Emerson ControlWave Instruction Manual

Instruction Manual

s

Document: CI-ControlWave
Part: D301381X012
November 2010

ControlWave Process Automation
Controller

ControlWave

Remote Automation 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 [phone]

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 Instruction Manual (CI-ControlWave)

Contents

Chapter 1 – Introduction 1-1

1.1 Scope of the Manual.................................................................................................................1-2

1.2 Physical Description..................................................................................................................1-2

1.3 Housings ...................................................................................................................................1-3

1.4 CPU Module..............................................................................................................................1-5

1.5 Power Supply/Sequencer Module (PSSM)...............................................................................1-7

1.6 I/O Modules...............................................................................................................................1-7

1.7 Software Tools ..........................................................................................................................1-8

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.................................................................................................................2-2

2.2.1 Unpacking Components................................................................................................2-3

2.2.2 Color Coding of Slot Connectors ..................................................................................2-4

2.2.3 Mounting the Housing...................................................................................................2-4

2.2.4 Grounding the Housing.................................................................................................2-6

2.3 Power Supply/Sequencer Module (PSSM)...............................................................................2-7

2.3.1 General Information about the PSSM...........................................................................2-9

2.3.2 PSSM Installation Overview..........................................................................................2-9

2.3.3 General Wiring Guidelines..........................................................................................2-10

2.3.4 Wiring a Bulk DC Power Supply to the PSSM............................................................2-10

2.3.5 Wiring an External Alarm or Annunciator to the Watchdog Connector and Wiring the

Redundancy Control Input (OPTIONAL)................................................................................2-15

2.4 CPU Module............................................................................................................................2-18

2.4.1 Setting DIP Switches on the CPU Module..................................................................2-19

2.4.2 Connections to RS-232 Serial Port(s).........................................................................2-22

2.4.3 Connections to RS-485 Serial Port(s) on Secondary Communication Board (SCB)..2-27

2.4.4 Connections to Ethernet Port(s) on the CPU Module.................................................2-29

2.5 Bezels......................................................................................................................................2-30

Chapter 3 – I/O Modules 3-1

3.1 Module Placement ....................................................................................................................3-3

3.2 Status LEDs ..............................................................................................................................3-4

3.3 Wiring........................................................................................................................................3-4

3.2.1 Local Termination..........................................................................................................3-5

3.2.2 Remote Termination......................................................................................................3-6

3.2.3 Shielding and Grounding...............................................................................................3-6

3.4 Digital Input (DI) Modules..........................................................................................................3-8

3.5 Digital Output (DO) Modules...................................................................................................3-13

3.6 Analog Input (AI) Modules.......................................................................................................3-19

3.7 Analog Output (AO) Modules..................................................................................................3-24

3.8 Universal Digital Input (UDI) Modules.....................................................................................3-29

3.9 Isolated Resistance Temperature Device (RTD) Input Module..............................................3-35

3.10 Isolated Low Level Analog Input (LLAI) Module .....................................................................3-39

Chapter 4 – Operation 4-1

4.1 Powering Up/Powering Down the ControlWave .......................................................................4-1

Issued Nov-2010 Contents v

ControlWave Instruction Manual (CI-ControlWave)

4.2 Setting the Operating Mode (Run/Remote/Local Switch).........................................................4-1

4.3 Communicating with the ControlWave......................................................................................4-2

4.3.1 Default Comm Port Settings .........................................................................................4-2

4.3.2 Collecting Data from the ControlWave..........................................................................4-3

4.4 Creating and Downloading an Application (ControlWave Project)...........................................4-3

4.5 Creating and Maintaining Backups...........................................................................................4-4

4.5.1 Creating a Zipped Project File (*.ZWT) For Backup.....................................................4-5

4.5.2 Saving Flash Configuration Parameters (*.FCP)..........................................................4-6

4.5.3 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.....................................................................................5-5

5.2.2 Removing/Replacing the Bezel.....................................................................................5-5

5.2.3 Removing/Replacing the CPU Module.........................................................................5-6

5.2.4 Removing/Replacing the PSSM....................................................................................5-6

5.2.5 Removing/Replacing an I/O Module (Hot Swapping)...................................................5-7

5.2.6 Removing/Replacing the Backup Battery...................................................................5-12

5.3 General Troubleshooting Procedures.....................................................................................5-12

5.3.1 Checking LEDs ...........................................................................................................5-13

5.3.2 Checking Wiring/Signals.............................................................................................5-21

5.3.3 Port 80 Display Codes ................................................................................................5-22

5.3.4 Reset Switch...............................................................................................................5-25

5.4 WINDIAG Diagnostic Utility.....................................................................................................5-25

5.4.1 Available Diagnostics..................................................................................................5-28

5.5 Core Updump..........................................................................................................................5-32

Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1

Appendix P - Redundant Power Supply Sequencer Module (RPSSM) P-1

Appendix Z – Sources for Obtaining Material Safety Data Sheets (MSDS) Z-1

Index IND-1

vi Contents Issued Nov-2010

Chapter 1 – Introduction

This manual focuses on the hardware aspects of the ControlWave
Process Automation Controller (called the “ControlWave” throughout
the rest of this manual). For information about the software used with
the ControlWave, refer to the ControlWave Quick Setup Guide (D5084),
the ControlWave Designer Programmer’s Handbook (D5125), and the
online help in ControlWave Designer.

This chapter details the structure of this manual and provides an
overview of the ControlWave and its components.

In This Chapter

1.1 ........................................................................1-2 Scope of the Manual

........................................................................1-2 Physical Description

1.2

..........................................................................................1-3 Housings

1.3

....................................................................................1-5 CPU Module

1.4

.....................................1-7 Power Supply/Sequencer Module (PSSM)

1.5

......................................................................................1-7 I/O Modules

1.6

.................................................................................1-8 Software Tools

1.7

ControlWave Instruction Manual (CI-ControlWave)

Features

ControlWave products have been designed and integrated as a highly
adaptable, high performance distributed open controller family with
exceptional networking capability that provides a complete process
automation management solution for the natural gas, water, and
wastewater industries. The ControlWave was designed with an
emphasis on providing high performance with low power consumption,
scalability, and modularity.

ControlWave process automation controllers have the following key
features:

 Low power consumption
 Wide operating temperature range: (–40 to +70C) (–40 to 158F)
 Small size (enabling panel mount or 19 inch rack-mount

installations)

 Two RS-232 ports
 One 10/100 MB Ethernet port

 Optional secondary communication board (SCB) provides additional

options for RS-232, RS-485, and Ethernet communications

 Housings to support four or eight I/O modules
 Variety of I/O modules and support for hot swapping of I/O modules

 Support for redundant operation with another ControlWave process

automation controller

 LED status indicators on the CPU, PSSM, and certain I/O modules
 Port 80 display to present status codes

Revised Nov-2010 Introduction 1-1

ControlWave Instruction Manual (CI-ControlWave)

 Battery backup for the real-time clock and the system’s static RAM

(SRAM)

 Class I, Division 2 Hazardous Location approvals

1.1 Scope of the Manual

This manual contains the following chapters:

Chapter 1
Introduction

Chapter 2
Installation

Chapter 3
I/O Modules

Chapter 4
Operation

Chapter 5 Service and
Troubleshooting

1.2 Physical Description

Each ControlWave has a printed circuit board (PCB) backplane
mounted in a stainless steel housing, a Power Supply/Sequencer Module
(PSSM), a CPU module which may include an optional Secondary
Communication Board (SCB) and—depending on the backplane and
housing size—up to eight I/O modules.

Provides an overview of the hardware and
general specifications for the ControlWave.

Provides information on the housings, the
Power Supply/Sequencer module (PSSM), and
the CPU module.

Provides general information and wiring
diagrams for the I/O modules.

Provides information on day-to-day operation of
the ControlWave.

Provides information on service and
troubleshooting procedures.

Figure 1-1. ControlWave with 8 I/O Modules

1-2 Introduction Revised Nov-2010

1.3 Housings

ControlWave Instruction Manual (CI-ControlWave)

Refer to the following sections in this chapter or to other chapters in this
manual for further information:

 Housings (chassis) with backplanes (see Section 1.3 and Chapter 2)
 Power Supply/Sequencer module (PSSM) (see Section 1.5 and

Chapter 2)

 CPU module (see Section 1.4 and Chapter 2)
 One or more I/O modules (see Section 1.6 and Chapter 3)

ControlWave housings are stainless steel designed for panel-mounting
or for some versions, for mounting in a 19-inch equipment rack. They
contain the printed circuit board (PCB) backplane into which you
connect the PSSM, the CPU module, and any I/O modules.

The following housings are available:

 6-slot backplane supports one PSSM, one CPU, and up to four I/O

modules.

 10-slot housing supports one PSSM, one CPU, and up to eight I/O

modules. The 10-slot housing is suitable for mounting in a 19-inch
equipment rack.

Revised Nov-2010 Introduction 1-3

ControlWave Instruction Manual (CI-ControlWave)

Figure 1-2. ControlWave Housing Options

1-4 Introduction Revised Nov-2010

1.4 CPU Module

ControlWave Instruction Manual (CI-ControlWave)

Note: For detailed technical specifications, please see document

CWPAC available on our website
http://www.emersonprocess.com/remote.

The CPU (central processing unit) module houses the multi-layer PCB,
which contains the ControlWave CPU, I/O monitor/control, memory,
and communication functions. It also may include the optional
Secondary Communications Board (SCB).

The CPU module includes:

 AMD Elan SC520 microprocessor running at 100 MHz
 two RS-232 communication ports
 one 10/100baseT Ethernet port
 2 MB of battery backed Static RAM (SRAM)
 64 MB of Synchronous Dynamic RAM (SDRAM)
 512 KB boot/downloader FLASH
 32 MB simultaneous read/write FLASH memory

CPU Module

Configurations

Number of

RS-232

Ports

2 0 1 No SCB.
3 1 2 For this port count, 1 RS-232, 1 RS-485,

3 1 1 For this port count, 1 RS-232 and 1 RS-

2 2 1 For this port count, both RS-485 ports

 transmit (TX) and receive (RX) LEDs for each communication port
 Keyed run/remote/local operation switch
 configuration DIP switches (described in Chapter 2)
 Port 80 display to show status codes

You can order the CPU module with the optional secondary
communication board (SCB) for additional communication ports. See
CPU Module Configurations.

The CPU module has several basic configurations, all of which have an
on-board backup battery and different combinations of
communications ports.

Table 1-1. CPU Module Configurations

Number of

RS-485

Ports

Number of

Ethernet Ports

Notes

and 1 Ethernet port reside on the SCB.

485 port reside on the SCB.

reside on the SCB.

Revised Nov-2010 Introduction 1-5

ControlWave Instruction Manual (CI-ControlWave)

CPU Backup Battery

CPU Memory

The CPU module includes a 3.6V, 950 mA-hr lithium ½ AA battery.
This battery provides backup power for the real-time clock, CMOS
RAM (within the microprocessor) and the system’s Static RAM
(SRAM).

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 32 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 the CPU backup 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.

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.

CMOS RAM

The Elan microprocessor includes 124 bytes of complementary metal
oxide semiconductor (CMOS) RAM to hold various internal
parameters.

1-6 Introduction Revised Nov-2010

ControlWave Instruction Manual (CI-ControlWave)

1.5 Power Supply/Sequencer Module (PSSM)

Note: If you need redundant power supply capabilities, you can install

a Redundant Power Supply/Sequencer Module (RPSSM) instead
of the PSSM. For details on the RPSSM, see Appendix P.

The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.

The PSSM operates from +22.2 to +30V (dc) and ships from the factory
with a nominal input supply configuration of 24V.

The PSSM includes:

 ON/OFF system power switch
 Pluggable terminal block to connect the external power supply

 Watchdog output connector to signal a watchdog failure to an

external device

 Status LEDs
Chapter 2 includes instructions for installing and configuring the PSSM.

1.6 I/O Modules

The ControlWave supports analog input, analog output, digital input,
digital output, universal digital input, isolated RTD, and isolated low
level analog input modules for either local or remote field device wiring
termination.

Refer to Chapter 3 for information on specific I/O modules. Figure 1-3
shows a typical I/O module housing.

Terminations are pluggable and accept a maximum wire size of #14
AWG. All I/O modules have surge protection that meets either C37.90­1978 or 472-1978 IEEE specifications.

Each I/O module connects to the backplane using a 110-pin male
connector and to its associated terminal block assembly using a 44 pin
header.

Revised Nov-2010 Introduction 1-7

ControlWave Instruction Manual (CI-ControlWave)

1.7 Software Tools

Figure 1-3. I/O Module (with door open)

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 1-4 graphically presents the programming environment.

1-8 Introduction Revised Nov-2010

ControlWave Instruction Manual (CI-ControlWave)

Figure 1-4. 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), the ControlWave Quick Setup Guide
(document D5084), 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).

Revised Nov-2010 Introduction 1-9

ControlWave Instruction Manual (CI-ControlWave)

 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 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.

1-10 Introduction Revised Nov-2010

Chapter 2 – Installation

This chapter discusses the physical configuration of the ControlWave,
considerations for installation, wiring instructions for the PSSM
module, and instructions for setting switches and jumpers on the CPU

module. For instructions on I/O installation, see Chapter 3.

In This Chapter

2.1 ..........................................................................2-1 Site Considerations

.............................2-2 Class I, Div 2 Installation Considerations

2.1.1

........................................................................2-2 Installation Overview

2.2

.......................................................2-3 Unpacking Components

2.2.1

..........................................2-4 Color Coding of Slot Connectors

2.2.2

..........................................................2-4 Mounting the Housing

2.2.3

........................................................2-6 Grounding the Housing

2.2.4

.....................................2-7 Power Supply/Sequencer Module (PSSM)

2.3

..................................2-9 General Information about the PSSM

2.3.1

.................................................2-9 PSSM Installation Overview

2.3.2

.................................................2-10 General Wiring Guidelines

2.3.3

...................2-10 Wiring a Bulk DC Power Supply to the PSSM

2.3.4

2.3.5

..................................................................................2-18 CPU Module

2.4

.........................2-19 Setting DIP Switches on the CPU Module

2.4.1

................................2-22 Connections to RS-232 Serial Port(s)

2.4.2

2.4.3

........2-29 Connections to Ethernet Port(s) on the CPU Module

2.4.4

............................................................................................2-30 Bezels

2.5

ControlWave Instruction Manual (CI-ControlWave)

Wiring an External Alarm or Annunciator to the Watchdog

Connector and Wiring the Redundancy Control Input
(OPTIONAL)

Connections to RS-485 Serial Port(s) on the Secondary

Communication Board (SCB)

.....................................................................2-15

...........................................2-27

2.1 Site Considerations

When choosing an installation site, check all clearances. Ensure that the
ControlWave is accessible for wiring and service.

To ensure safe use of this product, please review and follow the

Caution

Revised Nov-2010 Installation 2-1

instructions in the following supplemental documentation:

 Supplement Guide - ControlWave Site Considerations for

Equipment Installation, Grounding, and Wiring (S1400CW)

 ESDS Manual – Care and Handling of PC Boards and ESD

Sensitive Components (S14006)

ControlWave Instruction Manual (CI-ControlWave)

Specifications

for Temperature,

Humidity and

Vibration

Caution

2.1.1 Class I, Div 2 Installation Considerations

 See document CWPAC available on our website for detailed

technical specifications for temperature, humidity, and vibration for
the ControlWave. This document is available on our website at:
http://www.emersonprocess.com/remote.

 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 equipment rack for

mechanical vibrations. Make sure that the ControlWave is not
exposed to a level of vibration that exceeds that provided in the
technical specifications..

Placement of the ControlWave in Class 1, Division 2 (Group A, B, C, and
D) hazardous locations requires that you select an appropriate
enclosure that meets NEMA Type 3X or 4X specifications.

Underwriters Laboratories (UL) lists the ControlWave as non-incendive

and suitable only for use in Class I, Division 2, Group A, B, C, and D

hazardous locations and non-hazardous locations. Read this chapter and

Appendix A carefully before you install a ControlWave 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 environments.
When the ControlWave 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 connect or disconnect equipment unless the power is switched
off or the area is known to be non-hazardous.

2.2 Installation Overview

Installing a ControlWave involves several general steps:

1. Unpacking, assembling, and configuring the hardware

2. Installing PC-based software (ControlWave Designer)

2-2 Installation Revised Nov-2010

ControlWave Instruction Manual (CI-ControlWave)

3. Establishing communications

4. Creating an application-specific control strategy (ControlWave

project).

5. Creating application-specific web pages (optional)

6. Adding the ControlWave to an OpenBSI network

7. Downloading the application-specific ControlWave project into the

ControlWave

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

ControlWave Quick Setup Guide (D5084) for material related to
software installation and use.

2.2.1 Unpacking Components

Packaging

Depending upon how you order it, the ControlWave Micro may arrive
pre-assembled, with all modules installed in the housing, or as
individual components in a number of separate boxes. In the latter case,
you must identify, unpack, and assemble the components. Unless
otherwise noted, you can place modules in any slot in a base or
expansion housing.

Note: Do not install modules in the housing until you have mounted

and grounded the housing at the designated installation site.

Delivered boxes may include:

 Housing assemblies
 Power Supply/Sequencer module (PSSM)

Note: The PSSM must reside in slot #1 in the base housing.

 CPU module

Note: The CPU module must reside in slot #2 in the base housing.

 I/O Modules

Notes:

 There are many different types of I/O modules available. Chapter

3 contains detailed instructions on each I/O module.

 Universal Digital Input (UDI) modules can only reside in the first

four I/O slots.

 One or more bezel assemblies; each bezel covers two I/O

modules.

Revised Nov-2010 Installation 2-3

ControlWave Instruction Manual (CI-ControlWave)

2.2.2 Color Coding of Slot Connectors

A color tab on each backplane connector matches the color on the
module which you can place in that slot.

 PSSM goes in the first slot (Yellow tab)

 CPU goes in the second slot (Blue tab)

 I/O modules go in any other slot (Green tab)

2.2.3 Mounting the Housing

You can install a ControlWave equipped with a 4-I/O module housing

on a wall or panel. See Figure 2-2 for mounting hole patterns for a 4-

I/O unit.

You can install a ControlW

ave equipped with an 8-I/O module housing
in a 19-inch equipment rack, a panel or a wall. These units ship from the
factory with the end plates configured for 19-inch rack mounting.
Remove the end plates, rotate them 180° and then reinstall them to

accommodate panel or wall mounting. See Figure 2-1 for hole patterns

and dimensions.
When you install any of these units on a panel or wall, position it

according to the following restrictions:

 Position the unit so that you can see the front of the assembly and so

it is accessible for service such as installing a module or replacing a
battery.

 Do not install ControlWave modules until you mount the housing

and ground it properly.

2-4 Installation Revised Nov-2010

ControlWave Instruction Manual (CI-ControlWave)

Figure 2-1. 8-I/O Module ControlWave - Mounting Diagram

Revised Nov-2010 Installation 2-5

ControlWave Instruction Manual (CI-ControlWave)

Figure 2-2. 4-I/O Module ControlWave - Mounting Diagram

2.2.4 Grounding the Housing

Caution

2-6 Installation Revised Nov-2010

Do not install any modules in the housing until you mount and ground
the housing at the designated installation site.

Housings have a ground lug that accommodates up to a #4 AWG wire

Once you install the housing, you must run a ground wire between

size.
the housing ground lug and a known good earth ground.

When you install the various ControlWave modules into the housing
and secure them using the captured panel fasteners, this automatically
connects them to chassis ground.

ControlWave Instruction Manual (CI-ControlWave)

Note: After you install the PSSM in the housing, as an added

precaution we recommend that you run a #14 AWG wire from
the TB2-5 power connection (chassis ground) to the same known

good earth ground.

Additional grounding guidelines include:

 Use stranded copper wire (#4 AWG) for the housing 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).

 Tin the wire ends with solder (using a high-wattage soldering iron)

prior to inserting the wire into the housing ground lug.

 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.

2.3 Power Supply/Sequencer Module (PSSM)

Before we actually install the PSSM it in the housing, we’re going to
discuss some general information about how it works.

Revised Nov-2010 Installation 2-7

ControlWave Instruction Manual (CI-ControlWave)

Figure 2-3. Power Supply/Sequencer Module (PSSM)

2-8 Installation Revised Nov-2010

ControlWave Instruction Manual (CI-ControlWave)

2.3.1 General Information about the PSSM

The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.

The Power Supply/Sequencer module (PSSM) plugs into slot #1 (first
slot from the left) on the ControlWave’s backplane using connector J1.

Power

Supply

Hot Swap of I/O

Modules

WARNING

Watchdog

Switch

Redundancy

Control Input

The PSSM ships from the factory configured for a nominal input supply
of 24Vdc.

The PSSM supports “hot swapping” of I/O modules. This means you
can insert or remove an I/O module from the chassis while power is

live. There is no support for “hot swapping” of the PSSM itself, or the

CPU module.

Do not perform “hot swapping” in a Class I, Division 2 hazardous
location.

PSSMs include a watchdog metal oxide semiconductor field-effect
transistor (MOSFET) switch connector. The purpose of the watchdog
connector is to trigger an external alarm or annunciator if the
ControlWave enters a “watchdog” condition in which the CPU cannot
control your process. This occurs on power-up before the ControlWave
project starts, if the unit is reset, if the ControlWave project “crashes”

or if the system loses power. See Section 2.3.5.

The same terminal block (TB1) used for watchdog control also handles
a redundancy control line to a ControlWave Redundant I/O Switcher.

See Section 2.3.5.

2.3.2 PSSM Installation Overview

There are several steps you need to follow when you install the PSSM.

1. Identify the carton holding the PSSM and remove it from that carton.

See Section 2.2.1.

2. Slide the PSSM into slot #1 of the housing.

3. Tighten the captured panel fasteners to secure the PSSM in place.

4. Unplug terminal block connector TB2 from the PSSM and wire it to

an external bulk DC power supply. See Section 2.3.4.

5. If you want to use the watchdog connector TB1, or use this

ControlWave in a redundant system, unplug TB1 from the PSSM and
wire it to an external annunciator or similar device according to

instructions in Section 2.3.5 .

6. After you configure and install the CPU module in slot #2 re-connect

Revised Nov-2010 Installation 2-9

ControlWave Instruction Manual (CI-ControlWave)

terminal blocks to their connectors to apply power to the unit.

2.3.3 General Wiring Guidelines

 ControlWave PSSMs use compression-type terminals that

accommodate up to #14 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 wire.



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 a Bulk DC Power Supply to the PSSM

Caution

Operating

Range

One or Two

Power

Supplies

At this time you can also connect power and watchdog wiring.
However; for safety reasons and to prevent accidental damage to the
your bulk DC power supply, do not connect the pluggable terminal
block connectors TB1 and TB2 to the PSSM until after you install, wire,
and configure the CPU module.

Follow the instructions in Section 2.3.3 General Wiring Guidelines wh
wiring connections.

en

The ControlWave operates from +22.2 Vdc to +30.0 Vdc (with a
nominal +24Vdc input source).

You can connect one or two bulk DC power supplies (nominally +24
Vdc) to the PSSM.

The bulk DC supply you connect to terminal TB2-1 (+VIN) powers the

CPU, communications, and I/O logic circuits. The PSSM converts,
regulates, and filters the power to +5Vdc, +3.3Vdc, +12Vdc (optional)

and -12Vdc (optional).

+3.3 Vdc. For safety, this circuit has a 3A fuse.

The bulk DC supply (+20.0 to +30Vdc) you connect to terminal TB2-2

(+VINF) powers the I/O field devices connected to the I/O modules. For
safety, this circuit has a 10A fuse.

Notes:

 When you require two bulk power supplies, the first supply (VIN)

must be rated to handle 2 amps.

 The fuses for the PSSM cannot be replaced in the field.

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ControlWave Instruction Manual (CI-ControlWave)

Calculating the

Maximum Current

Required

Max Bulk +24 Vdc Supply Current = CPU

where

CPU

Σ I/O Module

Use the following formula to determine the maximum current required
for the +24 Vdc bulk power used with a particular ControlWave:

max_current

+ Σ I/O Module

max_current

:

max_current

max_current

refers to the maximum current required by the CPU (with or

without an SCB), backplane and the PSSM. This is 1A.

refers to the sum of the maximum current required by each
and every I/O module installed in the unit. The amount per
I/O module varies as follows:

16 AI Module 2A per module
8 AI Module 1A per module
8 AO Module 1A per module
16 DI Module 1A per module
32 DI Module 1A per module

16 DO Module See table (no surge current)

32 DO Module See table (no surge current)

6 UDI Module See table (no surge current)

4 RTD Module See table (no surge current)

6 LLAI Module See table (no surge current)

So, for example, if you have a ControlWave with a 16AI module, an
8AO module, and a 32DI module, the maximum current draw is 1A for
the CPU plus 2A for the 16AI module plus 1A for the 8AO module and
1A for the 32DI module, for a total of 5A.

Note: This calculation covers current draw during normal operation

(steady state) as well as the current draw during power-up in­rush when the unit is first powered on. Power up in-rush current
can last up to 100 milliseconds and is higher than the current
draw required during normal operation.

Refer to Table 2-1 for ControlWave steady state and loop current

requirements for bulk power supplies.

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ControlWave Instruction Manual (CI-ControlWave)

Table 2-1. Steady State Current Draw for Bulk Power Supplies

Component(s) System Current

draw for 24Vdc

Power Supply

CPU (with Ethernet),
PSSM and backplane

CPU (with Ethernet), SCB
(with Ethernet), PSSM and
backplane

CPU (with Ethernet), SCB
(with 2 RS-232), PSSM
and backplane

Analog Input Module 16
points (4-20 mA)

Analog Input Module 8
points (4-20 mA)

Analog Output Module 8
points (4-20 mA)

Analog Output Module 8
points (1-5V)

Digital Input Module 32
points

Digital Input Module 16
points

Digital Output Module 32
points

Digital Output Module 16
points

Universal Digital Input
(UDI) – 6 points

Isolated RTD 4 point 26.0 mA 0 mA

Isolated Low Level Analog
Input 6 points

290 mA Not applicable

400 mA Not applicable

310 mA Not applicable

40.5 mA 52.2 mA For 24Vdc supply add 25 mA per

36.1 mA 29.7 mA For 24Vdc supply add 25 mA per

20.0 mA 26.9 mA For 24Vdc supply add 23.6 mA

20.0 mA 56.8 mA For 24Vdc supply add 26.1 mA

29.2 mA 29.7 mA For 24Vdc supply add 4.74 mA

15.8 mA 29.7 mA For 24Vdc supply add 4.74 mA

42.6 mA 0 mA

22.6 mA 0 mA

16.7 mA 0 mA

40.0 mA 0 mA

Field Current draw for

24Vdc Power Supply

Notes

loop

loop

per loop

per loop. Output at 5 mA

per loop – dry contact

per loop – dry contact

Terminal Block
Connector TB2

Unplug removable connector TB2 from the PSSM and wire DC power

to the connector. We recommend you do not plug the connector back

into the PSSM until the CPU module is already installed in the housing.

TB2 provides five input connections for bulk power:

 TB2-1: = (+VIN) (+22.2V to +30V dc for +24V supply)
 TB2-2 = (+VINF) Connected to TB2-1 or +20Vdc to +30Vdc

supply

 TB2-3 = (-VIN) 1
 TB2-4 = (-VIN) 2
 TB2-5 = Chassis Ground - CHASSIS ( )

2-12 Installation Revised Nov-2010

st

supply ground

nd

supply ground internally connected to TB2-3

ControlWave Instruction Manual (CI-ControlWave)

Figure 2-4 shows the typical wiring at the PSSM’s TB1 block.

Figure 2-4. PSSM Wire Routing Diagram

Note

: As an added precaution, we recommend that you run a #14

AWG wire from the TB2-5 power connection (chassis ground)

to the same known good earth ground used for the housing.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 2-5. PSSM TB2 – Typical Wiring Schemes

2-14 Installation Revised Nov-2010