Emerson ControlWave EFM 3808, Bristol ControlWave Express Instruction Manual

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Instruction Manual

CI-ControlWave Express Part: D301386X012 March, 2011

ControlWave Express (Remote Terminal Unit)

ControlWave Express

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 Express Instruction Manual (CI-ControlWave Express)

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

1.4 Power Options...........................................................................................................................1-5

1.5 I/O Options................................................................................................................................1-5

1.6 Software Tools ..........................................................................................................................1-6

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 Unpacking Components................................................................................................2-4

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

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

2.3 Configuring the CPU/System Controller Board.........................................................................2-7

2.3.1 Setting DIP Switches on the CPU/System Controller Board ........................................2-8

2.3.2 Setting Jumpers on the CPU/System Controller Board..............................................2-10

2.3.3 General Wiring Guidelines..........................................................................................2-11

2.3.4 Wiring Power to the CPU/System Controller Board....................................................2-11

2.3.5 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board.............2-14

2.3.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller

Board .........................................................................................................................2-19

2.3.7 Connections to the Ethernet Port on the CPU/System Controller Board....................2-21

2.4 Optional Display/Keypads.......................................................................................................2-22

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 (HSC) / Discrete Inputs (DI) on TB4 of Process I/O

Board .........................................................................................................................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 Express.........................................................4-1

4.2 Communicating with the ControlWave Express........................................................................4-2

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

4.2.2 Collecting Data from the ControlWave Express............................................................4-2

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

Issued Mar-2011 Contents v

ControlWave Express Instruction Manual (CI-ControlWave Express)

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 Backup Battery.....................................................................5-6

5.2.4 Enabling / Disabling the Backup Battery.......................................................................5-7

5.3 General Troubleshooting Procedures.......................................................................................5-8

5.3.1 Checking LEDs .............................................................................................................5-8

5.4 WINDIAG Diagnostic Utility.....................................................................................................5-12

5.4.1 Available Diagnostics..................................................................................................5-13

5.5 Core Updump..........................................................................................................................5-16

5.6 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 Express Instruction Manual (CI-ControlWave Express)

Chapter 1 – Introduction

This manual focuses on the hardware aspects of the ControlWave Express Remote Terminal Unit (RTU). For information about the software used with the ControlWave Express, 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 Express and its

components and details the structure of this manual

In This Chapter

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

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

1.2

.........................................................1-3 CPU/System Controller Board

1.3

.................................................................................1-5 Power Options

1.4

.......................................................................................1-5 I/O Options

1.5

.................................................................................1-6 Software Tools

1.6

Features

ControlWave Express is designed to perform as the ideal platform for remote site automation, measurement, and data management in process control and manufacturing. Typical process inputs used by the ControlWave Express 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. When mounted in a suitable enclosure, you can operate the ControlWave Express in a protected outdoor environment.

ControlWave Express 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 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.)  Small size (enabling panel- or DIN-rail mounting installations)

 Two RS-232 and one RS-232/RS-485 asynchronous serial

communication ports

 Optional 10/100 MB Ethernet port

Revised Mar-2011 Introduction 1-1

 Optional Display/Keypad  Wide operating temperature range: (–40 to +70C) (–40 to 158F)  Battery backup for Static RAM (SRAM) and real-time clock.

ControlWave Express Instruction Manual (CI-ControlWave Express)

 Nonincendive Class I, Division 2 (Groups A, B, C and D)

Hazardous Location approvals when installed in a suitable enclosure

- 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 Express consists of a CPU/System Controller Board (SCB) with a piggy-back mounted LED board, an optional process I/O board, and a two-piece enclosure. The enclosure consists of a card-edge cover and a mounting chassis.

You can loosen the two thumb screws to remove the card edge cover and access the instrument field wiring.

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

Provides information on mounting the ControlWave Express 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 Express.

Provides information on service and troubleshooting procedures.

You can purchase an optional LCD display to provide runtime status information.

1-2 Introduction Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 1-1. ControlWave Express Component Identification

1.3 CPU/System Controller Board

The CPU (central processing unit) and System Controller Board (SCB) contains the ControlWave Express 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)

Revised Mar-2011 Introduction 1-3

ControlWave Express Instruction Manual (CI-ControlWave Express)

 transmit (TX) and receive (RX) LEDs for each communication port  2 MB of battery backed Static RAM (SRAM),  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.

No Yes Yes No

Yes No No Yes (same as

Solar

Regulator

Auxiliary

Power

Output?

RTD Input?

Connects to

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

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).

CPU Memory

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.

1-4 Introduction Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

FLASH Memory

The ControlWave Express 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 Express has 2 MB of static random access memory (SRAM). During power loss periods, SRAM enters data 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

1.5 I/O Options

You can power the ControlWave Express by:  a user supplied rechargeable 6/12V lead acid battery (used in

conjunction with a solar panel),

 other user-supplied battery systems  bulk (nominal +6Vdc, +12Vdc or +24Vdc) power supply.

If you connect solar panels to rechargeable battery systems to power the ControlWave Express, there is a secondary power input you can use to provide power if there is no power from the solar panel/battery system.

ControlWave Express 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:

Revised Mar-2011 Introduction 1-5

ControlWave Express Instruction Manual (CI-ControlWave Express)

Table 1-2. Process I/O Configurations

Type Discrete

A 2 4 2 2 B 2 4 2 2 3 C 2 4 2 2 3 1

1.6 Software Tools

Input / Output (DI/DO)

Discrete Input (DI)

Discrete

Output

(DO)

High Speed

Counter

(HSC)

Analog

Input (AI)

Analog Output

(AO)

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 Express. Figure 1-2 graphically presents the programming environment.

Figure 1-2. ControlWave Programming Environment

The tools which make up the programming environment include:

 ControlWave Designer is your load-building package. It offers

1-6 Introduction Revised Mar-2011

several different methods for you to create control strategy programs that run in your ControlWave Express. You can use pre-made function blocks, ladder logic, or structured languages. The resulting

ControlWave Express Instruction Manual (CI-ControlWave Express)

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).

 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).

 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).

Revised Mar-2011 Introduction 1-7

 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).

ControlWave Express Instruction Manual (CI-ControlWave Express)

Communication

Protocols

In addition to the Bristol Synchronous/Asynchronous Protocol (BSAP), ControlWave supports communications using:

Internet Protocol (IP) - You can use an Ethernet port or use a serial

port 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 Express Instruction Manual (CI-ControlWave Express)

Chapter 2 – Installation

This chapter discusses the physical configuration of the ControlWave Express, considerations for installation, and instructions for setting switches and jumpers.

In This Chapter

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

.............................2-3 Class I, Div 2 Installation Considerations

2.1.1

........................................................................2-3 Installation Overview

2.2

.......................................................2-4 Unpacking Components

2.2.1

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

2.2.2

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

2.2.3

...............................2-7 Configuring the CPU/System Controller Board

2.3

2-8 Setting DIP Switches on the CPU/System Controller Board

2.3.1

.....2-10 Setting Jumpers on the CPU/System Controller Board

2.3.2

.................................................2-11 General Wiring Guidelines

2.3.3

...........2-11 Wiring Power to the CPU/System Controller Board

2.3.4

2.3.5

2.3.6

2.3.7

..............................................................2-22 Optional Display/Keypads

2.4

Connections to RS-232 Serial Port(s) on the CPU/System

Controller Board

Connections to the COM3 (RS-485/RS-232) Serial Port on the

CPU/System Controller Board

Connections to the Ethernet Port on the CPU/System Controller

................................................................................2-21

Board

................................................................2-14

..........................................2-19

2.1 Site Considerations

When choosing an installation site, check all clearances. Ensure that the ControlWave Express is accessible for wiring and service. If present, make sure the optional display/keypad is accessible and visible.

The ControlWave Express comes in an enclosure/chassis that you can mount to a panel or a DIN-rail and is designed to operate in a protected Class I Division 2, Groups A, B, C & D environment with a

nonincendive rating (see Appendix A).

The enclosure consists of two pieces, the removable card edge cover and the main mounting chassis. You can loosen the two thumb screws to remove the card edge cover and connect instrument wiring.

See Figure 2-2 for a dimensional drawing of the NEMA enclosure.

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 Express Instruction Manual (CI-ControlWave Express)

Figure 2-1. ControlWave Express Component Identification

Specifications

for Temperature,

Humidity and

Vibration

 See document 420DS-6c

available on our website for detailed technical specifications for temperature, humidity, and vibration for the ControlWave Express.

 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 Express is not exposed to a level of vibration that exceeds that provided in the technical specifications.

2-2 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Caution

Placement of the ControlWave Express in Class 1, Division 2 (Group A, B, C, and D) hazardous locations requires that you install it in a NEMA 1 or better enclosure.

2.1.1 Class I, Div 2 Installation Considerations

Underwriters Laboratories (UL) lists the ControlWave Express 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

Express 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 Group A, B, C and D environments. When the ControlWave Express 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

Installing a ControlWave Express involves several general steps:

1. Unpacking, assembling, and configuring the hardware. This

includes:

a) Mounting the chassis on a panel or DIN-rail in an appropriate

b) Enabling the backup battery by setting jumper W3 on the

b) Setting switches and jumpers on the CPU/System Controller

enclosure. (See Section 2.2.2)

CPU/System Controller board to position 1 to 2. (See Section

2.3.2)

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 assem

bly) into the chassis.

Revised Mar-2011 Installation 2-3

d) Connecting communication cables. (See Sections 2.3.5, 2.3.6,

and 2.3.7) Wiring I/O. (See Section 3.3)

ControlWave Express Instruction Manual (CI-ControlWave Express)

f) Installing a ground wire between the enclosure and a known

good Earth ground. (See Section 2.2.3) g) Connecting the RTD probe (if required). (See Section 3.3.7) h) Wiring power to the unit. (See Section 2.3.4) i) 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 Express to an OpenBSI network.

7. Downloading the application-specific ControlWave project into the

ControlWave Express.

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 Unpacking Components

Packaging

Depending upon how you order it, the ControlWave Express may arrive pre-assembled, or in a number of separate boxes. If you did not order it pre-assembled, you must identify, unpack, and assemble the components. These include:

 ControlWave Express enclosure / mounting chassis  CPU/System Controller board and Process I/O board (one assembly)

 Removable card edge cover  RTD probe (optional)

2.2.2 Mounting the Housing

 You can position the ControlWave Express either vertically or

horizontally, but make sure the front of the assembly is visible and accessible for service, installation, and so on.

 Mount the unit to a panel directly, or to a 35mm DIN-rail using a

DIN-rail mounting bracket.

 Only connect power wiring after the unit is mounted and properly

grounded.

2-4 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

 I/O, power, and communication cabling enters the unit through a

slot on the left side of the removable card edge cover.

Refer to Figure 2-2 for mounting dimensions.

Figure 2-2. ControlWave Express Dimensions

Revised Mar-2011 Installation 2-5

ControlWave Express Instruction Manual (CI-ControlWave Express)

2.2.3 Grounding the Housing

The ControlWave Express enclosure does not include a ground lug. Instead, you must use one or more of the mounting screws to secure a ground cable to the unit. Once you have installed the unit, run a ground wire (#4 AWG max wire size) between one of the mounting screws for the enclosure to 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, crimp and solder the wire end

you will fasten to the ControlWave Express to a terminal ring/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.

2-6 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

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 CTS

Input

DCD 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 1

2 1 2

4 5

6 7 8

1 2 3 4 5 6 7 8

CR1

}

3 4 5 6 7 8

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 connected to connector J2!

Power

COM2

RS-232

COM3 RS-232 RS-485

Pulse

Input

RTD

Input

CAUTION:

COM1

RS-232

10/100

Base-T

Ethernet

Port

LCD/

Keypad

3 45678

1 2 34

RJ-45

CR1

RJ-45

3 2 1

T X

RJ-45

W12

W15

W18

COM1

RS-232

W13

W14

Ultra Low Power & Low Power

NOTE:

CPU/System Controller Bds. Don’t have an Ethernet Port.

Solar Pwr. In and Aux. Power Out

NOTE: J11 normally used for CW GFC and CW Express PAC only.

are not available on units e quipped with an Ethernet Port. Do Not Connect a 24V Solar Panel to Connector TB1-1 & TB1-2!

PG WD IDLE

STA6 STA5 STA4 STA3 STA2 STA1

TX1 RX1

TX2

RX2 TX3

RX3

SW3 - COM3 Config.

RS-485 Receiver Biasing & Termination

2-Wire, 4-Wire Selction

Emulation

Header

NOTE:

J7, J8, J9

Factory Use

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

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. Charging 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 TB1-1 & TB1-2!

MSP430

JTAG

Header

Shut-down Hysterisis

2-3 = 6V Power Supply

Shut-down Hysterisis Shut-down

2-3 = 6/24V Power Supply

Shut-down

2-3 = 6V Power Fail

2-3 = 6/24V Power Fail

Trip Point Hy sterisis Trip Point Hysterisis

Trip Point Trip Point

Trip Point

2-3 = COM3 RS-485

W18: COM1 connector selection 1 to 2 = J4 active

2 to 3 = J11 active

J5 - COM3 Piggy-back Radio Intf.

W17

PLD JTAG

Header

J3 - I/OBUS Intf. to CPU Board

W16

Figure 2-3. - CPU/System Controller Board Component I.D. Diagram

Revised Mar-2011 Installation 2-7

ControlWave Express Instruction Manual (CI-ControlWave Express)

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

2-3 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

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 all LEDs) OFF (Disable all LEDs except watchdog WD)

Table 2-2. CPU/System Controller Board Switch SW2

SW2 Setting Function Mode

Watchdog Enable

Lock/Unlock Soft Switches

Use/Ignore Soft Switches

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.

2-8 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

SW2 Setting Function Mode

7 8

Core Updump Causes the ControlWave Express to perform a core

updump, provided you have set the SW1 switches to allow recovery mode. Values are:

ON (Disables core updump; factory default) OFF Core updump

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.

Note: Table 2-3 describes switch settings for RS-485 port operation.

You may want to review Section 2.3.6 on RS-485 configuration

before you set these switches.

Table 2-3. RS-485 Configuration Switch SW3

Switch Setting

3 4

Revised Mar-2011 Installation 2-9

Function Mode

TX+ to RX+ Loopback / 2wire

TX- to RX- Loopback / 2wire

100 Ohm RX+ Termination 100 Ohm RX- Termination

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)

ControlWave Express Instruction Manual (CI-ControlWave Express)

Switch

Setting

5 6 7

Function Mode

N/A Not currently used N/A Not currently used 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:

2-10 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485

 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 Express 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

Caution

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 wh wiring connections.

Revised Mar-2011 Installation 2-11

ControlWave Express Instruction Manual (CI-ControlWave Express)

Power Supply

Current

Requirements

Depending upon the CPU type, the ControlWave Express accepts either a 6Vdc, 12Vdc or 24Vdc bulk power input. You can estimate the maximum current required for your ControlWave Express using the following equation:

Bulk +6/12/24 Vdc Supply Current = CPU/System Controller Board (with

Refer to Table 2-4 for ControlWave Express power requirements based

on the CPU type.

Table 2-4. ControlWave Express Bulk Power Requirements

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

options) + Process I/O Board + LCD display/keypad + optional external modem/radio

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

Caution

Terminal Block Connector TB1

Note: If your ControlWave Express includes an external modem or

radio, contact the radio/modem manufacturer for power consumption specifications.

If your ControlWave Express is configured to use a solar panel to charge a 7AH (6V or 12V) battery for power, NEVER CONNECT THE SOLAR PANEL/CHARGER WITHOUT ALSO CONNECTING THE BATTERY. Connections without the battery present can damage power supply components.

Unplug removable connector TB1 from the CPU/System Controller

board. We recommend you do not plug the connector back into the CPU

until the unit is already installed in the housing.

You can power the ControlWave Express using a bulk DC power supply using connections TB1-3 and TB1-4.

Nominal input source operating ranges for the DC power supply are:

 +6Vdc (+5.4Vdc to +16.0Vdc nominal operating range)  +12Vdc (+11.4Vdc to +16.0Vdc nominal operating range)  +24Vdc (+21.8Vdc to +28.0Vdc nominal operating range)

Not all ControlWave Express CPUs support all DC power supplies. Supported options are:

2-12 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

 14MHz Ultra Low Power CPU: Supports +6Vdc or +12Vdc

nominal power supply.

 33MHz Low Power CPU: Supports +12Vdc nominal or +24Vdc

nominal power supply.

 33MHz CPU with Ethernet: Supports +12Vdc nominal or +24Vdc

nominal power supply.

Alternatively, you can power low powered versions of the ControlWave Express using a solar panel connected to a user-supplied rechargeable 7AH (6V/12V) lead acid battery at connections TB1-1 and TB1-2.

TB1 connections are:

 TB1-1: (Solar Power IN+): Power from a 1W – 6V, 5W – 6V or

5W – 12V solar panel (internally wired to recharge a user-supplied

battery). Not available on units with Ethernet.

 TB1-2 = Ground (GND)  TB1-3 = Primary Power: Power from a user-supplied nominal

+6Vdc , +12Vdc or +24Vdc power supply, depending upon the CPU type.

 TB1-4 = Ground (GND)  TB1-5 = Auxiliary Power Out+: for an external radio or modem (if

supported). Not available on units with Ethernet.

 TB1-6 = Ground (GND) for Aux power out.

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

Figure 2-4. CPU/System Controller Board (TB1 & TB2) Power Wiring

Revised Mar-2011 Installation 2-13

ControlWave Express Instruction Manual (CI-ControlWave Express)

Terminal Block Connector TB2

The ControlWave Express includes an alternative power connecter, TB2, to provide power if none is available at TB1. For example, you can connect a bulk DC power supply to TB2 to handle situations where the solar panel/battery does not have sufficient power.

TB2 connections are:

 TB2-1 = Power Input  TB2-2 = Ground (GND)

2.3.5 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board

An RS-232 port provides point-to-point, half-duplex and full-duplex communications (for a maximum of 20 feet using data quality cable).

Your CPU includes two RS-232 ports and one port configurable for either RS-232 or RS-485 operation.

RS-232 COM

Port Names and

Connectors

RS-232 COM ports use different connector types.

Table 2-5. RS-232 Connectors

Connector Name # Pins and Type Notes

J4 COM1 9-pin male D-type Choice of active connector for COM1

determined by jumper W18.

J11 COM1 3-pin male Choice of active connector for COM1

determined by jumper W18. TB3 COM2 8-pin terminal block TB4 COM3 5-pin terminal block This port can be configured as either RS-232

or RS-485. See Section 2.3.6 for more

information.

RS-232

COM1/COM2

Port Cables

For the ControlWave Express, half-duplex communications use Modbus or BSAP protocol, while full-duplex communications use point-to-point

protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 2-6)

to connect with other devices (such as a PC, a printer, another ControlWave [except the CW_10/30/35]) when the ControlWave Express uses the full-duplex PPP protocol.

Note: You can configure the ControlWave Express as either a master

or slave node on a Modbus or BSAP network.

Figure 2-5 illustrates the CPU module’s male 9-pin D-type connector. for COM1. Use the content provided in Table 2-8 to determine pin

assignments for the COM1 and COM2 ports.

2-14 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 2-5. Male DB9 9-Pin Connector

Table 2-6. RS-232 COM1 and COM2 Port Connector Pin Assignment

1 DCD Data Carrier Detect Input 2 RXD Receive Data Input 3 TXD Transmit Data Output 4 DTR Data Terminal Ready Output 5 GND Power Ground 6 DSR Data Set Ready Input 7 RTS Request to Send Output 8 CTS Clear to Send Input 9 N/A

RS-232

Signal

RS-232 Description

Use the “null modem” cable for full-duplex (PPP protocol) communications when connecting a ControlWave Express to a PC. (See

top part of Figure 2-6.)

Table 2-7. RS-232 COM1 (J11) Alternate Connector Pin Assignment

1 GND Power ground 2 RXD Receive data input 3 TXD Transmit data output

RS-232

Signal

RS-232 Description

Revised Mar-2011 Installation 2-15

ControlWave Express Instruction Manual (CI-ControlWave Express)

CW or P

9-Pin Female

“D” Connector

5 = GND 4 = DTR

8 = CTS

3 = TXD 7 = RTS 2 = RXD 6 = DSR 1 = DCD

9-Pin Female

“D” Connector

5 = GND

8 = CTS 7 = RTS

4 = DTR

3 = TXD 2 = RXD

1 = DCD

J4 (COM1)

To P2 Pin-5 To P2 Pin-6 To P2 Pin-2

To P2 Pin-1 To P2 Pin-3 To P2 Pin-4 To P2 Pin-7

J4 (COM1)

To P2 Pin-5 To P2 Pin-1

To P2 Pin-2 To P2 Pin-3 To P2 Pin-4

vice

versa

vice

versa

9-Pin Fema

{

“D” Connec

1 = DCD 6 = DSR 2 = RXD 7 = RTS 3 = TXD 8 = CTS 4 = DTR

5 = GND

CW Express

9-Pin Female

{

“D” Connector

1 = DCD 2 = RXD

7 = RTS 3 = TXD

8 = CTS 4 = DTR

5 = GND

W Express

tor

TB3 (COM2)

1 = DCD 2 = RXD 3 = TXD 4 = DTR 5 = GND 6 = DSR 7 = RTS

8 = CTS

TB3 (COM2)

1 = DCD 2 = RXD 3 = TXD 4 = DTR 5 = GND

7 = RTS 8 = CTS

1 2 3 4 5 6

Configuration - D-Type)

7 8

1 2 3 4 5 6 7 8

Full-duplex

(Null Modem)

Cable

(PPP Protocol)

(Internal Radio/Modem

P/N

392843-01-3

Half-duplex

Cable

Figure 2-6. Full-duplex and Half-duplex Cable

Use the half-duplex cable (shown in the bottom part of Figure 2-6)

when connecting the ControlWave Express to another ControlWave series unit (again, with the exception of the CW_10/30/35).

When communicating with a Network 3000 series RTU 3305, RTU 3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of

the cables shown in Figure 2-7.

2-16 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

)

3305/3310/3330/3335/CW_10/30/35

9-Pin Male

“D” Connector

6 = CTS

5 = RTS

1 = DTR 2 = TXD

7 = DCD

4 = RXD 9= GND

To P2 Pin-1 To P2 Pin-2

To P2 Pin-4

To P2 Pin-3 To P2 Pin-5

J4 (COM1)

3305/3310/3330/3335/CW_10/30/35

9-Pin Male

“D” Connector

1 = DTR 6 = CTS

7 = DCD

5 = RTS

2 = TXD

4 = RXD 9 = GND

To P2 Pin-5

J4 (COM1)

To P2 Pin-2

To P2 Pin-3

W Expres

9-Pin Female

{

“D” Connector

1 = DCD

2 = RXD 7 = RTS

3 = TXD 8 = CTS

4 = DTR 5 = GND

CW Express

9-Pin Female

{

“D” Connector

1 = DCD 2 = RXD

7 = RTS 3 = TXD

8 = CTS 4 = DTR

5 = GND

TB3 (COM2)

1 = DCD 2 = RXD

3 = TXD 4 = DTR

5 = GND

7 = RTS 8 = CTS

1 2 3 4 5 6 7 8

TB3 (COM2)

1 = DCD 2 = RXD

3 = TXD 4 = DTR

5 = GND 6 = DSR 7 = RTS

8 = CTS

5 6

Full-duplex

Cable

(PPP Protocol

Half-dup

lex

Cable

To/From MODEM

To/From

RADIO

Figure 2-7. Full-duplex and Half-duplex Cable

Refer to Figure 2-8 when using COM2 of the ControlWave Express to

connect with an external modem or external radio.

To DCD

To RXD To TXD To DTR To GND

To RXD

To RTS

To TXD

To CTS

To GND

1 = DCD 2 = RXD

3 = TXD 4 = DTR

5 = GND

7 = RTS 8 = CTS

1 = DCD 2 = RXD

3 = TXD 4 = DTR

5 = GND 6 = DSR

7 = RTS 8 = CTS

3 4 5

6 7

1 2 3 4 5

6 7

PSTN Modem

Intf.

Cable

TB3

(COM2)

PL Modem

or Radio

Intf.

Cable

Revised Mar-2011 Installation 2-17

Figure 2-8. Connection from an External Modem/Radio to COM2 of the

ControlWave Express

ControlWave Express Instruction Manual (CI-ControlWave Express)

(

)

When interfacing to the COM3 port of a ControlWave, or the COM5 or

COM6 port a ControlWaveEXP unit, use the cable presented in Figure 2-9 along with one of the cables shown in Figure 2-6 or Figure 2-7.

RJ45 to DB9 Cable Ass’y .

(P/N 392844-01-0)

(COM3)

CWEXP

(COM5/6)

8-Pin

RJ45

Plug

(Looking into Connector Intf. Side of P1)

Pin 1 (Wht/Grn Stripe) to Pin 1 = DCD Pin 2 (Wht/Blu Stripe) to Pin 6 = DSR/RX+ Pin 3 (Blu/Wht Stripe) to Pin 2 = RXD/RXPin 4 (Grn/Wht Stripe) to Pin 7 = RTS Pin 5 (Wht/Org Stripe) to Pin 3 = TXD/TXPin 6 (Wht/Brn Stripe) to Pin 8 = CTS Pin 7 (Orn/Wht Stripe) to Pin 4 = DTR/TX+ Pin 8 (Brn/Wht Stripe) to Pin 5 = GND

Figure 2-9. Full-duplex and Half-duplex Cable

CW Express

J4 (COM1)

9-Pin Male

“D” Connector

Looking into Wire Terminal Side of P2

RS-232 Cable

Guidelines

Observe the following guidelines when constructing RS-232

communication cables:

 Ensure that DCD is high to transmit (except when dialing a modem)  Verify that each RS-232 transceiver has one active receiver while

disabled (in power down mode); connect the DCD signal to the active receiver.

 Set CTS to high to transmit.  If the port is set for full-duplex operation, RTS is always ON.  Ensure that DTR is always high when port is active; DTR enables

RS-232 transceivers.

Note: Control DTR using the PORTCONTROL function block and

the _Pn_AUTO_DTR system variable in your ControlWave

project. If you turn DTR off through these mechanisms, the

port remains off, even though hardware is fully configured.

 When port is set for half-duplex operation, CTS must go low after

RTS goes low.

 All RS-232 comm ports support RTS, DTR, CTS, DCD, and DSR

control signals.

 All RS-232 comm port I/O signals are protected by surge protectors.

2-18 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

2.3.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller Board

You use jumpers W12 through W16 to configure COM3 of the ControlWave Express for either RS-232 or RS-485 operation. See

Section 2.3.2 for information on these jumpers.

Table 2-8. COM3 RS-485 Connector (TB4) on CPU/System Controller Board

Connector Name # Pins and Type Notes

TB4 COM3 5-pin terminal block This port can be configured as

either RS-232 or RS-485.

RS-485 COM3

Port Cables

Table 2-9 shows connector pin assignments for COM3.

Note:

If you use COM3 for RS-232 operation, pins 1 and 4 do not apply.

Table 2-9. COM3 Connector Pin Assignment

Pin Signal Description

1 RXD+ Receive Data + input (Not applicable for

RS-232 usage) 2 RXD–/RXD Receive Data – Input 3 TXD–/TXD Transmit Data – Output 4 TXD+ Transmit Data + Output (Not applicable for

RS-232 usage) 5 Power Ground Ground

When serving as an RS-485 port, COM3 supports local network communications to multiple nodes up to 4000 feet away.

Since the RS-485 port is intended for network communications, refer to

Table 2-10 for the appropriate connections for wiring the master, first slave, and nth slave.

Essentially, the master and the first slave transmit and receive data on

opposite lines; all slaves (from the first to the nth) are paralleled (daisy-

chained) across the same lines. Wire the master node to one end of the RS-485 cable run using a 24-gauge paired conductor cable (such as a Belden 9843).

Revised Mar-2011 Installation 2-19

Note: ControlWave Express supports only half-duplex RS-485

networks.

ControlWave Express Instruction Manual (CI-ControlWave Express)

Table 2-10. RS-485 Network Connections

From Master To First Slave To nth Slave

TXD+ RXD+ RXD+

TXD– RXD– RXD– RXD+ TXD+ TXD+ RXD– TXD– TXD–

GND GND GND

To ensure that the “Receive Data” lines are in a proper state during inactive transmission periods, you must maintain certain bias voltage levels at the master and most distant slave units (end nodes). These end nodes also require the insertion of 100Ω terminating resistors to properly balance the network.

You must also configure switches at each node to establish proper network performance. Accomplish this by configuring switches listed so that the 100Ω termination resistors and biasing networks are installed at the end nodes and are removed at all other nodes on the network. You enable receiver biasing and termination (as well as 2-wire or 4-wire selection) using an 8-position DIP switch located on the CPU/System

Controller board. See Table 2-3 for more information.

2-20 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

2.3.7 Connections to the Ethernet Port on the CPU/System Controller Board

Caution

The RJ45 Ethernet port is connector (J1) located on the CPU/System Controller board. The board also has one RJ45 port (J2) for the optional Display/Keypad. Never or damage will result.

connect Ethernet to J2 (the Display/Keypad port)

The 33MHz ControlWave Express can support one Ethernet port. This port uses a 10/100Base-T RJ-45 modular connector (J1) that provides a shielded twisted pair interface to an Ethernet hub.

A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with port 8 having the capability to link either to another hub or to an Ethernet communications port). Both ends of the Ethernet twisted pair cable are equipped with modular RJ-45 connectors.

Looking into

receptacle

Figure 2-10. RJ-45 Ethernet Connector

These cables have a one-to-one wiring configuration as shown in Figure 2-11. Table 2-11 provides the assignment and definitions of the

8-pin 10/100Base-T connectors.

Figure 2-11. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)

Revised Mar-2011 Installation 2-21

Table 2-11. Ethernet 10/100Base-T CPU Module Pin Assignments

Pin Description

1 Transmit Data+ (Output) 2 Transmit Data– (Output) 3 Receive Data+ (Input) 4 Not connected 5 Not connected 6 Receive Data– (Input)

ControlWave Express Instruction Manual (CI-ControlWave Express)

Pin Description

7 Not connected 8 Not connected

Note: You can swap TX and RX at the hub.

You can connect two nodes in a point-to-point configuration without using a hub. However, you must configure the cable so that the TX+/Data pins connect to the RX+/- Data pins (swapped) at the opposite

ends of the cable (see Figure 2-12).

Figure 2-12. Point-to-Point 10/100Base T Ethernet Cable

The maximum length of one segment (CPU to hub) is 100 meters (328 feet). The use of Category 5 shielded cable is recommended.

2.4 Optional Display/Keypads

The ControlWave Express supports two optional display/keypads and a display without a keypad:

 A 2-button keypad (shown in the left of Figure 2-13)  A 25-button keypad (shown in the right Figure 2-13)

 Display only (no keypad) – (see Figure 2-14)

Figure 2-13. Optional 2-Button and 25-Button Keypads

2-22 Installation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 2-14. Display with No Keypad

Both keypads use the same 4-line by 20-character LCD displays.

The Display without a keypad has a 2-line display with 10 characters on the first line, and 6 characters on the second line. This display shows variable values on line 1, and variable names on line 2.

You connect the Display/Keypad or Display to the ControlWave Express using a cable, one end of which has an RJ-45 jack (connected into the RJ-45 equipped with two plugs. This cable connects between the RJ-45 display jack (J2) on the CPU/System Controller board and RJ-45 jack (J1) on the remote Display or remote Display/Keypad assembly. A potentiometer, provided on the keypad, allows you to set the contrast of the LCD display.

Note: For further information on the installation and use of the

optional keypads, refer to the ControlWave Display/Keypad Manual (D5135).

Revised Mar-2011 Installation 2-23

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ControlWave Express Instruction Manual (CI-ControlWave Express)

Chapter 3 – I/O Configuration and Wiring

This chapter discusses setting I/O configuration switches and jumpers and wiring I/O connections to the ControlWave Express.

In This Chapter

3.1 .......................................................................................3-1 I/O Options

3.2 ...........................................................................3-2 Process I/O Board

3.2.1 ..........................3-2 Setting Jumpers on the Process I/O Board

3.2.2 ..................3-2 Setting DIP Switches on the Process I/O Board

3.3 .........................................................................................3-4 I/O Wiring

3.3.1 Non-

3.3.2 Non-

3.3.3 Non-

3.3.4

3.3.5 Non-

3.3.6 Non-

3.3.7

3.3.8 ..............3-14 Connections to a Bristol Model 3808 Transmitter

Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O

..................................................................................3-6

Board

Isolated Discrete Outputs (DO) on TB3 of Process I/O

..................................................................................3-7

Board

Isolated Analog Inputs (AI) on TB6 of Process I/O

..................................................................................3-8

Board

Non-Isolated Analog Output (AO) on TB7 of Process I/O

..................................................................................3-9

Board

Isolated Pulse Counter/Discrete Inputs on TB5 of

CPU/System Controller Board

Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on

TB4 of Process I/O Board

Resistance Temperature Device (RTD) Inputs on CPU/System

Controller Board

................................................................3-12

..........................................3-10

.................................................3-11

3.1 I/O Options

Type Discrete

A 2 4 2 2

B 2 4 2 2 3

C 2 4 2 2 3 1

ControlWave Express 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 the 33MHz CPU with Ethernet also includes

a Resistance Temperature Device (RTD) probe.

In addition, three different versions of the optional process I/O board are available:

Table 3-1. Process I/O Configurations

Input / Output (DI/DO)

Discrete Input (DI)

Discrete

Output

(DO)

High Speed

Counter

(HSC)

Analog

Input (AI)

Analog Output

(AO)

Revised Mar-2011 I/O Configuration and Wiring 3-1

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.2 Process I/O Board

ControlWave Express may include an optional Process I/O board.

The Process I/O board mounts to the CPU/System Controller board using six nylon mounting posts.

To configure the Process I/O board, you need to set some switches and

jumpers. See Figure 3-1 for the location of the switches and jumpers.

3.2.1 Setting Jumpers on the Process I/O Board

The Process I/O board has several jumpers.

 JP1: AO output source (1-5V or 4-20mA):

o 1-to-2 Installed = 4-20mA analog output o 2-to-3 Installed = 1-5V analog output

 JP3: AO power source:

o 1-to-2 Installed = system power o 2-to-3 Installed = external power (+11 to +30 Vdc)

 JP4: AI field power configuration:

o 1-to-2 Installed = external 24Vdc power o 2-to-3 Installed = bulk input supply (system power)

 JP5: AI1 input type (1-5V or 4-20mA)

o 1-to-2 Installed = 4-20mA analog input o 2-to-3 Installed = 1-5V analog input

 JP6: AI2 input type (1-5V or 4-20mA)

o 1-to-2 Installed = 4-20mA analog input o 2-to-3 Installed = 1-5V analog input

 JP7: AI3 input type (1-5V or 4-20mA)

o 1-to-2 Installed = 4-20mA analog input o 2-to-3 Installed = 1-5V analog input

3.2.2 Setting DIP Switches on the Process I/O Board

The Process I/O board includes a single switch bank (SW1) to configure the frequency for the high speed counters (HSC), the source current for discrete inputs/counters, and the analog output.

Table 3-2. Process I/O Module Switch SW1

SW1 Function Mode

SW1-1

SW1-2

SW1-3

3-2 I/O Configuration and Wiring Revised Mar-2011

Frequency for High Speed Counter1 (HSC1)

Frequency for High Speed Counter2 (HSC2)

DI/HSC 2mA source current

OFF = 10 kHz (high speed) ON = 300 Hz (low speed) OFF = 10 kHz (high speed) ON = 300 Hz (low speed) OFF = disabled ON = enabled

ControlWave Express Instruction Manual (CI-ControlWave Express)

SW1 Function Mode

SW1-4

AO configuration

OFF = current ON = voltage

Revised Mar-2011 I/O Configuration and Wiring 3-3

Figure 3-1. Process I/O Board Component Identification Diagram

ControlWave Express Instruction Manual (CI-ControlWave Express)

Caution

3.3 I/O Wiring

Power down the ControlWave Express before you perform I/O wiring. Shut down any processes the ControlWave Express may be managing (or switch them over manually or handle with another controller). Perform any hardware configuration (wiring, jumper configuration, and installation) only when the ControlWave Express is powered down.

Before any I/O connections can become operational, you must use ControlWave Designer to configure and then download the application (project).

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

The ControlWave Express uses card edge terminal blocks to accommodate field wiring. You route the wires into the enclosure/chassis through a slot in the removable card edge cover.

ControlWave Express I/O uses compression-type terminals that accommodate up to #16 AWG wire. Insert the wire’s bared end (approx. ¼” max) into the clamp beneath 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 wires when making terminal connections. Slack makes the wires more manageable and helps

minimize mechanical strain on the terminal blocks.

Shielding and

Grounding

Use twisted-pair, shielded and insulated cable for I/O signal wiring to minimize signal errors caused by electromagnetic interference (EMI), radio frequency interference (RFI), and transients. When using shielded cable, ground all shields at only one point in the appropriate system. This prevents circulating ground current loops that can cause signal errors.

3-4 I/O Configuration and Wiring Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Revised Mar-2011 I/O Configuration and Wiring 3-5

Figure 3-2. Process I/O Board Wiring Diagrams

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board

Process I/O Board terminal block connector TB2 provides interface to four dedicated non-isolated Discrete Inputs DIs – DI1 through DI4. In addition, terminal block connector TB3 provides two additional points that can serve as either discrete inputs or discrete outputs (DI5 and DI6 when wired as inputs).

Table 3-3. Non-Isolated DI General Characteristics

Wiring

Type Number

Supported

Discrete Inputs (DI)

4 on TB2

(optionally

2 on TB3)

See Figure 3-2 for wiring diagrams.

Characteristics

 Supports dry contact inputs pulled

internally to 3.3 Vdc when field input is open.

 Source current for DI1 to DI4 of either

60 μA or 2 mA based on switch SW1-

3 setting. See Table 3-1.

 Source current for DI5 to DI6 of either

200 μA or 2.2 mA based on switch

SW1-3 setting. See Table 3-1.

 15 ms input filtering

Software Configuration

To use data from these DIs you must include a CWM_EIO board in

your ControlWave project using ControlWave Designer’s I/O

Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced

users, the I/O map for this board.

Note: You must specify whether a discrete input/output is a DI or a

DO in ControlWave Designer’s I/O Configurator by

configuring a DI pin or a DO pin.

3-6 I/O Configuration and Wiring Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O Board

Process I/O Board terminal block connector TB3 provides interface to two dedicated non-isolated discrete outputs DOs – DO1 and DO2. In addition, terminal block connector TB3 provides two additional points that can serve as either discrete inputs or discrete outputs (DO3 and DO4 when wired as outputs).

Table 3-4. Non-Isolated DO General Characteristics

Wiring

Type Number

Supported

Discrete Outputs (DO)

2 to 4 (on

TB3)

See Figure 3-2 for wiring diagrams.

Characteristics

 Supports 30V operating range. Can

sink 400 mA max at 30Vdc (open drain).

 Maximum output frequency of 20Hz.

 Surge protection between signal and

ground.

Software Configuration

To use data from these DOs you must include a CWM_EIO board in

your ControlWave project using ControlWave Designer’s I/O

Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced

users, the I/O map for this board.

Note: You must specify whether a discrete input/output is a DO or a

DI in ControlWave Designer’s I/O Configurator by

configuring a DO pin or a DI pin.

Revised Mar-2011 I/O Configuration and Wiring 3-7

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board

Process I/O Board terminal block connector TB6 provides interface to three single-ended analog inputs (AIs).

Table 3-5. Non-Isolated AI General Characteristics

Type Number Supported Characteristics

 Jumper-selectable using JP5, JP6, and

JP7 for either 4-20mA or 1-5V operation.

 Jumper JP4 determines whether AI

field power comes from system power (bulk input supply applied to TB1-3 and TB1-4 on the CPU/System Controller Board) or the external loop power source connected to TB7-3 and TB7-4 on the Process I/O board.

 2 Hz low pass filter for each AI.

 Surge Suppression.

 Self calibrating.

Setting Jumpers

Analog Inputs (AI)

3 (on TB6)

See Section 3.2.1 for details on setting jumpers.

Wiring

Software Configuration

Each AI includes three terminals (field power, AI# and DGND). See

Figure 3-2 for wiring diagrams. If using the ControlWave Loop Power Supply, see document PIP-ControlWave-LS.

Notes:

 You must connect cable shields associated with AI wiring to the

ControlWave Express chassis ground.

 Multiple shield terminations require you to supply a copper ground

bus. You must connect the ground bus to the ControlWave Express chassis ground using up to a #4 AWG wire size. The ground bus must accommodate a connection to a known good Earth ground (in lieu of a direct connection from the ControlWave Express chassis ground) and to all AI cable shields.

 Use an appropriate terminal lug for shield wires and secure them to

the copper bus using industry rugged hardware (screw/bolt, lock washer and nuts).

To use data from these AIs you must include a CWM_EIO board in

your ControlWave project using ControlWave Designer’s I/O

Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced

users, the I/O map for this board.

3-8 I/O Configuration and Wiring Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board

Process I/O Board terminal block connector TB7 provides interface to a single analog output (AO).

Table 3-6. Non-Isolated AO General Characteristics

Setting Jumpers

Type Number

Supported

Analog Output (AO)

1 (on TB7)

See Section 3.2.1 for details on setting jumpers.

Characteristics

 Supports either 4-20mA or 1-5V

operation. Selection using jumper JP1 and switch SW1-4.

 Jumper JP3 determines whether AO

field power comes from system power (nominally 12 or 24V from bulk input supply applied to TB1-3 and TB1-4 on the CPU/System Controller Board) or from an external 24V power source (+11 to +30Vdc connected to TB7-3 and TB7-4) such as the ControlWave Loop Power Supply.

 Maximum external load you can

connect to a 4-20mA output is 250 ohms for an external 11V power source or 650 ohms for an external 24V power source.

 Maximum external load current for the

1-5V output is 5 mA (with an external 11 to 30 V power source.)

 Self calibrating.

Wiring

See Figure 3-2 for wiring diagrams. If using the ControlWave Loop Power Supply, see document PIP-ControlWave-LS.

Note: If your ControlWave Express uses 6V bulk power, you

Software Configuration

must provide external power for the AO.

To use data from this AO you must include a CWM_EIO board in

your ControlWave project using ControlWave Designer’s I/O

Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced

users, the I/O map for this board.

Revised Mar-2011 I/O Configuration and Wiring 3-9

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Board

CPU/System Controller Board connector TB5 provides interface to two internally sourced open collector pulse counter/discrete inputs (Pulse1 and Pulse2) with a 1 second scan rate. Pulse counters act like high speed counters but cannot function with contact relays because they lack contact debounce circuitry.

Table 3-7. Non-Isolated Pulse Counter/Discrete Inputs General Characteristics

Wiring

Type Number

Supported

Pulse Counter / Discrete Inputs

2 on TB5 of

CPU/Syste

m Controller

board

Pulse counter/discrete inputs are field driven by open collector circuits and are sourced for 3.3V (internally) with a 200μA source current. See

Figure 3-3for information on the open collector wiring arrangement.

Characteristics

 Signal conditioning circuitry provides

20 microsecond filtering.

 Surge suppression.

 Maximum input frequency for each

pulse counter/discrete input circuit is

10 KHz.

Software Configuration

Figure 3-3. Pulse Input Wiring Diagram

To use data from these pulse counter/discrete inputs you must include

a CWM_ECPU board in your ControlWave project using

ControlWave Designer’s I/O Configurator, and then configure it. See

the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that

describes, for advanced users, the I/O map for this board. To read a DI value, look at the appropriate offset for the _STATE variable for the board.

3-10 I/O Configuration and Wiring Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on TB4 of Process I/O Board

Process I/O Board connector TB4 provides interface to two internally sourced single-ended high speed counter/discrete inputs (HSC1 and HSC2).

Table 3-8. Non-Isolated High Speed Counter/Discrete Inputs General Characteristics

Type Number

High Speed Counter / Discrete Inputs

Supported

2 on TB4

of Process

I/O board

Characteristics

 Surge suppression and signal

conditioning.

 HSCs can use dry contacts or open

collector field circuits.

 High speed counter switch-selectable

frequency of 10kHz or 300Hz.

 Sourced from 3.3Vdc and switch

selectable for a source current of 200μA (switch SW1-3 = OFF) or

2.2mA (switch SW1-3 = ON). Note:

These switches affect all DIs and HSCs.

Wiring

Switch Settings

Software Configuration

See Figure 3-2 for wiring diagrams.

See Table 2-1 for details on setting switches.

To use data from these high speed counter/discrete inputs you must

include a CWM_EIO board in your ControlWave project using

ControlWave Designer’s I/O Configurator, and then configure it. See

the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that

describes, for advanced users, the I/O map for this board. To read a DI value, look at the appropriate offset for the _STATE variable for the board.

Revised Mar-2011 I/O Configuration and Wiring 3-11

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board

CPU/System Controller Board connector TB6 provides connection to a 3-wire 100 ohm platinum bulb RTD (using the DIN 43760 curve).

Wire the RTD according to Table 3-9 and Figure 3-4 and Figure 3-5. In

this configuration, the return lead connects to the RTD- terminal and the two junction leads (Sense and Excitation) connect to the RTD+ and RTD EXC terminals.

Never ground the RTD cable shield at both ends or allow it to come in

Caution

contact with metallic/conductive conduit because multiple ground paths can cause RTD input errors.

Table 3-9. RTD Connections to CPU/System Controller Board Connector TB6

TB6 Pin Signal Function

1 RTD EXC Reference

2 RTD+ Sense

3 RTD- Return

Figure 3-4. 3-Wire RTD Temperature Input Wiring

3-12 I/O Configuration and Wiring Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Installing the RTD

Probe

Figure 3-5. RTD Probe Installation/Removal Diagram

Software Configuration

To install the RTD probe, screw the fitting body into the thermowell with a 7/8” open-end wrench. While you apply pressure against the sheath to force the tip of the RTD probe into the bottom of the thermowell (so that the probe tip is in contact with the bottom of the thermowell), tighten the 9/16” nut using an open-end wrench against the 7/8” fitting body.

To use data from the RTD you must include a CWM_ECPU board in

your ControlWave project using ControlWave Designer’s I/O

Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced

users, the I/O map for this module.

Revised Mar-2011 I/O Configuration and Wiring 3-13

ControlWave Express Instruction Manual (CI-ControlWave Express)

3.3.8 Connections to a Bristol Model 3808 Transmitter

You can connect a Bristol 3808 transmitter (digital) to the ControlWave Express through either an RS-232 or RS-485 port. Communication schemes and cable lengths determine the type of communication port you need to use. In general RS-232 communications require that you place the 3808 transmitter within 25 feet of the ControlWave Express (local communications). You can use RS-485 communications to reach transmitters up to 4000 feet away (remote communications).

Figure 3-6 details RS-232 wiring connections required between the

ControlW

ave Express and the 3808 transmitter.

Figure 3-6. 3808 Transmitter to ControlWave Express RS-232 Comm. Cable Diagram

Figure 3-7 details RS-485 wiring connections required between the

ControlWave Express and the 3808 transmitter.

Note: For loopback and termination control, use switch SW3 on the

3-14 I/O Configuration and Wiring Revised Mar-2011

CPU/System Controller board to configure COM3.

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 3-7. 3808 Transmitter to ControlWave Express RS-485 Comm. Cable

You can connect up to two 3808 transmitters to a ControlWave Express

using a half-duplex RS-485 network. See Figure 3-8 for an illustration

of this type of network.

Figure 3-8. ControlWave Express to 3808s - RS-485 Network Diagram

Revised Mar-2011 I/O Configuration and Wiring 3-15

This page is intentionally left blank

ControlWave Express Instruction Manual (CI-ControlWave Express)

Chapter 4 – Operation

This chapter provides general operational details for using the ControlWave Express.

In This Chapter

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

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

4.2

4.2.1

4.2.2

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

4.3

..................................................4-3 Creating and Maintaining Backups

4.4

4.4.1

4.4.2

4.4.3

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

...................4-2 Collecting Data from the ControlWave Express

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

.................4-5 Saving Flash Configuration Parameters (*.FCP)

...................................................................4-6 Backing up Data

WARNING

EXPLOSION HAZARD Substitution of components may impair suitability for use in Class I,

Division 2 environments. When the ControlWave Express 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.

4.1 Powering Up/Powering Down the ControlWave Express

The ControlWave Express receives power either from a solar panel and user-supplied battery or from an external bulk power supply attached using connector TB1 on the CPU/System Controller board. It can also receive power through alternate connector TB2 on the same board. Chapter 2 includes instructions for wiring power to the ControlWave Express. See Figure 2-3 for the location of these connectors.

Power Up

To apply power to the ControlWave Express, plug in connectors TB1 and optionally TB2 on the CPU/System Controller board. If your ControlWave project resides in flash memory, the project will load into SRAM and begin execution. Depending upon the setting of the SRAM control switch, retain variable values may load as well.

Caution

Revised Mar-2011 Operation 4-1

When you disconnect power from the ControlWave Express, your running control strategy is erased from SRAM, as is any process data not stored in retention mode. When configured for retention and the backup battery remains good, SRAM stores the last states of all I/O points, audit/archive data not residing in FLASH, the values of all variables marked RETAIN, the values of variables stored in the static memory area, and any pending unreported alarm messages.

ControlWave Express Instruction Manual (CI-ControlWave Express)

Power

Down

To remove power from the ControlWave Express, unplug connectors TB1 and TB2 from the CPU/System Controller board.

4.2 Communicating with the ControlWave Express

You communicate to the ControlWave Express by connecting a cable between a port on your PC workstation and one of the ControlWave Express ports.

The port at the PC workstation must match the configuration of the ControlWave Express port.

4.2.1 Default Comm Port Settings

As delivered from the factory, ControlWave Express communication ports have default settings. Table 4-1 details these defaults.

Table 4-1. Default Comm Port Settings (by PCB)

Port PCB Default Configuration

COM1 CPU RS-232; 115.2 Kbps using BSAP or ControlWave Designer

protocol.

COM2 CPU RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or

ControlWave Designer protocol

COM3 CPU RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or

ControlWave Designer protocol. Intended for use with Bristol 3808 transmitters. You use jumpers W12 through W16 to configure COM3 for either RS-232 or RS-485

Note: You can re-enable the factory comm settings at any time by

setting switch 3 on the CPU module’s SW3 to “OFF.”

Ethernet

Using an optional Ethernet port (located on the CPU module), you can connect either directly or through a network to a PC equipped with an Ethernet port. The default IP address and mask for the Ethernet port is:

 ETH1 IP Address: 10.0.1.1 IP Mask: 255.255.255.

4.2.2 Collecting Data from the ControlWave Express

OpenBSI utilities such as DataView, Data Array Save/Restore and Harvester allow you to collect real time data (values of variables, array values, alarm messages) and historical data (audit records, archive files) from the ControlWave. See the OpenBSI Utilities Manual (D5081) for details. SCADA software such as OpenEnterprise can then present this data to an operator in the form of graphical displays and reports.

4-2 Operation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

4.3 Creating and Downloading an Application (ControlWave Project)

Your ControlWave Express executes an application called a ControlWave project. You create the project using PC-based ControlWave Designer software. Instructions for creating a ControlWave project are beyond the scope of this manual. Please refer to the following sources for information:

 Getting Started with ControlWave Designer (D5085)  ControlWave Designer Programmer’s Handbook (D5125)  ControlWave Designer online help

You must connect the Express to a PC running ControlWave Designer software and OpenBSI software.

Note: You can download an application either from ControlWave

Designer or from the OpenBSI 1131 Downloader.

1. Connect a serial cable between your PC and COM2 of the

ControlWave Express.

2. Define the ControlWave project in ControlWave Designer, and

set communication and configuration parameters.

3. Download the project according to instructions in the

Downloading section of the ControlWave Designer Programmer's Manual (D5125).

4.4 Creating and Maintaining Backups

You should always maintain a current backup of each ControlWave project and keep it in a safe place, preferably in a location physically separate from the controller.

The reason we recommend you keep backup files is that if a disaster occurs that damages or destroys your ControlWave hardware (flood, lightning strike, etc.) you don’t want to also lose its control strategy software programs. Otherwise, when the unit is repaired or replaced, you’d have to create a new ControlWave project from scratch, which might take a lot longer than replacing a few damaged modules.

Caution

Always maintain a backup copy of your ControlWave project in a safe place.

Anytime you modify your ControlWave project, be sure to create a new backup of the new project.

Revised Mar-2011 Operation 4-3

ControlWave Express Instruction Manual (CI-ControlWave Express)

Notes:

 You may find it useful to maintain more than one backup copy in

case the backup media itself fails, for example, a CD-ROM becomes unreadable because it melted in the sun or a thumb drive fails because someone spilled coffee on it.

 If you don’t keep more than one backup copy, it’s a good idea to

periodically test your backup copy to verify that the media has not failed.

4.4.1 Creating a Zipped Project File (*.ZWT) For Backup

Note: The .zwt file is a complete backup of your entire project

including code, comments and graphics. It may be stored on your PC or removable storage media. It may also be downloaded and archived to ControlWave Flash memory where it may be uploaded at a later time for editing.

With your current ControlWave project open in ControlWave Designer, perform the following steps:

1. Click File > Save Project As / Zip Project As.

Figure 4-1. Saving a Backup of Your Project

2. In the “Save/Zip project as” dialog box, specify a project name in

3. In the Save as type field, choose Zipped Project Files (*.zwt).

4. In the Zip Options area, select which additional files you want to

4-4 Operation Revised Mar-2011

the File name field. In Figure 4-1 we chose the name mynewproj.

include in the zwt file. Other than increasing the file size of the zwt, it doesn’t hurt to check any or all of these options.

ControlWave Express Instruction Manual (CI-ControlWave Express)

Zip Option Description Zip User-Libraries

Zip Frontend-Code If you selected Zip User-Libraries you

Zip FW-Libraries

Zip Pagelayouts

If you created your own user-defined functions or function blocks, you must select this to preserve them.

should also select this option to include compiled code for libraries in your zip file. Otherwise, you need to re-compile your user libraries with the project when you unzip the zwt.

This includes firmware libraries, such as ACCOL3.FWL in your zwt.

This includes pagelayout information for printing your project, as well as graphical elements used in certain 1131 languages.

5. Click Zip and a progress bar displays the percent complete of the

zipping process.

6. When the zip process completes, you’ll see a message box reporting

successful completion. Click OK.

7. Copy the resulting zwt file to backup media (CD-ROM, thumb

drive, etc.) If you ever need to restore the project, just open the zwt file in ControlWave Designer, load libraries as needed, then compile the project and download it into the ControlWave.

4.4.2 Saving Flash Configuration Parameters (*.FCP)

You must establish communications with the ControlWave Express using NetView, LocalView, or TechView before you can run the Flash Configuration utility.

Note: For detailed information on using the Flash Configuration utility,

see Chapter 5 of the OpenBSI Utilities Manual (D5081).

1. Start the Flash Configuration utility. To do this in NetView or

LocalView, right-click on the icon for this ControlWave and choose RTU > RTU Configuration Parameters.

Revised Mar-2011 Operation 4-5

ControlWave Express Instruction Manual (CI-ControlWave Express)

To do this in TechView, click Operations > Access Flash Parameters or click the Access Flash icon

2. Depending upon how your system is configured, the Flash

Configuration – Loading Options dialog box may open. If it does, choose Load from device and wait for the utility to retrieve all parameters from the ControlWave Express, then skip to step 4, otherwise, just proceed to step 3.

3. Click and wait for the utility to retrieve all

parameters from the ControlWave.

4. Click and specify a name for your FCP file,

then click Save. When the status line indicates successful completion, your FCP file in done.

5. Copy the resulting FCP file to backup media (CD-ROM, thumb

drive, etc.) If you ever need to restore the FCP parameters to the controller, establish communications with the unit, start the Flash Configuration utility, and load the FCP file using the Read from FCP button, then choose the Write to RTU button.

4.4.3 Backing up Data

You can back up certain types of data and restore it if needed. There are other types of data that you can only collect, but you cannot restore.

 If you have certain variables that represent tuning parameters

(setpoints, for example) you can use tools such as the OpenBSI DataView recipe feature to save those values to a recipe file on the PC, and then restore them at a later time. See Chapter 8 of the OpenBSI Utilities Manual (D5081).

 You can store the contents of read/write data arrays using the

OpenBSI Data Array Save/Restore utility. See Chapter 13 of the OpenBSI Utilities Manual (D5081).

 You can collect alarms, and historical data (audit records, archive

files) but you cannot restore alarms or historical data.

4-6 Operation Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Chapter 5 – Service and Troubleshooting

This chapter provides general diagnostic and test information for the ControlWave Express, as well as some common maintenance procedures.

In This Chapter

5.1 ........................................................................5-2 Upgrading Firmware

..............................................5-5 Removing or Replacing Components

5.2

............................................5-5 Accessing Modules for Testing

5.2.1 Removing/Replacing the CPU/System Controller Board

and the Process I/O Board

.................................................5-5

............................5-6 Removing/Replacing the Backup Battery

..............................5-7 Enabling / Disabling the Backup Battery

.....................................................................5-8 Checking LEDs

.........................................................5-13 Available Diagnostics

Equipment

5.2.2

5.2.3

5.2.4

.............................................5-8 General Troubleshooting Procedures

5.3

5.3.1

...........................................................5-12 WINDIAG Diagnostic Utility

5.4

5.4.1

................................................................................5-16 Core Updump

5.5

.........................................................................5-17 Calibration Checks

5.6

You need the following equipment to perform the procedures described in this chapter:

To run diagnostics software:

 PC with WINDIAG software, and either OpenBSI LocalView,

NetView, or TechView for communications

 Null modem interface cable  Loop-back plug (See Figure 5-10 and Figure 5-11.)

To perform firmware upgrades:

 Null modem interface cable  PC with the following software:

o OpenBSI LocalView o OpenBSI System Firmware Downloader and either NetView,

LocalView, or TechView for communications.

o HyperTerminal (included in Windows®)

To replace the SRAM backup battery:

 Tweezers or needle-nose pliers

Note: When you service a ControlWave Express on site, we

recommend that you close down (or place under manual control) any associated processes. This precaution prevents any processes

from accidentally running out of control when you conduct tests.

Revised Mar-2011 Service & Troubleshooting 5-1

ControlWave Express Instruction Manual (CI-ControlWave Express)

Caution

Harmful electrical potentials may still exist at the field wiring terminals even though the ControlWave Express power source may be turned off or disconnected. Do not attempt to unplug termination connectors or perform any wiring operations until you verify that all associated power supply sources are turned off and/or disconnected.

Always turn off any external supply sources for externally powered I.O circuits before you change any modules.

5.1 Upgrading Firmware

The ControlWave Express ships from the factory with system firmware already installed. If you need to upgrade the system firmware (stored in Flash memory) to acquire new functionality or restore firmware, you can use one of several methods.

System

Firmware

Downloader

Use this tool to download system firmware to an unattended remote ControlWave Express. To use this utility, you must set CPU/System

Controller board switch SW2-6 ON (the factory default position).

Note: For further information and detailed use instructions, refer to

Appendix J of the OpenBSI Utilities Manual (D5081).

LocalView

HyperTerminal

One of the standard OpenBSI utilities, LocalView requires OpenBSI version 5.1 (or newer). If you have an older version of OpenBSI, use HyperTerminal.

Note: For further information and detailed use instructions, refer to the

Flash Mode section of Chapter 5 of the OpenBSI Utilities Manual (D5081).

HyperTerminal is a communications utility program included with Microsoft® Windows® XP.

Notes:

 If you are using a version of OpenBSI older than 5.1, or do not have

OpenBSI software, you can only perform a firmware upgrade using HyperTerminal.

 While HyperTerminal is included in Microsoft® Window® XP,

some newer versions of Window® do not include it.

 The screens shown here may appear different depending upon the

version of HyperTerminal you use.

 HyperTerminal requires *.BIN files; newer ControlWave firmware

5-2 Service & Troubleshooting Revised Mar-2011

upgrade files use *.CAB files. In cases such as those, you should use the Remote System Firmware Downloader.

ControlWave Express Instruction Manual (CI-ControlWave Express)

1. Connect a null modem cable between COM1 of the

ControlWave Express and any RS-232 port on the associated PC.

2. Click Start > Programs > Accessories > Communications >

HyperTerminal

3. If using HyperTerminal for the first time, set the communication

properties (for the PC port) via the Properties Menu as follows: Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop

bits: = 1, and Flow control: = None and then click OK.

4. Set CPU/System Controller board switch SW1-3 ON (ON =

Force Recovery).

5. Apply power; to the ControlWave Express. The resident BIOS

initializes and tests the hardware, this process is referred to as POST (Power On Self Test). Unless there is a problem, status LEDS show status code 10 (LED #5 ON). If you see a different

status code, see Section 5.3.1.

6. From the HyperTerminal Mode menu (Figure 5-1), press the F

key to enter FLASH download. A message warns that the

FLASH is about to be erased; press the Y key at the prompt. The

screen displays dots as the system erases the flash memory; this could take a few minutes.

Revised Mar-2011 Service & Troubleshooting 5-3

Figure 5-1. HyperTerminal Mode Menu

7. When the FLASH is ready for download, HyperTerminal

repeatedly displays the letter C on the screen. In the

HyperTerminal menu bar click Transfer > Send File (see Figure 5-2).

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 5-2. HyperTerminal (Ready to Download)

8. In the Send File dialog box (see Figure 5-3), select 1KXmodem

for the protocol, enter the filename of the appropriate .bin file in

the format “E1Sxxxxx.bin” or “E3Sxxxxxx.bin” (where E1S

refers to 14 MHz CPUs, and E3S refers to 33 MHz CPUs and

xxxxx varies from release to release) and click Send to start the flash upgrade (see Figure 5-4). When you see the

HyperTerminal Mode Menu again, it means the download has completed.

9. Exit HyperTerminal and power down the ControlWave Express.

If desired, you can disconnect the null modem cable between the

ControlWave Express and the PC.

10. Set switch SW1-3 to the OFF position (OFF = Recovery Mode

Disabled).

11. Restore power to the ControlWave Express.

5-4 Service & Troubleshooting Revised Mar-2011

Figure 5-3. Send File dialog box

ControlWave Express Instruction Manual (CI-ControlWave Express)

CWEXP01

E1S0410.bin

Figure 5-4. HyperTerminal (Download in Progress)

5.2 Removing or Replacing Components

This section provides information on accessing ControlWave Express components for testing, as well as removal/replacement procedures.

Field repairs to the ControlWave Express are strictly limited to the

Caution

replacement of complete boards. Replacing board components constitutes tampering and violates the product warranty. Return defective boards or housings to the factory for authorized service.

5.2.1 Accessing Modules for Testing

Only technically qualified personnel should test and/or replace ControlWave Express components. Read completely the disassembly and test procedures described in this manual before starting. Any damage to the ControlWave Express resulting from improper handling or incorrect service procedures is not covered under the product warranty agreement. If you cannot properly perform these procedures, obtain authorization and then return the device to the factory for evaluation and repairs.

5.2.2 Removing/Replacing the CPU/System Controller Board and the Process I/O Board

Revised Mar-2011 Service & Troubleshooting 5-5

Use this procedure to remove or replace the CPU/System Controller board and the Process I/O board.

1. If the ControlWave Express is running, place any critical control

processes under manual control.

ControlWave Express Instruction Manual (CI-ControlWave Express)

2. Shut down the ControlWave Express by disconnecting the

power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2).

3. Loosen the two thumb screws and remove the removable card

edge cover. Also loosen the captive fastener that secures the CPU/System Controller and Process I/O board assembly in the

housing. See Figure 2-1 to locate these components.

4. Disconnect all removable card edge connectors from the

CPU/System Controller board and the Process I/O board. Label or otherwise identify them so you can easily re-connect them later.

5. If present, disconnect the display/keypad from connector J2 on

the CPU/System Controller board.

6. Carefully slide the board assembly out of the mounting

chassis/enclosure.

7. If you need to replace either the CPU/System Controller board

or Process I/O board, you need to separate the two boards. Use a pair of needle-nosed pliers to squeeze the pair of tabs associated with each of the six nylon mounting posts, while gently pulling the CPU/System Controller board away from the Process I/O board. Carefully unplug the boards from their interface connectors. Align the replacement boards with each other and press them together so that the interface connectors and mounting posts properly mate; then squeeze together so that the mounting post tabs capture the CPU/System Controller board.

8. To install the replacement boards, power must be off. Align the

boards (assembly) with the mounting chassis/enclosure so that the Process I/O board is adjacent to the bottom of the unit and then slide the assembly into the unit.

9. Replace all cables removed in steps 2 through 5.

10. Replace the removable card edge cover and tighten the two

thumb screws. Apply power and test the unit.

5.2.3 Removing/Replacing the Backup Battery

Note: The CPU/System Controller board draws power from the battery

only if the board loses power. The system SRAM has a standby current draw of 20 μA maximum for each part plus 2 μA for the real time clock. For a ControlWave Express containing 2MB of SRAM, a worst-case current draw of 42 μA allows a battery life of approximately 9,000 hours. This means you should not need to replace a battery until the ControlWave Express has been in

service for an extended period (normally many years).

5-6 Service & Troubleshooting Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

The CPU/System Controller board accommodates a 3 V, 300 mA lithium coin cell backup battery housed in a coin-cell socket (S1). A supervisory circuit on the CPU switches to battery power when the regulated 3.3 Vdc falls out of specification. The battery then provides backup power for the real-time clock (RTC) and the system SRAM on the CPU/System Controller board.

Note: If the real-time clock loses its battery backup, the ControlWave

system variable _QUEST_DATE turns ON. You can monitor

this to generate an alarm. See the System Variables section of the ControlWave Designer Programmer's Handbook (D5125) for

more information.

Caution

Removing /

Replacing the

Battery

You lose SRAM contents when you remove the backup battery.

If you replace a backup battery, wait at least one minute before repowering the system. This enables the SRAM to completely discharge.

After you install the new battery, ensure that you have placed jumper W3 on pins 1-2 (to enable the battery).

1. If the ControlWave Express is running, place any critical control

processes under manual control.

2. Remove power from the ControlWave Express.

3. Remove the CPU/System Controller board assembly from the

housing.

4. To remove the lithium battery, gently pry up the tab holding the

battery in the coin cell socket and remove the battery with a pair of tweezers or needle-nosed pliers. Install the replacement battery.

5. Replace the CPU/System Controller board assembly in the housing.

6. Re-connect power to the ControlWave Express.

7. Once the battery has been replaced, the unit executes its Flash-

based application (“boot project”) at power-up, but all of the current process data is lost. At power-up, the ControlWave Express acts as though it had just been booted and reverts back to the initial values specified in its application.

5.2.4 Enabling / Disabling the Backup Battery

Enabling

Revised Mar-2011 Service & Troubleshooting 5-7

For maximum shelf life, the CPU/System Controller board ships from the factory with the installed lithium backup battery disabled. You must enable it when you install the CPU/System Controller board.

To enable the battery, install jumper W3 on pins 1-2.

ControlWave Express Instruction Manual (CI-ControlWave Express)

Disabling

For maximum shelf life, you can isolate the battery from the circuit by placing jumper W3 on pins 2-3.

5.3 General Troubleshooting Procedures

This section presents some procedures to troubleshoot problems with the Express.

5.3.1 Checking LEDs

The ControlWave Express includes light emitting diodes (LEDs) that provide operational and diagnostic functions.

These LEDs are visible through the chassis cover window.

LEDs visible through window

Figure 5-5. ControlWave Express LEDs

Figure 5-6 shows the various status LEDs on the CPU/System

Controller board’s piggyback LED board.

5-8 Service & Troubleshooting Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 5-6. CPU/System Controller LEDs

Table 5-1. LEDs on Piggy-back LED board

LED Color Description

PG RED ON = Power good WD RED ON = Watchdog condition – program crash; OFF = Normal operation IDLE RED ON = CPU has free time at end of execution cycle. Should be on

frequently.

OFF = CPU overloaded STAn RED See Figure 5-7 and Table 5-1 for LED patterns and explanations TX1 RED Transmit activity on COM1 RX1 RED Receive activity on COM1 TX2 RED Transmit activity on COM2 RX2 RED Receive activity on COM2 TX3 RED Transmit activity on COM3 RX3 RED Receive activity on COM3 Receive GREEN Receive activity on Ethernet port Transmit YELLOW Transmit activity on Ethernet port

Revised Mar-2011 Service & Troubleshooting 5-9

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 5-7 shows the possible LED patterns for the STAn codes and Table 5-1includes descriptions for the various LED patterns and LCD status codes (if you have an attached Display/Keypad).

STA6

STA5 STA4

STA3 STA2 STA1

STA6

STA5

STA4

STA3

STA2

STA1 STA6

STA5 STA4 STA3 STA2 STA1

STA6

STA5

STA4

STA3 STA2 STA1

HEX

STA6 STA5 STA4 STA3

STA2

STA1 STA6

STA5 STA4 STA3 STA2 STA1

STA6

STA5

STA4 STA3 STA2 STA1

STA6

STA5

STA4

STA3 STA2

STA1

HEX

STA6 STA5 STA4 STA3 STA2 STA1

HEX

STA6 STA5 STA4

STA3 STA2 STA1

STA6

STA5

STA4

STA3

STA2

STA1

STA6

STA5

STA4

STA3

STA2

STA1

STA6

STA5

STA4

STA3

STA2

STA1

STA6 STA5 STA4 STA3

STA2

STA

STA6 STA5 STA4

STA3 STA2 STA

STA6 STA5 STA4 STA3 STA2 STA1

STA6 STA5 STA4 STA3 STA2 STA

Figure 5-7. CPU/System Controller Board LED Patterns - LED Hexadecimal Codes

Table 5-2. LEDs on CPU/System Controller Board and LCD Display Status Codes

LED6 STA6

LED5 STA5

0 0 0 0 0 0 00 Blank Application Running 0 0 0 0 0 1 01 DIAG Unit in Diagnostic Mode 0 0 0 0 1 1 03 R DIAG Unit Running Diagnostics 0 0 0 1 0 0 04 FWXSUM Flash XSUM Error 0 0 0 1 0 1 05 DEVERR Error Initializing Application

0 0 0 1 1 1 07 FLASH Flash Programming Error 0 0 1 0 0 0 08 FACT Using Factory Defaults * 0 0 1 0 0 1 09 BATT Battery Failure Detected * 0 0 1 0 1 0 0A STRTUP Currently Loading the Boot

LED4 STA4

LED3 STA3

LED2 STA2

LED1 STA1

Status In Hex

LCD Display

Indication Definition

Device

Project

5-10 Service & Troubleshooting Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

LED6 STA6

LED5 STA5

0 0 1 0 1 1 0B INIT System Initialization in Progress 0 1 0 0 0 0 10 RECOV Waiting in Recovery Mode 0 1 0 0 1 0 12 RAMERR Error Testing SRAM 1 0 0 0 0 0 20 STOP Application Loaded 1 0 1 0 0 0 28 HALT Stopped at a Break Point 1 1 0 0 0 0 30 NO APP No Application Loaded 1 1 1 0 0 0 38 BREAKP Running with Break Points 1 1 1 0 1 1 3B POWERD Waiting for Power-down (after

1 1 1 1 1 0 3E UPDUMP Waiting for Updump to be 1 1 1 1 1 1 3F NOTRUN Unit Crashed (Watchdog

LED4 STA4

LED3 STA3

LED2 STA2

LED1 STA1

Status In Hex

LCD Display

Indication Definition

NMI) Performed Disabled)

In addition to the LEDs on the piggy-back LED board, the CPU/System Controller board includes a watchdog LED (WD – CR1 right) and an idle LED (IDLE – CR1 left) that have identical functions to WD and

IDLE described in Table 5-1.

Revised Mar-2011 Service & Troubleshooting 5-11

WD LEDIDLE LED

Figure 5-8. WD and IDLE LEDs

ControlWave Express Instruction Manual (CI-ControlWave Express)

5.4 WINDIAG Diagnostic Utility

Caution

The ControlWave Express cannot execute your control strategy while it runs diagnostic routines; place any critical processes controlled by the ControlWave Express under manual control before starting this procedure.

WINDIAG is a software-based diagnostic tool you use to test the performance of I/O, CPU memory, communication ports, and other system components. .

WINDIAG is a PC-based program, so the ControlWave Express must be attached to and communicating with a PC running WINDIAG. Establish communication between the ControlWave Express (with/without an application loaded) and the PC with a local or network port under the following conditions:

 Set CPU module switches SW2-3 to OFF and SW2-8 to OFF.

Turning these switches off sets all serial ports on the ControlWave Express to 9600 baud in preparation for diagnostic testing and prevents the boot project from running and also places the ControlWave Express in diagnostic mode.

 Connect any ControlWave Express serial communication port to the

PC provided their port speeds match. Use a null modem cable to connect RS-232 ports between the ControlWave Express and the PC; use an RS-485 cable to connect the RS-485 port of the

ControlWave Express and the PC. See Chapter 2 for information on

cables.

 Reserve the port running a diagnostic test for exclusive use; you

cannot use that port for any other purpose during testing.

Follow these steps:

1. Start OpenBSI communications using NetView, TechView, or

2. Select Start >Programs > OpenBSI Tools >Common Tools >

5-12 Service & Troubleshooting Revised Mar-2011

LocalView, and select the RTU you want to test.

Diagnostics. The Main Diagnostics menu (Figure 5-9) opens.

ControlWave Express Instruction Manual (CI-ControlWave Express)

Figure 5-9. WINDIAG Main Diagnostics Menu

3. Select the component to be tested. See Section 5.4.1 for a

description of the tests. Enter any prompted parameters (slot #, etc.). WINDIAG performs the diagnostics and displays pass/fail results.

After performing all diagnostic testing, exit WINDIAG.

4. Set switches SW2-3 and SW2-8 on the CPU module to ON. The

ControlWave Express should resume normal operation.

5.4.1 Available Diagnostics

WINDIAG’s Main Diagnostics Menu (see Figure 5-9) provides the

following diagnostic selections:

Option Tests

CPU & Peripherals Checks the CPU/System Controller board except

Analog Output Checks the AO on the Process I/O board. High Speed Counter Checks HSCs on the Process I/O board and

Prom/Ram Checks the SRAM and FLASH memory. Analog Input Checks AIs on the Process I/O board. Communications Checks serial communication ports COM1,

for memory.

Pulse Counter inputs on the CPU/System Controller board.

Revised Mar-2011 Service & Troubleshooting 5-13

ControlWave Express Instruction Manual (CI-ControlWave Express)

Option Tests

COM2, and COM3. The External loop-back tests

require the use of a loop-back plug. Discrete I/O Checks DIs and DOs on the Process I/O board. Ethernet Checks the Ethernet port. Keypad & Display Checks the optional display/keypad hardware.

Port Loop-back

Test

WINDIAG allows you to select the communication port to test. Depending on the type of network (RS-232 or RS-485) and the port in

question, a special loop-back plug is required:  Port 1 - RS-232 uses a 9-pin female D-type loop-back plug (see

Figure 5-10).

Figure 5-10. COM1 & COM2 RS-232 Loop-back Plug/Wires

 Port 2 - RS-232 use loop-back wires (see Figure 5-10).  Port 3 - RS-232 use loop-back wires (see Figure 5-11).

Figure 5-11. COM3 RS-232 & RS-485 Loop-back Wires

5-14 Service & Troubleshooting Revised Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Note: You can configure RS-485 loopback by setting CPU/System

Controller board switches SW3-1 & SW3-2 ON.

 Port 3 - RS-485 use loop-back wires or CPU Switch SW3 (see

Figure 5-11).

These tests verify the correct operation of the communication ports.

Note: You cannot test a communications port while you are using it.

You can only test currently unused ports. After you complete testing on all other communication ports (and verify their correct functioning), you must reconnect (using a now validated port)

and test the remaining untested port.

Test Procedure

Use this procedure to test the communication ports.

1. Connect an external loop-back plug to the port on the CPU you

want to test. Valid ports are:

2. Select Communications on the WINDIAG Main Diagnostics

Menu. The Communications Diagnostic screen opens:

Revised Mar-2011 Service & Troubleshooting 5-15

Figure 5-12. Communications Diagnostic Menu

3. Enter 5 in the Number of Passes field.

4. Select a port to test (click  to display all available ports).

ControlWave Express Instruction Manual (CI-ControlWave Express)

Note: The port you select must correlate to the port on which you

placed the loop-back plug in step 1.

5. Select 115200 or ALL ASYNC as the baud rate (click  to

display all available rates).

6. Click RUN to start the test. At the completion of the test (which

generally takes about 5 seconds), any failed results appear in the Status field to the right of the RUN button:

 TXD RXD Failure  CTS RTS Failure

7. Click Return to Menu to display the WINDIAG Main Menu.

5.5 Core Updump

In some cases—such as when a ControlWave Express fails for no apparent reason—you can upload a copy of the contents of SRAM and SDRAM to a PC for support personnel and service engineers to evaluate. This upload is called a “core updump.”

A core updump may be required if the ControlWave Express spontaneously enters a watchdog state that affects all system operation. This occurs when the system crashes as a result of a CPU timeout (resulting from improper software operation, a firmware glitch, and so on). In some cases, the watchdog state can recur but you cannot logically reproduce the conditions.

The CPU’s RAM contains “crash blocks,” a firmware function provided specifically for watchdog troubleshooting. You can view and save the crash blocks by viewing the Crash Block Statistic Web Page (see the

Web_BSI Manual, D5087). On request, you can forward crash block

files to our technical support personnel. If they need additional information to evaluate the condition, the technical support group may request a core updump. Once the core updump process generates a file, you can forward that file to the support personnel for evaluation and resolution.

Use the following steps to preserve the “failed state” condition at a system crash and perform a core updump:

1. Set switch SW2-1 on the CPU/System Controller board to OFF

(Disable Watchdog Timer). If switch SW2-4 is ON, set it to OFF (Enable Core Updump).

2. Wait for the error condition (typically 3F on the status LEDs or

3. Connect the ControlWave Express’s Comm Port 1 to a PC using

5-16 Service & Troubleshooting Revised Mar-2011

Note: The factory default setting for switch SW2-4 is OFF.

“NOTRUN” on the optional display).

a half duplex null modem cable.

ControlWave Express Instruction Manual (CI-ControlWave Express)

4. Set the ControlWave Express for Recovery Mode by setting

both SW1-1 and SW1-2 to the right for open operation or both to the left for closed operation.

5. Start the PC’s HyperTerminal program (at 115.2 kbaud) and

generate a receive using the 1KX-Modem protocol. Save the resulting core updump in a file so you can forward it later to the

technical support group.

By setting the CPU/System Controller board switches SW2-1 and SW2-

4 both off before the ControlWave Express fails you prevent the

Express from automatically recovering from the failure and enable it to wait for you to take a core updump.

Once you complete the core updump, set the CPU/System Controller

board’s switch SW2-1 to ON (Watchdog Enabled) and SW2-4 to OFF

(Core Updump Enabled).

Additionally, set switch SW1-1 to OFF and SW1-2 to ON.

With these switches set, power up the ControlWave Express and begin standard operations.

5.6 Calibration Checks

The AO and AI on the Process I/O board are self-calibrating.

To calibrate the RTD, use TechView software. See the TechView User’s Guide (D5131) for more information.

Revised Mar-2011 Service & Troubleshooting 5-17

This page is intentionally left blank

Special Appendix for ControlWave Express Instruction Manual (CI-ControlWave Express)

Appendix A – ControlWave Express– Special Instructions

for Class I, Division 2 Hazardous Locations

1. The ControlWave Express RTU is listed by Underwriters

Laboratories (UL) as nonincendive (when installed in a NEMA 1 or better enclosure) and is suitable for use in Class I, Division 2, Groups A, B, C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive ControlWave Express RTU. Refer to CI-ControlWave Express for general information. In the event of a conflict between the ControlWave Express Customer Instruction Manual (CI- ControlWave Express) and this document, always follow the instructions in this document.

2. The ControlWave Express RTU includes both nonincendive and

unrated field circuits. Unless a circuit is specifically identified in this document as nonincendive, the circuit is unrated. Unrated circuits must be wired using Div. 2 wiring methods as specified in Article 501-4(b) of the National Electrical Code (NEC), NFPA 70 for installations in the United States, or as specified in Section 18- 152 of the Canadian Electrical Code for installation in Canada.

3. The power system (solar panel and battery) are not supplied by

Emerson Process Management Remote Automation Solutions division and are therefore unrated (see paragraph 2). Connection to the solar panel is approved as a nonincendive circuit so that Division 2 wiring methods are not required. The nominal panel voltage must match the nominal battery voltage (6V or 12V).

4. An optional RTD may be supplied with the ControlWave Express.

Connection to the RTD is approved as a nonincendive circuit, so the Division 2 wiring methods are not required.

5. Signal connectors available for customer wiring are listed in Table

A-1. Network communications port and I/O wiring connections are

unrated and must be wired using Division 2 wiring methods. No temporary connections may be made to the local port (COM1 –J4 or J11 on CPU/System Controller board) unless the user ensures that the area is known to be nonhazardous. Field service connections to this port are typically temporary, and must be short in duration to ensure that flammable concentrations do not accumulate while it is in use.

WARNING

EXPLOSION HAZARD Do not disconnect solar power from the battery

or any other power connections within the ControlWave Express enclosure or any power connections to optional items such as radio/modem, or cabling to the display/keypad unless the area is known to be nonhazardous.

Revised Mar-2011 Special Instructions for Class I, Division 2 A-1

Special Appendix for ControlWave Express Instruction Manual (CI-ControlWave Express)

WARNING

EXPLOSION HAZARD Substitution of components may impair

suitability for use in Class I, Division 2 environments.

WARNING

EXPLOSION HAZARD The area must be known to be nonhazardous

before servicing/replacing the unit and before installing or removing I/O wiring.

EXPLOSION HAZARD Do NOT disconnect equipment unless power

has been disconnected and the area is known to be non-hazardous.

Table A-1. Module/Board Customer Wiring Connectors

Module/Item Connector Wiring Notes

CPU/System Controller board TB1: 6-pin terminal block Solar power: User wired *

Primary power: User wired * Auxiliary output: User wired *

CPU/System Controller board TB3: COM2, 8-pin

terminal block RS-232

CPU/System Controller board TB4: COM3, 5-pin

terminal block RS-232/RS485

CPU/System Controller board TB5: 4-pin terminal block

pulse input interface

CPU/System Controller board TB6: 3-pin terminal block

RTD interface

CPU/System Controller board J1: 8-pin RJ-45 jack

10/100Base-T Ethernet port

CPU/System Controller board J2: 8-pin RJ-45 female

connector – display or display/keypad interface

CPU/System Controller board J4: COM1, 9-pin male D-

sub RS-232 J11: COM1, 3-pin RS-232

Process I/O board TB2: 6-pin terminal block

D1 interface

Remote comm. port: For radio or external network comm.. Refer to model spec. and item 5 of this document. When used for network comm. use Div 2 wiring methods.

RS-232/485 comm. port: For external network comm.. Refer to model spec. and item 5 of this document.

Pulse input field wiring: Field I/O wiring connector is unrated, use Div. 2 wiring methods. *

Field wired: Refer to item 4 of this document.

10/100Base-T Ethernet port jack for external connection to an Ethernet hub. Refer to model spec. and item 5 of this document.

User-connected using factory wired cable *

RS-232 Comm. Port connectors: For external network comm. Refer to model spec. and item 5 of this document.

Discrete input field wiring: Field I/O wiring connector is unrated, use Div. 2 wiring methods. *

A-2 Special Instructions for Class I, Division 2 Revised Mar-2011

Special Appendix for ControlWave Express Instruction Manual (CI-ControlWave Express)

Module/Item Connector Wiring Notes

Process I/O board TB3: 8-pin terminal block

DO/DI interface

Process I/O board TB4: 8-pin terminal block

HSC interface

Process I/O board TB6: 9-pin terminal block

AI interface

Process I/O board TB7: 4-pin terminal block

AO interface

Discrete output/input field wiring: Field I/O wiring connector is unrated, use Div. 2 wiring methods. *

High speed counter field wiring: Field input wiring connector is unrated, use Div. 2 wiring methods. *

Analog input field wiring: Field input wiring connector is unrated, use Div. 2 wiring methods. *

Analog output field wiring: Field output wiring connector is unrated, use Div. 2 wiring methods. *

Note: *

These wires should only be installed/removed when the item (PCB) in question is installed / removed or when checking wiring continuity. The area must be known to be nonhazardous before servicing / replacing the unit and before installing or removing PCBs, connectors, or individual I/O or power wires. Refer to the warnings in this document. All input power and I/O wiring must be performed 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.

Revised Mar-2011 Special Instructions for Class I, Division 2 A-3

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ControlWave Express Instruction Manual (CI-ControlWave Express)

Appendix Z – Sources for Obtaining Material Safety Data

Sheets

This device includes certain components or materials which may be hazardous if misused. For details on these hazards, please contact the manufacturer for the most recent material safety data sheet.

Manufacturer General

Description

DURACELL http://www.duracell.com

3V LITHIUM MANGANESE DIOXIDE BATTERY

P/N: DL 2450

Emerson Part

Number

395620-01-5

Revised Mar-2011 Appendix Z Z-1

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ControlWave Express Instruction Manual (CI-ControlWave Express)

Index

ACCOL3 Firmware Library ................................. 1-7

address

default IP ........................................................ 4-2

Analog Inputs...................................................... 3-8

Analog Output..................................................... 3-9

Backup battery

description...................................................... 1-4

disconnecting.................................................. 5-7

jumper W3....................................................2-10

removing/replacing......................................... 5-7

Backups.............................................................. 4-3

Battery

replacing......................................................... 5-6

Boot FLASH memory

amount............................................................ 1-4

Cables

RS-232 ......................................................... 2-14

RS-485 ......................................................... 2-19

Shielding.........................................................3-4

Checking

LEDs...............................................................5-8

Class I, Division 2........................................2-3, A-1

Communication Ports

defaults........................................................... 4-2

Ethernet........................................................ 2-21

RS-232 ......................................................... 2-14

RS-485 ......................................................... 2-19

Communications

Loop-back Test....................................5-14, 5-15

protocols supported........................................ 1-8

ControlWave project

downloading ................................................... 4-3

Core Updump ................................................... 5-16

CPU/System Controller board

battery backup................................................ 5-7

description...................................................... 1-3

Jumpers........................................................ 2-10

removing.........................................................5-5

switches.......................................................... 2-8

Defaults

Comm Ports.................................................... 4-2

Diagnostic software .......................................... 5-12

Disconnecting RAM Battery................................5-7

Discrete Inputs.................................................... 3-6

Discrete Outputs.................................................3-7

Display/Keypad................................................. 2-22

Downloading

the ControlWave project................................. 4-3

Environmental specifications .............................. 2-2

Ethernet Port.....................................................2-21

Features..............................................................1-1

Field repair.......................................................... 5-5

Figures

1-1. ControlWave Express Component

Identification................................................. 1-3

1-2. ControlWave Programming Environment1-6 2-1. Co

2-2. ControlWave Express dimensions..........2-5

2-3. CPU/System Controller Board Component 2-4. CPU/ System Controller Board (TB1 & TB2)

2-5. Male DB9 9-Pin Connector ................... 2-15

2-6. Full-duplex and Half-duplex Cable........ 2-16

2-7. Full-duplex and Half-duplex Cable........ 2-17

2-8.Connection from an External Modem/Radio

2-9. Full-duplex and Half-duplex Cable........ 2-18

2-10. RJ-45 Ethernet Connector .................. 2-21

2-11. Standard 10/100Base-T Ethernet Cable 2-12. Point-to-Point 10/100Base T Ethernet 2-13 Optional 2-Button and 25-Button Keypads

2-14 Display with No Keypad ....................... 2-23

3-1. Process I/O Board Component Identification

3-2. Process I/O Board Wiring diagrams........3-5

3-3. Pulse Input Wiring diagram................... 3-10

3-4. 3-Wire RTD Temperature Input Wiring.3-12 3-5. RTD Probe Installation/Removal diagram. 3-

3-6. 3808 Transmitter to ControlWave Express 3-7. 3808 Transmitter to ControlWave Express 3-8. ControlWave Express to 3808s - RS-485

4-1. Saving a Backup of Your Project ............ 4-4

5-1. HyperTerminal Mode Menu..................... 5-3

5-2. HyperTerminal (Ready to Download)......5-4

ntrolWave Express Component

Identification................................................. 2-2

I.D. Diagram ................................................. 2-7

Power Wiring.............................................. 2-13

to COM2 of the ControlWave Express....... 2-17

(CPU Module to Hub)................................. 2-21

Cable..........................................................2-22

....................................................................2-22

diagram.........................................................3-3

RS-232 Comm. Cable Diagram..................3-14

RS-485 Comm. Cable................................3-15

Network Diagram........................................ 3-15

Issue: Mar-2011 Index IND-1

ControlWave Express Instruction Manual (CI-ControlWave Express)

5-3. Send File dialog box................................ 5-4

5-4. HyperTerminal (Download in progress).. 5-5

5-5. ControlWave Express LED..................... 5-8

5-6. CPU/System Controller LED................... 5-9

5-7. CPU/System Controller Board LED Patterns

................................................................... 5-10

5-8. WD and IDLE LEDs .............................. 5-11

5-9. WINDIAG Main Diagnostics Menu........ 5-13

5-10. COM1 & COM2 RS-232 Loop-back

Plug/Wires.................................................. 5-14

5-11. COM3 RS-232 & RS-485 Loop-back Wires

................................................................... 5-14

5-12 Communications Diagnostic menu ...... 5-15

Firmware upgrade............................................... 5-2

HyperTerminal................................................ 5-2

LocalView....................................................... 5-2

System Firmware Downloader....................... 5-2

FLASH memory

amount............................................................ 1-5

Grounding.................................................... 2-6, 3-4

Hazardous locations

special instructions for....................................A-1

High Speed Counter/Discrete Inputs................ 3-11

Humidity

specifications.................................................. 2-2

HyperTerminal.................................................... 5-2

Loop-back Test........................................5-14, 5-15

Material Safety Data Sheets (MSDS)

how to obtain..................................................Z-1

Memory

Boot FLASH.................................................... 1-4

FLASH amount............................................... 1-5

SRAM amount................................................1-5

Mounting the housing ......................................... 2-4

Operator’

s keypad/display................................ 2-22

Power

connecting or disconnecting........................... 4-2

wiring............................................................ 2-11

Power connector TB1....................................... 2-12

Power connector TB2....................................... 2-14

Power options..................................................... 1-5

Process I/O board

options............................................................ 1-6

replacing......................................................... 5-5

configurations................................................. 3-1

Jumpers.......................................................... 3-2

switches.......................................................... 3-2

Protocols

supported in ControlWave.............................. 1-8

Pulse Counter/Discrete Inputs.......................... 3-10

I/O

Wiring ...................................................... 3-1, 3-4

I/O Configurator.................................................. 1-7

I/O Options.......................................................... 1-6

Installation........................................................... 3-4

Class 1, Div 2................................................. 2-3

Overview ........................................................ 2-3

IP address

default............................................................. 4-2

Jumpers

CPU/System Controller Board ..................... 2-10

Process I/O Board.......................................... 3-2

Keypad/Display................................................. 2-22

LEDs

Checking ........................................................ 5-8

disabling ......................................................... 2-8

LocalView ........................................................... 5-2

RAM Battery

Disconnecting................................................. 5-7

Recovery mode switches....................................2-8

Repair in field...................................................... 5-5

Resistance Temperature Device (RTD) ........... 3-12

RS-232 Ports .................................................... 2-14

Cables .......................................................... 2-14

RS-485 Ports .................................................... 2-19

Cables .......................................................... 2-19

configuration switch........................................ 2-9

Running diagnostic software............................. 5-12

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

Soft Switches

lock/unlock switch...........................................2-8

use/ignore switch............................................2-8

Software Tools.................................................... 1-6

Specifications

for temperature, humidity, vibration................ 2-2

SRAM memory

amount............................................................ 1-5

control switch..................................................2-9

Status codes.....................................................5-10

IND-2 Index Issue: Mar-2011

ControlWave Express Instruction Manual (CI-ControlWave Express)

Switches

CPU................................................................ 2-8

Process I/O board .......................................... 3-2

System Firmware Downloader............................ 5-2

Tables

1-1. CPU/System Controller board

Configurations.............................................. 1-4

1-2.Process I/O Configurations...................... 1-6

2-1. CPU/System Controller Board Switch SW1

...................................................................... 2-8

2-2. CPU/System Controller Board Switch SW2

...................................................................... 2-8

2-3. RS-485 Configuration Switch (SW3)....... 2-9

2-4. Power Requirements............................. 2-12

2-5. RS-232 Connectors on CPU................. 2-14

2-6. RS-232 Port Connector Pin Assignment2-15 2-7. RS-232 Port Alternate Connector Pin

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

2-8. RS-485 Connector on CPU................... 2-19

2-9. RS-485 Port Connector Pin Assignment2-19

2-10. RS-485 Network Connections............. 2-20

2-11. Ethernet 10/100Base-T CPU Module Pin

Assignments...............................................2-21

3-1.Process I/O Configurations...................... 3-1

3-2. Process I/O Module Switch SW1............ 3-2

3-3. Non-Isolated DI General Characteristics 3-6 3-4. Non-Isolated DO General Characteristics3-7 3-5. Non-Isolated AI General Characteristics. 3-8 3-6. Non-Isolated AO General Characteristics3-9 3-7. Non-Isolated Pulse Counter/Discrete Inputs

General Characteristics.............................. 3-10

3-8. Non-Isolated High Speed Counter/Discrete

Inputs General Characteristics...................3-11

3-9. RTD Connections to CPU/System Controller

Board Connector TB6................................. 3-12

4-1. Default Comm Port Settings (by PCB).... 4-2

5-1. LEDs on Piggy-back LED board ............. 5-9

5-2. LEDs on CPU/System Controller Board and

LCD Display Status Codes......................... 5-10

A-1. Module/Board Customer Wiring Connectors

......................................................................A-2

TB1 Connector..................................................2-12

TB2 Connector..................................................2-14

Temperature

specifications.................................................. 2-2

Tools ................................................................... 5-1

Transmitters

connecting .................................................... 3-14

Troubleshooting..................................................5-1

general............................................................ 5-8

Updump ............................................................ 5-16

switch..............................................................2-9

Upgrading firmware.............................................5-2

Vibration

specifications.................................................. 2-2

W3 Backup battery jumper ............................... 2-10

Watchdog

enable switch..................................................2-8

WINDIAG..........................................................5-12

Wiring

I/O............................................................3-1, 3-4

Issue: Mar-2011 Index IND-3

Instruction Manual

CI-ControlWave Express

ControlWave Express

March, 2011

Emerson Process Management Remote Automation Solutions

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wn, CT 06795 Phone: +1 (860) 945-2262 Fax: +1 (860) 945-2525 www.EmersonProcess.com/Remote

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n Process Management AP Pte Ltd.

Remote Automation Solutions Division

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. L4V 1H3

NOTICE

“Remote Automation Solutions (“RAS”), division of Emerson Process Management shall not be liable for technical or editorial errors in this manual or omissions from this manual. RAS MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND, IN NO EVENT SHALL RAS BE LIABLE FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.

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Emerson ControlWave EFM 3808, Bristol ControlWave Express Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual