Cerlic BB2 User manual

2002-11-18 MANE11/02 VER2.00
BB2 Control Box
BB2 is the control box to which most Cerlic sensors can be connected. The
measured signal 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
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 ....................................................................................5
7. Mounting of BB2 control box...............................................................................6
8. Wiring Connections...............................................................................................6
9. Jumper settings.....................................................................................................8
Analog outputs..................................................................................................8
Digital Inputs.....................................................................................................9
PC-cable connector ...........................................................................................9
Program Download............................................................................................9
10. Relay outputs.......................................................................................................10
11. Connection of external alarm............................................................................10
12. Connection of automatic flushing .....................................................................11
13. Operational interface..........................................................................................12
Main Display ...................................................................................................12
Sensor information menu .................................................................................12
Menus and dialogs ..........................................................................................12
“Time-out” for menus .......................................................................................12
Menu topology.................................................................................................13
Working in the menus ......................................................................................13
Changing values in the menus..........................................................................14
Dialogs ...........................................................................................................14
Sensor Menu...................................................................................................14
14. Menus for the BB2 control box..........................................................................15
15. Getting started.....................................................................................................17
16. Technical specification for BB2 control box....................................................18
Optional parts for BB2 control box: ...................................................................18
17. Dimensions ..........................................................................................................19
APPENDIX 1, Instructions for EMC .........................................................................20
APPENDIX 2, Connection of shielded cable to fitting ............................................22
APPENDIX 3, shielded cable without fitting.............................................................23
APPENDIX 4, Extending Shielded Cable.................................................................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 a selectable time
after the cleaning, the outputs for the sensor being cleaned is frozen.
Some sensors has 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 automatic 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
•Aluminum handrail mounting plate predrilled for BB2
or solenoid valves w/ u-bolts, outside US version P/N 10605533
•Aluminum handrail mounting plate predrilled for BB2
or solenoid valves w/ u-bolts, US version P/N 31204049
•33 ft. (10m) cable for. Connection cable with plug-in. P/N 20805510
•Y-Splitter for two sensors to one BB2 control box P/N 21505534
•Solenoid valve for flushing P/N 11705516

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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 1Connection of BB2 Control box with two sensors and two flushing valves
8. Wiring Connections
BB2 is connected to the power using a 3-lead cable approved for the rated current and
voltage. We recommend that the power be connected with an external on/off switch.
The sensors are connected to the BB2 box using 33ft. (10m) Orange cables (O2X and
ITX sensors have a 33ft. (10m) black cable attached). 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 Y-splitter is needed.
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
Solenoid Valve 2
Power to BB2
mA Outputs to
Control System or DSC
Se
nsor 1
Flushing Water/Air
6Bar/90 psi
Sensor 2
Flushing Water/Air
6Bar/90 psi
Splitter
Solenoid Valve 1

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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) 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) cable.
Figure 21 2 3 4 5
1. One sensor, or two sensors with Y-splitter, plug-and twist connection
2. Digital inputs (terminals 1 –5)
3. 4-20mA outputs (terminals 6 –9). Selected in each sensor set-up menu.
(Please refer to the sensor manual)
4. Relays (terminals 10 –13)
5. Power (terminals L (load or power), N (neutral) and ⊥(ground)
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.
When more than two sensors are connected to the BB2 control box, 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 500 ohms. They are galvanic isolated from the rest of the system, but the
two channels use a common ground. Channel 2 can be jumperd 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
Passive, sinking 1-2 and 3-4 3-4
Digital Inputs
3
1 2
3 4
1 2
3 4
1
1 5
2 6
External load
Passive
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 default using BB2’s internal 24 VDC, but can be jumpered
to use an external 24 VDC source, galvanic isolated from the rest of the system (e.g.
from a DCS or control system). These inputs can be used to control the selection of
calibration curve for sensors having more than one. The sensor then has to be set up to
use “External” calibration curve, please refer to the sensor manual for more information
on how to select calibration curve.
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
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
PROGRAM DOWNLOAD
Jumpers JP14 and JP25 are used when downloading new firmware to BB2. This may
only be done by authorized service personnel. Improper setting of jumpers JP14 and
JP25 may destroy the unit. Any change of these jumpers will void the warranty.
BB2 Active
Internal 24 VDC
1, 2 or 3
5External switch
Passive
3
2
4
1, 2 or 3
BB2 Passive
External switch
External 24 VDC
3
2

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10. Relay outputs
BB2 has two relay outputs, configurable for Alarm or Cleaning. The relays can be used
as Dry Contacts, 24 VDC output, or Mains AC output by setting jumpers according to
figure 3. We do not recommend using 24 VDC outputs to drive solenoids.
Figure 3. This drawing can also be found on the inside of the front door.
NOTE:
•The relays are a normally open contact. Do not overpower the relay contacts
(see figure 3 for max VA rating per relay).
•Do not use 24 VDC outputs to drive solenoids.
•During set-up, please verify that the relay is not already being used for
another function like flushing or brush cleaning.
•Several solenoid valves may be connected to the same terminal block.
However, the power rating of the relay output must not be exceeded.
11. Connection of external alarm
The relay outputs may be used for external alarms, flushing or brush signals.
1. Set the jumpers CN 3, 4, 5, 6, 7 and 8 to preferred voltage (see Figure 3)
2. Connect the alarm to relay 1 or 2 (see Figure 2)
3. Configure the relay for alarm as shown in the sensor service manual under
“Settings/Alarm Relay”.
AC Power 85
-
250V