Emerson Bristol ControlWave ExpressPAC User Manual
Instruction Manual
s
CI-ControlWave EPAC
Part: D301384X012
March, 2011
ControlWave ExpressPAC
ControlWave ExpressPAC
(Process Automation Controller / Remote Terminal Unit)
Remote Automa ti on Solution
www.EmersonProcess.com/Remote
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 division (RAS) for further information.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
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 RAS.
RETURNED EQUIPMENT WARNING
When returning any equipment to RAS for repairs or evaluation, please note the following: The
party sending such materials is responsible to ensure that the materials returned to RAS 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 RAS and save RAS harmless from
any liability or damage which RAS 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 gr ounded 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.
Remote Automation Solutions
A Division of Emerson Process Management
1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
Emerson Process Management
Training
GET THE MOST FROM YOUR EMERSON
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. Emerson offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at various locations. By participating in our training, your personnel
can learn how to install, calibrate, configure, program and maintain your Emerson products
and realize the full potential of your system.
For information or to enroll in any class, go to http://www.EmersonProcess.com/Remote
click on “Educational Services” or contact our training department in Watertown at (860)
945-2200.
and
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ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual.................................................................................................................1-2
1.2 Physical Description..................................................................................................................1-2
1.3 CPU/System Controller Board ..................................................................................................1-4
1.4 Power Options...........................................................................................................................1-6
1.5 I/O Options................................................................................................................................1-6
1.6 Software Tools ..........................................................................................................................1-7
Chapter 2 – Installation 2-1
2.1 Site Considerations...................................................................................................................2-1
2.1.1 Class I, Div 2 Installation Considerations......................................................................2-3
2.2 Installation Overview.................................................................................................................2-3
2.2.1 Mounting the Housing...................................................................................................2-4
2.2.2 Grounding the Housing.................................................................................................2-9
2.3 Configuring the CPU/System Controller Board.......................................................................2-10
2.3.1 Setting DIP Switches on the CPU/System Controller Board ......................................2-11
2.3.2 Setting Jumpers on the CPU/System Controller Board..............................................2-13
2.3.3 General Wiring Guidelines..........................................................................................2-14
2.3.4 Wiring Power to the CPU/System Controller Board....................................................2-14
2.3.5 Mounting the Solar Panel............................................................................................2-18
2.3.6 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board.............2-21
2.3.7 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller
Board .........................................................................................................................2-26
2.3.8 Connections to the Ethernet Port on the CPU/System Controller Board....................2-28
2.4 Radios and Modems...............................................................................................................2-29
2.5 Optional Display/Keypads.......................................................................................................2-29
Chapter 3 – I/O Configuration and Wiring 3-1
3.1 I/O Options................................................................................................................................3-1
3.2 Process I/O Board.....................................................................................................................3-2
3.2.1 Setting Jumpers on the Process I/O Board...................................................................3-2
3.2.2 Setting DIP Switches on the Process I/O Board...........................................................3-2
3.3 I/O Wiring ..................................................................................................................................3-4
3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board....................3-6
3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O Board..............................3-7
3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board.....................................3-8
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board..................................3-9
3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Bd..3-10
3.3.6 Non-Isolated High Speed Counter/ Discrete Inputs on TB4 of Process I/O Bd..........3-11
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board.....3-12
3.3.8 Connections to a Bristol Model 3808 Transmitter.......................................................3-14
Chapter 4 – Operation 4-1
4.1 Powering Up/Powering Down the ControlWave ExpressPAC..................................................4-1
4.2 Communicating with the ControlWave ExpressPAC ................................................................4-2
4.2.1 Default Comm Port Settings..........................................................................................4-2
4.2.2 Collecting Data from the ControlWave ExpressPAC....................................................4-2
4.3 Creating and Downloading an Application (ControlWave Project) ...........................................4-3
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ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
4.4 Creating and Maintaining Backups...........................................................................................4-3
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup.....................................................4-4
4.4.2 Saving Flash Configuration Parameters (*.FCP)..........................................................4-5
4.4.3 Backing up Data............................................................................................................4-6
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.....................................................................................5-5
5.2.2 Removing/Replacing the CPU/System Controller Board and the Process I/O Board..5-5
5.2.3 Removing/Replacing the Primary Battery System........................................................5-6
5.2.4 Removing/Replacing the Backup Battery.....................................................................5-7
5.2.5 Enabling / Disabling the Backup Battery.......................................................................5-8
5.2.6 Removing/Replacing the Case-Mounted Radio or Modem ..........................................5-9
5.3 General Troubleshooting Procedures.......................................................................................5-9
5.3.1 Checking LEDs .............................................................................................................5-9
5.3.2 Status Messages on LCD Display ..............................................................................5-10
5.3.3 WINDIAG Diagnostic Utility.........................................................................................5-11
5.3.4 Available Diagnostics..................................................................................................5-12
5.4 Core Updump..........................................................................................................................5-15
5.5 Calibration Checks..................................................................................................................5-17
Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets (MSDS) Z-1
Index IND-1
vi Contents Issued Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
ExpressPAC Process Automation Controller/Remote Terminal Unit
(RTU). For information about the software used with the ControlWave
ExpressPAC, refer to Getting Started with ControlWave Designer
(D5085), the ControlWave Designer Programmer’s Handbook (D5125),
and the online help in ControlWave Designer.
This chapter provides an overview of the ControlWave ExpressPAC and
its components and details the structure of this manual
In This Chapter
1.1 Scope of the Manual........................................................................1-2
1.2 Physical Description ........................................................................1-2
1.3 CPU/System Controller Board.........................................................1-4
1.4 Power Options.................................................................................1-6
1.5 I/O Options.......................................................................................1-6
1.6 Software Tools.................................................................................1-7
Features
ControlWave ExpressPAC is designed to perform as the ideal platform
for remote site automation, measurement, and data management in
process control and manufacturing. It can serve as a process automaticn
controller or remote terminal unit (RTU). Typical process inputs used
by the ControlWave ExpressPAC are pressure, flow, level, temperature
and frequency input [typically used for positive displacement (PD)],
turbine, or ultrasonic meters. In some cases, inputs may also be derived
from external multivariable transmitters using either the BSAP or
Modbus protocols. Emerson provides the ControlWave ExpressPAC in
a NEMA 3R rated enclosure which allows operation in an un-protected
outdoor environment.
ControlWave ExpressPAC has the following key features:
Exceptional performance and low power consumption through use
of the ARM microprocessor
Very low power consumption to minimize costs of integrated solar
panel / battery power systems
Three CPU / System Controller board configurations (see Table 1-
1.)
Three process I/O board configurations (see Table 1-2.)
Two RS-232 and one RS-232/RS-485 asynchronous serial
communication ports
Optional 10/100 MB Ethernet port
Broad selection of modem and wireless communication options
Optional display or display/keypad
Revised Mar-2011 Introduction 1-1
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Wide operating temperature range: (–40 to +70C) (–40 to 158F)
Battery backup for Static RAM (SRAM) and real-time clock.
Nonincendive Class I, Division 2 (Groups C and D) Hazardous
Location approvals - See Appendix A.
Cost-effective for small RTU/process controller applications.
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Chapter 2
Installation
Chapter 3
I/O Configuration
Chapter 4
Operation
Chapter 5 Service and
Troubleshooting
1.2 Physical Description
The ControlWave ExpressPAC includes the following major
components:
Enclosure with a local communication port and LCD
display/keypad.
CPU/System Controller Board (SCB) – See Section 1.3
Optional process I/O board – See Section 1.5
Internal mounting brackets and battery
Optional RTD probe– See Section 1.5
Provides an overview of the hardware and
general specifications for the ControlWave
ExpressPAC.
Provides information on mounting the
ControlWave ExpressPAC and setting CPU
jumpers and switches.
Provides general information on wiring the
process I/O points.
Provides information on day-to-day operation of
the ControlWave ExpressPAC.
Provides information on service and
troubleshooting procedures.
Radio/modem options
1-2 Introduction Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Figure 1-1. ControlWave ExpressPAC Enclosure shown with wall/panel mounting brackets and dual-
button display/keypad
Revised Mar-2011 Introduction 1-3
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Enclosure
Internal Mounting
Brackets and Battery
The ControlWave ExpressPAC enclosure is a standard NEMA 3R
rated fiberglass enclosure. The enclosure consists of the body and the
front cover. A continuous gasket seals the unit when you close the
front cover. Two latches on the enclosure’s right side secure the cover.
The enclosure includes a weatherproof connector (local port) mounted
to the bottom of the cover and connected internally to RS-232 COM
port 1.
The enclosure includes a display or display/keypad for an operator or
technician to view process values locally.
Internal mounting brackets support the various system components,
such as the battery, CPU/System Controller and Process I/O boards,
and the radio/modem option. These components attach to the one piece
mounting bracket which is secured to the inner rear wall of the
enclosure. A factory-supplied radio or modem mounts in front of the
battery on a battery cover/radio mounting plate.
You can order the ControlWave Express from the factory with one of
the following power options:
Single 6V lithium battery
Dual 12V lithium battery pack
6V, 7AH lead acid battery used with a 1W, 6V solar panel.
6V, 7AH lead acid battery used with a 5W, 6V solar panel.
12V, 7AH lead acid battery used with a 5W, 12V solar panel.
No battery; user-supplied power source.
Radio/Modem
You can order the ControlWave ExpressPAC with a factory-installed
modem or spread spectrum radio. The unit supports a variety of MDS
and FreeWave radios and modems. Contact Emerson Remote
Automation Solutions for more information.
1.3 CPU/System Controller Board
The CPU (central processing unit) and System Controller Board (SCB)
contains the ControlWave ExpressPAC CPU, I/O monitor/control,
memory, and communication functions.
The CPU/System Controller board includes:
Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core, with a
system clock speed of either 14 MHz or 33 MHz.
two RS-232 communication ports
one communication port configurable by jumpers as either RS-232
or RS-485
optional 10/100baseT Ethernet port (See Table 1-1)
2 MB of battery backed Static RAM (SRAM),
1-4 Introduction Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
512KB boot/downloader FLASH,
8MB simultaneous read/write FLASH memory
Board Variations
Table 1-1. CPU/System Controller board Variations
CPU Nominal
14MHz
ultra low
power
33MHz
low
power
33MHz +12V or
The CPU/System Controller board has three basic variations:
Input
Power
+6Vdc or
+12Vdc
+12V or
+24Vdc
+24Vdc
Ethernet
Port?
No Yes Yes Yes. Connects to
No Yes Yes No
Yes No No Yes (same as
Solar
Regulator
?
Auxiliary
Power
Output?
RTD Input?
100-ohm
platinum bulb.
Uses DIN 43760
curve.
ultra low power)
Note: Each of the variants shown in Table 1-1 may be ordered with or
without special gas calculation firmware.
CPU Backup Battery
CPU Memory
The CPU/System Controller board has a coin cell socket that accepts a
3.0V, 300 mA-hr lithium battery. This 3.0V battery provides backup
power for the real-time clock and the system’s Static RAM (SRAM).
There are several different types of memory used by the CPU:
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 ControlWave ExpressPAC includes 8 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 ControlWave ExpressPAC has 2 MB of static random access
memory (SRAM). During power loss periods, SRAM enters data
Revised Mar-2011 Introduction 1-5
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
retention mode (powered by a backup 3.0V lithium battery). Critical
system information that must be 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.
1.4 Power Options
You can power the ControlWave ExpressPAC by:
factory-supplied rechargeable 6/12V lead acid battery (used in
conjunction with a solar panel),
factory-supplied single or dual lithium battery pack
user-supplied bulk (nominal +6Vdc, +12Vdc or +24Vdc) power
supply.
If you connect solar panels to rechargeable battery systems to power the
ControlWave ExpressPAC, there is a secondary power input you can
use to provide power if there is no power from the solar panel/battery
system.
1.5 I/O Options
Type Discrete
A 2 4 2 2
B 2 4 2 2 3
C 2 4 2 2 3 1
ControlWave ExpressPAC comes with the following standard I/O
2 Pulse Counter Inputs with a 1 second scan rate (can be configured
as discrete inputs (DI))
The 14 MHz CPU and 33 MHz CPU with Ethernet also include a
Resistance Temperature Device (RTD) probe.
In addition, three different versions of the optional process I/O board are
available:
Table 1-2. Process I/O Configurations
Input /
Output
(DI/DO)
Discrete
Input (DI)
Discrete
Output
(DO)
High Speed
Counter
(HSC)
Analog
Input (AI)
Analog
Output
(AO)
1-6 Introduction Revised Mar-2011
1.6 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
ExpressPAC. Figure 1-2 graphically presents the programming
environment.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Figure 1-2. 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 ExpressPAC. 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 in the ControlWave and
configure the individual mapping of I/O points for discrete and
analog inputs and outputs. For information on the I/O Configurator
see the ControlWave Designer Programmer’s Handbook (document
D5125).
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ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
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.
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).
Communication
Protocols
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).
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 with 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.
1-8 Introduction Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
ExpressPAC, considerations for installation, and instructions for setting
switches and jumpers.
In This Chapter
2.1 Site Considerations..........................................................................2-1
2.1.1 Class I, Div 2 Installation Considerations.............................2-3
2.2 Installation Overview........................................................................2-3
2.2.1 Mounting the Housing..........................................................2-4
2.2.2 Grounding the Housing........................................................2-9
2.3 Configuring the CPU/System Controller Board.............................2-10
2.3.1 Setting DIP Switches on CPU/System Controller Board....2-11
2.3.2 Setting Jumpers on the CPU/System Controller Board.....2-13
2.3.3 General Wiring Guidelines.................................................2-14
2.3.4 Wiring Power to the CPU/System Controller Board...........2-14
2.3.5 Mounting the Solar Panel...................................................2-18
2.3.6 Connections to RS-232 Serial Port(s) on the CPU/System
2.3.7 Connections to the COM3 (RS-485/RS-232) Serial Port on the
2.3.8 Connections to the Ethernet Port on the CPU/System Controller
2.4 Radios and Modems......................................................................2-29
2.5 Optional Display/Keypads..............................................................2-29
Controller Board................................................................2-21
CPU/System Controller Board..........................................2-26
Board ................................................................................2-28
2.1 Site Considerations
When choosing an installation site, check all clearances. Ensure that you
can open the ControlWave ExpressPAC cover (hinged on the left side)
for wiring and service. If present, make sure the optional
display/keypad is accessible and visible. See Figure 2-2 for a
dimensional drawing of the NEMA enclosure.
Ensure adequate clearance for the solar panel (if required).
The ControlWave ExpressPAC comes in an enclosure/chassis that you
can mount to a panel, a wall or a 2 inch vertical pipe. The ControlWave
ExpressPAC is designed to operate in an outdoor un-protected Class I
Division 2, Groups C & D environment with a nonincendive rating (see
Appendix A).
To ensure safe use of this product, please review and follow the
Caution
instructions in the following supplemental documentation:
Supplement Guide - ControlWave Site Considerations for
ESDS Manual – Care and Handling of PC Boards and ESD
Equipment Installation, Grounding, and Wiring (S1400CW)
Sensitive Components (S14006)
Revised Mar-2011 Installation 2-1
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Figure 2-1. ControlWave ExpressPAC Component Identification
2-2 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Specifications
for Temperature,
Humidity and
Vibration
2.1.1 Class I, Div 2 Installation Considerations
See document 420DS-7d available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave ExpressPAC.
Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
Check the mounted enclosure, panel, or pipe for mechanical
vibrations. Make sure that the ControlWave ExpressPAC is not
exposed to a level of vibration that exceeds that provided in the
technical specifications.
Underwriters Laboratories (UL) lists the ControlWave ExpressPAC as
non-incendive and suitable only for use in Class I, Division 2, Groups
C, and D hazardous locations and non-hazardous locations. Read this
chapter and Appendix A carefully before you install a ControlWave
ExpressPAC in a hazardous location.
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 Groups C and D environments.
When the ControlWave ExpressPAC is situated in a hazardous location,
turn off power before servicing or replacing the unit and before
installing or removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
2.2 Installation Overview
ControlWave ExpressPAC ships from the factory with all components
wired and mounted, except for the unit’s solar panel and primary
battery; these items are shipped separately.
Installing a ControlWave ExpressPAC involves several general steps:
1. Installing and configuring the hardware. This includes:
a) Mounting the chassis on a panel, wall, or vertical pipe. (See
Section 2.2.1)
Revised Mar-2011 Installation 2-3
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
b) Enabling the backup battery by setting jumper W3 on the
CPU/System Controller board to position 1 to 2. (See Section
2.3.2)
b) Setting switches and jumpers on the CPU/System Controller
board (see Section 2.3.1 and Section 2.3.2) and on the Process
I/O board (see Section 3.2.1 and Section 3.2.2) and placing both
boards (as a single assembly) into the chassis.
d) Connecting communication cables, including a cable to a 3808
transmitter, if required. (See Sections 2.3.6, 2.3.7, 2.3.8, and
3.3.8.)
e) Wiring I/O. (See Section 3.3)
f) Installing a ground wire between the enclosure ground lug and a
known good Earth ground. (See Section 2.2.2)
g) Connecting the RTD probe (if required). (See Section 3.3.7)
h) Installing the solar panel and rechargeable battery (if
applicable).(See Section 2.3.5)
i) Wiring power to the unit. (See Section 2.3.4)
j) Turning on power. (See Section 4.1)
2. Installing PC-based software (ControlWave Designer).
3. Establishing communications.
4. Creating an application-specific control strategy (ControlWave
project).
5. Creating application-specific web pages (optional).
6. Adding the ControlWave ExpressPAC to an OpenBSI network.
7. Downloading the application-specific ControlWave project into the
ControlWave ExpressPAC.
Note: Steps 2 through 7 require that you install and use ControlWave
Designer software on your PC. This manual focuses on hardware
installation and preparation. Software installation and
configuration is beyond the scope of this manual. Refer to the
Getting Started with ControlWave Designer Manual (D5085)
and the ControlWave Designer Programmer’s Handbook
(D5125) for material related to software installation and use.
2.2.1 Mounting the Housing
You must position the ControlWave ExpressPAC vertically. See
Figure 2-2 for enclosure dimensions.
Make sure the front of the assembly is visible and you can open the
front cover for service, installation, and so on. Ensure you can
clearly see and use the optional LCD display/keypad.
2-4 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Figure 2-2. ControlWave ExpressPAC NEMA 3R Enclosure Dimensions
Mount the unit to a panel, a wall or to a vertical 2 inch pipe clamped
at the rear of the unit using two clamps and four bolts. See Figure 2-
4 and Figure 2-5. If you mount to a pipe, it must be anchored in
cement deep enough to conform to local building codes associated
with frost considerations.
Revised Mar-2011 Installation 2-5
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
If your unit requires a solar panel, you can mount it to the same 2
inch pipe that holds the controller. Make sure there is adequate
clearance for the solar panel. For more information on the solar
panel, see Section 2.3.5.
Only connect power wiring after the unit is mounted and properly
grounded.
I/O wiring, external power wiring, RTD wiring, antenna cabling,
and communication port cabling enters the bottom of the unit
through conduit or special function fittings. (See Figure 2-3.) I/O
wiring is routed through the left side of the unit (right when facing
the front) via a ¾ inch conduit fitting.
Figure 2-3. ControlWave ExpressPAC Bottom View
.
2-6 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Figure 2-4. Side View of ControlWave ExpressPAC (Mounted to a 2” Pipe)
Revised Mar-2011 Installation 2-7
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Figure 2-5. Side View of ControlWave ExpressPAC (Wall or Panel Mounted)
2-8 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
2.2.2 Grounding the Housing
The ControlWave ExpressPAC enclosure includes a ground lug that
accommodates up to a #4 AWG wire size. Once you install the unit, run
a ground wire between the enclosure’s ground lug and a known good
Earth ground. For more information on grounding see the ControlWave
Grounding Supplement (S1400CW):
Additional grounding guidelines include:
Use stranded copper wire (#4 AWG) to earth ground, and keep the
length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Using a high-wattage soldering iron, tin the ground wire with solder
before you insert it into the chassis ground.
Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.
Revised Mar-2011 Installation 2-9
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
2.3 Configuring the CPU/System Controller Board
To configure the CPU/System Controller board, you need to set some
switches and jumpers.
Solar Pwr. In +
GND
Power In +
GND
Aux. Power Out +
Input
Input
Output
Output
GND
GND
DCD
RXD
TXD
DTR
Sec. Battery Input
GND
DSR
Input
Output
RTS
Input
CTS
DCD
Input
RXD
Input
Output
TXD
DTR
Output
GND
Input
DSR
Output
RTS
CTS
Input
Receive LED
Transmit LED
1 = Idle
2 = Watchdog
Configuration
Options
Switch
Recovery
Mode &
COM./Status
LEDs
RXD+
Input
RXD-/RXD
Input
TXD-/TXD
Output
TXD+
Output
GND
PULSE 1
Input
PULSE 2
Input
GND
PULSE
Output
PWR
RTD EXC
RTD+
RTD-
1
2
3
4
5
6
6
1
2
1
2
3
6
4
5
9
6
7
8
1
2
3
4
5
6
7
8
CR1
1
}
O
N
12
3
4
56
7
8
O
N
1
2
3
4
1
2
3
4
5
1
2
3
4
1
2
3
Damage WILL occur to
the CPU if the Ethernet
network is conected
to connector J2!
Power
Power
1
5
COM2
RS-232
2
COM3
RS-232
RS-485
Pulse
Input
RTD
Input
CAUTION:
COM1
RS-232
10/100
Base-T
Ethernet
Port
LCD/
Keypad
1
23
45678
1
2
3
4
RJ-45
CR1
RJ-45
3 2 1
T
R
X
X
D
D
G
N
D
W12
W15
W18
COM1
RS-232
W3
W13
W14
NOTE:
F3
S1
NOTE:
J7, J8, J9
Factory Use
Ultra Low Power & Low Power
CPU/System Controller Bds.
Don’t have an Ethernet Port.
Solar Pwr. In and Aux. Power Out
are not available on units equipped
with an Ethernet Port.
Do Not Connect a 24V Solar Panel
to Connector TB1-1 & TB1-2!
W1 - 1-2 = COM1 CTS from Port
2-3 = COM1 CTS to RTS
W2 - 1-2 = COM2 CTS from Port
2-3 = COM2 CTS to RTS
W3 - 1-2 = Battery Enabled
2-3 = Battery Disabled
W5 - 1-2 = 12/24V Power Supply
W1
W2
W6 - 1-2 = 12V Power Supply
W7 - 1-2 = 12/24V Power Fail
W8 - 1-2 = 12V Power Fail
W12 - W16 - 1-2 = COM3 RS-232
W17: 6/12V CPUs
1-2 = 6V S.P. Charging System
2-3 = 12V S.P. Chargin g System
W17: 12/24V CPUs
1-2 = 12V S.P. Charging System
2-3 = N/A
Note: W17 is N/A on 24V Systems
Do NOT connect a 24V Solar
Panel to TB-1 & TB-2!
W18: COM1 connector
selection
1 to 2 = J4 active
2 to 3 = J11 active
SW3 - COM3 Config.
RS-485 Receiver Biasing & Termination
2-Wire, 4-Wire Selction
J8
Emulation
Header
J7
MSP430
JTAG
Header
P1 WE
Shut-down Hysterisis
2-3 = 6V Power Supply
Shut-down Hysterisis
Shut-down
2-3 = 6/24V Power Suppl y
Shut-down
W8
W7
2-3 = 6V Power Fail
2-3 = 6/24V Power Fail
W6
W5
Trip Point Hysterisis
Trip Point Hysterisis
Trip Point
Trip Point
Trip Point
2-3 = COM3 RS-485
J5 - COM3
Piggy-back
Radio Intf.
J5
W17
J9
PLD JTAG
Header
J3 - I/OBUS
Intf. to
CPU Board
W16
J3
Figure 2-6. - CPU/System Controller Board Component I.D. Diagram
2-10 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
2.3.1 Setting DIP Switches on the CPU/System Controller Board
Before you install the CPU/System Controller board, you must
determine the settings for three banks of DIP switches. Refer to Figure
2-6 for the location of the DIP switch banks. Refer to Tables 2-1, 2-2,
and 2-3 for an explanation of the DIP switch positions.
Note: Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF.
Table 2-1. CPU/System Controller Board Switch SW1
SW1 Setting Function Mode
1 & 2
3
4
Recovery
Mode
Force
Recovery
Mode
LED status
Recovery Mode = Both SW1-1 and SW1-2 ON or both
SW1-1 and SW1-2 OFF
Local Mode = SW1-1 OFF and SW1-2 ON (Factory
Default)
Enables recovery mode. Values are:
ON (enables recovery mode)
OFF (disables recovery mode). – This is the factory
default.
ON (Enable Idle LED)
OFF (Disable Idle LED)
Table 2-2. CPU/System Controller Board Switch SW2
SW2 Setting Function Mode
1
2
3
4
Watchdog
Enable
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump Causes the ControlWave ExpressPAC to perform a core
Controls whether the system enters a watchdog state
when a crash or system hangup occurs and automatically
restarts. Values are:
ON (Enables watchdog circuit; factory default)
OFF (Disables watchdog circuit and prevents automatic
restart)
Controls the ability to modify soft switches, other
configurations, and flash files. Values are:
ON (Unlocks soft switches and flash files; factory
default).
OFF (Locks soft switches, configurations, and flash files)
Controls the use of soft switches. Values are:
ON (Enable user-defined soft switches configured in flash
memory; factory default)
OFF (Disable soft switch configuration and use factory
defaults)
Note: Setting both switch 3 and switch 8 to OFF (closed)
sets all serial communication ports to 9600 bps
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.
updump, provided you have set the SW1 switches to allow
recovery mode. Values are:
Revised Mar-2011 Installation 2-11
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
SW2 Setting Function Mode
ON (Disables core updump; factory default)
OFF Core updump
5
6
7
8
SRAM Control Manages SRAM contents following a low power situation
or a power outage. Values are:
ON (Retain values in SRAM during restarts; factory
default)
OFF (Reinitialize SRAM) – Data in SRAM lost during
power outage or re-start.
System
Firmware
N/A Not currently used.
Enable
WINDIAG
Allows a remote download of system firmware (on units
equipped with boot PROM version 4.7 or higher and
system PROM version 4.7 and higher). Values are:
ON (Enable remote download of system firmware; factory
default)
OFF (Disable remote download of system firmware)
Suspends normal operation and allows diagnostic
routines. Values are:
ON (Permits normal system operation, including the boot
project, and disables the WINDIAG diagnostics from
running; factory default)
OFF (Allow WINDIAG to run test; disable boot project and
normal system operation.)
Note: Setting both switch 8 and switch 3 to OFF (closed)
sets all communication ports to 9600 bps operation.
All serial communication ports must be set at 9600
bps before WINDIAG can perform communication
tests.
Switch
Setting
1
2
3
4
5
6
Note: Table 2-3 describes switch settings for RS-485 port operation.
You may want to review Section 2.3.7 on RS-485 configuration
before you set these switches.
Table 2-3. RS-485 Configuration Switch SW3
Function Mode
TX+ to RX+ Loopback / 2wire
TX- to RX- Loopback / 2wire
100 Ohm RX+ Termination
100 Ohm RX- Termination
N/A Not currently used
N/A Not currently used
ON (2-wire operation or loopback enabled)
OFF (4-wire operation and loopback
disabled)
ON (2-wire operation or loopback enabled)
OFF (4-wire operation and loopback
disabled)
ON (End nodes only)
ON (End nodes only)
2-12 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
Switch
Setting
7
8
Function Mode
RX+ Bias (End Node)
RX- Bias (End Node)
ON (4-wire = Both End nodes only; 2-wire=
One end node only)
OFF = No bias
ON (4-wire = Both End nodes only; 2-wire=
One end node only)
OFF = No bias
2.3.2 Setting Jumpers on the CPU/System Controller Board
The CPU has several jumpers.
W1: COM1 CTS usage:
o 1-to-2 Installed = COM1 CTS source is from device.
o 2-to-3 Installed = COM1 RTS to CTS loopback
W2: COM2 CTS usage:
o 1-to-2 Installed = COM2 CTS source is from device.
o 2-to-3 Installed = COM2 RTS to CTS loopback
Note: You must enable the backup battery by setting jumper W3 to
position 1-2.
W3: Enable/disable battery backup selection:
o 1-to-2 Installed = Enable battery backup.
o 2-to-3 Installed = Disable battery backup
W5: Power supply shut down selection:
o 1-to-2 Installed = 12/24V power supply shut down hysteresis
o 2-to-3 Installed = 6V power supply shut down hysteresis
W6: Power supply shut down selection:
o 1-to-2 Installed = 12V power supply shut down
o 2-to-3 Installed = 6/24V power supply shut down
W7: Power fail trip point hysteresis selection:
o 1-to-2 Installed = 12/24V power fail trip point hysteresis
o 2-to-3 Installed = 6V power fail trip point hysteresis
W8: Power fail trip point selection:
o 1-to-2 Installed = 12V power fail trip point
o 2-to-3 Installed = 6/24V power fail trip point
W12: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W13: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
Revised Mar-2011 Installation 2-13
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
W14: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W15: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W16: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W17: Input power selection (controls solar power shunt regulation.
Not applicable for +24Vdc CPUs:
o 1-to-2 Installed = 6V power
o 2-to-3 Installed = 12V power
W18: COM1 connector selection:
o 1-to-2 Installed = connector J4 (D connector) is active
o 2-to-3 Installed = alternate connector J11 is active
2.3.3 General Wiring Guidelines
ControlWave ExpressPAC terminal blocks use compression-type
terminals that accommodate up to #16 AWG wire.
When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the screw.
To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.
2.3.4 Wiring Power to the CPU/System Controller Board
You can power the ControlWave ExpressPAC by:
factory-supplied 6V lithium battery
factory-supplied 12V lithium battery pack (dual lithium batteries)
factory-supplied 6V, 7AH lead acid battery – used with a 1W, 6V
solar panel system
factory-supplied 6V, 7AH lead acid battery – used with a 5W, 6V
solar panel system
factory-supplied 12V, 7AH lead acid battery – used with a 5W, 12V
solar panel system
user-supplied bulk (nominal +6Vdc, +12Vdc or +24Vdc) power
supply.
2-14 Installation Revised Mar-2011
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC)
If you connect solar panels to rechargeable battery systems to power the
ControlWave ExpressPAC, there is a secondary power input you can
use to provide power if there is no power from the solar panel/battery
system.
Caution
Power Supply
Current
Requirements
Table 2-4. ControlWave ExpressPAC Bulk Power Requirements
At this time you can connect power wiring. However; for safety reasons
and to prevent accidental damage to your bulk DC power supply, do not
connect the pluggable terminal block connectors TB1 and TB2 to the
CPU/System Controller board until after you install, wire, ground, and
configure the entire unit.
Follow the instructions in Section 2.3.3 General Wiring Guidelines when
wiring connections.
Depending upon the CPU type, the ControlWave ExpressPAC accepts
either a 6Vdc, 12Vdc or 24Vdc bulk power input. You can estimate the
maximum current required for your ControlWave ExpressPAC using
the following equation:
Bulk +6/12/24 Vdc Supply Current = CPU/System Controller Board (with
options) + Process I/O Board + LCD
display/keypad + optional external
modem/radio
Refer to Table 2-4 for ControlWave ExpressPAC power requirements
based on the CPU type.
CPU Type and Components
14 MHz Ultra Low Power CPU with LCD
display/keypad
33 MHz Low Power CPU without Ethernet, but
with LCD display/keypad
33 MHz CPU with Ethernet and LCD
display/keypad
Note: This summation accommodates steady state current draw and is
based on typical application loads. For 3808 power consumption,
see the 3808 manual (CI-3808). If your ControlWave
ExpressPAC includes a modem or radio, contact the
radio/modem manufacturer for power consumption
specifications.
If your ControlWave ExpressPAC is configured to use a solar panel to
Caution
charge a 7AH (6V or 12V) battery for power, NEVER CONNECT THE
SOLAR PANEL/CHARGER WITHOUT ALSO CONNECTING THE
Bulk 6Vdc
Power
Supply
7 mA without field supply
Not
Supported
Not
Supported
Bulk 12Vdc
Power Supply
and with AO output
under range: 5 mA
without process I/O
board: 14 mA
without process I/O
board: 80 mA
Bulk 24Vdc
Power Supply
Not Supported
without process I/O
board: 14 mA
without process I/O
board: 47 mA
Revised Mar-2011 Installation 2-15
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