s
Instruction Manual
Doc Number CI-ControlWave
Part Number D301381X012
August 2015
ControlWave®
Process Automation Controller
Remote Automa tio n 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 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 Remote Automation
Solutions.
RETURNED EQUIPMENT WARNING
When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions 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 Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions 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.
ControlWave Instruction Manual
Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual ................................................................................................................. 1-2
1.2 Physical Description .................................................................................................................. 1-2
1.3 Housings ................................................................................................................................... 1-3
1.4 CPU Module .............................................................................................................................. 1-5
1.5 Power Supply/Sequencer Module (PSSM) ............................................................................... 1-7
1.6 I/O Modules ............................................................................................................................... 1-7
1.7 Software Tools .......................................................................................................................... 1-8
1.8 Secure Gateway ...................................................................................................................... 1-10
Chapter 2 – Installation 2-1
2.1 Site Considerations ................................................................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ...................................................................... 2-2
2.2 Installation Overview ................................................................................................................. 2-3
2.2.1 Unpacking Components ................................................................................................ 2-3
2.2.2 Color Coding of Slot Connectors .................................................................................. 2-4
2.2.3 Mounting the Housing ................................................................................................... 2-4
2.2.4 Grounding the Housing ................................................................................................. 2-6
2.3 Power Supply/Sequencer Module (PSSM) ............................................................................... 2-7
2.3.1 General Information about the PSSM ........................................................................... 2-7
2.3.2 PSSM Installation Overview .......................................................................................... 2-8
2.3.3 Setting Jumpers ............................................................................................................ 2-9
2.3.4 General Wiring Guidelines .......................................................................................... 2-11
2.3.5 Wiring a Bulk DC Power Supply to the PSSM ............................................................ 2-12
2.3.6 Hot-swapping a Power Supply .................................................................................... 2-15
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog Connector and Wiring the
Redundancy Control Input (OPTIONAL) ................................................................................ 2-16
2.3.8 Wiring Digital Inputs to indicate Power Supply Failure ............................................... 2-18
2.3.9 PSSM Specifications ................................................................................................... 2-19
2.4 CPU Module ............................................................................................................................ 2-20
2.4.1 Setting DIP Switches on the CPU Module .................................................................. 2-21
2.4.2 Connections to RS-232 Serial Port(s) ......................................................................... 2-24
2.4.3 Connections to RS-485 Serial Port(s) on tSecondary Communication Board (SCB) . 2-28
2.4.4 Connections to Ethernet Port(s) on the CPU Module ................................................. 2-30
2.5 Bezels ...................................................................................................................................... 2-32
Chapter 3 – I/O Modules 3-1
3.1 Module Placement .................................................................................................................... 3-3
3.2 Status LEDs .............................................................................................................................. 3-4
3.3 Wiring ........................................................................................................................................ 3-4
3.3.1 Local Termination .......................................................................................................... 3-5
3.3.2 Remote Termination ...................................................................................................... 3-6
3.3.3 Shielding and Grounding ............................................................................................... 3-6
3.4 Digital Input (DI) Modules .......................................................................................................... 3-8
3.5 Digital Output (DO) Modules ................................................................................................... 3-13
3.6 Analog Input (AI) Modules ....................................................................................................... 3-20
3.7 Analog Output (AO) Modules .................................................................................................. 3-25
3.8 Universal Digital Input (UDI) Modules ..................................................................................... 3-30
3.9 Isolated Resistance Temperature Device (RTD) Input Module .............................................. 3-36
3.10 Isolated Thermocouple Module ............................................................................................... 3-40
Issued Aug-2015 Contents iii
ControlWave Instruction Manual
Chapter 4 – Operation 4-1
4.1 Powering Up/Powering Down the ControlWave ....................................................................... 4-1
4.2 Communicating with the ControlWave ...................................................................................... 4-2
4.2.1 Default Comm Port Settings ......................................................................................... 4-2
4.2.2 Changing Port Settings ................................................................................................. 4-3
4.2.3 Collecting Data from the ControlWave .......................................................................... 4-4
4.3 Creating and Downloading an Application (ControlWave Project) ........................................... 4-4
4.4 Creating and Maintaining Backups ........................................................................................... 4-5
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-5
4.4.2 Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-7
4.4.3 Backing up Data ............................................................................................................ 4-8
Chapter 5 – Service and Troubleshooting 5-1
5.1 Upgrading Firmware .................................................................................................................. 5-2
5.2 Removing or Replacing Components ....................................................................................... 5-5
5.2.1 Accessing Modules for Testing ..................................................................................... 5-5
5.2.2 Removing/Replacing the Bezel ..................................................................................... 5-5
5.2.3 Removing/Replacing the CPU Module ......................................................................... 5-6
5.2.4 Removing/Replacing the PSSM .................................................................................... 5-6
5.2.5 Removing/Replacing an I/O Module (Hot Swapping) ................................................... 5-7
5.2.6 Removing/Replacing the Backup Battery ................................................................... 5-11
5.3 General Troubleshooting Procedures ..................................................................................... 5-12
5.3.1 Common Communication Configuration Problems ..................................................... 5-12
5.3.2 Checking LEDs ........................................................................................................... 5-12
5.3.3 Checking Wiring/Signals ............................................................................................. 5-21
5.3.4 Port 80 Display Codes ................................................................................................ 5-22
5.3.5 Reset Switch ............................................................................................................... 5-25
5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-25
5.4.1 Available Diagnostics .................................................................................................. 5-28
5.5 Core Updump .......................................................................................................................... 5-32
Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1
Index IND-1
iv Contents Issued Aug-2015
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Process Automation Controller (called the “ControlWave” throughout
the rest of this manual). For information about the software used with
the ControlWave, refer to the ControlWave Quick Setup Guide (D5084),
the ControlWave Designer Programmer’s Handbook (D5125), and the
online help in ControlWave Designer.
This chapter details the structure of this manual and provides an
overview of the ControlWave and its components.
In This Chapter
1.1 Scope of the Manual ........................................................................ 1-2
1.2 Physical Description ........................................................................ 1-2
1.3 Housings .......................................................................................... 1-3
1.4 CPU Module .................................................................................... 1-5
1.5 Power Supply/Sequencer Module (PSSM) ..................................... 1-7
1.6 I/O Modules...................................................................................... 1-7
1.7 Software Tools ................................................................................. 1-8
1.8 Secure Gateway ............................................................................ 1-10
ControlWave Instruction Manual
Features
ControlWave products have been designed and integrated as a highly
adaptable, high performance distributed open controller family with
exceptional networking capability that provides a complete process
automation management solution for the natural gas, water, and
wastewater industries. The ControlWave was designed with an
emphasis on providing high performance with low power consumption,
scalability, and modularity.
ControlWave process automation controllers have the following key
features:
Low power consumption
Wide operating temperature range: (–40 to +70C) (–40 to 158F)
Small size (enabling panel mount or 19 inch rack-mount
installations)
Two RS-232 ports
One 10/100 MB Ethernet port
Optional secondary communication board (SCB) provides additional
options for RS-232, RS-485, and Ethernet communications
Housings to support four or eight I/O modules
Variety of I/O modules and support for hot swapping of I/O modules
Support for redundant operation with another ControlWave process
automation controller
LED status indicators on the CPU, PSSM, and certain I/O modules
Revised Aug-2015 Introduction 1-1
ControlWave Instruction Manual
Port 80 display to present status codes
Battery backup for the real-time clock and the system’s static RAM
(SRAM)
Class I, Division 2 Hazardous Location approvals
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Chapter 2
Installation
Chapter 3
I/O Modules
Chapter 4
Operation
Chapter 5 Service and
Troubleshooting
1.2 Physical Description
Each ControlWave has a printed circuit board (PCB) backplane
mounted in a stainless steel housing, a Power Supply/Sequencer Module
(PSSM), a CPU module which may include an optional Secondary
Communication Board (SCB) and—depending on the backplane and
housing size—up to eight I/O modules.
Provides an overview of the hardware and
general specifications for the ControlWave.
Provides information on the housings, the
Power Supply/Sequencer module (PSSM), and
the CPU module.
Provides general information and wiring
diagrams for the I/O modules.
Provides information on day-to-day operation of
the ControlWave.
Provides information on service and
troubleshooting procedures.
Figure 1-1.
ControlWave with 8 I/O Modules
Refer to the following sections in this chapter or to other chapters in this
manual for further information:
Housings (chassis) with backplanes (see Section 1.3 and Chapter 2)
1-2 Introduction Revised Aug-2015
1.3 Housings
ControlWave Instruction Manual
Power Supply/Sequencer module (PSSM) (see Section 1.5 and
Chapter 2)
CPU module (see Section 1.4 and Chapter 2)
One or more I/O modules (see Section 1.6 and Chapter 3)
ControlWave housings are stainless steel designed for panel-mounting
or for some versions, for mounting in a 19-inch equipment rack. They
contain the printed circuit board (PCB) backplane into which you
connect the PSSM, the CPU module, and any I/O modules.
The following housings are available:
6-slot backplane supports one PSSM, one CPU, and up to four I/O
modules.
10-slot housing supports one PSSM, one CPU, and up to eight I/O
modules. The 10-slot housing is suitable for mounting in a 19-inch
equipment rack.
Note: For detailed technical specifications, please see document
CWPAC available on our website
http://www.emersonprocess.com/remote.
Revised Aug-2015 Introduction 1-3
ControlWave Instruction Manual
Figure 1-2. ControlWave Housing Options
1-4 Introduction Revised Aug-2015
1.4 CPU Module
ControlWave Instruction Manual
The CPU (central processing unit) module houses the multi-layer PCB,
which contains the ControlWave CPU, I/O monitor/control, memory,
and communication functions. It also may include the optional
Secondary Communications Board (SCB).
The CPU module includes:
AMD Elan SC520 microprocessor running at 100 MHz
two RS-232 communication ports
one 10/100baseT Ethernet port
2 MB of battery backed Static RAM (SRAM)
64 MB of Synchronous Dynamic RAM (SDRAM)
512 KB boot/downloader FLASH
32 MB simultaneous read/write FLASH memory
transmit (TX) and receive (RX) LEDs for each communication port
Keyed run/remote/local operation switch
configuration DIP switches (described in Chapter 2)
Port 80 display to show status codes
You can order the CPU module with the optional secondary
communication board (SCB) for additional communication ports. See
CPU Module Configurations.
CPU Module
Configurations
The CPU module has several basic configurations, all of which
have an on-board backup battery and different combinations of
communications ports.
Table 1-1. CPU Module Configurations
Part Number Number of RS-232
Ports
396359-21-3 2 0 1 No SCB.
396359-26-4 3 1 1 For this port count, 1 RS-232
396359-25-6 3 1 3 For this port count, 1 RS-232
396359-32-9 2 2 3 For this port count, both RS-
CPU Backup
Battery
Number of RS-
485 Ports
Number of
Ethernet Ports
Notes
port and 1 RS-485 port reside
on the SCB.
port,1 RS-485 port, and 2
Ethernet ports reside on the
SCB.
485 ports and 2 Ethernet
ports reside on the SCB.
The CPU module includes a 3.6V, 950 mA-hr lithium
AA
battery. This battery provides backup power for the
½
real-time clock, CMOS RAM (within the microprocessor)
and the system’s Static RAM (SRAM).
Revised Aug-2015 Introduction 1-5
ControlWave Instruction Manual
CPU Memory
There are several different types of memory used on the CPU module:
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The CPU module contains 32 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.
System Memory (SRAM)
The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by the CPU backup battery). Critical system information that must be
retained during power outages or when the system has been disabled for
maintenance is stored here. This includes the last states of all I/O points,
audit/archive historical data (if not stored in FLASH), the values of any
variables marked RETAIN, the values of any variables assigned to the
static memory area, and any pending alarm messages not yet reported.
SDRAM
The CPU module contains 64MB of synchronous dynamic random
access memory (SDRAM). SDRAM holds the running application
(ControlWave project) as well as a copy of system firmware and the
current values of any variables not marked RETAIN or stored in the
static memory area. This allows the system to run faster than it will
from the SRAM memory. SDRAM is not battery-backed.
CMOS RAM
The Elan microprocessor includes 124 bytes of complementary metal
oxide semiconductor (CMOS) RAM to hold various internal
parameters.
1-6 Introduction Revised Aug-2015
1.5 Power Supply/Sequencer Module (PSSM)
The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.
You can order it with either a single on-board power supply or dual onboard power supplies to support hot-swapping of a power supply if one
should fail.
The PSSM operates from +22.2 to +30V (dc) and ships from the factory
with a nominal input supply configuration of 24V.
The PSSM includes:
ON/OFF system supply switch(es)
Pluggable terminal block to connect the external power supply
Watchdog output connector to signal a watchdog failure to an
external device
Status LEDs
Chapter 2 includes instructions for installing and configuring the PSSM.
ControlWave Instruction Manual
1.6 I/O Modules
The ControlWave supports analog input, analog output, digital input,
digital output, universal digital input, isolated RTD, and isolated low
level analog (thermocouple and mV) input modules for either local or
remote field device wiring termination.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-3
shows a typical I/O module housing.
Terminations are pluggable and accept a maximum wire size of #14
AWG. All I/O modules have surge protection that meets either C37.901978 or 472-1978 IEEE specifications.
Each I/O module connects to the backplane using a 110-pin male
connector and to its associated terminal block assembly using a 44 pin
header.
Revised Aug-2015 Introduction 1-7
ControlWave Instruction Manual
1.7 Software Tools
The ControlWave programming environment consists of a set of
integrated software tools which allow you to create, test, implement,
and download complex control strategies for use with the ControlWave.
Figure 1-4 graphically presents the programming environment.
The tools which make up the programming environment include:
ControlWave Designer is your load-building package. It offers
Figure 1-3. I/O Module (with door open)
several different methods for you to create control strategy programs
that run in your ControlWave. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), the ControlWave Quick Setup Guide
(document D5084), and the ControlWave Designer Programmer’s
Handbook (document D5125).
1-8 Introduction Revised Aug-2015
ControlWave Instruction Manual
Figure 1-4. ControlWave Programming Environment
The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O modules in the
ControlWave and configure the individual mapping of I/O points for
digital and analog inputs and outputs. For information on the I/O
Configurator see
the ControlWave Designer Programmer’s
Handbook (document D5125).
The ACCOL3 Firmware Library, available within ControlWave
Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see the
online help within ControlWave Designer.
OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).
OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).
Revised Aug-2015 Introduction 1-9
ControlWave Instruction Manual
A series of web page controls are available for retrieval of real-time
User-defined web pages - If desired, you can use the ActiveX web
Flash Configuration Utility – Parameters such as the BSAP local
Communication
Protocols
In addition to the Bristol Synchronous/Asynchronous Protocol
(BSAP), ControlWave supports communications using:
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. Alternatively,
developers can place the controls in third-party ActiveX compatible
containers such as Visual BASIC or Microsoft® Excel. For
information on the ActiveX controls, see the Web_BSI Manual
(document D5087).
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).
1.8 Secure Gateway
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port using serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
For enhanced data security when using an IP/Ethernet connection,
Emerson Remote Automation Solutions recommends adding an
industrial router with VPN and firewall security. Recommended
solutions include the MOXA EDR‐810, the Hirschman Eagle One, or
the Phoenix mGuard rs4000 (or equivalents). An example of how to
install one of these devices to the RTU can be found in the Emerson
Remote Automation Solutions MOXA® Industrial Secure Router
Installation Guide (part number D301766X012). For further
information, contact your Local Business Partner or the individual
vendor’s website.
1-10 Introduction Revised Aug-2015
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave,
considerations for installation, wiring instructions for the PSSM
module, and instructions for setting switches and jumpers on the CPU
module. For instructions on I/O installation, see Chapter 3.
In This Chapter
2.1 Site Considerations .......................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ............................. 2-2
2.2 Installation Overview ........................................................................ 2-3
2.2.1 Unpacking Components ....................................................... 2-3
2.2.2 Color Coding of Slot Connectors .......................................... 2-4
2.2.3 Mounting the Housing .......................................................... 2-4
2.2.4 Grounding the Housing ........................................................ 2-6
2.3 Power Supply/Sequencer Module (PSSM) ..................................... 2-7
2.3.1 General Information about the PSSM .................................. 2-7
2.3.2 PSSM Installation Overview ................................................. 2-8
2.3.3 Setting Jumpers ................................................................... 2-9
2.3.4 General Wiring Guidelines ................................................. 2-11
2.3.5 Wiring a Bulk DC Power Supply to the PSSM ................... 2-12
2.3.6 Hot-swapping a Power Supply ........................................... 2-15
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog
2.3.8 Wiring Digital Inputs to indicate Power Supply Failure ...... 2-18
2.3.9 PSSM Specifications .......................................................... 2-19
2.4 CPU Module .................................................................................. 2-20
2.4.1 Setting DIP Switches on the CPU Module ......................... 2-21
2.4.2 Connections to RS-232 Serial Port(s) ................................ 2-24
2.4.3 Connections to RS-485 Serial Port(s) on the Secondary
2.4.4 Connections to Ethernet Port(s) on the CPU Module ........ 2-30
2.5 Bezels ............................................................................................ 2-32
ControlWave Instruction Manual
Connector and Wiring the Redundancy Control Input
(OPTIONAL) ..................................................................... 2-16
Communication Board (SCB) ........................................... 2-28
2.1 Site Considerations
When choosing an installation site, check all clearances. Ensure that the
ControlWave is accessible for wiring and service.
To ensure safe use of this product, please review and follow the
Caution
Revised Aug-2015 Installation 2-1
instructions in the following supplemental documentation:
Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
ControlWave Instruction Manual
Specifications
for Temperature,
Humidity and
Vibration
Caution
2.1.1 Class I, Div 2 Installation Considerations
See document CWPAC available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave. This document is available on our website at:
http://www.emersonprocess.com/remote.
Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave is not
exposed to a level of vibration that exceeds that provided in the
technical specifications..
Placement of the ControlWave in Class 1, Division 2 (Group A, B, C, and
D) hazardous locations requires that you select an appropriate
enclosure that meets NEMA Type 3X or 4X specifications.
Underwriters Laboratories (UL) lists the ControlWave as non-incendive
and suitable only for use in Class I, Division 2, Group A, B, C, and D
hazardous locations and non-hazardous locations. Read this chapter and
Appendix A carefully before you install a ControlWave in a hazardous
location.
WARNING
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not connect or disconnect equipment unless the power is switched
off or the area is known to be non-hazardous.
2-2 Installation Revised Aug-2015
2.2 Installation Overview
Installing a ControlWave involves several general steps:
1. Unpacking, assembling, and configuring the hardware
2. Installing PC-based software (ControlWave Designer)
3. Establishing communications
4. Creating an application-specific control strategy (ControlWave
project).
5. Creating application-specific web pages (optional)
6. Adding the ControlWave to an OpenBSI network
7. Downloading the application-specific ControlWave project into the
ControlWave
Note: Steps 2 through 7 require that you install and use ControlWave
ControlWave Instruction Manual
Designer software on your PC. This manual focuses on hardware
installation and preparation. Software installation and
configuration is beyond the scope of this manual. Refer to the
ControlWave Quick Setup Guide (D5084) for material related to
software installation and use.
2.2.1 Unpacking Components
Packaging
Depending upon how you order it, the ControlWave may arrive preassembled, with all modules installed in the housing, or as individual
components in a number of separate boxes. In the latter case, you must
identify, unpack, and assemble the components. Unless otherwise
noted, you can place I/O modules in any slot in a base or expansion
housing.
Note: Do not install modules in the housing until you have mounted
and grounded the housing at the designated installation site.
Delivered boxes may include:
Housing assemblies
Power Supply/Sequencer module (PSSM)
Note: The PSSM must reside in slot #1 in the base housing.
CPU module
Note: The CPU module must reside in slot #2 in the base housing.
Revised Aug-2015 Installation 2-3
ControlWave Instruction Manual
I/O Modules
2.2.2 Color Coding of Slot Connectors
A color tab on each backplane connector matches the color on the
module which you can place in that slot.
PSSM goes in the first slot (Yellow tab)
CPU goes in the second slot (Blue tab)
I/O modules go in any other slot (Green tab)
Notes:
There are many different types of I/O modules available. Chapter
3 contains detailed instructions on each I/O module.
Universal Digital Input (UDI) modules can only reside in the first
four I/O slots.
One or more bezel assemblies; each bezel covers two I/O
modules.
2.2.3 Mounting the Housing
You can install a ControlWave equipped with a 4-I/O module housing
on a wall or panel. See Figure 2-2 for mounting hole patterns for a 4-
I/O unit.
You can install a ControlWave equipped with an 8-I/O module housing
in a 19-inch equipment rack, a panel or a wall. These units ship from the
factory with the end plates configured for 19-inch rack mounting.
Remove the end plates, rotate them 180° and then reinstall them to
accommodate panel or wall mounting. See Figure 2-1 for hole patterns
and dimensions.
When you install any of these units on a panel or wall, position it
according to the following restrictions:
Position the unit so that you can see the front of the assembly and so
it is accessible for service such as installing a module or replacing a
battery.
Do not install ControlWave modules until you mount the housing
and ground it properly.
2-4 Installation Revised Aug-2015
ControlWave Instruction Manual
Figure 2-1. 8-I/O Module ControlWave - Mounting Diagram
Revised Aug-2015 Installation 2-5
ControlWave Instruction Manual
Figure 2-2. 4-I/O Module ControlWave - Mounting Diagram
2.2.4 Grounding the Housing
Caution
2-6 Installation Revised Aug-2015
Do not install any modules in the housing until you mount and ground
the housing at the designated installation site.
Housings have a ground lug that accommodates up to a #4 AWG wire
Once you install the housing, you must run a ground wire between
size.
the housing ground lug and a known good earth ground.
When you install the various ControlWave modules into the housing
and secure them using the captive panel fasteners, this automatically
connects them to chassis ground.
Note: After you install the PSSM in the housing, as an added
precaution we recommend that you run a #14 AWG wire from
the TB2-3 power connection (chassis ground) to the same known
good earth ground.
Additional grounding guidelines include:
Use stranded copper wire (#4 AWG) for the housing to earth
ground, and keep the length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Tin the wire ends with solder (using a high-wattage soldering iron)
prior to inserting the wire into the housing ground lug.
Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.
2.3 Power Supply/Sequencer Module (PSSM)
ControlWave Instruction Manual
Before we actually install the PSSM it in the housing, we’re going to
discuss some general information about how it works.
2.3.1 General Information about the PSSM
The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.
The PSSM is used in the following ControlWave models:
ControlWave Process Automation Controller
ControlWave I/O Expansion Rack
ControlWave Redundant Controller
The PSSM plugs into slot #1 (first slot from the left) on the
ControlWave’s backplane using connector J1.
The PSSM provides your ControlWave with dual power supplies for
operational redundancy.
Note: You can optionally purchase the PSSM with only a single power
supply installed, however, this configuration does not allow for
redundancy within the PSSM which is discussed throughout this
section.
The PSSM includes two independent power supplies. Should either
power supply fail, operations automatically continue using the second
supply, and you can “hot-swap” the failed power supply with a spare
unit without interrupting control operations. The PSSM also supports
hot swapping of I/O modules. However, you cannot replace the entire
PSSM itself without first turning off power to the ControlWave.
Revised Aug-2015 Installation 2-7
ControlWave Instruction Manual
When used as part of a redundant system, the failure of one of the two
power supplies in a redundant power supply sequencer module would
not force a failover to the other controller. Only the loss of both power
supplies on the redundant power supply sequencer module would
trigger a failover.
Power
Supply
WARNING
Hot Swap of I/O
Modules
Hot Swapping of
Power Supplies
Watchdog
Switch
Redundancy
Control Input
The PSSM ships from the factory configured for a nominal input supply
of 24Vdc.
Do not perform “hot swapping” in a Class I, Division 2 hazardous
location.
The PSSM supports “hot swapping” of I/O modules. This means you
can insert or remove an I/O module from the chassis while power is
live.
There is no support for “hot swapping” of the entire PSSM itself, or the
CPU module, however, if you have the dual power supply version, you
can hot swap a power supply on the PSSM. For information on hot
swapping of power supplies see Section 2.3.6.
PSSMs include a watchdog metal oxide semiconductor field-effect
transistor (MOSFET) switch connector. The purpose of the watchdog
connector is to trigger an external alarm or annunciator if the
ControlWave enters a “watchdog” condition in which the CPU cannot
control your process. This occurs on power-up before the ControlWave
project starts, if the unit is reset, if the ControlWave project “crashes”
or if the system loses power. See Section 2.3.7.
The same terminal block (TB3) used for watchdog control also handles
a redundancy control line to a ControlWave Redundant I/O Switcher.
2.3.2 PSSM Installation Overview
There are several steps you need to follow when you install the PSSM.
1. Identify the carton holding the PSSM and remove it from that carton.
See Section 2.2.1.
2. If needed, set jumpers. See Section 2.3.3.
3. Slide the PSSM into slot #1 of the housing.
2-8 Installation Revised Aug-2015
ControlWave Instruction Manual
Slot 1
TB2
Power Supply
Module 1
Pin 7
TB3
Pin 1
Power Supply
TB1
Figure 2-3. PSSM Installed in ControlWave Slot #1 of a ControlWave Controller
4. Tighten the captive panel fasteners to secure the PSSM in place.
5. Unplug terminal block connectors TB1 and TB2 from the PSSM and
wire them to an external bulk DC power supply. See Section 2.3.5.
6. If you want to use the watchdog connector TB3, or use this
ControlWave in a redundant system, unplug TB3 from the PSSM and
wire it to an external annunciator or similar device according to
instructions in Section 2.3.7.
7. After you configure and install the CPU module in slot #2 re-connect
terminal blocks to their connectors to apply power to the unit.
2.3.3 Setting Jumpers
Depending upon how you are using the PSSM, you may have to change
one or more jumpers from their factory default positions. See Table 2-1
for a list of the jumpers and their functions; see Figure 2-5 for jumper
locations.
Table 2-1. PSSM Jumpers
Jumper Position Description
JP1 1-2
2-3 Disables the watchdog output.
JP2 1-2 Sets the PSSM as always the on-line unit.
Enables the watchdog output. This is the default. Watchdog wiring is discussed
later in this document.
This is the default. Use this setting if the PSSM is not installed in a redundant
system.
Revised Aug-2015 Installation 2-9
ControlWave Instruction Manual
Jumper Position Description
2-3 Specifies that the PSSM is part of a redundant system.
Choose this position if the PSSM is installed:
In a ControlWave Redundant Controller or
In a ControlWave Controller that is part of a redundant pair or
In a ControlWave I/O Expansion Rack that is part of a redundant pair.
JP3 1-2 Enables the 12V monitor.
This is the default. When enabled, the PSSM reports a failure when voltage falls
below 12V and lights the PWR Down LED to indicate the failure.
2-3 Disables the 12V monitor.
When disabled, the PSSM does not report a failure if voltage falls below 12V.
If you need to change the jumper positions, unscrew the protective case
from the PSSM using a Phillips screwdriver (see Figure 2-4).
screws
Figure 2-4.Removing the Protective Case from the PSSM
2-10 Installation Revised Aug-2015
ControlWave Instruction Manual
Figure 2-5. Jumper Locations
Make the necessary adjustments to the jumpers according to Table 2-1.
When finished, re-attach the case by first aligning the protective case
with the screw holes, then inserting and tightening each screw.
2.3.4 General Wiring Guidelines
ControlWave PSSMs use compression-type terminals. TB1 and TB2
accommodate up to #14 AWG wire. The maximum wire size for
TB3 is 16 AWG wire.
When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the wire.
To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.
Revised Aug-2015 Installation 2-11
ControlWave Instruction Manual
2.3.5 Wiring a Bulk DC Power Supply to the PSSM
Caution
Operating
Range
One or Two
Power
Supplies
At this time you can also connect power and watchdog wiring. However;
for safety reasons and to prevent accidental damage to the your bulk DC
power supply, do not connect the pluggable terminal block connectors
TB1 and TB2 (or TB3) to the PSSM until after you install, wire, and
configure the CPU module.
Follow the instructions in Section 2.3.4 General Wiring Guidelines when
wiring connections.
The ControlWave operates from +22.2 Vdc to +30.0 Vdc (with a
nominal +24Vdc input source).
You can connect one or two bulk DC power supplies (nominally +24
Vdc) to the PSSM. Use terminal blocks TB1 and TB2 to connect an
external bulk power supply to the PSSM.
The external bulk 24V DC power supply you connect to TB1-1 (+VIN)
provides system power to the ControlWave including the CPU boards,
communications and I/O boards (see Figure 2-6). The PSSM converts,
regulates, and filters the power to +5Vdc, +3.3Vdc, +12Vdc (optional)
and -12Vdc (optional).
+3.3 Vdc. For safety, this circuit has a 3A fuse.
The bulk DC supply you connect to terminal TB2-1 (+VINF) powers
the I/O field devices connected to the I/O modules. For safety, this
circuit has a 10A fuse.
Notes:
When you require two bulk power supplies, the first supply (VIN)
must be rated to handle 2 amps.
Be sure you route wires to the terminal block connectors so they do
not interfere with removal/replacement of the power supply
modules.
The fuses for the PSSM cannot be replaced in the field.
Figure 2-6. Wiring System Power to the PSSM
An external power supply (22.2 to 30V) connected to TB2 provides
field power to I/O boards, and any field devices (switches, relays, etc.)
powered through the I/O boards (see Figure 2-7).
2-12 Installation Revised Aug-2015
ControlWave Instruction Manual
Figure 2-7. Wiring Field Power to the PSSM
Calculating the
Maximum Current
Required
Max Bulk +24 Vdc Supply Current = CPU
where
CPU
Σ I/O Module
Use the following formula to determine the maximum current required
for the +24 Vdc bulk power used with a particular ControlWave:
max_current
+ Σ I/O Module
max_current
:
max_current
max_current
refers to the maximum current required by the CPU (with or
without an SCB), backplane and the PSSM. This is 1A.
refers to the sum of the maximum current required by each
and every I/O module installed in the unit. The amount per
I/O module varies as follows:
16 AI Module 2A per module
8 AI Module 1A per module
8 AO Module 1A per module
16 DI Module 1A per module
32 DI Module 1A per module
16 DO Module See table (no surge current)
32 DO Module See table (no surge current)
6 UDI Module See table (no surge current)
4 RTD Module See table (no surge current)
6 LLAI Module See table (no surge current)
So, for example, if you have a ControlWave with a 16AI module, an
8AO module, and a 32DI module, the maximum current draw is 1A for
the CPU plus 2A for the 16AI module plus 1A for the 8AO module and
1A for the 32DI module, for a total of 5A.
Note: This calculation covers current draw during normal operation
(steady state) as well as the current draw during power-up inrush when the unit is first powered on. Power up in-rush current
can last up to 100 milliseconds and is higher than the current
draw required during normal operation.
Refer to Table 2-2 for ControlWave steady state and loop current
requirements for bulk power supplies.
Revised Aug-2015 Installation 2-13
ControlWave Instruction Manual
Table 2-2. Steady State Current Draw for Bulk Power Supplies
Component(s) System Current
draw for 24Vdc
Power Supply
CPU (with Ethernet),
PSSM and backplane
CPU (with Ethernet), SCB
(with Ethernet), PSSM and
backplane
Analog Input Module 16
points (4-20 mA)
Analog Input Module 8
points (4-20 mA)
Analog Output Module 8
points (4-20 mA)
Analog Output Module 8
points (1-5V)
Digital Input Module 32
points
Digital Input Module 16
points
Digital Output Module 32
points
Digital Output Module 16
points
Universal Digital Input
(UDI) – 6 points
Isolated RTD 4 point 26.0 mA 0 mA
Isolated Low Level Analog
Input 6 points
290 mA Not applicable
400 mA Not applicable
40.5 mA 52.2 mA For 24Vdc supply add 25 mA per
36.1 mA 29.7 mA For 24Vdc supply add 25 mA per
20.0 mA 26.9 mA For 24Vdc supply add 23.6 mA
20.0 mA 56.8 mA For 24Vdc supply add 26.1 mA
29.2 mA 29.7 mA For 24Vdc supply add 4.74 mA
15.8 mA 29.7 mA For 24Vdc supply add 4.74 mA
42.6 mA 0 mA
22.6 mA 0 mA
16.7 mA 0 mA
40.0 mA 0 mA
Field Current draw for
24Vdc Power Supply
Notes
loop
loop
per loop
per loop. Output at 5 mA
per loop – dry contact
per loop – dry contact
Note: As an added precaution, we recommend that you run a #14
AWG wire from the TB2-3 power connection (chassis ground)
to the same known good earth ground used for the housing.
2-14 Installation Revised Aug-2015
2.3.6 Hot-swapping a Power Supply
ControlWave Instruction Manual
WARNING
ON/OFF switch for power
supply
OFF = down position (shown)
ON = up position
DO NOT ATTEMPT hot swapping in a Class I, Division 2
hazardous location.
Each power supply has a Power Good indication LED (see Chapter 5
for LED locations.) If this light goes out while the power supply is on,
the power supply’s output voltage is out of specification. This could
occur if the supply is not properly seated in the slot or if its fuse has
blown. Remove the power supply to check for these conditions. If
neither condition has occurred, you may need to replace the power
supply.
To remove one of the power supplies, first turn the power supply’s
ON/OFF switch off (the down position, as shown in Figure 2-8).
Loosen the plastic screw either by hand or with a Phillips screwdriver.
Grasp the bracket and gently pull the power supply straight out of the
assembly.
Bracket
Screw
Loosen the screw and grasp
the bracket to slide the
power supply out of the
PSSM.
Figure 2-8. Hot Swapping a Power Supply
To re-insert the power supply, grasp the bracket and line up the board
with the grooves in the assembly. Gently slide the card into the PSSM
until it inserts into the connector. Gently tighten the screw either by
hand or with a Phillips screwdriver. Now turn the On/Off switch on (the
up position).
Revised Aug-2015 Installation 2-15
ControlWave Instruction Manual
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog
Connector and Wiring the Redundancy Control Input
(OPTIONAL)
Caution
At this time you can also connect power and watchdog wiring.
However; for safety reasons and to prevent accidental damage to the
your bulk DC power supply, do not connect the pluggable terminal
block connectors TB1, TB2, or TB3 to the PSSM until after you install,
wire, and configure the CPU module.
Follow the instructions in Section 2.3.4 General Wiring Guidelines when
wiring connections.
When the CPU’s hardware detects improper software operation, it
triggers a watchdog condition and resets the CPU. If you have enabled
the watchdog output using jumper JP1, the watchdog condition triggers
a failure to the redundant unit.
The circuit that drives the watchdog switch is on the secondary side of
the power supply. A solid state relay actuates the watchdog hardware
and is factory enabled or disabled via jumper JP1 (see Setting Jumpers).
Figure 2-9. Watchdog Switch Field Wiring
The VI input of the terminal block (TB3-6) powers the watchdog
switch. Its switched output connects to the VO output of the terminal
block (TB3-5). Reference the external power source connected to the VI
terminal to the return point of the input source that powers the PSSM [VIN (TB1-2)].
PSSM connector TB3 provides watchdog switch and redundancy
control connections as follows:
Connections
TB3-5 = VO - Watchdog switch output
TB3-6 = VI - Watchdog switch input
TB3-7 = VR - Redundant unit control input (Used with CW RED I/O)
2-16 Installation Revised Aug-2015
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