Cerlic BB2 User manual

2009-03-04 C50A5EN10
BB2 Central Unit
BB2 is the central unit for the Cerlic sensors. The measured value is converted to a
linearized 4-20mA output signal. The BB2 allows the user to easily adjust settings
and serves as a display for the measured output. The central unit also includes
communication protocols for connection to various input systems.

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Table of contents
1.Introduction .............................................................................................. 3
2.A few words about this manual............................................................... 3
3.Design ....................................................................................................... 3
4.Working principle..................................................................................... 3
5.Installation and start-up........................................................................... 4
6.Unpacking the BB2 control box.............................................................. 5
Damages...................................................................................................................5
Packaging.................................................................................................................5
Content .....................................................................................................................5
Options and accessoriesP/N .....................................................................5
7.Mounting of BB2 control box.................................................................. 6
8.Wiring Connections ................................................................................. 6
9.Jumper settings........................................................................................ 9
Analog outputs..........................................................................................................9
Digital Inputs...........................................................................................................10
Program Download.................................................................................................11
10.Relay outputs.......................................................................................... 11
11.Connection of automatic flushing ........................................................ 12
12.Alarm Limits............................................................................................ 13
Alarm type...............................................................................................................13
Alarm Relays...........................................................................................................13
Connection of external alarm..................................................................................13
13.Operational interface ............................................................................. 14
Main Display ...........................................................................................................14
Sensor display ........................................................................................................14
Menus and dialogs..................................................................................................14
“Time-out” for menus ..............................................................................................14
Menu topology ........................................................................................................15
Working in the menus.............................................................................................15
Changing values in the menus ...............................................................................16
Dialogs....................................................................................................................16
Sensor Menu...........................................................................................................16
Symbols..................................................................................................................16
Messages................................................................................................................17
14.Menus for the BB2 control box............................................................. 18
15.Getting started........................................................................................ 20
Connect sensors.....................................................................................................20
How to get started:..................................................................................................20
16.Technical specifications for the BB2 control box ............................... 21
17.Dimensions............................................................................................. 21
APPENDIX 1, Optional 4-20 mA Output module .......................................... 22
Introduction.............................................................................................................22
Module Overview....................................................................................................22
Mounting in the 4-20 mA module in the BB2 control box .......................................23
Wiring Connections.................................................................................................23
Getting started with the 4-20 mA module ...............................................................24
Technical specification for the 4-20mA module......................................................24

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1. Introduction
The BB2 central unit is developed to make measurement easy. In combination with
different sensors BB2 is used to measure fiber and particle consistency in the pulp and
paper industry, or suspended solids, dissolved oxygen, pH, ORP and flow in water
treatment plants.
2. A few words about this manual
The manual primarily contains information about the BB2 central unit. The operation
and measuring principles of the sensors are described in the sensor manuals.
3. Design
The BB2 central unit is enclosed in a black plastic box, having a large graphic display
and only three buttons to operate it. The electronics has been designed to achieve the
highest reliability, and maximum ease of use. Measured values, settings and diagnostic
information is transferred to and from up to four sensors using digital communication
on a RS485-line. BB2 can be connected to a control or supervision system using
standard 4-20 mA analog signaling or a standardized fieldbus such as Profibus (option).
4. Working principle
BB2 is based on a powerful 16-bit microprocessor. The internal software uses a real-
time operating system, allowing multiple tasks to be carried out in “parallel”. One
process takes care of the display and the dialogs, one process is dedicated to handle each
attached sensor, and one task is taking care of all the housekeeping.
After power up, the software will initialize the functionality, and data structures, reading
information from a non-volatile memory. A welcome message is displayed for about ten
seconds, showing the software version and serial number of the BB2. The unit will then
start looking for sensors it already knows, and if found initialize them to start
measuring. Twice a minute the unit looks for unknown sensors, if one is found, BB2
will find out the type and serial number, and open up a dialog box to let the operator
select what slot to use for the new sensor.
All configuration of BB2 and connected sensors are done in menus, when a menu is
opened on the display, the analog outputs of BB2 are frozen in order not to cause an
alarm in the control system during calibration or while parameters are being changed.
If a sensor is disconnected, the analog output for this sensor will be frozen until the box
is powered off, the sensor reconnected or the slot emptied.
Some sensors have automatic cleaning controlled by BB2. During, and for a selectable
time after the cleaning, the output for the sensor being cleaned is frozen.
Some sensors have the possibility to save more than one calibration curve, e.g. to handle
different qualities of pulp. The calibration curve can then be chosen manually in the
menu, or automatically using digital inputs of BB2.

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5. Installation and start-up
Installation and start-up of a measuring system is best performed in the order stated
below. Please note that the different steps may vary in meaning, depending on the
particular sensor and the number of sensors that are to be connected to the control box.
Documentation of installation procedures and start-up can be done directly on this paper
or on a copy of the paper.
Steps Section Performed Note
date sign.
Unpacking the BB2
control box 6
Unpacking the sensor Refer to the
sensor manual
Mounting of BB2 control
box 7
Mounting of sensor Refer to the
sensor manual
Electrical installation of
BB2 control box 8 - 12
Electrical installation of
sensor Refer to the sensor manual
Using BB2 13 - 15
Settings and Calibration
of sensor Refer to the sensor manual

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6. Unpacking the BB2 control box
The unit has been tested and approved before delivery from the supplier. Please check
that no visible damages are apparent in this shipment.
Damages
If damages occurred during shipment, immediately contact the shipping company and
the Cerlic representative. The shipment should be returned only after an return
authorization number has been issued by Cerlic or representative.
Packaging
The original packaging is designed to protect the equipment and should be used for
storage or if the product must be returned.
Content
Please check that the content corresponds to your order and packing list.
Options and accessories P/N
•Aluminum mounting plate predrilled for BB2
and solenoid valves w/ u-bolts, 10305532
•10m plug-in sensor connection cable. 20805510
•Connection box for two sensors to one BB2 control box 11505748
with 1m cable to connect to BB2
•Connection box for four sensors to one BB2 control box 11505785
with 1m cable to connect to BB2
•Solenoid valve for flushing (220V) 11705516A
•2-channel 4-20 mA output module 11905782
•Communication module PROFIBUS-DP. 21705681

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7. Mounting of BB2 control box
The BB2 may be mounted on a mounting plate to a wall or handrail.
The mounting plate comes with a sun shield, so it can also be used for weather
protection in outdoor installations.
Figure 1 Connection of BB2 Control box with two sensors and two flushing valves
8. Wiring Connections
BB2 is connected to power using a 3-lead cable approved for the rated current and
voltage. We recommend that power be connected with an external on/off switch.
The sensors are connected to the BB2 box using 10m (33ft.) cables, O2X and ITX
sensors have a 10m (33ft.) cable attached without a connector. If the standard cable
length is not sufficient several cables may be connected in series. In the event that two
or more sensors are connected to the same control box, then the connection box is
needed.
Solenoid Valve 2
Power to BB2
mA Outputs to
Control System or DSC
Sensor 1
Flushing Water/Air
6Bar/90 psi
Sensor 2
Flushing Water/Air
6Bar/90 psi
Solenoid Valve 1
Connection box

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There are two analog 4-20 mA outputs to transfer the measuring results from the BB2
box to a SCADA, DCS, or other type of system. The use of the two outputs is
configured in the sensor menu, and the box will prevent two sensors from using the
same output. We suggest using a shielded twisted pair AWG20 (0.5mm2/ 0,2 inch²)
cable to connect the BB2 box to another system. If both outputs are connected to the
same system a double twisted pair cable may be used. Make sure the shield is properly
grounded according to good EMC practice.
The two relay outputs may be configured to be used for alarm or cleaning. The cable
type required depend on the use, and selected voltage. Make sure the relays are jumped
for the correct voltage, and that the maximum ratings of the outputs are not exceeded.
Chart for relay jumpers is attached to the inside of the front door.
Three digital inputs are used to select calibration curves for consistency or suspended
solids sensors from a remote location. They are activated by applying +24 VDC, and
have a common ground. We suggest the use of a 4-lead AWG20 (0.5mm2/ 0,2 inch²)
cable.
Figure 2
1. Digital in 1 10. + Channel 2 4-20 mA
2. Digital in 2 11. Relay 1
3. Digital in 3 12. Relay 1
4. Intern or extern power for digital 13. Relay 2
5. + 24V max 100mA 14. Relay 2
6. Signal ground L. Live
7. – Channel 1 4-20 mA N. Neural
8. + Channel 1 4-20 mA Ground
9. – Channel 2 4-20 mA
NOTE! Start-up of the instrument takes place as soon as power is supplied although it
may take up to 30 seconds before the sensor has been identified. When the instrument
starts, then type of sensor and version is shown in the screen window for ten seconds.

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When more than two sensors are connected to the BB2 control box, an extra 4-20 mA
module or a Field Bus communication module must be installed in the BB2 control box
to transfer the measuring results to a SCADA or DCS system.

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9. Jumper settings
BB2 has five jumpers to configure the board.
Jumpers on BB2
Analog outputs
The two analog outputs of BB2 are default active, sourcing 4-20 mA into a load of
maximum 450 ohms. They are galvanic isolated from the rest of the system, but the
two channels use a common ground. Channel 2 can be jumpered to be passive, and fully
isolated sink 4-20 mA from an external supply of max 24V DC, by changing JP1 and
JP7.
Analog Output channel 2 JP1 JP7
Active, sourcing 1-3 and 2-4 1-2 Default
Passive, sinking 1-2 and 3-4 3-4
Digital Inputs
3
12
34
12
34
1
15
2
6
External load
Pa
ss
i
ve
BB2 Active
Sourcing 4-20 mA 6 or 8
7 or 9
8
9
BB2 Passive
(Channel 2 only)
Sinking 4-20 mA
External load
External 24 VDC

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Digital Inputs
The three digital inputs are using BB2’s internal 24 VDC. To use an external 24 VDC
source, galvanic isolated from the rest of the system (e.g. from a DCS or control
system), the inputs need to be jumpered. These inputs can be used for selecting
calibration for sensors having more than one calibration curve by setting up the sensor
to use an external calibration. To connect a sensor using a multiple point calibration
(set up external calibration) the digital outputs are used to select calibration of the
sensor.
No active input will result in calibration curve “A”, if input 1 is activated calibration
curve “B” will be used, if input 2 is activated calibration curve “C” will be used, and
finally if input 3 is activated calibration curve “D” will be used. The higher the number
of the input the more dominant it is, in other words if input 3 is active calibration curve
“D” will be used regardless of the state of the other inputs.
Digital inputs JP2
Active, internal 24 VDC 1-2 Default
Passive, external 24 VDC 2-3
PC-cable connector
Connector X9 is a serial RS232 port that may be used to transfer values to a PC or
printer via the PC-cable (part no. 10805480). The functionality of the serial port is
configured in the settings menu of BB2 where the sensor(s) to be logged, and logging
interval is set. The serial port uses 19200 baud, 8 bits, 1 stop bit, no parity and no flow
control. Logging is done in a simple ascii-protocol. A log line starts with date and time,
followed by tab-separated measure values and is terminated by CR+LF. If one slot is
logged, three values are printed, if all slots are logged, two values per slot are printed.
The first value is always the sensors primary value, the following values depends on
type of sensor. The Log function is intended for service and troubleshooting, its
functionality may change in future releases.
BB2 Active
Internal 24 VDC 1, 2 or 3
5 External switch
Pa
ss
i
ve
3
2
4
1, 2 or 3
BB2 Passive
External switch
External 24 VDC
3
2