ABB TOTALFLOW WellTell Wireless IS User guide

Intellectual Property & Copyright Notice
©2010 by ABB Inc., Totalflow Products (“Owner”), Bartlesville, Oklahoma
74006, U.S.A. All rights reserved.
Any and all derivatives of, including translations thereof, shall remain the
sole property of the Owner, regardless of any circumstances.
The original US English version of this manual shall be deemed the only
valid version. Translated versions, in any other language, shall be
maintained as accurately as possible. Should any discrepancies exist,
the US English version will be considered final. ABB is not liable for any
errors and omissions in the translated materials.
Notice: This publication is for information only. The contents are subject
to change without notice and should not be construed as a commitment,
representation, warranty, or guarantee of any method, product, or device
by Owner.
Inquiries regarding this manual should be addressed to ABB Inc.,
Totalflow Products, Technical Communications, 7051 Industrial Blvd.,
Bartlesville, Oklahoma 74006, U.S.A.
Introduction
This is a quick start guide designed for typical installations only. It is
recommended that inexperienced technicians consult the Totalflow®
WellTell Wireless User’s Manual for more detailed information while
performing the installation and start-up.
The Totalflow WellTell wireless product is designed to replace expensive
cable with robust and inexpensive radio links. Cable trenching presents
drawbacks related to expense, inconvenience, maintainability and safety.
Spread spectrum radio technologies have made it possible to install low-
cost, easily maintainable RF links between many of the system
components. Trenching can be minimized, and in some instances, done
away with entirely.
The WellTell-IS is a simple protocol transport incorporating an RS-485
compatible, intrinsically safe (IS) barrier. The WellTell-IS has a wide
range of uses to include providing an RF link to the LevelMaster
products.
Scan through the guide to see what information is available before
beginning the installation. If there are questions that are not answered in
the guide or other documentation, call a local Totalflow representative or
call the number listed on the back page of this guide. Alternate methods
of installation are acceptable and may save time; however, it is
recommended that inexperienced technicians perform these procedures
in this order.

1
Unpack and inspect the WellTell-X and WellTell-IS and any other
optional equipment. Inspect all parts for damage, missing or incorrect
components.
Before Beginning
The WellTell-IS system is comprised of two parts: the host (WellTell-X)
and the intrinsically safe (IS) barrier client (WellTell-IS). The host,
WellTell-X, is generally installed in the site controller (XFC or XRC). The
IS barrier client, WellTell-IS, is installed near the LevelMaster application.
2100759-004
Intrinsically Safe
Barrier Outputs
Hosting Device
Com2 to Host Radio
Remote Wireless Barrier Client
Barrier supporting two Level Master sticks
NOTE: See larger detailed figures
Figure 1 – Basic Setup
Basic Installation
The following information covers the initial installation of the WellTell-X
host at the site controller (XFC/XRC), the installation of the WellTell-IS
client near the LevelMaster application and the final application
configuration and test at the site controller.
The instructions are broken down into segments that cover the
mechanical and electrical installation along with the configuration of the
system. It is assumed that this installation is taking place within either a
6400 or 6700 enclosure
Step 1 WellTell-IS Mechanical Installation
The mechanical installation for both the WellTell-IS client and WellTell-X
host is the same. Use the following instructions to accomplish the task.

2
1A Position the pipe saddle on the meter run. Select a location
that allows easy user access and is close to the equipment.
Temporarily attach the saddle on the meter run pipe using U-
bolts and associated hardware.
1B Screw the 2” by 40” mounting pipe into the saddle (see Figure
2). Place the level against the pipe and vertically align. Adjust
the pipe, mounted in the saddle, until vertical alignment is
achieved. After vertical alignment, securely tighten the 2” by
40” pipe in the saddle. Tighten the saddle mounting bolts.
Ascertain that the pipe is securely installed in the saddle.
1C Position the enclosure on the 2” mounting pipe, and secure in
place with two U-bolts, flat washers, lock washers and two
9/16” bolts (see Figure 3).
Figure 2 – Pipe and Saddle Mount

3
Figure 3 – Pipe Mounted 6400/6700 Enclosure
Step 2 WellTell-X Installation
The WellTell-X host unit is mounted in a communication tray (generally
at the factory) and is designed to be installed in a Totalflow 6400 or 6700
enclosure (see Figure 4).
At the top of the enclosure is the area where communication devices are
installed. This area is referred to as the communication compartment
(see Figure 5). All communication equipment is secured to the
communication tray and slid into this compartment. The WellTell-X is
mounted to standoffs on the communication tray and then slid into the
communication compartment.

4
Figure 4 – Communication Tray
Figure 5 – Communication Tray Installed in the 6700 Enclosure

5
Step 3 WellTell-X Host Communication Wiring
NOTE: If the unit came preconfigured from the factory, ignore the
following wiring instructions.
Wiring of the WellTell-X host to a parent device (XFC/XRC) is fairly
simple. In the example (see Figure 6), an XFC-195 board is used as the
parent meter. If the application involves something other than the XFC-
195, please check the meter pinouts before proceeding.
Additionally, the following example uses COM 2 of the XFC. COM 1 is
often defaulted for communication with a remote device (radio, modem,
etc.). Wiring is simplified by the use of pre-wired cable that is designed
specifically for the WellTell-X device.
Figure 6 – Wireless Host Wired to COM 2 of XFC-195
Step 4 Configuring COM 2 for the LevelMaster Application
After completing the electrical wiring for the WellTell-X to COM 2 on the
flow computer, the user needs to configure the COM 2 communication
port.
NOTE: In Figure 6, COM 2 (XA2) must have an RS-485 module inserted.
Figure 7 walks the user through the steps (A and B) to configure COM 2
for the LevelMaster application.

6
A - Move to the
Communications tab. Set
the Spare – COM 2 to
None and the LevelMaster
port to COM2:
B – Move to the
LevelMaster
Communications tab and
setup as shown
Figure 7 – Typical Communication Setup for the LevelMaster
WellTell-IS Wiring
Electrical wiring at the WellTell-IS (client) is accomplished with two basic
steps: powering the unit and wiring the RS-485 to the LevelMaster sticks.
Step 5 WellTell-IS Client Electrical Wiring
The WellTell-IS client can be mounted near or at the top of the storage
tank. It should be mounted in a Division 2 or non-hazardous location;
however, a short piece of cable can be run to the LevelMaster itself.
The WellTell-IS client also has an onboard battery charger to maintain
the charge on a 12 VDC lead-acid battery. Figure 8 illustrates the most
common way to provide power to the WellTell-IS.

7
Figure 8 – Powering of the WellTell-IS
Step 6 Wiring the LevelMaster Sticks to the IS Barrier
The second part of the electrical installation for the WellTell-IS is the
wiring of the LevelMaster sticks to the IS barrier on the WellTell-IS.
Figure 9 illustrates how this is accomplished.
Figure 9 – Wiring LevelMaster Sticks to the IS Barrier

8
System Configuration
Step 7 Configuring the WellTell-X
In a similar fashion to configuring the meters for the COM 2 port, the user
must also configure the WellTell-X radio.
To configure the WellTell-X (or the WellTell-IS) radio, the user must have
the WellTell Wireless Utility (WWU) program and a typical 9-pin to 9-pin
(male DB9 to female DB9) cable. The cable connects between a laptop
and the maintenance connector of the WellTell-X.
7A Configure the WellTell-X security. WWU supports two levels of
Access: Restricted Use and Admin (lower left side on the
System Config tab). Restricted Use gives the user access to
the basic setup parameters that are most often used (i.e.,
Network ID, FR Channel, etc.). Lesser used parameters (i.e.,
Encryption Key, Range Refresh, etc.) are grayed out, if
Restricted Use is selected. Normal setup does not require
Restricted Use. These lesser parameters can be accessed
through Admin. Admin is achieved by entering the password.
The factory password is 0000.
As opposed to providing an in-depth, screen-by-screen explanation of
the WWU, the opening screen is presented to the user along with
references to the various available tabs that contain relevant parameters
on each of the corresponding screens (see Figure 10).
7B System Config tab - Set the parameters as shown in Figure
10.
7C Radio Config tab – Set the parameters as shown in the
following table:
Parameter Field Value
Mode Server
Network ID 1 (Must match Client)
RF Channel Anything between 16 and 47 (must
match Client)
Baud Rate 9600
Delivery Mode Broadcast
RF Mode Acknowledge
Duplex Mode Half Duplex

9
7D Network View tab – Leave the values at their default settings.
Figure 10 – WWU Main Screen
7E PC Port tab – Set the parameters as follows:
Parameter Field Value
Port COM 1 (Communication port of
laptop PC)
Baud Rate 9600
Data Bits 7 or 8 bits based on user setup
Parity Even/Odd/None based on user
setup
Stop Bits 1

10
7F The remaining tabs (Flash Loader, PIC Loader and Test) can
be left at their default settings.
Step 8 Configuring the WellTell-IS
Just as the host radio, WellTell-X, was configured, it is necessary to
configure the WellTell-IS client radio.
As with the WellTell-X, it is necessary to have the WWU program and a
typical 9-pin to 9-pin (male DB9 to female DB9) cable. The cable
connects between the laptop and the maintenance connector on the
WellTell-IS.
The opening screen for the WellTell-IS client radio is similar to the
opening screen for the WellTell-X host, with the exception of a display
that states that this is a Wireless Client Server as opposed to a Wireless
Host Server.
Rather than providing an in-depth, screen-by-screen explanation of the
WWU, please refer to Figure 10 to view the available tabs. As with the
previous section, the following details each individual tab available to the
user and the corresponding parameter fields and values that must be
entered therein.
8A System Config tab – Set the parameters as shown in Figure
10.
8B Radio Config tab – Set the parameters as follows:
Parameter Field Value
Mode Client
Network ID 1 (Must match Host
RF Channel Anything between 16 and 47
(must match Host)
Baud Rate 9600
Delivery Mode Broadcast
RF Mode Acknowledge
Duplex Mode Half Duplex
8C Network View tab – These parameters should be left at their
default settings.
8D PC Port tab – Set the parameters as follows:
Parameter Field Value
Port COM 1 (Communication port of laptop PC)
Baud Rate 9600
Data Bits 7 or 8 bits based on user setup
Parity Odd/Even/None depending on user setup.
Stop Bits 1

11
8E The remaining tabs (Flash Loader, PIC Loader and Test) can
be left at their default settings.
Step 9 Final Configuration at the Site Controller (XFC/XRC)
With the WellTell-X host and the WellTell-IS client both installed and
configured, the last step is to configure the site controller (XFC/XRC at
the host end) for the LevelMaster application. There is no difference in
the configuration of the LevelMaster application due to the presence of
the WellTell products. LevelMaster is instantiated and configured as it
would be without the WellTell products.
With the system up and running, the WellTell-X host display looks similar
to Figure 11.
Figure 11 – WellTell-X (Host) Display
The antenna symbol is on. The “$” symbol is always active on the
WellTell-X or host server. The “-“ is the system heart beat and blinks
continuously. The blink slows down whenever the radio is dead or not
connected. The “F3” in the upper right of the display denotes that this is
a host server (WellTell-X). The main area of the display scrolls through
several parameters: baud rate, temperature, channel, etc. For more
information on the display, refer to the appropriate appendix.
LCD Display and Annunciators
Figure 12 – LCD Display

12
Description of Standard Displays (Annunciators)
Envelope Indicates “Snoop” mode (i.e., processor is “snooping” the
data stream).
Tx/Rx Indicates activity on the processor’s UART port.
Antenna The Host Server (WellTell-X) annunciator is always on.
The Client (WellTell-IS or WellTell-IO) is only on when
the Client is ‘synced’ to a Host.
Signal
Strength
A three section “progress bar” indicating incoming signal
strength between the Host and the Client.
Battery
Strength
A four section “progress bar” indicating incoming signal
strength between the Host and the Client.
Arrows The arrows represent up, down, left and right for a total
of four. These arrows describe the Routing Matrix of the
WellTell Product. This Routing Matrix connects the
microprocessor (also referred to as the Maintenance
Port) to either the radio or to the RS-485 device port. In
Pass Through mode, the Device Port is connected
directly to the radio while the microprocessor can be
enabled to “snoop” data from either the Device Port or
the radio. More on this topic can be found in the WWU
Help Files.
When the UP arrow is on, the Microprocessor can snoop
the Device Port. If the UP arrow is not on, the
microprocessor can snoop the radio. Snoop is only
operational in Pass Through mode (i.e., the Left and
Right arrows are lit).
The DOWN arrow being on informs the user that the
microprocessor is being connected in the Routing Matrix.
When the RIGHT arrow is on, this depicts that the radio
is being connected in the Routing Matrix.
The LEFT arrow being on depicts that the Device Port
(RS485) is being connected in the Routing Matrix.
An example of the Routing Matrix might be having the
Device Port (RS485) connected directly to the radio
(Pass Through mode). In this configuration the LEFT and
RIGHT arrows would both be on.
F1 – F5
Annunciators
F1 I.S. Barrier Client indicator (WellTell-IS)
F2 I/O Client indicator (WellTell-IO)
F3 Host Server indictor (WellTell-X)
F4 Reserved for future use
F5 Test mode indicator
[ ] Right and
Left Brackets
Indicate activity on the Maintenance (processor) port.
$ Always active on the Host and inactive on the Clients.
M Activates whenever a cable is connected to the
Maintenance port.

13
- The ‘dash’ or ‘underscore’ is the system heartbeat. It
blinks off and on continuously. The blinking slows
whenever the Radio is dead or not connected.
Description of Standard Displays (Alpha/Numeric Portion)
SLEEP When power drops below 10.5VDC the Host Server will
detect the low voltage and enter a “SLEEP” mode.
Host Server and the I/O and Barrier Client
b Ex: 9600 b Baud rate displayed in Numeric section.
n Ex: n 1 Network ID displayed in Numeric section.
ch Ex: ch 2 Channel displayed in Numeric section.
b Ex: b 12.3 Battery voltage displayed in Numeric section.
t Ex: t 72.1 Temperature displayed in Numeric section.
I/O and Barrier Clients (Not Applicable to the Host Server)
c Ex: c 0 Charger voltage.
L Ex: L .5 Lithium cell voltage.
Barrier Clients Only (Not Applicable to the Host Server or the I/O
Client)
o Ex: o .0 Overload voltage.
i Ex: i .0 Intrinsically safe voltage.
S Ex: S 4.5 Supply voltage supervisory.

ABB Inc.
Totalflow Products
7051 Industrial Blvd.
Bartlesville, Oklahoma 74006
Tel: USA [phone]
International 001-918-338-4880