Emerson Process Management EFM 3808 User Manual
Instruction Manual
s
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CI-ControlWave Express
Feb., 2009
Bristol ControlWave Express
Bristol ControlWave Express
(Remote Terminal Unit)
Remote Automa ti on Solution
www.EmersonProcess.com/Remote
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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 grounded in
accordance with OSHA rules and regulations pertaining to "Design Safety Standards for Electrical
Systems," 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are in agreement
with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that
include electrically operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an
electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this
can result in erratic operation or complete failure of the equipment. Read supplemental document
S14006 at the back of this manual 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
WARRANTY
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A. Remote Automation Solutions (RAS) warrants that goods described herein and manufactured by RAS are
free from defects in material and workmanship for one year from the date of shipment unless otherwise
agreed to by RAS in writing.
B. RAS warrants that goods repaired by it pursuant to the warranty are free from defects in material and
workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of
repaired goods, whichever is longer.
C. Warranties on goods sold by, but not manufactured by RAS are expressly limited to the terms of the
warranties given by the manufacturer of such goods.
D. All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused,
abused or otherwise damaged, (ii) repaired, altered or modified without RAS consent, (iii) not installed,
maintained and operated in strict compliance with instructions furnished by RAS or (iv) worn, injured or
damaged from abnormal or abusive use in service time.
E. These warranties are expressly in lieu of all other warranties express or implied (including without limitation
warranties as to merchantability and fitness for a particular purpose), and no warranties, express or
implied, nor any representations, promises, or statements have been made by RAS unless endorsed
herein in writing. Further, there are no warranties which extend beyond the description of the face hereof.
F. No agent of RAS is authorized to assume any liability for it or to make any written or oral warranties beyond
those set forth herein.
REMEDIES
A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost
to Buyer of any goods or parts found by Seller to be defective if Buyer notifies RAS in writing of the alleged
defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above,
and if the Buyer returns such goods to the RAS Watertown office, unless the RAS Watertown office
designates a different location, transportation prepaid, within thirty (30) days of the sending of such
notification and which upon examination by RAS proves to be defective in material and workmanship. RAS
is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to RAS, the Buyer can arrange to have a RAS
service person come to the site. The Service person's transportation time and expenses will be for the
account of the Buyer. However, labor for warranty work during normal working hours is n ot chargeable.
B. Under no circumstances will RAS be liable for incidental or consequential damages resulting from breach
of any agreement relating to items included in this quotation from use of the information herein or from the
purchase or use by Buyer, its employees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
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Before a product can be returned to Remote Automation Solutions (RAS) for repair, upgrade, exchange, or to verify
proper operation, Form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and
thus ensure an optimal lead time. Completing the form is very important since the information permits the RAS
Watertown Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-2220. A RAS Repair Dept. representative will
return the call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the RAS Web site (www.emersonprocess.c om/Bristol) and sending it
via E-Mail to Custserve.bristol@emersonprocess.com
. A RAS Repair Dept. representative will return E-
Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Remote Automation Solutions
A Division of Emerson Process Management
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795
A RAS Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the RAS Repair Department at (860) 945-2442. A RAS Repair Department representative will
record a RA number on the form and complete Part I, send the form to the Customer via fax (or other
requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product
being returned. This will allow us to quickly track, repair, and return your product to you.
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Remote Automation Solutions (RAS)
Repair Authorization Form (on-line completion)
(
Providing this information will permit Bristol, also doing business as Remote Automation Solutions (RAS) to
effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information
may result in increased lead times.)
Date RA # SH Line No.
Standard Repair Practice is as follows: Variations to
this is practice may be requested in the “Special
Requests” section.
• Evaluate / Test / Verify Discrepancy
• Repair / Replace / etc. in accordance with this form
• Return to Customer
Part I Please complete the following information for single unit or multiple unit returns
Address No. (office use only)
Bill to : Ship to:
Purchase Order: Contact Name:
Phone: Fax: E-Mail:
Please be aware of the Non warranty standard
charge:
• There is a $100 minimum evaluation charge,
which is applied to the repair if applicable (√ in
“returned” B,C, or D of part III below)
Part II Please complete Parts II & III for each unit returned
Model No./Part No. Description:
Range/Calibration: S/N:
Reason for return
: Failure Upgrade Verify Operation Other
1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.) (Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:
3. What is the Firmware revision? What is the Software & version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not
available
A. If product is within the warranty time period but is excluded due
to the terms of warranty,, would you like the product:
repaired returned replaced scrapped?
B. If product were found to exceed the warranty period, would you like the product:
C. If product is deemed not repairable would you like your product:
D. If RAS is unable to verify the discrepancy, would you like the product:
repaired returned replaced scrapped?
returned replaced scrapped?
returned replaced *see
below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person
to contact that has the most knowledge of the problem is: phone
If we are unable to contact this person the backup person is:
Special Requests:
Ship prepaid to: Remote Automation Solutions, Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-2220
Form GBU 13.01 Rev. D 12/04/07
phone
Emerson Process Management
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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 “Training” or contact our training department in Watertown at (860) 945-2343.
and
CI-ControlWave Express
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ControlWave Express
Remote Terminal Unit
INSTALLATION FORWARD
NOTE for all ControlWave Express Installers:
READ THIS SECTION FIRST!
This manual has been designed for the following audience:
• Customer Site Engineers, who must plan for the installation and implementation of the
ControlWave Express.
• Instructors who must become familiar with and teach Field Engineers/Technicians on
the installation, operation and repair of ControlWave Express.
• Field Engineers/Technicians who must install and service the ControlWave Express.
Installation of the ControlWave Express is provided in two formats as follows:
Section 2 - Installation & Operation
operation of the ControlWave Express. Section 2 provides all the information required for
instructors who are training individuals unfamiliar with the ControlWave Express. It is
also intended to support anyone who needs to learn how to install and operate the Control-
Wave Express for the first time.
Appendix C - Hardware Installation Guide
familiar with the ControlWave Express but need the configuration information in a
concise format. Field Engineers/Technicians who have previously installed one or more
ControlWave Express will find the necessary installation information logically sequenced
for their convenience.
A Windows driven diagnostic tool referred to as WINDIAG is provided on the
OpenBSI Software CDROM. WINDIAG is documented in instruction manual
D4041A – Window Diagnostics for Bristol Controllers
provides menu driven diagnostics that have been designed to assist a technician
or Process Engineer in troubleshooting the various ControlWave Express
circuits. A brief overview is provided in Section 3.5 of this manual. For more
detailed descriptions of ControlWave Express Windows Diagnostics than those
provided herein, see Document D4041A – Chapters 1 and 7C.
provides a detailed overview of the installation and
is intended for individuals who are already
NOTE:
. Bristol’s WINDIAG program
CI-ControlWave Express - Installation Forward
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CI-ControlWave Express
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ControlWave Express
Remote Terminal Unit
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 1 - ControlWave Express INTRODUCTION
1.1 GENERAL DESCRIPTION ...........................................................................................1-1
1.2 ControlWave PROGRAMMING ENVIRONMENT ......................................................1-3
1.3 PHYSICAL DESCRIPTION........................................................................................... 1-4
1.3.1 Enclosure/Chassis...........................................................................................................1-4
1.3.2 CPU/System Controller Board....................................................................................... 1-5
1.3.2.1 CPU/System Controller Board Connectors ...................................................................1-7
CPU/System Controller Board Optional Ethernet Port Connector J1 ........................ 1-8
CPU/System Controller Board Serial Comm. Port Connectors ................................... 1-8
CPU/System Controller Board Optional RTD Input Probe.......................................... 1-8
CPU/System Controller Board Pulse Counter Input Connector.................................. 1-8
CPU/System Controller Board Power Connections ...................................................... 1-8
1.3.2.2 CPU Memory................................................................................................................... 1-9
1.3.2.3 CPU/System Controller Board Configuration Jumpers ............................................. 1-10
1.3.2.4 CPU/System Controller Board Configuration Switches............................................. 1-11
1.3.2.5 CPU/System Controller Board LEDs ..........................................................................1-12
1.3.3 Process I/O Board .........................................................................................................1-12
1.3.3.1 Process I/O Board Configuration Jumpers and Switch SW1 ..................................... 1-13
1.3.3.2 Process I/O Board Connectors...................................................................................... 1-15
1.3.3.3 Process I/O Board Field I/Os........................................................................................ 1-15
1.3.3.3.1 Dedicated Non-isolated Digital Inputs........................................................................1-15
1.3.3.3.2 Dedicated Non-isolated Digital Outputs ..................................................................... 1-15
1.3.3.3.3 Selectable Non-isolated Digital Inputs/Outputs.........................................................1-15
1.3.3.3.4 Non-isolated Analog Inputs .........................................................................................1-15
1.3.3.3.5 Non-isolated Analog Output ........................................................................................1-16
1.3.3.3.6 Non-isolated High Speed Counter Inputs ................................................................... 1-16
1.4 FIELD WIRING............................................................................................................1-16
1.5 FUNCTIONS................................................................................................................. 1-16
1.5.1 Data Acquisition ........................................................................................................... 1-17
1.5.2 Optional LCD Display .................................................................................................. 1-17
1.5.3 Communications ...........................................................................................................1-17
Section 2 - ControlWave Express INSTALLATION & OPERATION
2.1 INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1
2.2 SITE LOCATION CONSIDERATIONS........................................................................ 2-1
2.2.1 Temperature & Humidity Limits .................................................................................. 2-2
2.2.2 Vibration Limits .............................................................................................................2-2
2.3 ControlWave Express INSTALLATION/CONFIGURATION...................................... 2-2
2.3.1 Mounting the ControlWave Express Enclosure/Chassis .............................................. 2-5
2.3.2 Process I/O Board Configuration ...................................................................................2-7
2.3.3 CPU/System Controller Board Configuration............................................................... 2-8
2.3.3.1 CPU/System Controller Board Switch Configuration .................................................. 2-8
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CI-ControlWave Express
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ControlWave Express
Remote Terminal Unit
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 2 - ControlWave Express
2.3.3.2 Communication Ports...................................................................................................2-10
2.3.3.3 RS-232 & RS-485 Interfaces ........................................................................................ 2-12
2.3.3.3.1 RS-232 Ports ................................................................................................................. 2-12
2.3.3.3.2 RS-485 Ports ................................................................................................................. 2-13
2.3.3.4 Ethernet Port ................................................................................................................ 2-14
2.3.4 I/O Wiring......................................................................................................................2-16
2.3.4.1 I/O Wire Connections....................................................................................................2-16
2.3.4.2 Shielding and Grounding ............................................................................................. 2-16
2.3.4.3 Dedicated Non-isolated Digital Inputs ........................................................................ 2-16
2.3.4.3.1 Dedicated Digital Input Configurations......................................................................2-16
2.3.4.4 Dedicated Non-isolated Digital Outputs ..................................................................... 2-18
2.3.4.4.1 Dedicated Digital Output Configurations ................................................................... 2-18
2.3.4.5 Selectable Non-isolated Digital Inputs/Outputs......................................................... 2-18
2.3.4.5.1 Selectable Digital Input/Output Configurations ........................................................2-18
2.3.4.6 Non-isolated Analog Inputs ......................................................................................... 2-18
2.3.4.6.1 Analog Input Configurations .......................................................................................2-18
2.3.4.7 Non-isolated Analog Output ........................................................................................ 2-19
2.3.4.7.1 Analog Output Configurations..................................................................................... 2-19
2.3.4.8 Non-isolated High Speed Counter/Digital Inputs.......................................................2-20
2.3.4.8.1 High Speed Counter Configurations............................................................................2-20
2.3.4.9 Non-isolated Pulse Counter/Digital Inputs.................................................................2-20
2.3.5 RTD Wiring ................................................................................................................... 2-21
2.3.6 Connection to a Model 3808 Transmitter.................................................................... 2-22
2.3.7 Power Wiring & Distribution ....................................................................................... 2-23
2.3.7.1 Bulk Power Supply Current Requirements ................................................................2-24
2.3.7.2 Power Wiring ................................................................................................................ 2-25
2.3.7.3 ControlWave Express System Grounding................................................................... 2-25
2.3.8 Operation of the Lithium Backup Coin-cell Battery .................................................. 2-26
2.4 OPERATIONAL DETAILS .......................................................................................... 2-26
2.4.1 Downloading the Application....................................................................................... 2-26
2.4.2 Upgrading ControlWave Express Firmware...............................................................2-27
2.4.2.1 Using LocalView to Upgrade ControlWave Express Firmware.................................2-27
2.4.2.2 Using HyperTerminal to Upgrade ControlWave Express Firmware ........................ 2-32
2.4.2.3 Remote Upgrade of ControlWave Express Firmware ................................................ 2-36
2.4.3 Operation of the Mode Switch......................................................................................2-36
2.4.4 Soft Switch Configuration and Communication Ports ...............................................2-36
2.4.5 Optional Display/Keypad Assemblies.......................................................................... 2-37
2.4.5.1 Operation of the Display Only Assembly ....................................................................2-37
2.4.5.2 Operation of the Dual-button Display/Keypad Assembly ..........................................2-38
INSTALLATION & OPERATION (Continued)
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CI-ControlWave Express
ControlWave Express
Remote Terminal Unit
TABLE OF CONTENTS
SECTION TITLE PAGE #
Section 3 - ControlWave Express SERVICE
3.1 SERVICE INTRODUCTION ........................................................................................3-1
3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES...................................3-1
3.2.1 Accessing Components For Testing ............................................................................... 3-1
3.2.2 Removal/Replacement of the CPU/System Controller Bd. & the Process I/O Bd. ...... 3-2
3.3 TROUBLESHOOTING TIPS......................................................................................... 3-2
3.3.1 CPU/System Controller Board Voltage Checks ............................................................ 3-2
3.3.2 LED & LCD Checks........................................................................................................3-3
3.3.3 Wiring/Signal Checks ..................................................................................................... 3-5
3.4 GENERAL SERVICE NOTES....................................................................................... 3-5
3.4.1 Extent of Field Repairs................................................................................................... 3-5
3.4.2 Disconnecting RAM Battery .......................................................................................... 3-9
3.4.3 Maintaining Backup Files..............................................................................................3-9
3.5 WINDIAG DIAGNOSTICS ............................................................................................ 3-9
3.5.1 Diagnostics Using WINDIAG ...................................................................................... 3-12
3.5.1.1 Communications Diagnostic Port Loop-back Test...................................................... 3-12
3.5.1.2 Serial Comm. Port Eternal Loop-back Test Procedure ..............................................3-13
3.6 CORE UPDUMP...........................................................................................................3-14
3.7 CALIBRATION CHECKS............................................................................................ 3-15
Section 4 - ControlWave Express SPECIFICATIONS
4.1 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1
4.2 CPU/SYSTEM CONTROLLER BOARD ...................................................................... 4-1
4.2.1 Input Power Specs. .........................................................................................................4-1
4.2.2 Power Supply Sequencer Specs. .................................................................................... 4-2
4.2.3 CPU/System Controller Board Connectors ................................................................... 4-2
4.2.3.1 Communication Ports.....................................................................................................4-2
4.2.3.2 Power Interface & Field Input Connections.................................................................. 4-4
4.3 PROCESS I/O BOARD SPECIFICATIONS.................................................................. 4-5
4.3.1 Process I/O Board Connectors........................................................................................ 4-5
4.3.2 Non-isolated Digital Input/Output Circuitry Specs...................................................... 4-7
4.3.3 Non-isolated Analog Input/Output Circuitry Specs. ....................................................4-7
4.3.4 Non-isolated High Speed Counter Input Circuitry Specs. ...........................................4-8
4.4 ENVIRONMENTAL SPECIFICATIONS...................................................................... 4-9
4.5 DIMENSIONS ................................................................................................................ 4-9
APPENDICES/SUPPLEMENTAL INSTRUCTION
Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A
HARDWARE INSTALLATION GUIDE..........................................................Appendix C
DISPLAY/KEYPAD ASSEMBLY GUIDE.......................................................Appendix E
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CI-ControlWave Express
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ControlWave Express
Remote Terminal Unit
TABLE OF CONTENTS
SECTION TITLE PAGE #
APPENDICES/SUPPLEMENTAL INSTRUCTION (Continued)
Sources for Obtaining Material Safety Data Sheets ..................................... Appendix Z
Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW
Care and Handling of PC Boards and ESD-Sensitive Components .....................S14006
REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS
WINDIAG - Windows Diagnostics for Bristol Controllers ...................................D4041A
ControlWaveMICRO Quick Setup Guide ................................................................ D5124
Open BSI Utilities Manual ...................................................................................... D5081
Getting Started with ControlWave Designer.......................................................... D5085
Web_BSI Manual...................................................................................................... D5087
ControlWave Designer Reference Manual .............................................................. D5088
ControlWave Designer Programmer’s Handbook................................................... D5125
TechView User’s Guide............................................................................................. D5131
ControlWave Loop Power Supply Product Installation Guide........ PIP-ControlWaveLS
0 - 4 / Contents CI-ControlWave Express
Section 1
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ControlWave Express INTRODUCTION
1.1 GENERAL DESCRIPTION
ControlWave Express remote terminal units (RTU) have been designed to perform as the
ideal platform for remote site automation, measurement and data management in process
control and manufacturing. ControlWave Express RTUs measure temperature and monitor
a variety of analog and digital inputs. In addition to operation in a protected outdoor
environment (once mounted in a suitable enclosure), ControlWave Express RTUs provides
the following key features.
Hardware/Packaging Features:
• 32-bit ARM9 processor (LH7A400) provides exceptional performance and low power
consumption
• Wide operating temperature range: (-40 to +70°C) (-40 to 158°F)
• Two Board Platform: (CPU/System Controller Bd.
Three CPU/System Controller Board Configurations
CPU/System Controller Bd.: 2 Pulse Counter/Digital Inputs
• Ultra Low Power 14MHz CPU: Supports a nominal +6Vdc or a nominal +12Vdc
input power, Solar Regulator and an Auxiliary Power Output
• Low Power 33MHz CPU: Supports a nominal +12Vdc or a nominal +24Vdc input
power, Solar Regulator and an Auxiliary Power Output
• 33MHz CPU (with 10/100Base-T Ethernet Port): Supports a nominal +12Vdc or a
nominal +24Vdc input power, without Solar Reg. and without Aux. Power Output
Three Optional Process I/O Board Configurations
• 2 DI/DO, 4 DI, 2 DO & 2 HSC
• 2 DI/DO, 4 DI, 2 DO & 2 HSC, 3 AI
• 2 DI/DO, 4 DI, 2 DO & 2 HSC, 3 AI, 1 AO
• Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,
300mA-hr lithium coin cell battery located on the CPU Module
• Very low power consumption - minimizes costs of solar panel/battery power systems
• Three serial communications ports (Two RS-232 and One RS-232/485)
• RTD Input (on 14MHz Ultra Low Power CPUs) (connection to a 100-ohm platinum bulb)
(using the DIN 43760 curve)
• Nonincendive Class I, Div. 2, Groups C & D Hazardous Locations (see Appendix A)
• Cost effective for small RTU/Process Controller applications
Firmware/Software Features
• Functions as a Process Controller or Remote Terminal Unit (RTU)
• Standard application programs will be introduced on a continual basis with WebBSI
Web pages that are preconfigured for all user operations.
• Using our ControlWave Designer IEC 61131-3 Programming Environment, any user or
third party can modify a standard application or create a completely customized
program.
• ControlWave Express RTUs are compatible with Bristol RTUs in software and
networking solutions for SCADA data editing/management, and are similar in all
operations.
ControlWave Express RTUs are comprised of a CPU/System Controller Board, an optional
Process I/O Board and a two piece enclosure (consisting of a card-edge cover and a
mounting chassis). Sharp’s LH7A400 System-on-Chip Advanced RISC Machine (ARM)
And optional Process I/O Bd.)
: Standard I/O included on
:
CI-ControlWave Express Introduction / 1-1
microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC) is the
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core of the CPU/System Controller Board. In addition to the microprocessor and control
logic, the CPU/System Controller Board includes two fixed RS-232 Communication Ports
(COM1 & COM2), 1 configurable (RS-232/RS-485) Communication Port (COM3), 2MB of
battery backed Static RAM (SRAM), 512kB Boot/Downloader FLASH, 8MB simultaneous
read/write FLASH, SPI I/O Bus Connector, Serial Real Time Clock, Power Supply
Sequencer, and Display/Keypad Interface. A piggy-back mounted LED Board provides
Power Good, Watchdog, Idle, Transmit and Receive (for each of the three communication
ports), and six Status LEDs. Additionally, when interfaced to an optional LCD Display, the
unit displays run time status information.
Figure 1-1 - ControlWave Express Component Identification
An optional Process I/O Board provides the circuitry and field interface hardware necessary
to interconnect all assigned field I/O circuits except the pulse counter circuits and the RTD
input that are located on the CPU/System Controller Board. Non-isolated power is
generated and regulated by the CPU/System Controller Board that provides +3.3Vdc for all
logic and bulk power for I/O field circuits from a nominal bulk +6Vdc, +12Vdc or +24Vdc
power source (depending on the type of CPU). +1.8Vdc, used by the ARM microprocessor, is
derived from the regulated 3.3Vdc logic power.
1-2 / Introduction CI-ControlWave Express
1.2 ControlWave PROGRAMMING ENVIRONMENT
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The ControlWave programming environment uses industry-standard tools and protocols to
provide a flexible, adaptable approach for various process control applications in the water
treatment, wastewater treatment, and industrial automation business.
Figure 1-2 - ControlWave - Control Strategy Software Diagram
ControlWave Express RTUs provide an ideal platform for remote site automation,
measurement, and data management in the oil and gas industry.
The control strategy file created and downloaded into the controller is referred to as a
ControlWave project. The tools that make up the programming environment are:
CI-ControlWave Express Introduction / 1-3
ControlWave Designer programming package offers several different methods for
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•
generating and debugging control strategy programs including function blocks, ladder
logic, structured languages, etc. The resulting programs are fully compatible with IEC
61131-3 standards. Various communication methods as offered, including TCP/IP, serial
links, as well as communication to Bristol Open BSI software and networks
.
• The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,
allows you to define process I/O modules in the ControlWave and configure the
individual mapping of I/O points for digital and analog inputs and outputs.
• The ACCOL3 Firmware Library which is imported into ControlWave Designer,
includes a series of Bristol-specific function blocks. These pre-programmed function
blocks accomplish various tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as PID control.
• The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows
real-time data access to any OPC [Object Linking and Embedding (OLE) for Process
Control] compliant third-party software packages.
• Flash Configuration Utility – Parameters such as the BSAP local address, IP
address, etc. are set using the Flash Configuration Utility, accessible via Open BSI
LocalView, NetView, or TechView. The ControlWave Express ships with a standard
Flash Configuration Profile (FCP) file, with default configuration parameters already
set.
1.3 PHYSICAL DESCRIPTION
ControlWave Express RTUs are comprised of the following major components:
• Enclosure/Chassis (Section 1.3.1)
• RTD Probe (Section 1.3.2.1)
• CPU/System Controller Board (Section 1.3.2)
ControlWave Express RTUs can be factory configured with one or more of the following
options:
• Process I/O Board (Section 1.3.3)
• Keypad/LCD Display (1.5.2 & 2.4.5)
1.3.1 Enclosure/Chassis
ControlWave Express RTUs are housed in an enclosure that accommodates mounting to a
Panel or a DIN-Rail. External dimensions are approximately 10.75” long, by 5.56” wide, by
2.06” deep (without mounting brackets). The enclosure consists of two pieces, the removable
Card Edge Cover and the Main Mounting Chassis. Two Thumb Screws can be loosened to
facilitate removal of the Card Edge Cover, and thus accommodating all instrument field
wiring.
RJ-45 connector J2 on the CPU/System Controller Board accommodates either an optional
standalone dual line LCD display or optional 4 x 20 LCD display supported with either a 2button or a 25-button keypad. In normal operation, the LCD associated with a keypad will
turn off after the unit has been configured and placed into service while standalone LCDs
1-4 / Introduction CI-ControlWave Express
will remain on. When interfaced to a keypad, the operator may activate the display at any
Click here to return to Table of Contents
time by pressing the appropriate front panel button.
1.3.2 CPU/System Controller Board
The multilayer CPU/System Controller Board provides ControlWave Express CPU, I/O
monitor/control, memory and communication functions. ControlWave Express CPU/System
Controller Boards operate over an extended temperature range with long-term product
reliability.
ControlWave Express CPU/System Controller Boards are based on a 32-bit ARM9TDMI
RISC Core Processor. The CPU/System Controller Board is specified to operate with an
input voltage range from a nominal +6Vdc, +12Vdc or +24Vdc power supply with a system
clock speed of either 14 MHz or 33 MHz. In addition to the microprocessor and control logic,
the CPU Board includes two fixed RS-232 communication Ports (COM1 & COM2), and one
configurable RS-232/RS-485 communication port (COM3). CPU Memory consists of 2MB of
battery backed Static RAM (SRAM), 512kB Boot/Downloader FLASH and 8MB
simultaneous read/write FLASH. Three unique CPU/System Controller Boards are offered
as follows:
• 14 MHz Ultra Low Power CPU: operates from a nominal +6Vdc or +12Vdc bulk input
power and is equipped with a Solar Regulator circuit and an Auxiliary Power Output
circuit.
• 33 MHz Low Power CPU: operates from a nominal +12Vdc or +24Vdc bulk input power,
is equipped with a Solar Regulator circuit and an Auxiliary Power Output circuit).
• 33 MHz Low Power CPU: operates from a nominal +12Vdc or +24Vdc bulk input power
and is equipped with a 10/100Base-T Ethernet Port. Note: Not equipped with a Solar
Regulator circuit or an Auxiliary Power Output circuit.
CPU/System Controller Boards are provided backup power via a coin cell socket that
accepts a 3.0V, 300mA-hr lithium battery. This 3.0V battery provides backup power for the
real-time clock and the system’s Static RAM (SRAM). Backup power is enabled when
Configuration Jumper W3 (adjacent to the battery) is installed in position 1 to 2.
If the 3.3Vdc that powers the unit goes out of specification, a supervisory circuit on the
CPU/System Controller Board switches the battery voltage to the VBAT3.3 hardware signal
(used by the CPU’s SRAM and RTC). This supervisory circuit also generates a
BATTERYGOOD signal when the battery voltage is above 2.35V.
The system SRAM is specified to have a standby current of 20:A maximum for each part
(plus 2uA for the RTC). For a system containing 2MB of system SRAM, a worst-case
current draw of 42:A allows a battery life of approximately 9000 hours.
The power supply operates from a nominal +6Vdc, +12Vdc or +24Vdc (depending on the
CPU type) with the nominal input supply configuration being user configured via on-board
jumpers. A supervisory circuit monitors the incoming power and the supply voltages. The
isolated supplies are shut down when the incoming voltage drops below +5.4V for a +6.0V
system, +11.4V for a +12V system or +21.8V for a +24V system.
CI-ControlWave Express Introduction / 1-5
Solar Pwr. In +
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GND
Power In +
GND
Aux. Power Out +
GND
Sec. Battery Input
Input
Input
Output
Output
GND
DCD
RXD
TXD
DTR
GND
Input
Output
Input
Input
Input
Output
Output
DSR
RTS
CTS
DCD
RXD
TXD
DTR
GND
Input
Output
Input
DSR
RTS
CTS
Receive
LED
Transmit
LED
1 = Idle
2 = Watchdog
Configuration
Options
Switch
Recovery
Mode &
COM./Status
LEDs
Input
Input
Output
Output
RXD+
RXD-/RXD
TXD-/TXD
TXD+
GND
Input
Input
PULSE 1
PULSE 2
GND
Output
PULSE
PWR
RTD EXC
RTD+
RTD-
Figure 1-3 - ControlWave Express CPU/System Controller Board
1
2
3
4
5
6
1
2
1
2
3
6
4
5
9
6
7
8
1
2
3
4
5
6
7
8
CR1
}
1
2
3
4
5
1
2
3
4
1
2
3
2
1
O
N
12
3
4
5
6
7
8
O
N
1
2
3
4
Damage WILL occur to
the CPU if the Ethernet
network is connected
to connector J2!
Power
Power
1
COM1
RS-232
5
COM2
RS-232
10/100
Base-T
Ethernet
COM3
RS-232
RS-485
Pulse
Input
RTD
Input
LCD/
Keypad
CAUTION:
Port
12
3
4
56
7
8
1
2
34
3 2 1
T
X
D
RJ-45
CR1
RJ-45
W18
R
G
RS-232
X
N
D
D
RJ-45
W12
W15
COM1
W3
W13
W14
NOTE:
F3
W1
NOTE:
J11 normally used
for CW GFC and CW
Express PAC only.
W2
PG
WD
IDLE
STA6
STA5
STA4
STA3
STA2
STA1
S1
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
Ultra Low Power & Low Power
CPU/System Controller Bds.
Don’t have an Ethernet Port.
Solar Pwr. In and Aux. Power Out
are not available on units equipped
with an Ethernet Port.
Do Not Connect a 24V Sol ar Panel
to Connector TB1-1 & TB1-2!
W1: 1-2 = COM1 CTS from Port
2-3 = COM1 CTS to RTS
W2: 1-2 = COM2 CTS from Port
2-3 = COM2 CTS to RTS
W3: 1-2 = Battery Enabled
2-3 = Battery Disabled
W5: 1-2 = 12/24V Power Supply
W6: 1-2 = 12V Power Supply
W8
W7
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
Shut-down Hysterisis
2-3 = 6V Power Supply
Shut-down Hysterisis
Shut-down
2-3 = 6/24V Power Supply
Shut-down
W6
W5
Trip Point Hysterisis
2-3 = 6V Power Fail
Trip Point Hysterisis
Trip Point
2-3 = 6/24V Power Fail
Trip Point
Trip Point
2-3 = COM3 RS-485
Panel to TB1-1 & TB1-2!
W18: COM1 connector
selection
1 to 2 = J4 active
2 to 3 = J11 active
J5 - COM3
Piggy-back
Radio Intf.
J5
J8
J7
MSP430
JTAG
Header
W17
J9
PLD JTAG
Header
J3 - I/OBUS
Intf. to
CPU Board
NOTE:
P1 is only available on
P1
WE
Ultra Low Power CPU/System Controller Bds.
W16
J3
1-6 / Introduction CI-ControlWave Express
A supervisory circuit is used to switch to battery power when VCC falls out of specification.
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For maximum shelf life, the battery may be isolated from the circuit by removing the
Backup Battery Jumper W3 from position 1 to 2 and then storing it in position 2 to 3. If the
real-time clock looses its battery backup a ControlWave Designer system variable bit
(_QUEST_DATE) is set. This bit can be used to post a message or alarm to the PC (see the
‘Systems Variables’ section of the ControlWave Designer Programmer’s Handbook D5125).
On 14MHz Ultra Low Power CPUs and 33 MHz Low Power CPUs, an on-board solar shunt
regulator is capable of charging a 7AH battery (6V or 12V) with the charging cycle
controlled by the MSP430 Microcontroller. Firmware turns on the shunt regulator when the
battery voltage exceeds the charge regulation threshold. When this happens, the shunt
regulator shorts the terminals of the solar panel connector thus eliminating further battery
charging. Note: Damage may result to the power supply components if the battery
charger is used without a battery present, i.e., do not connect a solar panel unless
a battery has first been connected.
An alternate battery connection is available through connector TB2 that provides power if
there is no power available from TB1.
Circuitry supports two Pulse Counter Inputs via connector TB5, and on 14 MHz Ultra Low
Power CPUs interface to a RTD via connector TB6.
Basic CPU components and features are summarized as follows:
• LH7A400 System-on-Chip 32-bit ARM9TDMI RISC Core microprocessor
• 512KB FLASH Boot/Downloader, 29LV040B, 90 nS, 8-bit access
• 2MB SRAM, 3.3V, 1M x 16, with Battery Backup
• 8MB simultaneous read/write FLASH, TSOP site
• 3 Serial Comm. ports
• Spread Spectrum clock for lower EMI
• Serial Real Time Clock with battery backup
• 8-Position configuration options switch bank (SW2), a 4-Position recovery switch bank
(SW1) and an 8-Position COM3 (RS-485) support switch bank (SW3)
• Coin cell socket accepts a 3.0V, 300mA-hr lithium battery
• LED Board (piggy-back)
• Nominal +6/12V or +12/24V) Power Input (both with Fail Safe Sequencer)
• Display/Keypad Interface
• 2 Pulse Counter Inputs with 1 second scan rate (Digital Input operation selectable)
• 10/100base-T Ethernet Port (Not on Low Power and Ultra Low Power CPUs)
1.3.2.1 CPU/System Controller Board Connectors
The CPU/System Controller Boards are equipped with up to ten (10) connectors that
function as stated in Table 1-1 below. Note: Additional connectors, not listed herein,
are for factory use only.
Table 1-1 - CPU/System Controller Board Connector Summary
Ref. # Pins Function Notes
J1 8-pin 10/100Base-T Ethernet Port RJ-45
J2 8-pin LCD Display/Keypad Intf. RJ-45
J3 20-pin IOBUS Intf. to Process I/O Board
J4 9-pin 9-pin Male D-type (COM1 - RS-232) Activated by W18
J10 20-pin LED Daughter Board Interface
J11 3-pin Alternate (COM1- RS-232) See Table 2-3B; Activated by W18
CI-ControlWave Express Introduction / 1-7
Click here to return to Table of Contents
Table 1-1 - CPU/System Controller Board Connector Summary (Continued)
Ref. # Pins Function Notes
TB1 6-pin Solar Panel, Battery/Power Supply &
Aux Out,
TB2 2-pin Secondary battery input
TB3 8-pin Term. Block (COM2 - RS-232) See Table 2-3A or 4-2
TB4 5-pin Term. Block (COM3 – RS-232/RS-485) See Table 2-3C or 4-3
TB5 4-pin Pulse Input Connector
TB6 3-pin RTD Input See Section 2.3.5
Main Power Connector
See Section 2.3.9
CPU/System Controller Board Optional Ethernet Port Connector J1
An optional Ethernet port is supported via 8-pin RJ-45 connector J1. The 10/100Base-T
Ethernet interface is implemented using an SMSC LAN91C111 controller. This device
provides for full or half-duplex implementation. It should be noted that units equipped with
an Ethernet Port do not support a Solar Panel or provide an Auxiliary Power Output.
CPU/System Controller Board Serial Comm. Port Connectors (see Section 1.5.5)
The CPU Module supports up to three serial communication ports (COM1, COM2 &
COM3). COM1 utilizes either a male 9-pin D-Type connector, or a male 3-pin connector –
choice of the active connector is determined by jumper W18. COM2 utilizes an 8-pin
Terminal Block and COM3 utilizes a 5-pin Terminal Block. COM1 and COM 2 support RS232 communications, COM3 can be configured to support RS-232 or RS-485
communications.
CPU/System Controller Board RTD Input Connector (also see Section 2.3.5)
Edge Connector TB6 (on 14MHz Ultra Low Power CPU/System Controller Boards) provides
connection to a 100-ohm platinum bulb (using the DIN 43760 curve). The common threewire configuration is accommodated. In this configuration, the return lead connects to the
RTD- terminal while the two junction leads (Sense and Excitation) connect to the RTD+
terminals.
CPU/System Controller Board Pulse Counter Input Connector (also see Section
2.3.4.9)
Edge Connector TB5 supports connection to two internally sourced Pulse Counter Inputs.
These inputs are sourced for 3.3V with a source current of 200μA and a maximum input
frequency of 10kHz. Pulse Counter inputs are not supported with debounce circuitry and
therefore should not be used with relays. Note: Pulse Counter Inputs can also be
configured for DI operation via ControlWave Designer.
CPU/System Controller Board Power Connections
A 6-position Terminal Block is provided for input power wiring as follows:
• 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) *
• TB1-2 - Ground (GND)
• TB1-3 - Primary Power: Power from a user supplied nominal +6Vdc, +12Vdc or
+24Vdc power supply (depending on the type of CPU)
1-8 / Introduction CI-ControlWave Express
• TB1-4 - Ground (GND)
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• TB1-5 - Auxiliary Power Out+: for an external radio/modem *
• TB1-6 - Ground (GND)
• TB2-1 - Secondary battery input
• TB2-2 - Ground (GND)
Note: * = Not available on units equipped with an Ethernet Port.
Power may be provided by a user supplied rechargeable 6/12V Lead Acid Battery (used in
conjunction with a Solar Panel), or a range of other user-supplied battery systems or bulk
(nominal +6Vdc, +12Vdc or +24Vdc) power supply.
Solar panels can be interfaced to rechargeable battery systems used to power a
ControlWave Express. Internally the solar panel wires connect to the rechargeable battery
via CPU/System Controller Board connector TB1-3 and TB1-4. A secondary power input
connection (TB2) is supported if no power is available through TB1.
Connector J2 (RJ-45) accommodates connection to one of three LCD Display configurations,
i.e., LCD Display only, LCD Display (with Dual-Button Keypad) or LCD Display (with 25Button Keypad). The LCD Display or LCD Display/Keypad is mounted on the Instrument
Front Cover.
1.3.2.2 CPU Memory
Boot/downloader FLASH
Boot/download code is contained in a single 512Kbytes uniform sector FLASH IC. This
device resides on the local bus, operates at 3.3V and is configured for 8-bit access. 4Position DIP-Switch SW1’s position 3 allows start-up menu options to be displayed or bootup from system FLASH. If SW1-3 is closed when a reset occurs, the boot-up code will cause
a recovery menu to be sent out the COM1 serial port to a terminal program running on an
external host computer. Note: Recovery Mode will also be initiated if CPU/System
Controller Board Switch SW1 positions 1 and 2 are both set ON or OFF when a reset occurs.
FLASH Memory
The base version of the CPU Module has 8Mbytes of 3.3V, simultaneous read/write (DL)
FLASH memory. FLASH memory is 16-bits wide. System Firmware and the Boot Project
are stored here. No hardware write protection is provided for the FLASH array.
System Memory (SRAM)
The base version of the CPU Module has 2Mbytes of soldered-down static RAM,
implemented with two 512K x 16 asynchronous SRAMs that are configured as a 1M x 16-bit
array. All random access memory retained data is stored in SRAM. During power loss
periods, SRAM is placed into data retention mode (powered by a backup 3.0V lithium
battery). SRAMs operate at 3.3V. Critical system information that must be retained during
power outages or when the system has been disabled for maintenance is stored here. Data
includes: Last states of all I/O, historical data, retain variables and pending alarm
messages not yet reported. The SRAM supports 16-bit accesses.
CI-ControlWave Express Introduction / 1-9
1.3.2.3 CPU/System Controller Board Configuration Jumpers
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ControlWave Express CPU/System Controller Board are provided with 12 User
Configuration Jumpers that function as follows:
• W1 - COM1 CTS Use Selection
1 to 2 = COM1 CTS Source is from Device
2 to 3 = COM1 RTS to CTS Loopback
• W2 - COM2 CTS Use Selection
1 to 2 = COM2 CTS Source is from Device
2 to 3 = COM2 RTS to CTS Loopback
• W3 - Enable/Disable Battery Backup Selection
1 to 2 = Enable Battery Backup
2 to 3 = Disable Battery Backup
• W5 - Power Supply Shut-down Selection
1 to 2 = 12/24V Power Supply Shut-down Hysterisis
2 to 3 = 6V Power Supply Shut-down Hysterisis
• W6 - Power Supply Shut-down Selection
1 to 2 = 12V Power Supply Shut-down
2 to 3 = 6/24V Power Supply Shut-down
• W7 - Power Fail Trip Point Hysterisis Selection
1 to 2 = 12/24V Power Fail Trip Point Hysterisis
2 to 3 = 6V Power Fail Trip Point Hysterisis
• W8 - Power Fail Trip Point Selection
1 to 2 = 12V Power Fail Trip Point
2 to 3 = 6/24V Power Fail Trip Point
• W12 - COM3 Configuration Selection
1 to 2 = COM3 is RS-232
2 to 3 = COM3 is RS-485
• W13 - COM3 Configuration Selection
1 to 2 = COM3 is RS-232
2 to 3 = COM3 is RS-485
• W14 - COM3 Configuration Selection
1 to 2 = COM3 is RS-232
2 to 3 = COM3 is RS-485
• W15 - COM3 Configuration Selection
1 to 2 = COM3 is RS-232
2 to 3 = COM3 is RS-485
• W16 - COM3 Configuration Selection
1 to 2 = COM3 is RS-232
2 to 3 = COM3 is RS-485
1-10 / Introduction CI-ControlWave Express
• W17 - Input Power Selection (Controls Solar Power Shunt Reg.) N/A for +24Vdc CPUs
Click here to return to Table of Contents
1 to 2 = 6V Power
2 to 3 = 12V Power
• W18 - COM1 Connector Selection
1 to 2 = Connector J4 (D connector) is active
2 to 3 = Alternate connector J11 is active
1.3.2.4 CPU/System Controller Board Configuration Switches
Three user-configurable DIP-Switches are provided on the CPU/System Controller Board.
These switches provide the following functionality:
• Four-bit DIP-Switch SW1 provides forced recovery functions. Recovery Mode as
supported by SW1-1 and SW1-2 or SW1-3 (forced by CW Console) accommodates FLASH
firmware upgrades to the CPU or allows the user to perform a Core Updump, i.e., upload
the contents of SRAM to a PC for evaluation (see Table 1-2).
• Eight-bit DIP-Switch SW2 is provided for user configuration settings (see Table 1-3).
• Eight-bit DIP-Switch SW3 provides loopback, termination control, and receiver bias
settings for the RS-485 port (COM3) (see Table 1-4).
Table 1-2 - CPU/System Controller Bd. SW1 Assignments
Recovery Mode/Local Mode Control
Switch Function Setting
SW1-1/2 Recovery/Local Mode
SW1-3 Force Recovery Mode
SW1-4 LED Status
Both ON or OFF = Recovery Mode
SW1 OFF & SW2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
OFF = Recovery Mode disabled
ON = Enable All LEDs
OFF = Disable All LED except Watchdog (WD)
* = Note: Only the Switch SW1 settings listed in this table, have been tested.
Table 1-3 - CPU/System Controller Bd. Configuration Switch SW2 Assignments
Note: Except for SW2-4, ON = Factory Default
Switch Function Setting - (ON = Factory Default)
SW2-1 Watchdog Enable
SW2-2
SW2-3
SW2-4
SW2-5 SRAM Control
SW2-6
SW2-7 N/A
SW2-8 Enable
* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
System Firmware
Load Control *
WINDIAG
ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Mode Switch (SW1)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote download of System Firmware
OFF = Disable remote download of System Firmware
ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)
CI-ControlWave Express Introduction / 1-11
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Table 1-4 - CPU/System Controller Bd. Switch SW3 Assignments
RS-485 Loopback & Termination Control (COM3)
Switch
SW3-1 TX+ to RX+ Loopback/2-Wire
SW3-2
SW3-3 100 Ohm RX+ Termination ON – End Nodes Only
SW3-4
SW3-7 RX+ Bias (End Nodes/Node)
SW3-8
RS-485 Function
Switch ON
TX− to RX− Loopback/2-Wire
100 Ohm RX− Termination
RX− Bias (End Nodes/Node)
Setting
ON – 2-Wire Operation or Loopback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – 2-Wire Operation or Loopback Enabled
OFF – 4-Wire Operation & Loopback Disabled
ON – End Nodes Only
ON – 4-Wire = Both End Nodes
2-Wire = One End Node Only
OFF – No Bias
ON – 4-Wire = Both End Nodes
2-Wire = One End Node Only
OFF – No Bias
1.3.2.5 CPU/System Controller Board LEDs – LED Board
CPU/System Controller Boards are equipped with a piggyback mounted LED Board. These
LEDs provide the following status conditions when lit:
PG (Red) - Power Good
WD (Red) - a Watchdog condition has been detected
IDLE (Red) - the CPU has free time at the end of its execution cycle
TX1, TX2, TX3 (Red) - transmit activity on COM1, COM2 & COM3 (respectively)
RX1, RX2, RX3 (Red) - receive activity on COM1, COM2 & COM3 (respectively)
Six Status LEDs (Red) - provide run time status codes.
Normally, the Idle LED should be ON most of the time (unless disabled). When the Idle
LED is OFF, it indicates that the CPU has no free time, and may be overloaded.
1.3.2.6 CPU/System Controller Board LEDs
CPU/System Controller Boards are equipped with two red LEDs that provide the following
status conditions when lit: WD (CR1 - Right) – Indicates Watchdog condition has been
detected & IDLE (CR1 - Left) - Indicates the CPU has free time at the end of its execution
cycle. Normally, the Idle LED should be ON most of the time (unless disabled). When the
Idle LED is OFF, it indicates that the CPU has no free time, and may be overloaded.
1.3.3 Process I/O Board
The Process I/O Board is mounted to the CPU/System Controller Board via six nylon
mounting posts.
Interface to the CPU/System Controller Board is provided via a 20-pin connector (P1).
Process I/O Boards contain I/O circuitry that supports the following I/O:
• Four Dedicated Non-Isolated Internally Sourced Digital Inputs
• Two Dedicated Non-Isolated Digital Outputs
• Two Selectable Non-Isolated Digital I/Os which can be individually wired for
Internally-Sourced DI operation or DO operation
1-12 / Introduction CI-ControlWave Express
• Two Non-Isolated Internally-Sourced High Speed Counter Inputs (or DI operation
Click here to return to Table of Contents
supported)
• Three Non-Isolated Single-Ended 1-5V or 4 to 20mA Analog Inputs (Optional)
• One Non-Isolated Externally-Powered 1-5V or 4 to 20mA Analog Output (Optional)
1.3.3.1 Process I/O Board Configuration Jumpers and Switch SW1
ControlWave Express I/O Boards are provided with 6 User Configuration Jumpers and one
4-position DIP-Switch (SW1) that function as follows:
• JP1 - AO Output Source (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Output
2 to 3 = 1-5V Analog Output
• JP3 - AO Power Source
1 to 2 = System Power
2 to 3 = External Power (+11 to +30 Vdc)
• JP4 - AI Field Power Configuration
1 to 2 = External Power
2 to 3 = System Power
• JP5 - AI1 Input Type (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Input
2 to 3 = 1-5V Analog Input
• JP6 - AI2 Input Type (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Input
2 to 3 = 1-5V Analog Input
• JP7 - AI3 Input Type (1-5V or 4-20mA)
1 to 2 = 4-20mA Analog Input
2 to 3 = 1-5V Analog Input
• SW1 - HSC high/low frequency select, DI/HSC Source Current & AO Configuration
SW1-1: HSC1 – OFF= 10 kHz (high speed), ON = 300 Hz (low speed)
SW1-2: HSC2 – OFF= 10 kHz (high speed), ON = 300 Hz (low speed)
SW1-3: DI/HSC 2mA Source Current – OFF = Disabled, ON = Enabled
SW1-4: AO Configuration – OFF = Current, ON = Voltage
CI-ControlWave Express Introduction / 1-13
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Figure 1-4 - ControlWave Express Process I/O Board
1-14 / Introduction CI-ControlWave Express
1.3.3.2 Process I/O Board Connectors
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Process I/O Boards are equipped with up to six (6) I/O interface connectors that function as
follows (see Table 1-5):
Table 1-5 - Process I/O Board Connector Summary
Ref. # Pins Function Notes
P1 20-Pin Bd. Power and I/O Bus Intf. to CPU/System Controller Bd.
TB2 6-Pin Digital Input (DI1 – DI4) Interface see Section1.3.3.3.1
TB3 8-pin Digital Output (DO1 & DO2) & DI/O
(DI5/DO3 & DI6/DO4) Interface
TB4 8-pin High Speed Counter Input Interface see Section 1.3.3.3.6
TB6 9-pin Analog Input Interface see Section 1.3.3.3.4
TB7 4-pin Analog Output Interface see Section 1.3.3.3.5
see Section 1.3.3.3.2 for DO
see Section 1.3.3.3.3 for DI/O
1.3.3.3 Process I/O Board Field I/Os
Field I/O Wiring is supported by card edge Terminal Block Connectors as follows:
Non-isolated Digital Input (DI) Connector (Section 1.3.3.3.1)
Non-isolated Digital Output (DO) & Digital I/O Connector (Sections 1.3.3.3.2 & 1.3.3.3.3)
Non-isolated Analog Input Connector (Section 1.3.3.3.4)
Non-isolated Analog Output Connector (Section 1.3.3.3.5)
Non-isolated High Speed Counter Input Connector (Section 1.3.3.3.6)
1.3.3.3.1 Dedicated Non-isolated Digital Inputs (also see Section 2.3.4.3)
Terminal Block TB2 provides interface to 4 dedicated non isolated Digital Inputs DIs). All
Digital Inputs support dry contact inputs that are pulled internally to 3.3 Vdc when the
field input is open. Source current for DI#1 through DI#4 is switch selectable for 60uA or
2mA from the 3.3V supply (SW1-3 ON = 2mA, OFF = 60uA). Note: SW1-3 also sets DI5 &
DI6 and both HSCs (for 200uA or 2.2mA operation). 15 millisecond input filtering protects
against contact bounce.
1.3.3.3.2 Dedicated Non-isolated Digital Outputs (also see Section 2.3.4.4)
Terminal Block TB3 provides interface to 2 dedicated non isolated Digital Outputs (DOs)
and two selectable DI/Os. Digital Outputs have a 30V operating range and are driven by
Open Drain FETs that sink 400 mA (Max.) at 30Vdc. The maximum output frequency is 20
Hz. Transorbs (30Vdc) provide surge suppression between each signal and ground.
Selectable DI/Os are discussed in section 1.3.3.3.3.
1.3.3.3.3 Selectable Non-isolated Digital Inputs/Outputs (also see Section 2.3.4.5)
Terminal Block TB3 also supports 2 user selectable Digital Inputs/Outputs. These DI/Os
may be unused or individually user wired as desired, i.e., both DI, both DO, one DI and/or
one DO. Their operation depends on how they are wired, i.e., DI or DO. These DI/Os are
rated identically to the DIs and DOs discussed in Sections 1.3.3.3.1 and 1.3.3.3.2.
1.3.3.3.4 Non-isolated Analog Inputs (also see Section 2.3.4.6)
Terminal Block TB6 provides interface to three single-ended Analog Inputs. Three field
terminals are assigned for each Analog Input, i.e., Field Power, AI# and DGND. AI field
CI-ControlWave Express Introduction / 1-15
power is applied to the field device (controlled via jumper JP4) and can be supplied by the
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system battery or an external power source. Each AI channel can be individually configured
for 4 to 20mA or 1-5V operation (via JP5 for AI1, JP6 for AI2 and JP7 for AI3).
AIs are supplied with a two hertz low pass filter and surge suppression (via 30Vdc
Transorbs).
1.3.3.3.5 Non-isolated Analog Output (also see Section 2.3.4.7)
Terminal Block TB7 provides interface to 1 Analog Output. The AO channel can be
configured for an internal or external power source via jumper JP3. External power can
range from +11 to + 30 Vdc.
Analog Output circuitry consists of a 12-bit resolution Digital to Analog Converter, a V to I
circuit and a V to V circuit. 4 to 20mA or 1-5V operation is jumper configured via JP1. An
ultra low power 16-bit RISC Microcontroller (MSP) reads the state of SW1-4 and selects the
appropriate calibration data for the AO channel.
1.3.3.3.6 Non-isolated High Speed Counter Inputs (also see Sections 2.3.4.8)
Terminal Block TB4 provides the interface to two internally-sourced single-ended High
Speed Counter or Digital Inputs (HSCI) with selectable high (10 kHz)/ or low (300 Hz)
frequencies (SW1-1 for HSC1 & SW1-2 for HSC2). All Input circuits have surge suppression
and signal conditioning. HSCs can be interfaced via Dry Contacts or Open Collector field
circuits. Note: High Speed Counter Inputs can also be configured for DI operation
via ControlWave Designer.
High Speed Counter/Digital inputs are sourced from 3.3Vdc and are switch selectable for a
source current of 200uA or 2.2mA (SW1-3 ON = 2.2mA, OFF = 200uA). Note: SW1-3 sets all
DIs and all HSCs. Each HSC circuit has a maximum input frequency of 10 kHz.
1.4 FIELD WIRING
ControlWave Express remote terminal units support connection to external field devices
through field wiring terminals on the CPU/System Controller Board and the Process I/O
Board. Connections to the following types of external devices may be made:
• RTD (CPU Bd.) • Pulse Inputs* (CPU Bd.)
• Analog Inputs (AIs) (I/O Bd.) • Analog Outputs (AOs) (I/O Bd.)
• Digital Inputs (DIs) (I/O Bd.) • Battery/Power Supply/Solar Panel (CPU Bd.)
• Digital Outputs (DOs) (I/O Bd.) • Communications (RS-232 and RS-485) (CPU Bd.)
• Relays (HSCs*) (I/O Bd.)
* Pulse Inputs and HSC Inputs can also be configured for use as Digital Inputs.
1.5 FUNCTIONS
ControlWave Express RTUs are shipped without a base application program. Using
ControlWave Designer, the user can readily modify this application and then add or
subtract functions, etc. An overview of a typical application is provided below.
1-16 / Introduction CI-ControlWave Express
• Uses pre-configured web pages for user readings, configuration and maintenance. Web
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pages can be modified and new pages configured to work with a modified application
load
• Resides on a BSAP SCADA network
• Provides audit trail and archives
• Allows the user to select engineering units, including English and metric
The primary function of the ControlWave Express is to provide data acquisition, a local
display, communications, output control, input status and self test and diagnostics. Items
below implement and supplement the primary function:
• Data acquisition (see Section 1.5.1)
• Local display (see Section 1.5.2)
• Communications (see Section 1.5.3)
• Control outputs (see Section 1.5.4)
• Status inputs (see Section 1.5.4)
• Self test and diagnostics (see Section 1.5.5)
1.5.1 Data Acquisition
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. Alternatively, the inputs may
be obtained via the local I/O Modules using analog transmitters. The ControlWave Express
application program will typically allow any combination of inputs to be selected.
1.5.2 Optional LCD Display
In normal operation, the Display only LCD Display remains ON while the Dual-Button or
25-Button Keypad/Displays turn OFF after the unit has been configured and placed in
service. The operator may activate the Keypad/Display at any time by pressing the
appropriate front panel button (depending on the keyboard type). When activated, the
display scrolls through a list of current values. The list defaults to an appropriate set of
values.
1.5.3 Communications
A ControlWave Express can be configured as a Master or Slave node on either a MODBUS
network or a BSAP network. Up to three serial communication ports are contained on the
ControlWave Express CPU/System Controller Board. Communication ports situated on the
CPU/System Controller Board are designated as follows:
CPU/System Controller Board:
COM1 - Port 1: J4 - 9-Pin Male D-Type Connector - RS-232 (Activated by jumper W18)
J11- 3-Pin Connector – RS-232 (Activated by jumper W18)
COM2 - Port 2: TB3 - 8-Pin Term Block - RS-232 (COM2 supports an External Modem or
Radio option)
COM3 - Port 3: TB4 - 5-Pin Term Block - RS-232/RS-485 (Configuration: RS232/485 via
jumpers W12 through W16 and RS-485 via switch SW3)
Communication Ports COM1, COM2 & COM3 support serial asynchronous operation.
Communication Ports COM1 and COM2 support RS-232 operation while COM3 supports
CI-ControlWave Express Introduction / 1-17
RS-232 or RS-485 operation. Any serial communication port can be configured for local
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communications, i.e., connected to a PC loaded with ControlWave Designer and OpenBSI
software.
RS-232 Ports
An RS-232 interface supports Point-to-Point, half-duplex and full-duplex communications
(20 feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWave Express utilize MODBUS or BSAP protocol, while full-duplex is supported by
the Point-to-Point (PPP) protocol. ControlWave Express RS-232 ports utilize the “null
modem” cable (Figure 2-11A) to interconnect with other devices such as a PC, printer,
another ControlWave series unit (except CW_10/30/35) when the ControlWave Express is
communicating using the full-duplex PPP protocol.
RS-485 Ports
ControlWave Express RTUs can use an RS-485 communication port for network
communications to multiple nodes up to 4000 feet away. 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. The master node should be wired to
one end of the RS-485 cable run. A 24-gauge paired conductor cable, such as Belden 9843
should be used. Note: Only half-duplex RS-485 networks are supported.
Comm. Port Defaults
From the factory COM1 defaults to 115.2 kilo-baud using the BSAP protocol. The
remaining serial communication ports, i.e., COM2 and COM3 default as follows:
COM2 – BSAP Slave @ 9600 Baud
COM3 – BSAP Master @ 9600 Baud (for use with Bristol 3808 MVT Transmitters)
1-18 / Introduction CI-ControlWave Express
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