s
User Manual
Document: D5085
Part: D301416X012
May, 2010
Getting Started with
ControlWave Designer
ControlWave Designer
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
BLANK PAGE
Table of Contents
Introduction – What is ControlWave?............................................................................................ 1
Starting ControlWave Designer...................................................................................................... 3
Opening A New Project.................................................................................................................. 3
Configuring I/O ..................................................................................................................... 7
I/O Configuration Wizard (Step 1 of 3): (Most users can skip to Step 2).......................... 8
I/O Configuration Wizard (Step 2 of 3):............................................................................. 9
I/O Configuration Wizard (Step 3 of 3):........................................................................... 11
Example – Creating A Simple Project.......................................................................................... 24
Step 1. Start ControlWave Designer:............................................................................... 25
Step 2. Open A New Project:........................................................................................... 25
Step 3. Start the I/O Configuration Wizard:.................................................................... 25
Step 4. Define Process I/O boards. .................................................................................. 25
Step 5. Create A Program Which Implements Your Control Strategy............................ 30
Step 6. Create A Task Which Can Run The Program...................................................... 42
Step 7. Compile the Program and, if necessary, correct any errors................................. 45
Step 8. Download the program into your ControlWave unit, or the I/O Simulator.......... 46
Step 9 Save Your Project................................................................................................. 51
iii
Introduction – What is ControlWave?
p
Introduction – What is ControlWave?
The ControlWave programming environment uses industry-standard tools and protocols to
provide a flexible, adaptable approach for various process control applications in the industrial
automation business.
The ControlWave Programming Environment consists of a set of integrated software tools which
allow a user to create, test, implement, and download complex control strategies for use with the
ControlWave series of Process Automation Controllers.
Build your Control Strategy
1
Creat e a new
control strategy
from scratch
ACCOL 3
Function Block
Library
2
Test your Control Strategy
I/O Simulator
IEC 6 1131 Real Time System
Load executable
ControlWave system Firmware
Process Automation
Controller
IEC 61131 Real Time System
Bristol Firmware
ControlWave System Firmware
Load executable
Configuration Parameters
Real Time and Historical Data
ControlWave
Designer
Development
Environment
I/O Configuration Wizard
Download your Control Strategy
3
OpenBSI
Downloader
OpenB S I Downloader ca n perform
downl oads. Contr olWave Designer can also
be used to download and test hardware.
Retrieve Data via
4
Web Pages
Dat a Ac ces s
ActiveX
Controls
HTML
Web page s ru nn ing
in Internet Explo r er
Other software
in which the
ActiveX controls
have been placed
e.g. Vis ual Basic,
Excel
Third
Party
software
Project Source - compressed
(OPTIONAL)
PROCESS I/O BOARDS
Data From Field In
ut Devices
ObjectServer
OpenB S I Utilities
e.g. DataView
Harvester
1 Getting Started with ControlWave
Introduction – What is ControlWave?
The tools which make up the environment are:
ControlWave Designer load building package offers several different methods for
generating and debugging control strategy programs including function blocks, ladder logic,
structured languages, etc. The resulting process control strategy programs (projects) are fully
compatible with IEC 61131 standards. Various communication methods are offered,
including TCP/IP, serial links, as well as communication to OpenBSI software and
networks. ControlWave Designer incorporates the KW MULTIPROG wt IEC 61131
programming tool.1
The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,
allows you to define process I/O boards in the ControlWave-series controller, and configure
the individual mapping of I/O points for digital and analog inputs and outputs.
The ACCOL3 Function Block Library which is imported into ControlWave Designer,
includes a series of ControlWave-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 I/O Simulator allows the control strategy programs (projects) generated through
ControlWave Designer to be tested on a PC, with simulated analog and digital inputs and
outputs. The I/O Simulator utilizes the identical IEC 61131 real time system used in the
ControlWave controller; this allows initial I/O testing and debugging to be performed in a
safe, isolated environment, without the need for a running ControlWave-series controller and
process I/O boards.
The ObjectServer – a package you purchase separately that allows real-time data access by
any OPC compliant third-party software package.
A series of Web Page Controls are also available for retrieval of real-time data values,
historical data values, and communication statistics. The web 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 applications such as Visual BASIC or Microsoft® Excel, or in their own userdefined web pages to provide a customized human-machine interface (HMI).
1
KW MULTIPROG wt is an industry-standard tool developed by Kl_pper und Weige Software GmbH. KW
MULTIPROG wt is used by various PLC and RTU vendors for generating IEC 61131 code.
Getting Started with ControlWave 2
Starting ControlWave Designer, Opening A Project
Installing the Software
ControlWave Designer software is included on the OpenBSI CD-ROM.
To install it, choose “Install OpenBSI” from the choices provided in the CD browser, and then
select “ControlWave Designer with ACCOL III”. For more information on the installation
process, see Chapter 2 of the OpenBSI Utilities Manual (document# D5081).
Starting ControlWave Designer
ControlWave Designer is your IEC 61131 program development tool. It allows you to create a
control strategy (project) in any of five standard IEC 61131 languages, compile the program,
debug it, and download it into your ControlWave controller.
To start ControlWave Designer click on:
StartProgramsOpenBSI Tools ControlWave Tools ControlWave Designer
IMPORTANT: If this is the very first time ControlWave Designer has been started on this
particular computer, you will be reminded to register the software. Otherwise, the software
can only be used for a maximum of 60 days. For more information on the registration
process, see Chapter 2 of the OpenBSI Utilities Manual (document# D5081).
Opening A New Project
ControlWave Designer will start. Then, click on the
New Project icon, shown above, or click on
FileNew Project.
3 Getting Started with ControlWave
Starting ControlWave Designer, Opening A Project
The New Project dialog box will appear.
Double-click on the ‘ControlWave’ icon (or the ‘CWMicro’ icon if you are using a ControlWave
Micro-series unit) and a project tree will be created which automatically includes the ACCOL3
function block library.
We will briefly discuss some of the terminology associated with the project tree. The project tree
includes a series of folders and worksheets which define the various elements of your project.
Among the most important elements of the project tree are:
Getting Started with ControlWave Designer 4
Starting ControlWave Designer, Opening A Project
Logical POUs Program Organization Units (POUs) hold the program code for your
project. They are defined on three separate worksheets. One worksheet
can optionally contain a textual description of the POU, a second
worksheet lists the variables associated with the POU, and a third
worksheet defines the POU code. POUs can be up to 640 K bytes in size,
and there is an enforced limit of 512 POUs per project. There are three
types of POUs:
Functions - Sometimes the term function is abbreviated as ‘FU’. These
are the simplest type of POU. They can take multiple inputs, but they
generate only one output. The memory allocated for a function’s data is
not persistent; i.e. once the function completes execution, that memory is
released. Functions are generally used to perform mathematical
operations; an example of a function is R_INT which truncates a real
number to an integer. Functions can only call other functions. Functions
can only be executed when included as part of a program POU.
Function Blocks - Sometimes the term function block is abbreviated as
‘FB’. Function blocks can take multiple inputs, and they can generate
multiple outputs. Unlike functions, they can have persistent memory. Most
of the POUs provided in the ACCOL3 library are function blocks, for
example, the AVERAGER, the INTEGRATOR, the PID3TERM, the
LEADLAG, etc. User-defined function blocks can be created which
consist of logical connections of various functions and function blocks.
Function blocks can only be executed when included as part of a program
POU.
Programs – Programs are essentially groups of functions and function
blocks which have been logically connected together to perform some
task. Programs are the only type of POU which can actually be executed.
Users can create more than one program in a project, and in fact, they can
create multiple instances of the same program. Programs can contain
persistent memory.
Libraries There are two types of libraries: Firmware libraries are libraries of
functions and function blocks created specifically for this controller
model. The ACCOL3 library is a firmware library containing functions
and function blocks created specifically for the ControlWave-series of
controllers. It is automatically loaded when you choose the ControlWave
Template in the New Project dialog box. User libraries are optionally
created by the user. They are libraries of programs, functions, and function
blocks called in from other previously saved projects.
Data Types The Data Type worksheets can be used to define customized data type
structures. For example, arrays of numbers. NOTE: The data entered here
5 Getting Started with ControlWave
Starting ControlWave Designer, Opening A Project
only defines the data type, it doesn’t actually set aside memory for storing
the data - - that occurs in a variable declaration.
Physical Hardware Physical hardware defines details of the actual controller which will
execute the project. It is divided into several sections:
RTU_CFG is the type of code generation required for the controller – for
ControlWave this always begins with IPC, and it is always configured via
the IO Configuration Wizard.
RTU_RESOURCE defines the type of run-time system used – in this
case, it is always 'ControlWave'.
Tasks are the actual mechanism by which programs are executed. When
you have completely defined a program, you must associate a program
instance with an executing task, and define the rate of execution.
Global_Variables is where any user-created global variables are defined.
IO_Configuration defines the inputs and outputs of the process I/O
boards in the ControlWave-series controller and optionally the
ControlWave Remote Ethernet I/O, and/or ControlWave I/O Expansion
Rack(s). This section should only be edited via the IO Configuration
Wizard; do NOT attempt to edit it manually.
Additional worksheets are added to the project tree as you build your project. Some of these are
added automatically, others must be manually added by the user.
IMPORTANT
Do not rename items in the project tree created automatically by ControlWave Designer,
such as the ‘IO_Configuration’ item. ControlWave Designer looks for worksheets under
specific items of the tree, and if you rename those items, ControlWave Designer will be
unable to locate those worksheets.
NOTE: We have introduced a lot of terminology in this section. Don’t worry about absorbing all
of it now. The most important parts should become clearer to you as you proceed through the
‘Configuring I/O’ and Example sections, later in this manual.
Getting Started with ControlWave Designer 6
Configuring I/O
Configuring I/O
In order to reference I/O points on the process I/O boards of your controller, you need to
configure them within your project.
Although it is possible to manually edit the “IO_Configuration” section of the project tree, we
strongly recommend you use the I/O Configuration Wizard, as it will perform syntax checking,
and is easier for most users.
The I/O Configuration Wizard is accessible from within ControlWave Designer by clicking as
follows: ViewIO Configurator
When started, any existing I/O configuration data will be read and displayed in the I/O
Configuration Wizard. The Configuration Wizard is a multi-page tool; [>>Next>>] and
[<<Back<<] buttons are provided to allow you to move between the pages. A [Settings] push
button allows the user to rename default variable names, if necessary. (See ‘Changing Default
Variable Names’, later in this section.) NOTE: Page 1 allows the user to define multiple
resources. Typically, only a single resource is used, so by default, page 2 will appear first since
most users do not need to use Page 1.
IMPORTANT
The IO Configuration Wizard will add a variable group to the Global_Variables worksheet
called IO_GLOBAL_VARIABLES. Both the IO_GLOBAL_VARIABLES group in the
Global_Variables worksheet and the IO_Configuration worksheet should never be manually
edited by the user; these should only be modified through the IO Configuration Wizard.
7 Getting Started with ControlWave Designer
Configuring I/O
I/O Configuration Wizard (Step 1 of 3): (Most users can skip to Step 2)
The first page of the I/O Configuration Wizard allows the user to select from the available I/O
configurations and I/O resources. NOTE: Because most projects utilize a single configuration
and resource, this page is skipped when first starting the I/O Configuration Wizard. It is
accessible, however, by clicking on the [<<Back<<] button from the second page of the Wizard.
Available
Configurations
Available Resources
Click on [Next>] to proceed to the next step.
Getting Started with ControlWave Designer 8
This lists all configurations in the current project. Select the I/O
Configuration Section for which you are defining the I/O.
NOTE: Typically, projects utilize a single I/O configuration
section.
This lists all resources for the selected I/O configuration. Choose
the resource for which I/O is to be defined. NOTE: Typically,
projects utilize a single resource.
Configuring I/O
I/O Configuration Wizard (Step 2 of 3):
The second page of the I/O Configuration Wizard allows the user to specify which process I/O
boards are actually installed in the ControlWave-series controller, as well as boards which are
installed in separate devices such as I/O Expansion Racks, or Remote Ethernet I/O units.
Boards should be selected from the selection boxes in the ascending order of their slot number.
First, use the “Unit Type” list box to identify which type of ControlWave controller you are
configuring, then select the desired boards, and click on [ADD].
If this controller has associated I/O racks, or Remote Ethernet I/O units, choose those boards in
the “Ext Rack Board” and “Remote IO Boards” selection boxes and click on [ADD].
For more information on the various fields, see below:
Unit Type
9 Getting Started with ControlWave Designer
This field allows you to identify the type of ControlWave-series
controller you are configuring, so that the proper board types can be
Configuring I/O
displayed for it. The types of controllers include:
CW_ ControlWave Process Automation Controller
CWM_ ControlWave MICRO Process Automation Controller
LP_ ControlWave Low Power (LP) Process Controller
CXX_ ControlWave CW_30 or CW_10 Controller
Once you select the type of controller, the boards which can be
installed in that unit will be displayed as possible choices.
For ease of configuration, select the boards from the list in ascending
order of their slot number in the ControlWave unit. Clicking once on
the board abbreviation will cause a description of the board to be
displayed at the bottom of the Wizard page. Double-clicking on the
board abbreviation (or clicking once on the board and then clicking
on [ADD]) will add the board to the “Selected Boards List”. The
‘I/O Configurator’ section of the ControlWave Designer
Programmer’s Handbook (document# D5125) lists the various types
of boards.
Ext Rack Boards
Remote IO Boards
Selected Boards List
Click on [Next] to verify configuration information, adjust slot numbering, define zeros and
spans for analog inputs, etc.
This lists boards which may be installed in the ControlWave I/O
Expansion Rack. If this ControlWave-series controller is configured
to use an I/O Expansion rack, select the appropriate boards in
ascending order of their slot number in the rack.
Double-clicking on the board abbreviation (or clicking once on the
board and then clicking on [ADD]) will add the board to the
“Selected Boards List”
This lists boards used in ControlWave Remote Ethenet I/O units. If
this ControlWave controller is configured to use Remote Ethernet
I/O, select the appropriate boards.
Double-clicking on the board abbreviation (or clicking once on the
board and then clicking on [ADD]) will add the board to the
“Selected Boards List”
This list allows the user to declare which boards reside in the
ControlWave controller or its configured ControlWave Remote
Ethernet I/O unit(s), or ControlWave I/O Expansion Racks. To
remove a board from the “Selected Boards List” double-click on it,
or click on it once, and then click on [REMOVE]. To remove all
boards click on [REMOVE ALL].
Getting Started with ControlWave Designer 10
Configuring I/O
I/O Configuration Wizard (Step 3 of 3):
The third page of the I/O Configuration Wizard displays configuration details for each board. To
see the details, click on the board abbreviation, and the configuration details will be displayed on
the right hand side of the page. NOTE: The fields available for particular boards vary from
platform to platform.
Selected Boards List
Board Name
Map Type
Displays all boards selected on the previous page. Click on a particular
board abbreviation to display configuration details for the board.
A name for the board can be specified here. This name will be used
when configuring pins for the board.
(Information Only) Depending upon the type of board, separate
memory areas (called maps) are reserved for either inputs or outputs.
Some boards have both an input map and an output map. For example,
a digital output board has outputs (DOs) in its output map, but it may
also have inputs which indicate board status conditions and errors. For
more detailed information on the input and output maps for various
boards, see the ‘I/O Mapping’ section of the ControlWave Designer
Programmer’s Handbook (document# D5125).
NOTE: If you have an older ControlWave project in which you changed
the map type from the default choice, this may cause errors to be
11 Getting Started with ControlWave Designer
Configuring I/O
generated when the project is rebuilt. If this occurs, you should delete
the board definition and re-define the board.
Start… End Address
Slot Number
IP Address
Related Task
Mark Variables as
PDD OPC
When edits have been made to this page, click on the [Show xxx Information] button. The
name on this button, and the pin configuration details, vary depending on the type of board being
configured. See the pages that follow for the standard board types.
NOTE: If you are using RIO Open Modbus board types, please see the ‘I/O Configurator’
section of the ControlWave Designer Programmer’s Handbook (document# D5125).
Displays the range of memory addresses used by the board.
Displays either the physical I/O slot in the ControlWave controller
which holds the board, or if this is a Mixed I/O Board (MIOB) it
displays a board selection number. For ControlWave and ControlWave
Micro, I/O slot numbers are positive integers, e.g. 1, 2, 3, etc. For the
ControlWaveLP, the slot number is 0 for all boards except for the AO;
for the AO the slot can be 8 to 13. NOTE: I/O Slot number is NOT the
same as the chassis slot number. Chassis slots which hold the power
supply and CPU boards are not considered to be I/O slots, so the first
I/O slot is typically the third chassis slot.
ControlWave Remote Ethernet I/O boards are identified by their
Internet Protocol (IP) address, instead of the I/O slot number. The same
is true for boards residing in a ControlWave I/O Expansion Rack.
Shows the name of the task which uses this board. In some cases, for
example, when using Ethernet I/O, or analog boards in an RTU 3340, it
is important to associate a board with the task which uses the board.
When a board is associated with a task, that board will be read / written
to, at the rate cycle associated with the task, thereby ensuring up-to-date
information for calculations performed in the task. When no task is
associated with the board, board execution is associated with the default
task, which runs at a lower priority, and therefore may not provide
sufficient up-to-date I/O information when it is required by a task.
This determines how values of the I/O variables associated with this
board will be made available to other software programs. Checking
“PDD” allows the controller to reference variables by name, which is
necessary if you intend to access a variable by external software which
requires ‘read-by-name’ access, such as DataView, or one of the other
OpenBSI Utilities. Checking “OPC” adds this variable to a collection
list used by the ObjectServer or by the OpenBSI Signal Extractor. This
is necessary when data is to be extracted, and sent to a database.
Getting Started with ControlWave Designer 12
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