ABB TOTALFLOW WellTell Wireless IS User guide

Intellectual Property & Copyright Notice

Any and all derivatives of, including translations thereof, shall remain the

sole property of the Owner, regardless of any circumstances.

The original US English version of this manual shall be deemed the only

valid version. Translated versions, in any other language, shall be

maintained as accurately as possible. Should any discrepancies exist,

the US English version will be considered final. ABB is not liable for any

errors and omissions in the translated materials.

Notice: This publication is for information only. The contents are subject

to change without notice and should not be construed as a commitment,

representation, warranty, or guarantee of any method, product, or device

by Owner.

Inquiries regarding this manual should be addressed to ABB Inc.,

Totalflow Products, Technical Communications, 7051 Industrial Blvd.,

Bartlesville, Oklahoma 74006, U.S.A.

Introduction

This is a quick start guide designed for typical installations only. It is

recommended that inexperienced technicians consult the Totalflow®

WellTell Wireless User’s Manual for more detailed information while

performing the installation and start-up.

The Totalflow WellTell wireless product is designed to replace expensive

cable with robust and inexpensive radio links. Cable trenching presents

drawbacks related to expense, inconvenience, maintainability and safety.

Spread spectrum radio technologies have made it possible to install low-

cost, easily maintainable RF links between many of the system

components. Trenching can be minimized, and in some instances, done

away with entirely.

The WellTell-IS is a simple protocol transport incorporating an RS-485

compatible, intrinsically safe (IS) barrier. The WellTell-IS has a wide

range of uses to include providing an RF link to the LevelMaster

products.

Scan through the guide to see what information is available before

beginning the installation. If there are questions that are not answered in

the guide or other documentation, call a local Totalflow representative or

call the number listed on the back page of this guide. Alternate methods

of installation are acceptable and may save time; however, it is

recommended that inexperienced technicians perform these procedures

in this order.

Unpack and inspect the WellTell-X and WellTell-IS and any other

optional equipment. Inspect all parts for damage, missing or incorrect

components.

Before Beginning

The WellTell-IS system is comprised of two parts: the host (WellTell-X)

and the intrinsically safe (IS) barrier client (WellTell-IS). The host,

WellTell-X, is generally installed in the site controller (XFC or XRC). The

IS barrier client, WellTell-IS, is installed near the LevelMaster application.

2100759-004

Intrinsically Safe

Barrier Outputs

Hosting Device

Com2 to Host Radio

Remote Wireless Barrier Client

Barrier supporting two Level Master sticks

NOTE: See larger detailed figures

Figure 1 – Basic Setup

Basic Installation

The following information covers the initial installation of the WellTell-X

host at the site controller (XFC/XRC), the installation of the WellTell-IS

client near the LevelMaster application and the final application

configuration and test at the site controller.

The instructions are broken down into segments that cover the

mechanical and electrical installation along with the configuration of the

system. It is assumed that this installation is taking place within either a

6400 or 6700 enclosure

Step 1 WellTell-IS Mechanical Installation

The mechanical installation for both the WellTell-IS client and WellTell-X

host is the same. Use the following instructions to accomplish the task.

1A Position the pipe saddle on the meter run. Select a location

that allows easy user access and is close to the equipment.

Temporarily attach the saddle on the meter run pipe using U-

bolts and associated hardware.

1B Screw the 2” by 40” mounting pipe into the saddle (see Figure

2). Place the level against the pipe and vertically align. Adjust

the pipe, mounted in the saddle, until vertical alignment is

achieved. After vertical alignment, securely tighten the 2” by

40” pipe in the saddle. Tighten the saddle mounting bolts.

Ascertain that the pipe is securely installed in the saddle.

1C Position the enclosure on the 2” mounting pipe, and secure in

place with two U-bolts, flat washers, lock washers and two

9/16” bolts (see Figure 3).

Figure 2 – Pipe and Saddle Mount

Figure 3 – Pipe Mounted 6400/6700 Enclosure

Step 2 WellTell-X Installation

The WellTell-X host unit is mounted in a communication tray (generally

at the factory) and is designed to be installed in a Totalflow 6400 or 6700

enclosure (see Figure 4).

At the top of the enclosure is the area where communication devices are

installed. This area is referred to as the communication compartment

(see Figure 5). All communication equipment is secured to the

communication tray and slid into this compartment. The WellTell-X is

mounted to standoffs on the communication tray and then slid into the

communication compartment.

Figure 4 – Communication Tray

Figure 5 – Communication Tray Installed in the 6700 Enclosure

Step 3 WellTell-X Host Communication Wiring

NOTE: If the unit came preconfigured from the factory, ignore the

following wiring instructions.

Wiring of the WellTell-X host to a parent device (XFC/XRC) is fairly

simple. In the example (see Figure 6), an XFC-195 board is used as the

parent meter. If the application involves something other than the XFC-

195, please check the meter pinouts before proceeding.

Additionally, the following example uses COM 2 of the XFC. COM 1 is

often defaulted for communication with a remote device (radio, modem,

etc.). Wiring is simplified by the use of pre-wired cable that is designed

specifically for the WellTell-X device.

Figure 6 – Wireless Host Wired to COM 2 of XFC-195

Step 4 Configuring COM 2 for the LevelMaster Application

After completing the electrical wiring for the WellTell-X to COM 2 on the

flow computer, the user needs to configure the COM 2 communication

port.

NOTE: In Figure 6, COM 2 (XA2) must have an RS-485 module inserted.

Figure 7 walks the user through the steps (A and B) to configure COM 2

for the LevelMaster application.

A - Move to the

Communications tab. Set

the Spare – COM 2 to

None and the LevelMaster

port to COM2:

B – Move to the

LevelMaster

Communications tab and

setup as shown

Figure 7 – Typical Communication Setup for the LevelMaster

WellTell-IS Wiring

Electrical wiring at the WellTell-IS (client) is accomplished with two basic

steps: powering the unit and wiring the RS-485 to the LevelMaster sticks.

Step 5 WellTell-IS Client Electrical Wiring

The WellTell-IS client can be mounted near or at the top of the storage

tank. It should be mounted in a Division 2 or non-hazardous location;

however, a short piece of cable can be run to the LevelMaster itself.

The WellTell-IS client also has an onboard battery charger to maintain

the charge on a 12 VDC lead-acid battery. Figure 8 illustrates the most

common way to provide power to the WellTell-IS.

Figure 8 – Powering of the WellTell-IS

Step 6 Wiring the LevelMaster Sticks to the IS Barrier

The second part of the electrical installation for the WellTell-IS is the

wiring of the LevelMaster sticks to the IS barrier on the WellTell-IS.

Figure 9 illustrates how this is accomplished.

Figure 9 – Wiring LevelMaster Sticks to the IS Barrier

System Configuration

Step 7 Configuring the WellTell-X

In a similar fashion to configuring the meters for the COM 2 port, the user

must also configure the WellTell-X radio.

To configure the WellTell-X (or the WellTell-IS) radio, the user must have

the WellTell Wireless Utility (WWU) program and a typical 9-pin to 9-pin

(male DB9 to female DB9) cable. The cable connects between a laptop

and the maintenance connector of the WellTell-X.

7A Configure the WellTell-X security. WWU supports two levels of

Access: Restricted Use and Admin (lower left side on the

System Config tab). Restricted Use gives the user access to

the basic setup parameters that are most often used (i.e.,

Network ID, FR Channel, etc.). Lesser used parameters (i.e.,

Encryption Key, Range Refresh, etc.) are grayed out, if

Restricted Use is selected. Normal setup does not require

Restricted Use. These lesser parameters can be accessed

through Admin. Admin is achieved by entering the password.

The factory password is 0000.

As opposed to providing an in-depth, screen-by-screen explanation of

the WWU, the opening screen is presented to the user along with

references to the various available tabs that contain relevant parameters

on each of the corresponding screens (see Figure 10).

7B System Config tab - Set the parameters as shown in Figure

10.

7C Radio Config tab – Set the parameters as shown in the

following table:

Parameter Field Value

Mode Server

Network ID 1 (Must match Client)

RF Channel Anything between 16 and 47 (must

match Client)

Baud Rate 9600

Delivery Mode Broadcast

RF Mode Acknowledge

Duplex Mode Half Duplex

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