Emerson ControlWave EFM User manual

www.EmersonProcess.com/Remote
RemoteAutomation Solution
s
Instruction Manual
Doc Number CI-ControlWave EFM
Part Number D301383X012
December 2013
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 maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions 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 information is required, the purchaser is advised to contact Remote Automation
Solutions.
RETURNED EQUIPMENT WARNING
When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions 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 Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions 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 instruments 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 for proper care and handling of ESD-sensitive components.

ControlWave EFM Instruction Manual
Revised Dec-2013 Contents iii
Contents
Chapter 1 – Introduction 1-1
1.1Scope of the Manual ...............................................................................................................1-2
1.2Physical Description...............................................................................................................1-3
1.3Housings and Enclosure.......................................................................................................1-3
1.4CPU Module.............................................................................................................................1-4
1.5System Controller Module (SCM)..........................................................................................1-6
1.6Expansion Communications Modules..................................................................................1-7
1.7I/O Modules..............................................................................................................................1-8
1.8Software Tools.........................................................................................................................1-8
1.9Overview of the Gas Flow Measurement Application .......................................................1-10
Chapter 2 – Installation 2-1
2.1Site Considerations ................................................................................................................2-1
2.1.1Class I, Div 2 Installation Considerations.................................................................2-2
2.2Installation Overview ..............................................................................................................2-5
2.3Unpacking Components.........................................................................................................2-6
2.4Mounting the EFM Housing....................................................................................................2-7
2.4.1Grounding the Housing............................................................................................2-13
2.4.2Connecting to the Multi-Variable Transducer (MVT).............................................2-13
2.4.3Process Pipeline Connection (Meter Runs without Cathodic Protection)..........2-15
2.4.4Process Pipeline Connection (Meter Runs with Cathodic Protection)................2-15
2.5System Controller Module (SCM)........................................................................................2-17
2.5.1General Information about the SCM........................................................................2-17
2.5.2SCM Installation Overview.......................................................................................2-19
2.5.3Setting Jumpers on the SCM...................................................................................2-19
2.5.4Setting Mode Switch SW1 on the SCM...................................................................2-19
2.5.5General Wiring Guidelines.......................................................................................2-20
2.5.6Wiring a Bulk DC Power Supply to the SCM..........................................................2-21
2.6Using a Solar Panel and Lead Acid Battery to Power the EFM........................................2-22
2.6.1Mounting the Solar Panel.........................................................................................2-22
2.6.2Installing the Lead Acid Battery and Solar Panel Harness...................................2-24
2.7Power Distribution Board (Optional)...................................................................................2-26
2.821V Power Supply (Optional)...............................................................................................2-28
2.9CPU Module...........................................................................................................................2-29
2.9.1Setting Jumpers on the CPU Module......................................................................2-30
2.9.2Setting DIP Switches on the CPU Module..............................................................2-31
2.9.3Connections to RS-232 Serial Port(s) on CPU or ECOM Modules.......................2-34
2.9.4Connections to RS-485 Serial Port(s) on CPU or ECOM Modules.......................2-39
2.9.5Connections to Ethernet Port on the CPU Module................................................2-42
2.10Expanded Communications Module (ECOM).....................................................................2-44
2.10.1RS-232 Ports..............................................................................................................2-45
2.10.2RS-485 Ports..............................................................................................................2-45
2.10.3Modem Port (Type 1 ECOM only) ............................................................................2-46
2.11Bezels.....................................................................................................................................2-49
2.12Case Mounted Radio/Modem...............................................................................................2-50
2.13Optional Display/Keypads....................................................................................................2-50
Chapter 3 – I/O Modules 3-1
3.1Module Placement...................................................................................................................3-2
3.2Wiring .......................................................................................................................................3-3

ControlWave EFM Instruction Manual
iv Contents Revised Dec-2013
3.2.1Local Termination.......................................................................................................3-3
3.2.2Shielding and Grounding...........................................................................................3-4
3.3Non-isolated Digital Input/Output (DI/O) Module.................................................................3-5
3.4Non-isolated Analog Input/Output & Analog Input Module................................................3-7
3.5Non-isolated High Speed Counter (HSC) Input Module....................................................3-10
3.6Non-isolated Mixed I/O (MI/O) Module ................................................................................3-12
3.7Resistance Temperature Device (RTD) Inputs on SCM ....................................................3-16
3.8Digital to Relay I/O Board Option........................................................................................3-18
3.9Connections to a Bristol Model 3808 Transmitter.............................................................3-20
Chapter 4 – Operation 4-1
4.1Powering Up/Powering Down the ControlWave EFM..........................................................4-1
4.2Communicating with the ControlWave EFM ........................................................................4-2
4.2.1Default Comm Port......................................................................................................4-2
4.2.2Changing Port Settings..............................................................................................4-3
4.2.3Collecting Data from the ControlWave EFM ............................................................4-4
4.3Creating and Downloading an Application (ControlWave Project) ...................................4-4
4.4Creating and Maintaining Backups.......................................................................................4-5
4.4.1Creating a Zipped Project File (*.ZWT) For Backup.................................................4-5
4.4.2Saving Flash Configuration Parameters (*.FCP) .....................................................4-7
4.4.3Backing up Data..........................................................................................................4-8
Chapter 5 – Service and Troubleshooting 5-1
5.1Upgrading Firmware...............................................................................................................5-2
5.2Removing or Replacing Components...................................................................................5-5
5.2.1Accessing Modules for Testing.................................................................................5-6
5.2.2Removing/Replacing the Bezel..................................................................................5-6
5.2.3Removing/Replacing the CPU Module......................................................................5-6
5.2.4Removing/Replacing the SCM...................................................................................5-7
5.2.5Removing/Replacing an I/O Module..........................................................................5-7
5.2.6Removal/Replacement of an Expansion Communication Module.........................5-8
5.2.7Removal/Replacement of the Rechargeable Lead-acid Battery.............................5-8
5.2.8Removal/Replacement of a Power Distribution Board............................................5-9
5.2.9Removal/Replacement of a 21V Power Supply Board ............................................5-9
5.2.10Removal/Replacement of a Digital to Relay I/O Board..........................................5-10
5.2.11Removal/Replacement of a Case-Mounted Radio/Modem....................................5-10
5.2.12Removing/Replacing the Backup Battery ..............................................................5-10
5.2.13Enabling / Disabling the Backup Battery................................................................5-12
5.3General Troubleshooting Procedures ................................................................................5-12
5.3.1Checking LEDs..........................................................................................................5-12
5.3.2Checking Wiring/Signals..........................................................................................5-18
5.3.3Calibration Checks....................................................................................................5-18
5.3.4Common Communication Configuration Problems..............................................5-18
5.4WINDIAG Diagnostic Utility..................................................................................................5-19
5.4.1Available Diagnostics...............................................................................................5-22
5.5Core Updump ........................................................................................................................5-26
Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1
Appendix D – Modem Installation D-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1

ControlWave EFM Instruction Manual
Revised Dec-2013 Introduction 1-1
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Electronic Flow Meter (EFM) (called the “ControlWave EFM” or
“EFM” throughout the rest of this manual). For information about the
software used with the EFM, refer to Getting Started with ControlWave
Designer (D5085), the ControlWave Designer Programmer’s Handbook
(D5125), and the online help in ControlWave Designer. For information
on the flow measurement application used in the ControlWave EFM,
see the ControlWave Flow Measurement Applications Guide (D5137).
This chapter details the structure of this manual and provides an
overview of the ControlWave EFM and its components.
In This Chapter
1.1Scope of the Manual........................................................................1-2
1.2Physical Description ........................................................................1-3
1.3Housings and Enclosure.................................................................1-3
1.4CPU Module ....................................................................................1-4
1.5System Controller Module (SCM)....................................................1-6
1.6Expansion Communications Modules .............................................1-7
1.7I/O Modules......................................................................................1-8
1.8Software Tools.................................................................................1-8
1.9Overview of the Gas Flow Measurement Application....................1-10
The ControlWave EFM measures differential pressure, static pressure,
and temperature and computes flow for both volume and energy for up
to four meter runs in accordance with API (American Petroleum
Institute) and AGA (American Gas Association) standards.
Features ControlWave EFMs have the following key features:
Exceptional performance and low power consumption through use
of the ARM microprocessor
Two CPU options (33 MHz or 150 MHz)
Two RS-232 and one RS-485 asynchronous serial communication
ports
Optional Ethernet port (150 MHz CPU only)
Optional Expansion Communication modules (ECOMs) with
optional built-in modem and/or radio
Wide operating temperature range: (–40 to +70C) (–40 to 158F)
Variety of I/O modules (including mixed I/O)
RTD input
Lithium coin cell battery (located on the CPU module) provides
battery backup for the real-time clock and the system’s static RAM
(SRAM)
Keypad /. Display for operator interaction.

ControlWave EFM Instruction Manual
1-2 Introduction Revised Dec-2013
Nonincendive Class I, Division 2 (Groups C and D) Hazardous
Location approvals
Figure 1-1. ControlWave EFM Enclosure (shown with 25-Button Display/Keypad Assembly and local
circular port)
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction Provides an overview of the hardware and
general specifications for the ControlWave EFM.
Chapter 2
Installation Provides information on mounting the housing,
wiring power, configuring the CPU module and
optional Expanded Communications module
(ECOM), and related peripherals such as the

ControlWave EFM Instruction Manual
Revised Dec-2013 Introduction 1-3
optional keypad.
Chapter 3
I/O Modules Provides general information and wiring
diagrams for the I/O modules.
Chapter 4
Operation Provides information on day-to-day operation of
the ControlWave EFM.
Chapter 5 Service and
Troubleshooting Provides information on service and
troubleshooting procedures.
1.2 Physical Description
ControlWave EFMs are furnished in a NEMA 3X rated Hoffman®
enclosure. The flow computer hardware comprises a backplane board
(mounted in a housing), a system controller module (SCM) and a CPU
module. Optional expansion communication module(s) may reside in
slots 3 and 4 of the housing in lieu of I/O modules. The CPU module
includes the communication ports and the system memory.
All system modules plug into the backplane (either 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.
1.3 Housings and Enclosure
The ControlWave EFM housings are open-faced gold-irridite aluminum
which (whether base or expansion) are gold irridite-plated aluminum.
They house the printed circuit board (PCB) backplane and all
ControlWave EFM modules. The housing mounts to a fabrication panel
on the inner rear wall of the enclosure.
Two housings are available:
4-slot backplane supports one system controller module (SCM), one
CPU, and two I/O modules.
8-slot base housing supports one SCM, one CPU, and up to six I/O
modules. The 8-slot housing does not allow use of the internal
battery/solar panel option.
You can substitute one or two expansion communication modules
(ECOMs) for I/O modules in slots 3 and 4.
The ControlWave EFM sits in a standard NEMA 3X Hoffman®
enclosure, which also houses the multivariable transducer, battery, and
communication equipment such as a radio or modem. The enclosure
consists of two pieces, the body and the front cover. A continuous
gasket seals the unit when you close the cover. A hinge on the left side
(facing the front of the unit) if formed by molded channels on the front
cover and the body that capture a stainless steel pin. Two latches on

ControlWave EFM Instruction Manual
1-4 Introduction Revised Dec-2013
the enclosure’s right side secure the cover when you close it.
A weatherproof communication connector, either a 9-pin male D-type
connector or a circular 3-pin connector (the local port) mounts to the
bottom of the enclosure and connects internally to RS-232
communication port 1 for local communications.
The front cover includes a liquid crystal display (LCD) and keypad for
local operator access.
1.4 CPU Module
The CPU (central processing unit) module houses the multi-layer PCB,
which contains the CPU, I/O monitor/control, memory, and
communication functions.
The CPU module includes:
Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core,
operating at 1.8V with a system clock speed of 33 MHz or 150
MHz.
two RS-232 communication ports,
one RS-485 communication port
one 10/100baseT Ethernet ports (150 MHz units only)
2 MB of battery backed Static RAM (SRAM),
64MB of Synchronous Dynamic RAM (SDRAM),
512KB boot/downloader Flash,
16MB simultaneous read/write Flash memory
transmit (TX) and receive (RX) LEDs for each communication port
configuration DIP switches (described in Chapter 2.)
CPU Module
Configurations The CPU module has two basic configurations, both of which have
an on-board backup battery and different combinations of
communications ports:
Table 1-1. CPU Module Configurations
Number of
RS-232
Ports
Number of
RS-485
Ports
Number of
Ethernet Ports See Figure
2 1 0 left side of Figure 1-2
2 1 1 right side of Figure 1-2
Note: Do not confuse the CPU module (which has communication
components) with the Expansion Communication module
(ECOM), which does not have a CPU component or a battery
backup but does have additional communication components.

ControlWave EFM Instruction Manual
Revised Dec-2013 Introduction 1-5
Figure 1-2. 33MHz CPU Module with Three Serial Ports (left), 150 MHz CPU Module with Three
Serial Ports and One Ethernet Port (right)
CPU Backup Battery CPU modules have a coin cell socket that accepts a lithium battery.
This battery provides backup power for the real-time clock and the
system’s Static RAM (SRAM).
CPU Memory There are several different types of memory used on the CPU module:
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The CPU module contains 16 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.
System Memory (SRAM)
The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by a lithium backup battery). Critical system information that must be

ControlWave EFM Instruction Manual
1-6 Introduction Revised Dec-2013
retained during power outages or when the system has been disabled for
maintenance is stored here. This includes the last states of all I/O points,
audit/archive historical data (if not stored in FLASH), the values of any
variables marked RETAIN, the values of any variables assigned to the
static memory area, and any pending alarm messages not yet reported.
SDRAM
The CPU module contains 64MB of synchronous dynamic random
access memory (SDRAM). SDRAM holds the running application
(ControlWave project) as well as a copy of system firmware and the
current values of any variables not marked RETAIN or stored in the
static memory area. This allows the system to run faster than it will
from the SRAM memory. SDRAM is not battery-backed.
1.5 System Controller Module (SCM)
The System Controller Module (SCM) takes power from an external
bulk DC power supply (or an optional solar panel and lead acid battery
combination) and then provides +3.3Vdc power and GND through the
ControlWave EFM housing/backplane to all installed modules. The
SCM also supplies switched field power to I/O module slots.
Power Options The SCM operates with a nominal input of either 6V or 12V received
from a bulk supply connected to a pluggable terminal block, or from a
30 or 40 watt solar panel connected to a rechargeable lead acid battery.
If your EFM includes options such as the 21V power supply for external
transmitters, a case-mounted radio/modem, or a digital to relay I/O
board, you need a power distribution board as well.

ControlWave EFM Instruction Manual
Revised Dec-2013 Introduction 1-7
1.6 Expansion Communications Modules
Expansion Comm. Modules provide two additional serial
communications ports and optionally the choice of a piggy-backed dial-
line modem or piggy-backed 900 MHz Spread Spectrum radio (or both).
The top port (labeled C1) supports RS-232 operation while the second
one (labeled C2) supports RS-485 operation. You can optionally order
the RS-485 port with isolation to 500Vdc. You can install up to two
expansion communication modules in backplane slots 3 and 4.
Figure 1-3. Expansion Communications (ECOM) Module

ControlWave EFM Instruction Manual
1-8 Introduction Revised Dec-2013
1.7 I/O Modules
The ControlWave EFM supports factory-configured I/O modules
including analog I/O, analog input, digital I/O, high speed counter and
mixed I/O.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-4
shows a typical I/O module housing.
Configuration jumpers on I/O modules accommodate individual field
I/O user configuration. Terminations are pluggable and accept a
maximum wire size of #14 AWG. All I/O modules have surge
protection that meets C37.90-1978 and IEC 801-5 specifications. Each
I/O module connects to the backplane using a 36-pin male card-edge
connector. With the exception of the mixed I/O module, all I/O modules
are provided with two 10-point terminal block assemblies (for local
termination) or two 14-pin mass Termination headers (for remote
termination). Mixed I/O modules have two 10-point terminal blocks for
local termination only.
Figure 1-4. Two ControlWave EFM I/O Modules (with Bezel)
1.8 Software Tools
The ControlWave programming environment consists of a set of
integrated software tools which allow you to create, test, implement,
and download complex control strategies for use with the ControlWave.
Figure 1-5 graphically presents the programming environment.

ControlWave EFM Instruction Manual
Revised Dec-2013 Introduction 1-9
Figure 1-5. ControlWave Programming Environment
The tools which make up the programming environment include:
ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), and the ControlWave Designer
Programmer’s Handbook (document D5125).
The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O modules in the
ControlWave and configure the individual mapping of I/O points for
digital and analog inputs and outputs. For information on the I/O
Configurator see the ControlWave Designer Programmer’s
Handbook (document D5125).
The ACCOL3 Firmware Library, available within ControlWave
Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see
the online help within ControlWave Designer.

ControlWave EFM Instruction Manual
1-10 Introduction Revised Dec-2013
OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).
OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).
A series of web page controls are available for retrieval of real-time
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. Alternatively,
developers can place the controls in third-party ActiveX compatible
containers such as Visual BASIC or Microsoft® Excel. For
information on the ActiveX controls, see the Web_BSI Manual
(document D5087).
User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).
Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).
Communication
Protocols In addition to the Bristol Synchronous/Asynchronous Protocol (BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port using serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
1.9 Overview of the Gas Flow Measurement Application
Note: For detailed information on the gas flow measurement
application and web pages refer to the ControlWave Flow
Measurement Applications Guide (D5137).
You can purchase the ControlWave EFM with a pre-programmed flow
measurement application already loaded.

ControlWave EFM Instruction Manual
Revised Dec-2013 Introduction 1-11
The ControlWave standard gas flow measurement application collects
static pressure, differential pressure and temperature data and computes
flow, energy, and volume for a station.
A station typically refers to a single flow computer and all its
associated meter runs. Each meter run refers to measurement of natural
gas through a single pipeline. The ControlWave EFM supports up to
four meter runs. Meter runs can use orifice, turbine, or ultrasonic
meters.
The application includes an auto-selector, PID/flow pressure control
algorithm per run or per station.
If you have the optional expansion communication module, you can
interface to a chromatograph to provide energy throughput as well as
composition information.
The application also supports a nomination function.
1.9.1 Data Acquisition – Static Pressure, Differential Pressure,
Temperature Variables
The application requires these process inputs for orifice measurement:
static pressure (SP) collected once per second
differential pressure (DP) collected once per second
flowing temperature (T) collected once per second
The application requires these process inputs for measurement using a
positive displacement (PD), turbine, or ultrasonic meter:
static pressure (SP) collected once per second
frequency input collected once per second
flowing temperature (T) collected once per second
The application also collects self-test and compensation variables at
intervals of four seconds or less.
Pressure data can come from any of the following sources:
Analog pressure transmitters connected to analog input points on a
process I/O module in the ControlWave flow computer.
Built-in multivariable transducer.
External multivariable transmitters (Bristol or Rosemount) using
BSAP or Modbus communications through an RS-485
communication port.
1.9.2 Flow and Volume Calculations
Flow and volume calculations conform to American Petroleum Institute
(API) and American Gas Association (AGA) standards.
Supported flow calculations include:
AGA3-1985/NX-19

ControlWave EFM Instruction Manual
1-12 Introduction Revised Dec-2013
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
The application performs a complete flow calculation using the process
variables every second. Each calculation includes instantaneous rate
according to API 14.3, compressibility according to AGA 8 Detail or
Gross method, and updates of all volumes, totals, and archive averages.
1.9.3 Flow Rate and Flow Time Calculations (AGA3)
For orifice flow measurement, the application compares the differential
pressure value to a low flow cutoff value every second. If the
differential pressure falls below the low flow cutoff value, flow is
considered to be zero for that second. Hourly and daily flow time is
defined to be the number of seconds for which the differential pressure
exceeded the cutoff value for the period.
The values for static and differential pressure and temperature are used
as inputs to the flow equations. You can select API 14.3 (AGA3, 1992)
and AGA8 calculations, with compressibility calculations according to
AGA Report No. 8, 1992 (with 1993 errata). The application supports
both the detail method and the two gross methods of characterization
described in AGA 8. Users may also select the AGA3, 1995 and NX-19
flow equations to calculate the rate of flow.
1.9.4 Flow Rate and Flow Time Calculations (AGA7)
When using PD meters, turbine meters or ultrasonic meters, the
application calculates flow rate by applying the correction factor
computed by the AGA7 calculations to the frequency of the input
pulses. When the frequency drops below 1 Hz, the application sets the
flow rate estimate to zero; however, volume calculations still
accumulate. The flow time recorded is the time for which the flow rate
is non-zero.
1.9.5 Extension Calculation and Analog Averaging
For orifice meters, the application calculates the flow extension every
second. The extension is the square root of the product of the absolute
upstream static pressure times the differential pressure. This extension is
used in the flow rate calculation. When there is no flow, the application
reports the arithmetic averages of static pressure and temperature. This
allows you to monitor static pressure and temperature during shut-in
periods.

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1.9.6 Energy Calculation
The application offers the option of using a fixed volumetric heating
value or calculating the energy content of the gas according to AGA
Report No. 5.
1.9.7 Volume and Energy Integration
The application integrates and accumulates volume and energy at the
end of every calculation cycle. The application calculates the volume
for a cycle by multiplying the calculated rate by the flow time for that
cycle. The application calculates the energy for a cycle by multiplying
the volume at base conditions by the heating value.
1.9.8 Downstream Pressure Tap
The multivariable transducer typically measures static pressure from an
integral tap on the upstream, high-pressure leg of the differential
pressure connection. The transducer can also measure static pressure at
the downstream pressure tap, with the measurement taken from the low-
pressure side to the high-pressure side. In this installation, the
differential signal from the transducer is negative. If, while using the
integral smart multivariable transmitter (MVT) or an external MVT, you
select the downstream tap location during MVT configuration, the MVT
firmware changes the sign of the differential pressure to provide a
positive DP value.
1.9.9 Historical Data Storage (Audit Records/ Archive Files)
The ControlWave supports two distinct types of historical data storage –
audit records and archive files.
Where feasible, both forms of archive data conform to the requirements
of the API Chapter 21. Specifically, the averages of the process
variables stored in the data archive are for flowing periods, appropriate
to their usage in the equations, and any gas-related parameter designated
an event that is changed by an operator either remotely or locally causes
an entry in the audit log.
Audit Records
(Alarms and
Events)
The audit system maintains a history of alarms and certain events that
have an impact on the calculated and reported gas flow rates and
volumes.
The application stores the most recent 500 alarms and the most recent
500 events. As new alarms/events arrive, they overwrite the oldest
entries. Internally, the ControlWave stores alarms and events separately
to prevent recurring alarms from overwriting configuration audit data
events. The application reports alarms and events in the same log.
The following circumstances generate an audit record:

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Any operator change to a configuration variable
Any change in the state of an alarm variable
A system restart
Certain other system events
You can view audit records on-screen in the audit log.
See Appendix K of the OpenBSI Utilities Manual (D5081) for help on
interpreting audit records.
Archive Files
(Averages,
totals, and other
values)
Archive files store the value of process variables and other calculated
variables at specified intervals along with the date and time of each
entry. This includes flow rates, volumes and other calculated values.
When archive files fill up, new values overwrite the oldest entries in the
files.
The application displays archive file data in hourly, data, and periodic
logs you can view on screen.
Log Breaks
You can configure the application to support the "breaking" of a log
period when an operator-changes a parameter. When this occurs, the log
period in process closes out to make a log, and a new log begins.
Note: To prevent the system from creating several very short logs due
to a series of successive configuration changes, log breaks don’t
occur if a log contains less than 60 seconds (flowing or
otherwise) of data. This means that is a user enters 15
configuration changes over a two minute period, the log breaks
only twice. By default the log break feature is disabled.
Hourly Historical Data Log
Each meter run maintains an hourly data log that holds one record for
every contract hour. Hourly logs hold 840 entries or 35 days; this
ensures that the previous period of hourly data is always resident in
flash memory.
The hourly data log stores the following items:
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time

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uncorrected count
ControlWave EFM maintains an hourly historical log for each of up to
four runs.
Daily Historical Data Log
Each meter run maintains a daily data log that holds one record for
every contract gas day. You can change the contract hour so the contract
gas day starts at some time other than midnight. The daily log holds 62
entries; this ensures that the previous calendar month of daily data is
always resident in flash memory.
The daily data log stores the following items:
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
ControlWave EFM maintains a daily historical log for each of up to four
runs.
Periodic Historical Data Log
Each meter run maintains a periodic data log that holds one record for
every log interval. Each log interval is 15 minutes. The periodic
historical data log holds 1440 records, or four days of 15 minute data.
The periodic historical data log stores the following items:
flowing differential pressure
flowing static pressure
flowing temperature
frequency
ControlWave EFM maintains a daily historical log for each of up to four
runs.
1.9.10 Run Switching
If you use multiple meter runs in the application, you can configure run
switching. Run switching (also known as meter run staging or tube
switching) allows changes to the number of meter runs currently active
to meet the gas flow demand for the station.

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1.9.11 Sampler and Odorizer
Samplers are external devices which measure the quality of the gas
stream. Because natural gas is odorless and colorless, devices called
odorizers inject an additive to the gas stream that allows people to
detect the presence of natural gas in the event of a gas leak.
1.9.12 Flow Rate Control – DCC (Jog Control) Using PID
To configure the EFM to perform flow rate control you wire the two
discrete outputs to the open and close inputs of a controller. The EFM
uses a proportional/integral/derivative (PID) algorithm to cause the
measured rate of flow to match a user-entered setpoint. When the flow
rate falls below the setpoint, the open output is pulsed. When the flow
rate rises above the setpoint, the close output is pulsed. The PID
equation calculates the duration of the open or close pulse; the
minimum pulse duration is 1.0 seconds. The user changeable parameters
are:
Flow setpoint in MSCFH
Deadband in % of setpoint
Proportion gain
Integral time in repeats/minute
Derivative time in seconds
Valve travel time (full close to full open)
Process control limiting
Pressure override limits
The flow control algorithm runs once per second.
1.9.13 Pulse Output for External Totalizer or Sampler
When you configure the EFM to provide a pulse output based on
volume, the operator provides a control volume and pulse duration.
After each calculation cycle, the application compares an internal
volume accumulator to the control volume. If the accumulator exceeds
the control volume then a pulse is output and the accumulator is reduced
by the volume represented by the pulse. You can use the pulse output to
drive an external totalizer, odorizer, gas sampler, or similar device.
1.9.14 Nominations
Nominations allow you to configure the EFM to allocate precise
amounts of gas flow (called nomination values) during specific time
periods, called nomination periods. When the nomination value is
reached, the system performs an action (such as opening or closing a
valve). Prior to reaching the nomination value, the application compares
the volume/energy to a configured alarm level and generates an alarm
when the volume/energy meets or exceeds that alarm level.