 0 - 3


TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 6 - SPECIFICATIONS (Continued)

6.2.4 Communication Protocols (Network Ports)................................................................... 6-2


6.3 INPUT/OUTPUT SPECIFICATIONS .......................................................................... 6-2
6.3.1 Analog Inputs .................................................................................................................6-2
6.3.2 Analog Outputs............................................................................................................... 6-3
6.3.3 Discrete Inputs .............................................................................................................. 6-3
6.3.4 Discrete Outputs ............................................................................................................ 6-3
6.3.5 Watchdog Contacts ........................................................................................................6-4
6.3.6 High Speed Counter ...................................................................................................... 6-4
6.4 ENVIRONMENTAL SPECIFICATIONS...................................................................... 6-4
6.5 POWER SPECIFICATIONS .......................................................................................... 6-5
6.5.1 Input Power Specs. ......................................................................................................... 6-5
6.5.2 DC To DC Converter Specs. ........................................................................................... 6-5
6.5.3 Power Requirements ...................................................................................................... 6-6
6.6 RTU 3305 MODEL VARIATIONS................................................................................. 6-6

APPENDICES

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


TRANSMITTER INTERFRACE BOARDS (Appendix 1)......................... PIP-TIBS33XX
RADIO DELAY BOARD................................................................................... Appendix 2
RS-485 INTERFACE BOARD.......................................................................... Appendix 3
NETWORK INTERFACE BOX ....................................................................... Appendix 4
HIGHWAY ADDRESSABLE REMOTE TRANSDUCER (HART)
DEVICE INTERFACE (Appendix 5) ....................................................... PIP-HART33XX
RTU 3305 POWER SUPPLY/BATTERY CHARGER ..................................... Appendix 6
ISOLATED RS-485 INTERFACE BOARD (Appendix 7)......................... PIP-ISORS485
MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z

SUPPLEMENTAL INSTRUCTIONS

RTU 3305 STANDARD ENCLOSURE ....................................................... Supplement 1


GUIDELINES FOR SYSTEM GROUNDING ......................................................... S1400
CARE AND HANDLING OF PC BOARDS AND
ESD-SENSITIVE COMPONENTS......................................................................... S14006

REFERENCED BBI CUSTOMER INSTRUCTION MANUALS

BBI 1200 bps - PL & PSTN MODEMS..................................................................CI-1200


BBI 9600 bps - PSTN MODEM (396039-10-3).....................................................CI-9600
BBI 9600 bps - PSTN MODEM (392958-05-8).................................................. CI-9600A
33XX DIAGNOSTICS............................................................................................... D4041
WINDIAG – Windows Diagnostics for BBI Controllers.......................................D4041A

0 - 4 / Contents 3305 RTU


Section 1
INTRODUCTION

1.1 GENERAL DESCRIPTION


Model 3305 Remote Terminal Units are low priced ACCOL based controllers designed to
act as master or slave nodes in a Bristol Babcock 33XX communications network. An RTU
3305, loaded with a custom ACCOL program, will provide intelligent measurement and
control for a wide variety of process applications and will communicate with other Bristol
Babcock 33XX products within a local area network (LAN) or a wide are network (WAN).

Figure 1-1 - 3305 RTU (With 1200 bps Modem)

3305 RTU Introduction / 1- 1


The 3305 RTU has been designed to provide the following key features:

• Low cost
• Low power consumption
• Small size
• Four independent asynchronous serial ports
• Optional 16 character by 2 line LCD Display (local or remote) with 2 mechanical
buttons or 20 character by 4 line remote LCD Display/Keyboard
• Eight discrete inputs (DIs) with interrupt capability
• Two discrete outputs (DOs)
• Six selectable bi-directional DI/DO points
• Four analog inputs (AIs) - optional
• Two analog outputs (AOs) - optional
• One high-speed counter input (HSC)
• Flash EPROM for system/custom firmware, as-well-as storage of the ACCOL load.
• Soft (menu driven) configuration of the node address, baud rate and other selections
formerly configured by DIP switches and jumpers.

1.2 PHYSICAL DESCRIPTION


Model 3305 RTUs are comprised of the following major components:

• Backplane Board
• Processor Memory Peripheral Power Supply Board (PMPP)
• Multifunction Input/Output Board (MI/OB)
• Mounting Plate, Brackets & Hardware

1.2.1 Backplane Board

Figure 1-2 - The Backplane PCB

1-2 / Introduction 3305 RTU


The Backplane Board is a multilayer board that measures 6.25” wide by 3.8” long and is
used to interconnect the Processor Memory Peripheral Power Supply Board, Multifunction
Input/Output Board and one of three display assemblies, i.e., a local 16 character by 2 line
Display Module with two pushbuttons, a remote 16 character by 2 line Display Module
with two pushbuttons, or a remote 20 character by 4 line Display/Keyboard Module. The
Backplane Board contains up to four connectors which function as follows:

• Two 60-pin connectors P1 & P2 - connect the Multifunction I/O Board and the
Processor Memory Peripheral Power Supply Board together.
• One 26-pin connector P3 - for the local 2 X16 character LCD Module.
• One 50-pin connector P4 - for the remote 4 X20 character Display/Keyboard Module
or the remote 2X16 character LCD Module.

There are two versions of the Backplane Board; one supports only the local 2 X 16 LCD
Display (P4 not present), the other supports both the Local 2 X 16 LCD Display and the
Remote 2 X 16 Display or the 4 X 20 Display/Keyboard Module (P3 & P4 present).

1.2.2 Processor Memory Peripheral Power Supply Board (PMPP)

The PMPP Board is a double sided Surface-Mount PCB that measures 6” wide by 6.5” long
and provides the CPU/Memory function, communications subsystem, DC-to-DC power
regulation, Real Time Clock (RTC), the System I/O BUS, and Status LEDs.

The PMPP Board utilizes a 12MHz 80C186XL CMOS, high-integration, 16-bit microproces-
sor chip that provides the CPU, three 16-bit Programmable Timers, a Programmable Inter-
rupt Controller, Chip-Select/Ready Generation Logic, and Watchdog functions for the 3305
RTU.

The Processor/Memory Subsystem includes the Real Time Clock, Watchdog Timer, status
LEDs (6 firmware controlled plus Idle and Watchdog) and, in addition to the Microproces-
sor, contains the following memory devices:

• 512K bytes of System FLASH


• 504K bytes of RAM with battery backup
• 224K bytes of ACCOL Load Storage in FLASH
• 32K bytes of Boot & Configuration Firmware in FLASH

On board communication subsystems include the electronics for three RS-232 Ports (A, B &
C) and one TTL Port (D) (Port D becomes either an RS-232 or RS-485 Port on the MI/OB
Board). The D-type connectors associated with ports B, C and D are located on the MI/OB
Board. All 3305 RTU Communication Ports support asynchronous communications. Port A
is the “Customer/Local/Diagnostic/FLASH Port” and uses a 3-Pin Molex connector.

The Real-time Clock Module is a complete CMOS timekeeper which incorporates a crystal
oscillator, an integral real-time clock, and a lithium battery/power detect circuit. The RTC
Module combines three unique features: a complete time-of-day clock with alarm and one-
hundred year calendar, a programmable periodic interrupt and square-wave generator,
and 64 bytes of low-power static RAM. The integral crystal oscillator has an accuracy of 1
sec/day (from 0° to +50°C). Table 1-1 provides the accuracy for temperatures between -30°C
to +80°C.

3305 RTU Introduction / 1- 3


RTC Memory consists of 50 general purpose RAM bytes, ten RAM bytes containing time,
calendar and alarm data, and four bytes of RAM for control and status. Node Address and
Configuration data are stored in the RTC memory. Configuration data include the
Standard/Expanded Node Address selection, ACCOL load to RAM or FLASH, Updump
Switch, ACCOL FLASH lock, enable/disable Diagnostic messages on Port A, and the Cold
Download baud rate for Ports B, C and D.

Figure 1-3 - Processor Memory Peripheral Power Supply (PMPP) Board

1-4 / Introduction 3305 RTU


Table 1-1 - RTC Crystal Oscillator Accuracy Data

Temp. (Deg. C) Temp. (Deg. F) Sec./Day Max


-30 -22 8.0
-20 -4 5.0
0 32 1.0
10 50 0.8
20 68 0.4
30 86 0.4
40 104 0.6
50 122 1.0
60 140 2.8
70 158 5.0
80 176 7.4
Note: These numbers assume a standard 24 hour exposure to a
particular temperature, which can be considered worst case.
Most of the inaccuracy occurs at the extremes of the Temp.
range.

1.2.2.1 Configuration Jumpers

The following Processor Memory Peripheral Power Supply Board (PMPP Board) Jumpers
support configurable options:

• Jumper W2 - Board Status LEDs Enable/Disable


IN = Board Status LEDs enabled
OUT = Board Status LEDs disabled
• Jumper W4 - IN or OUT N/A to 3305
• Jumper W6 - Communications Status LEDs Enable/Disable
IN = Comm. Status LEDs enabled
OUT = Comm. Status LEDs disabled
• Jumper W7 - RAM Battery Back-up Enable/Disable
1 to 2 = RAM Battery back-up enabled
2 to 3 = RAM Battery back-up disabled
• Jumper W8 - Boot/Configuration FLASH Boot Sector Write Protect
1 to 2 = Boot Sector write protect
2 to 3 = Boot Sector write enabled (For Factory Use Only)
• Jumper W10 - Power Fail trip Point Select (Used in conjunction with R11)
1 to 2 = Selects the trip point for the 9-20V input voltage range
2 to 3 = Selects the trip point for the 20-30V input voltage range
• Jumper W11 - Low battery detect (Used in conjunction with R12)
1 to 2 = Selects the low battery detect trip point for the 9-20V range
2 to 3 = Selects the low battery detect trip point for 20-30V range
• Jumper W12 - Master Clear (MC) and Power Fail (PF) LEDs Enable/Disable
IN = MC and PF LEDs enabled
OUT = MC and PF LEDs disabled

1.2.2.2 Processor Memory Peripheral Power Supply Board Configuration Switch

Switch SW1 on the PMPP Board sets loopback (testing) for Ports A, B & C (see Table 1-2).

3305 RTU Introduction / 1- 5


Table 1-2 - Function of PMPP Board Switch SW1

Port ID Switch # ON Definition


Port C 1 TXD to RXD Loopback
Port C 2 RTS to CTS Loopback
Port C 3 DTR to DCD loopback
Port B 4 TXD to RXD Loopback
Port B 5 RTS to CTS Loopback
Port B 6 DTR to DCD Loopback
Port A 7 TXD to RXD Loopback
Port A 8 RTS to CTS Loopback

1.2.2.3 Processor Memory Peripheral Power Supply Board LED Indicators

The PMPP Power Supply Board contains 18 LEDs (LEDs DS10 through DS15 are discus-
sed in Section 5). These 18 LEDs are designated as follows:

DS1 - Port A (Transmit Status)


DS2 - Port A (Receive Status)
DS3 - Port B (Transmit Status)
DS4 - Port B (Receive Status)
DS5 - Port C (Transmit Status)
DS6 - Port C (Receive Status)
DS7 - Port D (Transmit Status)
DS8 - Port D (Receive Status)
DS9 - (System Halted/Running)
DS10 - STATUS 1
DS11 - STATUS 2
DS12 - STATUS 3
DS13 - STATUS 4
DS14 - STATUS 5
DS15 - STATUS 6
DS16 - State of MC* (ON = MC* inactive)
DS17 - State of PFIN* (ON = PFIN* inactive)
DS18 - WDOG (Watchdog Occurred)

1.2.2.4 Lithium Battery

A Lithium battery provides back-up power to the RAM when the +5V supply fails. This
battery provides a cumulative back-up period of four months. Battery status can be
determined by using the ACCOL TOOLS DIAG software Lithium Battery test (see 33XX
Diagnostics Manual - D4041) (see Section 4 - SERVICE of this manual). When the battery
is functioning properly, the RTU can lose power but still retain its ACCOL load and
continue running from the point of power loss once power is restored. The battery is
checked at 8:00 A.M. daily as a function of ACCOL.

1-6 / Introduction 3305 RTU


1.2.2.5 Communications Subsystem (also see Section 1.2.3.7)

The Communications Subsystem of the PMPP Board handles all 3305 RTU serial com-
munications via two Z85C30 Serial Communications Controllers. These ports are assigned
as follows:

Port A - Local Configuration/Communications Port (3-Pin Molex Connector J3)


Port B - RS-232 Network Port (P2 cable to MI/OB - 9-Pin D-Type Connector P5 on MI/OB)
Port C - RS-232 Network Port (J1 to MI/OB - 9-Pin D-Type Connector P4 on MI/OB)
Port D - TTL Port on Power Supply/CPU Board (J1 to MI/OB) (MI/OB RS-232/485 9-Pin D-
Type Connector P3)

Port A Local Configuration/Diagnostic/Communications Port


Port A is used to download FLASH configuration and FLASHWARE via a 3-Pin Molex type
connector (J3). This Local Port can be connected to a Process Engineer’s Interface (PEI)
computer RS-232 Comm. Port for BSAP Slave/Pseudo-Slave applications. Additionally, a
Terminal Emulator or a computer with a Terminal Emulation Software package (such as
PROCOMM) can be used to monitor the start-up sequence. Port A is not a network port and
therefore does not support interface to a modem.

Port B Local/Network RS232 Port


Port B can be used for local or network communications and supports external options such
as a modem. Port B supplies standard RS-232 signals: RX, TX, RTS, DTR, DSR, CTS, and
DCD with loopback switches for TX to RX, RTS to CTS and DTR to DCD. +5V can be ob-
tained from pin 3 of connector P5 for modems or other RS-232 devices that require 5V
power. When Jumper W18 is installed in position 2-3, +5V power can be obtained from pin
8 of connector P5. The 9-Pin D-Type Connector (P5) associated with Port B is situated on
the MI/OB Board.

Port C Local/Network RS232 or TTL Port


Port C can be used for local or network communications and it can be configured for TTL or
RS-232 operation. As a standard RS-232 port, Port C supplies the following signals: RX,
TX, RTS, DTR, DSR, CTS, and DCD with loopback switches for TX to RX, RTS to CTS and
DTR to DCD. When used in conjunction with TTL devices such as Bristol Babcock’s Trans-
mitter Interface (TI) Board, Radio Delay Interface (RDI) Board, RS-485 Interface Board
(Non-isolated), or a modem, the RS-232 Driver IC (U32) is replaced with a Jumper Block
(P/N 392511-01-0) allowing Port C to provide a TTL interface. For modems or other devices
that require 5V power and RS-232 logic, DO NOT replace IC U32 with the Jumper Block.
+5V can be obtained from pin 3 of connector P4. The 9-Pin D-Type Connector (P4) as-
sociated with Port C is situated on the MI/OB Board.

Port D Local/Network RS-232/RS-485 Port


Port D provides a TTL Interface to connector J2 of the Power Supply/CPU Board and J1 of
the MI/OB Board. These signals are converted on the MI/OB Board to either RS-232 or RS-
485 levels. The 9-Pin D-Type Connector (P3) associated with Port D is situated on the
MI/OB Board.

3305 RTU Introduction / 1- 7


1.2.2.6 Processor Memory Peripheral Power Supply Board Connectors

The PMPP Board contains four connectors; J1, J2, J3 and J4. Off-board Connector J1 inter-
faces the RS-232 signals associated with port B between the Board and the MI/OB Board
Connector P2 (see Section 1.2.3.8 - Table 1-5).

Connector J2 mates with P1 of the Backplane Board and handles all I/O between the
MI/OB and the PMPP Board (see Table 1-3).

Table 1-3 - PMPP PCB Bus Interface Connector J2 Pin Assignments

PIN PIN
MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION
# #
1 WDOGB* Reset 31 IOMADEN2 Board Select
2 - - 32 DCDC RS232 Comm Line
3 IODATA7* Data 33 IOMADEN3 Board Select
4 IODATA0* Data 34 IOMINT1* Slot 1 Interrupt (DI)
5 IODATA5* Data 35 +18V Analog Power
6 IODATA2* Data 36 IOMINT2* Interrupt 2 (Keybd)
7 IODATA3* Data 37 RTSC RS232 Comm Line
8 IODATA4* Data 38 CTSD* RS232 Comm Line
9 IODATA1* Data 39 TXDC* RS232 Comm Line
10 IODATA6* Data 40 DTRD* TTL Comm Line
11 IOMADEN1* Board Select 41 DTRC RS232 Comm Line
12 IOMADEN2* Board Select 42 CTSC RS232 Comm Line
13 IOMADEN3* Board Select 43 -18V Analog Power
14 TXDD Comm Line (TTL) 44 DSRC RS232 Comm Line
15 IOMADR1 Subfunction Address 45 IOINT3* I/O Slot 5 Interrupt 3
16 IOMADR0 Subfunction Address 46 PB1OUT Push-button 1 Intrpt
17 IOMADR3 Subfunction Address 47 - -
18 IOMADR2 Subfunction Address 48 PB2OUT Push-button 2 Intrpt
19 IOMWR* I/O Mem. Write 49 RTSD* TTL Comm Line
20 IOMRD* I/O Mem. Read 50 - -
21 IOMSEL* I/O System Select 51 - -
22 IOMRDYB* Access Ackng. 52 MC* Power Supply Reset
23 IOMRST+MC* Board Reset 53 DSRD* Sequencer Signal
24 RXDC* RS232 Comm Line 54 +21V Analog Power
25 DCDD* TTL Comm Line 55 VCC (+5V) Digital Logic Power
26 HSC High Speed Counter 56 GND Digital Logic Ground
27 RXDD TTL Comm Line 57 VCC (+5V) Digital Logic Power
28 IOMCLK 6MHz System Clock 58 GND Digital Logic Ground
29 IOMADEN1 Board Select 59 VCC (+5V) Digital Logic Power
30 - - 60 GND Digital Logic Ground
* = NOT

J3 is the 3-Pin Molex Connector associated with Port A. RS-232 level signals TXD, RXD,
and GND appear on pins 1, 2, and 3 respectively.

Off-board Connector J4 mates with Connector P1 on the MI/OB Board. Bulk (9-30Vdc)
Power is supplied on Pin 1 and power return is on Pin 2.

1-8 / Introduction 3305 RTU


1.2.3 Multifunction Input/Output Board (MI/OB)

The MI/OB Board is a multilayer board that measures 6” wide by 10.1” long and contains
the circuitry used for Discrete Inputs, Discrete Outputs, Analog Inputs, Analog Outputs, a
High Speed Counter, communications and watchdog functions. The MI/OB is the bottom
board of the RTU 3305 and is stoodoff from the 3305 Mounting Plate at six points via
mounting posts. The MI/OB Board is secured to four of the mounting posts via the PMPP
Board’s standoff/mounting posts and is secured to the remaining two mounting posts via
screws. Interface to the PMPP Board is accomplished via the Backplane Board. Terminal
blocks, cable connectors, and con-figuration jumpers are accessible without disassembly.
The MI/OB contains 3 terminal blocks (TB1, TB2 & TB3), three 9-pin D-type connectors
(P3, P4 & P5), a two-pin cable connector (P1), a 12-pin cable connector (P2) and a 60-pin
mass termination connector (J1).

1.2.3.1 Discrete Input Circuitry

Discrete Input Circuitry features optical isolation, surge suppression, and 1msec filtering
for DI7 through DI14 and 30msec filtering for DI1 through DI6. Input Range is (0-24 or 0-
12) Vdc ±10%. Field connections for DI1-DI14 are located at TB1. The DI is activated by
closing the connection between +DI and -DI with a dry contact (see Section 2.4.1).

The MI/OB Board DI interrupt circuitry can be used to generate an interrupt on a change
of state condition associated with DIs 7 though 14. This circuitry compares the previous
state of a DI with the present state and the interrupt mask for the DI in question. Each DI
is tested sequentially. Detection of a change of state causes the circuitry to halt until an
interrupt service routine has been completed. During the interrupt service routine, the
address of the DI that changed state (and generated the interrupt) is read. Upon
completion of the interrupt service routine, the change of state detection circuitry is started
and the next DI is examined.

A status register indicates which DI/O points are available as DIs. DI/O1 through DI/O6
(which can also be configured for DO operation) do not generate interrupts on change of
state. Therefore, DI1 through DI6 should not be used for counting applications.

Each DI is supported with a status LED, i.e., one each for DI7 through DI14 and one each
for DI/O1 through DI/O6. Jumper W7 is used to enable or disable these LEDs. W7 in
position 1-2 enables the LEDs; W7 in position 2-3 disables the LEDs.

1.2.3.2 Discrete Output Circuitry

The MI/OB Board supports up to eight open drain type DOs capable of handling 100mA @
35Vdc. Surge suppression is included. Field connections for DO1 through DO8 are located
at TB1 (see Section 2.4.2).

An 8-bit DO Load Register controls the ON/OFF state of each discrete output. Writing a 1
bit turns the corresponding DO to an “ON” state and writing a 0 turns the corresponding
DO to an “OFF” state. Writing to a bit which corresponds to an DI/O point configured as an
input has no effect on the input point. Upon power up or after a watchdog reset, the DO
register is cleared and all outputs are set “OFF.”

3305 RTU Introduction / 1- 9


An 8-bit DO Status Register provides the status of each DO. A bit set to “0” means that DO
is “OFF” and a bit set to “1” indicates the DO is “ON.” The DO Status Register will post a
“0“ for any DI/O point which has been configured for DI operation. The 6-bit DO
Configuration Status Register indicates which DI/O points have been configured as DOs.

Each DO is supported with a status LED, i.e., one each for DO7 and DO8 and one each for
DI/O1 through DI/O6. Jumper W7 is used to enable or disable these LEDs. W7 in positions
1-2 enables these LEDs; W7 in position 2-3 disabled these LEDs.

Figure 1-4 - The Multifunction Input/Output Board

1-10 / Introduction 3305 RTU


1.2.3.3 Analog Input Circuitry

The MI/OB Board’s analog input circuitry supports up to four 1-5V isolated inputs, 4-20mA
isolated inputs, or 4-20mA internally powered loops that are referenced to the PCOM of the
board. Analog inputs feature 180V Common Mode. The 180V Common Mode input circuitry
utilizes an input stage composed of 40:1 resistive dividers and a 1mF capacitor which func-
tions as a low pass filter.

An analog multiplexor is used to select one of four channels as the input to an instrument
Amplifier. An Analog-To-Digital Converter takes approximately 130 microseconds to con-
vert the selected input voltage to a 12-bit digitized value. Potentiometers R143 and R144
are provided for calibration of the analog input circuitry. ACCOL Diagnostics is used to
test the gain and offset of the analog input circuit. The gain is set by adjusting R144 (with
+5Vdc placed across TB2-2 and TB2-1). The offset is set by adjusting R143 (with +1Vdc
placed across TB2-2 & TB2-1). Four sets of jumper pairs (W8A/8B through W11A/11B) are
used to configure analog inputs AI1 through AI4 respectively (see Section 2.4.3).

1.2.3.4 Analog Output Circuitry

The MI/OB Board’s analog output circuitry supports two analog outputs and is comprised
of a bus interface, a two channel Digital-To-Analog Converter and a signal conditioning
circuit to generate a 4-20mA output (see Section 2.4.4). Two potentiometers per channel
are used to adjust the 4mA point and the 20mA point. ACCOL Diagnostics are required to
calibrate the analog outputs. A Current meter (or a 250 Ohm 0.01% tolerance resistor and
DVM) is required to measure the output current during the calibration adjustments.

1.2.3.5 High Speed Counter Circuitry

High Speed Counter circuitry is comprised of two opto-isolated circuits which are powered
from the 12V or 24V RTU 3305 power source, and a one shot IC used to limit the input
frequency to 15KHz. A debounce circuit (enabled with Jumper W15 installed) supports
relay contact type field signals.

High Speed Counter inputs are configured as dry contacts. Field connections are HSCSET,
HSCRESET, and PCOM. The frequency range of the High Speed Counter circuit is DC to
10KHz and inputs are surge protected. HSCSET, HSCRESET, and PCOM connections are
TB3-6, TB3-4 and TB3-5 respectively. Field devices can be either Open Collector Transistor
(Using Set Input) (Jumper W15, 2-3 installed) or SPDT Dry Contact (Using Set/Reset In-
puts) (Jumper W15, 1-2 installed) (see Section 2.4.5).

1.2.3.6 Watchdog Relay Circuitry

The MI/OB Board contains the Watchdog Relay which de-energizes when MC* or WDOGB*
are active. A SPDT contact is routed to three terminal blocks: TB3-7, TB3-8 and TB3-9
where TB3-7 to TB3-9 is the NC contact and TB3-8 to TB3-9 is the NO contact. The
Watchdog Relay output can be used to drive an alarm or annunciation device (see Section
2.4.6).

3305 RTU Introduction / 1- 11


1.2.3.7 Communication Ports (also see Section 1.2.2.5)

The MI/OB Board contains three communications ports. All three ports support modems
and function as follows:

Port B - Port B provides RS-232 signals for a local communication device such as a PC
or an optional external Modem. Signals are routed through connector P2 of the PMPP
Board to the 9-Pin D-Type connector P5 on the MI/OB Board. MI/OB Jumper W18 is
used in conjunction with Port B to select +5V or DSR on P5 pin 8 as follows: standard
RS-232 operation - W18 in position 1-2 (DSR), modem requiring 5V power and RS-232
signal levels - W18 in position 2-3 (+5V).

Port C - Port C provides an interface for local communication (RS-232) or an optional


communications device such as a TIB, Modem, RS-485, or RDI Board. RS-232 signals
are routed through connector J1 of the PMPP Board to the 9-Pin D-Type connector P4.
Port C supplies standard RS-232 signals: RX, TX, RTS, DTR, DSR, CTS, and DCD with
loopback switches for TX to RX, RTS to CTS, and DTR to DCD. When used with a local
option, the RS-232 Driver (U32) is replaced with a Jumper Block (P/N 392511-01-0)
providing a TTL interface. The 9-Pin D-Type Connector (P4) associated with port C is
situated on the MI/OB Board. For modems requiring +5V power and RS-232 logic, DO
NOT replace U32 with the Jumper Block.

Port D - Port D provides either an RS-232 or RS-485 interface for local network com-
munication. TTL signals are routed through connector J1 from the PMPP Board to the
LTC-1322 Converter on the MI/OB Board and on to the 9-Pin D-Type connector P3.
When transmitting data, the LTC1322 Converter changes TTL level inputs (RX, TX,
RTS, CTS, CD, DCD and DSR) to RS-232/RS-485 levels. When receiving data, the
LTC1322 Converter changes RS-232/RS-485 signals to TTL levels. An eight position
DIP Switch (SW1) selects the mode of operation for Port D. SW1 also selects loopback
for RS-232 signals and transmitter/receiver line terminations for RS-485 mode.

1.2.3.8 Multifunction I/O Board Terminal Blocks and Connectors

Functionality of the MI/OB’s Terminal Blocks and Connectors are discussed below:

J1 - Bus Interface Connector:


The 60-pin Bus Interface Connector (J1) supports the I/O Bus between the PMPP Board
and the MI/OB Board (via Backplane Board Connector P1). The I/O Bus consists of 8 data
lines, 4 address lines, 4 control lines, a 6MHz clock line, board enable lines (which are
selected from 6 board enable signals), and 14 communications lines. The typical board cycle
time is 1mSec. All signals are CMOS compatible except the data lines, which are TTL
compatible (see Table 1-4).

P1 - MI/OB Power Connector:


The 2-pin Power Connector (P1) supplies +12V or +24V power on pin 1 and Power Return
on pin 2.

P2 - Port B RS-232 Interface Connector:


P2 is a 12-pin connector that interfaces the port B RS-232 signals between the MI/OB and
the PMPP Board. P2 mates with PMPP Board Off-board Connector J1 (see Table 1-5).

1-12 / Introduction 3305 RTU


Table 1-4 - PMPP PCB Bus Interface Connector P2 Pin Assignments

PIN PIN
MNEMONIC DESCRIPTION MNEMONIC DESCRIPTION
# #
1 WDOGB* Reset 31 IOMADEN2 Board Select
2 VIN - 32 DCDC RS232 Comm Line
3 IODATA7* Data 33 IOMADEN3 Board Select
4 IODATA0* Data 34 IOMINT1* Slot 1 Interrupt (DI)
5 IODATA5* Data 35 +18V Analog Power
6 IODATA2* Data 36 - -
7 IODATA3* Data 37 RTSC RS232 Comm Line
8 IODATA4* Data 38 CTSD* RS232 Comm Line
9 IODATA1* Data 39 TXDC* RS232 Comm Line
10 IODATA6* Data 40 DTRD* TTL Comm Line
11 IOMADEN1* Board Select 41 DTRC RS232 Comm Line
12 IOMADEN2* Board Select 42 CTSC RS232 Comm Line
13 IOMADEN3* Board Select 43 -18V Analog Power
14 TXDD Comm Line (TTL) 44 DSRC -
15 IOMADR1 Subfunction Address 45 - -
16 IOMADR0 Subfunction Address 46 - -
17 IOMADR3 Subfunction Address 47 - -
18 IOMADR2 Subfunction Address 48 - -
19 IOMWR* I/O Mem. Write 49 RTSD* TTL Comm Line
20 IOMRD* I/O Mem. Read 50 - -
21 IOMSEL* I/O System Select 51 - -
22 IOMRDYB* Access Ackng. 52 MC* Power Supply Reset
23 IOMRST+MC* Board Reset 53 DSRD* Sequencer Signal
24 RXDC* RS232 Comm Line 54 +21V Analog Power
25 DCDD* TTL Comm Line 55 VCC (+5V) Digital Logic Power
26 HSC High Speed Counter 56 GND Digital Logic Ground
27 RXDD TTL Comm Line 57 VCC (+5V) Digital Logic Power
28 IOMCLK 6MHz System Clock 58 GND Digital Logic Ground
29 IOMADEN1 Board Select 59 VCC (+5V) Digital Logic Power
30 - - 60 GND Digital Logic Ground
* = NOT

Table 1-5 - Port B Interface Connector P2 (MI/OB) J1 (PMPP) Pin Assignments

Pin # MNEMONIC DESCRIPTION COLOR CODE


1 TXDB* Transmit Data NOT White (1)
2 RTSB Request To Send Blue (2)
3 RXDB* Receive Data NOT Gray (3)
4 CTSB Clear To Send Violet (4)
9 DCDB Data Carrier Detect Yellow (5)
10 PCOM Power Common Green (6)
11 DTRB Data Terminal Ready Tan (7)
12 DSRB Data Set Ready Pink (8)

Note:
Column labeled Pin # applies to MI/OB Connector P2 and PMPP
Board Off-board Connector J1. Numbers in parenthesis in Column
labeled COLOR CODE, apply to PMPP Board On-board Connector J1.

3305 RTU Introduction / 1- 13


Figure 1-5 - MI/OB’s Field Wiring Terminals

1-14 / Introduction 3305 RTU


TB1 - Discrete I/O Interface Termination Connector:
Removable Terminal Blocks TB1-1 through TB1-32 are used for Discrete I/O field wiring
(see Table 1-6 and Figure 1-5).

Table 1-6 - Discrete I/O Wiring Connector (TB1) Pin Assignments

Pin # MNEMONIC DESCRIPTION


1 -DI1/DO1 PCOM
2 +DI1/DO1 Discrete I/O Source
3 -DI2/DO2 PCOM
4 +DI2/DO2 Discrete I/O Source
5 -DI3/DO3 PCOM
6 +DI3/DO3 Discrete I/O Source
7 -DI4/DO4 PCOM
8 +DI4/DO4 Discrete I/O Source
9 -DI5/DO5 PCOM
10 +DI5/DO5 Discrete I/O Source
11 -DI6/DO6 PCOM
12 +DI6/DO6 Discrete I/O Source
13 -DI7 PCOM
14 +DI7 Discrete Input Source
15 -DI8 PCOM
16 +DI8 Discrete Input Source
17 -DI9 PCOM
18 +DI9 Discrete Input Source
19 -DI10 PCOM
20 +DI10 Discrete Input Source
21 -DI11 PCOM
22 +DI11 Discrete Input Source
23 -DI12 PCOM
24 +DI12 Discrete Input Source
25 -DI13 PCOM
26 +DI13 Discrete Input Source
27 -DI14 PCOM
28 +DI14 Discrete Input Source
29 -DO7 PCOM
30 +DO7 Discrete Output Source
31 -DO8 PCOM
32 +DO8 Discrete Output Source

TB2 - Analog I/O Interface Termination Connectors:


Removable Terminal Blocks TB2-1 through TB2-12 are used for Analog I/O field wiring
(see Table 1-7 and Figure 1-5).

TB3 - Power, High Speed Counter & Watchdog I/O Interface Connector:
TB3-1 through TB3-9 provide High Speed Counter inputs and Watchdog outputs in ad-
dition to +12V or +24V (Bulk 9 to 30 Vdc) power and ground (see Table 1-8 & Figure 1-5).

3305 RTU Introduction / 1- 15


Table 1-7 - Analog I/O Field Wiring Connector (TB2) Pin Assignments

Pin # MNEMONIC DESCRIPTION


1 -AI1 Analog Input Channel 1
2 +AI1 Analog Input Channel 1
3 -AI2 Analog Input Channel 2
4 +AI2 Analog Input Channel 2
5 -AI3 Analog Input Channel 3
6 +AI3 Analog Input Channel 3
7 -AI4 Analog Input Channel 4
8 +AI4 Analog Input Channel 4
9 -AO1 Analog Common
10 +AO1 Analog Output 1 Source
11 -AO2 Analog Common
12 +AO2 Analog Output 2 Source

Table 1-8 - PWR, HSC & WD Circuits I/O Wiring Connector (TB3) Pin Assignments

Pin # MNEMONIC DESCRIPTION


1 PCOM System Ground
2 POWER System Power (12/24V)
3 CHASSIS Chassis Ground
4 +HSCRESET HSC Reset Input
5 PCOM System Ground
6 +HSCSET HSC Set Input
7 NCWDOG NC Watchdog Contact
8 NOWDOG NO Watchdog Contact
9 COMMON COMMON Watchdog Contact

Ports B, C & D - RS-232 Connectors:


The 9-Pin D-Type communication port connectors are wired for RS-232 operation as
detailed in Table 1-9 below. P3 is assigned as Port D, P4 is assigned as Port C, and P5 is
assigned as Port B. Note: Pin #3 is unassigned on Port D (P3) for RS-232 operation.

Table 1-9 - RS-232 Ports B, C & D Wiring

Pin # MNEMONIC DESCRIPTION


1 DTR Data Terminal Ready (Output)
2 TXD Transmit (Output)
P3/5-3 PWR +5Vdc
4 RXD Receive (Input)
5 RTS Request To Send (Output)
6 CTS Clear To Send (Input)
7 DCD Data Carrier Detect (Input)
P3-8 DSR Data Set Ready (Input)
5V (U32 = 392511-01-0 Intf. Adapter +5Vdc
P4-8
DSR (U32 = DS232 IC) Data Set Ready
5V (W18 in Position 2-3) +5Vdc
P5-8
DSR (W18 in Position 1-2) Data Set Ready
9 PCOM Port Ground

1-16 / Introduction 3305 RTU


Port D - 9-Pin D-Type Connector P3 Configured For RS-485 Operation:
The 9-Pin D-Type communication port connector associated with Port D can be configured
for RS-232 or RS-485 operation. When configured for RS-485 operation, Port D appears as
detailed in Table 1-10 below.

Table 1-10 - Port D (Configured for RS-485 Operation) Wiring

Pin # MNEMONIC DESCRIPTION


1 +TX Transmit (Pos.)
2 -TX Transmit (Neg.)
3 +RX Receive (Pos.)
4 -RX Receive (Neg.)
9 PCOM Port Ground

1.2.3.9 Multifunction I/O Board Jumpers & Switch SW1

The MI/OB Board contains 18 Jumpers (4 factory installed) and 1 Switch that function as
follows:

• Jumpers W1 through W6 - Set individual DI/O points 1 through 6 (respectively) for


discrete input or discrete output operation. When set in position A, the associated
point will be configured for DI operation. When set in the B position, the associated
point will be configured for DO operation.
• Jumper W7 - Enables/Disables eight (8) DI LEDs, six (6) DI/O LEDs, two (2) DO
LEDs, and one (1) HSC LED on the MI/OB Board. When set in position 1-2, the
LEDs are enabled. When set in position 2-3 these LEDs are disabled.
• Jumpers W8A/W8B, W9A/W9B, W10A/W10B & W11A/W11B - Set individual Analog
Inputs 1 through 4 (respectively) for Isolated Voltage Input, Isolated Current Input
or Internally Sourced Current Input operation (see Section 1.2.3.3).
• Jumper W15 - Enables/Disables the High Speed Counter debounce circuitry. W15
must be installed in position 2-3 to disable the debounce circuit for HSC Open
Collector operation and installed in position 1-2 to enable the debounce for SPDT
Dry Contact operation.
• Jumper W17 - Enables/Disables the Watchdog Relay circuitry. W17 must be in-
stalled in position 2-3 to disable the Watchdog Relay and installed in position 1-2 to
enable the Watchdog Relay.
• Jumper W18 - Selects +5V or DSR on P5 pin 8.
• Standard RS-232 Operation - W18 in position 1-2 (DSR).
• Modem requiring 5V power and RS-232 signal levels - W18 in position 2-3 (+5V).
• Switch SW1 - SW1 is an 8-position DIP switch used for configuring Port D for RS-
232 or RS-485 operation (see Table 1-11).

1.2.3.10 MI/OB LEDs

The MI/OB Board contains 17 LEDs which are enabled when Jumper W7 is set in position
1-2 and disabled when W7 is set in position 2-3. These LEDs follow the state of the input or
output field circuit to which they are assigned. LEDs are situated behind the I/O Card
Edge Connectors. Table 1-12 provides assignments for the MI/OB LEDs.

3305 RTU Introduction / 1- 17


Table 1-11 - MI/OB -Port D Configuration Switch SW1 Assignments

RS-485 RS-485 Most RS-485


SW1 RS-232
Function Master Distant Other
# Operation
station Slave Slaves
1 - - - - -
ON = 232 OFF = 485 OFF = 485 OFF = 485
2 RS-232/485 Selection
Enabled Enabled Enabled Enabled
RS-484 XMTR 120S ON = ON = OFF =
3 N/A
Term. Resistor Enabled Enabled Disabled
RS485 RCVR 120S ON = ON = OFF =
4 N/A
Term. (+ Bias) Resistor Enabled Enabled Disabled
RS485 RCVR 120S ON = ON = OFF =
5 N/A
Term. (- Bias) Resistor Enabled Enabled Disabled
RS-232 TXD/RXD ON enables
6 N/A N/A N/A
Loopback Local Loopback
RS-232 RTS/CTS ON enables
7 N/A N/A N/A
Loopback Local Loopback
RS-232 DTR/DCD ON enables
8 N/A N/A N/A
Loopback Local Loopback
Note: SW1-4 & SW1-5 must be set together, i.e., both must be set ON to enable (install) the
RS-485 120S Receiver (Bias) Resistor.
Note: SW1 switches -6, -7 & -8 are provided for RS-232 configuration. These switches are
typically set ON for test purposes and with the exception of SW1-7 are otherwise set
OFF. When Port D is connected to a PC, SW1-7 should be set ON (see Figure 2-19).

Table 1-12 - MI/OB LED Assignments

LED Name I/O Assignment LED Name I/O Assignment


CR29 DI/O1 CR75 DI10
CR30 DI/O2 CR76 DI11
CR31 DI/O3 CR77 DI12
CR32 DI/O4 CR78 DI13
CR70 DI/O5 CR79 DI14
CR71 DI/O6 CR80 DO7
CR72 DI7 CR81 DO8
CR73 DI8 CR82 HSC
CR74 DI9 - -

1.2.3.11 MI/OB On-Board Fuse F1

A replaceable Fuse (F1) in the bulk dc supply circuit provides short circuit or excessive cur-
rent protection for the 3305 RTU. This fuse is located near the MI/OB’s Card Edge
Terminal Blocks and is rated at .5 Amps for the bulk 20-30 Vdc supply or 1 Amp when a
bulk 9-20 Vdc supply is used.

1.3 OPTIONS
Options fall into three categories; LCD Displays, Communication Assemblies and Power
Supplies. Note: An optional Power Supply is only available with the RTU 3305
Standard Enclosure Assembly.

1-18 / Introduction 3305 RTU


1.3.1 LCD Displays

Each 3305 RTU can be interfaced to one LCD Display. LCD Displays available for the RTU
3305 are listed as follows:

• 2 X 16 Character LCD Display (locally mounted)


• 2 X 16 LCD Display (remotely mounted)
• 4 X 20 Display/Keyboard (remotely mounted)

Figure 1-6 - Front & Side Views of 4 X 20 Display/Keyboard Assembly

3305 RTU Introduction / 1- 19


Figure 1-7 - Front View of 2 X 16 LCD Display Assembly

These LCD Display Assemblies are powered by the 3305 RTU via the Interface Ribbon
Cable. The 2 X 16 LCD Displays are physically and functionally identical except for the In-
terface Ribbon Cable. The Remote 2 X 16 LCD Display and the 4 X 20 Display/Keyboard
assemblies interface with the RTU via Backplane Assembly Connector P4 (a 50-pin
Header), while the Local 2 X 16 LCD Display interfaces via Backplane Assembly Connector
P3 (a 26-pin Header) and is mounted on standoffs which in turn are mounted on brackets
at the top of the unit (see Figure 2-23). When connecting a Ribbon Cable to Backplane Con-
nector P3 or P4, make sure that the arrows adjacent to Pin 1 (Ribbon Cable Connector and
appropriate Backplane PCB Connector) are aligned.

Figure 1-8 - Bottom View of 2 X 16 LCD Display Assembly

DC power for the Local 2 X 16 LCD Display is available on pins 2 & 17 of Backplane
Connector P3 with PCOM on pins 1, 16, and 20 through 26. In the case of the remotely
mounted Display assemblies, DC power is available on pins 46 through 50 of Backplane
Connector P4 with PCOM on pins 1, 29, 30, 44 & 45.

1-20 / Introduction 3305 RTU


Operation of the 2 X 16 LCD Display Assemblies and the 4 X 20 Display/Keyboard Assem-
bly are discussed in Section 3.

1.3.2 Network Communication Options

The 3305 RTU can be interfaced to one of the following communication options via Port C
on the MI/OB Board:

• BBI 9600 bps PSTN Modem (see CI-9600 or CI-9600A Manual)


• BBI 1200 bps PL/PSTN Modem (see CI-1200 Manual)
• BBI Transmitter Interface Board (see Appendix 1 - PIP-TIBS33XX)
• BBI Radio Delay Board (see Appendix 2)
• BBI RS-485 Intf. Board (see Appendix 3) or (see Appendix 7 - PIP-ISORS485 for
Isolated version)
• BBI Highway Addressable Remote Transducer (HART®) Device Interface (see
Appendix 5 – PIP-HART33XX)

The 3305 RTU can be interfaced to one of the following communication options via Port D
on the MI/OB Board:

• BBI Network Interface Board for surge protection of 3305 on an RS-485 configured
multidrop HART Network (see Appendix 4 & Appendix 5), or for surge protection
and bias termination of industry standard (non-BBI) RS-485 Interface boards (see
Appendix 4).

Figure 1-9 - BBI 9600 bps PSTN Modem Layout (P/N 396039-10-3)

1.3.2.1 Modems (see Figures 1-9, 1-10, & 1-11)

Either a BBI 1200 bps Private Line (PL)/Public Switched Telephone Network (PSTN)
Modem or a Hayes Compatible BBI 9600 bps Public Switched Telephone Network (PSTN)

3305 RTU Introduction / 1- 21


Modem can be directly mounted to the 3305 RTU. When installed, the modem will be
mounted to the top of the 3305’s Option Mounting Brackets. The modem interface is
between TB3 (with TB4 providing Ground, i.e., PCOM) on the modem in question and Port
C (P4) on the MI/OB Board. Figures 1-9 through 1-11 provide partial surface views of these
modems.

Figure 1-10 - BBI 9600 bps PSTN Modem Layout (P/N 392958-05-8)

Figure 1-11 - BBI 1200 bps PL/PSTN Modem Layout

1-22 / Introduction 3305 RTU


1.3.2.2 BBI Transmitter Interface Board (see Figure 1-12)

The Transmitter Interface Board (TI Board) allows up to five Bristol Babcock, Series 3508
Transmitters to communicate with a series 3305 RTU. The 3305 RTU polls and stores data
from each transmitter and communicates with the network. The TI Board will be stood off
from the top of the 3305’s Option Mounting Brackets with 1” standoffs. Interface occurs
via connector P1A of the TI Board and Port C (P4) on the MI/OB Board. Power for the TI
Board (TB1) will be derived from the MI/OB Board as follows: TB3-2 = Power & TB3-1 =
PCOM. Figure 1-12 provides a surface view of the BBI Transmitter Interface Board. See
Appendix 1 for details on the BBI TI Board.

Figure 1-12 - +24V TI Board Layout

1.3.2.3 RS-485 Interface Board (see Figure 1-13)

The RS-485 Interface Board allows an RTU 3305 to be multidropped with up to 31 other
BBI 33XX Controllers. The RS-485 Interface Board will be mounted to the top of the 3305’s
Option Mounting Brackets. Interface occurs via connector J1A of the RS-485 Interface
Board and Port C (P4) on the MI/OB Board. The RS-485 Interface Board requires a +9V
External Power Source. Power for the RS-485 Interface Board will be derived from the
MI/OB Board as follows: TB3-2 = Power & TB3-1 = PCOM. Quick Disconnects are used to
connect field wiring to the RS-485 Board. Appendix 3 in the rear of this manual provides
details on the BBI RS-485 Interface Board.

An Isolated RS-485 Interface Board is also available. The Isolated RS-485 Interface Board
allows any BBI Network 3000 product to communicate over an isolated master/slave
network. Each node on the network that incorporates an Isolated RS-485 Interface Board
is optically isolated from the rest of the network, thereby eliminating ground loop and
potential difference effects that may degrade network communication performance. The
result is a reliable communication medium for in-plant or building to building LANs. PIP-

3305 RTU Introduction / 1- 23


ISORS485 in the rear of this manual provides details on the BBI Isolated RS-485 Interface
Board.

Figure 1-13 - RS-485 Interface Board Layout

Figure 1-14 - Radio Delay Board Layout

1-24 / Introduction 3305 RTU


1.3.2.4 Radio Delay Board (see Figure 1-14)

The Radio Delay Board acts as an interface between the RTU 3305 and an external radio
frequency (rf) transceiver or modem. This board will be mounted to the top of the 3305’s
option Mounting Brackets. Interface occurs via Port C on the MI/OB Board and connectors
TB3 and TB1 on the Radio Delay Board (TB1 is used for Ground - PCOM). Appendix 2 in
the rear of this manual provides details on the BBI Radio Delay Board.

1.3.2.5 BBI Network Interface Box (NIB) (see Appendix 4)

The BBI Network Interface Box (NIB) is required on RS-485 communication networks in
order to maintain the correct line status during periods of inactivity. While a NIB is
recommended for each node, only the master and the most distant slave require bias
termination. If these nodes are not biased, communication errors can result and the system
may go into a “watchdog” condition. All NIBs include surge protection circuitry designed to
protect the communication port of a node.

When used in conjunction with the 3305 RTU, the NIB’s jumpers W2 and W3 should be set
in the A position to provide surge protection (without bias termination). The 3305 RTU
handles bias and termination via Switch SW1 on the MI/OB Board (see Table 1-11).

1.3.2.6 HART Device Interface Option (see Appendix 5)

Highway Addressable Remote Transducer (HART) Device Interfaces (HDI) allows HART
slave devices or BBI 3508 transmitters to communicate with a BBI Series 33XX DPC/RTU,
i.e., 3305s, 3310s, 3330s, and 3335s. The HDI supports RS-232 and RS-485 interfaces. The
interface to the field devices is composed of a jumper selectable 249 ohm resistor in parallel
with an AC coupled transformer. An HART/TIB ACCOL Custom Module and the con-
figuration of a host (33XX) communications port as a custom port in ‘HART mode’ are
required to support the protocol (Data Link Layer) for HART devices. The ACCOL Master
Module is used to support RS-232 configured HDIs for communication with BBI 3508
transmitters. Each HDI can interface with up to 15 HART slave devices.

1.3.3 Power Supplies (see Appendix 6)

The RTU 3305 Standard Enclosure is available with a 40 Watt Power Supply Module
(+12Vdc or +24Vdc) or a compact Power Supply/Battery Charger. The 12V version of the 40
Watt Power Supply Module provides a maximum of 13.8Vdc while the 24V version provides
a maximum of 28Vdc. A 40 Watt Power Supply Module is mounted to a Power Supply
Mounting Bracket via two (2) screws. The Power Supply Mounting Bracket is secured to
the RTU 3305 Standard Enclosure’s “Back Fabrication Panel” via three (3) screws (See
Figures 1-15 and 1-16).

The RTU 3305 Power Supply/Battery Charger is a compact assembly that mounts ex-
ternally to the RTU 3305. This linear power supply is actually a battery charger that con-
tains temperature compensation circuitry. Peak output of the supply is +17.6V for a 24V
system and +13.8V for a 12V system with a 10mA or greater load applied. Appendix 6 in
the rear of this manual provides details on the RTU 3305 Power Supply/Battery Charger.

3305 RTU Introduction / 1- 25


Figure 1-15 - 40 Watt Power Supply Module

Figure 1-16 - 40 Watt Power Supply Module Mounted on Mounting Bracket

1-26 / Introduction 3305 RTU


Section 1A
APPLICATION SOFTWARE

1A.1 CATEGORIES OF APPLICATION SOFTWARE


There are basically three categories of application software used with the RTU 3305:

1) ACCOL Tools and related software which are used to program your RTU 3305
Remote Terminal Unit for its intended application (pump control, pipeline
monitoring, etc.). In general, this type of software is used by the System Engineer or
ACCOL programmer.

2) Supervisory Software which is used to allow operator interaction with the


controller via graphical displays, trending, and printed reports. In general, this type
of software is used by the Process Operator, or Technician.

3) Open BSI Utilities Software which facilitates communication between the RTU
3305 and certain types of Supervisory software. In general, this software is
configured by the System Engineer.

Each of these application software categories will be discussed briefly in this section.
Additional information on these subjects is found in documents referenced within the text.

1A.2 ACCOL TOOLS SOFTWARE


ACCOL stands for Advanced Communications and Control-Oriented Language, and is
Bristol Babcock's proprietary language for programming Network 3000-series controllers,
such as the RTU 3305. The ACCOL compilers and related software are collectively referred
to as the ACCOL Tools. Each of these tools will be discussed later in this section.

The ACCOL language includes a large set of pre-programmed software modules and
control statements which can perform various mathematical, logical, process control, or
communication functions.

For example, the PID3TERM module allows proportional, integral, and derivative control
over a process input value; the AGA3ITER module computes natural gas volume flow rates,
and the DIFFERENTIATOR module calculates the rate of change of an input. There are
over 100 different modules and control statements to choose from. For more detailed
information on particular modules or statements, see the ACCOL II Reference Manual
(document # D4044).

These modules and control statements are organized by the ACCOL programmer into
individual tasks. Each task is specified to execute at a specific rate, and with a specific
priority, relative to other tasks. One or more tasks are then combined by the ACCOL
programmer into an ACCOL program. This program must be tailored for the particular use
of this controller, for example, measuring and controlling natural gas flows, monitoring
pressure of a pump, etc.

3305 RTU Application Software / 1A- 1


Depending upon which ACCOL Tools you are using, your ACCOL program is initially
created as ASCII text in an ACCOL source file (.ACC file).

When editing of the ACCOL program has been completed, it must be compiled and linked to
generate an ACCOL load file. The ACCOL load file contains the original programming
instructions in a machine-readable format which can be executed by the RTU 3305
controller. In order to get the load file into the controller, the file is downloaded into the
RTU 3305, which then executes the programming instructions in the load file.

The Windows™-based ACCOL Tools set consists of ACCOL Workbench 7.0 (or newer),
together with the WINDIAG diagnostic program. Note: Windows diagnostics are
detailed in the WINDIAG Diagnostics Manual - Document # D4041A.

ACCOL Workbench allows you to create, modify, compile, link, and document an
ACCOL source file, all using a single integrated tool. Workbench allows direct editing
of an ACCOL source file, without the need for a separate ASCII text editor, and allows
the user to call up a pre-defined template of any ACCOL module or statement. The user
can then edit the template to conform to the requirements of the intended application.
See the ACCOL Workbench User Manual (document # D4051) for more information.

Figure 1A-1 - Files Created by Windows™-based ACCOL Workbench

(NOTE: All workbench on-line communication and downloading is facilitated via Open
BSI Utilities software, discussed later in this chapter).

1A-2 / Application Software 3305 RTU


1A.3 SUPERVISORY SOFTWARE
Supervisory software allows operator interaction with the Bristol Babcock controllers via
graphical displays, trends, and reports of historical data. Generally, the supervisory
software requires a customized communication driver in order to communicate with the
Bristol devices. In some cases this is provided via Open BSI Utilities.

Among the types of supervisory software currently supported are:

1) OpenEnterprise software is Bristol Babcock's own supervisory system. OpenEnterprise


utilizes a Windows™ server and one or more PC client workstations. Communication
with the controller network is supported via Open BSI. OpenEnterprise provides large
real time and historical data bases, which may be displayed, logged or exported.

2) Iconics Inc. Genesis software is a popular PC-based supervisory package which is


suitable for systems with smaller numbers of ACCOL signals. Genesis, and the Bristol
driver may be purchased from Bristol Babcock (see "Local Area Network" on page 7).

1A.4 OPEN BSI UTILITIES SOFTWARE


The Open Bristol System Interface (Open BSI) is a layer of communications software which
provides access to a network of Bristol Babcock remote process controllers. Above this
communications layer are a group of applications (programs) which are collectively known
as the Open BSI Utilities. These utilities interact with the communications layer to:

Download ACCOL load files to 33xx controllers in the network


Collect and display data from the 3xxx controllers
Monitor and control Open BSI communications

Third-party supervisory software can also use Open BSI communications, and data files
generated by Open BSI utilities, to access the Bristol network in order to display and report
information from field instrumentation about a running process. An operator then uses this
information to monitor and/or interact with the process.

The standard set of Open BSI utilities is accessed from within a Windows program group on
the PC; some of the major utilities are described, briefly, below. Full details on each utility
are included in Open BSI Utilities Manual [document # D5076 (Ver. 2.x users) or D5081
(Ver. 3.x users)].

Downloader transfers a linked ACCOL load file (*.ACL) to a remote 3xxx DPC/RTU.

DataView collects and displays several types of process data from a 3xxx-series
controller, including signal values, data array values, signal lists, archive data, and
audit trail information. In addition, it allows the user to search for signals based on
various criteria.

Remote Communication Statistics Tool allows additional monitoring of Open BSI


communication information. Details on buffers, communication ports, and custom
protocols are accessible via this tool. Some of the information collected via this tool is
primarily of interest to Bristol Babcock support personnel.

3305 RTU Application Software / 1A- 3


Figure 1A-3 - Open BSI Interface Diagram

SigWrite reads ASCII files containing ACCOL signal values, and writes those values to
corresponding signals or signal lists in a 3xxx controller. SigWrite scans for such files at
a user-definable interval.

NetView allows the user to define communication network characteristics, define


details about individual RTUs, and to change these characteristics on-line NetView
supports existing BSAP networks.

LocalView is used for local communication only. It is used for performing field
upgrades of system firmware.

In addition to the standard set of Open BSI Utilities, just described, there are other
utilities, available from Bristol Babcock as add-ons to the standard utilities, which provide
capabilities for scheduled data collection, and file export. These utilities include the Open
BSI Harvester and the Data File Conversion utility (see the Ooen BSI Harvester manual
(document # D5120) for details.

For more information on these packages, consult the manuals accompanying them, or
contact Bristol Babcock's application support group for assistance.

1A-4 / Application Software 3305 RTU


1A.5 SYSTEM APPLICATIONS
An RTU 3305 can operate as an independent, stand-alone unit, or as a node in a local or
wide area network. These applications are described in sections 1A.5.1 through 1A.5.3.

Note: The RTU 3305 cannot serve as a serial Communications Front End (CFE).

1A.5.1 Stand-Alone Unit

Figure 1A-4 shows an RTU used as a stand-alone unit in a non-network application. This
arrangement is ideal for small local systems requiring a limited number of monitoring and
control points. The PC for this application runs Bristol Babcock's ACCOL Workbench
Software and Open BSI Utilities. Data stored in the RTU can be observed or edited via the
PC.

Figure 1A-4 - Basic Stand-Alone Application

Once on line, the RTU executes the ACCOL load and performs its configured tasks.
Although the PC is attached to the RTU 3305 in Figure 1A-4, it can be disconnected and
removed once the 3305 has been loaded and made operational.

1A.5.2 Local Area Network (LAN)

LANs typically support the communications requirements of computers and equipment in


one or more buildings at a site or plant complex. A local area network requires a PC with
extended graphics capability. This PC will typically run the Iconics GENESIS software
package to display process parameters, real time or historical process data, and graphic
displays, etc.

An example of a local area network is shown in Figure 1A-5. This network can
communicate directly through RS-485 cable connections for short distances (1000 feet max.
from master to most distant slave) or over longer distances when interconnected on RS-232
ports. For much greater distances (miles) network communications require the use of
phone line modems, fiber modems or broadband/carrier band modems (on coaxial cable).

3305 RTU Application Software / 1A- 5


Figure 1A-5 shows a network that contains a PC as the network master and a DPC 3330 at
the first level of the network hierarchy. The data concentrator, which functions as a
communications traffic director, communicates upward with the PC through a slave (S) port
and downward with the second level through a master (M) port. This pattern repeats
through each descending level. The second level contains two controllers; one
communicates with three other controllers at the third level, while the other communicates
with two at the third level. Each master (configured) port has the capability of supporting
up to 127 slaves.

Figure 1A-5 - Local Area Network

1A-6 / Application Software 3305 RTU


The communication ports of each controller require hardware and soft switch configuration
in addition to ACCOL configuration. In the case of the RTU 3305, the hardware
configuration for Ports A through D are performed using the following hardware: PMPP
Board's Jumper (W1) for Port B, PMPP Board’s Switch SW3 for Ports A, B and C and the
MI/OB Board's Switch SW1 for Port D. Soft switch configuration is performed via a PEI
equipped with (in addition to other programs) the BBI SYSTEM CONFIG/FLASH
DOWNLOADER Software (see Section 2.3.2). Additionally, communication ports must be
defined in the ACCOL load using ACCOL Workbench Software. Note: SW3 on the PMPP
Board controls Ports A, B & C normal/testing, i.e., loopback, functions. When SW3 switch is
set in the ON position, the associated loopback function is set. SW1 on the MI/OB Board
sets RS-232 or RS-485 operation for Port D. SW1 also provides loopback testing and RS-485
network end node termination resistor installation. Note: NetView is used to configure
the hierarchy of the network.

The PC, which runs the supervisory software, oversees the activities of the local area
network. It displays process parameters, real-time data, and historical process information
in both tabular and graphic formats. Journaling and system configuration utilities can also
be employed as required.

A Bristol Babcock BSAP network supports a maximum of six levels starting with the
master device at level 1. Slave nodes at each descending level communicate upward
through its preceding master node. Each master node stores data from its slaves until
polled.

A local area network can also include printers and/or display terminals. Figure 1A-5 shows
a printer connected directly to a PC port; however, a controller port could have been
configured as a logger and used in the same manner.

1A.5.3 Wide Area Network (WAN)

WANs typically support the communications requirements of computers and equipment at


numerous geographical locations and may encompass many local and remote sites. A
Network 3000 system can also be constructed as a wide area network encompassing many
local area networks. This application places a dedicated “Area Operator” computer at the
top of the hierarchy as shown in Figure 1A-6. The central system includes all the interface,
monitoring and data recording equipment necessary to operate all the subservient
networks. The central system employs Open BSI software to provide the on-line network
interface.

The Area Operator computer running Open BSI software provides the operator with real-
time communications with remotes. Depending on the associated Human Machine
Interface (HMI) software package (such as Open Enterprise, Genesis, etc.), various features
such as real-time management, historical data, alarm logging, event journaling, color
graphics, CRT trending, report logging, process modeling, supervisory control, and high-
level language support may be employed. The Area Operator PC of Figure 1A-6
communicates with the local area networks and discrete remote BBI RTUs, Flow
Computers and a Smart Transmitter through a DPC 3330. Depending on the configuration
of the DPC 3330, four or more asynchronous channels for use with phone line or modem
applications, as-well-as a single, redundant channel for data highway applications may be
utilized.

3305 RTU Application Software / 1A- 7


Figure 1A-6 - An Example of a Wide Area Network

1A-8 / Application Software 3305 RTU


Section 2
INSTALLATION

2.1 INSTALLATION IN HAZARDOUS AREAS


The Model 3305 RTU is not furnished in a housing. The three PCBs which comprise the
system are mounted to a metal plate, which in turn, is ready for user supplied backplate
mounting. The 3305 RTU is approved for operation in Class I, Division 2, groups A, B, C &
D hazardous areas. Use in hazardous areas will require the selection of an appropriate
enclosure that meets the NEMA Type 4X specification.

Figure 2-1 - 3305 RTU Dimensions - Top View

3305 RTU Installation / 2- 1


Figure 2-2 - 3305 RTU Dimensions - Lower Edge View

2.2 MOUNTING THE MODEL 3305 RTU


Check all clearances when choosing an installation site. Make sure that the 3305 RTU is
accessible for wiring and service. Make sure that the LCD Display Panel (and keyboard if
present) are accessible to the on-site operator.

The RTU’s Mounting Plate measures 7.375” in width by 11.5” in length by 4.30” or 5.32” in
height (see Figures 2-1 & 2-2). The 3305 RTU may be vertically mounted (Backplane PCB
at top) with the following restrictions;

The bottom of the 3305’s Mounting Plate must mount to the selected enclosure’s
backplate.

The unit must be positioned so that the top plate or the Local LCD Display Option is
completely visible for service; reading the LEDs on the Processor Memory Peripheral
Power Supply (PMPP) Board and MI/OB Board, installation or removal of an option,
i.e., Modem, Radio Delay, Transmitter Interface Board, RS-485 Interface Board, and
replacement of the RAM Battery, Fuse or a PCB.

2.2.1 Temperature & Humidity Limits

The Model 3305 RTU is designed to operate over a -40 to 158 °F (-40 to +70 °C)
temperature range and a 15% 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 / Installation 3305 RTU


2.2.2 Vibration Limits

Check the mounted enclosure for mechanical vibrations. Make sure that the 3305 RTU is
not exposed to a level of vibration that exceeds those given in the specifications. The 3305’s
vibration limits are 1g for 10-150 Hz & .5g for 150-2000 Hz.

2.3 3305 RTU INSTALLATION/CONIGURATION

Figure 2-3 - Processor Memory Peripheral Power Supply (PMPP) Board

3305 RTU Installation / 2- 3


To configure the 3305 RTU follow the steps listed below:

1. Install appropriate I/O wiring to the MI/OB Board’s removable Terminal Blocks (see
Section 2.4.1 through 2.4.6).
2. Configure the Jumpers on the PMPP Board (see Section 2.3.1).
3. Configure/Connect appropriate communication port(s) (see Sections 2.4.8 & 1.2.2.2).
4. Connect DC Power to 3305 RTU (see Section 2.4.7).
5. Connect Port A of the RTU to a Process Engineer’s Interface (PEI), apply power and
configure the 3305’s “Soft Switches” for an ACCOL Load (see Section 2.3.2).
6. After receiving the ACCOL Load, the RTU 3305 is ready for on line operation (see
Chapter 4).

2.3.1 PMPP Board Jumper Configurable Options

The 3305 RTUs Processor Memory Peripheral Power Supply (PMPP) Board contains 7
Jumpers which must be set for the desired performance options.

Jumper W2 - PMPP Board Status LEDs Enable


IN - Board Status LEDs Enabled
OUT - Board Status LEDs Disabled

Jumper W6 - Communications Status LEDs Enable


IN - Comm. Status LEDs Enabled
OUT - Comm. Status LEDs Disabled

Jumper W7 - RAM Battery back-Up Enable/Disable


1 to 2 - RAM Battery Back-Up Enabled
2 to 3 - RAM Battery Back-Up Disabled

Jumper W8 - Boot/Configuration FLASH Boot Sector Write Protect


1 to 2 - Boot Sector Write Protected
2 to 3 - Boot Sector Write Enabled (FOR ATE ONLY)

Jumper W10 - Power Fail Trip Point Select


1 to 2 - Selects the Power Fail Trip Point for the 9-20V input voltage range
2 to 3 - Selects the Power Fail Trip Point for the 20-30V input voltage range

Jumper W11 - Low Battery Detect


1 to 2 - Selects the Low Battery Detect Trip Point for the 9-20V input voltage range
2 to 3 - Selects the Low battery Detect Trip Point for the 20-30V input voltage range

Jumper W12 - Master Clear and Power Fail LEDs Enable/Disable


IN - MC and PF LEDs Enabled
OUT - MC and PF LEDs Disabled

2.3.2 Soft Switch Configuration

Prior to installing of the ACCOL load, it is necessary to configure the 3305’s Unit
Configuration Parameters (Soft Switches) using a (Process Engineer’s Interface) PEI
equipped with the BBI SYSTEM CONFIG/FLASH DOWNLOADER Software, the ACCOL

2-4 / Installation 3305 RTU


Load and a Terminal Emulation program (such as PROCOMM Plus or SMARTCOM). For a
complete description of the operation of the BBI SYSTEM CONFIG/FLASH DOWN-
LOADER Software Program, see Chapter 4 - Section 4.5.

1. Connect the PEI to Port A on the PMPP Board using the special BBI Download
cable (Part Number 395414-02-4) and apply power to the PEI and the 3305 RTU.
Note: Port A defaults to a rate of 38.4K baud, but will automatically fall back to
19.2K baud if required by handshake routine (transparent to user). The cold down-
load baud rates for Ports B, C and D are configurable via the Soft Switches.

2. Select the CONFIG. SYSTEM PARAMETER Poke Point on the SYSTEM FLASH
DOWNLOAD/PARAMETER CONFIGURATION ENTRY Menu (see Figure 2-4) and
press the INSERT key

Figure 2-4
System FLASH Download/Parameter Configuration Entry Menu of
BBI SYSTEM CONFIG/FLASH DOWNLOADER Program

3. Within 30 seconds, press the Reset Button (SW2) on the 3305’s Power Supply/CPU
Board. This action will evoke the SYSTEM PARAMETER CONFIGURATION Menu
on the PEI (see Figure 2-5).

Figure 2-5
System Parameter Configuration menu of
BBI SYSTEM CONFIG/FLASH DOWNLOADER Program

3305 RTU Installation / 2- 5


• Node Address (Default = 127)
The Node Address is a value from 1 to 127 (with 127 being the default).

• Group Number (Default = 0)


The Group Number (0 to 127) selects the relative group of the 3305. Normal BSAP
messages occupy group zero. When expanded BSAP is selected, the Group Number
identifies the group in which the unit resides. If standard BSAP is selected, the
Group Number will default to zero (0).

• RAM/FLASH ACCOL Load (Default = RAM)


The RAM/LASH ACCOL Load field selects where ACCOL will be stored upon down-
load, i.e., in FLASH where it will reside until it is changed by another download, or
in RAM where it resides as long as power is applied (from system power or battery
backup). An ACCOL load stored in FLASH is copied into and executed out of RAM.

• ACCOL Flash Lock (Default = Locked)


The ACCOL Flash Lock feature gives the user the ability to prevent a FLASH-based
ACCOL load from being overwritten accidentally. With this feature enabled (locked)
(the default state), all ACCOL downloads will be rejected; however, if the unit
detects that there is no ACCOL load currently in FLASH, it will allow the ACCOL
load to be downloaded to the 3305 RTU.

• Std/Exp BSAP (Default = Standard)


The Standard or Expanded BSAP Slave option allows the user to select the mode for
the BSAP slave port, i.e., either standard or expanded). If the standard mode is
selected, Group Number will have no meaning and the unit is assumed to reside in
Group 0. When the expanded option is selected, the Group Number defines the
group in which the unit resides. In A BSAP Master/Slave network, the first 127
nodes connected to a single master reside in Group 0.

• Cold Download Rate (Default = 9600)


The Cold Download Rate option defines the parameters associated with Ports B, C
and D for the Cold Download baud rate (Port A defaults to 9600). The available
baud rates are: 1200, 2400, 4800, 9600, 19200 and 38400 baud. The list of values
will be provided to the BBI SYSTEM CONFIG/FLASH DOWNLOADER
Program Software after a connection has been established. The chosen baud rate
takes effect during a reset of the unit. Once downloaded, the ACCOL load controls
the rate and function of each port.

• Updump (Default = Disabled) The Updump option is reserved for factory use only.

• Diagnostic Msgs (Default = Enabled)


Diagnostic Messages (available through a separate “terminal emulation” program
such as PROCOMM) (see Chapter 5) can be enabled or disabled via this poke point.

• Put RTU in Updump State and exit FLASH (Poke Point).


This poke point is only available (viewed) on 3305s that are equipped with boot
firmware level LB501 and higher. Selection of this poke point should only be
performed for debugging purposes under direction from BBI.

2-6 / Installation 3305 RTU


• Make Changes (Poke Point).
When the Make Changes poke point is selected the pending changes are
automatically loaded into 3305 system firmware. Pending changes can also be
loaded into the RTU 3305 at any time by pressing the F4 key. When the F4 Key has
been pressed the following message will appear on the bottom of the menu:

Changes are pending. Change the target before exiting? ---


At this point the user can press Y for yes, N for no, or the Insert key (for yes).
Changes will be downloaded and the previous menu, i.e., the SYSTEM FLASH
DOWNLOAD/PARAMETER CONFIGURATION ENTRY Menu (Figure 2-4) will
appear.

Note: When the F4 key is pressed, the Exit Mode (see EXIT CONFIG/Flash
download Poke Point below) controls the next step performed by the BBI SYSTEM
CONFIG/FLASH DOWNLOADER Program Software.

• EXIT CONFIG/Flash download (Poke Point)


The EXIT CONFIG/Flash download poke point sets the exit mode from this menu.
Uppercase indicates the mode selected. Use the Insert or Enter key to switch
between selections. A System FLASH download is required when new 3305
firmware has been issued by BBI for field upgrade installation. Use the Insert Key
to change this prompt to exit config/FLASH DOWNLOAD if a system download is
desired. If EXIT/CONFIG mode is selected (and the F4 key is pressed), the System
Parameter Configuration Menu is exited and the System FLASH Download/-
Parameter Configuration Entry Menu is displayed. If FLASH DOWNLOAD mode is
selected (and the F4 key is pressed), the program enters the download mode and the
selected firmware file is downloaded into the RTU 3305. If a file has not been
selected, the system will prompt the user for the file to be Flashed.

4. Configure the soft switches as required. To download Standard or Custom System


Firmware, see Section 4.5.1. Select the Make Changes poke point to send these
changes to the RTU 3305 (see • Make Changes above). If firmware is not to be
downloaded, make sure that the exit mode is set to EXIT CONFIG and press the F4
key. If either system or custom firmware is to be downloaded, set the exit mode to
FLASH DOWNLOAD and press the F4 key. See Section 4.5.1 for the firmware
download procedure.

5. To download an ACCOL load into FLASH Memory, see Section 4.5.2. To download
an ACCOL load into RAM see Section 4.5.3.

2.4 WIRING NOTES


54 Field Wiring Terminals (53 used) are located on the Multifunction I/O Board (see Figure
2-6).

Terminal Connections

The 3305 uses compression-type terminals that accommodate up to #12 AWG wire. A
connection is made by inserting the wire’s bared end into the clamp beneath the screw and
securing the screw. The wire should be inserted fully so that no bared wires are exposed to

3305 RTU Installation / 2- 7


cause shorts. If using standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.

Figure 2-6
Multifunction Input/Output Board’s Field Wiring Edge Connectors

2-8 / Installation 3305 RTU


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.
Wiring may be placed in trays or panduit to improve appearance and increase ease of
maintenance.

Signal 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 system. This is necessary to prevent circulating ground current loops that can
cause signal errors. Connect all shields to a common terminal block tied to the system
ground. The terminal Block should be placed at the RTU 3305 location.

2.4.1 Discrete Inputs (see Figures 2-7 & 2-8)

A total of 14 Discrete Inputs are available. DI7-14 are dry contact inputs with 1msec
filtering and DI/O1-6 (when configured for DI operation) are dry contact inputs with
30msec filtering. Inputs are internally sourced from the system power (12 or 24 V). DIs
feature surge suppression. Their input range is dependent on the RTU 3305 system input
power, i.e., 0-24 or 0-12 Vdc ±10%. In addition to Dry Contact inputs from relays, switches
etc., DI7 through DI14 can accept inputs from Low Speed Turbine Meters.

Field connections for DI1 through DI14 are located at TB1. A Discrete Input is activated by
closing the connection between the +DI and -DI terminal in question with a dry contact
(see Table 2-1).

To configure DI/O1 through DI/O6 for DI operation the MI/OB Board Jumper associated
with the DI/O in question must be set in the “A” position (see Figure 2-7).

Figure 2-7 - DI/O Jumper Block For DI Operation

3305 RTU Installation / 2- 9


Figure 2-8 - Discrete Input Wired to 3305 RTU

Table 2-1 - Discrete Input Connections to TB1

DI TB1 (-DI) Assignment TB1 (+DI) Assignment


Designation (Bottom Row of Connectors) (Top Row of Connectors)
DI1 TB1-1 TB1-2
D12 TB1-3 TB1-4
DI3 TB1-5 TB1-6
DI4 TB1-7 TB1-8
DI5 TB1-9 TB1-10
DI6 TB1-11 TB1-12
DI7 TB1-13 TB1-14
DI8 TB1-15 TB1-16
DI9 TB1-17 TB1-18
DI10 TB1-19 TB1-20
DI11 TB1-21 TB1-22
DI12 TB1-23 TB1-24
DI13 TB1-25 TB1-26
DI14 TB1-27 TB1-28

2.4.2 Discrete Outputs (see Figures 2-9 & 2-10)

A total of 8 (Open Drain) Discrete Outputs (DOs) with surge protection are provided for
control or signaling functions. Each DO is wired to the source terminal of an N Channel
MOSFET capable of switching up to 35 volts at up to 100mA. When closed, the FET shorts
the output to ground with a voltage drop of .8 volts. 38V MOVs are provided to protect each
DO.

Field connections for DO1 through DO8 are located at TB1 (see Table 2-2).

To configure DI/O1 through DI/O6 for DO operation the jumper associated with the DI/O in
question must be set in the “B” position (see Figure 2-8). Jumpers are assigned to DI/Os as
follows:

2-10 / Installation 3305 RTU


Figure 2-9 - DI/O Jumper Block Set for DO Operation

Table 2-2 - Discrete Output Connections to TB1

DI TB1 (-DO) Assignment TB1 (+DO) Assignment


Designation (Bottom Row of Connectors) (Top Row of Connectors)
DO1 TB1-1 TB1-2
DO2 TB1-3 TB1-4
DO3 TB1-5 TB1-6
DO4 TB1-7 TB1-8
DO5 TB1-9 TB1-10
DO6 TB1-11 TB1-12
DO7 TB1-29 TB1-30
DO8 TB1-31 TB1-32

Figure 2-10 - Discrete Output Wired to 3305 RTU

3305 RTU Installation / 2- 11


2.4.3 Analog Inputs (see Figures 2-11, 2-12 & 2-13)

A total of 4 Analog Inputs are available. The Multifunction I/O Board can support four 1-
5V isolated inputs, four 4-20mA isolated inputs, or four 4-20mA internally powered loops
that are referenced to the PCOM of the board. Analog inputs feature 180V Common Mode
for noise suppression. The use of twisted pair cable enhances this feature. Refer to Figures
2-11, 2-12 and 2-13 for setting the range of each input

Figure 2-11 - Analog Input (Isolated Voltage Source) Field Wiring (AI1 Shown)

Figure 2-12 - Analog Input (Isolated Current Source) Field Wiring (AI1 Shown)

Potentiometers R143 and R144 are provided on the MI/OB Board for calibration of the
analog input circuitry. ACCOL Diagnostics is used to change the gain and offset of the
analog input circuit. The gain is set by adjusting R144 (with +5Vdc placed across TB2-2
and TB2-1. The offset is set by adjusting R143 (with +1Vdc placed across TB2-2 and TB2-
1). Four sets of jumpers (W8A/8B through W11A/11B) are used to configure analog inputs
AI1 through AI4 respectively.

Field connections for AI1 through AI4 are located at TB2 (see Table 2-3).

2-12 / Installation 3305 RTU


Table 2-3 - Analog Input Connections to TB2

AI TB2 (-AI) Assignment TB2 (+AI) Assignment


Designation (Bottom Row of Connectors) (Top Row of Connectors)
AI1 TB2-1 TB2-2
AI2 TB2-3 TB2-4
AI3 TB2-5 TB2-6
AI4 TB2-7 TB2-8

Figure 2-13 - Analog Input (Internal Current Source) Field Wiring


(AI1 Shown)

2.4.4 Analog Outputs (see Figure 2-14)

Figure 2-14 - Analog Output Field Wiring

A total of 2 Analog Outputs are available. The MI/OB Board’s analog output circuitry is
comprised of a bus interface, a two channel Digital-To-Analog Converter (DAC) and a
signal conditioning circuit which generates 4-20mA outputs. Two potentiometers per
channel are used to adjust the 4mA and 20mA points; [(AO1 - R93 for 20mA, & R94 for

3305 RTU Installation / 2- 13


4mA) (AO2 - R98 for 20mA & R101 for 4mA)]. Utilizing ACCOL Diagnostics, a Current
Meter (or a 250 ohm 0.01% tolerance resistor) is required to measure the output current
during the calibration adjustments. Field connections for AO1 and AO2 are located at TB2
(see table 2-4).

Table 2-4 - Analog Output Connections to TB2

AO TB1 (+AO) Assignment TB1 (-AO) Assignment


Designation (Bottom Row of Connectors) (Top Row of Connectors)
AO1 TB2-10 TB2-9
AO2 TB2-12 TB2-11

2.4.5 High Speed Counter Circuitry (see Figures 2-15 & 2-16

The High Speed Counter circuitry is comprised of two opto-isolated circuits which are
powered from either the 12V or 24V RTU 3305 power source and a one shot IC which is
used to limit the input frequency. A debounce circuit which is enabled when Jumper W15
is installed in position 1-2 supports SPDT Dry Contact (Using Set/reset Inputs) type field
signals.

The frequency range of the High Speed Counter circuit is DC to 10KHz and the inputs are
surge protected. Field connections are HSCSET (TB3-6), HSCRESET (TB3-4), and PCOM
(TB3-5). Field devices can be either Open Collector (Using Set Input) (Jumper W15 in-
stalled in position 2-3) or SPDT Dry Contact (Using Set/Reset Inputs) (W15 installed in
position 1-2).

Figure 2-15 - High Speed Counter (SPDT Dry Contacts Using Set/Reset Inputs)
Field Wiring

2-14 / Installation 3305 RTU


Figure 2-16 - High Speed Counter (Open Collector Using Set Input) Field Wiring

2.4.6 Watchdog Relay Circuitry (see Figure 2-17)

The Watchdog Relay Output circuit can be used to drive an alarm or annunciation device.
The Watchdog Relay is inactive when the signals Master Clear NOT (MC*) or Watchdog B
NOT (WDOGB*) are active. The Watchdog Relay Output circuit drives a Single Pole
Double Throw (SPDT) relay from terminal blocks TB3-7 (WDNC), TB3-8 (WDNO) and
TB3-9 (WDCOM). The Watchdog Relay is enabled when Jumper W17 is installed in
position 1-2 and is disabled when W17 is installed in position 2-3.

Figure 2-17 - Watchdog Relay Field Wiring

2.4.7 DC Power Configuration & Wiring

The 3305 RTU requires a DC power source within the range of +9 to +30 V. A DC to DC
Converter on the Processor Memory Peripheral Power Supply (PMPP) Board (which
operates from 9 to 30 VDC) has been designed to shut down at 20V for 24V units (Jumpers
W10 & W11 in position 2-3), i.e., systems with inputs of 20 to 30V) or to shut down at 9V
for 12V units (Jumpers W10 & W11 in position 1-2, i.e., systems with inputs of 9-20V).

3305 RTU Installation / 2- 15


Jumper W10 selects the Power Fail Trip Point and Jumper W11 selects the Low Battery
Detect Trip point. These Jumpers are situated on the PMPP Board (see Figure 2-3).

DC Power is connected to TB3 pins 1 and 2 of the MI/OB Board, where pin 2 = PWR+
(12/24V), and pin 1 = PCOM (see Figure 2-6). The input power source is coupled to the
PMPP Board via connector P1 of the MI/OB and J4 of the PMPP Board. The PMPP Board
contains the DC To DC Converter that produces the +5V, +18V, -18V and +21V sources
required for 3305 RTU operation. Regulated power for the MI/OB is provided through the
Backplane Board.

2.4.8 Communication Ports

The 3305 RTU contains 4 Comm. Ports, i.e., Ports A through D. Port A is physically located
on the PMPP Board; the remaining ports are physically located on the MI/OB Board. 8-
position DIP Switch SW1 on the PMPP Board selects RS-232 loopback for Ports A, B and C
while 8-position DIP Switch SW1 on the MI/OB Board supports Port D by providing for
selection of RS-232 loopback signals or transmitter/receiver line terminations for RS-485
mode. All Ports support asynchronous operation (not synchronous) and RS-232 operation.
These ports originate on the PMPP Board and are assigned as follows:

Port A = RS-232 Local Configuration FLASH Download and Diagnostic Port (3-Pin Molex
Connector J3 on PMPP Board. Note: Port A can also be used by ACCOL the same
as Ports B, C and D except for Comm. Options.
Port B = RS-232 Local/Network Port (J1 of PMPP Board connected to P2 of MI/OB Board).
Network connection is provided via 9-Pin D-Type Connector P5 on MI/OB.
Port C = RS-232 Local/Network Port (routed to/from MI/OB via the Backplane Board).
Network connection is provided via 9-pin D-Type Connector P4 on MI/OB.
Port D = RS-232/RS-485 Local/Network Port (TTL Port on PMPP Board and routed to/from
MI/OB via the Backplane Board). Network connection via 9-Pin D-Type
Connector P3 on MI/OB.

Any of the four communication ports can be configured for local communications, i.e.,
connected to a PEI (portable engineers interface). A PEI is any terminal or computer
running ACCOL Tools. Port A is dedicated to this function since the other ports may be
used for networking via modems, radios, or in the case of Port D, direct LAN connections.

2.4.8.1 RS-485 Interface (Port D)

Figure 2-18 - RS-485 Connector

3305 RTUs require an RS-485 configured port for local network communications to multiple
nodes up to 4000 feet away. The connections for the 9-pin, RS-485 interface are shown in
Figure 2-18, while the corresponding pin labels are given in Table 2-5. Since this interface is

2-16 / Installation 3305 RTU


intended for network communications, Table 2-6 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, while 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.

Table 2-5 - RS-485 Pin Identifiers

Pin No. Pin Code Signal Name


1 TXD+ Transmit Data +
2 TXD- Transmit Data -
3 RXD+ Receive Data +
4 RXD- Receive Data-
9 GND Ground

Table 2-6 - RS-485 Network Connections (see Note below)

From To 1st To nth


Master Slave Slave
1 TXD+ 3 RXD+ 3 RXD+
2 TXD- 4 RXD- 4 RXD-
3 RXD+ 1 TXD+ 1 TXD+
4 RXD- 2 TXD- 2 TXD-

Note
Pins 5 to 8 of each connector are unused.

Table 2-7 - MI/OB -Port D Configuration Switch SW1 Assignments

RS-485 RS-485 Most RS-485


SW1 RS-232
Function Master Distant Other
# Operation
station Slave Slaves
1 - - - - -
ON = 232 OFF = 485 OFF = 485 OFF = 485
2 RS-232/485 Selection
Enabled Enabled Enabled Enabled
RS-484 XMTR 120S ON = ON = OFF =
3 N/A
Term. Resistor Enabled Enabled Disabled
RS485 RCVR 120S ON = ON = OFF =
4 N/A
Term. (+ Bias) Resistor Enabled Enabled Disabled
RS485 RCVR 120S ON = ON = OFF =
5 N/A
Term. (- Bias) Resistor Enabled Enabled Disabled
RS-232 TXD/RXD ON enables
6 N/A N/A N/A
Loopback Local Loopback
RS-232 RTS/CTS ON enables
7 N/A N/A N/A
Loopback Local Loopback
RS-232 DTR/DCD ON enables
8 N/A N/A N/A
Loopback Local Loopback
Note: SW1-4 & SW1-5 must be set together, i.e., both must be ON to enable (install) the RS-
485 120S Receiver (Bias) Resistor.
Note: SW1 switches -6, -7 & -8 are provided for RS-232 configuration. These switches are
typically ON for test purposes and with the exception of SW1-7 are otherwise left
OFF. When Port D is connected to a PC, SW1-7 should be ON (see Figure 2-19).

3305 RTU Installation / 2- 17


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. This is accomplished by configuring MI/OB Board Switch SW1 (at these
locations) so that the 100-Ohm termination resistors are installed (see Table 2-7). Note:
Pin # 3 is unassigned on Port D for RS-232 operation.

2.4.8.2 RS-232 Interface (Ports B, C & D)

An RS-232 port can be used to provide a communication interface to devices such as


printers, VDTs, PCs, and options such as an external modem (see supplemental manuals
and appendixes in rear of manual). For RS-232 applications the device must be located
within 25 feet of the distributed controller (this interface scheme is not intended for
network communications). Pin connections for RS-232 are shown in Figure 2-19 and are
defined in Table 2-8. PMPP Board Switch SW1 provides for selection of RS-232 loopback
signals associated with Ports B and C (see Table 1-2 in Section 1.2.2.3) while MI/OB Board
Switch SW1 provides for selection of the RS-232 loopback signals associated with Port D
(see Table 2-7).

Figure 2-19 - RS-232 Interface (Ports B, C & D) for IBM PC AT or Compatible

Port C can be used for local or network communications and it can be configured for TTL or
RS-232 operation. When used in conjunction with TTL devices such as Bristol Babcock’s
Transmitter Interface (TI) Board, Radio Delay Interface (RDI) Board, RS-485 Interface
Board (Non-isolated), or a modem, the RS-232 Driver IC (U32) is replaced with a Jumper
Block (P/N 392511-01-0) allowing Port C to provide a TTL interface. For modems or other
devices that require 5V power and RS-232 logic, DO NOT replace IC U32 with the Jumper
Block. +5V can be obtained from pin 3 of connector P4.

Table 2-8 - RS-232 Pin Identifiers

Pin # MNEMONIC DESCRIPTION


1 DTR Data Terminal Ready
2 TXD Transmit
3 PWR +5V
4 RXD Receive
5 RTS Request To Send
6 CTS Clear To Send
7 DCD Data Carrier Detect
8 DSR Data Set Ready
9 PCOM Port Ground

2-18 / Installation 3305 RTU


2.4.8.3 Port A RS-232 Interface

Port A is a standard BSAP Port dedicated to support the 3305 RTU in a local or remote
port capacity. As a local port, it can serve as an interface to a Process Engineer’s Interface
(PEI) for diagnostics, ACCOL configuration, or FLASH downloading. Port A utilizes a
three-pin Molex connector and is wired to a PEI as illustrated in Figure 2-20.

Figure 2-20 - RS-232 Interface (Port A) To PEI

2.5 INSTALLING LCD OPTIONS


The are three versions of LCD Displays that can be installed into an RTU 3305.

• 2 X 16 Character LCD Display (locally mounted) (see Section 2.5.1)


• 2 X 16 LCD Display (remotely mounted) (see Section 2.5.2)
• 4 X 20 Display/Keyboard (remotely mounted) (see Section 2.5.2)

2.5.1 Installing the 2 X 20 Local LCD Display Module

There are two possible scenarios for installation of the Local LCD Display option. Section
2.5.1.1 covers installation of the Local LCD Display option when the unit is not equipped
with a network option. Section 2.5.1.2 covers installation of the Local LCD Display option
when a network option (such as a modem) is present.

2.5.1.1 Installation of Local LCD Display (No Network Option Present)

Follow steps 1 through 6 to install the Local 2 X 16 LCD Display into an RTU 3305.

1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).

2. Remove the four screws (A) that secure the blank Name Plate to the Options
Mounting Brackets (C) (see Figure 2-21).

3. Remove the blank Name Plate, install the Standoffs (B) and install the Local LCD
Display Assembly (see Figure 2-22).

4. Install the four screws (A) to secure the LCD Display Assembly to the 4 mounting
post (B) (see Figure 2-23).

3305 RTU Installation / 2- 19


5. Plug the LCD Display Ribbon Cable Connector into Connector P3 on the Backplane
Board.

6. Apply Power and test the LCD Display (see Section 3 for details on operation of the
LCD Display).

Figure 2-21 - 3305 RTU Without Options (Face Plate Present)

2.5.1.2 Installation of Local LCD Display (Network Option Present)

Follow steps 1 through 6 to install the Local 2 X 16 LCD Display into an RTU 3305.

2-20 / Installation 3305 RTU


1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).

2. Remove the four screws (A) that secure the blank Name Plate to the four Mounting
Standoffs (B) which secure the local Network Option to the Options Mounting
Brackets (C) (see Figure 2-23).

3. Remove the blank Name Plate and replace it with the Local LCD Display Assembly
(see Figures 2-24 & 2-25).

4. Install the four screws (A) to secure the LCD Display Assembly to the 4 mounting
post B).

5. Plug the LCD Display Ribbon Cable Connector into Connector P3 on the Backplane
Board.

6. Apply Power and test the LCD Display (see Section 3 for details on operation of the
LCD Display).

Figure 2-22 - 3305 RTU Without Options (Name Plate Removed)

3305 RTU Installation / 2- 21


Figure 2-23 - 3305 RTU Local LCD Display Installation Diagram

2-22 / Installation 3305 RTU


Figure 2-24 - 3305 With Network Comm. Option (Modem) (Name Plate Removed)

3305 RTU Installation / 2- 23


Figure 2-25 - 3305 RTU With LCD Display & Network Comm. (Modem) Option

2-24 / Installation 3305 RTU


Figure 2-26 - 3305 RTU With Network Comm. Option (Modem)

3305 RTU Installation / 2- 25


2.5.2 Installing the Remote LCD Display Module

There are two versions of remote LCD Display options; the Remote 2 X 16 LCD Display
Assembly and the 4 X 20 LCD Display/Keyboard Assembly. The Remote 2 X 16 LCD Dis-
play Assembly is similar to the Local 2 X 16 LCD Display Assembly with the exception of
the Ribbon Cable assembly. Both versions of remote LCD Display assemblies use 50-pin
Headers while the Local LCD Display utilizes a 26-pin Headers. Remote LCD Displays can
be situated up to 50 feet (standard cable lengths of 3 feet or 10 feet are offered) from the
Backplane Connector (P4). The Remote 2 X 16 LCD Display Assembly is provided with a
Bezel Cover Plate to accommodate panel mounting (see Figure 2-27). The 4 X 20 LCD Dis-
play/Keyboard Assembly is provided with a self-adhesive tape and 6 Mounting Studs that
accommodates panel mounting (see Figures 2-28 & 2-29).

Figure 2-27 - Remote LCD Display Installation Diagram

2-26 / Installation 3305 RTU


The Panel or Cover onto which the Remote 2 X 16 LCD Display Assembly will be mounted
will require eight .140” diameter holes and a cutout area of 1.140” x 5.532” (see Figure 2-
27). The Panel or Cover onto which the Remote 4 X 20 Display/Keyboard Assembly is to be
mounted will require six .166” diameter holes and a cutout area of 1.4” x 3.4” for the Dis-
play and a cutout area of .25” x 1.875” for the Keyboard’s flat cable (see Figure 2-28). After
machining the area where the unit is to be mounted, follow steps 1 through 4 of Section
2.5.2.1 to install the Remote 2 X 16 LCD Display Assembly or follow steps 1 through 9 of
Section 2.5.2.2 to install the Remote 4 X 20 Display/Keyboard Assembly.

Figure 2-28 - 4 X 20 Display/Keyboard Assembly Installation Diagram

2.5.2.1 Installing the Remote 2 X 16 LCD Display Assembly

1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).

3305 RTU Installation / 2- 27


2. Place the Bezel or Mounting Plate in question into the machined panel or cover
aligning the eight mounting posts with the eight mounting holes. In the case of the
2 X 16 LCD Display Assembly, install the assembly onto the inside (rear side) of the
machined panel or cover, aligning the assembly’s eight mounting holes with the
Bezel’s eight mounting studs.

3. Install the securing nuts to the eight mounting studs to secure the LCD Display
Assembly to the panel/cover.

4. Plug the LCD Display Ribbon Cable Connector into Connector P4 on the Backplane
Board. Apply Power and test the LCD Display (see Section 3 for details on operation
of the LCD Display).

2.5.2.2 Installing the Remote 4 X 20 Display/Keyboard Assembly (see Figure 2-28)

1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).

2. Unplug the 4 X 20 Display/Keyboard’s Keyboard Cable from its connector P1 on the


Backplane Board (the larger Printed Circuit Board). Remove the six screws that
secure the assembled boards to the Mounting Spacers and place the assembled
boards on an ESD safe area

3. Remove the six Mounting Spacers from the rear of the units Face/Mounting Plate.

4. Carefully remove the paper from the self-adhesive mounting tape.

5. Carefully align the Face/Mounting Plate with the machined mounting area (on the
panel or enclosure in question) and feed the Keyboard Cable and the flat Ground
Lead through the area that was cutout to accommodate them.

6. With Mounting Studs aligned with their machined mounting holes, firmly press the
Face/Mounting Plate onto the panel or enclosure in question.

7. Install the flat Ground Lead over its designated Mounting Stud. Install the six
Washers and the six Mounting Spacers onto the Mounting Studs that protrude
through the inside of the panel or enclosure in question. Note: The flat Ground
Lead is to be attached to the associated equipment’s Chassis Ground in the
event that the mounting panel or enclosure is plastic.

8. With the units Display aligned with its cutout area, place the assembled boards
onto the six Mounting Spacers and replace the six screws.

9. Plug the Keyboard Cable Connector into Connector P1 of the Backplane Board (the
larger Printed Circuit Board). Plug the 50 conductor LCD Display Ribbon Cable
Connector into Connector P4 on the Backplane Board. Apply Power and test the 4 X
20 LCD Display/Keyboard (see Section 3 for details on operation of the LCD
Display).

2-28 / Installation 3305 RTU


Figure 2-29 - RTU 3305 Remote 4 X 20 Display/Keyboard Assembly

2.6 INSTALLING A COMMUNICATION OPTION


3305 RTUs support one of the following communications options via port C on the MI/OB
Board.

• BBI 9600 bps PSTN Modem (see Manual CI-9600 for 396039-10-3 or CI-9600A for
392958-05-8)
• BBI 1200 bps PL/PSTN Modem (see Manual CI-1200)
• BBI Transmitter Interface Board (see Appendix 1 - PIP-TIBS33XX)
• BBI Radio Delay Board (see Appendix 2)
• BBI RS-485 Interface Board (see Appendix 3) (Also see Appendix 4 - Network Inter-
face Box)

3305 RTU Installation / 2- 29


• BBI Highway Addressable Remote Transducer (HART®) Device Interface (see
Appendix 5 - PIP-HART33XX)
• BBI Isolated RS-485 Interface Board (see Appendix 7 - PIP-ISORS485) (Also see
Appendix 4 - Network Interface Box)

With the exceptions of the HART® Device Interface, the Isolated RS-485 Interface Board,
and the Network Interface Box, the option in question mounts to the 3305’s Option
Mounting Brackets (see Figures 2-21 through 2-26).

To install a communication option (other than a Network Interface Box, HART® Device
Interface or an Isolated RS-485 Interface option) into a RTU 3305, follow steps 1 through 9
below. See Appendices 4, 5 & PIP-ISORS485 (respectively) for information on the
installation of a Network Interface Box, HART® Device Interface, or Isolated RS-485
Interface option.

1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).

2. Remove the four screws that secure the Top Plate or Local LCD Display Assembly
to the four Mounting Standoffs. If the Local LCD Display Assembly is present
discon-nect it’s Ribbon cable from P3 on the Backplane Board.

3. Remove the four 2” Mounting Standoffs (if present) from the two Option Mounting
Brackets.

4. Remove the Integrated Circuit U32 (the RS-232 IC associated with Port C) from it’s
socket on the Power Supply/CPU Board and install the Jumper Plug Assembly (BBI
Part Number 392511010) in its place.

5. In the case of the TIB option, install four 1” Mounting Standoffs onto the option
Mounting Brackets and place the TIB assembly onto the standoffs aligning the
mounting holes. Secure the TIB assembly to the four 1” Mounting Standoffs with
the four 2” Mounting Standoffs. For all other Communication assemblies, place the
option in question onto the two Option Mounting Brackets aligning the mounting
holes. Secure the Communication option assembly to the two Option Mounting
Brackets with the four 2” Mounting Standoffs.

6. Connect the Communication Option Cable D-Type connector to Port C (P4) on the
MI/OB Board. In the case of a modem install the wires on the other end of this cable
onto the modem in question (see Table 2-9). In the case of Radio, RS-485 or TIB
options, install the other end of the Comm. Option Cable onto the appropriate board
as follows: For the RS-485 option the other end of the Comm. Option cable plugs
into the RS-485 Board’s connector J1A. Power and Ground must be wired to the
MIOB Board connectors TB3-2 and TB3-1 respectively. It should be noted that the
RS-485 Board will require a +9V to +30V power source to operate (see Table 2-10)
and the TIB Board will require an external +24V power source to operate. For the
Radio Delay Board install the other end of the Comm. Option cable into the Radio
Delay Board’s TB3 and TB1 connectors (see Table 2-13). In the case of the
Transmitter In-terface Board (TIB) option, install the other end of the Comm.
Option cable into TIB connector P1 (see Table 2-14) and install power between the
MIOB Board and Transmitter Interface Board Connector TB1 (see Table 2-11).

2-30 / Installation 3305 RTU


7. Complete the required field I/O wiring connections (see Table 2-12 for RS-485
Board) (see appropriate Manual or Appendix).

8. Install the Top Plate or Local LCD Display Assembly to the four 2” Mounting
Standoffs. If the Local LCD Display Assembly is present connect it’s Ribbon cable to
P3 on the Backplane Board.

9. Apply Power and test the unit (see appropriate manual or Appendix).

Table 2-9 - Wiring List for BBI Modems (Cable Ass’y 396049-02-8)

MI/OB
Port C Wire
Signal TB3 TB2 TB4 Notes
P4/D-Type Color
Pin #
1 Green DTR NOT 4 - - TTL Signal
2 Brown TXD NOT 2 - - TTL Signal
3 Yellow +5V 1 - - +5V Power (Rev 5 & Higher MI/OB)
4 Blue RXD NOT 5 - - TTL Signal
5 White RTS NOT 3 - - TTL Signal
6 Black CTS NOT 6 - - TTL Signal
7 Red DCD NOT 7 - - TTL Signal
8 Yellow +5V 1 - - +5V Power (Rev 4 & Earlier MI/OB)
9 Orange PCOM - 10 1 +5V Ground
Loose Wire to MIOB TB3-2 (Power)
- - +12/24V 8 - -
for 1200 bps PL/PSTN Modem
Note: TB2, TB3 & TB4 are located on the Modem Assembly. Use TB2 for 1200 bps
PL/PSTN Modem. Use TB4 for 9600 bps PSTN Modem.

Table 2-10 - Wiring List for BBI RS-485 Board (Cable Ass’y 396049-01-0)

P4/D-Type Wire
Signal P1A Notes
Pin # Color
1 - DTR NOT - -
2 Brown TXD NOT 7 TTL Signal
3 - - - -
4 Blue RXD NOT 8 TTL Signal
5 White RTS NOT 9 TTL Signal
6 Black CTS NOT 10 TTL Signal
7 Red DCD NOT 14 TTL Signal
8 Yellow +5V 13 +5V Power
9 Orange PCOM 12 +5V Ground
- Tan - 1 Loose Wire to MIOB TB3-2 (Power)
- Gray - 2 Loose Wire to MIOB TB3-1 (GND)

Table 2-11 - Power Wiring List for Transmitter Interface Board

TIB Connector TB1 MIOB Connector TB3


+24V TB3-2
+24VRET TB3-1

3305 RTU Installation / 2- 31


Table 2-12 - Wiring List for BBI RS-485 Board Field Wiring
(Cable Ass’y 396049-03-6)

J2 Pin # Wire Color RS-485 Signal


1 Black TX+
2 Brown TX-
3 Red RX+
4 Orange RX-
5 Yellow ISOGND
6 Green SURGE

Table 2-13 - Wiring List for BBI Radio Delay Board (Cable Ass’y 396049-02-8)

P4/D-Type Wire
Signal TB3 TB1 Notes
Pin # Color
1 Green DTR NOT 4 - TTL Signal
2 Brown TXD NOT 2 - TTL Signal
3 Yellow +5V 1 - +5V Power
4 Blue RXD NOT 5 - TTL Signal
5 White RTS NOT 3 - TTL Signal
6 Black CTS NOT 6 - TTL Signal
7 Red DCD NOT 7 - TTL Signal
8 - - - - -
9 Orange PCOM - 6 +5V Ground

Table 2-14 - Comm. Wiring List for Transmitter Interface Board


(Cable Ass’y 396049-04-4)

P4/D-Type Wire
Signal J1 Notes
Pin # Color
1 Green DTR NOT - -
2 Brown TXD NOT 6 TTL Signal
3 - - - -
4 Blue RXD NOT 9 TTL Signal
5 White RTS NOT 7 TTL Signal
6 Black CTS NOT 10 TTL Signal
7 Red DCD NOT - -
8 Yellow +5V 3 +5V Power
9 Orange PCOM 2 +5V Ground

2-32 / Installation 3305 RTU


Section 3
LIQUID CRYSTAL DISPLAYS

3.1 INTRODUCTION TO LCDs


The 3305 RTU can be equipped with one of three Liquid Crystal Displays:

• Local 2 X 16 LCD with 2 Pushbuttons


• Remote 2 X 16 LCD with 2 Pushbuttons
• Remote 4 X 20 LCD Display/Keyboard Assembly

The Local LCD mounts on the top of the 3305 RTU and interfaces to the system via
Backplane Connector P3. Remote versions of the LCD interface to the system via
Backplane Connector P4. Except for the Ribbon Cable/Interface Connector, both versions of
the 2 X 16 LCD Display are functionally identical.

These Displays allow an operator or engineer to view (and in the case of the Key-
pad/Display, modify) ACCOL signal values and associated status bit information. ACCOL
signals 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 inhibit state, manual inhibit state, and ques-
tionable data.

Setting up the display is a simple matter of creating a Keyboard Module in the ACCOL
load.

3.1.1 2 X 16 LCD Display & Sensor Buttons

The 2 by 16 character LCD Display with 2 push-buttons provides a set of lists which are
organized from left to right with each list organized top to bottom. The Main Display
(Identifier Display) contains user defined data (using the SELECT-n and LIST terminals of
the ACCOL KEYBOARD Module). The Scroll List is activated using the Down (↓) arrow
and is unique because it contains system data and user defined data such as Data, Time,
Node I.D. and System Firmware I.D. All other lists are user-defined using the INPUT-n
terminals of the ACCOL Keyboard Module. The information displayed on the screen is
controlled by two push-buttons located just to the right of the LCD screen.

When the left push-button (↓) has been pressed, automatic scrolling from top to bottom
(circular) will start and continue through the selected list at a user defined rate. The right
push-button (→), when pressed, steps from left to right (circular) through the set of lists.
Once scrolling is active, the left push-button (↓) causes the LCD Module to toggle between
“Hold” and “Resume” modes to allow the user to halt the screen at a particular signal and
then resume scrolling when it is so desired. Scrolling stops when the right push-button (→)
has been pressed and the identifier of the next list is displayed.

3305 RTU Liquid Crystal Displays / 3- 1


3.1.2 4 X 20 LCD Display/Keyboard

The Display/Keyboard is comprised of a four line by twenty character liquid crystal display,
with adjustable viewing angle, and a five-by-five membrane key matrix. Each key has a
microswitch for positive tactile feedback. This means that as you firmly press the keys, you
will feel it click as it engages. The Display/Keyboard assembly is always mounted
“remotely.”

3.2 PREPARING THE ACCOL LOAD


In order for the LCD Display in question to operate, the ACCOL load must include a
properly configured “Keyboard Module.” Use the ACCOL Interactive Compiler (AIC), or
ACCOL Batch Compiler (ABC), or version 5.13 (or higher 5.X revision) of ACCOL
Workbench to create this module in Task 0 and assign the “Module Terminals” according to
the five following steps.

Figure 3-1 - ACCOL Keyboard Module Symbol

Step 1: Creating the Identifier Display (see Figures 3-1, 3-2 & 3-3)

The Identifier Display is the first display to appear when the ACCOL load begins to
execute. This display will look similar to Figure 3-2C or 3-3C. Each line of the display
contains the text value of a string signal (in the case of the Display/Keyboard this is true
for each of the first three lines). These string signals are named on the SELECT terminals
of the Keyboard Module (See Figure 3-1). 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.

In the case of the Display/Keyboard assembly, the bottom line on the Identifier 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 3, Using the Keypad.

3-2 / Liquid Crystal Display 3305 RTU


The legend line in Figure 3-2C shows that the user has two choices: to sign-on (using [F1])
or scroll (using [F3]).

Figure 3-2 - Creating the Identifier Message for Display/Keyboard Units

Step 2: Defining a Scroll List (see Figure 3-4

Once the Keyboard Module has been configured and the LCD Display in question is
operating properly, you can automatically scroll through a list of signals. Scrolling can be
done without entering a password (discussed in the next step.) The signals in the list are
displayed one at a time and in the same order in which they were entered in the signal list.
This list might contain summary information about the process the RTU 3305 is con-
trolling.

3305 RTU Liquid Crystal Displays / 3- 3


(Later, we'll discuss other signal lists that can be accessed via an LCD Display. To
distinguish this list from others, this signal list is called the Scroll List.)

On the LIST terminal, enter the number of a signal list to be scrolled. (You may also enter
a signal name whose value equals the number of the signal list.) This signal list becomes
the Scroll List. The Scroll List can contain different types of signals (that is, logical, analog
and string). You can create a specific scroll signal list or use any list in the ACCOL load.

Figure 3-3 - Creating the Identifier Message for 2 X 16 LCD Display Units

3-4 / Liquid Crystal Display 3305 RTU


Each signal in the Scroll List will be displayed for the number of seconds defined at the
TIME terminal. If you don't specify a time on this terminal, 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 this is unacceptable, sign-off (INIT key) before starting scrolling.

Figure 3-4 - Defining a Scroll List Diagram

Step 3: Assigning Passwords (see Figure 3-5)

Once the Display/Keyboard is operating, a password will be needed to go beyond the initial
displays. These passwords are defined on the PASSWORD_RD and PASSWORD_WT
terminals.

Someone using the password named on the PASSWORD_RD terminal will only be allowed
to read signal information. When the password named on the PASSWORD_WT terminal is
used, that person can also change signal values and other parameters.

These terminals can accept a value or signal name.

Passwords can be any combination of numbers up to 6 digits in length, from 000001 to


999999. If none are specified on the Keypad Module, the default values are 333333 for read
only access and 666666 for read/write access.

Step 4: Assigning Monitoring Signals (see Figure 3-6)

Enter signal names on the STATE, FAIL_STATE, and STATUS terminals.

Enter a logical alarm signal name on the STATE terminal. This signal will turn ON when
a valid password has been entered. It will be set OFF when the user has signed off. In each
case, an alarm will be reported to notify the network of this activity.

3305 RTU Liquid Crystal Displays / 3- 5


Enter a logical alarm signal name on the FAIL_STATE terminal. The module will turn the
signal ON after three invalid passwords have been entered. It will be turned off when the
user signs off. In each case an alarm will be reported.

Enter an analog signal name on the STATUS terminal. When the load is executing, the
value of this signal, when read by the PEI, will indicate the present module state. The
signal will assume one of the following codes:

Figure 3-5 - Assigning Passwords Diagram

Figure 3-6 - Assigning Monitoring Signals Diagram

3-6 / Liquid Crystal Display 3305 RTU


Table 3-1 - Status Codes Associated with LCD Displays

STATUS Code: Meaning


-1.0 No Display Device or Both Local & Remote types detected
2.0 Waiting for push-button/key press
3.0 Waiting for push-button/key press or timeout
4.0 Writing to display
5.0 Writing to display
6.0 Clearing LCD display

Step 5: Defining the List Menu (see Figure 3-7)

The INPUT terminals are used to define the menu and signal lists to be accessed from the
List Menu. Once the Keypad is operating, a user who has signed on with a password can
scroll through the names of signal lists and choose a list to read or change.

Figure 3-7 - Defining the List Menu Diagram

Up to 255 INPUT terminals are available. Each terminal can contain a signal list number
or signal name. These terminals should be used consecutively, that is, unwired INPUT
terminals should only appear after the last used INPUT terminal and will generate an
'unwired input' message on the display. Unwired terminals between wired terminals will
use ACCOL load memory space. Unwired terminals after the last used terminal do not use
memory.

If the terminal is assigned a number, this number will be presented on the List Menu.
When the terminal is assigned a signal name, both the signal name and its value are
shown on the List Menu. If you have properly configured the ACCOL Keyboard Module,
you will see the Identifier Display when the ACCOL load begins to execute.

3.2.1 ACCOL Module Terminals

ACCOL Module Terminals supported by the 3305 RTU with 2 X 16 LCD Displays are
described in Table 3-2. ACCOL Module Terminals supported by 3305s with a Key-
board/Display are described in Table 3-3.

3305 RTU Liquid Crystal Displays / 3- 7


Table 3-2 - Definitions of Module Terminals for 3305s with a 2 X 16 LCD Display

Name Default Format I/O Description


SELECT 1 None String Input SELECT 1 and SELECT 2 are String Signals
& Signal which provide the text for the initial or Main
SELECT 2 Display. Each string can be up to 16 characters in
length. This information is displayed on load
startup and is typically used to identify the
location and/or function of the unit, e.g.,
BARTLESVILLE, OK
WELL-PATCH 27
LIST None Analog Input LIST specifies the number of the signal list for the
Signal Main Display. The elements in this list are part of
or the Main Display and will appear in order
Constant following the display of internal data when
scrolling is active. Scrolling is activated from the
Main Display using the Down Arrow (left push-
button).
TIME 2 Seconds Analog Input TIME sets the time in seconds that each display
Signal item will appear on the screen for when scrolling
or has become active. The value assigned to TIME
Constant should not be less than 1 second.
STATE None Logical Output STATE provides an indicator to the ACCOL load,
Alarm or to the network, of activity at the display device.
Signal This signal (along with a 20-second timer) is set
ON whenever an operator presses one of the two
push-buttons associated with the LCD Display.
The STATE Signal will be set OFF after 20-
minutes without any push-button activity. The
signal can also be turned OFF via ACCOL logic or
from an external source such as Toolkit. Note: No
action is taken at the device when the 20 minute
timer expires. If the last action was to activate
scrolling a list, that scrolling will continue.
STATUS None Analog Output STATUS is set to one of the following status
Signal codes:
1.0 No Display Device or Both Display types
detected.
2.0 Waiting for push-button press.
3.0 Waiting for push button press or timeout.
4.0 Writing to display.
5.0 Writing to display.
6.0 Clearing display.
When scrolling has been activated, the module
will alternate between 1 and 4, or between 2 and
4.
INPUT_n None Analog Input INPUT is set of up to 255 terminals which may be
Signal used to define the List menu. The List menu is
or activated and scanned using the Right Arrow
Constant (Right push-button). When viewing the Main
Display, pressing the Right Arrow causes the first
element in the List Menu to be displayed.

3-8 / Liquid Crystal Display 3305 RTU


Table 3-2 - Definitions of Module Terminals for 3305s with a 2 X 16 LCD Display
(Continued)

Name Default Format I/O Description


INPUT_n None Analog Input n Continued from previous page -
Signal
or Each subsequent press of the Right Arrow prompts a
Constant move to the next element in the List menu. When at
the last element in the menu, pressing the Right
Arrow Button will cause a return to the main
Display. Pressing the Down Arrow Button at any
time activates scrolling from top-to-bottom in the
current list. The Down Arrow Button then toggles
between “Hold” and “Resume” modes until the Right
Arrow Button has been pressed to select a different
list.

Each INPUT terminal can contain a signal list


number (Constant) or a signal name where the name
provides a title for the list and the value of the signal
is the list number, e.g., signal name = CONFIG.LIST
and the signal value = 10.

INPUT terminals should be used consecutively, that


is , unwired terminals should appear only after the
last used INPUT terminal. Unwired terminals
between wired terminals will use memory space in
the ACCOL load and the message ‘unwired input’ will
appear when the menu position is displayed.

The individual signal lists defined in the List Menu


can be of variable lengths and can contain any
mixture of signal types.

Table 3-3 - Definitions of Module Terminals for 3305s with a Display/Keyboard

Name Default Format I/O Description


SELECT 1 None String Input SELECT 1, SELECT 2 & SELECT 3 are String
Signal Signals which provide the text for the initial or
SELECT 2 entry Identifier Display. Each string can be up to 20
required characters in length. The value of each signal will
& appear on the display. The signal named on
SELECT 1 will appear on the top line. SELECT 2
SELECT 3 will be on the middle line and SELECT 3 will be on
the third line. This information is displayed on load
startup and is typically used to identify the
location and name and/or function of the unit, e.g.,
BARTLESVILLE, OK
WELL-PATCH 27
PUMP 14
SIGN-ON SCROLL

3305 RTU Liquid Crystal Displays / 3- 9


Table 3-3 - Definitions of Module Terminals for 3305s with a Display/Keyboard
(Continued)

Name Default Format I/O Description


LIST None Analog Input LIST specifies the number of the signal list
Signal which is called the Scroll List. The elements
entry or in this list are part of the Main Display and
required Constant will appear in order following the display of
internal data when scrolling is active.
Scrolling is activated from the Main Display
using the Scroll (F3) key.
TIME 2 Analog Input TIME sets the time in seconds that each
Seconds Signal signal in the Scroll List/Scroll Display will
or appear on the screen for when scrolling has
Constant become active. The value assigned to TIME
should not be less than 1 second.
PASSWORD_RD None Analog Input PASSWORD_RD is the password for ‘read-
Signal only’ access. The password cannot exceed 6
entry or digits.
required Constant
PASSWORD_WT None Analog Input PASSWORD_WT is the password for read-
Signal /write access. The password cannot exceed 6
entry or digits. Note: The user will be logged off if the
required Constant keyboard is inactive for a period of 20
consecutive minutes.
STATE None Logical Output STATE provides an indicator to the ACCOL
Alarm load, or to the network, of activity at the
Signal display device. This signal (along with a 20-
minute timer) is set ON whenever a valid
password is entered and set OFF when the
operator has signed off. It is also set OFF if
20-minute elapse without any keyboard
activity, while an operator is signed on. The
signal can also be turned OFF via ACCOL
logic or from an external source such as
Toolkit. Note: No action is taken at the device
when the 20 minute timer expires. If the last
action was to activate scrolling a list, that
scrolling will continue.
FAIL_STATE None Analog Output FAIL_STATE is set ON after three invalid
Signal passwords have been entered consecutively
and is turned OFF when the user signs off. In
each case an alarm will be reported.
STATUS None Analog Output STATUS is set to one of the following status
Signal codes:
1.0 Display/Keyboard hardware
(or both) not detected.
2.0 Waiting for key press
3.0 Waiting for key press or timeout.
4.0 Writing to display.
5.0 Writing to display.
6.0 Clearing LCD display.

3-10 / Liquid Crystal Display 3305 RTU


Table 3-3 - Definitions of Module Terminals for 3305s with a Display/Keyboard
(Continued)

Name Default Format I/O Description


INPUT_n None Analog Input INPUT is set of up to 255 terminals which may be
Signal used to define the List Menu. The List menu is
or activated at the display using the MENU option. The
Constant user can scroll through the names/numbers of signal
lists and choose individual lists to be displayed.

Each INPUT terminal may contain a signal list


number (Constant), or a signal name where the
name provides a title for the list and the value of the
signal is the list number, e.g., signal name =
CONFIG.LIST and the signal value = 10.

INPUT terminals should be used consecutively, that


is , unwired terminals should appear only after the
last used INPUT terminal. Unwired terminals
between wired terminals will use memory space in
the ACCOL load and the message ‘unwired input’ will
appear when the menu position is displayed.

The individual signal lists defined in the List Menu


can be of variable lengths and can contain any
mixture of signal types.

3.3 USING THE 4 X 20 DISPLAY/KEYBOARD


The Identifier Display is the starting point from which you can go to other displays. It
shows an identification message and the words SIGN-ON 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 signals you can expect to see when you use this
display.

Note 1: If your display shows something else, press the [F4] key until you see the words
SIGN-ON and SCROLL on the bottom line.

If your screen is blank, adjust the Display Intensity (see Figure 1-6). If no letters
appear, either a hardware failure has occurred or the controller has not been
programmed properly to operate the keypad.

The words SIGN-ON and SCROLL at the bottom of the screen are on the legend line. It
tells you which function keys (that is, keys [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 3-8 only [F1] and [F3] are
active.

3305 RTU Liquid Crystal Displays / 3- 11


Figure 3-8 - The Identifier Display

Figure 3-9 - Identifier Display Legends and Corresponding Keypad Alignment

Figure 3-10 - Display/Keyboard Scrolling

3-12 / Liquid Crystal Display 3305 RTU


From the Identifier Display, you have two choices. Pressing [F1] will allow you to sign-on if
you have a password. By pressing [F3] you can activate automatic scrolling through a list
of signals.

3.3.1 Display/Keyboard Scrolling

To begin automatic scrolling, press [F3] from the Identifier Display (Figure 3-4). After
pressing F3, the three sequential screens followed by a screen which contains the first item
from the Scroll List which in turn is followed by 2nd, 3rd, etc. items from the Scroll List.
After the last item from the scroll List has been displayed, the sequence returns to the 1st
Screen and repeats the pattern until disabled. Each screen is displayed for 2 to 10 seconds.
In the case of the 4th through last screens the signal name appears on the first line. Signal
value and units appear on the second line and status appears on the third line. An example
is shown in Figure 3-10.

When all signals in the list have been displayed, they will be shown again in the same
order.

Press HOLD ([F1]) to halt scrolling and freeze the display. Press GO ([F2]) to resume
scrolling.

Press EXIT ([F4]) to return to the Identifier Display (Figure 3-8).

3.3.2 Signing-On With the Display/Keyboard

To access the List Menu, you must first sign-on with a proper password. From the
Identifier Display (Figure 3-8), press [F1]. The screen will look like Figure 3-11A or 3-11B.

If the display looks like Figure 3-11B:

Someone else has already signed on. Go to the paragraph below that starts "Once the
correct password has been entered...".

If the display looks like Figure 3-11A:

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. Press [ENT] to enter your
password into the system.

If your password is not recognized, the asterisks will be erased after you press [ENT].
Check your password and try again. After three unsuccessful attempts to sign-on, an
alarm signal is turned ON. The alarm signal can be reported to the external network
(via message).

Once the correct password has been entered, the display will look like Figure 3-11B.

When the second line shows READ/WRITE, you can read and write signal parameters.
When it shows READ ONLY you cannot change signal parameters. You are only permitted
to read signal information. If your display shows READ ONLY and you want to change
signal values, sign-off (press the [INIT] key), press [F1] from the Identifier Display, and
enter the password for READ/WRITE access.

3305 RTU Liquid Crystal Displays / 3- 13


Once you have successfully signed on, the legend line will show that you have three
options. You can view and change the time and date of the local clock, access more signal
lists, or return to the Identifier Display. Let's start by setting the local clock.

Figure 3-11 - Signing On

3.3.3 Clock Functions Via the Display/Keyboard

From the Sign-On Display (Figure 3-11B), press [F1]. The screen will show the present
date and time and will look like Figure 3-12. 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 format hours:minutes:seconds.

Figure 3-12 - Clock Display

Changing the Time

From the display shown in Figure 3-12, press [F1]. Colons (:) will appear on the third line
(see Figure 3-13). Enter the new time there and press [ENT]. 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.

3-14 / Liquid Crystal Display 3305 RTU


Figure 3-13 - Time Set Display

If you make a mistake while entering the new time, press [CLR] and start again or use
[DEL] to backspace and delete one character at a time.

Press [F2] to return to the clock display (Figure 3-12).

Changing the Date

From the clock display (Figure 3-12), press [F2]. Slash marks (/) will appear on the third
line (see Figure 3-14). Enter the new date there and press [ENT].

Figure 3-14 - Date Set Display

If you make a mistake while entering the new date, press [CLR] and start again or use
[DEL] to back space and delete one character at a time.

Press [F4] to return to the Sign-On Display (Figure 3-11B).

3.3.4 Choosing a Signal List from the List Menu via the Display/Keyboard

The List Menu is another area where signal information can be seen. As explained earlier
in this section, your first opportunity to read signal information is by choosing the
SCROLL function from the Initial Display. Signal name, value and units text 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 signals which you can choose to read. This infor-
mation will be more detailed than the Scroll List.

To get to the List Menu, choose MENU (press [F2]) from the Sign-On Display (Figure 3-
11B).

The first signal list number in the menu will appear on the first line. If a signal name was
used to name the list in the ACCOL load, the signal name appears on the second line;
otherwise, the display indicates NO NAME.

Press NEXT and BACK to see the other signal lists that are available in the List Menu.
The List Menu can contain up to 255 signal list numbers.

3305 RTU Liquid Crystal Displays / 3- 15


Figure 3-15 - Using the List Menu Display

To advance or backup in large increments, enter a one to three digit number on line 3 and
press NEXT or BACK. For example, if the fifth signal is being displayed and you enter the
number 22 and press NEXT, the twenty-seventh signal will appear.

Wraparound will occur for increments exceeding the list length. For example, suppose the
second signal in a 10-signal list is displayed. If the number 11 is entered and NEXT is
pressed, the third signal in the list will be displayed.

To move directly to a list, enter the list number, then press pick.

3.3.5 Moving Through a Signal List via the Display/Keyboard

After READ or CONF has been pressed, the display will show the first signal in the list. An
example is shown in Figure 3-16. Each time NEXT is pressed, the display will show the
next signal in the list. BACK will show the previous signal.

To move in large increments, enter a one to three digit skip count and press NEXT. The
display will skip over that number of signals. The maximum skip count is 255; larger
values default to 255.

Automatic wraparound occurs in either direction. When you reach the end of the list, [F1]
will display the first signal again. At the top of the list, [F2] will display the last signal.
You can skip through long lists by entering a one to three digit number and pressing NEXT
or BACK. For example, to move 50 signals down the list, press 5, then 0, then [F1].

3.3.6 Changing Signal Parameters via the Display/Keyboard

From Figure 3-15, you can change signal parameters by pressing CONF [F2]. Then follow
the directions summarized below (see Note 2).

Note 2: If your display does not contain the legend CONF in the legend line, your password
will only allow you to read signals. If you want to change signal values at this
time, you must first sign-off and then sign-on using the correct password. See your
Systems Engineer for the correct password.

3-16 / Liquid Crystal Display 3305 RTU


Before making any changes, first check the signal inhibit status field (See Figure 3-16).
When the display shows ME (manual enable) you can change signal parameters. When it
shows MI (manual inhibit), you cannot alter the parameters of this signal. If the field
indicates MI, press the OPER IE key to change it to ME.

To change an analog value:

Press CLR 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 [ENT].
If you make a mistake, press CLR 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 [F4] and [INIT] keys). These keys will raise and lower the value by
1% of the displayed amount.

To change the status of a logical signal:

Press CLR, then use either the down and up arrow keys or the [0/OFF] and [1/ON] keys
to change the state of a logical signal. If the [0/OFF] and [1/ON] keys are used, you
must also press [ENT].

While editing an analog value or digital status, you may see the following messages:

PRESS CLR TO CHANGE


NOT IN MANUAL MODE

The first message is a reminder that the first thing you must do to change an analog value
or digital status is to press CLR.

The second message will appear when the signal cannot be changed because it is not in
manual enable (ME) mode.

To acknowledge an alarm: Press [ALM ACK].

To change the alarm enable/inhibit status for alarm signals:

Press [ALM I/E] key. (Note, this will only inhibit alarm reporting, and not alarm level
detection.)

3305 RTU Liquid Crystal Displays / 3- 17


Figure 3-16 - Interpreting Signal Information

Notes for Figure 3-16

1. Signal Name - base name (8 characters max.), extension (6 characters max.), and attribute
(4 characters max.)

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 signals, column 1 will be clear if the status is valid. It
will display a question mark if the status is questionable (requires Firmware Level AL.00
or RMS02 or later).

4. Skip - how far to move in the list when NEXT or BACK is pressed (Default = 1, Max = 255).

5. Signal Inhibit Status

CE (Control Enable) means this signal can be updated by the ACCOL program.

CI (Control Inhibit) means the signal cannot be updated by the ACCOL program.

ME (Manual Enable) means the signal can be changed manually.

MI (Manual Inhibit) means the signal cannot be changed manually.

6. Alarm Enable (for alarm signals only)

AE - signal is alarm enabled (changes will be reported).

AI - signal is alarm inhibited (changes will not be reported).

3-18 / Liquid Crystal Display 3305 RTU


Notes for Figure 3-16 (Continued)

7. Units - units text (for analog signals only), if any units have been defined.

8. Alarm Type

For Analog Signals: For Logical Signals:


HH - high-high alarm TA - true alarm
HI - high alarm FA - false alarm
LO - low alarm CA - change-of-state alarm
LL - low-low alarm NA - no alarm
NA - no alarm

! - alarm is unacknowledged

9. Multiple Signal Display

In Read Mode, pressing MULT will display the signal name extension, value, and units for
three signals at one time. These signals include the signal displayed when NEXT was
pressed and the next two signals in the list. Press SNGL [F3] to return to viewing one
signal at a time (see Figure 3-17).

Figure 3-17 - Example of MULT Display in READ mode

Signals 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 GALS.
CE MI

3) Logical
FLOW.ALARM
OFF
CE MI AE NA

3305 RTU Liquid Crystal Displays / 3- 19


3.3.7 Signing-Off via the Display/Keyboard

Once you have signed-on, use the [INIT] key at any time to sign-off. When this key has
been pressed, the screen will look like Figure 3-18. Press YES to sign-off. You are signed-
off when the Identifier Display (Figure 3-2C) appears.

Figure 3-18 - Sign Off Display

If you do not want to sign-off, press EXIT to leave the Sign-Off Display.

Once you are signed-on an automatic sign-off will occur if 20 minutes has elapsed since the
last key was pressed.

3.4 INTERPRETING ERROR MESSAGES

NO INPUT LISTS

Meaning: This may occur when the MENU function is selected. No input lists were
entered during configuration.

Remedy: Values or signal names must be entered on the INPUT terminals of the
Keyboard Module using the ACCOL Interactive Compiler (AIC) or ACCOL
Batch Compiler (ABC) (See Step 5, page 5).

UNWIRED INPUT

Meaning: No value has been entered at this INPUT terminal in the ACCOL load.

Remedy: Using the AIC or ABC, enter a valid value.

NON-EXISTENT LIST

Meaning: The list was not found in the load. An invalid signal list number was entered
on the LIST or INPUT terminals.

Remedy: Using the AIC or ABC, enter a valid signal list number on the LIST or
INPUT terminals (See Steps 2 and 5, pages 3 and 7).

3-20 / Liquid Crystal Display 3305 RTU


NO SCROLL LIST

Meaning: The Scroll Terminal has been left unwired.

Remedy: Use the AIC or ABC to enter a value or signal name on the LIST terminal
(See Step 2, page 3).

EMPTY LIST

Meaning: A valid signal list number has been requested but the signal list is empty.

Remedy: Use the AIC or ABC to create a signal list and/or place the appropriate sig-
nal names into the empty list.

NOT IN MANUAL MODE

Meaning: The signal is manual inhibited (MI) mode.

Remedy: Use the OPER I/E key to change mode to ME.

STRING SIGNAL:

Meaning: User is trying to change a string signal

Remedy: None - String signals cannot be changed with the keypad.

Figure 3-19 – Keypad

3305 RTU Liquid Crystal Displays / 3- 21


Table 3-5 - The Keypad Keys

KEY FUNCTION
Function keys will take on a variety of different functions depending on the
F1, F2, F3, F4 situation. The function of these keys is listed on the legend line (bottom line) of the
display.
INIT The INIT key is used to terminate the keyboard session and sign-off.

These keys are used to change the value of analog signals in the CON-
0 to 9, -, . FIGURATION mode. The 0/OFF and 1/ON keys are used to change the state of
logical signals.
∆ Each press of this key will raise an analog signal value by 1% of the displayed
value or turn a logical signal ON.
∇ Each press of this key will lower an analog signal value by 1% of the displayed
value or turn a logical signal OFF.
ALM I/E Use this key to enable or inhibit alarm signals.

ALM ACK Use this key to acknowledge alarms.

A/M Toggle between AUTO (CE) and MANUAL (CI) with this key.

OPER I/E Toggle between manual inhibit (MI) and enable (ME) with this key.

DEL Use this backspace key to erase digits that have been entered on the keypad.

ENT This key is used to enter new data from the display into the RTU 3305, e.g.,
password or signal values.

3.5 2 X 16 LCD DISPLAY SCROLLING DETAILS

3.5.1 Main 2 X 16 LCD Display

The Main Display is comprised of both user-defined and internal system data. The screens
associated with the Main Display are defined as follows:

1st Screen: User defined text (contents of SELECT-1 & SELECT-2)

Figure 3-20 - Identifier Display Screen

The following screens occur when scrolling has started:

2nd Screen: Data


Time

3rd Screen: System Firmware Version String


Custom Firmware Version String

3-22 / Liquid Crystal Display 3305 RTU


4th Screen: Local ID (Node Address)
Group ID (Group Number)

5th Screen: First element from LIST terminal signal list

Nth Screen: Last element from LIST terminal signal list


(Continues from 2nd Screen)

Note 3: If your screen is blank, adjust the Display Intensity (see Figure 1-8). If no letters
appear, either a hardware failure has occurred or he controller has not been
programmed properly to operate the keypad.

3.5.2 Other Lists Associated with the 2 X 16 LCD Display

All other lists are defined in a List Menu using the INPUT_n terminals of the Dis-
play/Keyboard Module. The signal name provides a title for the list and the signal value
provides the list number. Note: If only the signal value is entered, NO NAME is displayed.

The screens associated with the Other Lists are defined as follows:

1st Screen: List No: nnn


List Title (Name of signal from INPUT terminal)

The following screens occur when scrolling has started:

2nd Screen: First element from list

Nth Screen: Last element from list


(Continues from 2nd Screen)

3.5.3 Display Of Signal Data Associated with the 2 X 16 LCD Display

The first line of the Signal Data Display will contain the signal name. The first 16
characters of the full name will be displayed. It is the users’ responsibility to create signal
names which can be fully displayed without truncation, i.e., if the full field width for
BASE.EXTENSION.ATTRIBUTE (8.6.4) was used, the Attribute text will not be displayed.

The second line of the display contains signal value, units or OFF/ON text, or state in-
formation as described in Table 3-6 (see Figures 3-21 through 3-26).

Note 4: The floating point value displayed in 10 character positions is similar to but more
accurate than the Display/Keypad MULT Mode (associated with the Keypad-
/Display) where 8 character positions are available.

3305 RTU Liquid Crystal Displays / 3- 23


Figure 3-21 - Analog Signals on the 2 X 16 LCD Display

Figure 3-22 - Analog Alarms on the 2 X 16 LCD Display

Figure 3-23 - Logical Signals on the 2 X 16 LCD Display

3-24 / Liquid Crystal Display 3305 RTU


Figure 3-24 - Logical Alarms on the 2 X 16 LCD Display

Figure 3-25 - String Signals on the 2 X 16 LCD Display

Notes for Figures 3-21 Through 3-25

1. Signal Name - base name (8 characters max.), extension (6 characters max.), and attribute (4
characters max.) (Not to exceed 16-character limit).

2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be
shown as asterisks. The Sign will be blank for (positive) and - for (negative).

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 signals, column 1 will be clear if the status is valid. It
will display a question mark if the status is questionable.

4. Units - units text (for analog signals only), if any units have been defined.

3305 RTU Liquid Crystal Displays / 3- 25


Notes for Figures 3-21 Through 3-25 (Continued)
5. Alarm Type

For Analog Signals: For Logical Signals:

HH - high-high alarm TA - true alarm


HI - high alarm FA - false alarm
LO - low alarm CA - change-of-state alarm
LL - low-low alarm NA - no alarm
NA - no alarm

! - alarm is unacknowledged

6. User defined ON/OFF Text for Logical signals or Logical Alarms (not to exceed 6-character
limit).

7. String Signals

Up to 16 character user defined string.

3.6 RESET & DIAGNOSTIC


3.6.1 Reset/Self-Test Diagnostics

On a reset (Rest Button pressed or power up of a unit without an ACCOL load) the
following sequence will occur at the display (for both the 2 X 16 LCD Display and the 4 X
20 Display/Keyboard):

All pixels OFF (clear screen)


All pixels ON (for 3 seconds)
All pixels OFF (for at least 3 seconds)

Local ID: nnn Line 1 (Node Address)


Group ID: nnn Line 2 (Group Number)

The Node Address and Group Number (No.) will remain on the LCD screen until an
ACCOL load containing a DISPLAY/KEYBOARD module is activated; at which time the
text for the Main Display (or Identifier Display) will appear on the LCD screen. If there is
no DISPLAY/KEYBOARD Module in the load, the Node Address and Group No. will
remain on the screen.

3.6.2 OFF-Line/ACCOL Diagnostics

Off-Line Diagnostics require a Process Engineer’s Interface (PEI) equipped with BBI
ACCOL Diagnostic Control Program (DIAG05.ACL) Software. The WINDIAG Manual
D4041A describes the communication interface between the PEI and the 3305 RTU and the
procedures for loading DIAG5, downloading the ACCOL diagnostic load file (DIAG05.ACL)
to the 3305 RTU, and for testing the Display/Keypad. The 33XX Diagnostic Manual test
for the 4 X 20 Display/Keyboard Module also apply to the 2 X 16 LCD Display.

Also see Chapter 5 SERVICE of this manual.

3-26 / Liquid Crystal Display 3305 RTU


Section 4
OPERATION

4.1 GENERAL
This section provides Guidelines for starting and operating an RTU 3305. Since a variety of
options and peripheral equipment can be present in any given installation, specific
information cannot be provided to cover every situation. The user must be familiar with
the equipment contained in his system and be alert to any trouble or danger that could
result from improper startups.

4.2 PRELIMINARY CHECKS


Before applying power, the following items should be checked:

a) Be sure that all PC boards and I/O circuits have been properly configured. Set all
board jumpers and switches for the desired application. Refer to "Section 2 INSTAL-
LATION to identify the appropriate boards and assemblies.

b) All RTUs should have jumper W7 on the Processor Memory Peripheral Power
Supply (PMPP) Board set so that the battery is in the circuit, i.e., in position 1 to 2.
If this is not done, all ACCOL load data will be lost during a power interruption or
failure. FLASH memory will maintain the programmable portion of the load, but
the RAM portion (running states of program) will be lost without battery backup. As
such, the RTU will "cold start" when power reappears and all related process
signals will be set to initial values specified in the load.

3305 RTUs require battery backup to initiate a "warm start" after a power inter-
ruption. A good battery ensures that the RTU will provide power-fail recovery
whereby all variables maintain the same values and statuses they held prior to the
failure.

c) Make sure that all PC boards are plugged into their proper sockets and are properly
secured.

d) Check that all I/O terminal block connectors are secure.

e) Check that the dc supply voltage matches the supply voltage specified for the RTU
(12V battery or +9V to +20V Bulk) or (24V Battery or +20V to +30V Bulk).

f) Check for proper size fuse on the MI/OB Board, i.e., .5 Amp.

g) Clear the RTU of any stray tools, test clips, test probes, wire leads, etc. that could
cause shorts or intermittent operating problems.

h) Check that all external process functions associated with the RTU are closed down
or under some form of guarded control.

3305 RTU Operation / 4- 1


Warning

Some processes are hazardous by nature and can


become extremely dangerous during power-ups,
power-downs, or power failures. If such processes are
allowed to run out of control, property damage and
injury to persons may result. The use of manual or
automatic backup control equipment and alarm
warning devices are recommended to ensure safety.

4.3 STARTING THE RTU


The startup procedure described herein is general for most applications. Installations that
utilize optional or specialized equipment may require additional steps not listed here.
When such equipment is encountered, the user should refer to the manufacturer's manuals
before applying power to the system.

4.3.1 Equipment Required

Digital Multimeter (DMM) - 5-1/2 digit resolution


Personal Computer (PC) - Required to communicate with RTU
System Config/FLASH
Downloader Software* To set system soft switches (see Section 2.3.2)
AIC Software* - Required to install ACCOL load
AIC Software Manual, D4042 - Contains on-line operating instructions
User's ACCOL load - Contains RTU configuration data

• = ACCOL Tools for DOS Version 5.13 or Workbench 5.13 or later.

4.3.2 General Startup Procedure

After performing the steps listed under PRELIMINARY CHECKS on page 4-1, proceed as
follows:

1. Turn on the external supply source (24V or 12V) that powers the RTU. Using a
DMM (Digital Multimeter), check the external supply for the correct output voltage.
If the supply is adjustable, set the DC output to its proper output level.

2. When power is applied, the Power Fail Indicator (PFIN*) LED (DS17) on the PMPP
Board should light to indicate the presence of the +24V (or +12V), +18V, -18V, +5V
and 32V (for 24V systems & DI/O) or +21V (for 12V systems) dc supply outputs. If
DS17 does not light, it may indicate a blown fuse. Check fuse F1 on the MI/OB and
replace it if necessary. If Fuse F1 continues to blow, recheck wiring at the signal
ter-minals for a possible short. Further details are covered in "Section 5 Service."

3. When the RTU is operating, the MASTER CLEAR indicator (MC*) LED (DS16) on
the PMPP Board should be continuously lit to indicate that the supply is performing
properly.

4-2 / Operation 3305 RTU


4. If an ACCOL load has not been installed, the RTU will execute an internal
diagnostic startup test upon powerup. This type of startup is called a "cold start"
and it is identical to the sequence that is executed once the Reset Button (SW2) on
the PMPP Board has been pressed.

Warning

An RTU that has not been loaded (or one that has been reset)
will provide defaults of 0% for analog outputs, and OFF for all
discrete outputs. For some critical processes, these defaults
could represent dangerous output levels. Critical processes
should in-clude automatic/manual control stations or limiting
devices to maintain safe operation during startups or power-
downs.

5. The internal RTU diagnostic test cycle can be observed on the status LEDs of the
PMPP Board. In general, LEDs DS10 through DS15, as well as the WATCHDOG
LED (DS18), will be lit throughout the test sequence. A momentary flash at the
beginning of the sequence signifies the initiation of the RAM diagnostic test cycle.

Any failure detected during testing will cause the IDLE/RUN LED (DS9) indicator
on the PMPP Board to turn ON. At the same time, the lighting pattern of status
LEDs DS10-DS15 will display the type of failure.

If the battery voltage is low, there will be a momentary flashing LED sequence,
after which the diagnostic cycle will resume.

During the next part of the test, LEDs DS10-DS15 will go off for 1 second, on for 1
second, then go off for 1 second. The status of the 3305’s I/Os, if any, is then
displayed. Details are contained in Chapter 5 Service.

6. Full completion of the diagnostic test cycle is indicated by a "ripple" pattern


whereby each STATUS LED is turned on and off in sequence beginning with LED
DS15 and ending with LED DS10.

At this point a 3305 RTU which has previously received download FLASH memory
will execute it’s ACCOL load. The WATCH-DOG LED (DS18) should turn OFF and
the IDLE/RUN LED (DS9) should be blinking.

A unit which does not have the ACCOL load installed, will wait to be downloaded.
It’s WATCHDOG LED will remain on until a download is performed. See Chapter 5
for a list of failures that can be displayed on STATUS LEDs DS10-DS15 when a
3305 RTU unit is waiting for a download.

7. In order to download locally or globally to a 3305 RTU, there must be a communications


path from the external device (PC or supervisory computer) to any of the 3305’s four
Comm. Ports. Port A will default to 9600 baud for a "cold start" download. The
download baud rate for ports B, C and D is selectable via soft switch settings in the
BBI SYSTEM CONFIG/FLASH DOWNLOADER program. A RAM or FLASH down-
load can be initiated using AIC, TOOLKIT, Open BSI Downloader or the DIAGNOSTIC
software program utilities

3305 RTU Operation / 4- 3


A local download is typically initiated from a PC connected directly to a local RS-232
port. A global download is typically initiated from a supervisory computer or PC
positioned at a higher echelon of the network and directed downward to a target
node (The required network files must be present at the originating device in order
to perform a global download). Refer to User Manual D4042, ACCOL II Interactive
Compiler for download procedures.

8. When the download is complete, the RTU will begin executing the ACCOL load. At
this stage the WATCHDOG LED will turn OFF and the IDLE/RUN LED will blink.
Note: The IDLE/RUN LED will be OFF when the processor is executing and ON
when the processor is idle.

Once a download is complete, all RTU communication ports will take on the usage
and characteristics specified by the user in the ACCOL load. For example, if "port
A" was used for a download but it turned out that no functions were specified for
"port A" in the load, the communications between the RTU and the external loading
device will be lost when the download is complete. Similarly, if the baud rate used
for the download is different from the baud rate specified for that port in the
ACCOL load, or if the port is not a slave/pseudo slave BSAP port it will be necessary
to modify the local link baud rate to communicate properly when the download con-
cludes.

Note
Should communications become lost or erratic
after a download, transfer the PC connection over
to the appropriately assigned port. Remember,
the ACCOL load determines the port's function!

9. Once it has received the appropriate ACCOL load file, the RTU will execute its
control program. Any manually-controlled process valves and operating devices that
were previously set to a guarded condition may now be set to their operating
positions. If automatic-manual control panels are included in the installation, their
operating mode should now be switched from manual to automatic control.

10. The startup procedure is now complete. The RTU should be performing the user
functions programmed into the ACCOL load.

The on-line activities can be monitored in various ways depending on the user's con-
figuration. For example, a PC can be connected to a Slave or Pseudo-Slave port and
the AIC or TOOLKIT software utilities can be used to communicate with the unit.

11. Cold Starts: If the Manual Reset button is pressed, the RTU will perform a "cold
start" (i.e. the RTU will execute its diagnostic startup sequence and, if it has lost its
ACCOL load (as it would in a RAM-based unit), it will wait for a new download).

Caution

Prior to initiating a “Reset,” make sure that any critical process functions
associated with the RTU have been turned off or placed under guarded
manual control.

4-4 / Operation 3305 RTU


12. Warm Downloads: A running RTU can be reloaded at any time without doing a
manual reset. This procedure is called a "warm download." When the download
procedure is initiated from a supervisory computer or a PC, the target RTU will
Watchdog momentarily and then begin accepting the new load. The RTU diagnostic
startup cycle, in this situation, does not execute.

Note:

The baud rate for a “warm download” is determined by the on-line ACCOL
load currently executed by the RTU.

13. Warm Start: A running RTU will resume execution of the active load after a power-
fail providing that RAM data has been preserved via the battery backup. This is
called a "warm start." The active environment is saved when the power fails, and is
resumed when the power is restored. The diagnostic startup cycle is not executed for
this type of startup. Note that RAM backup batteries are required for both RAM
and FLASH based units in order to successfully Warm Start.

4.4 SHUTDOWN PROCEDURE


The procedure for shutting down an RTU will vary with the user’s application. The fol-
lowing steps provide a general check list.

1. If critical processes are involved, close down all related process elements, valves,
switches, etc. as required. If the installation includes user-supplied, manual control
panels, switch them over to manual control and bring the processes to a safe stand-
by level; then close each process down as required.

2. Turn off the associated power source.

3. Turn off all associated signal power sources.

Warning

High voltages may still be present at the field wiring terminals even though
the RTU is OFF. This voltage can emanate from sources that are used to
power external devices such as Discrete Inputs. Make sure that all external
power sources are turned off or disconnected before working in these areas.

4. When the RTU is shut down, the contents of RAM will be retained because of the
RAM battery backup system. This battery provides RAM retention for a period of
approximately 4000 hours (167 days). If the RTU is not powered up within that time
frame, the battery will become completely discharged and the RAM data will be lost.
If it is planned to shut the equipment down for an extended period of time, the
backup battery should be disconnected (Jumper W7 on the Power Supply/CPU
Board installed in position 2 to 3) to prevent unnecessary current drain. Conversely,
the battery must be reconnected just before the equipment is restored to service.

Before disconnection the battery, it is recommended that the user ensures that a
backup copy of the ACCOL load is available (not required for FLASH-based RTUs).

3305 RTU Operation / 4- 5


A RAM-based RTU that has been turned off and left dormant under these
conditions will require a reload upon startup. A FLASH-based RTU will
automatically restart its ACCOL load upon completion of the startup diagnostics.

5. The shutdown procedure is now complete.

4.5 USING THE BBI SYSTEM CONFIG/FLASH DOWNLOADER PROGRAM

The BBI System Config/FLASH Downloader Program is required for configuring the RTU
3305’s Soft Switches, i.e., the switches associated with ACCOL communications
parameters. This program allows the user to change configurations options (node address,
cold download baud rates, FLASH RAM ACCOL selection, etc.) as-well-as enabling the
download of system and/or custom firmware to FLASH, and/or forcing units equipped with
level LB501 (or higher) boot firmware into UPDUMP mode. The ACCOL parameters to
configure include the following:

• Node Address
• Cold Download Parameters
• Updump ability
• FLASH or RAM based ACCOL loads
• ACCOL FLASH Lock
• Standard or Expanded BSAP Slave
• Group Number
• Normal or Debug Operation

NOTE: This configuration may also be performed using the LocalView Utility in
OpenBSI (see chapter 5 of the OpenBSI Utilities Manual - D5081).

As part of the installation of a 3305 RTU, it is necessary to configure the 3305’s Unit Con-
figuration Parameters (Soft Switches). To begin configuration, start the BBI SYSTEM
CONFIG/FLASH DOWNLOADER Program. The initial menu will be displayed.

Figure 4-1
System FLASH Download/Parameter Configuration Entry Menu of

• The Select a File To Download Poke Point


When the Select a File To Download poke point is selected (highlight poke point and
press the Insert key), a new display appears that provides a lists of available binary
files (files with .BIN extensions). The user must select the files he wants to load and

4-6 / Operation 3305 RTU


then press the Insert Key. The program will return to the menu of Figure 4-1 and
will provide the user the .BIN file(s) selected. If the user has no idea of the .BIN file
name(s) required for a new system firmware download, then the Select a File To
Download poke point should be selected prior to using the Configure System
Parameters poke point.

• Download System Flash Poke Point


The Download System Flash poke point is only applicable when the System
Parameter Configuration Menu has been entered and the exit config/FLASH
DOWNLOAD poke point has been selected.

• The Configure System Parameter Poke Point


The Configure System Parameter poke point is chosen to set the 3305’s Soft Con-
figuration Switches displayed in Figure 4-2. Selection of this poke point is also
required to initiate a System Firmware download to 3305 FLASH Memory.

• The Reconfigure Communications Set-up Poke Point


The Reconfigure Communications Set-up poke point is used to set the current com-
munications parameters for the connection with the PEI

• The EXIT Poke Point


The EXIT Poke is used to exit out of the BBI SYSTEM CONFIG/FLASH DOWN-
LOADER Program.

Figure 4-2
System Parameter Configuration Menu

• Node Address (Default = 127)


The Node Address is a value from 1 to 127 (with 127 being the default).

• Group Number (Default = 0)


The Group Number (0 to 127) selects the relative group of the 3305. Normal BSAP
messages occupy group zero. When expanded BSAP is selected, the Group Number
identifies the group in which the unit resides. If standard BSAP is selected, the
Group Number will default to zero (0).

3305 RTU Operation / 4- 7


• RAM/FLASH ACCOL Load (Default = RAM)
The RAM/FLASH ACCOL Load field selects where the ACCOL load will be stored
when downloaded, i.e., in FLASH where it will reside until it is changed by another
download, or in RAM where it resides as long as power is applied (from system
power or battery backup). An ACCOL load stored in FLASH is copied into and
executed out of RAM.

• ACCOL Flash Lock (Default = Locked)


The ACCOL Flash Lock feature gives the user the ability to prevent a FLASH-based
ACCOL load from being overwritten accidentally. With this feature enabled (locked)
(the default state), all ACCOL downloads will be rejected; however, if the unit
detects that there is no ACCOL load currently in FLASH, it will allow the ACCOL
load to be downloaded to the 3305 RTU.

• Std/Exp BSAP (Default = Standard)


The Standard or Expanded BSAP Slave option allows the user to select the mode for
the BSAP slave port, i.e., either standard or expanded). If the standard mode is
selected, Group Number will have no meaning and the unit is assumed to reside in
Group 0. When the expanded option is selected, the Group Number defines the
group in which the unit resides. In a BSAP Master/Slave network, the first 127
nodes connected to a single master reside in Group 0.

• Cold Download Rate (Default = 9600)


The Cold Download Rate option defines the parameters associated with Ports B, C
and D for the Cold Download baud rate (Port A defaults to 9600). The available
baud rates are: 1200, 2400, 4800, 9600, 19200 and 38400 baud. The list of values
will be provided to the BBI SYSTEM CONFIG/FLASH DOWNLOADER
Program Software after a connection has been established. The chosen baud rate
takes effect during a reset of the unit. Once downloaded, the ACCOL load controls
the rate and function of each port.

• Updump (Default = Disabled)


The Updump option is reserved for factory use only. Note: The Updump Option must
be OFF. Do NOT enter updump mode following reset unless so directed by a
representative of BBI.

• Diagnostic Msgs (Default = Enabled)


Diagnostic Messages (available through a separate “Terminal Emulation” program
such as PROCOMM or equivalent) (see Chapter 5 SERVICE) can be enabled or
disabled. via the Diagnostic Msgs poke point.

• Put RTU in Updump State and exit FLASH (Poke Point)


This poke point is only available (viewed) on 3305s that are equipped with boot
firmware level LB501 and higher. Selection of this poke point should only be
performed for debugging purposes under direction from BBI. When this poke point
has been selected, the menu will post the following message:

4-8 / Operation 3305 RTU


“Put RTU in Updump and exit? _”

Type Y for yes if BBI has instructed you to perform this procedure, otherwise type N
for no.

• Make Changes (Poke Point).


When the Make Changers poke point is selected the changes made so far are
automatically loaded into 3305 system firmware. Pending changes can also be
loaded into the RTU 3305 at any time by pressing the F4 key. When the F4 key has
been pressed the following message will appear on the bottom of the menu:

Changes are pending. Change the target before exiting?


At this point the user can press in Y for yes, N for no, or the Insert key (for yes). If
Changes will be downloaded and the program will display the previous menu, i.e.,
the SYSTEM FLASH DOWNLOAD/PARAMETER CONFIGURATION ENTRY
Menu (Figure 4-1). However; if the N key is pressed, the current pending changes
will not be made and the menu of Figure 4-1 will be displayed.

• EXIT CONFIG/Flash download (Poke Point)


The EXIT CONFIG/Flash download poke point sets the exit mode from this menu.
Uppercase indicates the mode selected. Use the Insert or Enter key to switch
between selections. A System Firmware FLASH download is required when new
3305 system firmware has been issued by BBI for field upgrade installation. Use the
Insert key to change this prompt to exit config/FLASH DOWNLOAD if a system
download is desired. If EXIT/CONFIG mode is selected (and the F4 key is pressed),
the System Parameter Configuration Menu is exited and the System FLASH
Download/Parameter Configuration Menu is displayed. If FLASH DOWNLOAD
mode is selected (and the F4 key is pressed), the program enters the download mode
and the selected firmware file is downloaded into the RTU 3305. If a file has not
been selected, the system will prompt the user for the file to be Flashed.

4.5.1 Downloading Standard System or Custom System Firmware

A system Firmware FLASH download is required when new 3305 system firmware
been issued by BBI for field upgrade installation or if the pre-installed firmware has
been lost for some reason.

1. Connect the PEI to Port A on the Power Supply/CPU Board and apply power to the
PEI and the 3305 RTU. Note: Ports A and D default to a rate of 38.4K baud, but will
automatically fall back to 19.2K baud if required by handshake routine (transparent
to user). Only Ports B, C and D are configurable via the Soft Switches. Evoke the
BBI SYSTEM CONFIG/FLASH DOWNLOADER software.

2. Select the CONFIG. SYSTEM PARAMETER Poke Point on the SYSTEM FLASH
DOWNLOAD/PARAMETER CONFIGURATION ENTRY Menu (see Figure 4-1) and
press the INSERT key

3. Within 30 seconds, press the Reset Button (SW2) on the 3305’s Power Supply/CPU
Board or turn OFF and then ON the system power. This action will evoke the
SYSTEM PARAMETER CONFIGURATION Menu (see Figure 4-2) on the PEI.

3305 RTU Operation / 4- 9


4. Make the changes that are required to configure the soft switches. Change the EXIT
CONFIG/Flash download poke point to exit config/FLASH DOWNLOAD and press
the PF4 key. The BBI SYSTEM CONFIG/FLASH DOWNLOADER PRO-GRAM and
the 3305 now enter the download firmware mode and the menu of Figure 4-1 will be
displayed.

5. If a .BIN file was already selected, download will begin. Otherwise, select the
desired .BIN file at the prompt, e.g., LS500.BIN, STP08.BIN and press the INSERT
key. If the file names are not known use the Select A File To Download poke point
and choose the file(s) to be downloaded. Download of the firmware should begin.
Wait for the download to complete.

4.5.2 Download An ACCOL Load into FLASH Memory

1. Perform steps 1 through 3 of section 4.5.1.

2. Set the Ram/Flash Accol Load poke point to FLASH. This will cause the 3305 to
store the next ACCOL load into FLASH memory.

3. In order for the load to successfully download, the ACCOL Flash Lock poke point
must be set to UNLOCK. If this poke point is set in the LOCK state, the 3305’s
system firmware will reject the download request and post an error message.

4. If required, change the exit config/FLASH DOWNLOAD poke point to read EXIT
CONFIG/Flash download. Press the F4 key. Exit from the tool. If a load already
exist in FLASH memory from a previous download, the 3305 will perform a Cold
Start and then start running that load.

5. Select the desired ACCOL load download tool and activate it.

6. Select the desired ACCOL load file and select download option. Acknowledge the
confirmation prompt, if presented. Download of the ACCOL load should begin. Wait
for the download to complete. The ACCOL load will be placed into FLASH memory.

Note:
All subsequent ACCOL loads downloaded while this configuration is
active will be placed into FLASH memory, over writing the previous
load in the FLASH memory. To prevent over writing the load in
FLASH memory, change the ACCOL Flash lock poke point to the
LOCK state.

4.5.3 Download An ACCOL Load into RAM

1. Perform steps 1 through 3 of section 4.5.1.

2. Set the Ram/Flash Accol Load poke point to Ram. This will cause the 3305 to store
the next ACCOL load into RAM memory, over-writing any previous ACCOL load in
the RAM. The state of the ACCOL Flash Lock poke point has no effect on a RAM
download.

4-10 / Operation 3305 RTU


3. If required, change the exit config/FLASH DOWNLOAD poke point to read EXIT
CONFIG/Flash download. Press the F4 key. Exit from the tool. If a load already
exist in FLASH memory from a previous download, the 3305 will start that load.

4. Select the desired ACCOL load download tool and activate it.

5. Select the desired ACCOL load file and select download option. Acknowledge the
confirmation prompt, if presented. Download of the ACCOL load should begin. Wait
for the download to complete. The ACCOL load will be placed into RAM memory.
The ACCOL load in FLASH (if any) is not disturbed.

Note:
All subsequent ACCOL loads downloaded while this configuration is
active will be placed into RAM, over writing the previous load.

4.5.4 Using BBI System/Flash Downloader Program Diagnostics

To use the BBI System/Flash Downloader program’s diagnostic capabilities, the PEI
will have to be equipped with a Terminal Emulation program such as SMARTCOM
or PROCOMM.

1. Connect the 3305’s Port A to the PEI. Evoke the BBI System Config/Flash Down-
loader Program and set the Diagnostic Msgs poke point to ON. If required, change
the exit config/FLASH DOWNLOAD poke point to read EXIT CONFIG/Flash down-
load. Press the F4 key. Exit the BBI System Config/Flash Downloader program. The
3305 will now send diagnostic messages to the PEI whenever a Master Reset or
Power Up occurs.

2. At the PEI, enter terminal emulation mode and configure the program (PROCOMM,
SMARTCOM, etc.) for 9600 Baud, 8 data bits, 1 stop bit, no parity for the
appropriate communications port of the PC, i.e., either COM1 or COM2. Set the
program to receive ASCXII data. Since the messages will scroll by quickly, you may
want to store the data to an ASCII file for comparison against expected results, e.g.,
SELFTEST.LOG.

3. Power on the 3305 (if off) or reset it. The general sequence of messages is
notification of start of a test followed by successful completion or failed status. For
example, the selftest RAM diagnostic, displays the segment as-well-as the starting
and ending offsets as each block is successfully tested. For both Make RAM (upper
512 bytes of BASE RAM) and SELFRAM, failure is identified to the component level
(socket designation) where:

Byte Addr Range Chip


Odd 20000h - 5FFFFh U33
Even 20000h - 5FFFFh U34
Odd 60000h - 9EFFFh U36
Even 60000h - 9EFFFh U38

3305 RTU Operation / 4- 11


The message sequence ends if a failure occurs, or ends with notification of start of
MI/OB board testing if no hard failures have occurred. Section 5.2.2 provides the
message sequence when the unit self-test is successful.

Diagnostic messages and associated source files for each diagnostic area are
provided below.

MAKE RAM DIAGNOSTICS

DGSELF.ASM
mk_ram_pass: “Make RAM Diag Success”

DGGOX.ASM
u33_fail-str: “Make RAM Diag - RAM chip U33 failed”
u34_fail_str: “Make RAM Diag - RAM chip U34 failed”

NOTE: There is no make RAM diag start message.

SELFTEST RAM DIAGNOSTICS

SELFRAM.ASM
ib1: “Self Test RAM Diag”

sarm-pass: “passed”
u33_fail_str: “RAM chip U33 failed”
u34_fail_str: “RAM chip U34 failed”
u36_fail_str: “RAM chip U36 failed”
u38_fail_str: “RAM chip U38 failed”
ib1: “Self test Ram Diag”

SYSTEM BATTERY/RTC INTERNAL BATTERY DIAGNOSTICS

DGBAT.ASM
ib_start_str: “System Battery diag start”
ib_fail_str: “WARNING - Sys,Btry. Low or Dead (or not enabled)”
ib_succ_str: “System Battery diag success”
rb_start_str: “RTC Internal Battery diag start”
rb_fail_str: “WARNING - RTC Internal battery Dead”
rb_succ_str: “RTC Internal Batery diag success”

RTC/PIC DIAGNOSTICS

DGRTC.ASM
start_str: “RTC/PIC Diag start”
succ0_str: “RTC Diag success”
succ1_str: “PIC Diag success”
fail0_str: “RTC Diag failed”
fail1_str: “PIC Diag failed”

4-12 / Operation 3305 RTU


PROM DIAGNOSTICS (SYSTEM/CUSTOM/ACCOL)

DGSELF.ASM
rm_diag_strt: “PROM Diagnostics Strt”
prm_diag_ok: “System PROM Diag Success”
prm_diag_fail: “System PROM Diag failed”
aclflash_fail: “ACCOL PROM diag failed”

DGPROM.ASM
aclflash_pass: “ACCOL PROM Diag Success”
aclflash_inv: “ACCOL PROM Diag bypassed - no valid load”
cstprom_pass: “Custom PROM diag Success”
cstprom_warning: “Custom PROM Warning - Checksum Failed”

TIMER 2 DIAGNOSTICS

DGSELF.ASM
tmr2_diag_strt: “Timer 2 Diag Strt”
tmr2_diag_ok: “Timer 2 Diag Success”
tmr2_diag_fail: “Timer 2 Diag Failed”

CPU CLOCK SPPED DIAGNOSTICS

DGSELF.ASM
cpuspd_start-str: “CPU Speed Diag start”
cpu-succ-srt: “CPU running at 12 MHz”
cpu-fail-str: “CPU Speed Diag Failed - Clock speed unknown”

DMA DIAGNOSTICS
DGDMA.ASM
dma-start-str: “DMA Diag start”
dma-success: “DMA Diag success”
dma-fail: “DMA Diag Failed”

I/O BOARD DIAGNOSTICS


DGSELF.ASM
io_diag_strt: “I/O Board Diag Start - See LED pattern for status”

3305 RTU Operation / 4- 13


BLANK PAGE
Section 5
SERVICE

5.1 SERVICE INTRODUCTION


This section provides general, diagnostic and calibration test information for the Model
3305 RTU.

The service procedures described herein will require the following test equipment:

1. PC with BBI’s WINDIAG Software


2. BBI Cable P/N 395414-02-4 (Port A)
3. BBI Cable P/N 390486-03-5 (Ports B, C & D)
4. DMM (Digital Multimeter): 5-1/2 digit resolution
5. Oscilloscope: 10mV to 10V per division sensitivity; 100 to 200 MHz vertical frequency
response; 1 mSec to 1 Sec/division time base.
6. Variable DC Supply: Variable to 30Vdc ± .001Vdc.
7. Two 250-Ohm ±.01% Resistors (AO Calibration)

Accurate measurements will require properly shielded test leads. All test equipment
measurements described in the text are referenced to power ground (PCOMM) unless
specified otherwise.

When RTUs 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 ac-
cidentally losing control when test are conducted.

Warning
Harmful electrical potentials may still be present at the field wiring
terminals even though the RTU’s power source may be turned off or
discon-nected. 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
Never attempt to install or remove any modules (plug-in boards) from an
RTU while it is powered and running. Doing so can cause sudden
electrical transients or imbalances that are capable of causing damage to
the module itself, as-well-as other associated circuit boards. Always turn
off the Main power, including any additional supply sources used for ex-
ternally-powered I/O circuits, before changing any modules.

5.1.1 Accessing PC Boards For Testing

Testing and replacement of PC boards should only be performed by technically-qualified


persons having advanced mechanical and electrical skills and possess the service equip-
ment described in the text. It is important that the reader study the disassembly and test

3305 RTU Service / 5- 1


procedures described in this manual before starting. Any damage to the RTU 3305
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 Babcock (with prior authorization from Bristol Babcock)
for factory evaluation and repairs.

Caution

PC board components can be damaged by electrostatic


discharges (ESD) during disassembly/reassembly and test
procedures. Use grounded wrist straps and surface pads when
working near or handling circuit boards. See attached instruc-
tion supplement S14006 for proper grounding and handling
techniques.

5.1.2 Removal/Replacement of the PMPP Board

1. Place any critical control processes under manual control and shut down the RTU
3305.

2. Disconnect power wires from TB3 pins 1 & 2 or pull off Terminal Plugs A1 and B1.

3. If a Network Communications Option Board is installed disconnect its power from


TB3 pins 1 and 2 and disconnect its connection to PORT C, i.e., P4 on the MI/OB
Board. If the Local LCD Display option is installed disconnect its ribbon cable
connector from P3 on the Backplane Board.

4. Remove the four screws (A) that secure the Name Plate/LCD Module to the four
mounting standoffs (see Figures 5-1 & 5-2) and remove the Name Plate/LCD
Module.

5. If a Network Comm. Option Board is present, remove the Name Plate/LCD Module
standoffs (B) (see Figures 5-1 & 5-2) and remove the Network Comm. Option Board.

6. Remove the four screws that secure the Option Mounting Brackets (C) (2 each) to
the Baseplate (see Figures 5-1 & 5-2) and remove these two brackets.

7. Disconnect the PMPP Board Port B TTL Connector (J1) from the MI/OB Connector
P2. Disconnect PMPP Board Connector J4 from MI/OB Board Connector P1.

8. Remove the four screws (D) that secure the PMPP Board to the PMPP Board
Mounting Standoffs (E).

9. Slide the PMPP Board away from the Backplane Board and carefully remove the
PMPP Board.

10. To replace the PMPP Board follow steps 1 through 9 in reverse order.

5-2 / Service 3305 RTU


Figure 5-1 - 3305 Board Removal/Replacement Diagram

3305 RTU Service / 5- 3


Figure 5-2 - 3305 with Top Plate/Options Removed

5.1.3 Removal/Replacement of the MI/OB Board

1. Perform steps 1 through 9 of section 5.1.2 (see Figures 5-1 & 5-2).

2. Remove the unpluggable I/O Terminal Blocks from the MI/OB’s card edge con-
nectors.

3. Remove the two short screws (G) that secure the MI/OB Board to the lower two
MI/OB Mounting Standoffs (F) (see Figures 5-1 & 5-3).

5-4 / Service 3305 RTU


4. Remove the Medium Length Standoffs (E) that secure the MI/OB Board to the
middle two and upper two MI/OB Mounting Standoffs (F) (see Figure 5-1).

Figure 5-3 - 3305 with Top Plate/Options & PMPP Board Removed

3305 RTU Service / 5- 5


5. Slide the MI/OB Board away from the Backplane Board and carefully remove the
MI/OB Board.

6. To replace the MI/OB Board follow steps 1 through 5 in reverse order.

5.1.4 Removal/Replacement of the Backplane Board

1. Perform steps 1 through 9 of section 5.1.2 to remove the PMPP Board.

2. Perform steps 1 through 5 of section 5.1.3 to remove the MI/OB Board.

3. Remove the Backplane Board by sliding it out of its Card Guides/Holders.

4. To replace the Backplane Board perform steps 1 through 3 in reverse order.

5.2 DIAGNOSTIC TEST PROCEDURES


Testing and calibration are performed using Self-Test and Off-Line methods. Self-tests are
described in sections 5.2.1 and 5.2.2. Off-Line tests are described in section 5.3.

5.2.1 Self-Test Diagnostics (PMPP Board Status LEDs)

LEDs on the PMPP Board (see Figure 5-4) provide an indication of the RTU's operating
condition. The WATCHDOG and IDLE/RUN LEDs display the status of the CPU, while
LEDs DS10-DS15 display diagnostic faults.

Some general observations should be noted. The WATCHDOG LED (DS18) will turn ON at
power-up (or when the RTU is reset) and turn off as soon as the RTU starts executing an
ACCOL load; this LED will remain off as long as the system is functioning normally.
Should this LED turn on during operation, it indicates that a CPU failure has occurred or
that the system has been reset. The IDLE/RUN LED (DS9)will also turn on to indicate that
system activity has halted.

The IDLE LED provides an indication of the activity level of the system. When this LED is
on, it indicates that the CPU is in a "halted" or "idle" state. When it is off, it indicates that
the CPU is busy.

LEDs DS1 through DS8 provide port status (see Figure 5-4).

LEDs DS10 through DS15 are used during a "cold start" to convey information on failure
detection and I/O Module configuration. The failure patterns for these LEDs are given in
Table 5-1.

LED DS16 (MC*) will indicates that Master Clear (NOT) is inactive when it is in the ON
state while LED DS17 (PFIN*) in the ON state indicates that a power fail has not
occurred. These LEDs should remain ON during normal operation and will go OFF if the
+5V, +12V or input voltage go out of specification. LEDs DS16 and DS17 will remain OFF
until the +5V, +12V and input voltage are all within specification.

5-6 / Service 3305 RTU


When using Table 5-1, note that it is organized into five categories: CPU/Internal Perip-
herals, External Peripherals, I/O Modules, Download Communication Initialization, and
Configuration. Tests in all categories (except Download Comm. Initialization) can be
initiated by pressing the Reset Button for a "cold start." Tests in the Download Comm.
Initialization category are automatically initiated when a DPC with RAM-based memory is
preparing for a download (either a cold or warm download).

Figure 5-4 - Processor Memory Peripheral Power Supply (PMPP) Board

3305 RTU Service / 5- 7


The diagnostic test sequence for RTU 3305s runs as follows:

1. The system is initially powered up or manually reset (cold start) by the user. The
WATCHDOG LED will turn ON and all six (6) status LEDs (DS10 - DS15) will be
ON.

2. The CPU Registers, identified in Table 5-1, are the first items to be tested. If a
failure is detected, the test will halt and the IDLE/RUN LED will turn ON. The
STATUS LEDs will simultaneously display the failure pattern shown for this con-
dition in the table: 0-0-0-0-0-1, where 0 is OFF and 1 is ON.

3. Assuming there was no failure in step 2, the Make-RAM test is executed next (tests
are not in the same sequence shown in the table). This test checks a portion of the
RAM to be used as a working stack during subsequent tests. The PIC (Program-
mable Interrupt Controller) is tested to verify that interruptions required for RAM
testing are available. The full RAM test is then executed. If there are any failures,
the IDLE LED will turn ON and the STATUS LEDs will display one of the patterns
given in Table 5-1.

4. The remaining diagnostic tests are then executed in the following order:

RAM Backup Battery


RTC (Real Time Clock) Battery
RTC - includes External PIC test.
PROM (FLASH)
Internal Timer
DMA (Direct Memory Access H/W)

5. Any failures are displayed as described in the previous steps with the exception of
the battery tests and the Custom PROM test. If the RAM battery is weak or defec-
tive, a different pattern will be displayed: 0-1-0-0-X-X. In this pattern, LED DS14
will be ON, LEDs DS15, DS13 and DS12 will be OFF, and LEDs DS10 and DS11
will blink for a short period of time. Note that a defective battery will not halt this
test. The diagnostics will proceed to the next test.

In the next test, the I/O Module slots are interrogated and tested as required. All
I/O circuitry is contained on the MI/OB Board and with respect to System Firmware
is organized as follows: Slot 1 = DIs, Slot 2 = DOs, Slot 3 = AIs, & Slot 4 = AOs.

At the conclusion of the I/O tests, LEDs DS10-DS15 will turn OFF for 1 second,
then turn ON for 1 second, and then OFF again for 1 second. The status of the I/O
Module interrogation is then displayed on LEDs DS10-DS15. The status for slots 1
through 6 is displayed as follows: LED DS15 indicates the status for slot #1, LED
DS14 for slot #2 ... and LED DS10 for slot #6. A LED will turn ON for each slot
having a module installed, providing that the module's self test was successful. The
LEDs for all unoccupied or failed slots will be OFF.

After displaying the status for slots #1-6, all six LEDs will go OFF for 1 second. The
status for slots #7-12 will then be displayed using LED DS15 to indicate the status
for slot #7, LED DS14 for slot #8 ... and LED DS10 for slot #12.

5-8 / Service 3305 RTU


If no I/O Modules are installed, LEDs DS10-DS15 will remain OFF for several
seconds between the completion of the diagnostic test cycle and the final "ripple"
pattern described in step 6.

Table 5-1 - Power Supply/CPU Board Diagnostic LED Failure Indications

TEST DS15 DS14 DS13 DS12 DS11 DS10


CPU/INTERNAL PERIPHERALS FAILURES:

CPU Registers 0 0 0 0 0 1
Internal Timer (IT) 2 0 0 0 0 1 0
Internal PIC 0 0 0 0 1 1
DMA 0 0 0 1 0 0
Internal Timer 0 & 1/Incorrect CPU 0 0 0 1 0 1
Speed
NPX present with Software Library 0 0 0 1 1 0
link* or NPX not present with
Hardware link.
Error Programming ACCOL FLASH 0 0 0 1 1 1

EXTERNAL PERIPHERALS FAILURES:

System RAM 0 1 0 0 0 1
System Low Battery Warning* 0 1 0 0 X X
Redundancy Registers 0 1 0 1 0 0
Redundancy RAM 0 1 0 1 0 1
System/ACCOL PROM 0 1 1 0 0 0
Custom PROM Warning* 0 1 1 0 X X
Make RAM (System RAM upper 512) 0 1 1 0 0 1
Real Time Clock (RTC) 0 1 1 0 1 1
RTC Internal Battery Warning* 0 1 1 1 X X

I/O MODULE STATUS:

Slot Nos. - > #1 #2 #3 #4 #5 #6


First Display T T T T T T

Slot Nos - > #7 #8 #9 #10 #11 #12


Second Display T T T T T T
(see Note 2 below)

DOWNLOAD COMM. INITIALIZATION


FAILURES: (RAM based units only)

Port A/B Failed 1 0 0 0 0 1


Port C/D Failed 1 0 0 0 1 0
Example: Ports A & B Failed 1 0 0 0 0 1
CONFIGURATION ERRORS:

Load Version Fail 1 1 0 0 0 1


Memory Configuration Error 1 1 0 0 1 0
-ACCOL load too large for Flash
PROM.
Note 1: * = This is only a warning the unit doesn't stop.
Note 2: If there is an I/O Module in the indicated slot and the module has
passed the self test (if applicable), the corresponding LED will be
ON. If the I/O Module didn’t respond (slot is unoccupied/unassigned

3305 RTU Service / 5- 9


or the module has failed its self test), the LED will be OFF. With
respect to system firmware and the ACCOL load, the 3305’s I/O Slots
are assigned as follows: Slot 1 = DIs, Slot 2 = DOs, Slot 3 = AIs and
Slot 4 = AOs.

6. The conclusion of the above test cycle is indicated by a "ripple" pattern on the
STATUS LEDs that sequences from LED DS15 through LED DS10. All six LEDs
will then be turned OFF. At this time, an EPROM-based DPC will begin executing
its ACCOL load, while a RAM-based DPC will check and initialize its ports to
prepare for a download. LEDs DS14 to DS10 will identify the port status as shown
in Table 5-1; active or vacant ports will be indicated by an OFF LED, while a
defective port will be indicated by an ON LED. If there is one or more defective
ports, LED DS15 will be ON for this test. The IDLE/RUN LED will also be OFF for
this test since the CPU will remain busy monitoring all of the ports for a download
sequence.

7. Configuration errors are indicated prior to the completion of the download if LEDs
DS14 and DS15 are ON. LED DS10 in an ON state indicates a load version failure.
If LED DS11 is ON, the probable cause is that the ACCOL load is too large for
FLASH.

8. At the completion of the download, the LEDs DS10-DS15 and the WATCHDOG
LED will turn OFF. The IDLE/RUN LED will start blinking to indicate the activity
level of the ACCOL load.

5.2.2 Startup Diagnostics Using a Terminal Emulator

By connecting Port A (Local/Diagnostic Port) to a PEI (Process Engineer’s Interface), i.e., a


computer equipped with Terminal Emulation Software such as WINDOWS TERMINAL,
PROCOMM, SMARTCOM, etc. and the BBI SYSTEM CONFIG/FLASH DOWNLOADER
Software (see Figure 5-5 and section 4.5.4) the following startup diagnostic sequence can be
observed upon successful completion of the startup sequence:

Make RAM Diag Success

PIC Diag Start


PIC Diag Success

Self Test RAM Diag - 504K RAM Present


Sgmt Strt End
2000 0000 7FFF Passed
2000 8000 FD5F Passed
3000 0000 7FFF Passed
3000 8000 FFFF Passed
4000 0000 FFFF Passed
5000 0000 FFFF Passed
6000 0000 FFFF Passed
7000 0000 FFFF Passed
8000 0000 FFFF Passed
9000 0000 DFFF Passed

5-10 / Service 3305 RTU


CPU Speed Diag Start
CPU Running at 12 MHz

System Battery Diag Start


System Battery Diag Success

RTC Internal Battery Diag Start


RTC Internal Battery Diag Success

RTC Diag Start


RTC Diag Success
Timer 2 Diag Start
Timer 2 Diag Success

DMA Diag Start


DMA Diag Success

LCD Diag Start


4x20 LCD Is Present (see Note 1)

I/O Board Diag Start - See LED pattern for status

Note 1 This line depends on the type of LCD Module or the lack of an LCD Module.
For a 2 x 16 LCD Module, the line should read as follows:
2x16 LCD Is Present
If an LCD Module isn’t present the line should read as follows:
No LCD Device Is Present

Figure 5-5 - 3305 RTU Connected to PEI Via the Local Communications Cable

5.3 DIAGNOSTIC LOAD (DIAG05.ACL)


Detailed off-line diagnostics allow the user to perform a more extensive evaluation of the
RTU by isolating faults to specific areas such as the CPU, RAM, Serial Communications, or

3305 RTU Service / 5- 11


I/O. They also provide support for calibrating the I/O. All I/O circuitry is contained on the
MI/OB Board and with respect to ACCOL is organized as follows:

Slot 1 = DIs, Slot 2 = DOs, Slot 3 = AIs, & Slot 4 = AOs

These tests are initiated through the DIAGNOSTIC Program (DIAG0.5.ACL) (which is run
on a personal computer (Global Diagnostics are not supported, i.e., should not be done).
This program is furnished on a disk contained in the AIC software package. For a
description of these test procedures, refer to User Manual D4041A, WINDIAG - Windows
Diagnostics for BBI Controllers.

5.3.1 Testing the 3305 RTU CPU Peripherals and Comm Ports

Chapter 2 33XX & 3305 CPU and Peripherals of the WINDIAG Manual (D4041A) provides
detailed tests for the CPU internal and external peripherals. Internal Peripherals include
the Programmable Interrupt Controller (PIC), Direct Memory Access (DMA) device, and
Inter-nal Timers. External Peripherals include LEDs, the Real Time Clock, the Lithium
Battery, and the External Timers.

Chapter 3 33XX & 3305 Memory of the WINDIAG Manual (D4041A) provides detailed
tests for the CPU’s RAM and FLASH memory. It should be noted that with respect to these
diagnostic tests, the 3305 RTU’s CPU is tested like a 3330 Real Mode (386-EX). RAM &
FLASH memory is organized as follows:

! 512K bytes of System FLASH


! 504K bytes of RAM with battery backup
! 224K bytes of ACCOL Load Storage in FLASH
! 32K bytes of Boot & Configuration Firmware in FLASH

Chapter 4 33XX & 3305 Communications of the WINDIAG Manual (D4041A) provides
detailed tests for checking the 3305’s Communication Ports (A, B C & D). Loopback testing
is accommodated via switches SW1 (on the PMPP Board for Ports A, B & C) and SW1 (on
the MI/OB Board - for Port D). Loopback switch settings are provided in Tables 5-2 and 5-3
below. The ALL ASYNC Test should be performed for all Comm. Ports except Port A, since
Port A serves as the PEI connection.

Table 5-2 - PMPP Board Switch SW1 Assignments

Port ID Switch # ON Definition


Port C 1 TXD to RXD Loopback
Port C 2 RTS to CTS Loopback
Port C 3 DTR to DCD Loopback
Port B 4 TXD to RXD Loopback
Port B 5 RTS to CTS Loopback
Port B 6 DTR to DCD Loopback
Port A 7 TXD to RXD Loopback
Port A 8 RTS to CTS Loopback

The 3305 must be reset to ensure correct acquisition of communication and configuration
data. Go to the Communication Menu and set the number of passes to four (4) or higher.

5-12 / Service 3305 RTU


Note: The 3305 RTU Comm. Ports don’t operate in synchronous mode.

Table 5-3 - MI/OB Board Switch SW1 Assignments

RS-485 RS-485 Most RS-485


SW1 RS-232
Function Master Distant Other
# Operation
station Slave Slaves
1 - - - - -
ON = 232 OFF = 485 OFF = 485 OFF = 485
2 RS-232/485 Selection
Enabled Enabled Enabled Enabled
RS-484 XMTR 120S ON = ON = OFF =
3 N/A
Term. Resistor Enabled Enabled Disabled
RS485 RCVR 120S ON = ON = OFF =
4 N/A
Term. (+ Bias) Resistor Enabled Enabled Disabled
RS485 RCVR 120S ON = ON = OFF =
5 N/A
Term. (- Bias) Resistor Enabled Enabled Disabled
RS-232 TXD/RXD ON enables
6 N/A N/A N/A
Loopback Local Loopback
RS-232 RTS/CTS ON enables
7 N/A N/A N/A
Loopback Local Loopback
RS-232 DT/DCD ON enables
8 N/A N/A N/A
Loopback Local Loopback
Note: SW1-4 & SW1-5 must be set together, i.e., both must be ON to enable (install) the RS-
485 120S Receiver (Bias) Resistor.
Note: SW1 switches -6, -7 & -8 are provided for RS-232 configuration. These switches are
typically ON for test purposes and with the exception of SW1-7, are otherwise left
OFF. When Port D is connected to a PC, SW1-7 should be ON (see Figures 2-19 and
2-20).

5.3.2 Analog Input Circuitry Offset Calibration

Analog Input calibration is performed in conjunction with Section 5.3.1 of the WINDIAG
Manual (D4041A). Access to adjustable resistors on the MI/OB Board is provided by access
holes on the PMPP Board (see Figure 5-6). The Analog Input Circuitry Offset is calibrated
as follows:

1. Set MI/OB Board Jumpers W8A/B through W11A/B for 1-5V operation (see Section
2.4.3 Figure 2-11).

2. Apply 1.000V DC (0% Span) between TB2-2 (AI+)and TB2-1 (AI-) and adjust
potentiometer R143 on the MI/OB Board. From the Analog Input Diagnostic Menu
(Figure 5-4 of D4041A), select the Analog Input poke point. With 1.000V applied to
TB2-2 (AI+) and TB2-1 (AI-) and R143 properly adjusted, the Diagnostics program
will display the correct value for AI1 as 0BA hexadecimal.

3. Apply 5.000V DC (100% Span) between TB2-2 (AI+) and TB2-1 (AI-) and adjust
potentiometer R144 on the MI/OB Board. With 5.000V applied to TB2-2 (AI+) and
TB2-1 (AI-) and R144 properly adjusted, the Diagnostics program will display the
correct value for AI1 as F46 hexadecimal.

3305 RTU Service / 5- 13


4. Repeat steps 2 and 3 until the Analog Input Circuitry Offset calibration is within
specification.

5. Set MI/OB Board Jumpers W8A/B through W11A/B for the desired input con-
figuration.

5.3.3 Analog Output Circuitry Calibration

Analog Output calibration is performed in conjunction with Section 5.2.1 of the WINDIAG
Manual (D4041A). Access to adjustable resistors on the MI/OB Board is provided by access
holes on the PMPP Board (see Figure 5-6). This procedure requires one or two 250-Ohm
±.01% Resistors. The Analog Output Circuitry is calibrated as follows:

1. For AO1, connect a 250 Ohm 0.01% Resistor across Terminals TB2-10 (AO1+) and
TB2-9 (AO1-). For AO2, connect a 250 Ohm 0.01% Resistor across terminals TB2-12
(AO2+) and TB2-11 (AO2-).

2. On the Analog Output Diagnostic Menu (Figure 5-1 of D4041A), select the “Signal
Cond. Zero” poke point and press [ENTER].

3. Use the DVM to measure across the field terminals associated with AO1 or AO2
(depending on which AO is being calibrated), or use a current meter in series with
AO1+ and AO1- or AO2+ and AO2- and adjust the respective potentiometer (R95 for
AO1 & R101 for AO2) for either +1.000V dc ±0.001V or 4mA ±0.004mA.

4. On the Analog Output Diagnostic Menu (Figure 5-1 of D4041A), select the “Signal
Cond. Span” poke point and press [ENTER].

5. Use the DVM to measure across the field terminals associated with AO1 or AO2
(depending on which AO is being calibrated), or use a current meter in series with
AO1+ and AO1- or AO2+ and AO2- and adjust the respective potentiometer (R93 for
AO1 & R98 for AO2) for either +5.000V dc ±0.001V or 20mA ±0.004mA.

6. Repeat steps 2 through 5 until outputs are within specification.

7. Remove the test resistor.

5.3.4 Discrete Output & Discrete Input Tests

Discrete I/O testing is performed in conjunction with Chapter 5 of the WINDIAG Manual
(D4041A). The 3305 RTU can have a maximum of 14 DIs or 8 DOs. DI/O1-6 can be con-
figured either way, i.e., for DO or DI operation or a combination of each, e.g., DI/O1 may be
configured for DI operation and DI/O2 and DI/O3 etc. may be configured for DO operation.

5-14 / Service 3305 RTU


Figure 5-6 - Adjustable Resistors & DC Measurement Points

3305 RTU Service / 5- 15


5.3.5 LCD Display & Display/Keyboard Tests

LCD Display testing is performed in conjunction with Chapter 14 of the WINDIAG Manual
(D4041A). All four off-line diagnostic tests can be performed for the Local/Remote 2 X 16
LCD Display and the Remote 4 X 20 Display/Keyboard.

When the LCD Character ROM Test (associated with the 4 X 20 Display/Keyboard)
executes, the 4 X 20 Display should look like Figure 5-8. When the LCD Character ROM
Test (associated with the 2 X 16 LCD Display) executes, the LCD display will proceed
through the test providing three (3) sequential displays (see Figure 5-7).

Figure 5-7 - LCD Character Test for 2 X 16 LCD Display

Figure 5-8 - LCD Character Test for 4 X 20 LCD Display

5.4 POWER SUPPLY TESTS & TRIP POINT ADJUSTMENTS

5.4.1 Setting the Power Fail Trip Point (see Figure 5-6)

Resistor R11 in conjunction with Jumper W10 (both on PMPP Board) provide for setting
the Power Fail Trip Point. W10 must be installed for the 9-20V input range and must be
removed for 20-30V input range. In the case of a 9-20V (12V Battery) input supply, the DC-
to-DC Converter will shut down at 9V and will be restarted when the input supply once
again exceeds 9.5V. In the case of a 20-30V (24V Battery) input supply, the DC-to-DC Con-

5-16 / Service 3305 RTU


verter will shut down at 20V and will be restarted when the input supply once again ex-
ceeds 22V.

During a power fail (Input Power is less than 9V or 20V), the PFINT* signal is generated
to the CPU by a Sequencer which monitors a Comparitor circuit. Two milliseconds later,
MC* is generated to the CPU by the Sequencer and power will shut down. When the input
sup-ply exceeds 9.5V or 22V, the Power Fail Circuitry will once again indicate good power
and the Power Controller will be restarted. 100 milliseconds later, the PFINT* and MC*
signals will be released to take the CPU out of the reset state.

To set the Power Fail Trip Point a variable DC Power Supply is required. With power OFF,
turn R11 fully counterclockwise. Connect the variable DC Power Supply to TB3-1 (+) and
TB3-2 (-) on the MI/OB Board. In the case of a 9-20V System (12V Battery) apply greater
than 9.5V and in the case of a 20-30V System (24V Battery) apply greater than 22V.

Set the variable DC Power Supply to either 9V or 20V (for 12V or 24V 3305 system,
respectively). Adjust R11 (clockwise) on the PMPP Board until the unit just turns OFF, i.e.,
LEDs DS16 (MC*) and DS17 (PFIN*) on the PMPP Board turn OFF.

5.4.2 Setting the Low Battery Voltage Detection Trip Points (see Figure 5-6)

Resistor R12 in conjunction with Jumper W11 (both on PMPP Board) provide for setting
the Low Battery Voltage Detection Trip Point. Jumper W11 must be installed for the 9-20V
input range (12V Battery) and must be removed for the 20-30V input range (24V Battery).
In the case of a 12V Battery supply, LBIN* will go low when the input voltage drops below
11V and will go high when the input voltage rises above 11.2V. In the case of a 24V Battery
supply, LBIN* will go low when the input voltage drops below 23.5V and will go high when
the input voltage exceeds 24V.

To set the Low Battery Voltage Detection Trip Point a variable DC Power Supply is
required. Additionally, an Encode Module must exist in an executing task within the
ACCOL load. Low power (battery) status is reported using Function 7 of the Encode
Module (see the ACCOL II Reference Manual D4044). Taskspy, On Line AIC or Toolkit
must be used to monitor the signal wired to the Input 1 Terminal of the Encode Module.
With power off, turn R12 fully counterclockwise. Connect the variable DC Power Supply to
TB3-2 (+) and TB3-1 (-) on the MI/OB Board. In the case of a 9-20V System (12V Battery)
apply 11.2V and in the case of a 20-30V System (24V Battery) apply 24V. Carefully adjust
R12 on the PMPP Board until a value of 1 or ON is reported on the Input 1 Terminal of the
Encode Module.

5.4.3 Power Checks (see Figure 5-6)

System Power is supplied on TB3 pins 1 & 2 of the MI/OB Board and is supplied to the
PMPP Board on J4 pins 1 & 2. The DC-To-DC Converter (on the PMPP Board) produces
+18V, -18V, +5V and +21V (+32V for 24V Models and DI/O Models. Referring to Figure 5-6
measure the DC output supplies and make sure that they are within the following ranges:

+18VDC (±5%, i.e., ±.9V)


-18VDC (±5%, i.e., ±.9V)

3305 RTU Service / 5- 17


+5VDC (±.1V)
+21VDC (±5% for a 9-20V input supply, or 12V Battery, i.e., ±1.05V)
+21VDC (Clamped at approximately 31V ±5%, i.e., ±1.55V for 24V Models and
DI/O Models)

The input supply is considered good if the voltage is higher than the Power Fail (OFF) Trip
Point, i.e., 9.5V or 22V for 9-20V or 20-30V systems respectively.

5.5 GENERAL NOTES

Certain questions or situations frequently arise when servicing the BBI Controllers. Some
items of interest are provided in Sections 5.5.1 through 5.5.3.

5.5.1 Extent of Field Repairs

Field repairs to Series 3305 units that are used in Class I, Division 2 hazardous areas are
strictly limited to the replacement of complete PC boards and assemblies. Any repairs
made down to the component replacement level will violate the hazardous area
classification of the unit. Defective PC boards or assemblies must be returned to Bristol
Babcock for authorized service.

5.5.2 Disconnecting RAM Battery

If the RAM battery of the FLASH-based RTU 3305 is disconnected when the power is off,
the RTU will still execute its ACCOL load but all of the current process data will be lost.
Upon power-up, the FLASH-based RTU will act as though it had just been booted and it
will revert back to the initial values specified in its ACCOL load.

5.5.3 Maintaining Backup Files

It is essential to maintain a backup disk of each ACCOL load file to guard against an ac-
cidental loss of process configuration data. Without a backup record, it will be necessary to
reconfigure the entire ACCOL load which can be a very time consuming procedure. Always
play it safe and keep backup copies of your ACCOL loads.

5-18 / Service 3305 RTU


Section 6
SPECIFICATIONS

6.1 CPU, MEMORY & PROGRAM INTERFACE


Processor: 80C186XL, 12MHz

Memory: 512K bytes of system FLASH


256K or 504K bytes battery-backed RAM; 224K
bytes ACCOL Load FLASH and 32K Boot/-
Configuration FLASH

Real Time Clock: DS1287 accurate to one second per day

Program Interface: ACCOL programming language tools, which are run


on an attached PC, allow the user to configure the
RTU and to obtain access to current data,
configurable constants, and a variety of logs.

6.2 COMMUNICATION PORTS

6.2.1 Communication Ports

Local Port: Port A - RS-232

Network Port: Port B & C - RS-232


Port D - RS-232 or RS-485

ESD: Ports A, B & C - 10KV 150Ω Source Resistance


Port D - 10KV 1.5KΩ Source resistance

6.2.2 Network Ports (B, C & D)

Interface: RS-232 (Ports B, C & D)


RS-485 (Port D)

Baud Rate: 1.2K, 2.4K, 4.8K, 9.6K, 19.2K & 38.4K (bps)

Address: Software selectable network address from 1 to 126

Optional Modem: Ports may be furnished with a private line modem


(PLM) or a switched network modem (SNM) board.

Optional Radio Delay: A Port may be furnished with a Radio Delay Board
to provide a radio transceiver interface.

3305 RTU Specifications / 6- 1


Optional TIB A Port may be furnished with a Transmitter Inter-
face Board to allow up to 5 BBI Series 3508 to
communicate with an RTU 3305.

Optional RS-485 Interface A Port may be furnished with an RS-485 Interface


Board which allows the 3305 to be included in a 4-
Wire multi-dropped LAN along with other BBI 33XX
Controllers and Transmitters as-well-as RS-485
capable devices.

6.2.3 Customer Port (A)

Interface: RS-232 (3-Wire)

Baud Rate: 1.2K, 2.4K, 4.8K, 9.6K, 19.2K & 38.4K (bps)

Address: Software selectable network address from 1 to 126

6.2.4 Communication Protocols (Network Ports)

BSAP (Bristol Standard Asynchronous Protocol):

Compatibility: Compatible with all Bristol Network 3000 Products

Local Addressing: 127 Nodes

Global Addressing 32767 Nodes

ISO Standard: 1745/2111/2629

6.3 INPUT/OUTPUT SPECIFICATIONS

6.3.1 Analog Inputs

Number of Inputs: 4 Analog Differential Inputs (Selectable for Current


or Voltage type inputs)

Input Type: Voltage Input 1-5 Vdc


Current Input 4-20 mA
Internally Sourced 4-20mA Curent Loop

Input Impedance:

High Common Mode Version: 1-5V Input = 2M Ohms


4-20mA Input = 250 Ohms

Common Mode Range:

High Common Mode version: 180Vdc

6-2 / Specifications 3305 RTU


Accuracy:
At Ambient Temp. (23°C) Voltage/Current Input 0.1% of Span

At -20°C to +70°C Voltage/Current Input 0.2% of Span

At -40°C to +70°C Voltage/Current Input 0.3% of Span

Input Filtering: Single Pole (50 msec time constant)


300 msec to within .1% of input value
Settling Time of any AI is 18µsec to .01%
Common Mode Rejection Ratio 47 to 63 Hz - 100dB
Normal Mode Rejection Ratio at 60Hz - 26dB

6.3.2 Analog Outputs

Number of Outputs: 2

Range: 4-20 mA into a 650 Ohm Load

Accuracy: +23°C 0.1% os Span


-20°C to 70°C 0.2% of Span
-40°C to 70°C 0.3% of Span

Setting Time: 100msec to .1%

Surge Suppression: 16V Transorb across output


(Meets ANSI/IEEE C37.90-1978)

6.3.3 Discrete Inputs

Number of Inputs: 8 non-isolated inputs


6 non-isolated selectable inputs

Input Type: Dry Contact

Input Current: 5mA ±10% (Contact Closure)

Input Filtering: 30msec time constant for DI/O1-DI/O6


1msec time constant for DI7-DI14

Input Impedance: 2.2KΩ ±10% for 12V Input Range


4.7KΩ ±10% for 24V input Range

Surge Suppression: 38V MOV Across Input


(Meets ANSI/IEEE C37.90-1978)

6.3.4 Discrete Outputs

Number of Outputs: 2 (standard) 6 (selectable)

3305 RTU Specifications / 6-3


Output Type: Open Drain

Surge Suppression: 38V MOV Across Output


Reverse Voltage Diode Clamp
(Meets ANSI/IEEE C37.90-1978)

Maximum Load: 100mAdc @ 35Vdc

6.3.5 Watchdog Contacts

Rating: 2 Amps Resistive @ 30Vdc

6.3.6 High Speed Counter

Number of Inputs: 1

Input Type: SPDT Dry Contact/Open Collector

Input Current: 5mA ±10% (Open Collector/Contact Closure)

Input Voltage: +12V ±10% @ 5mA


+24V ±10% @ 5mA

Input Filtering: 20µsec Time Constant

Input Frequency: DC to 10KHz

Input Impedance: 2.2KΩ ±10% for 12V Input Range


4.7KΩ ±10% for 24V Input Range

Surge Suppression: 38V MOV Across Input


(Meets ANSI/IEEE C37.90-1978)

6.4 ENVIRONMENTAL SPECIFICATIONS


Temperature: Operating: -40 to +158 °F (-40 to +70 °C)
W/LCD Option: -4 to +158 °F (-20 to +70 °C)
Storage: -40 to +185 °F (-40 to +85 °C)
W/LCD Option: -22 to +185 °F (-30 to +85 °C)

Relative Humidity: 15-95% Non-condensing

Vibration: 1g for 10-150 Hz


.5g for 150-2000 Hz

RFI Susceptibility: 10V/Meter from 20MHz to 500MHz

Approvals: FM rated for Class I, Division 2, Groups A, B, C,


and D Hazardous Areas.

6-4 / Specifications 3305 RTU


6.5 POWER SPECIFICATIONS

6.5.1 Input Power Specs.

Operating Range: 9V - 30V (DC)


Inrush Current: 4 Amps peak (during 2ms)

Fusing: .5 Amp Slow-Blow (for 20-30 Vdc source)


1 Amp Slow Blow (for 9-20 Vdc source)

Efficiency: 75% Min @ 9V Input

Reverse Voltage Protection: Diode Clamp

Overvoltage Protection: Transorb Clamp

6.5.2 DC To DC Converter Specs.

Outputs - Currents & Voltages: 5V @ 600mA Non-Isolated


21V @ 200mA Non-Isolated
-18V @ 100mA Non-Isolated
+18V @ 100mA Non-Isolated

Regulation: Line: 5V - .2% for 9-30 V


Load: 5V - 0.1% for 100% Load Change

Ripple: RMS: 0.1% or 10mV RMS Max.


Peak to Peak: 1% or 50mV pk-to-pk, (whichever
is greater)

Transient Response: Output voltage returns to within 1% in less than


500µsec in response to a 25% load step. Maximum
excursion less than 200mV from nominal.

Short Circuit Protection: Current Limit to 150% of rated load.

Overvoltage Protection: Transorb on 5V Non-isolated Output

Power Fail Trip Points: 9-20V Range (Jumper WX Installed)


ON (Active Low)- Vin <9.0 V
OFF - Vin >9.5 V
Hysteresis: - 0.2 V

22-30V Range (Jumper WX Removed)


ON (Active Low)- Vin <20 V
OFF - Vin >21.5V
Hysteresis: - 1.5 V

Output Configuration: Open Collector

3305 RTU Specifications / 6-5


Low Battery Trip Points: 9-20V Operation
ON (Active Low) - Vin <11 V
OFF - Vin >11.2 V
Hysteresis: - 0.2 V

22-30V Operation
ON (Active Low) - Vin <23.5 V
OFF - Vin >24 V
Hysteresis: - 0.5 V
Output Configuration: Open Collector

6.5.3 Power Requirements

3305 RTU Power Requirements: 434 mAmps Max. at +24VDC (+20V - +30V)
829 mAmps Max. at +12VDC (+9V - +20V)
100 µAmps Max. at +3.6VB (256K RAM battery
back-up)
200 µAmps Max. at +3.6VB (512K RAM battery
back-up)

Optional Communication
Boards Power Requirement: TIB: .73W @ 24Vdc
RDI: .10W @ 24Vdc
RS-485: <250mW @ 30Vdc
PLM: 85Ma @ (9.5 to 18)Vdc
SNM: 125Ma @ (9.5 to 18)Vdc

6.6 RTU 3305 MODEL VARIATIONS


Table 6-1 RTU 3305 Models

I/O System Input Voltage Display Type


DISCRETE I/O None
8 DIs 12 VDC Local 2x16
2 DOs or Remote 2x16
6 DI/Os 24 VDC Remote 4x20
ANALOG IN
8 DI 12 VDC None
2 DO or Local 2x16
6 DI/DO 24 VDC Remote 2x16
4 AI Remote 4x20
ANALOG OUT
8 DI None
2 DO 12 VDC Local 2x16
6 DI/DO or Remote 2x16
4 AI 24 VDC Remote 4x20
2 AO

6-6 / Specifications 3305 RTU


Model 3305 Remote Terminal Unit
Special Instructions for Class I, Division 2 Hazardous Locations

1. The BBI Model 3305 Remote Terminal Unit (RTU) is listed by Underwriters
Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups
A, B, C and D hazardous locations and nonhazardous locations only. Read this
document carefully before installing a nonincendive BBI Model 3305 RTU. In the event
of a conflict between the Model 3305 RTU Customer Instruction Manual (CI-3305) and
this document, always follow the instructions in this document.

2. All 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.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair


suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,


turn off power before servicing/replacing the unit and before installing or
removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the


power has been switched off or the area is known to be nonhazardous.

07/12/00 Appendix A, Document CI-3305 Page 1 of 1


BLANK PAGE
Product Information Package
PIP-TIBS33XX
Mar., 2007 Series 3305, 3310& 3330

Transmitter Interface Boards


Part No. 392912-XX-X & 392523-XX-X
For The Following Bristol Instruction Manuals:
CI-3305, CI-3310 & CI-3330

www.EmersonProcess.com/Bristol
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this device in some applications may result in
damage or injury. The user is urged to keep this book filed in a convenient location for
future reference.

These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or main-
tenance. Should problems arise that are not covered sufficiently in the text, the pur-
chaser 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, fail-
safe 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 in-


struments 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.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from
defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited
to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part
thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER


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

F. No agent of Bristol is authorized to assume any liability for it or to make any written
or oral warranties beyond those set forth herein.

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 Water-
town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

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


damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.
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 Depart-
ment representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in-
cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.
Bristol Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol to effectively and efficiently process your return. Completion is required to
receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH Line No.____________

Standard Repair Practice is as follows: Variations to this is Please be aware of the Non warranty standard charge:
practice may be requested in the “Special Requests” section. • There is a $100 minimum evaluation charge, which is
• Evaluate / Test / Verify Discrepancy applied to the repair if applicable (√ in “returned”
• Repair / Replace / etc. in accordance with this form B,C, or D of part III below)
• Return to Customer
Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)

Bill to : Ship to:

Purchase Order: Contact Name:____________________________________


Phone: Fax: E-Mail:

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

Model No./Part No. Description


Range/Calibration S/N
Reason for return: Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)


2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________
3. What is the Firmware revision? _____________________ What is the Software & version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due
to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B. If product were found to exceed the warranty period,
would you like the product: 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: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
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) 685-
6200.
A Few Words About Bristol Inc.

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

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

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis-
tance 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.
PIP-TIBS33XX
TRANSMITTER INTERFACE BOARDS
PT. NO. 392912-XX-X & 392523-XX-X

TABLE OF CONTENTS
TITLE PAGE #

DESCRIPTION............................................................................................................................................. 1
RTU-3305 Boards......................................................................................................................................... 1
DPC-3330 Boards ......................................................................................................................................... 1
RTU-3310 Boards......................................................................................................................................... 1
Model 3508 Transmitter Operation .............................................................................................................. 1
Model 3808 Transmitter operation ............................................................................................................... 3

CONFIGURATION & WIRING .................................................................................................................. 4


Wiring Connections ...................................................................................................................................... 4
12V Transmitter Interface Board Jumper Configuration.............................................................................. 5

LED INDICATORS...................................................................................................................................... 5

SPECIFICATIONS ....................................................................................................................................... 5
12V TIB ........................................................................................................................................................ 5
24V TIB ........................................................................................................................................................ 6

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

PIP-TIBS33XX Page 0-1 Table Of Contents


BLANK PAGE
TRANSMITTER INTERFACE BOARDS
For Models
RTU-3305, RTU-3310 & DPC-3330

DESCRIPTION

Two versions of the Transmitter Interface Board (+12VDC and +24VDC) are available for
models RTU-3305 and two versions are available for models, RTU-3310 and DPC-3330. The
Transmitter Interface Board (TI Board) allows up to five Bristol, Series 3508 or Series 3808
Transmitters to communicate with a host DPC/RTU. The DPC/RTU polls and stores data
from each transmitter and communicates with the network. Three LEDS on the TI Board
(TXD, CTS and RXD) indicate the communication status.

The +24V TIB can provide loop power for its associated transmitters directly from the +24V
supply used to power the DPC 3330, RTU 3310 or RTU 3305. The +12V TIB includes an on-
board DC-DC converter to provide +24V loop power for transmitters not designed to operate
from a +12V source.

The +24V version of the TI Board does not contain any switches or jumpers that require
con-figuration; however, the +12V version of the TI Board does contain three configuration
jumpers which must be set to support LED operation and either of two field wiring con-
figurations.

RTU-3305 Boards

Either of the TI Board shown in Figure 1 (24 Vdc) or Figure 2 (12 Vdc), can be mounted to
an RTU-3305’s Option Mounting Brackets and interfaced to the 3305’s Port C via TI Board
connector P1 (see Section 2.6 of the CI-3305 Instruction manual).

DPC-3330 Boards

The TI Board shown in Figure 3 (24Vdc) or Figure 4 (12Vdc) plugs into the modem utility
connector (J3) on the DPC-3330’s 2-Port CE Board and is assembled to the CE Board using
screws and spacers. A TI Board cannot be mounted on the 4-Port Enhanced Comm. Board.

RTU-3310 Boards

The TI Board shown in Figure 3 (24Vdc) or Figure 4 (12Vdc) plugs into the modem utility
connector (J7) on the RTU-3310’s Multi-Function Interface Board (MFIB) and is assembled
to the MFI Board using screws and spacers.

Model 3508 Transmitter Operation

Each Model 3508 Transmitter must be assigned a unique address via the SMARTKIT
program as described in Section 4.2 PROGRAM LOADING AND STARTUP of the
appropriate 3508 Transmitter manual. Additionally, all Model 3508 Transmitters wired to
the TI Board must be operated in the minimum current mode (3.8 mA). This mode is

PIP-TIBS33XX Page 1 Transmitter Interface Bds.


selected via the SMARTKIT program as described in Section 4.7 TRANSMITTER
OPERATING MODES of the appropriate 3508 Transmitter manual, i.e., CI-3508-10C, CI-
3508-30C or CI-3508-99C.

Figure 1 - 24V Transmitter Interface Board P/N 392523-02-7 for RTU 3305

Figure 2 - 12V Transmitter Interface Board P/N 392912-02-3 for RTU 3305

PIP-TIBS33XX Page 2 Transmitter Interface Bds.


Model 3808 MVT Transmitter Operation

Each Model 3808 MVT Transmitter must be assigned a unique address via the WebBSI
Sign On/Off Menu (see Section 3 of Customer Instruction Manual CI-3808). Additionally,
only analog versions of the 3808 MVT can be interfaced to a Transmitter Interface Board.

Figure 3 - 24V Transmitter Intf. Board P/N 392523-01-9 (RTU 3310 or DPC 3330)

Figure 4 - 12V Transmitter Intf. Board P/N 392912-01-5 (RTU 3310 or DPC 3330)

PIP-TIBS33XX Page 3 Transmitter Interface Bds.


CONFIGURATION & WIRING

Wiring Connections

TI Boards are equipped with six dual-terminal blocks for field wiring connections. Terminal
block TB1 connects to the transmitter power source, while TB2 through TB6 connect to the
signal/power inputs of the transmitters. Two field wiring conventions are supported by the
TI Boards; Internally Powered (see Figure 5) and Externally Powered (see Figure 6).

Figure 5 - Internally Powered Transmitter Field Wiring

Figure 6 - Externally Powered Transmitter Field Wiring

PIP-TIBS33XX Page 4 Transmitter Interface Bds.


In the case of an Internally Powered Transmitter (powered from TIB’s on-board +24V
Supply/Regulator) an external +24 Vdc or +12 Vdc power supply is wired to the TI Board
connector TB1 as shown in Figure 5. The supply is wired across the +24V EXT and +24V
RETEXT (+12V EXT and +12V RETEXT) terminals. The input voltage range for a 24V TIB
is +22Vdc to +28Vdc. The input voltage range for a 12V TIB is +9Vdc to +15Vdc.

In the case of an Externally Powered Transmitter the -24Vdc side of the Transmitter Power
Source is connected to the TIB’s +12V/24VRET Terminal (TB1-2) as shown in Figure 6

The 12V TI Board contains jumpers that must be configured to support the field wiring
option. The 24V TI Board; however, doesn’t contain jumpers. Both versions of the TI Board
(12V and 24V) contain an internal loop resistor and therefore external ones are not
required.

12V Transmitter Interface Board Jumper Configuration

Two-position Jumper W1 enables or disables the Internal 24V Power Supply/Regulator.


Jumper W1 is installed, to disable power supply “shutdown” for “Internally Powered Trans-
mitters”. For “Externally Powered Transmitters,” Jumper W1 must be stored in position 1
or 2.

Three-position Jumper W2 enables LED operation when installed in position 1 to 2. To


disable LED operation, install Jumper W2 in position 2 to 3.

Jumper W3 must be installed in position 1 to 2 to connect the 249-Ohm Loop Resistor used
for Internally Powered Transmitters. When wiring to Externally Powered Transmitters,
Jumper W3 must be installed in position 2 to 3 to remove the 249-Ohm Loop Resistor.

LED INDICATORS

The board contains three LEDs which have the following functions: Transmit Data (TXD),
Receive Data (RXD), and Clear to Send (CTS). When the board is sending data, TXD and
CTS are on and RXD is off. Conversely, when the board is receiving data, TXD and CTS are
off and RXD is on. 12V versions of the TI Board contain a two-position Jumper (W2) which
is used to enable or disable the LEDs.

SPECIFICATIONS

12V TIB

Communication Interface: TTL

3508/3808 Interface: FSK Modem - Bell 202 Compatible


(1200 Hz/2200 Hz modulation)

24V Output: 24.4Vdc ±6.5%


180mV pk/pk ripple

Power Consumption Internal +5V: 8.5mA

Power Consumption Internal -5V: 2mA

PIP-TIBS33XX Page 5 Transmitter Interface Bds.


Power Consumption External +9V: 14mA Per Transmitter

Power Consumption External +15V: 8mA Per Transmitter

Operating Temperature: -40ºC to +70ºC (-40ºF to +152ºC)

Storage Temperature: -40ºC to +85ºC (-40ºF to +185ºC)

Relative Humidity: 15% - 95% Non-condensing

Vibration: 1G for 10Hz to 150Hz


0.5G for 150Hz to 2000Hz

RFI Susceptibility: 10V/meter - 20MHz to 500MHz

Part Numbers: 392912-02-3 (for RTU-3305)


392912-01-5 (for DPC-3330 & RTU-3310)

24V TIB

Communication Interface: TTL

3508/3808 Interface: FSK Modem - Bell 202 Compatible


(1200 Hz/2200 Hz modulation)
Baud rate is 1200

24V Output: External 24V Supply


22 - 28Vdc

Power Consumption Internal +5V: 4mA

Power Consumption External +24V: 4mA Per Transmitter

Operating Temperature: -40ºC to +70ºC (-40ºF to +152ºC)

Storage Temperature: -40ºC to +85ºC (-40ºF to +185ºC)

Relative Humidity: 15% - 95% Non-condensing

Vibration: 1G for 10Hz to 150Hz


0.5G for 150Hz to 2000Hz

RFI Susceptibility: 10V/meter - 20MHz to 500MHz

Part Numbers: 392523-02-7 (for RTU-3305)


392523-01-9 (for DPC-3330 & RTU-3310)

PIP-TIBS33XX Page 6 Transmitter Interface Bds.


Transmitter Interface Boards
Special Instructions for Class I, Division 2 Hazardous Locations

1. The Bristol Transmitter Interface Boards (TIBs) part numbers 392912-01-5, 392912-02-
3, 292523-01-9 & 392523-02-7 are listed by Factory Mutual (FM) as nonincendive and
are suitable for use in Class I, Division 2, Groups A, B, C and D hazardous locations or
non-hazardous locations only. Read this document carefully before installing a
nonincendive Bristol TIB Board. In the event of a conflict between the TIB Board User
Manual (PIP-TIBS33XX) and this document, always follow the instructions in this
document.

2. 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.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair


suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,


turn off power before servicing/replacing the unit and before installing or
removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the


power has been switched off or the area is known to be nonhazardous.

03/14/2007 Appendix A of PIP-TIBS33XX - TIB Boards Page 1 of 1


Product Information Package
PIP-TIBS33XX
Transmitter Intf. Bd. Part Nos. 392912-XX-X & 392523-XX-X Mar., 2007

The information in this document is subject to change without notice. Every effort has
Emerson Process Management
been made to supply complete and accurate information. However, Bristol, Inc.
Bristol, Inc.
assumes no responsibility for any errors that may appear in this document.
1100 Buckingham Street
Watertown, CT 06795
If you have comments or questions regarding this manual, please direct them to your
Phone: +1 (860) 945-2262
local Bristol sales representative, or direct them to one of the addresses listed at left.
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Bristol
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
Emerson Electric Canada, Ltd.
materials to his/her satisfaction before using them with important data.
Bristol Canada
6338 Viscount Rd.
There are no warranties, expressed or implied, including those of merchantability and
Mississauga, Ont. L4V 1H3
fitness for a particular purpose, concerning the software and other materials delivered
Canada
herewith.
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Bristol 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
Emerson Process Management this document are for information only, and belong to their respective companies, or
BBI, S.A. de C.V. trademark holders.
Homero No. 1343, 3er Piso
Col. Morales Polanco Copyright (c) 2007, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part
11540 Mexico, D.F. of this manual may be reproduced in any form without the express written permission of
Mexico Bristol, Inc.
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
Appendix 2 Issue: 04/99

RADIO DELAY INTERFACE BOARD

For Instruction Manual CI-3305

TB3
7
DCD

CTS
MULTIPLIER
U11
U10

RXD
x8

ABCDEFG
ABCDEFG

x6 DTR

TRAIL DELAY
x5
x4
LEAD DELAY

RTS
x3
x2 TXD
x1
W4
W2

+5V

1
UNIT
U9
U8

INFINITE

TIME OUT
CARRIER
ABCDEFG
1S
ABCD

ABCD

17 MIN.
100mS 4 MIN.
10mS 1 MIN.
1.25mS
16 SEC.
W3
W1

8 SEC.
W5 4 SEC.

TB1
6

GND
U7

U6

RX RRTS
U13

U14
U2

U4

ST RDTR

RTXD

RRXD

RDCD
U5

U1

1
U12

1
U3
Y1

ENA
LED
DS3

DS4

W6

TB4
1

GND
KEY
RTS

DCD

Bristol Babcock
Appendix 2
RADIO DELAY INTERFACE (RDI) BOARD

TABLE OF CONTENTS
TITLE PAGE #

DESCRIPTION..........................................................................................................................1

JUMPER CONFIGURATION...................................................................................................2

Leading Edge Delay .......................................................................................................2

Trailing Edge Delay .......................................................................................................2

Carrier Time Out ...........................................................................................................3

WIRING CONNECTIONS ........................................................................................................4

RDI Board to Transceiver ..............................................................................................4

Carrier Keyed Output ....................................................................................................4

DISPLAY LEDS.............................................................................................................5

ENVIRONMENTAL SPECIFICATIONS......................................................................5

CI-3305 Appendix 2 Page 0-1 Table Of Contents


RADIO DELAY INTERFACE BOARD

DESCRIPTION

The Radio Delay Interface Board (RDI Board) functions as an interface between a Series
33XX Distributed Process Controller and an external radio frequency (rf) transceiver or
modem. The board includes an open collector output that can be used to key the carrier
"ON" or "OFF."

In a 3305 the RDI Board interfaces to Port C on the MI/OB Board and contains a 6-pin
connector (TB1) that provides an RS-232 interface to an external modem or transceiver.
Terminal block (TB4) provides an open collector output that can be used to key a radio
carrier. The following timing options can be used for communications:

‡ Leading Edge Delay (RTS-to-CTS Delay). This feature delays the start of data
transmissions after a "Request To Send" (RTS) signal has been initiated. It allows
the rf carrier to reach full power before initiating a "Clear To Send" (CTS) signal. The
leading edge delay also allows sufficient time for the remote rf receiver to recover
from a squelched condition, thereby preventing a loss of the initial data.

‡ Tailing Edge Delay. This delay keeps the transmitter "on" for a short period at the
conclusion of a transmission even though RTS has just been set "off." This action
ensures that the radio carrier remains on the air so that the last data are not
corrupted by premature squelching or carrier "turn off" transients at the receiver.

Figure 1. RDI Board No. 392504-02-2

CI-3305 Appendix 2 Page 1 Radio Delay Interface Board


‡ Carrier Time Out. This feature prevents a transceiver from tying up network
communications should it fail with the rf carrier set "on." This is especially true in an
application where a master station polls a field of remotes that operate on the same
frequency; a remote that fails with the "carrier on" will halt network polling. By
using this feature, the carrier of the failed remote will be forced of the air after the
"time out" has lapsed. In this application RTS must be inactive in order to reset the
carrier time out.

JUMPER CONFIGURATION

Board jumpers provide configuration of leading and trailing edge delays and carrier time out.

Leading Edge Delay

The leading edge delay is the time from the start of a Request To Send (RTS) signal to the
start of a Clear To Send (CTS) signal. The delay times are determined by plugging in a
combination of two jumper headers, W1 and W2. Header W1 provides four time periods
from 1.25 ms to 1 sec, while header W2 provides seven multiplier positions from X1 to X8.
Table A is a matrix that shows the time periods for all combinations of W1 and W2. For
example, if W1 is placed in the "C" position and W2 in the "A" position, the delay will be 100
milliseconds, but if W2 is moved to the "B" position the delay will be 200 milliseconds.

TABLE A - LEADING EDGE DELAY SELECTIONS

Jumper W2 Jumper W1 Set To:


W2 Set To: A B C D
Position Multiplier (ms) (ms) (ms) (s)

A X1 1.25 10 100 1
B X2 2.50 20 200 2
C X3 3.75 30 300 3
D X4 5.00 40 400 4
E X5 6.25 50 500 5
F X6 7.50 60 600 6
G X8 10.0 80 800 8

Example: Above Jumpers set for 100ms leading edge delay.

Trailing Edge Delay

The trailing edge delay occurs from the time RTS is made inactive by the initiating station
(with CTS still enabled) until the time that the RD Board removes RTS from the radio. This
delay will not apply if the initiating station inhibits RTS before it receives CTS. Since there

CI-3305 Appendix 2 Page 2 Radio Delay Interface Board


is no data to be protected, RTS will be removed instantly from the radio.

The delay times are determined by plugging in a combination of two jumper headers, W3 and
W4 as noted in Table B. Header W1 provides four time periods from 1.25 ms to 1 sec, while
header W2 provides seven multiplier positions from X1 to X8. This table is used in the same
manner as previously described for Table A.

TABLE B - TRAILING EDGE DELAY SELECTIONS

Jumper W4 Jumper W3 Set To:


W4 Set To: A B C D
Position Multiplier (ms) (ms) (ms) (s)
A X1 1.25 10 100 1
B X2 2.50 20 200 2
C X3 3.75 30 300 3
D X4 5.00 40 400 4
E X5 6.25 50 500 5
F X6 7.50 60 600 6
G X8 10.0 80 800 8

Example: Above Jumpers set for 6 second trailing edge delay.

Carrier Time Out

The carrier time out period starts when an RTS is received by the RD Board. If RTS is not
inhibited within the selected time out period, the rf carrier or the modem will be turned off.
The timer is reset only when RTS is inhibited by the initiating station.

The time out period is determined by jumper header W5. This jumper provides seven
selectable periods from 4 seconds to infinity as shown in Table C. The infinite selection
prevents a time out when the delay is not needed.

TABLE C - CARRIER TIME OUT SELECTIONS

W5 Time Out
Set To: Period
A 4 Sec.
B 8 Sec.
C 16 Sec.
D 1 Min.
E 4 Min.
F 17 Min.
G Infinite

CI-3305 Appendix 2 Page 3 Radio Delay Interface Board


Example: Above Jumper (W5) set for 1 Minute Carrier Time Out

WIRING CONNECTIONS

RDI Board to Transceiver

The basic wiring concept is shown in Figure 2. The RDI Board interfaces to the 3305’s
MI/OB Board (Port C) and requires an RS-232 cable connection to the transceiver or external
modem. Pin connections for RDI/Transceiver Comm. cable are shown in Figure 3.

The RDI Board is wired to the rf transceiver as described in the manufacturer's instruction
manual.

Carrier Keyed Output

A carrier keyed output is present across terminal block TB4. These terminals provide an
open collector output (50 mA max.) that may be applied to rf transmitters requiring a
separately keyed input. Essentially the open collector conducts when the RTU sends an RTS
to the RDI Board. This action switches on the transmitter and places the carrier on the air.
The carrier stays on the air as long as RTS is on.

Figure 2 - Block Diagram of Application

CI-3305 Appendix 2 Page 4 Radio Delay Interface Board


Figure 3 - Pin Connections for RDI Board RS-232 Connector TB1

TABLE D - WIRING LIST FOR BBI RADIO DELAY INTERFACE BOARD

P4/D-Type Pin # Wire Color Signal TB3 TB1


MIOB Bd. MIOB/RDI MIOB/RDI RDI RDI
1 Green DTR NOT 4 -
2 Brown TXD NOT 2 -
3 Yellow +5V 1 -
4 Blue RXD NOT 5 -
5 White RTS NOT 3 -
6 Black CTS NOT 6 -
7 Red DCD NOT 7 -
8 - - - -
9 Orange PCOM - 6

DISPLAY LEDS

The Radio Delay Board contains two LEDs, labeled DS3 and DS4 (see Figure1). LED DS3
(RTS) lights when the board receives a “Request To Send.” LED DS4, Data Carrier
Detected (DCD) lights when the board receives data from the transceiver; this also denotes
the presence of a radio carrier.

ENVIRONMENTAL SPECIFICATIONS

Operating Temperature: -20°C to +70°C (-4°F to +158°F)

Storage Temperature: -40°C to +85°C (-40°F to +185°F)

Humidity: 0-95% Non-condensing

Vibration: 20-150 Hz at 1.0G


150-200 Hz at 0.5G

RFI: 10 V/M at 20-500 MHz


with no operational degradation

CI-3305 Appendix 2 Page 5 Radio Delay Interface Board


BLANK PAGE
Appendix 3 Issue: 04/99

RS-485 INTERFACE BOARD

For Instruction Manual CI-3305

J1
P2

J2
J3
P1A
J1A

Bristol Babcock
Appendix 3
RS-485 INTERFACE BOARD
PT. NO. 392566-00-1

TABLE OF CONTENTS
TITLE PAGE #

DESCRIPTION .............................................................................................................................................1
Function ................................................................................................................................................1
Features .................................................................................................................................................1
Assembly Description ...........................................................................................................................2

HEADERS & JUMPERS..............................................................................................................................2


J1/W1 ....................................................................................................................................................2
J2/W2 ....................................................................................................................................................3
J3/W3 ....................................................................................................................................................3
J4/W4 ....................................................................................................................................................3

NEWTWORK WIRING ...............................................................................................................................3


Field Terminations For RS485..............................................................................................................3
End Node Configuration .......................................................................................................................3

RS-485 INTERFACE BOARD SPECIFICATIONS ....................................................................................3


Performance Specifications ..................................................................................................................3
Environmental Specifications ...............................................................................................................4
Input/Output Specifications ..................................................................................................................4

CI-3305 Appendix 3 Page 0-1 Table Of Contents


RS-485 INTERFACE BOARD

DESCRIPTION

Function

The RS-485 Interface Board for the 3305 RTU provides a communications interface on Port
C. The RS-485 Interface Board allows the 3305 RTU to be included in a 4-wire, multi-
dropped (up to 32 nodes) LAN along with other Bristol Babcock 33XX Controllers,
Transmitters and RS-485 capable devices. Multiple 3508B Smart Transmitters equipped
with an RS-485 interface can be networked to the 3305 RTU.

Features

‡ On-Board isolated Output Power Supply

A galvanically isolated power supply, operating from a bulk 8 to 30 Volt source,


powers the RS-485 circuitry, generating 5V (VCCISO) and Isolated Ground
(GNDISO). The 8 to 30 volt source for this on-board power supply is provided to Pin 1
on connectors P1A or J1A, that is, the customer is able to connect the power source to
Pin 1 and ground to PCOMM, Pin 2, on J1A; or to the same pins on P1A.

‡ Reverse Voltage & Over-Voltage Protection

Input power to pins on both connectors can be reversed without damaging the
components, because the RS-485 Interface Board has reverse voltage and over-voltage
protection. Fuse F1 (1/4 Amp) protects circuitry at the input source, Pin 1, for P1A
and J1A. Input power is less than 250 milliwatts on the average.

‡ Optical & Electrical Isolation

Transmit, Receive, and Request-To-Send functions are optically isolated on the RS-
485 Interface Board. These channels pertain to logic level inputs and outputs.
Additionally, the RS-485 compatible transmitter and receiver are electrically isolated.

‡ 100-Ohm Line Terminators For Transmitter & Receiver Biasing

For the transmitter, this interface board has a selectable (via W1) 100-Ohm line
terminator. The receiver has two (2) selectable 800-Ohm biasing resistors (via W2 &
W3) and a selectable (via W4) 100-Ohm line terminator.

‡ Transmitter & Receiver Circuit Surge Protection

The circuits for the transmitter and receiver each have identical surge protectors.
Surge protection meets IEEE C37.90-1978 to isolated ground. A surge path terminal
is available for local connection from isolated ground to earth ground through a 180V
Metal Oxide Varistor (MOV).

CI-3305 Appendix 3 Page 1 RS-485 Interface Board


Figure 1 - RS-485 Interface Board Component Identification Diagram

Assembly Description

The 6” x 3.9” RS-485 Interface Board has the same locations for the mounting holes as the
switched network modem and the RDI Board. The board has three connectors: J1A, P1A,
and P2. Connector J1A of the RS-485 Interface Board connects to the 3305 RTU’s D-Type
Port C, i.e., Connector P4 on the MI/OB Board. The two floating (open ended) wires
connected to J1A pins 1 and 2 are connected to the 3305 terminal Block TB3 with J1A pin-1
connected to TB3-2 (power) and J1A pin-2 connected to TB3-1 (Ground). Connector P1A is
typically used to power the RS-485 Interface Board, but is not used for this function when
connecting to a 3305 RTU.

Note: Connector P1A is not used with the RTU 3305.

HEADERS AND JUMPERS

Mounted on the assembly board are four 3--pin Jumpers; W1, W2, W3, and W4. Each Header
has a jumper wire permanently attached across Pins 2 and 3, i.e., their position ²B.³ Each
Header has a Suitcase Jumper which when stored across position ²B³ removes the 100-Ohm
Biasing or 800-Ohm Terminating Resistor from the circuit in question. A Suitcase Jumper
will provide the desired biasing/termination when moved from²B³ to ²A.³

J1/W1
With the Suitcase Jumper associated with Header W1 is set in the ²A position,² a 100-Ohm
carbon Termination Resistor is placed across the RS-485 Network transmitter lines, i.e., P2
(Pins 1 and 2). The Suitcase Jumpers associated with W1 at the two most distant nodes
should be placed into the ²A Position.³

CI-3305 Appendix 3 Page 2 RS-485 Interface Board


J2/W2
With Suitcase Jumper J2 at Header W2’s ²A Position,³ an 800-Ohm, metal film, Biasing
Resistor (R39) connects isolated ground (GNDISO) to the RS-485 Receiver’s negative input
(P2 Pin-4). This Jumper should be set in the ²B Position³ for all nodes except the two most
distant nodes, i.e., the ²End Nodes.³ Note: At any given node, W2 & W3 should be set
together, i.e., both should be in either the ²A Position³ (for End Nodes) or the ²B
Position³ (for all other nodes).

J3/W3
With Suitcase Jumper J3 at Header W23s ²A Position,³ an 800-Ohm, metal film, Biasing
Resistor (R37) connects the isolated +5V supply (VCCISO) to the RS-485 Receiver’s positive
input (P2 Pin-3). This Jumper should be set in the ²B Position³ for all nodes except the two
most distant nodes, i.e., the ²End Nodes.³

J4/W4
A 100-Ohm, carbon Resistor (R38) is connected between the two Biasing Resistors at the
receiver termination lines when Suitcase Jumper J4 has been set in Header W4’s ²A
Position.³ Note: Jumper W4 at W4’s ²A Position³ has no effect on line termination
unless J3/W3 and/or J2/W2 are also in their ²A Positions.³ Jumper J4 should be
placed in the ²A Position³ (for End Nodes), or the²B Position³ (for all other Nodes).

NETWORK WIRING

Field Terminations for RS-485

The maximum number of nodes that can be connected to an RS-485 network is 32 including
the master. One node should be tied to a common ground for the system. For all other nodes,
the SURGE termination should be tied to the common ground at a local point near the 3305.

Two twisted pairs of wire are required. Shielding is not required (but may be utilized). The
maximum length of the network is 4000 feet for the available asynchronous baud rates.

End Node Configuration

Excessive noise on the RXD (Receive) Terminals can be interpreted as signal error by a
Model 3305 RTU. A Jumper Selectable Noise Bias Circuit has been built into the RXD+ and
RXD- circuitry. This circuit provides a 100-Ohm termination for the input and a DC Bias
Voltage for the Transmitter output when the receive signal is in the OFF or IDLE state.

RS-485 INTERFACE BOARD SPECIFICATIONS

Performance Specification

Baud Rate (Max.): 38.4K Asynchronous

Multidrop (Max.): 32 Nodes

Network Termination: 100 Ohm Resistors for TX and RX Circuits

CI-3305 Appendix 3 Page 3 RS-485 Interface Board


Network Biasing: Selectable on Receivers:
800-Ohms (Between Positive (+) Input & IsolatedGround)
800-Ohms (Between Negative (-) Input & Isolated ground)

Topology: Master/Slave: (TX+ to RX+) & (TX- to RX-)

Isolation: Galvanically Isolated Power Source


Optically Isolated Control & Data Signals

Common Mode Range: -7 Volts to +12 Volts (DC)

Surge Protection: Meets IEEE C37.90-1978 (To Isolated Ground)

Isolated Ground Terminal Provided for Local Connection toEarth Ground

Surge Path: Terminal Provided for Local Connection from Isolated Ground
to Earth Ground through an 180V MOV

Input Voltage: +8 to +30 Volts

Input Power: < 250 mW (Average)

Environmental Specifications

Operating Temperature: -40ƒ to +70ƒ (C) [-40ƒ to +158ƒ (F)]

Storage Temperature: -40ƒ to +85ƒ (C) [-40ƒ to +185ƒ (F)]

Humidity: 5% to 95% (Non-condensing)

RFI Susceptibility: Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)

Vibration: 10-150 Hz, 2g


150-2000 Hz, 1g

Input/Output Specifications

Tables 1 and 2 provide the Pin assignments of the various on-board connectors.

Table 1 - Connector J1A Pin Assignment (Use cable Ass’y. 396049-01-0)

Pin # FUNCTION SIGNAL DESCRIPTION


1 PWR +8V to +30V DC Source (TB3-2)
2 PCOM Power (Logic) Ground (TB3-1)
3 AI+ 21 Volt Source (NOT USED)
4 AI- 250-Ohm Input (NOT USED)
5 HSC+ HSC Positive Input (NOT USED)
6 HSC- HSC Negative Input (NOT USED)
7 TXD N/A

CI-3305 Appendix 3 Page 4 RS-485 Interface Board


Table 1 (Continued)
Connector J1A Pin Assignment (Use cable Ass’y. 396049-01-0)

Pin # FUNCTION SIGNAL DESCRIPTION


7 TXD NOT TX Data (Logic Level Input)
8 RXD NOT RX Data (Logic level Output)
9 RTS NOT Request To Send (Logic Level Input)
10 CTS NOT Clear To Send (Logic Level Output)
11 NC No Connection
12 PCOM RTU 3305 Logic Ground
13 VCC RTU 3305 (5Vdc) Source
14 DCD NOT Data Carrier Detect (Logic Level Input)

Table 2 - Connector P2 Pin Assignment (Use Cable Ass’y. 396049-03-6)

Pin # FUNCTION SIGNAL DESCRIPTION


1 TXD+ Transmit Data +
2 TXD- Transmit Data -
3 RXD+ Receive Data +
4 RXD- Receive Data -
5 ISOGND RS-485 Circuit Isolated Ground
6 SURGE MOV Connection to External Ground for RS-485 Circuit

Figure 2 - RTU 3305 Connected on RS-485 Network

CI-3305 Appendix 3 Page 5 RS-485 Interface Board


BLANK PAGE
Appendix 4 Issue: 04/99

NETWORK INTERFACE BOX (NIB)

For Instruction Manual CI-3305

Bristol Babcock
Appendix 4
NETWORK INTERFACE BOX
(NIB)

TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION.......................................................................................1


1.2 PHYSICAL DESCRIPTION..........................................................................................2

Section 2 - CONFIGURATION & CONNECTIONS

2.1 MASTER-TO-SLAVE DISTANCES ..............................................................................3


2.2 INSTALLING THE NIBs ..............................................................................................4
2.3 LIMITS OF SURGE PROTECTION .............................................................................4
2.4 USING NIBs IN HART§ NETWORKS .........................................................................5

Section 3 - SPECIFICATIONS

3.1 OPERATIONAL REQUIREMENTS .............................................................................7


3.2 ENVIRONMENTAL SPECIFICATION........................................................................7
3.3 SURGE PROTECTION LIMITS ...................................................................................7
3.4 POWER REQUIREMENTS ..........................................................................................7
3.5 DIMENSIONS...............................................................................................................8

CI-3305 Appendix 4 Page 0-1 Table Of Contents


Section 1
INTRODUCTION

1.1 GENERAL INTRODUCTION

The Network Interface Box (NIB) is a compact assembly that mounts externally to a
distributed controller. It contains a dc/dc converter assembly that converts the +24 V power
source to separate +15 V and -15 V regulated outputs. These outputs are used to bias the
communication line through a resistive circuit.

The NIB can also be furnished on a mounting plate capable of holding four units. The plate
has a 5-1/4 x 19 inch surface that is suitable for mounting in a standard 19-inch width rack.

A NIB is required for all RS-485 communication networks in order to maintain the correct
line status during periods of inactive transmissions. While a NIB is recommended for each
node, only the master and the most distant slave require bias termination. If they are not
biased, communication errors can result and the system may go into a "watchdog" condition.
This can lead to excessive delays as the system is checked for non-existent faults. Installing
NIBs from the start will avert this problem.

Electrical surges or spikes on the communication line are another source of trouble that can
damage the input circuitry of one or more nodes. All NIBs include surge suppression
circuitry designed to protect the communication ports of a node.

Figure 1-1 - Network Interface Box with Cover Removed

CI-3305 Appendix 4 Page 1 NIB


The NIB contains two jumpers that are used to Enable or Disable the bias termination
discussed above. Since bias termination is only used with the master and most distant slave
units, it should be turned off for all units in between.

1.2 PHYSICAL DESCRIPTION (see Figures 1-1 and 3-1)

The NIB Board measures 3.5” by 3.5” and is mounted in a box. It has four holes located near
its corners which accommodate mounting to its enclosure box which in turn measures 4.25”
by 4.625” by 1.125”. It contains 3 terminal blocks and two configuration jumpers.

Table 1 - Terminal Block TB1 -Power

TB1 PIN SIGNAL SIGNAL DESCRIPTION


1 +24V (+) Side of the 24V Supply
2 24V RET Return to (-) side of the 24V Supply
3 EARTH GROUND Return to Earth of Surge Currents

Table 2 - Terminal Block TB2 - Connections to Terminal Equipment Comm. Port

TB2 PIN SIGNAL SIGNAL DESCRIPTION


1 SDT+ SD+ or TXD+ of Term. Equipment Comm. Port
2 SDT- SD- or TXD- of Term. Equipment Comm. Port
3 RDT+ RD+ or RXD+ of Term. Equipment Comm. Port
4 RDT- SD- or RXD- of Term. Equipment Comm. Port

Table 3 - Terminal Block TB3 - Connections to Communication Lines

TB3PIN SIGNAL SIGNAL DESCRIPTION


1 SDL+ (+) Side of the Transmit Line Twisted Pair
2 SDL- (-) Side of the Transmit Line Twisted Pair
3 RDL+ (+) Side of the Receive Line Twisted Pair
4 RDL- (-) Side of the Receive Line Twisted Pair

Table 4 - Jumper Settings

W2 W3 +24V DC
FEATURES
POSITION POSITION POWER
A A Not Required Surge Protection without Termination
B B Mandatory Surge Protection and Termination
A B Not Allowed Combination
B A Not Allowed Combination

CI-3305 Appendix 4 Page 2 NIB


Section 2
CONFIGURATION & CONNECTIONS

2.1 MASTER-TO-SLAVE DISTANCES

The maximum distance of an RS-485 network line should not exceed 4000 feet. Shown
graphically in Figure 2-1, this distance extends from the master unit to the last or most
distant slave. Although this illustration shows three slaves, this distance is applicable to
any number of slaves (each master port can support a maximum of 32 slaves).

The distance from a network line drop to a slave should be kept as small as possible. The
NIBs, which are required in the wiring scheme of Figure 2-1, should be located as close as
possible to the node they are serving.

Figure 2-1 - Application Using NIB Connected to RTU Comm. Port

CI-3305 Appendix 4 Page 3 NIB


2.2 INSTALLING THE NIBs

Once a communication network plan has been established, use the following steps as a
wiring and setup guide:

1. Start at the location of the MASTER node.

2. Mount the NIB as close as possible to the DPC.

3. Remove the NIB's cover. The cover is secured by two captive screws.

4. With the power for the RTU turned off, wire the 24 V dc supply source to the +24V
and -24V terminals of TB1 as shown in Figure 2. Connect a reliable earth ground to
the grounding terminal.

5. Wire up the SDL, RDL, SDT and RDT terminals of the NIB as shown in Figure 2-1.
This arrangement effectively connects the NIB in the TXD (transmit) and RXD
(receive) lines of the DPC. Keep these connections as short as possible.

6. Referring to the left of Figure 2-1, insert jumpers W2 and W3 of the NIB into their
"B" positions. This configuration implements bias termination required at this
location.

7. Replace and secure the cover of the NIB. The NIB installation at this site is now
complete. Note: No other NIBs are required for HART applications.

8. Move to the location of the farthest slave on the line. Repeat steps 2 through 7 but
this time apply the same wiring techniques and jumper configurations to the LAST
SLAVE shown in Figure 2-1.

9. Wire up all MIDDLE SLAVES as shown in Figure 2-1 but do not make any power
connections to the +24V and -24V terminals. However, be certain that the grounding
terminal of each slave node is connected to a reliable earth ground.

10. For all MIDDLE SLAVES, plug in jumpers W2 and W3 as shown at the left. This
configuration disables bias termination while retaining the surge protection feature
required for all nodes.

11. Apply 24 Vdc power to all nodes and check the network for proper operation.

2.3 LIMITS OF SURGE PROTECTION

For RS-485 networks the NIB provides full protection from surges in accordance with ANSI-
IEEE STANDARD C37.90-1978 (published earlier as IEEE STANDARD 472-1974).
However, the limits of this protection are not automatically extended to other types of
communication equipment requiring different drivers. These exceptions are noted in the
following warning:

CI-3305 Appendix 4 Page 4 NIB


Warning

The NIB does not provide surge protection for RS-423 drivers (Type 26LS29) wired
in parallel to RS-485 or RS-422 IC drivers of other equipment. For these situations,
the RS-423 driver should be disengaged by using strapping options where
provided, or by removing the Type 26LS29 plug-in IC from its socket at the
appropriate communication port. A damaged RS-423 driver that is paralleled
across an RS-485 driver will inhibit network communications.

2.4 USING NIBs IN HART§ NETWORKS

Note: HART· is a registered trademark of the HART· Communication


Foundation of Austin, Texas, USA. Any time the term HART is used
hereafter in this document, the term implies the registered
trademark.

NIBs are required on a HART Network when the HART Device Interface (HDI) is configured
for RS-485 Operation and multiple HDI assemblies are connected to a single 33XX
DPC/RTU. Figure 3 shows a single 33XX DPC/RTU interfaced to multiple HDI assemblies
which in turn are each connected to a groups of HART slaves.

@?G5B

CE@@<I 

##HH 
BC$(% 849 81BD C<1F5
gYdX 9> BC$(%  !  !%
>92
!  !& 7B?E@C ?6
C<1F5 45F935C
 81BD C<1F5
849
9> BC$(%  !  !%

Figure 2-2 - Multiple HDI Assemblies Connected to Multiple groups of HART Slaves

Refer to Appendix 5 for information on installing and configuring the HDI Board.

CI-3305 Appendix 4 Page 5 NIB


CI-3305 Appendix 4 Page 6 NIB
Section 3
SPECIFICATIONS

3.1 OPERATIONAL REQUIREMENTS

The NIB requires 24VDC power when used for line termination.

3.2 ENVIRONMENTAL SPECIFICATIONS

Temperature: Operating = -30…C to +70…C


-22…F to +158…F

Storage = -40…C to +100…C


-40…F to +212…F

Relative Humidity: 0 - 95% Non-condensing

Vibration: 10 - 150 Hz @ .5g

RFI Susceptibility: 10V/Meter from 10MHz to 550MHz

3.3 SURGE PROTECTION LIMITS

RS-485 Networks: Full protection from surges in accordance


with ANSI-IEEE Standard C37.90-1978,
published earlier as IEEE Standard 472-
1974. (See Page 5 - Warning prior to
implementation).

RS-422 Networks: Partial protection from surges. Typically


at 60% of the surge voltages of the
ANSI/IEEE Standard C37.90-1978. If full
protection is desired, it may be
accomplished by replacing the RS-422 IC
drivers with RS-485 IC drivers in the
appropriate communications ports in all
the BBI equipment throughout the
network. (See Page 5 - Warning prior to
implementation).

3.4 POWER REQUIREMENTS

Power must be provided if the NIB is used with the termination engaged.

Input Voltage: Nominal = 24V DC


Range = 21V to 28V DC

Input Current: 45mA Max.

CI-3305 Appendix 4 Page 7 NIB


Isolation: 500V DC between the input power
terminals and the termination network.

Fusing: 1/8A subminiature fuse for protection from


reverse DC connection.

Grounding: Earth ground must be connected to TB1-3


at all times using proper grounding
practices.

CAUTION:
In the absence of a good earth ground, the
surge protection by the NIB is
compromised or nullified.

3.5 DIMENSIONS (See Figure 3-1)

Figure 3-1 - NIB Assembly Dimensions

CI-3305 Appendix 4 Page 8 NIB


HIGHWAY ADDRESSABLE
REMOTE TRANSDUCER
(HARTÒ)
DEVICE INTERFACE
Part No. 392930-01-3
(For Models 33XX)

For The Following BBI Instruction Manuals:


CI-3305, CI-3310, CI-3330 & CI3335

Bristol Babcock
Product Information Package PIP-HART33XX - January 2003
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 at-
tention 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.

HART® is a registered trademark of the HART Communication Foundation, Austin, Texas


USA. ACCOL™ is a 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) 2003, 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.
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 Babcock 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, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional information is required, the purchaser is advised to contact Bristol
Babcock.

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol Babcock for repairs or evaluation,


please note the following: The party sending such materials is responsible to ensure
that the materials returned to Bristol Babcock 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 Babcock and save
Bristol Babcock harmless from any liability or damage which Bristol Babcock 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 BBI supplemental document S14006 for proper care and handling
of ESD-sensitive components.

Bristol Babcock 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.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from
defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol are expressly limited
to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part
thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER


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

F. No agent of Bristol is authorized to assume any liability for it or to make any written
or oral warranties beyond those set forth herein.

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 Water-
town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

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


resulting from breach of any agreement relating to items included in this quotation
from use of the information herein or from the purchase or use by Buyer, its
employees 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 Babcock 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 Babcock 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 BBI 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 Babcock Web site
(www.bristolbabcock.com) and sending it via E-Mail to brepair@bristolbabcock.com.
A BBI 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 Babcock Inc.


Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

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

D. Phone
Calling the BBI Repair Department at (860) 945-2442. A BBI 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 in-
cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.
&VMWXSP &EFGSGO -RG 6ITEMV %YXLSVM^EXMSR *SVQ
(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to
receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is Please be aware of the Non warranty standard charge:
practice may be requested in the “Special Requests” section. • There is a $100 minimum evaluation charge, which is
• Evaluate / Test / Verify Discrepancy applied to the repair if applicable (√ in “returned”
• Repair / Replace / etc. in accordance with this form B,C, or D of part III below)
• Return to Customer
Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)

Bill to : Ship to:

Purchase Order: Contact Name:____________________________________


Phone: Fax: E-Mail:

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

Model No./Part No. Description


Range/Calibration S/N
Reason for return : Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)


2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________
3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due
to BBI’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 BBI 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 Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-3875

Form GBU 13.01 Rev. A


Bristol Babcock
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 Babcock offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at four locations: Houston, Birmingham, 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 Babcock 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) 945-2269. For Houston classes, you can also contact our Houston office, at (713) 685-
6200.
BLANK PAGE
A Few Words About Bristol Babcock

For over 100 years, Bristol7 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 Babcock 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 assis-
tance in using this product from the following sources:

Contacting Bristol Babcock Directly

Bristol Babcock's world headquarters are 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 Babcock's Application Support Group can provide
telephone support for your technical questions.

For technical questions about TeleFlowÔ products call (860) 945-8604.

For technical questions about ControlWave call (860) 945-2244 or (860) 945-2286.

For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-2501 or
e-mail: openenterprise@bristolbabcock.com

For technical questions regarding ACCOL products, Open BSI Utilities, as well as
Bristol's Enterprise Server7/Enterprise Workstation7 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 Babcock hardware to radios, contact Bristol Babcock’s
Communication Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-
9464.

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) or to
your Bristol-authorized sales representative. A list of

Please call the main Bristol Babcock 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 Babcock and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol Babcock’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) 945-2269 for course
information, enrollment, pricing, and scheduling.
PIP-HART33XX
HIGHWAY ADDRESSABLE REMOTE TRANSDUCER
(HART®)
DEVICE INTERFACE

TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION......................................................................................................... 1


1.2 FEATURES...................................................................................................................................... 1
1.3 THEORY .......................................................................................................................................... 1
1.4 HDI DESCRIPTION ....................................................................................................................... 2
1.4.1 HDI Board Connectors .................................................................................................................... 2
1.4.2 HDI Board Status LEDs ................................................................................................................. 3
1.4.3 HDI Board Circuitry........................................................................................................................ 4

Section 2 - CONFIGURATION & CONNECTIONS

2.1 RESTRICTIONS & ASSUMPTIONS ............................................................................................. 7


2.1.1 HART Slave Devices........................................................................................................................ 7
2.1.2 3508 Smart Transmitters ............................................................................................................... 7
2.2 CONFIGURAING A SINGLE HDI BOARD .................................................................................. 8
2.2.1 RS-485 Interface - To a Single HDI Board..................................................................................... 8
2.2.2 RS-232 Interface - To a Single HDI Board................................................................................... 10
2.2.3 Configuring Multiple HDI Assemblies into a Single 33XX Master ............................................ 11
2.2.3.1 Multiple HDI Boards Configured for RS-485 Operation ............................................................. 11
2.2.3.2 Multiple HDI Boards Configured for RS-232 Operation ............................................................. 13

Section 3 - SPECIFICATIONS

3.1 HART COMMUNICATION PROTOCOL PARAMETERS


FOR PHYSICAL LINK ................................................................................................................. 15
3.2 HART DEVICE IMPEDANCE SPECIFICATION....................................................................... 15
3.3 HART DEVICE POWER SUPPLY REQUIREMENTS ............................................................... 15
3.4 PHASE SHIFT SPECIFICATION................................................................................................ 15
3.5 PERFORMANCE SPECIFICATION............................................................................................ 15
3.6 ENVIRONMENTAL SPECIFICATION ....................................................................................... 16

SUPPLEMENTS

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

REFERENCE DOCUMENTS

(Note: These documents are not provided in this manual)

BBI HART MASTER PROTOCOL MANUAL........................................................................D4068


BBI ACCOL II REFERENCE MANUAL ...............................................................................D4044
HART® FSK PHYSICAL LAYER SPECIFICATION -
HART® Communication Foundation Document Number .......................................HCF_SPEC-54

PIP-HART33XX Page 0-1 Table Of Contents


BLANK PAGE
Section 1
INTRODUCTION

1.1 GENERAL INTRODUCTION

Note: HART® is a registered trademark of the HART® Communication


Foundation of Austin, Texas, USA. Any time the term ‘HART’ is
used hereafter in this document, the term implies the registered
trademark.

Highway Addressable Remote Transducer (HART) Device Interfaces (HDI) allows HART
slave devices or BBI 3508 transmitters to communicate with a BBI Series 33XX DPC/RTU,
i.e., 3305s, 3310s, 3330s, and 3335s. The HDI supports RS-232 and RS-485 interfaces. The
interface to the field devices is composed of a jumper selectable 249 ohm resistor in parallel
with an AC coupled transformer. An HART/TIB ACCOL Custom Module and the con-
figuration of a host (33XX) communications port as a custom port in ‘HART mode’ are
required to support the protocol (Data Link Layer) for HART devices. The ACCOL Master
Module is used to support RS-232 configured HDIs for communication with BBI 3508 trans-
mitters. Each HDI can interface with up to 15 HART slave devices.

1.2 FEATURES

· Selectable RS-232 or RS-485 Interface to DPC/RTU


· Transformer Coupled Comm. Interface to HART devices
· Operates from external 9 to 30 VDC power source
· Usable with both HART slave devices and BBI 3508 transmitters. RS-232/RS-485 mode
of communications is valid for HART slave devices. RS-232 mode is valid for BBI 3508s.
· Conforms to HART® FSK Physical Layer Specification.

1.3 THEORY

The BBI HART Device Interface (HDI) provides for master/slave communications, with the
master originating each transaction, and slaves only generating replies when prompted by
the master. HART allows for 2 ‘masters’ on a single link. The “Primary Master” is the
normal control-system master, and when required, a hand-held communicator can be used
as the “Secondary Master,” for maintenance purposes. Primary and secondary masters must
be configured to use separate addresses.

The BBI HDI board provides an RS-485/232 interface to a BBI 33XX DPC/RTU Com-
munications Port and a two-wire (voltage sourced or current sourced) connection to a ‘HART
device’ or to a BBI 3508. Twisted-pair copper cable is used as the medium.

The HART Device Interface operates from 9 to 30 VDC bulk supply. The assembly supports
RS-232 or RS-485 interfaces to the host BBI 33XX DPC/RTU. The signals are TXD, RXD,
CTS, RTS and CD for RS-232 operations and +TXD, -TXD, +RXD and -RXD for RS-485
operation. Interface to the field device is composed of a jumper selectable 249 ohm resistor
in parallel with an AC coupled transformer. FSK signal amplitude during transmission is
between 400 to 600 mV with the average value of the FSK signal at 0 V. The HDI board

PIP-HART33XX Page - 1 HART Device Interface


receiver input requires a signal that must be in the range of 120 mV to 1.5 V (Peak-to-Peak).
FSK signals from the field devices below 80 mV (Peak-to-Peak) will be ignored by the inter-
face board.

1.4 HDI DESCRIPTION

The HART Adapter Interface Board is assembled in a DIN Rail Mounting Assembly. This
assembly measures 5.56” long by 4.37” in high by 1.06” deep. In addition to 8 selectable
jumpers and 4 status LEDs, the HDI Board contains three connectors (see Figures 1 & 10).

1.4.1 HDI Board Connectors

J1 - a 9-Pin D-Type Connector for the RS-232 Interface (see Table 1)


TB1 - a 6-Point Term. Block for the RS-485 Interface and the Input Power (see Table 2)
TB2 - a 2-Point Terminal Block for Slave Device Field Connections (see Table 3)

Figure 1 - HART Device Interface Assembly

PIP-HART33XX Page - 2 HART Device Interface


Table 1 - RS-232 Interface Connector J1 Signal Identification

PIN # RS-232 SIGNAL SIGNAL DESCRIPTION DCE I/O


1 DCD Data Carrier Detect Output
2 /TXD Transmit Data NOT Input
3 /RXD Receive Data NOT Output
5 GND Ground -
6 CTS Clear to Send Output
7 RTS Request to Send Input

Table 2 - Power & RS-485 Interface Connector TB1 Signal Identification

PIN # NAME DESCRIPTION


1 VIN +9 - +28 VDC Input Power (+)
2 GND Power Ground (-)
3 -RXD - TX Data from 33XX
4 +RXD + TX Data from 33XX
5 -TXD - RX Data to 33XX
6 +TXD + RX Data to 33XX

Table 3 - Slave Device Field Connector TB2 Signal Identification

PIN # FIELD CONNECT


1 Field Loop (no polarity)
2 Field Loop (no polarity)

Table 4 - HDI Board Jumper Identification and Assignment

JUMPER # DESCRIPTION POS. 1-2 POS. 2-3


W1 RS-232 Mode Disabled N/A**
W2 3508 Mode (10 mS ON Delay) Disabled Enabled
W3 *RS-485 Rcvr. 120 ohm Terminator Enabled Disabled
W4 *RS-485 Rcvr. Positive Bias Enabled Disabled
W5 *RS-485 Rcvr. Negative Bias Enabled Disabled
W6 *RS-485 Xmtr. 120 ohm Terminator Enabled Disabled
W7 Status LED Enable Enabled Disabled
W8 249 Ohm Loop Resistor Connected Open
* = Install on RS-485 End Node
** = W1 is a 2 position Jumper, Installed = RS-232 Disabled/RS-485 Enabled,
Removed = RS-232 Enabled/RS-485 Disabled

1.4.2 HDI Board Status LEDs

There are four status LEDs on the HDI Board. LEDs CR14 through CR17 reflect the status
of the active states of Transmit Data NOT (/TXD), Receive Data NOT (/RXD), Data Carrier
Detect NOT (/DCD) and Request to Send NOT (/RTS). A logic “0” state of TXD or RXD will

PIP-HART33XX Page - 3 HART Device Interface


light CR14 or CR15 respectively. The four LEDs can be disabled by placing jumper W7 in
position 2-3.

CR14 = /TXD (Transmit Data NOT)


CR15 = /RXD (Receive Data NOT)
CR16 = /DCD (Data Carrier Detect NOT)
CR17 = /RTS (Request to Send NOT)

1.4.3 HDI Board Circuitry

The HDI board has a built-in ±5V DC Switching Power Supply that is fused and operates
from a bulk 9V to 30V DC. A blocking diode protects the power supply circuitry from
reversed input power conditions.

Except for the Power Supply, the major components of the HART Device Interface board are
shown in the block diagram (Figure 2).

There are independent RS-232 and RS-485 transceivers which are jumper selectable. A 120
ohm biasing resistor is jumper selectable for the RS-485 transmit lines. A 120 ohm
terminator and biasing resistors are jumper selectable for the RS-485 receive lines.

TXD RS485 +TX


RTS485/232 TXD -TX
20C12 RTS XMTR
RXD GEN. RXD RCVR +RX
DCD DCD +TERM -RX

BANDPASS RS485/
RTS RS232
RS232
FILTER/ CONTROL
SWITCH SELECT

RTS232
TXD
XMTR 3508 RXD
RTS/CTS CTS RS232 RTS
DRIVE/ XCEIVER
SWITCH 10 MSEC RXD CTS
DELAY DCD DCD

3508/HART

XFORMER
249 OHM/
JUMPER

Figure 2 - Block Diagram of BBI HDI Board

PIP-HART33XX Page - 4 HART Device Interface


When the HDI is configured to communicate with slave devices which support the HART
protocol, and the communication mode between the HDI and the 33XX device is RS-232.
CTS NOT is asserted 100 microseconds after RTS NOT becomes valid. In the RS-485 mode,
RTS NOT is generated by a 1 to 0 transition of TXD. For BBI 3508 applications in RS-232
mode, a 10 millisecond RTS NOT to CTS NOT delay is selected to emulate the existing TIB
design. The added combination of RTS232 NOT and RTS485 NOT enables the 20C12 FSK
modem’s transmit circuitry, enables the CMOS switch to the transformer and disconnects
the receive signal to the FSK modem’s receiver.

The 20C12 FSK modem operates at Bell 202 standards with a 460.8 KHz clock. The
modulated CMOS digital signal from the 20C12 is scaled to a constant ±0.6V level via a
transformer drive circuit that provides a constant output signal with varying loads. The
transformer drive circuit is isolated from the output transformer with a CMOS switch. This
switch is only closed during transmission cycles. The received FSK signal is routed through
a doubler and bandpass filter to the FSK modem. A CMOS switch disconnects the filtered
signal from the input of the FSK receiver during transmit cycles.

The field side of the transformer is AC coupled with a 2.2 µF capacitor to the field devices
and to a jumper selectable 249 ohm load resistor.

RS-232 and RS-485 signals are transorb protected from surge transients and electo-static
discharge (ESD).

PIP-HART33XX Page - 5 HART Device Interface


Section 2
CONFIGURATION & CONNECTIONS
2.1 RESTRICTIONS & ASSUMPTIONS

For multidrop configurations, the field devices are placed in a “digital mode” of operation
with the loop current for the device set at 4mA or less. The input impedance of the master in
receive mode is 249 ohms. The maximum number of field devices that can be placed in
parallel with a 24V supply is determined by the following equation: Max. # of Field devices
= {(24V - V(Field device) - [4mA x 249 x #(Field Devices)] - [4mA x #(Field devices) x Wire
Resistance] - 2Vloop} >0V. This calculation implies that the maximum number of trans-
mitters, which require a minimum of 12V to operate in a loop, is 10 when the wire
resistance is not included. The power supply voltage must exceed 24V if more than 10 trans-
mitters are to be connected in parallel. Note: The maximum number of transmitters that can
be connected in parallel is not to exceed 15.

Field devices with a maximum ID number of 15 cannot be mixed with field devices with a
maximum ID number of 2 24.

2.1.1 HART Slave Devices

The Carrier On Delay and Carrier Off Delay as specified in the HART Foundation Data
Link Layer specification, states that the delay from an idle line to/from an acceptable signal
level is 5 bit times maximum. For HDIs configured for RS-232 communications mode, the
carrier On delay will be met, but, the off delay may exceed the 5 bit time requirement (but
the delay will be less than 12 bit times). HART slave devices are required to send a
minimum of 5 preambles. The 20C12 FSK Modem located on the HDI board will output
receive data within 9 to 15 milliseconds after the transmit cycle is completed. At 1200 baud,
one character time is 11 x 0.833 milliseconds or 10 milliseconds. The slave device will start
to transmit the preamble one character time after the end of the last character sent from the
master device. The total delay from the end of the last character sent from the master to
valid receive data is 25 milliseconds. Since there is a 1 character delay from the HART
module, the receive communications driver will synchronize on the third preamble at the
latest. The receive communications driver for the HART ACCOL module requires one
preamble before the start of data.

For the RS-485 mode, the off delay will be between 12 to 18 milliseconds. This is equivalent
to 2 characters. The 20C12 FSK Modem takes 9 to 15 milliseconds to assert Carrier Detect
(CD) and valid data. The total delay is 33 milliseconds. The slave device will delay 1
character time, which is 9 milliseconds. The difference is 33 - 9.2 = 23.8 milliseconds. This is
about 2.6 characters. Two valid preambles will be seen by the receive communications
driver for the HART ACCOL module, which is sufficient before the start of data.

2.1.2 3508 Smart Transmitters

In the RS-232 communications mode, the HDI can operate properly with 3508 transmitters.
The 10 millisecond RTS/CTS delay must be selected.

PIP-HART33XX Page - 6 HART Device Interface


With existing 33XX firmware, the HDI will not communicate with 3508 TELETRANS when
configured in the RS-485 communications mode. A programmable length preamble is
required.

2.2 CONFIGURING A SINGLE HDI BOARD

2.2.1 RS-485 Interface - To a Single HDI Board (see Figures 3, 4 & 5)

Note: The maximum length of an RS-485 cable should not exceed 4000 feet.

Follow steps 1 through 4 below to configure a single HDI assembly for RS-485/HART inter-
face operation.

1. Install the HDI Assembly in a suitable location (DIN Rail mounted). Connect the power
supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.

2. Connect the HDI board to the HART slaves as shown in Figure 4 (for 4-20mA current
sourced transmitters) or to a single HART slave device as shown in Figure 5 (for a +12 to
+45 VDC voltage sourced transmitter).

3. Configure the 33XX Port in question for RS-485 operation (see the HART Master
Protocol Manual, Document # D4068) and connect the port in question to TB1 of the HDI
board (see Table 2 for HDI - TB1 designations) (see Figure 3 for 33XX D-Type RS-485
designations). Note: With existing 33XX firmware, the HDI board will not communicate
with a 3508 TELETRANS when configured for RS-485 operation.

Figure 3 - 33XX RS-485 D-Type Port Assignment

4. Set the HDI board Jumpers as follows:

Jumper W1 - RS-232 Mode - in position 1-2 (Disabled).


Jumper W2 - In position 1-2 (Disabled) - for all except 3508 Mode.
Jumper W3 - In position 1-2 (Enabled) places a 120 ohm termination resistor across
the RS-485 receive lines.
Jumper W4 - RS-485 Receiver Positive Bias - position 1-2 = Enabled.
Jumper W5 - RS-485 Receiver Negative Bias - position 1-2 = Enabled.
Jumper W6 - In position 1-2 (Enabled) places a 120 ohm termination resistor across
the RS-485 transmit lines.
Jumper W7 - In position 1-2 to Enable the Status LEDs, or position 2-3 to disable
them.

PIP-HART33XX Page - 7 HART Device Interface


Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the
Power Supply loop (for 4-20 mA Current Loop Transmitters). In position
2-3 for a voltage output slave device.

Figure 4 - Hart Slaves (Transmitters)(with 4-20 mA Current Source)


Connected to 33XX via HDI Board in RS-485 Mode

Figure 5 - Hart Slave (Transmitter)(with +12 to +45 VDC Voltage Source)


Connected to 33XX via HDI Board in RS-485 Mode

PIP-HART33XX Page - 8 HART Device Interface


2.2.2 RS-232 Interface - To a Single HDI Board (see Figures 6, 7 & 8)

Follow steps 1 through 4 below to configure a single HDI assembly for RS-232 interface
operation.

Note: The maximum length of an RS-232 cable should not exceed 25 feet.

1. Install the HDI Assembly in a suitable location (DIN Rail mounted). Connect the power
supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.

2. Connect the HDI board to the HART slaves as shown in Figure 7 (for 4-20mA current
sourced transmitters) or to a single HART voltage output slave device as shown in
Figure 8.

3. Configure the 33XX Port in question for RS-232 operation (see the HART Master
Protocol Manual, Document # D4068 if HART operation is required or the ACCOL II
Reference Manual, Document # D4044 when interfacing to a 3508 transmitter). Connect
the port in question to J1 of the HDI board (see Table 1 for HDI - J1 designations) (see
Figure 6 for 33XX RS-232 cable designations.

Figure 6 - 33XX RS-232 Cable

Figure 7 - Hart Slaves (Transmitters)(with 4-20 mA Current Source)


Connected to 33XX via HDI Board in RS-232 Mode

PIP-HART33XX Page - 9 HART Device Interface


4. Set the HDI board Jumpers as follows:

Jumper W1 - RS-232 Mode - stored in position 1 or 2 (Enabled).


Jumper W2 - In position 2-3 (Enabled) for 3508 Mode - 10 millisecond delay. In position
1-2 (Disabled) - for all except 3508 Mode.
Jumper W3 - In position 2-3 = Disabled.
Jumper W4 - In position 2-3 = Disabled.
Jumper W5 - In position 2-3 = Disabled.
Jumper W6 - In position 2-3 = Disabled.
Jumper W7 - In position 1-2 to Enable the Status LEDs, or position 2-3 to disable them.
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the Power
Supply loop (for 4-20 mA Current Loop Transmitters). In position 2-3 for a
HART voltage output slave device.

Figure 8 - Hart Slaves (Transmitters) (with +12 to +45 VDC Voltage Source)
Connected to 33XX via HDI Board in RS-232 Mode

2.2.3 Configuring Multiple HDI Assemblies into a Single 33XX Master

2.2.3.1 Multiple HDI Boards Configured for RS-485 Operation

When configured for RS-485 operation, more than one HDI board may be used in
conjunction with a single 33XX Port to support multiple groups (1 to 15 slave devices
interfaced to a single HDI board) of HART slave devices. When so configured, the 33XX port
as well as the HDI boards must be configured for RS-485 communications. Figure 9 shows
an example of such a network (configured for RS-485 operation). Depending on the type of
transmitter, the HDI board will be configured for Current Source or Voltage Source as
described earlier.

This configuration requires the use of a BBI Network Interface Box at the 33XX.

Note: The maximum length of an RS-485 cable should not exceed 4000 feet.

Follow steps 1 through 5 below to configure multiple HDI assemblies for RS-485/HART
inter-face operation.

1. Install each HDI Assembly in a suitable location (DIN Rail mounted). Connect the power
supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.

PIP-HART33XX Page - 10 HART Device Interface


2. Connect each HDI board to the HART slaves as shown in Figure 4 (for 4-20mA current
sourced transmitters) or to a single HART slave device as shown in Figure 5 (for a +12 to
+45 VDC voltage output transmitter).

3. Install a BBI NIB assembly at the 33XX in question. Refer to the appropriate 33XX
product manual for information on installing the NIB assembly.

4. Configure the 33XX Port in question for RS-485 operation (see the HART Master
Protocol Manual, Document # D4068) and connect the port in question to TB1 of the HDI
board (see Table 2 for HDI - TB1 designations) (see Figure 3 for 33XX D-Type RS-485
desig-nations).

Figure 9 - Multiple HDI Assemblies Connected to Multiple Groups of HART Slaves

5. Set the HDI board Jumpers as follows:

Jumper W1 - Installed = RS-485 Mode Enabled.


Jumper W2 - In position 1-2.
Jumper W3 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 receive lines. Jumper W3 should be placed in position 1-2 for the
most distant HDI board (End Node) and placed in position 2-3 (Disabled)
for all other nodes.
Jumper W4 - RS-485 Receiver Positive Bias - position 1-2 = Enabled, position 2-3 =
Disabled. Jumper W4 should be placed in position 1-2 for the most distant
HDI board (End Node) and placed in position 2-3 (Disabled) for all other
nodes.
Jumper W5 - RS-485 Receiver Negative Bias - position 1-2 = Enabled, position 2-3 =
Disabled. Jumper W5 should be placed in position 1-2 for the most distant
HDI board (End Node) and placed in position 2-3 (Disabled) for all other
nodes.

PIP-HART33XX Page - 11 HART Device Interface


Jumper W6 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 transmit lines. Jumper W6 should be placed in position 1-2 for the
most distant HDI board (End Node) otherwise in position 2-3 (Disabled).
Jumper W7 - In position 1-2 to Enable the Status LEDs, or in position 2-3 to disable
them.
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the Power
Supply loop (for 4-20 mA Current Loop Transmitters). In position 2-3 for a
HART voltage output slave device.

2.2.3.2 Multiple HDI Boards Configured for RS-232 Operation

When configured for RS-232 operation, no more than one HDI board may be used in
conjunction with a single 33XX Port. Each 33XX Port can support a group of up to fifteen
(15) HART or five (5) 3508 slave devices. If a single 33XX device must communicate with
multiple groups, the HDI board associated with each group must be wired to a discrete
33XX Port, i.e., a Port dedicated to the HDI board (and group) in question. Depending on the
type of transmitters, each HDI board will be configured for Current Source or Voltage
Source as described earlier.
4.370“

5.70“ 1.06“

Figure 10 - HART Device Interface Assembly Dimensions

PIP-HART33XX Page - 12 HART Device Interface


Section 3
SPECIFICATIONS
3.1 HART COMM. PROTOCOL PARAMETERS FOR PHYSICAL LINK

DESCRIPTION VALUE
Min 400 mV p-p
Master Transmitted Signal
Max 600 mV p-p
Min 0.8 mA p-p
Slave Transmitted Signal
Max 1.2 mA p-p
Minimum Slave Signal, Converted by a 230 ohm load 184 mV p-p
Maximum Slave Signal, Converted by a 1100 ohm load 1320 mV p-p
Receiver Sensitivity (must receive correctly) 120 mV to 2.0 V p-p
Receiver Sensitivity (must ignore) 80 mV p-p

3.2 HART DEVICE IMPEDANCE SPECIFICATION

DEVICE DESIGNATION VALUE


Primary Master (Including Shunt Impedance (Rx) 230 - 1100 ohms
Load Resistor) Max. Source Impedance (Tx) 700 ohms
Min. Shunt Impedance (Rx) 5 Kohms
Secondary Master
Max. Source Impedance (Tx) 100 ohms
Min. Shunt Resistance 100 Kohms
Slave Device
Maximum Shunt Capacitance 5000 pF
Min. Shunt Impedance 10 Kohms
Miscellaneous Devices (Total)
Max. Series Impedance 100 ohms

3.3 HART DEVICE POWER SUPPLY REQUIREMENTS

DESCRIPTION VALUE
Maximum Ripple (47 to 125 Hz) 0.2V p-p
Maximum Noise (500 Hz to 10 KHz) 1.2mV rms
Maximum Series Impedance (500 Hz to 10 KHz) 10 ohms

3.4 PHASE SHIFT SPECIFICATION

The maximum phase shift for the master or slave at 1200 and 2200 Hz input frequencies is
45 degrees [3dB (0.707) attenuation]. Each device in the loop and the loop wire must be
considered for capacitance and resistance.

3.5 PERFORMANCE SPECIFICATION

HDI Communications Interface: RS-232/485 Interface - switch selectable

HART Device Interface: Current Input Device

PIP-HART33XX Page - 13 HART Device Interface


3.5 PERFORMANCE SPECIFICATION (Continued)

FSK Modem: Bell 202 Compatibility (1200 Hz/2200 Hz Modulation)

Power Consumption: RS-232 @ 9V - 35.57mA


@ 28V - 17.9mA
RS-485 @ 9V - 42.66mA when receiving
@ 28V - 20.09mA when receiving

3.6 ENVIRONMENTAL SPECIFICATIONS

Temperature: Operating - (-40 to 70)ºC (-40 to 152)ºF


Storage - (-40 to 85)ºC (-40 to 185)ºF

Relative Humidity: 15 - 95% non-condensing

Vibration: 1G for 10 - 150 Hz


0.5G for 150 - 2000 Hz

RFI Susceptibility: 10V/Meter - 20MHz to 500MHz

PIP-HART33XX Page - 14 HART Device Interface


HART® Device Interface
Special Instructions for Class I, Division 2 Hazardous Locations

1. The BBI Highway Addressable Remote Transducer (HART) Device Interface (HDI) is
listed by Underwriters Laboratories (UL) as nonincendive and is suitable for use in
Class I, Division 2, Groups A, B, C and D hazardous locations or nonhazardous
locations only. Read this document carefully before installing a nonincendive BBI
HART Device Interface. In the event of a conflict between the HART Device Interface
User Manual (PIP-HART33XX) and this document, always follow the instructions in
this document.

2. 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.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair


suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,


turn off power before servicing/replacing the unit and before installing or
removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the


power has been switched off or the area is known to be nonhazardous.

07/21/2000 Appendix A of PIP-HART33XX - HDI Page 1 of 1


BLANK PAGE
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DOCUMENT NUMBER: PIP-HART33XX


TITLE: Highway Addressable Remote Transducer Device Interface for Instruction Manuals
CI-3305, CI-3310, CI-3330 & CI-3335 Product Information Package
ISSUE DATE: JAN., 2003
COMMENT/COMPLAINT:

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Appendix 6 Issue: 04/02

RTU 3305 POWER SUPPLY/BATTERY CHARGER

For Instruction Manual CI-3305

+
6 _
5
4
3
2
1

Bristol Babcock
RTU 3305 POWER SUPPLY/BATTERY CHARGER

TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION .......................................................................................... 1


1.2 PHYSICAL DESCRIPTION.............................................................................................. 2

Section 2 - CONFIGURATION & CONNECTIONS

2.1 MOUNTING LOCATION/RESTRICTIONS .................................................................... 3


2.2 WIRING THE POWER SUPPLY...................................................................................... 4
2.2.1 Connection to an RTU 3305 & External 12V Battery System........................................ 4
2.2.2 Connection to an RTU 3305 & External 24V Battery System........................................ 5

Section 3 - SPECIFICATIONS

3.1 OPERATIONAL REQUIREMENTS..................................................................6


3.1.1 Power Supply/Battery Charger Specifications ................................................................ 6
3.1.2 Battery Specifications ....................................................................................................... 6
3.2 ENVIRONMENTAL SPECIFICATIONS......................................................................... 7
3.3 BBI PART NUMBERS ...................................................................................................... 7

Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheets on Battery P/N 395407-02-8.

CI-3305 Appendix 6 Page 0-1 Table Of Contents


Section 1
INTRODUCTION

1.1 GENERAL INTRODUCTION

The RTU 3305 Power Supply/Battery Charger is a compact assembly that mounts
externally to the RTU 3305. This linear power supply is actually a battery charger that
contains temperature compensation circuitry. Peak output of the supply is 27.6V for a 24V
system and 13.8V for a 12V system with a 10mA or greater load applied.

The RTU 3305 Power Supply/Battery Charger can operate from 109V to 129V AC at 60 Hz.
Battery charger circuitry will support two 7AH batteries in series for 24V systems and two
7AH batteries in parallel for 12V systems.

Figure 1-1 - RTU 3305 Power Supply/Battery Charger

CI-3305 Appendix 6 Page 1 Power Supply/Battery Charger


The BBI supplied battery system (12V or 24V) will supply power to the RTU 3305 for up to 8
hours.

1.2 PHYSICAL DESCRIPTION (see Figure 1-1)

The open frame RTU 3305 Power Supply/Battery Charger measures 5.5” x 2.75” x 3.5”. It
has eight holes located near its corners which accommodate mounting to an enclosure box or
mounting plate. The unit provides two terminals (1 & 6) for connection to a 117V AC
source, two turret-shaped terminals for DC output power, and a lug on the transformer core
for chassis connection.

CI-3305 Appendix 6 Page 2 Power Supply/Battery Charger


Section 2
CONFIGURATION & CONNECTIONS

2.1 MOUNTING LOCATION/RESTRICTIONS

The RTU 3305 Power Supply/Battery Charger assembly is to be mounted to a backplate. To


maintain correct charging voltage, batteries should be located adjacent to the supply (as
closely as possible) so that their ambient temperature is as close as possible to that of the
battery charger circuit board. To minimize temperature variations between the battery
charger circuit board and the batteries, the battery charger bracket (that has the regulator
attached) should be mounted to a painted aluminum backplate. Heat sink compound should
be placed between the RTU 3305 Power Supply/Battery Charger surface (to which the
Regulator is attached) and the backplate.

BACKPLATE

Heatsink Compound
Between Backplate
&
Power Supply Mounting Surface

BACKPLATE

1
2
3
4
5
_ +
6

Figure 2-1 RTU 3305 Power Supply/Battery Charger Mounting Diagram

CI-3305 Appendix 6 Page 3 Power Supply/Battery Charger


CAUTION

For a power supply that is not heatsunk, the full load ambient operating temperature range
is -40°C to +40°C (-40°F to +104°F). Full load condition only occurs when the batteries are
being charged after a loss of AC power in normal operation; a condition which occurs
infrequently. For full load operation with an ambient temperature range of -40°C to +60°C
(-40°F to +140°F), the power supply should be mounted vertically to a painted aluminum
backplate. Heat sink compound should be placed between the RTU 3305 Power
Supply/Battery Charger surface (to which the Regulator is attached) and the backplate.

2.2 WIRING THE POWER SUPPLY

The following two basic wiring configurations are possible:

1. Connecting the supply to +12V battery system and the RTU 3305 (see Figure 2.2).
2. Connecting the supply to a +24V battery system and the RTU 3305 (see Figure 2-3).

2.2.1 Connection to an RTU 3305 & External 12V Battery System (see Figure 2-2)

Figure 2-2 RTU 3305 Power Supply/Battery Charger Ass’y. Connected to RTU 3305
(With External +12V Battery System)

1. Connect the (+) terminal of the Power Supply to TB3-2 of the MI/OB board and to a 3.0
Amp fuse. Connect the other end of the fuse to the (+) terminal of the 12V battery
system.

CI-3305 Appendix 6 Page 4 Power Supply/Battery Charger


2. Connect the (-) terminal of the Power Supply to TB3-1 of the MI/OB board and the (-)
terminal of the 12V battery system.
3. Connect the AC terminals of the Power Supply to a 60 Hz (109VAC to 129VAC) power
source. A 1 Amp fuse in series with the #1 lead of the transformer is required.
4. Connect the lug on the transformer core to chassis (earth) ground.
5. Connect a 10mA load to the output of the power supply, i.e., a 1K to 1.2K Ohm resistor
and measure the voltage at the power supply output terminals. Adjust the single turn
potentiometer on the battery charger circuit board for a reading of 13.8VDC ±.2%.

2.2.2 Connection to an RTU 3305 & External 24V Battery System (see Figure 2-3)

Figure 2-3 RTU 3305 Power Supply/Battery Charger Ass’y. Connected to RTU 3305
(With External +24V Battery System)

1. Connect the (+) terminal of the Power Supply to TB3-2 of the MI/OB board and to a 1.5
Amp fuse. Connect the other end of the fuse to the (+) terminal of 12V battery 1.
2. Connect the (-) terminal of battery 1 to the (+) terminal of battery 2.
3. Connect the (-)terminal of the Power Supply to TB3-1 of the MI/OB board and to the (-)
terminal of 12V battery 2.
4. Connect the lug on the transformer core to chassis (earth) ground.
5. Connect the AC terminals of the Power Supply to a 60 Hz (109VAC to 129VAC) power
source. A 1 Amp fuse in series with the #1 lead of the transformer is required.
6. Connect a 10mA load to the output of the power supply, i.e., a 2K to 2.4K Ohm resistor
and measure the voltage at the power supply output terminals. Adjust the single turn
potentiometer on the battery charger circuit board for a reading of 27.6VDC ±0.2%.

CI-3305 Appendix 6 Page 5 Power Supply/Battery Charger


Section 3
SPECIFICATIONS

3.1 OPERATIONAL REQUIREMENTS

3.1.1 Power Supply/Battery Charger Specifications

AC Input Voltage: 117VAC ±10% at 60Hz

DC Output Voltage .01A to 1.7A @ 13.8V


.01A to .9A @ 27.6V

Output Ripple Voltage: 10mV RMS for loads of 10mA to 75% of full load

Initial DC Voltage: 13.8V or 27.6V ±0.2%

Long Term Stability: ±1% for 30 days (with constant ambient


temperature, input voltage and load)

Output Voltage TC: ±.03%/Degree C

Line Regulation: ±1% for 10mA to 75% of rated load for


117VAC ±10%

Load Regulation Current Limit: ±20%

Recovery Time: 200msec for 25% to 75% load step change,


voltage change ±1%

Short Circuit Protection: Self resetting thermal shutdown

Reverse Battery: Requires external fuse in battery circuit

Battery Charger TC: -4mV/Degree C/Cell


(12V system -24mV, 24V system -48mV)

3.1.2 Battery Specifications

Open Circuit output Voltage: 12.8VDC

Nominal Output Voltage: 12VDC

Amp Hour Rating: 7.0 AH

Operating Temperature Range: -40°C to +60°C (-40°F to +140°F) (With Heatsink)


-40°C to +40°C (-40°F to +104°F) (w/o Heatsink)

CI-3305 Appendix 6 Page 6 Power Supply/Battery Charger


Charging Temperature Range: -20°C to +50°C (-4°F to +122°F)

3.2 ENVIRONMENTAL SPECIFICATIONS

Temperature: Operating = -40°C to +60°C (-40°F to +140°F)


Storage =-40°C to +70°C (-40°F to +158°F)

Relative Humidity: 15 - 95% Non-condensing

Vibration: 10 - 150 Hz @ 1g
150 - 2000 Hz @ .5g

RFI Susceptibility: 10V/Meter from 20MHz to .5 GHz

3.3 BBI PART NUMBERS

12V RTU 3305 Power Supply/


Battery Charger Assembly BBI P/N 396174-01-9

24V RTU 3305 Power Supply/


Battery Charger Ass’y. BBI P/N 396174-02-7

BBI Supplied +12 Lead Acid Battery BBI P/N 395407-02-8

Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheet on Battery P/N 395407-02-8.

CI-3305 Appendix 6 Page 7 Power Supply/Battery Charger


BLANK PAGE
Product Information Package
PIP-ISORS485
Mar., 2007 Series 33XX, 3508-XX-X, 3530-XX-X & 3808-XX-X

Isolated RS-485 Interface Board


For The Following Bristol Instruction Manuals:
CI-3305, CI-3310, CI-3330, CI-3335
CI-3508-XXX, CI-3530-XXX & CI-3808

www.EmersonProcess.com/Bristol
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this device in some applications may result in
damage or injury. The user is urged to keep this book filed in a convenient location for
future reference.

These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or main-
tenance. Should problems arise that are not covered sufficiently in the text, the pur-
chaser 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, fail-
safe 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 in-


struments 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.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from
defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited
to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part
thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER


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

F. No agent of Bristol is authorized to assume any liability for it or to make any written
or oral warranties beyond those set forth herein.

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 Water-
town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

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


damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.
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 Depart-
ment representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in-
cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.
Bristol Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol to effectively and efficiently process your return. Completion is required to
receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH Line No.____________

Standard Repair Practice is as follows: Variations to this is Please be aware of the Non warranty standard charge:
practice may be requested in the “Special Requests” section. • There is a $100 minimum evaluation charge, which is
• Evaluate / Test / Verify Discrepancy applied to the repair if applicable (√ in “returned”
• Repair / Replace / etc. in accordance with this form B,C, or D of part III below)
• Return to Customer
Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)

Bill to : Ship to:

Purchase Order: Contact Name:____________________________________


Phone: Fax: E-Mail:

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

Model No./Part No. Description


Range/Calibration S/N
Reason for return: Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)


2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________
3. What is the Firmware revision? _____________________ What is the Software & version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due
to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B. If product were found to exceed the warranty period,
would you like the product: 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: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
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) 685-
6200.
A Few Words About Bristol Inc.

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

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

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis-
tance 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.
PIP-ISORS485
ISOLATED RS-485 INTERFACE BOARD
PT. NO. 392909-XX-X

TABLE OF CONTENTS
TITLE PAGE #

DESCRIPTION

Function .................................................................................................................................... 1
Features .................................................................................................................................... 1

COMPONENT IDENTIFICATION

Two-Wire End Node Jumpers W1, W3 & W4 .......................................................................... 3


Four-Wire End Node Jumpers W2, W5 & W6 ......................................................................... 3
Connectors ................................................................................................................................ 4
Switches .................................................................................................................................... 5
Indicators .................................................................................................................................. 5

WIRING

RS-232 Interface Between Isolated RS-485 Intf. Board and the Host Node .......................... 5
RS-485 Interface Between Isolated RS-485 Intf. Board and the Host Node .......................... 6
Isolated RS-485 Port Interface to LAN .................................................................................... 6
Field Terminations for RS-485................................................................................................. 6

ISOLATED RS-485 INTERFACE BOARD SPECIFICATIONS

Performance Specifications ...................................................................................................... 9


Environmental Specifications .................................................................................................. 9
Part Numbers ........................................................................................................................... 9

SUPPLEMENTS

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

PIP-ISORS485 Page 0-1 Table Of Contents


BLANK PAGE
ISOLATED RS-485 INTERFACE BOARD

DESCRIPTION
Function

An Isolated RS-485 Interface Board allows any Bristol Network 3000 product to com-
municate over an isolated master/salve network. Each node on the network that incur-
porates an Isolated RS-485 Interface Board is optically isolated from the rest of the
network, thereby eliminating ground loop and potential difference effects that may degrade
network communication performance. The result is a reliable communication medium for
in-plant or building to building LANs. The Isolated RS-485 Board effectively replaces the
Network Interface Box (NIB).

Features

• On-Board Power Supply


A power supply, operating from a bulk +9 to +35 VDC source, powers the RS-485
circuitry, generating a regulated 5VDC. A 30V transient Voltage Suppresser provides
over-voltage protection on the input terminals. A separate IC provides the -5VDC
required by the RS-232 transceiver. Bulk DC power is interfaced to the board on
Connector TB1. The + DC Bulk is connected to TB1 Pin 1 and the VDC Return or
Ground is supplied to TB1 Pin 2. TB1 Pin 3 is not used.

• Optical Isolation
Optically Isolated 2-Wire or 4-Wire RS-485 circuits with 300VDC isolation eliminates
ground loops and potential difference effects.

• 100Ω Isolated RS-485 Termination For 2\4-Wire Boards & Receiver Biasing
Installation of Jumper W1 is required at each Isolated RS-485 Board associated with
an end node of a Two-wire or Four-wire RS-485 network. In the case of a Four-wire RS-
485 network, the Isolated RS-485 Board’s Jumper W2 must also be installed at each
end node. Units installed at the master node of a 2-wire RS-485 network must also
have Jumper W3 (Receiver Bias to Isolated Ground) & Jumper W4 (Receiver Bias to
Isolated VCC) installed, while units installed at the master node of a 4-wire RS-485
network must also have Jumper W5 (Receiver Bias to Isolated Ground) & Jumper W6
(Receiver Bias to Isolated VCC) installed (See Section - End Node Jumpers W1 through
W6).

• RS-232 or RS-485 Node Interfaces


Networks nodes may connect to the Isolated RS-485 Interface Board via an RS-232 or
RS-485 interface. For installations where each node will include its own Isolated RS-
485 Interface Board and asynchronous operation is required (38.4 KBaud max) an RS-
232 interface may be used. In situations where several nodes will be mounted in close
proximity, as in an equipment cabinet containing two or more DPCs, a single Isolated
RS-485 Interface Board may be employed by multidropping to each slave using the RS-
485 Interface Connector TB3. For LANs that will operate synchronously (187.5 KBaud
to 1 MBaud), all nodes are required to have an RS-485 interface. As with the isolated
LAN itself, up to 32 nodes can be included in a multidrop arrangement. The maximum
distance between communicating nodes on a 2-wire 187.5 KBaud LAN is approximately

PIP-ISORS485 Page 1 Isolated RS-485 Interface Board


1000 feet (300 meters). The maximum distance between communicating nodes on a 4-
wire 1 MBaud LAN is approximately 200 feet (60 meters).

• Surge Protection
Surge suppression on input ports and on the isolated output port meets IEC-801 to
isolated ground.

• Isolated RS-485 Common-Mode Voltage Range


The Isolated RS-485 Port features -7V to +12V common-Mode Input Voltage range with
respect to Isolated ground. The port also includes current limiting and thermal
shutdown circuitry for driver overload protection.

• Switch Selectable Termination, Operating Mode, and 2/4-Wire Configuration


8 position DIP switches S1 and S2 are used to configure the Isolated RS-485 Board’s
various operating parameters associated with port usage and LAN configuration.

• Mounting
The Isolated RS-485 Interface Board measures 4.302” (10.917cm) in width x 4.230”
(10.744cm) in height and may be mounted externally or to the top of an RTU 3305 via a
DIN Rail and DIN Rail Mounting Base. When mounted in a DIN Rail Mounting Base
the unit measures 4.375” (12.112cm) in width x 4.375” (12.112cm) in height.

• PC LAN Functionality
The RS-232 Interface port allows PCs (which only have an RS-232 port) to be net-
worked over an Isolated RS-485 LAN at asynchronous communication rates.

Figure 1 - Isolated RS-485 Board Component Identification Diagram

PIP-ISORS485 Page 2 Isolated RS-485 Interface Board


COMPONENT IDENTIFICATION

The Isolated RS-485 Interface Board has four wiring connectors; J1, TB1, TB2 and TB3,
two configuration switches; S1 and S2, six 2-pin end node configuration jumpers; W1
through W6. Jumpers W1, W3 and W4 are used in on 2-wire networks and Jumpers W1,
W2, W5 & W6 are used on 4-wire networks. The board is protected by an on-board fuse F1
that is rated at .25A.

Figure 2 - Isolated RS-485 Board in a DIN Rail Mounting Base

Two-Wire End Node Jumpers W1, W3 & W4

Jumpers should be placed in an open position, i.e., installed on pin 1 or pin 2 for all nodes
except the end nodes. Jumper W1 provides a 100-Ohm termination across TXD/RXD- and
TXD/RXD+ at the most distant (end) nodes. Two-wire RS-485 LANs also require the use of
jumper W3 to provide Tx\Rx bias to isolated ground and jumper W4 to provide Tx\Rx bias
to isolated VCC. Jumpers W3 and W4 are only required at the Master Node (see Table 1
and Figure 3).

Four-Wire End Node Jumpers W2, W5 & W6

Jumpers should be placed in an open position, i.e., installed on pin 1 or pin 2 for all nodes
except the end nodes. Jumper W2 provides a 100-Ohm termination across RXD- and RXD+
at the most distant (end) nodes. On these networks, W5 provides receiver bias to isolated

PIP-ISORS485 Page 3 Isolated RS-485 Interface Board


ground and W6 provides receiver bias to Isolated VCC. Four-wire networks use W2, W5 and
W6 at the master node and W2 at the other end node, unless the network is to operate at
other than 1Mbaud (synchronous), in which case jumpers W5 & W6 must also be installed
at both end nodes (see Table 1 and Figure 4).

Table 1 - End Node Jumper Assignment

Network Master Node Last Node (Slave


Type Jumpers Installed Jumpers Installed
RS-485 - 2-Wire W1, W3, W4 W1
RS-485 - 4-Wire - 1Mbaud W2, W5, W6 W2
RS-485 - 4-Wire - Not 1Mbaud W2, W5, W6 W2, W5, W6

Connectors

When Connector J1 (9-Pin D-Type) of the Isolated RS-485 Interface Board is connected to a
DPC/RTU, transmitter or computer communications D-Type Connector, an RS-232
interface is established. Connector TB3 of the Isolated RS-485 Interface Board is a 6-Pin
Terminal Block that accommodates interface to an RS-485 port. RS-485 Input Connector
TB3 can be multidropped with up to 32 other RS-485 ports. Connector TB2 provides an
interface to a 2-wire or 4-wire isolated RS-485 network. Input power is provided on
Terminal Block TB1. Tables 2 through 5, which follow, provide a description of each
connector’s functionality:

Table 2 - Power Connector TB1 Wiring List

Pin # Signal Name Description


1 +VDC Input +9V to +35V DC Bulk
2 VDC Return Bulk Return/Ground
3 Not Used N/A

Table 3 - Isolated RS-485 Port Interface Connector TB2 Wiring List

Pin # Signal Name Description


1 TXD/RXD+ (2-Wire) TXD/RXD+ Signal on 2-wire circuits
TXD+ (4-Wire) TXD+ Signal on 4-wire circuits
2 TXD/RXD-(2-Wire) TXD/RXD- Signal on 2-wire circuits
TXD- (4-Wire) TXD- Signal on 4-wire circuits
3 RXD+ (4-Wire) RXD+ Signal on 4-wire circuits
4 RXD- (4-Wire) RXD- Signal on 4-wire circuits
5 Isolated GND Isolated Ground
6 Chassis GND Chassis Ground

Table 4 - RS-232 Input Port Interface Connector J1 Wiring List

Pin # Signal Name Description


2 TXD RS-232 Transmit Data
4 RXD RS-232 Receive Data
5 RTS RS-232 Request To Send
9 GND RS-232 Ground
Note: Connector Pins 1, 3, 6, 7 & 8 are not used on Connector J1

PIP-ISORS485 Page 4 Isolated RS-485 Interface Board


Table 5 - TB3 RS-485 Input Port Interface Connector TB3 Wiring List

Pin # Signal Name Description


1 TXD+ RS-485 Input Interface Signal Transmit Data Plus (+)
2 TXD- RS-485 Input Interface Signal Transmit Data Minus (-)
3 RXD+ RS-485 Input Interface Signal Receive Data Plus (+)
4 RXD- RS-485 Input Interface Signal Receive Data Minus (-)
5 RTS+ RS-485 Input Interface Signal Request To Send Plus (+)
6 RTS- RS-485 Input Interface Signal Request To Send Minus (-)

Switches

Two eight position DIP Switches are provided for board and network configuration. The
functionality of these switches are provided in Tables 6 and 7 below:

Table 6 - Switch S1 Configuration Settings

Position Setting Function


1 ON Select RS-232 Input Port
1 OFF Select RS-485 Input Port
3&4 ON Enable RS-485 Terminator for TXD+/-
3&4 OFF Disable RS-485 Terminator for TXD+/-
5&6 ON Enable RS-485 Terminator for RTS+/-
5&6 OFF Disable RS-485 Terminator for RTS+/-
7&8 ON Enable RS-485 Terminator for RXD+/-
7&8 OFF Disable RS-485 Terminator for RXD+/-

Table 7- Switch S2 Configuration Settings

Position Setting Function


1, 3 & 5 ON Select RS-232 Input Port
1, 3 & 5 OFF Select RS-485 Input Port
2, 4 & 6 ON Select RS-485 Input Port
2, 4 & 6 OFF Select RS-232 Input Port
7 ON 4-Wire Network
7 OFF 2-Wire Network
8 ON 2-Wire Network
8 OFF 4-Wire Network

Indicators

There are Two LEDs on the Isolated RS-485 Interface Board. LED DS1 will be illuminated
when data is being transmitted and LED DS2 will be illuminated when data is being
received.

WIRING
RS-232 Interface Between Isolated RS-485 Intf. Board and the Host Node

When it is desired to establish an RS-232 Interface between the Isolated RS-485 Interface
Board and the Host DPC/RTU, transmitter or computer a 24-gauge conductor cable, such as

PIP-ISORS485 Page 5 Isolated RS-485 Interface Board


Belden 9535 should be used. It should be noted that the Isolated RS-485 Interface Board
provides 15KV surge protection per IEC-801 on all signals associated with this interface.

RS-485 Interface Between Isolated RS-485 Intf. Board and the Host Node

When it is desired to establish an RS-485 Interface between the Isolated RS-485 Interface
Board and the Host DPC/RTU or transmitter a low capacitance 24-gauge 3-twisted pair
communications grade cable, such as Belden 9843 should be used. It should be noted that
the Isolated RS-485 Interface Board provides 15KV surge protection per IEC-801 on all sig-
nals associated with this interface.

Isolated RS-485 Port Interface to LAN

Two-wire or four-wire RS-485 networks are supported. For two-wire applications, a low
capacitance 24-gauge communications grade 2-twisted pair cable, such as Belden 9842,
should be used. The cable shield should be connected to the Chassis Ground terminal, i.e.,
TB2 Pin 6 (at one end only). For four-wire applications a similar 3-twisted pair cable, such
as Belden 9843, should be used. Again, the cable shield should be connected to the Chassis
Ground terminal (at one end only). It should be noted that the Isolated RS-485 Interface
Board provides 15KV surge protection on all signals associated with this interface.

Figure 3 - 2-Wire RS-485 LAN using Isolated RS-485 Interface Boards

Note: Jumpers W5 & W6 aren’t required at the most distant Slave Node
unless the LAN is operating at other than 1Mbaud; however, they aren’t
detrimental if they are installed.

Figure 4 - 4-Wire RS-485 LAN using Isolated RS-485 Interface Boards

Field Terminations for RS-485

The maximum number of nodes that can be connected to a RS-485 network is 32 including
the master. For maximum protection against unwanted interference, noise and spurious

PIP-ISORS485 Page 6 Isolated RS-485 Interface Board


emission, the shield of each LAN segment should be terminated to the Chassis Ground at
one end only. This practice will eliminate the formation of ground loops, thereby
minimizing ground induced noise currents in the LAN. A Chassis Ground connection is
provided on each Isolated RS-485 Interface Board at TB2 - Pin 6. In addition, the chassis of
each Isolated RS-485 Interface Board should be connected to the nearest earth ground via a
short length of 12-gauge stranded copper wire in order to take advantage of the built-in
surge protection capability. The Isolated Ground terminal (TB2-5) of all nodes on the two-
wire RS-485 LAN must be connected via a third wire (within the second twisted pair).

For four-wire LANs 3-twisted pairs of wires are required. Shielding is not required (but is
recommended). The maximum network length for the available asynchronous speeds (up to
38.4 KBaud) is 4000 feet (point to point) 1000 feet (for multiple nodes). For LANs utilizing
synchronous speeds up to 187.5 KBaud (for two-wire LANs) or up to 1 MBaud (for four-wire
LANs) the maximum network length is 1000 feet (300 meters) or 200 feet (60 meters)
respectively. The Isolated Ground terminal (TB2-5) of all nodes on the four-wire RS-485
LAN must be connected via a fifth wire (within the third twisted pair).

Figure 5 - Typical 2-Wire Asynchronous RS-485 LAN

Figure 6 - Typical 2-Wire Synchronous 187.5KBaud RS-485 LAN

Figure 7 - Typical 4-Wire Synchronous 1MBaud RS-485 LAN

PIP-ISORS485 Page 7 Isolated RS-485 Interface Board


Figure 8 - Isolated RS-485 LAN - Typical Installation

PIP-ISORS485 Page 8 Isolated RS-485 Interface Board


ISOLATED RS-485 INTERFACE BOARD SPECIFICATIONS
Performance Specifications

Baud Rate (Max.): 38.4K Asynchronous (2-wire or 4-wire)


187.5K Synchronous (2-wire), 1M Synchronous (4-wire)

Multidrop (Max.): 32 Nodes

Network Termination: 100 Ohm Resistors for TX and RX Circuits on End Nodes

Topology: Master/Slave: (TXD+ to RXD+) & (TXD- to RXD-)

Isolation: Optically Isolated Data Signals

Common Mode Range: -7 Volts to +12 Volts (DC) (With respect to Isolated Ground)

Surge Protection: Meets IEC-801 (To Isolated Ground)

Isolated Ground Terminal Provided for Local Connection to Cable Shield


(one end of shield only)

Surge Path: Terminal Provided for Local Connection from Isolated Chassis
Ground to Earth Ground through a 280V Sealed Surge
Absorber

Input Voltage: +9 to +35 VDC

Input Power: (4-Wire) 65 mA @ 24 VDC (1.56 watt)


(2-Wire) 40 mA @ 24 VDC (1 watt)

Environmental Specifications

Operating Temperature: -40° to +70° (C) [-40° to +158° (F)]

Storage Temperature: -40° to +85° (C) [-40° to +185° (F)]

Humidity: 5% to 95% (Non-condensing)

RFI Susceptibility: Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)

Vibration: 10-150 Hz, 1g


150-2000 Hz, 0.5g

Part Numbers

Two-wire Isolated RS-485 Interface Board: With DIN Base: 392909-01-4


Without DIN Base: 392909-02-2
Four-wire Isolated RS-485 Interface Board: With DIN Base: 392909-03-0
Without DIN Base: 392909-04-9

PIP-ISORS485 Page 9 Isolated RS-485 Interface Board


Isolated RS-485 Interface Board
Special Instructions for Class I, Division 2 Hazardous Locations

1. The Bristol, Inc. Isolated RS-485 Interface Board is listed by Underwriters Laboratories
(UL) as nonincendive and is suitable for use in Class I, Division 2, Groups A, B, C and D
hazardous locations and non-hazardous locations only. Read this document carefully
before installing a nonincendive Bristol Isolated RS-485 Interface Board. In the event of
a conflict between the Isolated RS-485 Interface Board User Manual (PIP-ISORS485)
and this document, always follow the instructions in this document.

2. All 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.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair


suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,


turnoff power before servicing/replacing the unit and before installing or
removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the


power has been switched off or the area is known to be nonhazardous.

03/14/2007 Appendix A, Document PIP-ISORS485 Page 1 of 1


BLANK PAGE
Product Information Package
PIP-ISORS485
Isolated RS-485 Interface Board - 33XX, 3508, 3530 & 3808 Mar., 2007

The information in this document is subject to change without notice. Every effort has
Emerson Process Management
been made to supply complete and accurate information. However, Bristol, Inc.
Bristol, Inc.
assumes no responsibility for any errors that may appear in this document.
1100 Buckingham Street
Watertown, CT 06795
If you have comments or questions regarding this manual, please direct them to your
Phone: +1 (860) 945-2262
local Bristol sales representative, or direct them to one of the addresses listed at left.
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Bristol
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
Emerson Electric Canada, Ltd.
materials to his/her satisfaction before using them with important data.
Bristol Canada
6338 Viscount Rd.
There are no warranties, expressed or implied, including those of merchantability and
Mississauga, Ont. L4V 1H3
fitness for a particular purpose, concerning the software and other materials delivered
Canada
herewith.
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Bristol 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
Emerson Process Management this document are for information only, and belong to their respective companies, or
BBI, S.A. de C.V. trademark holders.
Homero No. 1343, 3er Piso
Col. Morales Polanco Copyright (c) 2007, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part
11540 Mexico, D.F. of this manual may be reproduced in any form without the express written permission of
Mexico Bristol, Inc.
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
RTU 3305
Material Safety Data Sheets

Material Safety Data Sheets are 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 Model RTU 3305 Instruction Manual CI-3305

Bristol Babcock Part Number


Manufacturer General Description
3.6V Lithium
Eagle Pitcher 390147-01-0
Thionyl Chloride Battery

Power Sonic
12V Sealed Lead-Acid Battery 395407-02-8
Corp.

Eagle Pitcher 12V Sealed Lead-Acid Battery 395407-02-8

7/23/97 Appendix Z - CI-3305 MSDS


BLANK PAGE
MATERIAL SAFETY DATA SHEET
Product Name: Sealed Maintenance Free Lead-Acid Batteries

DATE: 10/1/2003 ISSUED BY ENGINEERING TELEPHONE NO. (619) 661-2030


HAZARDOUS COMPONENTS
LD50 LC50 LC50
COMPONENTS WEIGHT % TLV
ORAL INHALATION CONTACT
Lead (Pb, Pb02, PBSO4) about 70% N/A (500) mg/kg N/A N/A
Sulfuric Acid about 20% 1mg/m3 (2,140) mg/kg N/A N/A
Fiberglass Separator about 5% N/A N/A N/A N/A
ABS Plastic about 5% N/A N/A N/A N/A
PHYSICAL DATA
SOLLUBILITY
COMPONENTS DENSITY MELTING POINTS ODOR APPEARANCE
(H2O)
Lead 11.34 327.4º C (Boiling) None None Silver-Gray Metal
0
Lead Sulfate 6.2 1070º C (Boiling) 40 mg/l(15 C) None White Powder
Lead Dioxide 9.4 290º C (Boiling) None None Brown Powder
Sulfuric Acid about 1.3 about 114º C (Boiling) 100% Acidic Clear Colorless Liquid
Fiberglass Separator N/A N/A Slight Toxic White Fibrous Glass
ABS Plastic N/A N/A None No Odor Solid
FLAMMABILITY DATA
COMPONENTS FLASHPOINT EXPLOSIVE LIMIT COMMENTS
Lead None None
Sulfuric Acid None None
Sealed batteries can emit hydrogen if over charged
Hydrogen 4% - 72.4%
(float voltage > 2.40 VPC).
Toxic vapors may be released. In case of fire, wear
Fiberglass Separator N/A N/A self-contained breathing apparatus.
Temp. over 300º C (572º F) may release combustible gases. In case
ABS Plastic None N/A
of fire: wear positive pressure self-contained breathing apparatus.
FIRST AID
SULFURIC ACID PRECAUTIONS
Skin Contact: Flush with water, see physician if contact area is large or if blisters form.
Eye Contact: Call physician immediately and flush with water until physician arrives.
Call physician. If patient is conscious, flush mouth with water, have patient drink milk or sodium
Ingestion:
bicarbonate solution.
Continued on Page 2
MATERIAL SAFETY DATA SHEET
(PAGE 2 OF 2)

R EACTI VI TY DATA
C O M PO N E N T Sulfuric Acid
i
STABI LI TY Stable at all temperatures
COLYM ER I ZATI ON Will not polymerize
I NCOM PATI BI LI TY Reactive metals, strong bases, most organic compounds
DECOM POSI TI ON PR ODUCTS Sulfuric dioxide, trioxide, hydrogen sulfide, hydrogen
CONDI TI ONS TO AVOI D Prohibit smoking, sparks, etc. from battery charging area. Avoid mixing acid with other chemicals
SPI LL OR LEAK PR OCEDUR ES
If sulfuric acid is spilled from a battery, neutrilize acid with bicarbonate (baking soda), sodium
St e ps t o t a k e in ca s e of le a k or s pill: carbon (soda ash), or calcium oxide (lime). Flush area with water and discard to the sewage
system. Do not allow unneutralized acid into sewage system.
Neutrilized acid may be flushed down the sewer. Spent batteries must be treated as hazardous
Wa s t e dis pos a l me t hod: waste and disposed of according to local, state, and federal guidelines. A copy of this MSDS must
be supplied to any scrap dealer or secondary lead smelter with battery.
PR O T E C T I O N
EXPOSUR E SI TE PR OTECTI ON COM M ENTS
SK I N Rubber gloves, Apron
Protective equipment must be worn if the battery is cracked or
R ESPI R ATORY Respirator (for lead) otherwise damaged. A respirator should be worn during reclaim
operations if the TLV is exceeded.
EYES Safety goggles, Face Shield
ELECTR I CAL SAFETY
Due to the battery's low internal resistance and high power density, high levels of short circuit current can be developed across the battery
terminals. Do not rest tools or cables on the battery. Use insulated tools only. Follow all installation instructions and diagrams when installing or
maintaining battery systems.
HEALTH HAZAR D DATA
LEAD: The toxic effects of lead are accumulative and slow to appear. It affects the kidneys, reproductive, and central nervous systems. 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 oftern occurs during lead reclaim operations through the breathing or ingestion of lead dust or fumes.
SULFUR I C ACI D: Sulfuric acid is a strong corrosive. Contact with acid can casue severe burns on the skin and in eyes. Ingestion of sulfuric
acid will cause GI tract burns. Acid can be released if the battery case is damaged or if vents are tampered with.
FI BER GLASS SEPAR ATOR : Fibrour glass is an irritant of the upper repiratory tract, skin and eyes. For exposure up to 10F/CC use MSA
Comfoll with type H filter. Above 10F/CC up to 50F/CC use Ultra- Twin with type H filter. This product is not considered carcinogenic by
NTP or OSHA.
ALL DATA M UST BE PASSED TO ANY SCR AP DEALER OR SM ELTER WHEN BATTERY I S R ESOLD.

Power-Sonic Corporation
9163 Siempre Viva Road, San Diego, CA 92154 Tel (619) 661-2020 Fax (619) 661-3650
Website: www.power-sonic.com E-Mail: battery@power-sonic.com
Material Safety Data Sheet U.S. Department of Labor
May be used to comply with Occupational Safety and Health Administration
OSHA's Hazard Communication Standard. (Non-Mandatory Form)
29 CFR 1910.1200 Standard must be Form Approved
consulted for specific requirements. OMB No. 1218-0072
Identity (As Used on Label and List) Note: Blank spaces are not permitted. If any item is not applicable, or
KEEPER II/Lithium/Thionyl Chloride Battery no information is available, the space must be marked to indicate that
Section I
Manufacturer's Name Emergency Telephone Number
Eagle-Picher Technologies, LLC 417-776-2256 800-424-9300 (CHEMTREC)
Address (Number, Street, City State, and Zip Code) Telephone Number for Information
P.O. Box 130 417-776-2256
14212 Bethel Road Date Prepared
Seneca, MO 64865 1-Jul-98
Signature of Preparer (optional)

Section II - Hazardous Ingredients/Identity Information


Hazardous Components (Specific Chemical Identity, Common Name(s)) OSHA PEL ACGIH TLV Other Limits Recommended % (optional)
Lithium metal Cas #7439-93-2 N/A-reactive alkali metal
Thionyl chloride (SOC12) Cas #007719-09-7 1/0 ppm 5/0 ppm

Section III - Physical/Chemical Characteristics


Boiling Point Specific Gravity (H2O=1)
N/A N/A
Vapor Pressure (mm Hg.) Melting Point
N/A N/A
Vapor Density (Air=1) Evaporation Rate (Butyl Acetate=1)
N/A N/A
Solubility in Water
N/A
Appearance in Odor
N/A
Section IV - Fire and Explosion Hazard Data
Flash Point (Method Used) Flammable Limits LEL UEL
N/A
Extinguishing Media
Do not use water. Use dry chemical, soda ash, sand.
Special Fire Fighting Procedures
Use self contained breathing apparatus and full protective equipment.
Unusual Fire and Explosion Hazards
Do not recharge, disassemble, heat above 125°C (257°F), incinerate or expose contents to water.
Vent, rupture or explosion may result and cause severe burns.
(Reproduce Locally) OSHA 174, Sept. 1985
Section V - Reactivity Data
Stability Unstable Conditions to Avoid:
Stable XX Vent rupture or explosion will release thionyl chloride
Incompatibility (Materials to Avoid)
SOC12 Water, humid air, alkalies, and temperature above 140°C (284°F)
Hazardous Decomposition or Byproducts
SOC12 In presence of water or humid air, hydrochloric acid & sulfur oxide.
Hazardous May Occur Conditions to Avoid
Polymerization Will Not Occur XX
Section VI - Health Hazard Data
Routes(s) of Entry Inhalation? Skin? Ingestion?
Eyes Yes Yes Yes
Health Hazards (Acute and Chronic)
SOC12 - Will burn and irritate eyes & skin. Upper respiratory irritant. Continuous inhalation of fumes
may cause lung damage.

Carcinogenicity NTP? IARC Monographs? OSHA Regulated?


N/A
Signs and Symptoms of Exposure
SOC12 - Eye and skin irritation, pungent odor and respiratory irritation.

Medical Conditions Generally Aggravated by Exposure


N/A

Emergency and First Aid Procedures


If free(S0C1 2) is present, evacuate areas and provide ventilation, wash exposed area with soda ash
or sodium bicarbonate solution. Seek medical attention.

Section VII - Precautions for Safe Handling and Use


Steps to Be Taken in Case Material is Released or Spilled
Avoid contact if vent rupture or explosion has occurred. Other wise protect from heat,
short circuit of terminals, an accumulation of shorted batteries, which may cause dangerous
elevated temperatures
Waste Disposal Method
Dispose of waste according to federal EPA, state and local regulations.

Precautions to be taken in Handling and Storing


Do not short circuit, heat above 125°C (257°F), recharge, disassemble, incinerate or
expose to water.
Other Precautions

Section VIII - Control Measures


Respiratory Protection (Specific Type)
Self-contained breathing apparatus
Ventilation Local Exhaust Specific

Mechanical (General) Other


N/A
Protective Gloves Eye Protection
Neoprene Recommended
Other Protective Clothing or Equipment
N/A
Work/Hygienic Practices
N/A
Supplement 1 Issue: 04/02

RTU 3305 STANDARD ENCLOSURE

For Instruction Manual CI-3305

R E Y N OL D S GA S S Y S T E M
L OC K P O R T S T A T I O N
8 R UN S
S I GN ON S CROL L

F1 F2 F3 F4

7 8 9 INIT

ALM
4 5 6 I/E
ALM
ACK

1 OPER
2 3 A/M
I/E
ON

0
-
OFF
DEL ENTER

Bristol Babcock
RTU 3305

Bristol Babcock
RTU 3305 STANDARD ENCLOSURE

TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION ....................................................................Sect. 1 - Pg. 01


1.2 FEATURES ..................................................................................................Sect. 1 - Pg. 01
1.3 PHYSICAL DESCRIPTION........................................................................Sect. 1 - Pg. 04
1.3.1 Power Supply & Rechargeable Battery/Batteries .....................................Sect. 1 - Pg. 05
1.3.2 DIN Rail Mounted Power Distribution Block ............................................Sect. 1 - Pg. 05
1.3.3 DIN Rail Mounted Form C Relays for Discrete Outputs ..........................Sect. 1 - Pg. 07
1.3.4 Local Communication Port..........................................................................Sect. 1 - Pg. 08
1.3.5 Wire Routing ................................................................................................Sect. 1 - Pg. 09
1.3.6 Phone Line Surge Protectors ......................................................................Sect. 1 - Pg. 10
1.4 OPTIONS .....................................................................................................Sect. 1 - Pg. 11
1.4.1 Power Supply Option...................................................................................Sect. 1 - Pg. 11
1.4.2 LCD Display Option ....................................................................................Sect. 1 - Pg. 11
1.4.3 Communications Options ............................................................................Sect. 1 - Pg. 11
1.4.4 Relay Option for Discrete Outputs .............................................................Sect. 1 - Pg. 12

Section 2 - INSTALLATION

2.1 INSTALLATION IN HAZARDOUS AREAS..............................................Sect. 2 - Pg. 01


2.2 MOUNTING THE RTU 3305 STANDARD ENCLOSURE.......................Sect. 2 - Pg. 01
2.2.1 Wire Routing ................................................................................................Sect. 2 - Pg. 01
2.2.2 Field Wiring DOs Associated with the Form C Relay Option ..................Sect. 2 - Pg. 04
2.2.3 Signal Shielding and Grounding ................................................................Sect. 2 - Pg. 05

Section 3 - SERVICE

3.1 3305 STANDARD ENCLOSURE SERVICE INTRODUCTION ..............Sect. 3 - Pg. 01


3.1.1 Accessing Parts For Testing........................................................................Sect. 3 - Pg. 01
3.2 REMOVAL/REOLACEMENT PROCEDURES .........................................Sect. 3 - Pg. 02
3.2.1 Removal/Replacement of Power Distribution Block Fuses .......................Sect. 3 - Pg. 02
3.2.2 Removal/Replacement of Form C Relays ...................................................Sect. 3 - Pg. 03
3.2.3 Removal/Replacement of the Phone Line Surge Protector .......................Sect. 3 - Pg. 04
3.2.4 Removal/replacement of an External Communications Option ...............Sect. 3 - Pg. 04
3.2.5 Removal/Replacement of a Power Supply Option .....................................Sect. 3 - Pg. 06
3.2.5.1 Removal/Replacement of the Power Supply/Battery Charger Option .....Sect. 3 - Pg. 07
3.2.5.2 Removal/Replacement of the 40 Watt Power Supply Option....................Sect. 3 - Pg. 08

Section 4 - SPECIFICATIONS

4.1 ENVIRONMENTAL RATING & APPROVALS ............................ Sect. 4 - Pg. 01


4.2 POWER REQUIREMENTS ........................................................................Sect. 4 - Pg. 01
4.3 ACCESSORY SPECIFICATIONS ..............................................................Sect. 4 - Pg. 01
4.3.1 Power Supply/Battery Chargers.................................................................Sect. 4 - Pg. 01
4.3.2 Private Line Modem (External Version) ....................................................Sect. 4 - Pg. 02
4.3.3 Switched Network Modem (External Version) ..........................................Sect. 4 - Pg. 02
4.3.4 Isolated RS-485 Board (External Version).................................................Sect. 4 - Pg. 02

CI-3305 Supplement 1 Page 0-1 Table Of Contents


TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 4 - SPECIFICATIONS (Continued)

4.3.5 HARTÒ Device Interface..............................................................................Sect. 4 - Pg. 03


4.3.6 Internal Communication Options...............................................................Sect. 4 - Pg. 03

Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheets on Battery P/N 395407-02-8.

CI-3305 Supplement 1 Page 0-2 Table Of Contents


BLANK PAGE
Section 1
RTU 3305 STANDARD ENCLOSURE
INTRODUCTION
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed
information about the basic RTU 3305 is contained in Instruction Manual CI-3305.

1.1 GENERAL DESCRIPTION

The RTU 3305 Standard Enclosure is a completely assembled unit consisting of an RTU
3305 mounted within a NEMA 4X fiberglass enclosure, along with other, optional
components required in many SCADA RTU applications. Package variations support any
model 3305, including display type and any internally mounted communication option.
Units are fully wired and tested and simply require installation, FLASH configuration of
the RTU, and downloading of the application.

The RTU 3305 Standard Enclosure features a pipe or panel mount NEMA 4X enclosure,
steel backplate, and a choice of power supply with optional backup battery, an internal or
door mounted display, DIN rail mounted relays, and a variety of communication options,
including modems, smart transmitter, radio and local network interfaces. Standard
features include DIN rail mounted power distribution system, inlets for power, I/O and
communication wiring, external PC interface port, and a grounding lug.

RTU 3305 Standard Enclosures provide a high performance and economical choice for
measurement and control in the following applications:

· SCADA RTU
· Lift Stations
· Metering Stations
· Well Monitoring
· Reservoir and Tank Monitoring
· Pump Controller
· Custody Transfer
· Pressure Monitor

1.2 FEATURES

The following items are standard features with all RTU 3305 Standard Enclosures:

· NEMA 4X Fiberglass Enclosure; 16” (40.64cm) H x 14” (35.56cm) W x 8” (20.32cm) D


(NEMA 3X with battery vent open)
· Aluminum Rear Plate
· DIN Rail Mounted Power Distribution Block with fusing and power cutoff
· Dual 1-inch threaded I/O inlets; accommodate up to 50, 14AWG wires
· 3/4 inch threaded power inlet
· Sealed Telephone/Communication Line Port
· External PC/Laptop Interface & Configuration Port

CI-3305 Supplement 1 Section 1 - Page 1 ENC 3305 RTU


· External Grounding Lug
· Panel or 2-inch Pipe Mount
· Choice of RTU 3305 Model (Including display type & internal communication option)

Figure S1-1
RTU 3305 Standard Enclosure with Remote 4x20 Keypad/Display Option

CI-3305 Supplement 1 Section 1 - Page 2 ENC 3305 RTU


Figure S1-2
Inside Cover of RTU 3305 Standard Enclosure
with Remote 4x20 Keypad/Display Option & External Modem

All components mount comfortably within the enclosure making installation and main-
tenance of the unit straight forward. All but two (2) components (the Display Module &
External Modem) are mounted to the aluminum “Back Fabrication Panel” which in turn is
mounted to the interior rear wall of the enclosure. The RTU 3305 Power Supply/Battery
Charger, external modem and Surge Suppressor utilize keyed mounting brackets for easy
component removal and replacement. A power distribution block, consisting of fused
sections for AC line and low voltage DC, is DIN Rail mounted to the aluminum Back
Fabrication Panel. All necessary cabling is neatly contained within half-inch snake ducting

CI-3305 Supplement 1 Section 1 - Page 3 ENC 3305 RTU


routed throughout the Back Fabrication Panel. The Back Fabrication Panel also serves as
the instrument’s chassis and is cabled to an external ground lug on the enclosures bottom.
To further simplify installation, all packages include threaded conduit fittings for I/O,
power and communications on the bottom of the enclosure. The enclosure is panel or wall-
mount ready, or can be attached to a vertically mounted 2-inch pipe.

Figure S1-3
RTU 3305 Standard Enclosure Component Identification

1.3 PHYSICAL DESCRIPTION

In addition to the base RTU 3305, RTU 3305 Standard Enclosures are comprised of the
following major components:

· NEMA 4X Fiberglass Enclosure; 16” (40.64cm) H x 14” (35.56cm) W x 8” (20.32cm) D


(NEMA 3X with battery vent open)
· Aluminum Rear Plate
· UPS Power Supply (12VD or 24VDC) (see Appendix 6 of CI-3305) (Optional)
· UPS & Backup Battery (ies) (Optional)
· DIN Rail Mounted Power Distribution Block with fusing and power cutoff

CI-3305 Supplement 1 Section 1 - Page 4 ENC 3305 RTU


· Phone Line Surge Protector (Optional)
· Threaded Conduit Fittings
· Ground Lug
· Local Communications Port
· Up to 8 DIN Rail Mounted Form C Relays (for Discrete Outputs) (Optional)

1.3.1 Power Supply & Rechargeable Battery/Batteries (see Appendix 6)

The power supply option consists of a linear supply/charger that produces a regulated peak
output of 27.6V for a 24V system or 13.8V for a 12V system with a 10mA or greater load
applied, and a temperature compensated current limiting circuit that will safely charge one
or two lead-acid gel cells. Under normal conditions, the charger maintains the battery (ies)’
EMF potential, while the battery (ies) supply RTU system power. During line loss, the
battery (ies) act alone for a backup period of 8 hours minimum with one battery (12V only),
and 16 hours with two batteries. The supply/charger unit, used independently (without
backup battery (ies), will support the RTU 3305 inrush current at 4 Amps for 12V systems
or 2 Amps for 24V systems. However; as options are added to the package, the backup
battery(s) become necessary to meet the total inrush current requirement. A complete
system, i.e., Power Supply & Battery (ies), will support a fully loaded RTU.

1.3.2 DIN Rail Mounted Power Distribution Block

The standard six-section Din Rail mounted Power Distribution Block accommodates the in-
terconnection of power and system grounding between the base RTU 3305 and the optional
Power Supply, battery/batteries, modem and Transmitter Interface Board (TIB). This unit
is equipped with fusing and Power Cutoff. The fused power cutoff panel opens to break
power or replace the fuse. When both the Power Supply/Charger and battery (ies) option
are present, an additional fused power cutoff panel is provided to interconnect the battery
(ies) with the Power Supply/Charger. The fuse associated with the second fused power
cutoff panel (F2) is rated at 3 Amps or 1.5 Amps for 12V and 24V systems, respectively
while the fuse associated with the primary Fused Power Cutoff Panel (F1) is rated at 1
Amp for either 12V or 24V systems (see Figures S1-4 through S1-7).

Figure S1-4 - Power Distribution Block

CI-3305 Supplement 1 Section 1 - Page 5 ENC 3305 RTU


Figure S1-5 - Power Distribution Wiring Diagram
Base Unit without Battery/Batteries or Power Supply Charger

CI-3305 Supplement 1 Section 1 - Page 6 ENC 3305 RTU


Figure S1-6 - Power Distribution Wiring Diagram
Base Unit with Battery/Batteries & Power Supply Charger

1.3.3 DIN Rail Mounted Form C Relays for Discrete Outputs

Up to 8 DIN Rail mounted Form C Relays can be installed on the same DIN Rail that
accommodates the Power Distribution Block. The relay modules are small, enclosed plug-in
modules that mount to a pre-wired terminal base, with single-pole, double throw contacts
left available for customer wiring. Each relay requires a minimum of 18 V @ 9 mA to

CI-3305 Supplement 1 Section 1 - Page 7 ENC 3305 RTU


energize, therefore 12V systems will not support them. Each relay includes a polarity
reversal protection diode and an LED indicator.

Figure S1-7 - DIN Rail Mounted Power Distribution Block & Form C Relays

1.3.4 Local Communication Port

The local communications port is used for configuration and diagnostic communications but
is not a network port. Port A of the Processor Memory Peripheral Power Supply Board is
used for downloading FLASH configuration and FLASHWARE via the 3-Pin Molex type
connector (J3). This port is interconnected to the Laptop VII connector on the bottom of the
enclosure (see Section 2.4.8.3 of CI-3305). This Local Port can be connected to a Process
Engineer’s Interface (PEI) computer RS-232 Comm. Port for BSAP Slave/Pseudo-Slave ap-
plications. Additionally, a Terminal Emulator or a computer with a Terminal Emulation
Software package (such as PROCOMM) can be used to monitor the start-up sequence.
Note: Port A is not a network port and therefore does not support interface to a
modem or other communication devices.

Figure S1-8 - Local Communications Cable Connector VII Plug/Jack

CI-3305 Supplement 1 Section 1 - Page 8 ENC 3305 RTU


Figure S1-9 - RTU 3305 Local Port Communications Link

1.3.5 Wire Routing

Wiring will enter the RTU 3305 Standard Assembled Package through holes in the bottom
of the case. Up to seven holes may be provided in the bottom of the case. The purpose of
each of these holes is provided in Figure S1-10 below.

Figure S1-10 - RTU 3305 Standard Enclosure Bottom Wiring Holes

CI-3305 Supplement 1 Section 1 - Page 9 ENC 3305 RTU


It should be noted that when a Battery Vent is provided the enclosure rating goes
to NEMA 3X.

1.3.6 Phone Line Surge Protectors

Older RTU 3305 Standard Enclosures may be equipped with the SP Model 8792-20A Surge
Protector illustrated in Figure S1-11A. This device will protect against surges up to 300 V
for one millisecond or 16 Vdc continuously. The Phoenix Model MT-2FM-RJ12 Surge
Protector currently provided (see Figure S1-11B) has been designed for use in high
impedance telecommunications networks. The circuit will protect against surges up to 300
V (Normal Mode) or 450 V (Common Mode) for up to (1.2/50 + 8/20) microseconds.

Each Phone Line Surge Protector provides two surge protection circuits that may be used
to protect against surges on one four-wire line or two two-wire lines.

Figure S1-11A - Phone Line Surge Protector SP 8792-20A

Figure S1-11B - Phone Line Surge Protector Phoenix MT-2FM-RJ12

TB2 of either the SP Model 8792-20A or Phoenix MT-2FM-RJ11 Phone Line Surge
Protector is wired to a phone company Jack/Terminal Block in accordance with Table S1-1.

CI-3305 Supplement 1 Section 1 - Page 10 ENC 3305 RTU


Table S1-1 - Phone Line Surge Protector TB2 Wiring Assignments

Configuration TB2-1 TB2-2 TB2-3 TB2-4


TB2-a1 TB2-b1 TB2-a2 TB2-b2
PL 2-Wire T/R1 (TX/RX) T/R2 (TX/RX) N/A N/A
PL 4-Wire T/R1 (TX 4-Wire) T/R2 (TX 4-Wire) R1 (RX 4-Wire) R2 (RX 4-Wire)
PSTN 2-Wire T/R1 (Tip) T/R2 (Ring) N/A N/A
Note: The green wire connected to the Phoenix MT-2FM-RJ11 Surge Protector
is connected to the RTU 3305 Standard Enclosure’s Ground Lug.

1.4 OPTIONS

A basic RTU 3305 Standard Enclosure contains a RTU 3305, a DIN Rail Mounted Power
Distribution Block, Local Port Laptop Connector, External Ground Lug, and a NEMA
4X/3X Box equipped with Water Tight Conduit Fitting and other fittings or sealing plugs
as specified by customer order.

Configuration options are available for power, LCD Display, communications, and form C
Relays for Discrete Outputs.

1.4.1 Power Supply Option

The following Power Supply Options are available:

· RTU 3305 Standard Enclosure without Power Supply or Battery (ies)


· +12VDC Power Supply (with one +12VDC Lead-acid Battery)
· +12VDC Power Supply with two +12VDC Lead-acid Batteries tied in parallel
· +24VDC Power Supply with two +12VDC Batteries tied in series
· +24VDC Power Supply (40 Watt)
· +12VDC Power Supply (40 Watt)

Note: When a battery option is provided, the enclosure will be equipped with a
Battery vent and the enclosure will have a NEMA 3X rating.

1.4.2 LCD Display Option

The RTU 3305 Standard Enclosure may be packaged with one of the following LCD
Display Options:

· 3305 SAP without LCD Display


· 2 X 16 Character LCD Display (locally mounted), i.e., mounted on top of the base 3305
· 2 X 16 Character LCD Display (remotely mounted), i.e., mounted on the Enclosure Door
· 4 X 20 Keyboard Display (remotely mounted), i.e., mounted on the Enclosure Door

1.4.3 Communications Options

The RTU 3305 Standard Enclosure may be ordered with one or more of the following
communication options:

CI-3305 Supplement 1 Section 1 - Page 11 ENC 3305 RTU


· 9600 bps Hayes Compatible PSTN Modem (+12VDC, +24VDC, or AC)
· 1200 bps Hayes Compatible PL Modem (+12VDC, +24VDC, or AC)
· Surge Protector Option (may be used with any BBI supplied modem)
· Radio Delay Interface Board (with or without external MDS Radio) (see Appendix 2 of
CI-3305)
· Transmitter Interface Board (TIB) (For BBI 3508 Transmitters) (see Appendix 1 of CI-
3305)
· RS-485 Interface Board (see Appendix 3 of CI-3305)
· Network Interface Box (External) (see Appendix 4 of CI-3305)
· Highway Addressable Remote Transducer (HARTÒ) Device Interface (see Appendix 5 of
CI-3305)

1.4.4 Relay Option for Discrete Outputs

Up to 8 Din Rail Mounted Form C Relays (for +24VDC systems only) are available for
customer use (see Section 1.3.3 and Section 2 of this supplement).

CI-3305 Supplement 1 Section 1 - Page 12 ENC 3305 RTU


Section 2
RTU 3305 STANDARD ENCLOSURE
INSTALLATION
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed
information about the basic RTU 3305 is contained in Instruction Manual CI-3305.

2.1 INSTALLATION IN HAZARDOUS AREAS

An RTU 3305 Standard Enclosure that is installed without any of the available package
options (i.e., without Power Supply, Communication, Surge Protection or Relay options)
will meet FM approval for Class I, Division 2 hazardous environments. When a battery
option is not installed (battery vent closed) the enclosure has a NEMA 4X rating. The
enclosure rating for units equipped with a battery option (battery vent open) is NEMA 3X.
Package variations support any model 3305, including display type and any internally
mounted communication option. Units are fully wired and tested and simply require
installation, FLASH configuration of the RTU, and downloading of the application.

To simplify installation, all packages include threaded conduit fittings for I/O, power and
communications on the bottom of the enclosure.

2.2 MOUNTING THE RTU 3305 STANDARD ENCLOSURE

Check all clearances when choosing an installation site. Make sure that the enclosure cover
(door - hinged on left side) can be opened for wiring and service. Make certain that the LCD
Display (if present) is visible and accessible to the on-site operator.

The RTU 3305 Standard Enclosure is to be positioned vertically with the threaded conduit
fittings on the bottom of the enclosure. The enclosure is panel or wall-mount ready (see
Figure S2-2), or can be attached to a vertically mounted 2 inch pipe (see Figure S2-1). In
the case of an outdoor pipe mounted unit, the pipe is to be cemented into the ground deep
enough to conform to the local building code.

2.2.1 Wire Routing

Wiring enters the 3305 Standard Enclosure through holes in the bottom of the case. Two 1-
inch Water Tight Fittings (each accommodating up to 25 #14 AWG wires) provide for field
I/O wiring along with a 3/4 inch Water Tight Fitting for External Power, and a Sealed
Communications Port Fitting for a phone or external modem cable (see Figure S1-10 in
Section 1.3.5 of this supplement). Basic I/O wiring is covered in CI-3305 Section 2.4. The
3305 Standard Enclosure’s unique wiring is covered in the following sections of this
supplement:

· DIN Rail Mounted Power Distribution Block - Section 1.3.2


· DIN Rail Mounted Form C Relays for DOs - Section 1.3.3 and 2.2.2
· Local Communication Port - Section 1.3.4
· Phone Line Surge Protector - Section 1.3.6 and appropriate modem manual.

CI-3305 Supplement 1 Section 2 - Page 1 ENC 3305 RTU


· Communications Options - Section 1.4.3 and appropriate appendix to CI-3305

Figure S2-1 - Side View of 3305 Standard Enclosure


Mounted to a 2” Pipe

CI-3305 Supplement 1 Section 2 - Page 2 ENC 3305 RTU


Figure S2-2 - Side View of 3305 Standard Enclosure
Mounted to a Wall or Panel

CI-3305 Supplement 1 Section 2 - Page 3 ENC 3305 RTU


2.2.2 Field Wiring DOs Associated with the Form C Relay Option

The RTU 3305 Standard Enclosure DIN Rail Mounted Relay Block accommodates up to
eight (8) Form C Relays. The Relay Holders utilize compression type terminals that
accommodate up to #12 AWG wire. A connection is made by inserting the wire’s bared end
into the clamp beneath the screw and then securing the screw. The wire should be inserted
fully such that no bared wires are exposed, thus eliminating the possibility of shorts. If
using stranded wire, tin the bare end with solder to prevent flattening and to maintain
conductivity.

Ordinarily, field connections for DO1 through DO8 are located at TB1 of the MI/OB Board.
When the Relay Option is installed, field connections are provided at the DIN Rail
Mounted Form C Relay Block as illustrated in Figure S2-3. To configure DI/O1 through
DI/O6 for DO operation, the MI/OB Board jumper associated with the DI/O in question
must be set in the “B” position (see Figure 2-9 of Instruction Manual CI-3305).

Figure S2-3
Form C Relay DO Connections to TB1 of 3305 Standard Enclosure

It should be noted that the 3305 Standard Enclosure contains two Terminal Blocks that
are labeled TB1. One is contained on the MI/OB Board and can accommodate wires up to
14 AWG in size, the other is as illustrated in Figure S2-3 and encompasses power dis-
tribution as-well-as Form C Relay wiring.

CI-3305 Supplement 1 Section 2 - Page 4 ENC 3305 RTU


2.2.3 Signal Shielding and Grounding

The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize
signal error 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 system. This is necessary to prevent circulating ground loops that can cause
signal error. Connect all shields to a common terminal point that is tied to the system
ground. A customer ground lug is provided on the bottom of the enclosure. Also see
Supplement manual S1400 - Guidelines For System Grounding.

CI-3305 Supplement 1 Section 2 - Page 5 ENC 3305 RTU


BLANK PAGE
Section 3
RTU 3305 STANDARD ENCLOSURE
SERVICE
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed
Service information on the basic RTU 3305 is contained in Instruction Manual CI-3305.

3.1 3305 STANDARD ENCLOSURE SERVICE INTRODUCTION

General, diagnostic and calibration test information for the Model 3305 RTU are provided
in Section 5 - SERVICE of Instruction Manual CI-3305.

The service procedures described herein supports those elements that are unique to the
RTI 3305 Standard Enclosure.

When RTUs are serviced on site, it is recommended that any associated processes be closed
down or placed under manual or redundant/backup control. This precaution will prevent
any processes from accidentally losing control when tests or service are conducted.

Warning

Harmful electrical potentials may still be present at the field


wiring terminals even though the RTU’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

Never attempt to install or remove any modules (plug-in boards


or Form C Relays) from an RTU while it is running. Doing so
can cause sudden electrical transients or imbalances that are
capable of causing damage to the module itself, as-well-as other
associated circuits. Always turn off the Main power, including
any additional supply sources used for externally-powered I/O
circuits, before changing any modules.

3.1.1 Accessing Parts For Testing

Testing and replacement of RTU hardware should only be performed by technically-


qualified persons having advanced mechanical and electrical skills and proper test
equipment (see Section 5.1 of CI-3305). It is important that the reader study the
disassembly procedures described herein and the disassembly and test procedures
described in the base manual CI-3305 before starting. Any damage to the RTU 3305
Standard Enclosure resulting from improper handling or incorrect service procedures will
not be covered under the product warranty agreement. If these procedures cannot be

CI-3305 Supplement 1 Section 3 - Page 1 ENC 3305 RTU


performed properly, the unit should be returned to Bristol Babcock (with prior
authorization from Bristol Babcock) for factory evaluation and repairs.

Caution

PC board components can be damaged by electrostatic


discharge (ESD) during disassembly/reassembly and test
procedures. Use grounded wrist straps and surface pads when
working near or handling circuit boards. See attached in-
struction supplement S14006 for proper grounding and
handling techniques.

3.2 REMOVAL/REPLACEMENT PROCEDURES

3.2.1 Removal/Replacement of Power Distribution Block Fuses

System power is supplied to the RTU 3305 from the DIN Rail Mounted Power Distribution
Block of the RTU 3305 Standard Enclosure. Units equipped with the Power Supply Option
have two fuses; F1 for AC and F2 for DC while units which are not equipped with the
Power Supply Option have one Fuse (F1) for DC. The Slow Blow AC Fuse is rated for 1
Amp at 120V. The DC Fuse is rated as follows:

· 12VDC System with Power Supply Option - F2 = 3A Slow Blow (see Figure S1-6)
· 24VDC System with Power Supply Option - F2 = 1.5A Slow Blow (see Figure S1-6)
· 12V System without Power Supply Option - F1 = 4A Slow Blow (see Figure S1-5)
· 24VDC System with Power Supply Option - F1 = 2A Slow Blow (see Figure S1-5)

Figure S3-1 - Power Distribution Panel with Fused Power Cutoff Panel Open
(End View)

CI-3305 Supplement 1 Section 3 - Page 2 ENC 3305 RTU


For enclosures equipped with a built-in Power Supply/Battery Charger, measure the DC
output (at Terminals 6 & 5 of the Power Distribution Block) and make sure that it is
within the following ranges:

+13.8VDC ±0.2% for +12VDC Systems, i.e., +13.77VDC to +13.83VDC


+27.6VDC ±0.2% for +24VDC Systems, i.e., +27.54VDC to +27.66VDC

If Power is present at the input to the system but not at the left side terminals (1 through 6
of the Power Distribution Block check fuse F1 and in the case of units equipped with the
Power Supply Option check fuse F2. Power Supply Distribution Block fuses are easily
replaced by opening the appropriate Fused Power Cutoff Panel (see Figure S3-1). For ad-
ditional power checks see Section 5.4.3 of CI-3305. If DC Power is not present, measure
line power (at L1 & L2) for 120VAC. Replace the Line Fuse (F1) if necessary.

3.2.2 Removal/Replacement of Form C Relays

Up to eight (8) Form C Relays can be installed in DIN Rail mounted holders that are
ganged on the Power Distribution Block. Relays are easily removed or installed when the
Relay Clamp/Release Lever associated with the Form C Relay in question has been moved
to its left position (see Figure 3S-2).

Figure S3-2
DIN Rail Mounted Power Distribution Block & Form C Relays
with Relay Associated with DO8 Removed

CI-3305 Supplement 1 Section 3 - Page 3 ENC 3305 RTU


3.2.3 Removal/Replacement of the Phone Line Surge Protector

When a modem is provided, a Phone Line Surge Protector Assembly is mounted in the RTU
3305 Standard Enclosure as illustrated in Figure S1-2. The Surge Protector is assembled to
a mounting bracket. The mounting bracket with Surge Protector Board installed is secured
to the RTU 3305 Standard Enclosure’s Rear Mounting Panel via two screws.

To remove an installed Phone Line Surge Protector follow steps 1 through 3 below:

1. Loosen the two screws that secure the Phone Line Surge Protector’s mounting
bracket to the Rear Mounting Panel.

2. Slide the Surge Protector’s mounting bracket toward the unit’s right side to
facilitate removal and carefully raise the unit and then disconnect the wires to the
phone circuit and the wires to the modem.

3. The Surge Protector can now be removed from the mounting bracket.

To install a replacement Phone Line Surge Protector, perform the steps above and then
follow steps 1 through 3 below:

1. Install the wires associated with the modem. In the case of the standard BBI PL or
PSTN modems, the modem interface harness plugs into connector J1 on the Modem
Interface Board. In the case of an external modem, the modem interface harness
plugs into the modem’s RJ-11 Jack.

2. Install wires associated with the phone circuit. The wiring harness associated with
the line side of the circuit will typically plug into a phone company supplied RJ-11
type Jack (see Section 1.3.6 of this supplement and the appropriate modem
manual).

3. Slide the Phone Line Surge Protector’s mounting bracket over the two screws that
secure it to the Rear Mounting Panel and then tighten these screws.

3.2.4 Removal/Replacement of an External Communications Option

An external 9600 bps PSTN Modem or an external 1200 bps private Line Modem may be
mounted on the inside of the Instrument Front Cover as illustrated in Figure S1-2. Other
communications options (with the exception of the HARTÒ Device Interface and the
Network Interface Box) are mounted piggy-back on the RTU 3305 assembly. The HARTÒ
Device Interface (see Appendix 5) or the Network Interface Box (NIB) (see Appendix 4)
may be mounted on the inside of the Instrument Front Cover via a mounting plate or may
be mounted in a location external to the RTU 3305 Standard Enclosure.

External Modems are enclosed units as illustrated in Figures S1-2, S3-3A and S3-3B and
are secured to a “Upper Modem Mounting Plate” that accommodates installation to a
“Lower Modem Mounting Plate” on the inside of the Instrument Front Cover. To remove an
External Modem option follow steps 1 through 4 below:

CI-3305 Supplement 1 Section 3 - Page 4 ENC 3305 RTU


1. Disconnect the Power Harness from the Modem in question.

2. Disconnect the phone cord from the 9600 bps PSTN modem’s RJ-11 Telco Port Jack
or the 1200 bps PL modem’s Terminal Block TB1. In the case of a 1200 bps PL
modem, this cable may be connected on the other end to TB1 of the SP Model 8792-
20A Surge Protector (see Figure S1-11A) or to the OUT Terminals (TB1) of a
Phoenix MT-2FM-RJ12 Surge Protector (see Figure S1-11B). In the case of a 9600
bps PSTN modem, this cable may be connected on the other end to TB1 of the SP
Model 8792-20A Surge Protector (see Figure S1-11A) or to either of the RJ-11
connectors on the Phoenix MT-2FM-RJ12 Surge Protector (see Figure S1-11B).

3. Disconnect the RS-232 D-Type Connector from the modem. The other end of this
cable is connected to Port B of the RTU 3305 MI/OB Board.

4. Remove the two (2) screws that secure the Modem Cover to the Modem Mounting
Bracket and remove the modem from the unit.

Figure S3-3A - External 1200 bps PL Modem End View Interface Diagram

CI-3305 Supplement 1 Section 3 - Page 5 ENC 3305 RTU


Figure S3-3B - External 9600 bps PSTN Modem End View Interface Diagram

To install an External Modem Option follow steps 1 through 4 above in reverse installing
and securing rather than loosening and/or removing the item in question. If an external
modem is being field installed for the first time you will have to install the two “Mounting
Strips” to the inside of the Instrument Front Cover as illustrated in Figure S1-2. Press the
Mounting Strips onto the ends of Modem Mounting Bracket prior to installation. The
Mounting Strips are secured to the inside of the Instrument Front Cover via double sided
tape.

3.2.5 Removal/Replacement of a Power Supply Option

There are two types of power supplies available with the RTU 3305 Standard Enclosure,
i.e., a 40 Watt Power Supply or a Power Supply/Battery Charger. Both are available in
+12Vdc or +24Vdc versions.

CI-3305 Supplement 1 Section 3 - Page 6 ENC 3305 RTU


3.2.5.1 Removal/Replacement of the Power Supply/Battery Charger Option

The Power Supply/Battery Charger option is mounted above the DIN Rail Mounted Power
Distribution Block on the “Back Fabrication Panel.” It is secured to the “Power Supply
Mounting Plate” via four (4) screws. The Power Supply Mounting Plate is in turn secured
to the Back Fabrication Panel via four (4) screws as illustrated in Figure S3-4. To remove a
Power Supply/Battery Charger from the RTU 3305 Standard Enclosure, follow steps 1
through 5 below:

1. Shut off or disconnect AC Power to the unit.

Figure S3-4 -Location of Power Supply/Battery Charger


& Power Distribution Block

2. Disconnect the Power Supply/Battery Charger wires from the RTU 3305 Standard
Assembled Package DIN Rail Mounted Power Distribution Block (see Figure S3-4).
To get the black AC wire assigned to terminal L1 you will have to raise the Fused
Power Cutoff panel on the Power Distribution Block. The wires are assigned to the
Power Distribution Block’s right side as follows:

CI-3305 Supplement 1 Section 3 - Page 7 ENC 3305 RTU


Power Supply Wire Dist. Block
Description
Terminal Color Terminal
+OUT Red +12/24DC Supply 5 - Right
-OUT Black -12/24DC Supply 6 - Right
PIN1 (L1) Black 120VAC L1 - Right
PIN2 (L1) White 120VAC L2 - Right
GND Green Chassis Ground GND - Right

3. Remove the Power Supply/Battery Charger wires from the Wire Duct.

4. Loosen the four (4) screws that secure the Power Supply Mounting Plate to the Back
Fabrication Panel and slide the unit to the left and remove the Power Supply/-
Battery Charger from the RTU 3305 Standard Enclosure.

5. A replacement Power Supply/Battery Charger Assembly will have to be assembled


to the Power Supply Mounting Plate and the Power Supply Cover that was removed
from the 3305 Standard Enclosure in steps 1 through 4 above. To remove the Power
Supply Mounting Plate remove the four (4) screws from the bottom of the unit that
secure the plate to the Power Supply/Battery Charger and Power Supply Cover.
The removal of two (2) more screws is required to separate the supply from the
cover.

To install a Power Supply/Battery follow steps 1 through 5 above in reverse order, instal-
ling and securing rather than loosening and/or removing the item in question. Be careful
not to confuse the two black wires (see Figures S1-6 and S3-4).

3.2.5.2 Removal/Replacement of the 40 Watt Power Supply Option

The 40 Watt Power Supply option is mounted above the DIN Rail Mounted Power
Distribution Block on the “Back Fabrication Panel.” It is secured to a “Power Supply
Mounting Plate” via two (4) screws. The Power Supply Mounting Plate is in turn secured to
the Back Fabrication Panel via three (3) screws as illustrated in Figure S3-5. To remove a
40 Watt Power Supply from the RTU 3305 Standard Enclosure, follow steps 1 through 4
below:

1. Shut off or disconnect AC Power to the unit.

2. Disconnect the 40 Watt Power Supply wires from the units AC and DC connectors.

3. Loosen the three (3) screws that secure the Power Supply Mounting Plate to the
Back Fabrication Panel and slide the unit to the left and remove the 40 Watt Power
Supply from the RTU 3305 Standard Enclosure.

4. A replacement 40 Watt Power Supply will have to be assembled to the Power


Supply Mounting Plate that was removed from the 3305 Standard Enclosure in
steps 1 through 3 above. To remove the Power Supply Mounting Plate remove the
two (2) screws from the bottom of the unit that secure the plate to the Power
Supply.

CI-3305 Supplement 1 Section 3 - Page 8 ENC 3305 RTU


Figure S3-5 - 40W Power Supply
Mounted on 40W Power Supply Mounting Bracket

CI-3305 Supplement 1 Section 3 - Page 9 ENC 3305 RTU


BLANK PAGE
Section 4
RTU 3305 STANDARD ENCLOSURE
SPECIFICATIONS
This supplement provides information about the RTU 3305 Standard Enclosure. Detailed
specifications on the basic RTU 3305 are contained in Instruction Manual CI-3305.

4.1 ENVIRONMENTAL RATING & APPROVALS

An RTU 3305 Standard Enclosure that is installed without any of the available package
options (i.e., without Power Supply, Communication, Surge Protection or Relay options)
will meet FM approval for Class I, Division 2 hazardous environments.

4.2 POWER REQUIREMENTS

Power Current (mA)


Unit
(Watt) @ 24VDC
Base 3305 RTU 3.50 145
Local 2x16 Display 0.02 1
Remote 2x16 Display 0.40 17
4x20 Display/Keypad 0.88 37
1200 bps PL Modem 1.15 48
9600 bps PSTN Modem 1.45 60
RDI Board 0.10 4
TIB Board 0.73 30
RS-485 Board 0.24 10

4.3 ACCESSORY SPECIFICATIONS

4.3.1 Power Supply/Battery Chargers

Versions: 13.8VDC @ 1.8A Max. (Continuous & Surge)


27.6VDC @ 0.9A Max. (Continuous & Surge)

Size: 5.5” x 3.6” x 2.7” (14cm x 9.2cm x 6.9cm)

Battery Backup: Rechargeable Lead-acid Gel Cell


12V @ 7.2 A-Hrs. - One Batt. (8 Hrs. Min. Backup)
12V @ 14.4 A-Hrs. - 2 Batts. (16 Hrs. Min. Backup)
24V @ 7.2 A-Hrs. - 2 Batts. (16 Hrs. Min. Backup)
Note: Drained batteries require up to 10 hours
recharge time before unit returns on-line.

Operating Temperature: -40°C to +60°C (-40°F to +140°F)

CI-3305 Supplement 1 Section 4 - Page 1 ENC 3305 RTU


4.3.2 Private Line Modem (External Version)

Speed: 1200 bps over 3002 type voice-grade leased lines

Standards: Bell 202 or V.23

Line Type: 2 or 4 wire (600 Ohms)

Serial Port Connector: 9-Pin D-Type

Input Voltage Versions: 9 to 36 VDC


48 to 220 VAC

Dimensions: 5.25”W x 4”H x 1.5”D (13.4cm x 10.2cm x 3.8cm)

4.3.3 Switched Network Modem (External Version)

Speed: 9600 bps over PSTN lines

Standards: Bell 212 or V.32

Line Type: 2 wire loop start lines

Serial Port Connector: 9-Pin D-Type

Phone Functions: Auto Dial/Answer (Master or Slave Dial)

Input Voltage Versions: 9 to 36 VDC


48 to 220 VAC

Dimensions: 5.25”W x 4”H x 1.5”D (13.4cm x 10.2cm x 3.8cm)

4.3.4 Isolated RS-485 Board (External Version) (see PIP-ISORS485)

Speed: Up to 38.4 Kbps

Connection Standard: External version connects to any full RS-232 or RS-


485 Port
Internal version connects to 3305 RTU Port C (TTL)

Termination & Biasing: Selectable

Multi-dropping: Up to 32 nodes

Input Voltage Version: 9 to 35 VDC

Isolation: 300VDC

Surge Protection: Meets IEEE C37.90-1978 to isolated ground

CI-3305 Supplement 1 Section 4 - Page 2 ENC 3305 RTU


Dimension External Version: 4.375” x 4.135” (11.1cm x 10.5cm)

4.3.5 HART® Device Interface (see PIP-HART33XX)

4.3.6 Internal Communication Options

Internal Communications Options mount on the RTU 3305 as described in the RTU 3305
Manual CI-3305.

Private Line Modem: See Customer Instruction Manual CI-1200-PL


Switched Network Modem: See Customer Instruction Manual CI-9600
Transmitter Interface Board: See Appendix 1 of CI-3305
Radio Delay Board: See Appendix 2 of CI-3305
RS-485 Interface Board; See Appendix 3 of CI-3305

CI-3305 Supplement 1 Section 4 - Page 3 ENC 3305 RTU


BLANK PAGE
Supplement Guide - S1400 Issue: 09/01

SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING

A Guide for the Protection of


Site Equipment & Personnel
In the Installation of
BBI Series 33XX DPCs & RTUs

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.

Trademarks or copy-righted products mentioned in this document are for information only,
and belong to their respective companies, or trademark holders.

Copyright (c) 2001 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 S1400
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING

TABLE OF CONTENTS
SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION ....................................................................................... 1-1


1.2 MAJOR TOPICS ............................................................................................................. 1-1

Section 2 - PROTECTION

2.1 PROTECTING INSTRUMENT SYSTEMS................................................................... 2-1


2.1.1 Quality Is Conformance To Requirements.................................................................... 2-1
2.2 PROTECTING EQUIPMENT & PERSONNEL ........................................................... 2-1
2.2.1 Considerations For The Protection of Personnel .......................................................... 2-2
2.2.2 Considerations For The Protection of Equipment ........................................................ 2-2
2.3 OTHER SITE SAFETY CONSIDERATIONS............................................................... 2-3

Section 3 - GROUNDING & ISOLATION

3.1 POWER & GROUND SYSTEMS................................................................................... 3-1


3.2 IMPORTANCE OF GOOD GROUNDS......................................................................... 3-1
3.3 transients and interference............................................................................................ 3-2
3.4 EARTH GROUND CONNECTIONS............................................................................. 3-2
3.4.1 Establishing a Good Earth Ground. .............................................................................. 3-2
3.4.1.1 Soil Conditions ................................................................................................................ 3-4
3.4.1.2 Soil Types ........................................................................................................................ 3-4
3.4.1.3 Dry, Sandy or Rocky Soil................................................................................................ 3-6
3.5 GENERAL RECOMMENDATIONS ............................................................................. 3-7
3.5.1 Noise and Signal Errors ................................................................................................. 3-7
3.5.2 General Considerations.................................................................................................. 3-8
3.5.3 Other Grounding Considerations. ................................................................................. 3-8
3.6 GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS ................................ 3-12
3.6.1 Several DPCs Mounted in Metal Cabinet with Power Supply .................................. 3-12
3.6.2 Multiple DPC Cabinets with Local Power Supply in Each Cabinet.......................... 3-14
3.6.3 Multiple DPC Cabinets Powered by Single Power Supply ........................................ 3-14
3.6.4 Multiple Clusters of DPC Cabinets Powered by Local Supplies................................ 3-16

Section 4 - LIGHTNING ARRESTERS & SURGE PROTECTORS

4.1 STROKES & STRIKES .................................................................................................. 4-1


4.1.1 Chance of Being Struck by Lightning. .......................................................................... 4-1
4.1.2 Antenna Caution ............................................................................................................ 4-3
4.1.3 Ground Propagation ....................................................................................................... 4-5
4.1.4 Tying it all Together....................................................................................................... 4-5
4.1.5 Impulse Protection Summary ........................................................................................ 4-5
4.2 USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS................................ 4-6

Supplement S1400 Page 0-1 Table Of Contents


Supplement Guide S1400
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING

TABLE OF CONTENTS
SECTION TITLE ..................................................................................................... PAGE #

Section 5 - WIRING TECHNIQUES

5.1 OVERVIEW ....................................................................................................................5-1


5.2 INSTRUMENT WIRING. .............................................................................................. 5-1
5.2.1 Common Returns ............................................................................................................5-1
5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation).................................. 5-2
5.2.3 Grounding of Cable Shields. .......................................................................................... 5-3
5.2.4 Use of Known Good Earth Grounds .............................................................................. 5-3
5.2.5 Earth Ground Wires ....................................................................................................... 5-3
5.2.6 Working Neatly & Professionally .................................................................................. 5-3
5.2.7 High Power Conductors and Signal Wiring .................................................................. 5-4
5.2.8 Use of Proper Wire Size ................................................................................................. 5-4
5.2.9 Lightning Arresters & Surge Protectors ....................................................................... 5-4
5.2.10 Secure Wiring Connections ............................................................................................ 5-5

REFERENCE DOCUMENTS

1. IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std
142-1982
2. IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise inputs to Controllers
from External Sources - IEE Std 518-1982
3. Lightning Strike Protect; Roy B. Carpenter, Jr. & Mark N. Drabkin, Ph.D.; Lightning Eliminators &
Consultant, Inc., 6687 Arapahoe Road, Boulder Colorado
4. Lightning Protection Manual for Rural Electric Systems, NRECA Research Project 82-5, Washington DC,
1983
5. Grounding for the Control of EMI; Hugh W. Denny; Don White Consultants, Inc., 1983, 1st Edition
6. Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam
Street, Shreveport, Louisiana 71151

Supplement S1400 Page 0-2 Table Of Contents


Section 1 - Overview

1.1 INTRODUCTION

This document provides information pertaining to the installation of BBI Series 33XX
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 likelyhood
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 S1400


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 en-


vironments, 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 in-
stallation practices will minimize injury, equipment failure and the customer frustrations
that accompany failing and poorly operating equipment (of even the finest design). Ad-
ditionally, 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

Series 33XX 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 Page 2-1 S1400


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

# Guide
1 Indoor or outdoor – Dress Appropriately
2 If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees,
spiders, snakes, etc.)
3 If indoor or outdoor – determine if there are any pieces of dangerous equipment or any
processes which might be a risk to your safety
4 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.)
5 Hazardous or Non-Hazardous Environment – Wear appropriate safety equipment and
perform all necessary safety measures.
6 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.
7 Never assume that adjacent or peripheral equipment has been properly installed and
grounded. Determine if this equipment and the 33XX unit in question can be touched
simultaneously without hazard to personnel and/or equipment?
8 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!
9 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, 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

# Guide Reference Section


1 Environment - Class I, Division 2 - Nonincendive See Appendix A of CI Manual
Environment - Class I, Division 1 - Intrinsically Safe See Appendix B of CI Manual
Other - Safe or unrated area
2 Earth Ground - Established by mechanical/electrical or See Section 3
(both) or not at all.
3 Is the area prone to lightning strikes? See Section 4
4 Are there surge suppressors installed or to be installed? See Section 4
5 Are there overhead or underground power or com- See Section 2.3
munication cables in the immediate area?

S1400 Page 2-2 Section 2 - Protection


Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued)

# Guide Reference Section


6 Is there an antenna in the immediate area? See Section 4.1.2
7 How close is other equipment? Can someone safely touch this See Section 2.3
equipment and a 33XX unit simultaneously?
8 Determine equipment ground requirements. How will the 33XX unit See Section 3
and its related wiring be grounded? Consider Earth Ground, Circuit
Ground, Conduit Ground, Site Grounds!
9 Are there any obviously faulty or questionable power or ground See Section 2.3
circuits?

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.

Section 2 - Protection Page 2-3 S1400


Section 3 - Grounding & Isolation

3.1 POWER & GROUND SYSTEMS

Series 33XX DPCs and RTUs (3305, 3310, 3330, 3331, 3332, 3335) utilize DC power
systems. With the exception of some 3305 SAPs, AC power supplies are not provided with
these units. Series 3305 SAP RTUs and 3335 DPCs are provided with a Ground Lug that
accommodates up to a #4 AWG size wire for establishing a connection to Earth Ground.
Table 3-1 provides ground connection information for these units.

Model Gnd. Jumpers Doc. Ref. Location Notes


# 12 AWG Wire
Pin 1 = PCOM (DC Ret.)
3305 RTU None CI-3305 - C2 MI/OB Bd.
Pin 2 = POWER (DC+)
Pin 3 = CHASSIS
CI-3305 - Sup 1 #4 AWG - see Figs.
3305 SAP None Ground Lug
Section 2.2.3 S1-5, -6
W1A, W1B
#14 AWG Wire - see Figs.
3310 RTU See C3A - topic CI-3310 - C3A MFIB Bd.
3A-1, -2, -4, -6
Grounding Option
W1A, W1B, W1C
3330 DPC CI-3330 - C3A #14 AWG Wire - see Figs.
See C3A - topic SI Bd.
3332 RED CI-3330 - C3K 3A-1, -2, -3, 3K-7, 3K-8
Grounding Option
# 12 AWG Wire from
SMM - TB1 pin 2 (GND)
Jumpers = SI Bd.
W13A, W13B to Zero Ref. Point - see
3331 RIO CI-3335 - C3L Wiring = System
See C3A - topic Figs 3A-1, -2, -7, -8, -9
3335 DPC CI-3335 - C3A Monitor Module
Grounding Option #4 AWG Wire from
& Ground Lug
Chassis Bonding Bolt to
Power Grid Ground

3.2 IMPORTANCE OF GOOD GROUNDS

Series 33XX DPCs and RTUs 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 relationship 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.

Section 3 - Grounding & Isolation Page 3-1 S1400


3.3 TRANSIENTS AND INTERFERENCE

The extensive use of low-power integrated circuitry in modern electronic equipment


requires proper grounding techniques to insure reliable system operation. The following
checklist will help identify some critical areas:

1. All instrumentation devices at the site should be checked so that no potential greater
than the standoff voltage can exist within or between devices.

2. To minimize outside signal interference and provide equipment protection from


lightning or transients, the earth ground at the site must be tested to insure that its
impedance measures less than 10 ohms at 7 MHz. This qualification is essential since a
transient potential or an interference signal at the instrument site can vary over the
entire electromagnetic spectrum from DC to several hundred MHz.

Note that transients can be produced through natural phenomena and man-made
conditions. Natural transients may result from lightning (7-14 MHz), static (many
frequencies), and wind (DC charge and static). Man-made transients can result
from defective light bulbs or electrical appliances, sudden electrical load shifts,
inductive load surges, arcing contacts and poor AC power connections.

3. If radio frequency (RF) interference is present at the input of an instrument, observe if


it has a consistent or irregular pattern. Constant interference can come from
commercial radio stations, while irregular interference can come from private stations.
Although shielding and grounding will eliminate or minimize most cases of RF
interference, obstinate cases may require attenuation filters.

RF interference can also be caused by power companies that apply modulated RF


signals to power lines to communicate data. Other RF noise sources include digital
clocks, computers, relay contacts, motors transformers, switches, arc welders, etc.

3.4 EARTH GROUND CONNECTIONS

To properly ground a DPC or RTU 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.

3.4.1 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
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.

S1400 Page 3-2 Section 3 - Grounding & Isolation


Figure 3-1 - Basic Ground Rod Installation

Figure 3-2 - Overhead Map of Ground Bed for Gas Metering Station

Section 3 - Grounding & Isolation Page 3-3 S1400


3.4.1.1 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).

3.4.1.2 Soil Types: Good Poor


Damp Loam Back Fill
Salty Soil or Sand Dry Soil
Farm Land 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
ground has been established, it should be tested on a regular basis to preserve system
integrity.

Figure 3-3 - Basic Ground Bed Soil Test Setup

S1400 Page 3-4 Section 3 - Grounding & Isolation


Figure 3-3 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
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 3-4). * 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 - Basic Ground Bed Soil Test Setup with Additional Ground Rods

Figure 3-5 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 3-6 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 3-5 - Ground Electrode Construction for Poor Soil Conditions

Section 3 - Grounding & Isolation Page 3-5 S1400


3.4.1.3 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.

Figure 3-6 - Poor Soil Ground Bed Construction Diagram

S1400 Page 3-6 Section 3 - Grounding & Isolation


3.5 GENERAL RECOMMENDATIONS

When wiring equipment into a system, the electrical conduit must have a diameter that will
accommodate the desired number of wires. The cross- sectional area of the conduit should
be large enough to allow the wires to be pulled through without excessive tightness or
binding. A conduit that is too tight can shred insulation, damage wiring, and result in
possible opens, shorts, or intermittent effects. Such conditions are often difficult to trace
because the defect is concealed inside the conduit.

3.5.1 Noise and Signal Errors

Noise and signal errors are often the result of poor wiring and grounding practices. Some
common problem areas are listed as follows:

o Shielding AIs and AOs. Very often analog DC signal leads must run parallel to
wires radiating AC fields, pulse information, or switching transients. Due to
inductive and capacitive pickup, some of this information can leak into an analog I/O
and cause peculiar effects in the control systems. To minimize or eliminate this
problem, the use of insulated and shielded, twisted lead pairs is recommended
between the external devices (transmitters, sensors, etc.) and the instrument inputs
(controllers, recorders, etc.).

The shields of each analog signal source should only be grounded at the input of the
in-strument. In some equipment, the shield will connect to the instrument chassis.
In other equipment, a "shield" terminal will be provided with several grounding
options. The user should refer to the instrument manual and follow grounding
recom-mendations.

o Common Returns. The use of a single "common" return wire for two or more input
signals is not recommended. This approach may introduce system ground loops that
cause erroneous readings at the instrument. Shielded transmitter or sensor wires
should be grounded at the input of the instrument, or connected to a shield terminal
(where provided) to prevent "sneak" ground paths.

o Discrete Outputs. Instruments provided with bi-state discrete outputs perform


functions such as control switching, alarm switching or pulse duration com-
munications. These outputs are furnished as either open collector or relay contact
outputs that operate at low power levels. While these levels are sufficient to operate
many devices, some will require much higher power levels. The use of external
amplifiers or repeating relays to drive end devices will prevent output overload and
add to the reliability of the system.

o Placement of Wiring. The dressing or physical placement of wiring requires close


scrutiny. Cables inside cabinets should be neatly secured at regular intervals.
Cables running between cabinets at different locations should be placed in conduits.
The cable length should allow sufficient slack for routine operational checks and
maintenance of the equipment. Wiring from input signal circuits and power circuits
should be separated as much as possible to minimize noise and transient pickup.
Power and signal leads should be run in separate conduit to minimize inductive
pickup.

Section 3 - Grounding & Isolation Page 3-7 S1400


o Terminal Lugs. The use of crimp-type terminal lugs as connections for screw
terminals should be avoided. Terminal lugs, in many industrial climates, can be
affected by hidden corrosion. It is preferable to tin the wire end with solder and loop
it around the terminal screw. The screw should be tightened sufficiently to hold the
lead in place but not excessively so that the lead is sheared or the screw is stripped.
Equipment furnished with compression-type terminals includes an opening for
inserting tinned ends.

3.5.2 General Considerations

The following considerations are provided for the installation of 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.

3.5.3 Other Grounding Considerations

Instrument enclosures, measuring devices, metal process vats, metal piping, and other
associated mechanical and electrical devices should all be grounded. The method of
grounding an instrument rack is shown in Figure 3-6. In this application the ground lead
typically attaches to a ground bus that is common to all equipment in the rack.

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 3-7. The
ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.

Applications that use transmitters or transducers require grounding and shielding. In


Figure 3-8, the ground conductor feeds through the electrical conduit and connects to the
ground screw of the transmitter even though the support pipe is grounded. However, if the
transmitter uses shielded wiring for its signal output, the shield should not be grounded at
the transmitter. For maximum signal accuracy, the shield should only be grounded at one
point in the system, typically at the input of the associated equipment.

S1400 Page 3-8 Section 3 - Grounding & Isolation


Figure 3-6 - Grounding of Equipment Housing

Figure 3-7 - Grounding of Phone Line

Section 3 - Grounding & Isolation Page 3-9 S1400


Figure 3-8 - Grounding of Transmitter

Figure 3-9 - Grounding of Thermometer Well in Gas Line

S1400 Page 3-10 Section 3 - Grounding & Isolation


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 arrestor as shown in Figure 3-9. A copper braid,
brazed to the thermal well, is dressed into a smooth curve and connected to the arrestor as
shown. The curve is necessary to minimize arcing caused by lightning strikes or high static
surges. The path from the lightning arrestor to the ground bed should also be smooth and
free from sharp bends for the same reason.

The ac power required to operate a system typically includes a service transformer located
at the street and a main breaker box and rate meter assembly at the building as shown in
Figure 3-10. The service transformer is grounded at the company's pole, while the breaker
box is grounded at the building. A lightning arrestor should be included at the breaker box
in each phase of the AC line, and each arrestor should be grounded accordingly.

Figure 3-10 - AC Power Grounding System

Section 3 - Grounding & Isolation Page 3-11 S1400


3.6 GROUNDING TECHNIQUES FOR SERIES 33XX SYSTEMS
When installing a system that includes a number of Bristol Babcock, Series 33XX
Distributed Process Controllers (DPCs), it is essential to follow the procedures set forth by
the National Electrical Code (NEC) to minimize risk of equipment damage and electrical
shock.

WARNING

Electrically powered equipment must be properly grounded to


protect users from electrical shock and injury. All such devices
must be installed, wired, and grounded in accordance with the
National Electrical Code (NEC).

Series 33XX DPCs employ a power grid ground terminal (CHASSIS) and an instrument
ground terminal (24VRET) that connects to the "zero reference point" of the system.
Improper grounding of these terminals can produce multiple ground paths throughout the
system and result in increased noise pickup and signal offset errors. If more information is
required on this subject, the reader should refer to the publications cited at the end of this
document.

The examples that follow describe the grounding techniques for several types of Bristol
Babcock systems employing DPCs. Refer to the system description that is closest to your
application.

3.6.1 Several DPCs Mounted in Metal Cabinet with Power Supply

A small system can consist of one or more DPCs mounted in a single metal cabinet or rack
with a power supply. A power wiring diagram for this arrangement is shown in the example
of Figure 8. The following installation procedures apply:

1. Instrument Ground. The instrument ground of the DPCs (24VRET terminal of each
DPC) must connect to a terminal block within the cabinet that is electrically isolated
from the cabinet frame. This terminal block must provide termination for all in-
strument grounds and include termination for a multistranded, insulated, #4 gauge
wire (or greater). This wire, which will connect to the "zero reference point" of the
facility, must be run through metal conduit (pipe). Only the #4 wire will be contained
in this conduit. The conduit must also be connected by bonding strap to the cabinet
and facility frame as described in the NEC.

2. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis
connection from the 24VRET connection (see Figure 3-11). If it is a Model 3330,
jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers or Correctors, if used with these systems, provide an
isolated instrument ground without setting jumpers.

3. AC Power Source. The 24 Vdc power supply requires a 120 Vac power source. The ac
power terminals of this supply are identified in Figure 3-11. The 120 Vac wiring for
this supply must be contained in cable trays along with the power grid grounding
wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical

S1400 Page 3-12 Section 3 - Grounding & Isolation


facility. The cabinet frame and the DPC chassis must be connected with bonding strap
at points specified in the NEC.

Figure 3-11 - Grounding for DPCs and Power Supplies


in Single Metal Cabinet

4. Grounding of Peripheral Equipment. Some peripheral devices such as printers, CRTs,


personal computers, etc., have their internal logic ground connected to the chassis.
This configuration will cause loss of isolation between the DPC's instrument ground
and chassis. These devices may still be used providing that opto-isolated circuits,

Section 3 - Grounding & Isolation Page 3-13 S1400


galvanic isolation, or other types of circuitry between the device and the DPC are
added to maintain the integrity of the DPC's instrument ground-to-chassis isolation.

3.6.2 Multiple DPC Cabinets with Local Power Supply in Each Cabinet

This application consists of two or more DPC cabinets either separated or clustered
together in a room. Each cabinet has its own 24 Vdc power supply. The following
procedures apply:

1. Multi-Cabinet Instrument Grounding using Multiple Supplies. The instrument


ground (24VRET terminal) of each DPC in a cabinet must connect to a terminal block
within that cabinet that is electrically isolated from the cabinet frame. This terminal
block must provide termination for all DPC instrument grounds within that cabinet
and include termination for a #4 gauge (or greater), multistranded, insulated wire
that will connect to the zero reference point of the facility. This #4 wire will be run
through metal conduit (pipe) to the same termination point in the other cabinets. Only
the #4 wire will be containe in this conduit. This conduit must also be connected by
bonding strap to the cabinet and facility frame as described in the NEC.

2. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis
connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330,
jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers, if used with these systems, provide an isolated
instrument ground without setting jumpers.

3. AC Power Source. The 24 Vdc power supply requires a 120 Vac power source. The ac
power terminals of this supply are identified in Figure 3-11. The 120 Vac wiring for
this supply must be contained in cable trays along with the power grid grounding
wire. Figure 3-12 illustrates the cable tray layout and grounding points of a typical
facility. The cabinet frame and the DPC chassis must be connected with bonding strap
at points specified in the NEC.

4. Grounding of Peripheral Equipment. Some peripheral devices such as printers, CRTs,


personal computers, etc., have their internal logic ground connected to the chassis.
This configuration will cause loss of isolation between the DPC's instrument ground
and chassis. These devices may still be used providing that opto-isolated circuits,
galvanic isolation, or other types of circuitry between the device and the DPC are
added to maintain the integrity of the DPC's "instrument ground to chassis" isolation.

3.6.3 Multiple DPC Cabinets Powered by Single Power Supply

All of the DPC cabinets in this installation operate from a single power supply which may
be installed in one of the cabinets or in a separate cabinet. The following procedures apply:

1. Multi-Cabinet Instrument Grounding using Single Supply. The instrument ground


(24VRET terminal) of each DPC in a cabinet must connect to a terminal block within
that cabinet that is electrically isolated from the cabinet frame. This terminal block
must provide termination for all instrument grounds within that cabinet and include
termination for a multistranded, insulated, #4 gauge wire (or greater).

S1400 Page 3-14 Section 3 - Grounding & Isolation


From: Grounding for the Control of EMI by Hugh W. Denny (see ref. 1)
- Courtesy of Interference Control Technologies -

Figure 3-12 - Elements of a Facility Ground System

2. Routing of Instrument Ground and 24 V Power Wires. The #4 wire, along with +24V
and 24VRET wires, are run through conduit trays to the power supply. The #4 wire

Section 3 - Grounding & Isolation Page 3-15 S1400


connects to the 24VRET terminal of the supply and to the zero reference point of the
facility. The +24V and 24RET wires connect to corresponding terminals on the power
supply.

3. Cable Trays. Figure 3-12 illustrates the cable tray layout and grounding points of a
typical facility. The cabinet frame and the DPC chassis must be connected with
bonding strap at points specified in the NEC. The NEC also applies to the connection
of the 120 Vac power supply terminals to the line.

4. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis
connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330,
jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers, if used with these systems, provide an isolated
instrument ground without setting jumpers.

3.6.4 Multiple Clusters of DPC Cabinets Powered by Local Supplies

A cluster consists of two or more DPC cabinets that may be grouped together as shown in
Figure 9. Several such clusters performing related functions in the same facility make up a
multiple cluster system. The following procedures apply:

1. Grounding for DPC Cabinet Cluster using Local Supply. The instrument ground
(24VRET terminal) of each DPC in a cabinet must connect to a terminal block within
that cabinet that is electrically isolated from the cabinet frame. This terminal block
must provide termination for all instrument grounds within that cabinet and include
termination for a multistranded, insulated, #4 gauge wire (or greater) that will
connect to the same termination point to other cabinets of that cluster, and to the
24VRET terminal of the local power supply.

2. Routing of Cluster Grounds. The instrument grounds (isolated terminal) from each
cabinet cluster must connect to each other and then to a single wire that connects to
the zero reference point of the facility. This wire should be #4 gauge minimum
(multistranded and insulated) and be contained in a metal conduit (pipe). A heavier
stranded #4/0 gauge could be used to connect each cluster to the zero reference point
while the #4 wire instrument grounds could be locally terminated to the #4/0 wire.
The conduit containing this wire must also be connected by bonding strap to the
cabinet and facility frame as described in the NEC.

3. AC Power Source. The 24 Vdc power supply of each cluster requires a 120 Vac power
source. The ac power terminals of this supply are identified in Figure 3-11. The 120
Vac wiring for this supply must be contained in cable trays along with the power grid
grounding wire. Figure 3-12 illustrates the cable tray layout and grounding points of a
typical facility. The frame of each cabinet and each DPC chassis a cluster must be
connected with bonding strap at points specified in the NEC.

4. Setting DPC Power Jumpers. If the DPC is a Model 3335 or 3310, jumpers W1A and
W1B on the System Interconnect Board must be removed to isolate the chassis
connection from the 24V RET connection (see Figure 3-11). If it is a Model 3330,
jumpers W1A, W1B and W1C on the System Interconnect Board must be removed.
Series 3308 Gas Flow Computers and Correctors, if used with these systems, provide
an isolated instrument ground without setting jumpers.

S1400 Page 3-16 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 various 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 S1400


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 Chart 2
I “A” LAT.° “B”
5 8 25 .170
10 26 30 .200
20 85 35 .236
30 169 40 .280
40 275 45 .325
50 402
60 548
70 712 Note for these charts:
80 893 I = Thunderstorm Days Per Year (Isokeraunic Number)
90 1069 A= Stroke activity for associated Isokeraunic Area
100 1306 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 BBI Series 33XX 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 modem
has been interfaced to a 33XX unit, the possibility of damage due to a lightning strike on

S1400 Page 4-2 Section 4 - Lightning & Surge


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 S1400


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. Additional communication equipment lightning arresters and surge suppressors
should be tied to the same system ground. System ground consists of the tower leg grounds

S1400 Page 4-4 Section 4 - Lightning & Surge


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
33XX 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 33XX units would then have a single ground point from its Chassis
Ground Terminal/Ground Lug to this panel. In lieu of this, the 33XX 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 Use more than one ground rod.


i Place multi-ground stakes more than their length apart.
i Tie Power, Telco, Tower, Bulkhead and equipment ground together.
i 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.
i Watch out for dissimilar metals connections and coat accordingly.

Section 4 - Lightning & Surge Page 4-5 S1400


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
Southwaset 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.

S1400 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 S1400


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.

S1400 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

33XX units should only have one connection to earth ground. 33XX units (with the
exception of 3305 SAPs and DPC 3335s) require the installation of a ground lug, ground bus
or ground plate/panel. Since 33XX 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
33XX unit. 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.

Remember loose connections, bad connections, intermittent connections, corroded connec-


tions, etc., are hard to find, waste time, create system problems and confusion in addition to
being costly.

Section 5 - Wiring Techniques Page 5-3 S1400


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

Series 33XX units utilize compression-type terminals that accommodate up to #12 or #14
AWG gauge wire (see Table 3-1). 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
33XX unit.

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
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 recom-

S1400 Page 5-4 Section 5 - Wiring Techniques


mended 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 that 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 S1400


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DOCUMENT NUMBER: S1400


TITLE: SITE CONSIDERATIONS For EQUIPMENT INSTALLATION, GROUNDING &
WIRING
ISSUE DATE: SEPT., 2001
COMMENT/COMPLAINT:

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Bristol Babcock Inc.
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Attn: Technical Publications Group, Dept. 315
Bristol Babcock Inc.
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Telephone: (860) 945-2200
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 1

ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 2

1. Introduction 2

2. General Rules 3

3. Protecting ESD-Sensitive Components 5

4. Static-Safe Field Procedure 6

5. Cleaning and Lubricating 8

6. Completion 10

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 compo-
nents 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).

2. A 15-foot long ground cord for grounding the work surface.

3. Wrist strap (available in two sizes, large and small, for proper fit and
comfort) with a female snap fastener for ground cord attachment.

4. A coiled ground cord with a practical extension length of 10 feet for


attachment to the wrist strap.

Toothbrush (any standard one will do)

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2. Materials
● Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent)
● Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent)
● Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent)

ESD-SENSITIVE COMPONENT HANDLING PROCEDURE

1. Introduction

Microelectronic devices such as PC boards, chips and other components are electro-
static-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.

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Table 1

Typical Electrostatic Voltages

Electrostatic Voltages

Means of Static 10-20 Percent 65-90 Percent


Generation Relative Humidity Relative Humidity

Walking across carpet 35,000 1,500


Walking over vinyl floor 12,000 250
Worker at bench 6,000 100
Vinyl envelopes for work instructions 7,000 600
Poly bag picked up from bench 20,000 1,200
Work chair padded with poly foam 18,000 1,500

2. 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.

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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 compo-
nents. This helps eliminate damage caused by mishandling. Do not strip used PC
boards for parts. Ship defective boards promptly to Bristol Babcock in a static-
shielding bag placed inside static-shielding foam and a box to avoid damage
during shipment.

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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.

3. 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:

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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.

4. 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.

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(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
E F
A
R

G
B
R
R

EARTH GROUND FLOOR OF BUILDING

LEGEND

A - Chair with ground (optional)

B - ESD protective floor mat (optional)


C - Wrist strap

D - ESD protective trays, etc.


E - Ionizer

F - Other electrical equipment


G - Workbench with ESD protective table top

✰ NOTE: ALL RESISTORS 1M Ω +/-10% 1/2W

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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.

5. 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 proce-
dure.

(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.

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(2) Clean PC board connectors as follows:

a. Review the static-safe field procedure detailed earlier.

b. Following the ESD-sensitive component handling procedures, remove


the connectors from the boards and remove the PC boards from their
holders.

c. Use cleaner to remove excessive dust build-up from comb connectors


and other connectors. This cleaner is especially useful for removing dust.

d. 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

e. Clean the comb contacts using a lint-free wiping cloth.

f. Lightly mist all comb contacts again with Inhibitor.

NOTE: Do not use so much Inhibitor that it drips.

g. Repeat the above procedure for the other PC boards from the device.

(3) Cleaning PC edge connectors

a. Use cleaner to remove excessive dust build-up from connectors. This


cleaner is especially useful for removing dust.

b. Liberally spray the outboard connector with Inhibitor.

c. Lightly brush the outboard connector with a soft, non-metallic, bristle


brush such as a toothbrush.

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d. Spray the connector liberally to flush out any contaminants.

e. Remove any excess spray by shaking the connector or wiping with either
a toothbrush, or a lint-free wiping cloth.

6. Completion

(1) Replace any parts that were removed.

(2) Make sure that the component cover is secure.

(3) Return the system to normal operation.

(4) Check that the component operates normally.

10
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DOCUMENT NUMBER: CI-3305


TITLE: Remote Terminal Unit RTU 3305 Instruction Manual
ISSUE DATE: DEC., 2005
COMMENT/COMPLAINT:

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Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Attn: Technical Publications Group, Dept. 315
Bristol Babcock
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2200
Fax: +1 (860) 945-2213
Website: www.bristolbabcock.com

U.S.A. Locations:
Northern Region Gulf Coast Region Western Region Southeast Region
Bristol Babcock Inc. Bristol Babcock Inc. Bristol Babcock Inc. Bristol Babcock Inc.
1100 Buckingham Street 2000 Governor's Circle 1609 South Grove Avenue 317 S. North Lake Blvd.
Watertown, CT 06795 Suite F Suites 106 & 107 Suite 1016
Phone: +1 (860) 945-2381 Houston, TX 77092-8731 Ontario, CA 91761 Altamonte Springs, FL 32701
Fax: +1 (860) 945-2525 Phone: +1 (713) 685-6200 Phone: +1 (909) 923-8488 Phone: +1 (407) 740-7084
Fax: +1 (713) 681-7331 Fax: +1 (909) 923-8988 Fax: +1 (407) 629-2106

Helicoid Instruments Central Region Rocky Mountain Region Communications


1100 Buckingham Street Bristol Babcock Inc. Bristol Babcock Inc. Technology Group
Watertown, CT 06795 300 North Coit Road 906 San Juan Blvd., Suite A Bristol Babcock Inc.
Phone: +1 (860) 945-2218 Suite 1300 Farmington, NM 87401 317 S. North Lake Blvd.
Fax: +1 (860) 945-2213 Richardson, TX 75080 Phone: +1 (505) 320-5046 Suite 1016
Phone: +1 (972) 238-8935 Fax: +1 (505) 327-3273 Altamonte Springs, FL 32701
Fax: +1 (972) 238-8198 Phone: +1 (407) 629-9464
Fax: +1 (407) 629-2106

International Affiliates:
Canada Mexico United Kingdom Asia Pacific
Bristol Babcock, Canada BBI, S.A. de C.V. Bristol Babcock Ltd. Bristol Babcock, Inc.
234 Attwell Drive Homero No. 1343, 3er Piso Blackpole Road PO Box 1987
Toronto, Ont. M9W 5B3 Col. Morales Polanco Worcester, WR3 8YB Bunbury, Western Australia
Canada 11540 Mexico, D.F. United Kingdom 6231
PH: 416-675-3820 Mexico PH: +44 (0) 1905 856950 PH: +61 (0) 8 9791 3654
FAX: 416-674-5129 PH: (52-55)-52-81-81-12 FAX: +44 (0) 1905 856969 FAX: +61 (0) 8 9791 3173
FAX: (52-55)-52-81-81-09
Victoria, Australia
PH: +61 (0) 3 9384 2171
FAX: +61 (0) 3 8660 2501
Calgary Office Villahermosa Office Middle East
Bristol Babcock, Canada BBI, S.A. de C.V. Bristol Babcock Ltd.
3812 Edmonton Trail N.E. Av. Plomo No.2 Blackpole Road
Calgary, Alberta T2E 5T6 Bodega No. 1 - Ciudad Worcester, WR3 8YB
Canada Industrial United Kingdom
PH: 403-265-4808 Villahermosa, Tabasco 86010 PH: +44 (0) 1905 856950
FAX: 403-233-2914 Mexico FAX: +44 (0) 1905 856969
PH: 52-993-353-3142
FAX: 52-993-353-3145

RC Rev: 05-Feb-04

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