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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.
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.
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.
ELECTRICAL GROUNDING
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.
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.
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.
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
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)
Part II Please complete Parts II & III for each unit returned
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
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.
In addition to the information contained in this manual, you may receive additional assis-
tance in using this product from the following sources:
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.
Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
(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.
During regular business hours, Bristol Babcock's Application Support Group can provide
telephone support for your technical questions.
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.
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.
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.
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
Section 2 - INSTALLATION
Section 4 - OPERATION
Section 5 - SERVICE
Section 6 - SPECIFICATIONS
APPENDICES
SUPPLEMENTAL INSTRUCTIONS
• 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.
• Backplane Board
• Processor Memory Peripheral Power Supply Board (PMPP)
• Multifunction Input/Output Board (MI/OB)
• Mounting Plate, Brackets & Hardware
• 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).
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:
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.
The following Processor Memory Peripheral Power Supply Board (PMPP Board) Jumpers
support configurable options:
Switch SW1 on the PMPP Board sets loopback (testing) for Ports A, B & C (see Table 1-2).
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:
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.
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:
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).
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.
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).
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.
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.”
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.
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).
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.
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).
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).
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 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.
Functionality of the MI/OB’s Terminal Blocks and Connectors are discussed below:
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
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.
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).
Table 1-8 - PWR, HSC & WD Circuits I/O Wiring Connector (TB3) Pin Assignments
The MI/OB Board contains 18 Jumpers (4 factory installed) and 1 Switch that function as
follows:
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.
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.
Each 3305 RTU can be interfaced to one LCD Display. LCD Displays available for the RTU
3305 are listed as follows:
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.
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.
The 3305 RTU can be interfaced to one of the following communication options via Port C
on the MI/OB Board:
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)
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)
Figure 1-10 - BBI 9600 bps PSTN Modem Layout (P/N 392958-05-8)
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.
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-
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.
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).
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.
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.
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.
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.
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.
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.
(NOTE: All workbench on-line communication and downloading is facilitated via Open
BSI Utilities software, discussed later in this chapter).
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.
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.
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.
Note: The RTU 3305 cannot serve as a serial Communications Front End (CFE).
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.
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.
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).
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.
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.
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.
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.
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.
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).
The 3305 RTUs Processor Memory Peripheral Power Supply (PMPP) Board contains 7
Jumpers which must be set for the desired performance options.
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
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
• Updump (Default = Disabled) The Updump option is reserved for factory use only.
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.
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.
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
Figure 2-6
Multifunction Input/Output Board’s Field Wiring Edge Connectors
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.
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).
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:
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).
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
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
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.
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).
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.
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.
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
Note
Pins 5 to 8 of each connector are unused.
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.
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.
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.
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).
6. Apply Power and test the LCD Display (see Section 3 for details on operation of the
LCD Display).
Follow steps 1 through 6 to install the Local 2 X 16 LCD Display into an RTU 3305.
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).
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).
1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).
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).
1. Disconnect power from the RTU 3305 (Shut down or place under manual control
any critical processes prior to disconnecting power).
3. Remove the six Mounting Spacers from the rear of the units Face/Mounting Plate.
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).
• 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)
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).
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 2-13 - 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
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
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.
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.
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.”
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.
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.
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
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.
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.
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:
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.
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.
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.
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.
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.
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.
Someone else has already signed on. Go to the paragraph below that starts "Once the
correct password has been entered...".
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.
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.
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.
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.
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].
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.
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.
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.
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].
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.
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.
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:
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.
Press [ALM I/E] key. (Note, this will only inhibit alarm reporting, and not alarm level
detection.)
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).
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.
7. Units - units text (for analog signals only), if any units have been defined.
8. Alarm Type
! - alarm is unacknowledged
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).
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
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.
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.
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.
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).
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.
STRING SIGNAL:
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.
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.
The Main Display is comprised of both user-defined and internal system data. The screens
associated with the Main Display are defined as follows:
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.
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:
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.
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.
! - alarm is unacknowledged
6. User defined ON/OFF Text for Logical signals or Logical Alarms (not to exceed 6-character
limit).
7. String Signals
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):
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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
Figure 4-2
System Parameter Configuration Menu
Type Y for yes if BBI has instructed you to perform this procedure, otherwise type N
for no.
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.
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.
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.
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. 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.
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:
Diagnostic messages and associated source files for each diagnostic area are
provided below.
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”
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”
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”
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”
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”
The service procedures described herein will require the following test equipment:
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.
Caution
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.
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.
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).
Figure 5-3 - 3305 with Top Plate/Options & PMPP Board Removed
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.
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:
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.
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
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
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.
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
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:
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.
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.
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.
5. Set MI/OB Board Jumpers W8A/B through W11A/B for the desired input con-
figuration.
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.
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.
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).
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-
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.
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:
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.
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.
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.
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.
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.
Baud Rate: 1.2K, 2.4K, 4.8K, 9.6K, 19.2K & 38.4K (bps)
Optional Radio Delay: A Port may be furnished with a Radio Delay Board
to provide a radio transceiver interface.
Baud Rate: 1.2K, 2.4K, 4.8K, 9.6K, 19.2K & 38.4K (bps)
Input Impedance:
Number of Outputs: 2
Number of Inputs: 1
22-30V Operation
ON (Active Low) - Vin <23.5 V
OFF - Vin >24 V
Hysteresis: - 0.5 V
Output Configuration: Open Collector
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
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.
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.
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 .
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
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.
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.
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.
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)
Part II Please complete Parts II & III for each unit returned
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
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.
In addition to the information contained in this manual, you may receive additional assis-
tance in using this product from the following sources:
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.
(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.
During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.
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.
The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/
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.
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
LED INDICATORS...................................................................................................................................... 5
SPECIFICATIONS ....................................................................................................................................... 5
12V TIB ........................................................................................................................................................ 5
24V TIB ........................................................................................................................................................ 6
Supplements
Special Instructions for Class I, Division 2 Hazardous Locations......................... Appendix A
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.
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
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
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)
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).
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.
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
24V TIB
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.
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
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
DISPLAY LEDS.............................................................................................................5
ENVIRONMENTAL SPECIFICATIONS......................................................................5
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.
JUMPER CONFIGURATION
Board jumpers provide configuration of leading and trailing edge delays and carrier time out.
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.
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
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
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.
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.
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
WIRING CONNECTIONS
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.
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.
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
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
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
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.
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.
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.
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).
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.
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
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
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.
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.
Performance Specification
Surge Path: Terminal Provided for Local Connection from Isolated Ground
to Earth Ground through an 180V MOV
Environmental Specifications
RFI Susceptibility: Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)
Input/Output Specifications
Tables 1 and 2 provide the Pin assignments of the various on-board connectors.
Bristol Babcock
Appendix 4
NETWORK INTERFACE BOX
(NIB)
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 1 - INTRODUCTION
Section 3 - SPECIFICATIONS
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.
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.
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
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.
Once a communication network plan has been established, use the following steps as a
wiring and setup guide:
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.
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:
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.
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.
The NIB requires 24VDC power when used for line termination.
Power must be provided if the NIB is used with the termination engaged.
CAUTION:
In the absence of a good earth ground, the
surge protection by the NIB is
compromised or nullified.
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.
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.
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.
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.
ELECTRICAL GROUNDING
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.
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.
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.
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
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)
Part II Please complete Parts II & III for each unit returned
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
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.
In addition to the information contained in this manual, you may receive additional assis-
tance in using this product from the following sources:
Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
(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.
During regular business hours, Bristol Babcock's Application Support Group can provide
telephone support for your technical questions.
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.
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.
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.
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
Section 3 - SPECIFICATIONS
SUPPLEMENTS
REFERENCE DOCUMENTS
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
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
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).
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
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.
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
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).
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.
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.
In the RS-232 communications mode, the HDI can operate properly with 3508 transmitters.
The 10 millisecond RTS/CTS delay must be selected.
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.
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 8 - Hart Slaves (Transmitters) (with +12 to +45 VDC Voltage Source)
Connected to 33XX via HDI Board in RS-232 Mode
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.
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).
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“
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
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
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.
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.
Please help us make our documentation more useful to you! If you have a complaint, a
suggestion, or a correction regarding this manual, please tell us by mailing this page with your
comments. It's the only way we know we're doing our job by giving you correct, complete, and
useful documentation.
______________________________________________________________________________
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______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
U.S.A. Locations:
Northern Region Southwest 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: (860) 945-2381 Houston, TX 77092-8731 Ontario, CA 91761 Altamonte Springs, FL 32701
Fax: (860) 945-2525 Phone: (713) 685-6200 Phone: (909) 923-8488 Phone: (407) 740-7084
NorthernUS@bristolbabcock.com Fax: (713) 681-7331 Fax: (909) 923-8988 Fax: (407) 629-2106
SouthwestUS@bristolbabcock.com WesternUS@bristolbabcock.com SoutheastUS@bristolbabcock.com
Helicoid Instruments Dallas District Office Sales Office New Mexico Communications
1100 Buckingham Street Bristol Babcock Inc. Bristol Babcock Inc. Technology Group
Watertown, CT 06795 777 South Central 906 San Juan Blvd., Suite A Bristol Babcock Inc.
Phone: (860) 945-2218 Expressway Farmington, NM 87401 317 S. North Lake Blvd.
Fax: (860) 945-2213 Suite 1-C Phone: (505) 320-5046 Suite 1016
jmcgrail@bristolbabcock.com Richardson, TX 75080 Fax: (505) 327-3273 Altamonte Springs, FL 32701
Phone: (972) 238-8197 NewMexUS@bristolbabcock.com Phone: (407) 629-9464
Fax: (972) 238-8198 Fax: (407) 629-2106
dallas@bristolbabcock.com orlandoRFgroup@bristolbabcock.com
International Affiliates:
Canada Mexico United Kingdom Australia
Bristol Babcock, Canada BBI, S.A. de C.V. Bristol Babcock Ltd. Bristol Babcock, Inc.
234 Attwell Drive Ejercito Nacional No. 718, 4 Vale Industrial Estate 22 Hastie St.
Toronto, Ont. M9W 5B3 Piso Stourport Road PO Box 1987
Canada Colonia Polanco Kidderminster Banbury, Western Australia
PH: 416-675-3820 Mexico, D.F. 11560 Worcestershire DY11 7QU 6230
FAX: 416-674-5129 Mexico United Kingdom PH: 61 (0)8 9791 3654
info@bristolbabcock.ca PH: 52-555-254-5281 PH: +44 (0) 1562 820001 FAX: 61 (0)8 9791 3173
FAX: 52-555-254-3408 FAX: +44 (0) 1562 746721 dtrench@bdsa.com.au
Mexico@bristolbabcock.com enquiries@bristol-babcock.com
+
6 _
5
4
3
2
1
Bristol Babcock
RTU 3305 POWER SUPPLY/BATTERY CHARGER
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 1 - INTRODUCTION
Section 3 - SPECIFICATIONS
Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheets on Battery P/N 395407-02-8.
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.
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.
BACKPLATE
Heatsink Compound
Between Backplate
&
Power Supply Mounting Surface
BACKPLATE
1
2
3
4
5
_ +
6
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.
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.
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%.
Output Ripple Voltage: 10mV RMS for loads of 10mA to 75% of full load
Vibration: 10 - 150 Hz @ 1g
150 - 2000 Hz @ .5g
Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheet on Battery P/N 395407-02-8.
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.
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 .
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
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.
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.
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.
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)
Part II Please complete Parts II & III for each unit returned
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
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.
In addition to the information contained in this manual, you may receive additional assis-
tance in using this product from the following sources:
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.
(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.
During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.
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.
The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/
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.
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
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
SUPPLEMENTS
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
• 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).
• Surge Protection
Surge suppression on input ports and on the isolated output port meets IEC-801 to
isolated ground.
• 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.
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.
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).
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
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:
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:
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
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.
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.
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.
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
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).
Network Termination: 100 Ohm Resistors for TX and RX Circuits on End Nodes
Common Mode Range: -7 Volts to +12 Volts (DC) (With respect to Isolated Ground)
Surge Path: Terminal Provided for Local Connection from Isolated Chassis
Ground to Earth Ground through a 280V Sealed Surge
Absorber
Environmental Specifications
RFI Susceptibility: Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)
Part Numbers
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.
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
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
Power Sonic
12V Sealed Lead-Acid Battery 395407-02-8
Corp.
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)
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
Section 2 - INSTALLATION
Section 3 - SERVICE
Section 4 - SPECIFICATIONS
Note: See Appendix Z of the CI-3305 Instruction Manual for Material Safety Data
Sheets on Battery P/N 395407-02-8.
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:
Figure S1-1
RTU 3305 Standard Enclosure with Remote 4x20 Keypad/Display Option
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
Figure S1-3
RTU 3305 Standard Enclosure Component Identification
In addition to the base RTU 3305, RTU 3305 Standard Enclosures are comprised of the
following major components:
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.
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).
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
Figure S1-7 - DIN Rail Mounted Power Distribution Block & Form C Relays
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.
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.
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.
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.
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.
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.
The RTU 3305 Standard Enclosure may be packaged with one of the following LCD
Display Options:
The RTU 3305 Standard Enclosure may be ordered with one or more of the following
communication options:
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).
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.
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.
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:
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.
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.
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
Warning
Caution
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)
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.
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
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.
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:
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
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.
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.
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:
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:
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.
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).
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:
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.
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.
Multi-dropping: Up to 32 nodes
Isolation: 300VDC
Internal Communications Options mount on the RTU 3305 as described in the RTU 3305
Manual CI-3305.
SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING
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.
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
Section 2 - PROTECTION
TABLE OF CONTENTS
SECTION TITLE ..................................................................................................... PAGE #
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
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.
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.
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.
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.
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.
# 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.
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.
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.
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.
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
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.
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.
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.
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.
Figure 3-2 - Overhead Map of Ground Bed for Gas Metering Station
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).
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.
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.
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.
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.
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.
The following considerations are provided for the installation of system grounds:
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.
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.
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.
WARNING
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.
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
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:
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.
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:
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
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.
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.
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.
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)
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.
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
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.
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.
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
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.
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.
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.
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.
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.
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 2 - Use twisted shielded pairs (with overall insulation) on all Signal/Control circuits.
Rule 4 - Use known good earth grounds (Rod, Bed, System) and test them periodically,
Rule 7 - Route high power conductors away from signal wiring according to NEC Rules.
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!
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.
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).
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).
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.
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.
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.
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
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-
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.
Please help us make our documentation more useful to you! If you have a complaint, a sug-
gestion, or a correction regarding this manual, please tell us by mailing this page with your
comments. It's the only way we know we're doing our job by giving you correct, complete, and
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BRISTOL BABCOCK
BLANK PAGE
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TABLE OF CONTENTS
PAGE
1. Introduction 2
2. General Rules 3
6. Completion 10
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:
3. Wrist strap (available in two sizes, large and small, for proper fit and
comfort) with a female snap fastener for ground cord attachment.
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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)
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.
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Table 1
Electrostatic Voltages
2. General Rules
(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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(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
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.
(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.
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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.
(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.
(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
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A
R
G
B
R
R
LEGEND
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(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.
The following procedure should be performed periodically for all PC boards and
when a PC board is being replaced.
CAUTION
Do not use any abrasive cleaning substance or object such as a pencil eraser to
clean connectors.
WARNING
(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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g. Repeat the above procedure for the other PC boards from the device.
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e. Remove any excess spray by shaking the connector or wiping with either
a toothbrush, or a lint-free wiping cloth.
6. Completion
10
READER RESPONSE FORM
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comments. It's the only way we know we're doing our job by giving you correct, complete, and
useful documentation.
______________________________________________________________________________
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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
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