ABB TOTALFLOW WellTell Wireless IS User guide

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74006, U.S.A. All rights reserved.
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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