Emerson ControlWave EFM 4710A User manual

www.EmersonProcess.com/Bristol
Instruction Manual
CI-ControlWave EFM
Oct., 2006
C
ontrolWave EFM
ControlWave EFM
(Electronic Flow Meter)

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.
EQUIPMENT APPLICATION WARNING
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 .
RETURNED EQUIPMENT WARNING
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
Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic in-
struments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by
exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude
and duration of the ESD, this can result in erratic operation or complete failure of the
equipment. Read supplemental document S14006 at the back of this manual for
proper care and handling of ESD-sensitive components.
Bristol 1100 Buckingham Street, Watertown, CT 06795
Telephone [phone]

WARRANTY
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.
E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
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.
B. Under no circumstances will Bristol be liable for incidental or consequential
damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.

How to return material for Repair or Exchange
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.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to [phone]. 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 [email protected]. 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 [phone]. 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 Inc. Repair Authorization Form (off-line completion)
(Providing this information will permit Bristol Inc. 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
practice may be requested in the “Special Requests” section.
•Evaluate / Test / Verify Discrepancy
•Repair / Replace / etc. in accordance with this form
•Return to Customer
Please be aware of the Non warranty standard charge:
•There is a $100 minimum evaluation charge, which is
applied to the repair if applicable (√in “returned”
B,C, or D of part III below)
Part I Please complete the following information for single unit or multiple unit returns
Address No. (office use only) Address No. (office use only)
Bill to : Ship to:
Purchase Order: Contact Name:____________________________________
Phone: Fax: E-Mail:
Part II Please complete Parts II & III for each unit returned
Model No./Part No. Description
Range/Calibration S/N
Reason for return : Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________
3. What is the Firmware revision? _____________________ What is the Software &version?
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: [phone] Fax: [phone] Form GBU 13.01 Rev. B 04/11/06

Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
•Avoid Delays and problems in getting your system on-line
•Minimize installation, start-up and maintenance costs.
•Make the most effective use of our hardware and software.
•Know your 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
[phone]. 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.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assis-
tance in using this product from the following sources:
Help Files / Release Notes
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.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
[phone]
[phone] (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.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.
For technical questions about TeleFlow products call [phone].
For technical questions about ControlWave call [phone] or [phone].
For technical questions regarding Bristol’s OpenEnterprise product, call [phone]
or e-mail: [email protected]

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call [phone].
For technical questions about Network 3000 hardware, call [phone].
You can e-mail the Application Support Group at: [email protected]
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 hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at [phone] or [phone].
You can e-mail the Communication Technology Group at:
[email protected]
Telephone Support - Non-Technical Questions, Product Orders, etc.
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.
Visit our Site on the World Wide Web
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 [phone] for course
information, enrollment, pricing, and scheduling.

CI-ControlWave EFM - Installation Forward
CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
INSTALLATION FORWARD
NOTE for all ControlWave EFM Installers:
READ THIS SECTION FIRST!
This manual has been designed for the following audience:
•Customer Site Engineers, who must plan for the installation and implementation of the
ControlWave EFM.
•Instructors who must become familiar with and teach Field Engineers/Technicians on
the installation, operation and repair of ControlWave EFM.
•Field Engineers/Technicians who must install and service the ControlWave EFM.
Installation of the ControlWave EFM electronic flow meter is provided in two formats as
follows:
Section 2 - Installation & Operation provides a detailed overview of the installation and
operation of the ControlWave EFM. Section 2 provides all the information required for
instructors who are training individuals unfamiliar with the ControlWave EFM. It is also
intended to support anyone who needs to learn how to install and operate the
ControlWave EFM for the first time.
Appendix C - Hardware Installation Guide is intended for individuals who are already
familiar with the ControlWave EFM but need the configuration information in a concise
format. Field Engineers/Technicians who have previously installed one or more
ControlWave EFM electronic flow meters will find the necessary installation information
logically sequenced for their convenience.
NOTE:
A Windows driven diagnostic tool referred to as WINDIAG is provided on the
OpenBSI Software CDROM. WINDIAG is documented in instruction manual
D4041A – Window Diagnostics for Bristol Controllers. Bristol’s WINDIAG program
provides menu driven diagnostics that have been designed to assist a technician
or Process Engineer in troubleshooting the various ControlWave EFM circuits. A
brief overview is provided in Section 3.5 of this manual. For more detailed
descriptions of ControlWave EFM Windows Diagnostics than those provided
herein, see Document D4041A – Chapters 1 and 7B.

CI-ControlWave EFM Contents / 0 - 1
CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 1 - ControlWave EFM INTRODUCTION
1.1 GENERAL DESCRIPTION ........................................................................................... 1-1
1.2 ControlWave PROGRAMMING ENVIRONMENT ....................................................1-5
1.3 PHYSICAL DESCRIPTION........................................................................................... 1-7
1.3.1 Enclosure......................................................................................................................... 1-8
1.3.2 CPU Module .................................................................................................................... 1-8
1.3.2.1 CPU Module Connectors ..............................................................................................1-10
1.3.2.2 CPU Memory................................................................................................................. 1-10
1.3.2.3 CPU Module Configuration Jumpers .......................................................................... 1-11
1.3.2.4 CPU Module Configuration Switches.......................................................................... 1-11
1.3.2.5 CPU Module LEDs ....................................................................................................... 1-12
1.3.3 System Controller Module (SCM)................................................................................ 1-12
1.3.3.1 SCM Mode Switch......................................................................................................... 1-13
1.3.3.2 SCM Board Fuse........................................................................................................... 1-13
1.3.3.3 SCM Board Connectors ................................................................................................ 1-14
1.3.3.4 SCM Jumpers ............................................................................................................... 1-14
1.3.3.5 SCM LEDs..................................................................................................................... 1-14
1.3.4 ControlWave EFM Backplanes.................................................................................. 1-14
1.3.5 ControlWave EFM Base Assembly Chassis..............................................................1-15
1.3.6 ControlWave EFM I/O Modules ................................................................................1-16
1.3.6.1 Non-isolated Analog I/O & Analog Input Modules ..................................................... 1-17
1.3.6.2 Non-isolated Digital Input/Output Module................................................................. 1-17
1.3.6.3 Non-isolated High Speed Counter Input Module........................................................ 1-17
1.3.6.4 Non-isolated Mixed Input/Output Module .................................................................. 1-17
1.3.7 ControlWave EFM Expansion Communications Modules.......................................1-17
1.3.8 Internal Mounting Brackets ........................................................................................ 1-18
1.3.9 Multivariable Transducer ............................................................................................ 1-19
1.3.10 Power Distribution Board ............................................................................................ 1-19
1.3.11 Digital to Relay I/O Option .......................................................................................... 1-19
1.3.12 21V Power Supply Option ............................................................................................ 1-20
1.3.13 Power System................................................................................................................ 1-20
1.3.14 RTD Probe..................................................................................................................... 1-21
1.3.15 External Radio/Modem................................................................................................. 1-21
1.4 FIELD WIRING............................................................................................................1-21
1.5 FUNCTIONS................................................................................................................. 1-21
1.5.1 Data Acquisition ........................................................................................................... 1-22
1.5.2 Flow and Volume Calculations .................................................................................... 1-22
1.5.2.1 Flow Rate and Flow Time Calculations (AGA3) ......................................................... 1-23
1.5.2.2 Flow Rate Calculations and Flow Time Accumulations (AGA7) ............................... 1-23
1.5.2.3 Extension Calculation and Analog Averaging ............................................................ 1-23
1.5.2.3.1 Energy Calculation ....................................................................................................... 1-23
1.5.2.3.2 Volume and Energy Integration .................................................................................. 1-23
1.5.2.4 Downstream Pressure Tap...........................................................................................1-23
1.5.3 Archives......................................................................................................................... 1-24
1.5.3.1 Hourly Historical Data Log.......................................................................................... 1-24

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CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 1 - ControlWave EFM INTRODUCTION (Continued)
1.5.3.2 Daily Historical Data Log ............................................................................................1-24
1.5.3.3 Periodic Historical Data Log........................................................................................1-25
1.5.3.4 Alarm and Event Storage.............................................................................................1-25
1.5.4 LCD Display.................................................................................................................. 1-25
1.5.5 Communications ...........................................................................................................1-26
1.5.5.1 BSAP Message Support................................................................................................ 1-27
1.5.6 Discrete and Analog I/O EFM Functionality .............................................................. 1-27
1.5.6.1 Flow Rate Control - DDC (jog control) using PID....................................................... 1-27
1.5.6.2 Pulse Output for External Totalizer or Sampler ........................................................ 1-28
1.5.6.3 Nominations.................................................................................................................. 1-28
1.5.7 Self Test & Diagnostics ................................................................................................ 1-28
Section 1A - PRODUCT FEATURES & OVERVIEW
1A.1 PRODUCT OVERVIEW.............................................................................................. 1A-1
1A.1.1 Hardware Features......................................................................................................1A-1
1A.1.2 Firmware and Software Features............................................................................... 1A-1
1A.2 PRODUCT FAMILY COMPATIBILITY .................................................................... 1A-2
1A.2.1 Open Standards for Programming, Network Config. and Communication ............. 1A-2
1A.2.2 ControlWave Designer with ACCOL III................................................................... 1A-2
1A.2.3 ACCOL III.................................................................................................................... 1A-2
1A.3 STANDARD APPLICATION PROGRAM.................................................................. 1A-3
1A.3.1 OpenBSI - Simply Creative......................................................................................... 1A-3
1A.3.2 OpenBSI Utilities ........................................................................................................ 1A-4
1A.3.3 Real-time ActiveX Controls......................................................................................... 1A-4
1A.3.3.1 ActiveX Controls .......................................................................................................... 1A-5
1A.3.3.2 Required Software ....................................................................................................... 1A-5
1A.3.4 Historical Data Collection ........................................................................................... 1A-5
1A.3.5 OPC Server .................................................................................................................. 1A-5
1A.4 ControlWave OPEN NETWORK CONNECTIVITY................................................ 1A-6
1A.4.1 Communication Protocols............................................................................................ 1A-6
1A.4.1.1 BSAP Protocol.............................................................................................................. 1A-6
1A.4.1.2 Modbus Protocol........................................................................................................... 1A-7
1A.4.1.3 Generic Serial Interface ..............................................................................................1A-7
Section 2 - INSTALLATION & OPERATION
2.1 INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1
2.2 SITE LOCATION CONSIDERATIONS........................................................................ 2-4
2.2.1 Temperature & Humidity Limits .................................................................................. 2-4
2.2.2 Vibration Limits ............................................................................................................. 2-4
2.3 ControlWave EFM INSTALLATION/CONFIGURATION ........................................ 2-4
2.3.1 Mounting the ControlWave EFM Enclosure .............................................................. 2-8

CI-ControlWave EFM Contents / 0 - 3
CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 2 - INSTALLATION & OPERATION (Continued)
2.3.1.1 Connection to the Multivariable Transducer (MVT) .................................................. 2-10
2.3.1.2 Process Pipeline Connection (Meter Runs without Cathodic Protection) ................. 2-11
2.3.1.3 Process Pipeline Connection (Meter Runs with Cathodic Protection)....................... 2-11
2.3.2 System Controller Module (SCM) Configuration........................................................ 2-13
2.3.3 CPU Module & ECOM Module Configuration ............................................................ 2-14
2.3.3.1 CPU Module Switch Configuration ............................................................................. 2-14
2.3.3.2 Communication Ports................................................................................................... 2-16
2.3.3.3 RS-232 & RS-485 Interfaces ........................................................................................2-17
2.3.3.4 Piggy-back Spread Spectrum Modem (Radio) Port .................................................... 2-22
2.3.3.5 Piggy-back 56K PSTN Modem Port............................................................................. 2-23
2.3.3.6 Radio Ready and External (Case Mounted) Modem or Radio.................................... 2-27
2.3.4 I/O Module Installation & Wiring................................................................................ 2-27
2.3.4.1 Installation of I/O Modules ..........................................................................................2-27
2.3.4.2 I/O Wire Connections.................................................................................................... 2-30
2.3.4.3 Shielding and Grounding ............................................................................................. 2-30
2.3.4.4 Non-isolated Digital Input/Output Module................................................................. 2-30
2.3.4.4.1 Digital Input/Output Configurations ..........................................................................2-30
2.3.4.5 Non-isolated Analog Input/Output & Analog Input Modules .................................... 2-31
2.3.4.5.1 Analog Input/Output Configurations .......................................................................... 2-33
2.3.4.6 Non-isolated High Speed Counter Input Module........................................................ 2-33
2.3.4.6.1 High Speed Counter Configurations............................................................................ 2-35
2.3.4.7 Non-isolated Mixed I/O Module ................................................................................... 2-35
2.3.4.7.1 Mixed I/O Module Configuration ................................................................................. 2-37
2.3.5 RTD Wiring ................................................................................................................... 2-38
2.3.6 21V Power Supply Option ............................................................................................ 2-39
2.3.7 Digital to Relay I/O Board Option ............................................................................... 2-40
2.3.7.1 Digital to Relay I/O Board Jumper Settings ............................................................... 2-40
2.3.8 Connection to a Model 3808 Transmitter.................................................................... 2-42
2.3.9 Power Wiring & Distribution.......................................................................................2-44
2.3.9.1 Bulk Power Supply Current Requirements ................................................................ 2-45
2.3.9.2 Power Wiring ................................................................................................................ 2-46
2.3.9.3 Mounting an Optional Solar Panel.............................................................................. 2-47
2.3.9.3.1 Swivel (Directional Facing).......................................................................................... 2-47
2.3.9.3.2 Tilt Angle....................................................................................................................... 2-48
2.3.9.4 Installing the Rechargeable Battery and Solar Panel Harness................................. 2-48
2.3.9.5 ControlWave EFM System Grounding...................................................................... 2-49
2.3.10 Operation of the Lithium Backup Coin-cell Battery .................................................. 2-49
2.3.11 Installation of a Bezel Assembly.................................................................................. 2-50
2.4 OPERATIONAL DETAILS .......................................................................................... 2-51
2.4.1 Downloading the Application Load.............................................................................. 2-51
2.4.2 Upgrading ControlWave EFM Firmware ................................................................. 2-51
2.4.2.1 Using LocalView to Upgrade ControlWave EFM Firmware ................................... 2-52
2.4.2.2 Using Hyperterminal to Upgrade ControlWave EFM Firmware............................ 2-55

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CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 2 - INSTALLATION & OPERATION (Continued)
2.4.2.3 Remote Upgrade of ControlWave EFM Firmware ................................................... 2-58
2.4.3 Operation of the Mode Switch...................................................................................... 2-59
2.4.4 Soft Switch Configuration and Communication Ports ............................................... 2-59
2.4.5 Optional Display/Keypad Assemblies.......................................................................... 2-60
2.4.5.1 Operation of the Dual-button Display/Keypad Assembly .......................................... 2-62
Section 3 - SERVICE
3.1 SERVICE INTRODUCTION ........................................................................................ 3-1
3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1
3.2.1 Accessing Modules For Testing...................................................................................... 3-1
3.2.2 Removal/Replacement of the Bezel Assembly............................................................... 3-2
3.2.3 Removal/Replacement of the CPU Module ................................................................... 3-2
3.2.4 Removal/Replacement of the System Controller Module.............................................3-2
3.2.5 Removal/Replacement of an I/O Module ....................................................................... 3-2
3.2.6 Removal/Replacement of an Expansion Comm. Module .............................................. 3-3
3.2.7 Removal/Replacement of a Rechargeable Lead-acid Battery....................................... 3-3
3.2.8 Removal/Replacement of a Power Distribution Board .................................................3-4
3.2.9 Removal/Replacement of a 21V Power Supply Board .................................................. 3-5
3.2.10 Removal/Replacement of a Digital to Relay I/O Board................................................. 3-5
3.2.11 Removal/Replacement of an External Radio/Modem ................................................... 3-5
3.3 TROUBLESHOOTING TIPS......................................................................................... 3-5
3.3.1 System Controller Module (SCM) Voltage Checks ....................................................... 3-5
3.3.2 LED Checks .................................................................................................................... 3-6
3.3.3 Wiring/Signal Checks ...................................................................................................3-10
3.4 GENERAL SERVICE NOTES.....................................................................................3-10
3.4.1 Extent of Field Repairs................................................................................................. 3-11
3.4.2 Disconnecting RAM Battery ........................................................................................3-11
3.4.3 Maintaining Backup Files............................................................................................ 3-11
3.5 WINDIAG DIAGNOSTICS .......................................................................................... 3-11
3.5.1 Diagnostics Using WINDIAG ......................................................................................3-14
3.5.1.1 Communications Diagnostic Port Loop-back Test......................................................3-14
3.5.1.2 Serial Comm. Port Eternal Loop-back Test Procedure .............................................. 3-14
3.6 CORE UPDUMP........................................................................................................... 3-16
3.7 CALIBRATION CHECKS............................................................................................ 3-16
Section 4 - SPECIFICATIONS
4.1 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1
4.2 COMMUNICATION PORTS ......................................................................................... 4-1
4.3 SYSTEM CONTROLLER MODULE ............................................................................ 4-2
4.3.1 Input Power Specs. ......................................................................................................... 4-2
4.3.2 Power Supply Sequencer Specs. ....................................................................................4-3

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CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 4 - SPECIFICATIONS (Continued)
4.3.3 Power Supply External Power Monitor Specs. ............................................................4-3
4.3.4 System Controller Module Connectors.......................................................................... 4-3
4.4 INPUT/OUTPUT MODULE SPECIFICATIONS.........................................................4-4
4.4.1 Non-isolated Analog Input/Output Module................................................................... 4-4
4.4.2 Non-isolated Digital Input/Output Module................................................................... 4-5
4.4.3 Non-isolated High Speed Counter Input Module.......................................................... 4-6
4.4.4 Non-isolated Mixed Input/Output Module .................................................................... 4-6
4.5 DIGITAL TO RELAY I/O BOARD SPECIFICATION ................................................. 4-9
4.6 21V POWER SUPPLY BOARD SPECIFICATIONS.................................................... 4-9
4.7 ENVIRONMENTAL SPECIFICATIONS.................................................................... 4-10
4.8 DIMENSIONS ..............................................................................................................4-10
APPENDICES/SUPPLEMENTAL INSTRUCTION
Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A
Reserved ............................................................................................................Appendix B
HARDWARE INSTALLATION GUIDE..........................................................Appendix C
ECOM MODULE RADIO/MODEM INSTALLATION GUIDE .................... Appendix D
DISPLAY/KEYPAD ASSEMBLY GUIDE.......................................................Appendix E
UsingControlWave EFM WebBSI Web Pages ............................................. Appendix F
RADIO READY INSTALLATION GUIDE .................................................... Appendix G
MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z
Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW
Care and Handling of PC Boards and ESD-Sensitive Components .....................S14006
REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS
WINDIAG - Windows Diagnostics for BBI Controllers........................................D4041A
ControlWaveMICRO Quick Setup Guide ............................................................. D5124
Open BSI Utilities Manual ...................................................................................... D5081
Getting Started with ControlWave Designer.......................................................... D5085
Web_BSI Manual...................................................................................................... D5087
ControlWave Designer Reference Manual .............................................................. D5088
ControlWave Designer Programmer’s Handbook................................................... D5125
TechView User’s Guide............................................................................................. D5131
ControlWave Loop Power Supply Product Installation Guide........ PIP-ControlWaveLS
REFERENCED OEM MANUALS
Expansion Comm. Module Piggy-back Modem/Radio OEM Manuals
MDS Transnet Radio wired to Polyphaser - Spread Spectrum Data Transceiver
MDS document MDS 05-3946A01, Rev. A April, 2003 (PDF = 3946A-TNET_OEM-web.pdf)

0 - 6 / Contents CI-ControlWave EFM
CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
REFERENCED OEM MANUALS (Continued)
Expansion Comm. Module Piggy-back Modem/Radio OEM Manuals (Continued)
Internal FreeWave Radio (wired to Polyphaser) - Spread Spectrum Data Transceiver
FreeWave Spread Spectrum Wireless Data Transceiver User Manual - V5.0R (model FGR09CSU)
Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the
latest copy of the user manual.
MultiTech Systems wired to Surge Suppressor - Modem Module MT3334SMI & MT5634SMI
MultiTech Systems Developer Guide PN S000181C, version C 6/24/02 (PDF = S000181C.pdf)
External Modem/Radio OEM Manuals
MDS Transnet 900 - Spread Spectrum Data Transceiver
MDS TransNET 900 Spread Spectrum Data Transceiver Installation & Operation Guide – MDS Doc.
MDS 05-2708A01, Rev. C, Feb., 2004 (PDF = 2708C-TransNET-web.pdf) for MDS TransNet 900
MDS 4710A – Remote Data Transceiver (Radio)
MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver Installation and Operation Guide
– MDS Doc. 05-3305A01, Rev. B, Sept. 2000
(PDF = 3305B-710AC.pdf) for model MDS 4710A
MDS 4710B – Data Transceiver (Radio)
MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev.
E, Sept. 2000
(PDF = 3316E-x710B.pdf) for model MDS 4710B
MDS 9810 – Spread Spectrum Data Transceiver (Radio)
MDS 9810/24810 900 MHz/2.4GHz Spread Spectrum Transceivers Installation and Operation Guide
– MDS Doc. 05-3301A01, Rev. B, April 2000
(PDF = 3301B-x810.pdf) for model MDS 9810
MDS 9710A Remote Data Transceiver (Radio)
MDS 4710/9710 Series 400MHz/900 MHz Remote Data Transceiver – MDS Doc. 05-3305A01, Rev. B,
Sept. 2000
(Installation & Operation) (PDF = 3305B-710AC.pdf) for model MDS 9710A
MDS 9710B Data Transceiver (Radio)
MDS 4710B/9710B Data Transceiver Installation and Operation Guide – MDS Doc. 05-3316A01, Rev.
E, Sept. 2000
(PDF = 3316E-x710B.pdf) for model MDS 9710B

CI-ControlWave EFM Contents / 0 - 7
CI-ControlWave EFM
ControlWave EFM
Electronic Flow Meter
TABLE OF CONTENTS
SECTION TITLE PAGE #
REFERENCED OEM MANUALS (Continued)
External Modem/Radio OEM Manuals (Continued)
MDS iNET 900 Ethernet Radio
MDS iNET 900 Wireless IP/Ethernet Transceiver – User Guide = MDS 05-2806A01, Rev. D, Aug.
2003
(PDF = 2806D-iNET_User-web.pdf) for iNET 900 Ethernet Radio
Center Insert (Installation Reference Chart) = (PDF = 2873D-iNET_Center_Sheet.pdf)
MDS iNET 900 Wireless IP/Ethernet Transceiver – Installation Guide = MDS 05-2873A01, Rev. D,
Aug. 2003
(PDF = 2873D-iNET-Install_web.pdf) for iNET 900 Ethernet Radio
MDS entraNET Extended Range IP Networking Transceivers
MDS entraNET Extended Range IP Networking Transceivers – System Guide = MDS 05-4055A01,
Rev. A, Oct. 2003
(Installation & Operation) (PDF = 4055A-entraNET-web.pdf) for MDS entraNET 900 System
FreeWave Radio - Spread Spectrum Data Transceiver Model FGRM-501X005
Contact the FreeWave Tech Support group @ 303-444-3862 or at www.freewave.com to request the
latest copy of the user manual.

CI-ControlWave EFM Introduction / 1-1
Section 1
ControlWave EFM INTRODUCTION
1.1 GENERAL DESCRIPTION
ControlWave EFM electronic flow meters measure differential pressure, static pressure
and temperature for a single run and compute flow for both volume and energy. In addition
to operation in an unprotected outdoor environment, the ControlWave EFC electronic flow
meter provides the following key features.
•ARM processor provides exceptional performance and low power consumption
•Wide operating temperature range: (-40 to +70°C) (-40 to 158°F)
•CPU, SCM & I/O Modules provide LED status Indicators
•Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,
300mA-hr lithium coin cell battery located on the CPU Module.
•Very low power consumption
•Integral Multivariable Transducer (MVT) with “smart” performance
•Standard Application Program supports the following Flow calculations:
•Calculates AGA3-1995/NX-19
•AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
•AGA7/NX-19
•AGA7 with selectable AGA8 Gross or AGA8 Detail
•Auto Adjust AGA7/NX-19
•Auto Adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
•Instromet Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail
•Daniel Modbus AGA7 with selectable AGA8 Gross or AGA8 Detail
•Three serial communications ports (Two RS-232 & One RS-485)
•Four line alphanumeric display (with dual-button Keypad or 25-button Keypad)
•User choice of I/O Modules (AI/AO, AI, DI/DO, HSC and Mixed I/O)
•RTD input
•Nonincendive Class I, Div. 2, Groups C & D Hazardous Locations (see Appendix A)
•RTD input
•Optional Expansion Comm. Modules with/without built-in modem and/or radio
•Chassis Slots 3 and 4 support Expansion Comm. Modules or I/O Modules or one of each
•Optional Display/Keypad System
•Mixed I/O Modules provide cost effective I/O for small RTU applications
ControlWave EFC electronic flow meters are furnished in a NEMA 3X rated Hoffman®
Enclosure. The flow computer hardware is comprised of a Backplane Board (mounted in a
Housing), a System Controller Module and a CPU Module. Optional Expansion
Communication Modules may reside in Slots 3 and 4 of the Housing in lieu of I/O Modules.
The CPU Module utilizes Sharp’s LH7A400 System-on-Chip Advanced RISC Machine
(ARM) microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC)
Core. In addition to the microprocessor and control logic, the CPU Board includes two RS-
232 communication ports, one RS-485 Communication port, 2MB of battery backed Static
RAM (SRAM), 512kB Boot/Downloader FLASH, 8MB simultaneous read/write FLASH, and
an I/O Bus Connector.
All system modules plug into the Backplane Board (4-Slot or 8-Slot). Each I/O Module
provides the circuitry and field interface hardware necessary to interconnect the assigned
field I/O circuits. Non-isolated power is generated and regulated by the System Controller
Module (SCM) that provides +3.3Vdc for all logic and bulk power for I/O field circuits from
either a bulk 6Vdc or bulk 12Vdc source. +1.8Vdc, used by the ARM microprocessor, is

1-2 / Introduction CI-ControlWave EFM
generated on the CPU Module (derived from the regulated 3.3Vdc logic power). In addition
to Idle and Watchdog LEDs, there are six status LEDs located on the SCM that will display
run time status information.
Figure 1-1 - ControlWave EFM Enclosure
(with 25-Button Display/Keypad Assembly)(Shown with Circular Local Port)

CI-ControlWave EFM Introduction / 1-3
Figure 1-2A - 4-Slot ControlWave EFM (Internal View)
Component Identification Diagram (Shown with D-Type Local Port)

1-4 / Introduction CI-ControlWave EFM
Figure 1-2B - 8-Slot ControlWave EFM (Internal View)
Component Identification Diagram (Shown with Circular Local Port)