s
ControlWave Corrector
Instruction Manual
Doc Number CI-ControlWave Corrector
Part Number D301382X012
November 2013
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 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 Corrector Instruction Manual
Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual ................................................................................................................. 1-2
1.2 Physical Description .................................................................................................................. 1-2
1.3 CPU/System Controller Board .................................................................................................. 1-3
1.4 Power Options ........................................................................................................................... 1-5
1.5 I/O Options ................................................................................................................................ 1-5
1.6 Software Tools .......................................................................................................................... 1-6
1.7 Overview of the Gas Flow Measurement Application ............................................................... 1-8
1.7.1 Data Acquisition – Static Pressure, Differential Pressure, Temperature Variables ...... 1-8
1.7.2 Flow and Volume Calculations ...................................................................................... 1-8
1.7.3 Flow Rate and Flow Time Calculations (AGA3)............................................................ 1-9
1.7.4 Flow Rate and Flow Time Calculations (AGA7)............................................................ 1-9
1.7.5 Extension Calculation and Analog Averaging ............................................................... 1-9
1.7.6 Energy Calculation ...................................................................................................... 1-10
1.7.7 Volume and Energy Integration .................................................................................. 1-10
1.7.8 Historical Data Storage (Audit Records/ Archive Files) .............................................. 1-10
1.7.9 Run Switching ............................................................................................................. 1-12
1.7.10 Sampler and Odorizer ................................................................................................. 1-12
1.7.11 Chromatograph Interface ............................................................................................ 1-12
1.7.12 Nominations ................................................................................................................ 1-13
Chapter 2 – Installation 2-1
2.1 Site Considerations ................................................................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ...................................................................... 2-3
2.2 Installation Overview ................................................................................................................. 2-4
2.3 Unpacking Components ............................................................................................................ 2-5
2.4 Mounting the ControlWave Corrector Assembly ....................................................................... 2-5
2.4.1 Configuring the TeleCounter Assembly ...................................................................... 2-13
2.4.2 Configuring the ISPROX Module (Option) .................................................................. 2-13
2.4.3 Connection to the Gage Pressure Transducer (GPT) ................................................ 2-14
2.4.4 Grounding the Housing ............................................................................................... 2-17
2.5 Configuring the CPU/System Controller Board ....................................................................... 2-18
2.5.1 Setting DIP Switches on the CPU/System Controller Board ...................................... 2-19
2.5.2 Setting Jumpers on the CPU/System Controller Board .............................................. 2-21
2.5.3 General Wiring Guidelines .......................................................................................... 2-22
2.5.4 Wiring Power to the CPU/System Controller Board .................................................... 2-23
2.5.5 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board ............. 2-25
2.5.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller
Board ......................................................................................................................... 2-30
2.5.7 Connections to the Ethernet Port on the CPU/System Controller Board .................... 2-32
2.6 Radio-Ready and Case Mounted Modem or Radio ................................................................ 2-33
2.7 Mounting the Solar Panel ........................................................................................................ 2-34
2.8 Optional Display/Keypads ....................................................................................................... 2-37
Chapter 3 – I/O Configuration and Wiring 3-1
3.1 I/O Options ................................................................................................................................ 3-1
3.2 Process I/O Board ..................................................................................................................... 3-2
3.2.1 Setting Jumpers on the Process I/O Board ................................................................... 3-2
3.2.2 Setting DIP Switches on the Process I/O Board ........................................................... 3-2
3.3 I/O Wiring .................................................................................................................... .............. 3-4
Issued Nov-2013 Contents iii
ControlWave Corrector Instruction Manual
3.3.1 Non‐Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board ................... 3-6
3.3.2 Non‐Isolated Discrete Outputs (DO) on TB3 of Process I/O Board.............................. 3-7
3.3.3 Non‐Isolated Analog Inputs (AI) on TB6 of Process I/O Board .................................... 3-8
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board .................................. 3-9
3.3.5 Non‐Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Bd .. 3-10
3.3.6 Non‐Isolated High Speed Counter/ Discrete Inputs on TB4 of Process I/O Board .... 3-13
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board ..... 3-14
3.3.8 Connections to a Bristol Model 3808 Transmitter ....................................................... 3-16
Chapter 4 – Operation 4-1
4.1 Powering Up/Powering Down the ControlWave Corrector ....................................................... 4-1
4.2 Communicating with the ControlWave Corrector ...................................................................... 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 Corrector ......................................................... 4-3
4.3 Creating and Downloading an Application (ControlWave Project) ........................................... 4-3
4.4 Creating and Maintaining Backups ........................................................................................... 4-4
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-4
4.4.2 Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-6
4.4.3 Backing up Data ............................................................................................................ 4-7
Chapter 5 – Service and Troubleshooting 5-1
5.1 Upgrading Firmware .................................................................................................................. 5-2
5.2 Removing or Replacing Components ....................................................................................... 5-6
5.2.1 Accessing Modules for Testing ..................................................................................... 5-6
5.2.2 Removing/Replacing the CPU/System Controller Board and the Process I/O Board .. 5-6
5.2.3 Removing/Replacing the Primary Battery System ........................................................ 5-7
5.2.4 Removing/Replacing the Backup Battery ..................................................................... 5-8
5.2.5 Enabling / Disabling the Backup Battery ....................................................................... 5-9
5.2.6 Removing/Replacing the Case-Mounted Radio or Modem .......................................... 5-9
5.2.7 Removing/Replacing the GPT Transducer ................................................................. 5-10
5.2.8 Removing/Replacing the TeleCounter (Pulser) Assembly.......................................... 5-10
5.3 General Troubleshooting Procedures ..................................................................................... 5-11
5.3.1 Common Communication Configuration Problems ..................................................... 5-11
5.3.2 Checking LEDs ........................................................................................................... 5-12
5.3.3 Checking LCD Status Codes ...................................................................................... 5-12
5.3.4 Wiring/Signal Checks .................................................................................................. 5-12
5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-13
5.4.1 Available Diagnostics .................................................................................................. 5-14
5.5 Core Updump .......................................................................................................................... 5-17
5.6 Calibration Checks .................................................................................................................. 5-18
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 Nov-2013
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Corrector. For information about the software used with the
ControlWave Corrector, refer to:
ControlWave Flow Measurement Applications Guide (D5137),
Getting Started with ControlWave Designer (D5085)
ControlWave Designer Programmer’s Handbook (D5125)
ControlWave Designer online help
This chapter provides an overview of the ControlWave Corrector and its
components and details the structure of this manual
In This Chapter
1.1 Scope of the Manual ........................................................................ 1-2
1.2 Physical Description ........................................................................ 1-2
1.3 CPU/System Controller Board ......................................................... 1-3
1.4 Power Options ................................................................................. 1-5
1.5 I/O Options ....................................................................................... 1-5
1.6 Software Tools ................................................................................. 1-6
1.7 Overview of the Gas Flow Measurement Application ...................... 1-8
ControlWave Corrector Instruction Manual
Features
The ControlWave Corrector is pre-programmed to meet API 21.1
requirements for a two-run metering station and measures static
pressure and temperature for both runs and computes corrected volume
(i.e., volume or base conditions), uncorrected volume and energy rates
and totals. Most metering stations use the integral gauge pressure
assembly for the first meter run and an external transmitter, such as the
Bristol 3808 MVT, for the second meter run. ControlWave Correctors
are appropriate to all applications for electronic meter correction,
including those that require monitoring of additional I/O points or
extension to two meters. ControlWave Correctors are designed to
operate in an unprotected outdoor environment.
The ControlWave Corrector has the following key features:
Exceptional performance and low power consumption through use
of the ARM microprocessor.
Very low power consumption to minimize costs of solar panel /
battery power systems.
Two CPU / System Controller board configurations (see Table 1-1.)
Integral gage pressure transducer (GPT) can be removed and
replaced independently of the top-end electronics.
Optional integrated TeleCounter (pulser) assembly mounts directly
to rotary positive displacement meters.
Three process I/O board configurations (see Table 1-2).
Revised Nov-2013 Introduction 1-1
ControlWave Corrector Instruction Manual
Two RS-232 and one RS-232/RS-485 asynchronous serial
communication ports.
Optional 10/100 MB Ethernet port
Optional Display/Keypad.
Wide operating temperature range:
Without lead acid battery: (–40 to +70C) (–40 to 158F)
With lead acid battery: (–20 to +60C) (–4 to 140F)
Battery backup for Static RAM (SRAM) and real-time clock.
Nonincendive Class I, Division 2 (Groups A, B, C and D)
Hazardous Location approvals when installed in a suitable enclosure
- see Appendix A.
Cost-effective for small RTU/process controller applications.
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Chapter 2
Installation
Chapter 3
I/O Configuration
Chapter 4
Operation
Chapter 5 Service and
Troubleshooting
1.2 Physical Description
The ControlWave Corrector includes the following major components:
Enclosure with a local communication port and LCD
display/keypad.
CPU/system controller board (SCB) mounts on edge within the
enclosure – See Section 1.3
Optional I/O – see Section1.5.
Internal mounting brackets and battery
Provides an overview of the hardware Corrector
general information about the ControlWave
Corrector and its application software.
Provides information on mounting the
ControlWave Corrector and setting CPU
jumpers and switches.
Provides general information on wiring the
process I/O points.
Provides information on day-to-day operation of
the ControlWave Corrector.
Provides information on service and
troubleshooting procedures.
Gage pressure transducer (GPT) – See Chapter 2
Optional RTD probe – See Chapter 3
Radio/modem options
TeleCounter (pulser) assembly – See Chapter 2
1-2 Introduction Revised Nov-2013
Enclosure
ControlWave Corrector Instruction Manual
The ControlWave Corrector enclosure is a standard NEMA 3R rated
fiberglass enclosure. The enclosure consists of the body and the front
cover. A continuous gasket seals the unit when you close the front
cover. Molded channels on the cover and the body which capture a
stainless steel pin form a hinge on the left side (facing the front of the
unit).
The enclosure includes a weatherproof connector (local port) mounted
to the bottom of the cover and connected internally to RS-232 COM
port 1.
The enclosure includes a display or display/keypad for an operator or
technician to view process values locally.
Internal Mounting
Brackets and Battery
Internal mounting brackets support the various system components,
such as the battery, CPU/System Controller and Process I/O boards,
and the radio/modem option. These components attach to the one piece
mounting bracket which is secured to the inner rear wall of the
enclosure. A factory-supplied radio or modem mounts inside the
enclosure in front of the battery on a battery cover/radio mounting
plate.
Radio/Modem Options
You can order the ControlWave Corrector with a factory-installed
modem or spread spectrum radio. The unit supports a variety of radios
and modems. Contact Emerson Remote Automation Solutions for more
information.
1.3 CPU/System Controller Board
The CPU (central processing unit) and System Controller Board (SCB)
contains the ControlWave Corrector CPU, I/O monitor/control,
memory, and communication functions.
The CPU/System Controller board includes:
Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core, with a
system clock speed of either 14 MHz or 33 MHz.
two RS-232 communication ports
one communication port configurable by jumpers as either RS-232
or RS-485
optional 10/100baseT Ethernet port (See Table 1-1)
2 MB of battery backed Static RAM (SRAM),
512KB boot/downloader FLASH,
8MB simultaneous read/write FLASH memory
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ControlWave Corrector Instruction Manual
Board Variations
The CPU/System Controller board has two basic variations: `
Table 1-1. CPU/System Controller board Variations
14MHz
ultra low
power
33MHz +12V or
CPU Backup Battery
CPU Memory
CPU Nominal
Input
Power
+6Vdc or
+12Vdc
+24Vdc
Note: Each of the variants shown in Table 1-1 may be ordered with or
without special gas calculation firmware.
The CPU/System Controller board has a coin cell socket that accepts a
3.0V, 300 mA-hr lithium battery. This 3.0V battery provides backup
power for the real-time clock and the system’s Static RAM (SRAM).
There are several different types of memory used by the CPU:
Ethernet
Port?
No Yes Yes Yes.
Yes No No Yes (same as
Solar
Regulator
?
Auxiliary
Power
Output?
RTD Input?
Connects to
100-ohm
platinum bulb.
Uses DIN
43760 curve.
ultra low
power)
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 ControlWave Corrector includes 8 MB of FLASH memory. The
FLASH memory holds the system firmware and the boot project.
Optionally FLASH memory also stores the zipped ControlWave project
(*.zwt), user files, and historical data (audit/archive files).The FLASH
does not support hardware write protection.
System Memory (SRAM)
The ControlWave Corrector has 2 MB of static random access memory
(SRAM). During power loss periods, SRAM enters data retention mode
(powered by a backup 3.0V lithium battery). Critical system information
that must be retained during power outages or when the system has been
disabled for maintenance is stored here. This includes the last states of
all I/O points, audit/archive historical data (if not stored in FLASH), the
values of any variables marked RETAIN, the values of any variables
1-4 Introduction Revised Nov-2013
1.4 Power Options
ControlWave Corrector Instruction Manual
assigned to the static memory area, and any pending alarm messages not
yet reported.
You can power the ControlWave Corrector by:
a factory-supplied 6V lithium battery
a factory-supplied 6V lithium battery pack (dual 6V lithium
batteries in parallel)
a factory-supplied 6V, 7AH lead acid battery – used with a 1W, 6V
solar panel system
a factory-supplied 6V, 7AH lead acid battery – used with a 5W, 6V
solar panel system
a factory-supplied 12V, 7AH lead acid battery – used with a 5W,
12V solar panel system
an external (user-supplied) power supply with either +5.4Vdc to
+16Vdc (nominal +6Vdc), +11.4Vdc to +16Vdc (nominal +12Vdc)
or +21.8Vdc to + 28.0Vdc (nominal +24Vdc)
If you connect solar panels to rechargeable battery systems to power the
ControlWave Corrector, there is a secondary power input you can use to
provide power if there is no power from the solar panel/battery system.
1.5 I/O Options
Type Pulse
Standard 2
Option 1 2 2 4 2 2
Option 2 2 2 4 2 2 3
Option 3 2 2 4 2 2 3 1
ControlWave Corrector comes with the following standard I/O:
2 Pulse Counter Inputs with a 1 second scan rate (can be configured
as discrete inputs (DI))
Optional I/O includes:
Resistance Temperature Device (RTD) probe
Gage Pressure Transducer (GPT)
Process I/O board. Three different versions of the optional process
I/O board are available. See Table 1-2.
Table 1-2. Process I/O Configurations
Counter
Inputs (PI) /
Discrete
Input (DI)
Discrete
Input /
Output
(DI/DO)
Discrete
Input (DI)
Discrete
Output
(DO)
High Speed
Counter
(HSC)
Analog
Input (AI)
Analog
Output
(AO)
Revised Nov-2013 Introduction 1-5
ControlWave Corrector Instruction Manual
1.6 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
Corrector. Figure 1-1 graphically presents the programming
environment.
Figure 1-1. ControlWave Programming Environment
The tools which make up the programming environment include:
ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave unit. 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), and the ControlWave Designer
Programmer’s Handbook (document D5125).
The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O in the ControlWave and
configure the individual mapping of I/O points for discrete and
analog inputs and outputs. For information on the I/O Configurator
see the ControlWave Designer Programmer’s Handbook (document
D5125).
1-6 Introduction Revised Nov-2013
ControlWave Corrector Instruction Manual
The ACCOL3 Firmware Library, available within ControlWave
Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see the
online help within ControlWave Designer.
OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).
OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).
Communication
Protocols
A series of web page controls are available for retrieval of real-time
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. (See the
ControlWave Flow Measurement Applications Guide D5137)
Alternatively, developers can place the controls in third-party
ActiveX compatible containers such as Visual BASIC or
Microsoft® Excel. For information on the ActiveX controls, see the
Web_BSI Manual (document D5087).
User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).
Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).
In addition to the Bristol Synchronous/Asynchronous Protocol
(BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port with serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
Revised Nov-2013 Introduction 1-7
ControlWave Corrector Instruction Manual
1.7 Overview of the Gas Flow Measurement Application
Note: For detailed information on the gas flow measurement
application and web pages refer to the ControlWave Flow
Measurement Applications Guide (D5137).
You can purchase the ControlWave Corrector with a pre-programmed
flow measurement application already loaded.
The ControlWave standard gas flow measurement application collects
static pressure, differential pressure and temperature data and computes
flow, energy, and volume for a station.
A station typically refers to a single flow computer and all its
associated meter runs. Each meter run refers to measurement of natural
gas through a single pipeline.
1.7.1 Data Acquisition – Static Pressure, Differential Pressure, Temperature Variables
The application requires these process inputs for orifice measurement:
static pressure (SP) collected once per second
differential pressure (DP) collected once per second
flowing temperature (T) collected once per second
The application requires these process inputs for measurement using a
positive displacement (PD), turbine, or ultrasonic meter:
static pressure (SP) collected once per second
frequency input collected once per second
flowing temperature (T) collected once per second
The application also collects self-test and compensation variables at
intervals of four seconds or less.
Pressure data can come from any of the following sources:
Analog pressure transmitters connected to analog input points on a
process I/O module in the ControlWave flow computer.
Built-in gage pressure transducer.
External multivariable transmitters (Bristol or Rosemount) using
BSAP or Modbus communications through an RS-485
communication port.
1.7.2 Flow and Volume Calculations
Flow and volume calculations conform to American Petroleum Institute
(API) and American Gas Association (AGA) standards.
Supported flow calculations include:
AGA3-1985/NX-19
AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
AGA7/NX-19
1-8 Introduction Revised Nov-2013
ControlWave Corrector Instruction Manual
AGA7 with selectable AGA8 Gross or AGA8 Detail
Auto-adjust AGA7/NX-19
Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
The application performs a complete flow calculation using the process
variables every second. Each calculation includes instantaneous rate
according to API 14.3, compressibility according to AGA 8 Detail or
Gross method, and updates of all volumes, totals, and archive averages.
1.7.3 Flow Rate and Flow Time Calculations (AGA3)
For orifice flow measurement, the application compares the differential
pressure value to a low flow cutoff value every second. If the
differential pressure falls below the low flow cutoff value, flow is
considered to be zero for that second. Hourly and daily flow time is
defined to be the number of seconds for which the differential pressure
exceeded the cutoff value for the period.
The values for static and differential pressure and temperature are used
as inputs to the flow equations. You can select API 14.3 (AGA3, 1992)
and AGA8 calculations, with compressibility calculations according to
AGA Report No. 8, 1992 (with 1993 errata). The application supports
both the detail method and the two gross methods of characterization
described in AGA 8. Users may also select the AGA3, 1995 and NX-19
flow equations to calculate the rate of flow.
1.7.4 Flow Rate and Flow Time Calculations (AGA7)
When using PD meters, turbine meters or ultrasonic meters, the
application calculates flow rate by applying the correction factor
computed by the AGA7 calculations to the frequency of the input
pulses. When the frequency drops below 1 Hz, the application sets the
flow rate estimate to zero; however, volume calculations still
accumulate. The flow time recorded is the time for which the flow rate
is non-zero.
1.7.5 Extension Calculation and Analog Averaging
For orifice meters, the application calculates the flow extension every
second. The extension is the square root of the product of the absolute
upstream static pressure times the differential pressure. This extension is
used in the flow rate calculation. When there is no flow, the application
reports the arithmetic averages of static pressure and temperature. This
allows you to monitor static pressure and temperature during shut-in
periods.
Revised Nov-2013 Introduction 1-9
ControlWave Corrector Instruction Manual
p
1.7.6 Energy Calculation
The application offers the option of using a fixed volumetric heating
value or calculating the energy content of the gas according to AGA
Report No. 5.
1.7.7 Volume and Energy Integration
The application integrates and accumulates volume and energy at the
end of every calculation cycle. The application calculates the volume
for a cycle by multiplying the calculated rate by the flow time for that
cycle. The application calculates the energy for a cycle by multiplying
the volume at base conditions by the heating value.
1.7.8 Historical Data Storage (Audit Records/ Archive Files)
The ControlWave supports two distinct types of historical data storage –
audit records and archive files.
Where feasible, both forms of archive data conform to the requirements
of the API Chapter 21. Specifically, the averages of the process
variables stored in the data archive are for flowing periods, appropriate
to their usage in the equations, and any gas-related parameter designated
an event that is changed by an operator either remotely or locally causes
an entry in the audit log.
Audit Records
(Alarms and
Events)
The audit system maintains a history of alarms and certain events that
have an impact on the calculated and reported gas flow rates and
volumes.
The application stores the most recent 500 alarms and the most recent
500 events. As new alarms/events arrive, they overwrite the oldest
entries. Internally, the application stores alarms and events separately to
revent recurring alarms from overwriting configuration audit data
events. The application reports alarms and events in the same log.
The following circumstances generate an audit record:
Any operator change to a configuration variable
Any change in the state of an alarm variable
A system restart
Certain other system events
You can view audit records on-screen in the audit log.
See the Appendix K of the OpenBSI Utilities Manual (D5081) for help
on interpreting audit records.
1-10 Introduction Revised Nov-2013
ControlWave Corrector Instruction Manual
Archive Files
(Averages,
totals, and other
values)
Archive files store the value of process variables and other calculated
variables at specified intervals along with the date and time of each
entry. This includes flow rates, volumes and other calculated values.
When archive files fill up, new values overwrite the oldest entries in the
files.
The application displays archive file data in hourly, data, and periodic
logs you can view on screen.
Log Breaks
You can configure the application to support the "breaking" of a log
period when an operator-changes a parameter. When this occurs, the log
period in process closes out to make a log, and a new log begins.
Note: To prevent several very short logs from being created due to a
series of successive configuration changes, the application will
not create a log which contains less than 60 seconds (flowing or
otherwise) of data. Therefore if you enter 15 configuration
changes over a 2-minute period, the log will only breaks twice.
Hourly Historical Data Log
Each meter run maintains an hourly data log that holds one record for
every contract hour. Hourly logs hold 840 entries or 35 days; this
ensures that the previous period of hourly data is always resident in
flash memory.
The hourly data log stores the following items:
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
Daily Historical Data Log
Each meter run maintains a daily data log that holds one record for
every contract gas day. You can change the contract hour if the contract
gas day starts at some time other than midnight. The daily log holds 62
entries; this ensures that the previous calendar month of daily data is
always resident in flash memory.
The daily data log stores the following items:
Revised Nov-2013 Introduction 1-11
ControlWave Corrector Instruction Manual
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
uncorrected count
Periodic Historical Data Log
Each meter run maintains a periodic data log that holds one record for
every log interval. Each log interval is 15 minutes. The periodic
historical data log holds 1440 records, or four days of 15 minute data.
The periodic historical data log stores the following items:
flowing differential pressure
flowing static pressure
flowing temperature
frequency
1.7.9 Run Switching
If you use multiple meter runs in the application, you can configure run
switching. Run switching (also known as meter run staging or tube
switching) allows changes to the number of meter runs currently active
to meet the gas flow demand for the station.
1.7.10 Sampler and Odorizer
Samplers are external devices which measure the quality of the gas
stream.
Because natural gas is odorless and colorless, devices called odorizers
inject an additive to the gas stream that allows people to detect the
presence of natural gas in the event of a gas leak.
1.7.11 Chromatograph Interface
If you use a chromatograph to measure gas component information you
can integrate this into the application. You can also specify fixed gas
component percentages to use if the chromatograph fails.
1-12 Introduction Revised Nov-2013
1.7.12 Nominations
Nominations allow you to configure the ControlWave flow computer to
allocate precise amounts of gas flow during specific time periods, called
nomination periods.
ControlWave Corrector Instruction Manual
Revised Nov-2013 Introduction 1-13
This page is intentionally left blank
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
Corrector, considerations for installation, and instructions for setting
switches and jumpers.
In This Chapter
2.1 Site Considerations .......................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ............................. 2-3
2.2 Installation Overview ........................................................................ 2-4
2.3 Unpacking Components .................................................................. 2-5
2.4 Mounting the ControlWave Corrector Assembly ............................. 2-5
2.4.1 Configuring the TeleCounter Assembly ............................. 2-13
2.4.2 Configuring the ISPROX Module (Option) ......................... 2-13
2.4.3 Connection to the Gage Pressure Transducer (GPT) ....... 2-14
2.4.4 Grounding the Housing ...................................................... 2-17
2.5 Configuring the CPU/System Controller Board ............................. 2-18
2.5.1 Setting DIP Switches on the CPU/System Controller Bd ... 2-19
2.5.2 Setting Jumpers on the CPU/System Controller Board ..... 2-21
2.5.3 General Wiring Guidelines ................................................. 2-22
2.5.4 Wiring Power to the CPU/System Controller Board ........... 2-23
2.5.5 Connections to RS-232 Serial Port(s) on the CPU/System
2.5.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the
2.5.7 Connections to the Ethernet Port on the CPU/System Controller
2.6 Radio-Ready and Case Mounted Modem or Radio ...................... 2-33
2.7 Mounting the Solar Panel .............................................................. 2-34
2.8 Optional Display/Keypads.............................................................. 2-37
ControlWave Corrector Instruction Manual
Controller Board ................................................................ 2-25
CPU/System Controller Board .......................................... 2-30
Board ................................................................................ 2-32
2.1 Site Considerations
When choosing an installation site, check all clearances for the
enclosure, for the attached GPT, for the optional RTD probe, for the
TeleCounter assembly, and if applicable, for the solar panel. Ensure that
you can open the front cover of the ControlWave Corrector (hinged on
the left side) for wiring and service. Make sure the display/keypad is
accessible and visible.
See Figure 2-9 for a dimensional drawing of the NEMA 3R enclosure
with a GPT and TeleCounter. See Figure 2-10 for a dimensional
drawing of the NEMA 3R enclosure with a GPT and no TeleCounter.
The ControlWave Corrector is designed to operate in a Class I Division
2, Groups A, B, C & D environment with a nonincendive rating (see
Appendix A). The ControlWave Corrector can operate in an unprotected
outdoor environment.
Revised Nov-2013 Installation 2-1
ControlWave Corrector Instruction Manual
To ensure safe use of this product, please review and follow the
Caution
instructions in the following supplemental documentation:
Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
10
8
13
9
P1
P2
P3
11
P4
P5
3
2
1
NOTE: Units is equipped with Item 4 or 11, or Neither.NOTE: Units is equipped with Item 4 or 11, or Neither.
1.
1. One Piece/Battery Mounting Bracket
One Piece/Battery Mounting Bracket
2. CPU/System Controller Board
2.
CPU/System Controller Board
3. Local Comm. Port Connector & Cover
3.
Local Comm. Port Connector & Cover
4. Optional TeleCounter Assembly
4.
Optional TeleCounter Assembly
5. Optional Polyphaser
5.
Optional Polyphaser
6. Ground Lug
6.
Ground Lug
7. Optional External Radio
7.
Optional External Radio
(MDS - Transnet)
(MDS
8. Radio/Modem Mounting Bracket
8.
Radio/Modem Mounting Bracket
- Transnet)
9.
Optional Process I/O Board
9. Optional Process I/O Board
Optional Dual-Button Display/Keypad Ass’y.
10.
Optional Dual-Button Display/Keypad Ass’y.
10.
11. Optional ISProx Module
11.
Optional ISProx Module
12. 3/4” Conduit Fitting
12.
3/4” Conduit Fitting
13. Smart, Gage Pressure Sensor
13.
Smart, Gage Pressure Sensor
ONO
N
1
2
3
4
5
6
7
8
ONO
N
1
2
3
4
7
12
5
6
4
Figure 2-1. ControlWave Corrector (with MDS - Transnet Radio) (Internal View) Component
Identification Diagram
2-2 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Specifications
for Temperature,
Humidity and
Vibration
2.1.1 Class I, Div 2 Installation Considerations
See document 1665DS2c available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave Corrector.
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 Corrector is
not exposed to a level of vibration that exceeds that provided in the
technical specifications.
Underwriters Laboratories (UL) lists the ControlWave Corrector as non-
incendive and suitable only for use in Class I, Division 2, Groups A, B,
C, and D hazardous locations and non-hazardous locations. Read this
chapter and Appendix A carefully before you install a ControlWave
Corrector in a hazardous location.
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 Group A, B, C and D environments.
When the ControlWave Corrector is situated in a hazardous location,
turn off power before servicing or replacing the unit and before
installing or removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
Revised Nov-2013 Installation 2-3
ControlWave Corrector Instruction Manual
2.2 Installation Overview
Installing a ControlWave Corrector involves several general steps:
1. Unpacking, assembling, and configuring the hardware. This
includes:
a) Mounting the enclosure on site. (See Section 2.4)
b) Removing the CPU/System Controller board and optional
Process I/O board assembly so you can enable the backup
battery by setting jumper W3 on the CPU/System Controller
board to position 1 to 2. See Section 5.2.2 for instructions on
removing/replacing the board assembly, see Section 2.5.2 for
information on setting jumpers.
b) Setting other switches and jumpers on the CPU/System
Controller board (see Section 2.5.1 and Section 2.5.2) and on the
Process I/O board (see Section 3.2.1 and Section 3.2.2) and
placing both boards (as a single assembly) back into the chassis.
d) Connecting communication cables. (See Sections 2.5.5, 2.5.6,
and 2.5.7)
e) Wiring I/O. (See Section 3.3)
f) Connecting an external 3808 transmitter (see Section 3.3.8 if
required).
f) Installing a ground wire between the enclosure’s ground lug and
a known good Earth ground. (See Section 2.4.4)
h) Connecting the RTD probe (if required). (See Section 3.3.7)
g) Installing the solar panel (See Section 2.7) and rechargeable
battery (See Section 2.5.4 if applicable)
i) Wiring power to the unit. (See Section 2.5.4)
j) Turning on power. (See Section 4.1)
2. Installing PC-based software (TechView).
3. Establishing communications to perform calibration activities or
view data using the standard flow measurement application menus.
2-4 Installation Revised Nov-2013
Note: Steps 2 through 3 require that you install and use OpenBSI
TechView software to perform calibration and that you use the
standard menus. This manual focuses on hardware installation
and preparation. Software installation and configuration is
beyond the scope of this manual. Refer to the TechView User’s
Guide (D5131) and the ControlWave Flow Measurement
Applications Guide (D5137) for more information. If you are
not using the flow measurement application and plan to create
your own application, refer to the Getting Started with
ControlWave Designer Manual (D5085) and the ControlWave
Designer Programmer’s Handbook (D5125).
2.3 Unpacking Components
ControlWave Corrector Instruction Manual
Packaging
ControlWave Corrector units ship from the factory with all components
wired and mounted except for the unit’s solar panel and battery; these
items are shipped separately.
2.4 Mounting the ControlWave Corrector Assembly
You must position the ControlWave Corrector vertically. Units
equipped with the TeleCounter (Pulser) assembly mount directly to
a turbine meter. Units that do not have the optional TeleCounter
assembly can be mounted remotely to a panel or wall or to a vertical
2” pipe (clamped at the rear of the unit via two clamps and four
bolts – see Figure 2-4 and Figure 2-6). If used, the 2” pipe must be
anchored in cement (deep enough to conform to local building codes
associated with frost and support considerations).
See Figure 2-9 for a dimensional drawing of the NEMA 3R
enclosure with a GPT and TeleCounter. See Figure 2-10 for a
dimensional drawing of the NEMA 3R enclosure with a GPT and no
TeleCounter.
Position the unit so that the front of the unit is both visible and
accessible for service, i.e., installing an option or replacement of the
battery, or installation/removal of any ControlWave Corrector
module. Make sure the operator can see and access the
keypad/display.
You must allow clearance space for the optional Solar Panel (if
required).
The TeleCounter bolts to a turbine meter (via four nuts at the base of
the TeleCounter) (see Figure 2-2); the turbine meter, in-turn,
connects to the main (meter run). A gasket is required between the
TeleCounter assembly and the top of the turbine meter (see Figure
2-3). When mating the ControlWave Corrector to the turbine meter,
it is essential that the TeleCounter input shaft and the opening on the
turbine meter output shaft mate properly. Be careful not to damage
Revised Nov-2013 Installation 2-5
ControlWave Corrector Instruction Manual
the mating surfaces. Once the surfaces align, install and secure the
mounting washers and nuts. Be aware that the meter interface
(TeleCounter base plate) has an eight-bolt mounting pattern. The
bolt patterns allow the ControlWave Corrector to be mounted in two
positions that are 180° apart. The meter interface mounting hole
locations illustrated in Figure 2-3 accommodate the flow meters
listed in Table 2-1.
Table 2-1. Flow Meter Mounting Position
Manufacturer
American Meter, Root & Romet Forward mount A The base plate can be rotated in 90o
Rockwell Forward mount B The base plate can be rotated in 90 o
Rockwell Reverse mount C The base plate can be rotated in 90 o
Mounting
Position
Hole Pattern Notes
increments.
For reverse mounting, remove the base
plate screws (see Figure 2-3 hole
locations “D”) and rotate the base plate
o
.
180
increments.
increments.
Figure 2-2. ControlWave Corrector Mounted to Turbine Meter
2-6 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-3. ControlWave Corrector/Meter Interface Mounting Hole Pattern (Dimensions are in
Inches)
Power wiring should not be installed until the unit has been mounted
and grounded at a designated work site. External power wiring, RTD
cabling, local comm. port, antenna cable, and network (RS-232 and RS-
485) comm. port cabling enter the bottom of the unit though conduit or
special function fittings. I/O wiring is routed through the left side of the
unit (right when facing the front) via a .75” Conduit Fitting.
Revised Nov-2013 Installation 2-7
ControlWave Corrector Instruction Manual
(1) Local Port Connector (2) TeleCounter (Pulser) Holes
(3) RTD Cable Assembly or Sealing Plug (4) Battery Ventilation Assembly
(5) Solar Pwr. Cable, Ext. Pwr. Cable, or Plug (6) Ant. Cable, Polyphaser, or Plug
(7) Solderless Ground Lug (8) GP Transducer (1/4-18 NPT
(9) .75” Conduit Fitting Female)
Figure 2-4. ControlWave Corrector Bottom View
2-8 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-5. Side View of ControlWave Corrector (with TeleCounter)
Revised Nov-2013 Installation 2-9
ControlWave Corrector Instruction Manual
Figure 2-6. Side View of ControlWave Corrector (without TeleCounter)- (Pipe Mounted)
2-10 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-7. TeleCounter Assembly (1 to 1 Gear Ratio) Rotation Adjust Diagram
Revised Nov-2013 Installation 2-11
ControlWave Corrector Instruction Manual
Figure 2-8. TeleCounter Assembly (2 to 1 Gear Ratio) Rotation Adjust Diagram
2-12 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
2.4.1 Configuring the TeleCounter Assembly
When present, the TeleCounter Assembly (Pulser) is situated below the
enclosure and is mounted to the bottom of the unit with a gasket water
tight seal. The Pulser is secured to the enclosure with four screws. The
Pulser can be opened in the field to set its gears for proper rotation, i.e.,
so that the counter is increasing. The 8 digit odometer provides a count
of 0000000.0 to 9999999.9 revolutions. The magnet wheel and the
odometer's tenths wheel will increment 10 digits each time the turbine
meter completes one revolution.
Rotation of the
TeleCounter
Magnet Wheel
and Odometer
The TeleCounter can be configured to accept a clockwise or
counterclockwise turbine meter shaft rotation. Two sets of gears in the
TeleCounter assembly accommodate configuration of the ControlWave
Corrector. These gears are factory set (per order) but may be field
configured as required. The following steps are required to reconfigure
the TeleCounter gears:
1. Remove the seven (7) screws which secure the face plate to the
front of the TeleCounter assembly,
2. Using a .035” Hex wrench, loosen the set screw associated with
drive gear ‘A’ (CCW) or ‘B’ (CW) and slide this gear to its
resting position. Tighten the drive gear’s set screw (see Figure
2-7 and Figure 2-8).
3. Loosen the .035 Hex set screw which secures the other drive
gear “A” or “B” and slide this gear until it engages the main drive
gear. Tighten the drive gear’s set screw. Check for binding by
rotating the Input Wriggler.
4. Replace the face plate securing it with the seven (7) screws
removed in step 1.
2.4.2 Configuring the ISPROX Module (Option)
When present, an ISPRox Module Board will reside on the inside of the
front cover. ISProx boards provide an interface to one or two industry
standard variable impedance proximity sensors (NAMUR gap sensors)
and conditions and converts these signals to either open drain outputs
(DOs) which in turn drive the ControlWave Corrector’s pulse inputs on
the CPU/System Controller board. ISProx Modules are discussed in
document PIP-CW ISProx.
Revised Nov-2013 Installation 2-13
ControlWave Corrector Instruction Manual
2.4.3 Connection to the Gage Pressure Transducer (GPT)
One optional Gage Pressure Transducer (GPT) secured to the right side
of the enclosure (facing the front of the unit) can be provided with each
ControlWave Corrector. Gage pressure transducers are equipped with a
¼-18 NPT female pipe fitting (see Figure 2-4 and Figure 2-5).
You can mount units with a GPT remotely to a panel, a wall, or to a
vertical 2 inch pipe clamped at the rear of the unit using the two
mounting brackets with two clamps and four bolts.
You can only connect the gage pressure transducer via tubing. Within
the body of the transducer, metal diaphragms are exposed to the gas.
Solid-state strain gauge sensors in the neck of the transducer measure
the pressure applied to the diaphragms and produce proportional
electrical signals.
The neck of the GPT extends into the side of the enclosure, with the
body of the transducer outside the enclosure. The GPT cable connector
is factory mated with the CPU/System Controller board connector P1.
Caution
You cannot mount units with a GPT directly to the main (meter run).
2-14 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-9. ControlWave Corrector (with TeleCounter & GPT) - NEMA 3R Enclosure Dimensions
Revised Nov-2013 Installation 2-15
ControlWave Corrector Instruction Manual
Figure 2-10. ControlWave Corrector (with GPT - without TeleCounter) NEMA 3R Enclosure
Dimensions
2-16 Installation Revised Nov-2013
2.4.4 Grounding the Housing
The ControlWave Corrector enclosure includes a ground lug. If your
unit has a GPT, see Figure 2-4 to locate the ground lug. Once you have
installed the unit, run a ground wire (#4 AWG max wire size) between
the ground lug and a known good earth ground. Connect the cases of
temperature transducers, pressure transmitters, and so on to the known
good earth ground. For more information on grounding see the
ControlWave Grounding Supplement (S1400CW):
Additional grounding guidelines include:
Use stranded copper wire (#4 AWG) to earth ground, and keep the
length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Using a high-wattage soldering iron, tin the wire ends with solder
before you insert them into the chassis 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.
ControlWave Corrector Instruction Manual
Revised Nov-2013 Installation 2-17
ControlWave Corrector Instruction Manual
2.5 Configuring the CPU/System Controller Board
The CPU/System Controller board mounts vertically on edge inside the
enclosure on the right side of the Process I/O board. To configure the
CPU/System Controller board, you need to set some switches and
jumpers.
Do Not Connect a 24V Solar Panel
to Connector TB1-1 & TB1-2!
Solar Pwr. In +
Aux. Power Out +
Sec. Battery Input
Input
Input
Output
Output
Input
Output
Input
Input
Input
Output
Output
Input
Output
Input
NOTE: Carefully
examine DIP
switches to verify
proper ON/OFF
position. Different
versions of the
board may have
different switch
positions.
Input
Input
Output
Output
Input
Input
Output
GND
Power In +
GND
GND
GND
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
Receive
LED
Transmit
LED
RXD+
RXD-/RXD
TXD-/TXD
TXD+
GND
PULSE 1
PULSE 2
GND
PULSE
PWR
RTD EXC
RTD+
RTD-
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
O
N
1
Idle
2
3
4
5
6
7
8
O
N
1
2
3
4
1
2
3
4
5
1
2
3
4
1
2
3
Damage WILL occur to
the CPU if the Ethernet
network is connected
to connector J2!
TB1
Power
TB2
Power
1
J4
COM1
5
TB3
COM2
RS-232
J1
10/100
Base-T
Ethernet
Port
Watchdog
SW2
Configuration
Options
Switch
SW1
Recovery
Mode &
COM./Status
LEDs
TB4
COM3
RS-232
RS-485
Radio
TB5
Pulse
Input
TB6
RTD
Input
J2
LCD/
Keypad
CAUTION:
Fuse:
F4 on 6V Intrinsically Safe Units
F3 on Non Intrinsically Safe Units
W18
321
J11
COM1
RXD
GND
TXD
RS-232
RJ-45
RJ-45
CR1
1
2
3
4
5
6
7
8
1
2
3
4
W12
W15
S1
W13
W14
RJ-45
F3
W1
NOTE:
J11 normally used
for CW GFC and CW
Express PAC only.
W2
W3
ON
1
SW3 - COM3 Config.
2
3
4
5
6
7
8
J8
Emulation
Header
NOTE:
J7, J8, J9
Factory Use
W12 - W16 - 1-2 = COM3 RS-232
RS-485 Receiver Biasing & Termination
2-Wire, 4-Wire Selection
J7
MSP430
JTAG
Header
P1
NOTE:
Ultra 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 Ethernet Port.
F4
W1 - 1-2 = COM1 CTS from Port
2-3 = COM1 CTS to RTS
W2 - 1-2 = COM2 CTS from Port
2-3 = COM2 CTS to RTS
W3 - 1-2 = Battery Enabled
2-3 = Battery Disabled
W5 - 1-2 = 12/24V Power Supply
W6 - 1-2 = 12V Power Supply
W7 - 1-2 = 12/24V Power Fail
W8 - 1-2 = 12V Power Fail
Shut-down Hysterisis
2-3 = 6V Power Supply
Shut-down Hysterisis
Shut-down
2-3 = 6/24V Power Supply
Shut-down
W8
W7
2-3 = 6V Power Fail
2-3 = 6/24V Power Fail
W6
W5
Trip Point Hysterisis
Trip Point Hysterisis
Trip Point
Trip Point
2-3 = COM3 RS-485
W17 - 1-2 = 6V Input Power
2-3 = 12V Input Power
W18: COM1 connector
selection
1to2=J4active
2to3=J11active
J5 - COM3
Piggy-back
Radio Intf.
J5
W17
WE
J9
PLD JTAG
Header
J3 - I/OBUS
Intf. to
CPU Board
J3
W16
Figure 2-11. - CPU/System Controller Board Component I.D. Diagram
2-18 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
2.5.1 Setting DIP Switches on the CPU/System Controller Board
Before you install the CPU/System Controller board, you must
determine the settings for three banks of DIP switches. Refer to Figure
2-11 for the location of the DIP switch banks. Refer to Tables 2-2, 2-3,
and 2-4 for an explanation of the DIP switch positions.
Notes:
Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF. Different versions of the board may use
different switch positions.
Only switch combinations described have been tested.
Table 2-2. CPU/System Controller Board Switch SW1
SW1 Setting Function Mode
1 & 2
3
4
Recovery
Mode
Force
Recovery
Mode
LED status
Recovery Mode = Both SW1-1 and SW1-2 ON or both
SW1-1 and SW1-2 OFF
Local Mode = SW1-1 OFF and SW1-2 ON (Factory
Default)
Enables recovery mode. Values are:
ON (enables recovery mode)
OFF (disables recovery mode). – This is the factory
default.
ON (Enable IDLE LED status indication)
OFF (Disable IDLE LED status indication)
Table 2-3. CPU/System Controller Board Switch SW2
SW2 Setting Function Mode
1
2
3
Revised Nov-2013 Installation 2-19
Watchdog
Enable
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Controls whether the system enters a watchdog state
when a crash or system hang-up occurs and automatically
restarts. Values are:
ON (Enables watchdog circuit; factory default)
OFF (Disables watchdog circuit and prevents automatic
restart)
Controls the ability to modify soft switches, other
configurations, and flash files. Values are:
ON (Unlocks soft switches and flash files; factory
default).
OFF (Locks soft switches, configurations, and flash files)
Controls the use of soft switches. Values are:
ON (Enable user-defined soft switches configured in flash
memory; factory default)
OFF (Disable soft switch configuration and use factory
defaults)
Note: Setting both switch 3 and switch 8 to OFF (closed)
sets all serial communication ports to 9600 bps
ControlWave Corrector Instruction Manual
SW2 Setting Function Mode
4
5
6
7
8
Core Updump Causes the ControlWave Corrector to perform a core
SRAM Control Manages SRAM contents following a low power situation
System
Firmware
N/A Not currently used.
Enable
WINDIAG
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.
updump, provided you have set the SW1 switches to allow
recovery mode. Values are:
ON (Disables core updump; factory default)
OFF Core updump
or a power outage. Values are:
ON (Retain values in SRAM during restarts; factory
default)
OFF (Reinitialize SRAM) – Data in SRAM lost during
power outage or re-start.
Allows a remote download of system firmware (on units
equipped with boot PROM version 4.7 or higher and
system PROM version 4.7 and higher). Values are:
ON (Enable remote download of system firmware; factory
default)
OFF (Disable remote download of system firmware)
Suspends normal operation and allows diagnostic
routines. Values are:
ON (Permits normal system operation, including the boot
project, and disables the WINDIAG diagnostics from
running; factory default)
OFF (Allow WINDIAG to run test; disable boot project and
normal system operation.)
Note: Setting both switch 8 and switch 3 to OFF (closed)
sets all communication ports to 9600 bps operation.
All serial communication ports must be set at 9600
bps before WINDIAG can perform communication
tests.
Note: Table 2-4 describes switch settings for RS-485 port operation.
You may want to review Section 2.5.6 on RS-485 configuration
before you set these switches.
Table 2-4. RS-485 Configuration Switch SW3
Switch
Setting
1
2
2-20 Installation Revised Nov-2013
Function Mode
TX+ to RX+ Loopback / 2wire
TX- to RX- Loopback / 2wire
ON (2-wire operation or loopback enabled)
OFF (4-wire operation and loopback
disabled)
ON (2-wire operation or loopback enabled)
OFF (4-wire operation and loopback
disabled)
ControlWave Corrector Instruction Manual
Switch
Setting
3
4
5
6
7
8
Function Mode
100 Ohm RX+ Termination
100 Ohm RX- Termination
N/A Not currently used
N/A Not currently used
RX+ Bias (End
Nodes/Node)
RX- Bias (End
Nodes/Node)
ON (End nodes only)
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 only; 2-wire=
One end node only)
OFF = No bias
2.5.2 Setting Jumpers on the CPU/System Controller Board
The CPU has several jumpers.
W1: COM1 CTS usage:
o 1-to-2 Installed = COM1 CTS source is from device.
o 2-to-3 Installed = COM1 RTS to CTS loopback
W2: COM2 CTS usage:
o 1-to-2 Installed = COM2 CTS source is from device.
o 2-to-3 Installed = COM2 RTS to CTS loopback
Note: You must enable the backup battery by setting jumper W3 to
position 1-2.
W3: Enable/disable battery backup selection:
o 1-to-2 Installed = Enable battery backup.
o 2-to-3 Installed = Disable battery backup
W5: Power supply shut down selection:
o 1-to-2 Installed = 12/24V power supply shut down hysteresis
o 2-to-3 Installed = 6V power supply shut down hysteresis
W6: Power supply shut down selection:
o 1-to-2 Installed = 12V power supply shut down
o 2-to-3 Installed = 6/24V power supply shut down
W7: Power fail trip point hysteresis selection:
o 1-to-2 Installed = 12/24V power fail trip point hysteresis
o 2-to-3 Installed = 6V power fail trip point hysteresis
W8: Power fail trip point selection:
o 1-to-2 Installed = 12V power fail trip point
o 2-to-3 Installed = 6/24V power fail trip point
W12: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
Revised Nov-2013 Installation 2-21
ControlWave Corrector Instruction Manual
o 2-to-3 Installed = COM3 is RS-485
W13: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W14: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W15: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W16: COM3 configuration selection:
o 1-to-2 Installed = COM3 is RS-232
o 2-to-3 Installed = COM3 is RS-485
W17: Input power selection (controls solar power shunt regulation.
Not applicable for +24Vdc CPUs:)
o 1-to-2 Installed = 6V power
o 2-to-3 Installed = 12V power
W18: COM1 connector selection:
o 1-to-2 Installed = connector J4 (D connector) is active
o 2-to-3 Installed = alternate connector J11 is active
2.5.3 General Wiring Guidelines
ControlWave Corrector terminal blocks use compression-type
terminals that accommodate up to #16 AWG wire.
When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the screw.
To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.
Note: Fuse F4 applies only for Class I Division 1 hazardous locations
with the intrinsically safe ControlWave GFC-IS. See Figure 2-11
to locate the fuse. See Supplement CW-GFC-IS for more
information on the intrinsically safe ControlWave GFC-IS.
2-22 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
2.5.4 Wiring Power to the CPU/System Controller Board
Caution
Power Supply
Current
Requirements
Table 2-5. ControlWave Corrector Bulk Power Requirements
At this time you can connect power wiring. However; for safety reasons
and to prevent accidental damage to your bulk DC power supply, do not
connect the pluggable terminal block connectors TB1 and TB2 to the
CPU/System Controller board until after you install, wire, ground, and
configure the entire unit.
Follow the instructions in Section 2.5.3 General Wiring Guidelines when
wiring connections.
Depending upon the CPU type, the ControlWave Corrector accepts
either a 6Vdc, 12Vdc or 24Vdc bulk power input. You can estimate the
maximum current required for your ControlWave Corrector using the
following equation:
Bulk +6/12/24 Vdc Supply Current = CPU/System Controller Board (with
options) + Process I/O Board + LCD
display/keypad + optional modem /
radio
Refer to Table 2-5 for ControlWave Corrector power requirements
based on the CPU type.
CPU Type and Components
14 MHz Ultra Low Power CPU with LCD
display/keypad
33 MHz CPU with Ethernet and LCD
display/keypad
Note: If your ControlWave Corrector includes a modem or radio,
contact the radio/modem manufacturer for power consumption
specifications.
If your ControlWave Corrector is configured to use a solar panel to
Caution
charge a 7AH (6V or 12V) battery for power, NEVER CONNECT THE
SOLAR PANEL/CHARGER WITHOUT ALSO CONNECTING THE
BATTERY. Connections without the battery present can damage power
supply components.
Bulk 6Vdc
Power
Supply
7 mA without field supply
Not
Supported
Bulk 12Vdc
Power Supply
and with AO output
under range: 5 mA
without process I/O
board: 80 mA
Bulk 24Vdc
Power Supply
Not Supported
without process I/O
board: 47 mA
Revised Nov-2013 Installation 2-23
ControlWave Corrector Instruction Manual
Terminal Block
Connector TB1
Unplug removable connector TB1 from the CPU/System Controller
board. We recommend you do not plug the connector back into the CPU
until the unit is already installed in the housing.
You can power the ControlWave Corrector using a bulk DC power
supply using connections TB1-3 and TB1-4.
Nominal input source operating ranges for the DC power supply are:
+6Vdc (+5.4Vdc to +16.0Vdc nominal operating range)
+12Vdc (+11.4Vdc to +16.0Vdc nominal operating range)
+24Vdc (+21.8Vdc to +28.0Vdc nominal operating range)
Not all ControlWave Corrector CPUs support all DC power supplies.
Supported options are:
14MHz Ultra Low Power CPU: Supports +6Vdc or +12Vdc
nominal power supply.
33MHz CPU with Ethernet: Supports +12Vdc nominal or +24Vdc
nominal power supply.
Alternatively, you can power low powered versions of the ControlWave
Corrector using a solar panel connected to a user-supplied rechargeable
7AH (6V/12V) lead acid battery.
TB1 connections are:
TB1-1: (Solar Power IN+): Power from a 1W – 6V, 5W – 6V or
5W – 12V solar panel (internally wired to recharge a factory-
supplied battery). Not available on units with Ethernet.
TB1-2 = Ground (GND) Not available on units with Ethernet.
TB1-3 = Primary Power: Power from an internal factory-supplied
battery or from an external nominal +6Vdc , +12Vdc or +24Vdc
power supply, depending upon the CPU type.
TB1-4 = Ground (GND)
TB1-5 = Auxiliary Power Out+: for a radio or modem (if
supported). Aux power out enabled when DTR signal for COM2
goes high. Aux Power Out not available on units with Ethernet.
TB1-6 = Ground (GND) for Aux power out.
Figure 2-12 shows the typical wiring at the TB1 block.
2-24 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-12. CPU/System Controller Board (TB1 & TB2) Power Wiring
Terminal Block
Connector TB2
The ControlWave Corrector includes an alternative power connecter,
TB2, to provide power if none is available at TB1. For example, you
can connect a bulk DC power supply to TB2 to handle situations where
the solar panel/battery system does not have sufficient power.
TB2 connections are:
TB2-1 = Power Input
TB2-2 = Ground (GND)
2.5.5 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board
An RS-232 port provides point-to-point, half-duplex and full-duplex
communications (for a maximum of 20 feet using data quality cable).
Your CPU includes two RS-232 ports and one port configurable for
either RS-232 or RS-485 operation.
Revised Nov-2013 Installation 2-25
ControlWave Corrector Instruction Manual
ControlWave Corrector
Figure 2- 13. PC Connected to ControlWave Corrector via Circular Local Port
Notes:
Cable part number 395402-01-8 = 10 foot communication cable.
Cable part number 395402-02-6 = 25 foot communication cable.
RS-232 COM
RS-232 COM ports use different connector types.
Port Names and
Connectors
Table 2-6. RS-232 Connectors
Connector Name # Pins and Type Notes
J4 COM1 9-pin male D-type Choice of active connector for COM1
determined by jumper W18.
Ships from the factory connected to the local
port on the bottom of the front cover of the
unit.
J11 COM1 3-pin male Choice of active connector for COM1
determined by jumper W18.
TB3 COM2 8-pin terminal block Use this port for connection to a radio
mounted on the battery cover/radio mounting
plate.
2-26 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Connector Name # Pins and Type Notes
TB4 COM3 5-pin terminal block This port can be configured as either RS-232
or RS-485. See Section 2.5.6 for more
information.
RS-232
COM1/COM2
Port Cables
For the ControlWave Corrector, half-duplex communications use
Modbus or BSAP protocol, while full-duplex communications use
point-to-point protocol (PPP). RS-232 ports use a “null modem” cable
(see Figure 2-15) to connect with other devices (such as a PC, a printer,
another ControlWave [except the CW_10/30/35]) when the
ControlWave Corrector uses the full-duplex PPP protocol.
Note: You can configure the ControlWave Corrector as either a master
or slave node on a Modbus or BSAP network.
Figure 2-14 illustrates the CPU module’s male 9-pin D-type connector
for COM1. Use the content provided in Table 2-6 to determine pin
assignments for the COM1 and COM2 ports.
Figure 2-14. Male DB9 9-Pin Connector
Table 2-7. RS-232 COM1 and COM2 Port Connector Pin Assignment
Pin
1 DCD Data Carrier Detect Input 1 (Green wire)
2 RXD Receive Data Input 2 (Red wire)
3 TXD Transmit Data Output 7 (White wire)
4 DTR Data Terminal Ready Output 4 (Brown wire) Pin 4 connected to pin 4 at
5 GND Power Ground 6 (Black wire)
6 DSR Data Set Ready Input
7 RTS Request to Send Output
8 CTS Clear to Send Input
RS-232
Signal
RS-232 Description
Local Port Pin# Local Port Notes:
TB5 of CPU = external power
for local communication port
cable.
RTS connected to CTS at J4
of CPU for local port
communication cable.
RTS connected to CTS at J4
of CPU for local port
communication cable.
9 N/A
Revised Nov-2013 Installation 2-27
ControlWave Corrector Instruction Manual
r
r
Use the “null modem” cable for full-duplex (PPP protocol)
communications when connecting a ControlWave Corrector to a PC.
(See top part of Figure 2-15.)
Table 2-8. RS-232 COM1 (J11) Alternate Connector Pin Assignment
Pin
1 GND Power ground
2 RXD Receive data input
3 TXD Transmit data output
RS-232
Signal
RS-232 Description
CW Correcto
CW Correcto
Figure 2-15. Full-duplex and Half-duplex Cable
Use the half-duplex cable (shown in the bottom part of Figure 2-15)
when connecting the ControlWave Corrector to another ControlWave
series unit (again, with the exception of the CW_10/30/35).
When communicating with a Network 3000 series RTU 3305, RTU
3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of
the cables shown in Figure 2-16.
2-28 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
r
CW Correcto
CW Corrector
9-Pin Female
“D” Connector
Figure 2-16. Full-duplex and Half-duplex Cable
Refer to Figure 2-17 when using COM2 of the ControlWave Corrector
to connect with a case mounted modem or radio.
Figure 2-17. Connection from a Case Mounted Modem/Radio to COM2
of the ControlWave Corrector
When interfacing to the COM3 port of a ControlWave, or the COM5 or
COM6 port a ControlWaveEXP unit, use the cable presented in Figure
2-18 along with one of the cables shown in Figure 2-15 or Figure 2-16.
Figure 2-18. Full-duplex and Half-duplex Cable
Revised Nov-2013 Installation 2-29
ControlWave Corrector Instruction Manual
RS-232 Cable
Guidelines
Observe the following guidelines when constructing RS-232
communication cables:
Ensure that DCD is high to transmit (except when dialing a modem)
Verify that each RS-232 transceiver has one active receiver while
disabled (in power down mode); connect the DCD signal to the
active receiver.
Set CTS to high to transmit.
If the port is set for full-duplex operation, RTS is always ON.
Ensure that DTR is always high when port is active; DTR enables
RS-232 transceivers.
Note: Control DTR using the PORTCONTROL function block and
the _Pn_AUTO_DTR system variable in your ControlWave
project. If you turn DTR off through these mechanisms, the
port remains off, even though hardware is fully configured.
When port is set for half-duplex operation, CTS must go low after
RTS goes low.
All RS-232 comm ports support RTS, DTR, CTS, DCD, and DSR
control signals.
All RS-232 comm port I/O signals are protected by surge protectors.
2.5.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller Board
You use jumpers W12 through W16 to configure COM3 of the
ControlWave Corrector for either RS-232 or RS-485 operation. See
Section 2.5.2 for information on these jumpers.
Table 2-9. COM3 RS-485 Connector (TB4) on CPU/System Controller Board
Connector Name # Pins and Type Notes
TB4 COM3 5-pin terminal block This port can be configured as
either RS-232 or RS-485.
RS-485 COM3
Port Cables
Table 2-10 shows connector pin assignments for COM3.
Note:
If you use COM3 for RS-232 operation, pins 1 and 4 do not
apply.
Table 2-10. COM3 Connector Pin Assignment
Pin Signal Description
1 RXD+ Receive Data + input (Not applicable for
RS-232 usage)
2 RXD–/RXD Receive Data – Input
2-30 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Pin Signal Description
RXD- for RS-485 use
RXD for RS-232 use
3 TXD–/TXD Transmit Data – Output
TXD- for RS-485 use
TXD for RS-232 use
4 TXD+ Transmit Data + Output (Not applicable for
RS-232 usage)
5 Power Ground Ground
When serving as an RS-485 port, COM3 supports local network
communications to multiple nodes up to 4000 feet away.
Since the RS-485 port is intended for network communications, refer to
Table 2-11 for the appropriate connections for wiring the master, first
slave, and nth slave.
Essentially, the master and the first slave transmit and receive data on
opposite lines; all slaves (from the first to the nth) are paralleled (daisy-
chained) across the same lines. Wire the master node to one end of the
RS-485 cable run using a 24-gauge paired conductor cable (such as a
Belden 9843).
Note: ControlWave Corrector supports only half-duplex RS-485
networks.
Table 2-11. RS-485 Network Connections
From Master To First Slave To nth Slave
TXD+ RXD+ RXD+
TXD– RXD– RXD–
RXD+ TXD+ TXD+
RXD– TXD– TXD–
GND/ISOGND GND/ISOGND GND/ISOGND
Note: ISOGND only applies to RS-485 usage.
To ensure that the “Receive Data” lines are in a proper state during
inactive transmission periods, you must maintain certain bias voltage
levels at the master and most distant slave units (end nodes). These end
nodes also require the insertion of 100Ω terminating resistors to
properly balance the network.
You must also configure switches at each node to establish proper
network performance. Accomplish this by configuring switches listed so
that the 100Ω termination resistors and biasing networks are installed at
the end nodes and are removed at all other nodes on the network. You
enable receiver biasing and termination (as well as 2-wire or 4-wire
selection) using an 8-position DIP switch located on the CPU/System
Controller board. See Table 2-4 for more information.
Revised Nov-2013 Installation 2-31
ControlWave Corrector Instruction Manual
2.5.7 Connections to the Ethernet Port on the CPU/System
Controller Board
Caution
The RJ45 Ethernet port is connector (J1) located on the CPU/System
Controller board. The board also has one RJ45 port (J2) for the optional
Display/Keypad. Never
or damage will result.
connect Ethernet to J2 (the Display/Keypad port)
The 33MHz ControlWave Corrector can support one Ethernet port.
This port uses a 10/100Base-T RJ-45 modular connector (J1) that
provides a shielded twisted pair interface to an Ethernet hub.
A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with
port 8 having the capability to link either to another hub or to an
Ethernet communications port). Both ends of the Ethernet twisted pair
cable are equipped with modular RJ-45 connectors.
18
Looking into
receptacle
Figure 2-19. RJ-45 Ethernet Connector
These cables have a one-to-one wiring configuration as shown in
Figure 2-20. Table 2-12 provides the assignment and definitions of the
8-pin 10/100Base-T connectors.
Figure 2-20. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)
Table 2-12. Ethernet 10/100Base-T CPU Module Pin Assignments
Pin Description
1 Transmit Data+ (Output)
2 Transmit Data– (Output)
3 Receive Data+ (Input)
4 Not connected
5 Not connected
6 Receive Data– (Input)
2-32 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Pin Description
7 Not connected
8 Not connected
Note: You can swap TX and RX at the hub.
You can connect two nodes in a point-to-point configuration without
using a hub. However, you must configure the cable so that the TX+/Data pins connect to the RX+/- Data pins (swapped) at the opposite
ends of the cable (see Figure 2-21).
Figure 2-21. Point-to-Point 10/100Base T Ethernet Cable
The maximum length of one segment (CPU to hub) is 100 meters (328
feet). The use of Category 5 shielded cable is recommended.
2.6 Radio-Ready and Case Mounted Modem or Radio
The ControlWave Corrector ships from the factory with a user selected
radio or modem installed within the enclosure (in front of the battery
mounting bracket) or as a radio-ready unit, in other words, ready for
field installation of a factory-supplied radio. The installer must ensure
that the remote antenna (associated with a case mounted radio) is
properly installed and connected.
See the ControlWave Radio-Ready Installation Guide (D5138) for
information on installing factory-supplied radios in the field.
See the ControlWave PSTN Modem Installation Guide (D301734X012)
for information on installing the 9600 bps PSTN modem.
Revised Nov-2013 Installation 2-33
ControlWave Corrector Instruction Manual
2.7 Mounting the Solar Panel
Depending upon the type of power system you choose, your
ControlWave Corrector may require a solar panel. The solar panel
charges a rechargeable 6V or 12V 7AH lead acid battery. Solar panel
wires enter the unit through a liquid tight conduit fitting and connect to
TB1 on the CPU/System Controller board.
If your ControlWave Corrector is configured to use a solar panel to
Caution
charge a 7AH (6V or 12V) battery for power, NEVER CONNECT THE
SOLAR PANEL/CHARGER WITHOUT ALSO CONNECTING THE
BATTERY. Connections without the battery present can damage power
supply components.
You can mount the solar panel to a 2” to 2-3/8” pipe using muffler
(pipe) clamps. You secure the pipe clamps using four ¼-20 nuts and
washers. (See Figure 2-22 and Figure 2-23.)
You must swivel the solar panel for optimum alignment with the sun. In
the northern hemisphere, face the panel due south (not magnetic south).
In the southern hemisphere, face the panel due north (not magnetic
north).
1 and 5 watt solar panel systems have adjustable tilt angles. Adjust the
tilt angle for maximum performance to accommodate the latitude of
your installation site. Table 2-13 shows the angle (from horizontal) at
which you should install the solar panel to maximize annual energy
output. At most latitudes, performance can be improved by less of an
angle during the summer and more of an angle during winter.
Table 2-13. Solar Panel Tilt Angle
Latitude
0-4° 10° from Horizontal
5-20° Add 5° to the Local Latitude
21-45° Add 10° to the Local Latitude
46-65° Add 15° to the Local Latitude
66-75° 80° from Horizontal
Tilt Angle
2-34 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 2-22. 1 Watt Solar Panel Mounting Diagram
Revised Nov-2013 Installation 2-35
ControlWave Corrector Instruction Manual
Figure 2-23. 5 Watt Solar Panel Mounting Diagram
2-36 Installation Revised Nov-2013
2.8 Optional Display/Keypads
The ControlWave Corrector supports two optional display/keypads and
a display without a keypad:
A 2-button keypad (shown in the left of Figure 2-24)
A 25-button keypad (shown in the right Figure 2-24)
Display only (no keypad) – (see Figure 2-25)
ControlWave Corrector Instruction Manual
Figure 2-24. Optional 2-Button and 25-Button Keypads
Figure 2-25. Display with No Keypad
Both keypads use the same 4-line by 20-character LCD displays.
The Display without a keypad has a 2-line display with 10 characters on
the first line, and 6 characters on the second line. This display shows
variable values on line 1, and variable names on line 2.
Revised Nov-2013 Installation 2-37
ControlWave Corrector Instruction Manual
You connect the Display/Keypad or Display to the ControlWave
Corrector using a cable, one end of which has an RJ-45 jack (connected
into the RJ-45 equipped with two plugs. This cable connects between
the RJ-45 display jack (J2) on the CPU/System Controller board and
RJ-45 jack (J1) on the remote Display or remote Display/Keypad
assembly. A potentiometer, provided on the keypad, allows you to set
the contrast of the LCD display.
Notes:
For information on the status codes which appear on the display, see
Section 5.3.3 Checking LCD Status Codes in Chapter 5.
For further information on the installation and use of the optional
keypads, refer to the ControlWave Display/Keypad Manual
(D5135).
2-38 Installation Revised Nov-2013
ControlWave Corrector Instruction Manual
Chapter 3 – I/O Configuration and Wiring
This chapter discusses setting I/O configuration switches and jumpers
and wiring I/O connections to the ControlWave Corrector.
In This Chapter
3.1 I/O Options ....................................................................................... 3-1
3.2 Process I/O Board ........................................................................... 3-2
3.2.1 Setting Jumpers on the Process I/O Board .......................... 3-2
3.2.2 Setting DIP Switches on the Process I/O Board .................. 3-2
3.3 I/O Wiring ......................................................................................... 3-4
3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O
Board .................................................................................. 3-6
3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O
Board .................................................................................. 3-7
3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O
Board .................................................................................. 3-8
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O
Board .................................................................................. 3-9
3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of
CPU/System Controller Board .......................................... 3-10
3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on
TB4 of Process I/O Board ................................................. 3-13
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System
Controller Board ................................................................ 3-14
3.3.8 Connections to a Bristol Model 3808 Transmitter .............. 3-16
3.1 I/O Options
Type Pulse
Standard 2
Option 1 2 2 4 2 2
Option 2 2 2 4 2 2 3
Option 3 2 2 4 2 2 3 1
ControlWave Corrector comes with the following standard I/O:
2 Pulse Counter Inputs with a 1 second scan rate (can be configured
as discrete inputs (DI))
I/O Options include:
Gage Pressure Transducer (GPT)
The 14 MHz CPU and the 33MHz CPU with Ethernet also includes
a Resistance Temperature Device (RTD) probe.
In addition, three different versions of the optional process I/O board are
available. See Table 3-1.
Table 3-1. Process I/O Configurations
Counter
Inputs (PI) /
Discrete
Inputs (DI)
Discrete
Input /
Output
(DI/DO)
Discrete
Input (DI)
Discrete
Output
(DO)
High Speed
Counter
(HSC)
Analog
Input (AI)
Analog
Output
(AO)
Revised Nov-2013 I/O Configuration and Wiring 3-1
ControlWave Corrector Instruction Manual
3.2 Process I/O Board
The ControlWave Corrector may include an optional Process I/O board.
The Process I/O board stands vertically on edge against the inner left
side of the enclosure and mounts to the CPU/System Controller board
using six nylon mounting posts.
To configure the Process I/O board, you need to set some switches and
jumpers. See Figure 3-1 for the location of the switches and jumpers.
3.2.1 Setting Jumpers on the Process I/O Board
The Process I/O board has several jumpers.
JP1: AO output source (1-5V or 4-20mA):
o 1-to-2 Installed = 4-20mA analog output
o 2-to-3 Installed = 1-5V analog output
JP3: AO power source:
o 1-to-2 Installed = system power
o 2-to-3 Installed = external power (+11 to +30 Vdc)
JP4: AI field power configuration:
o 1-to-2 Installed = external power
o 2-to-3 Installed = bulk input supply (system power)
JP5: AI1 input type (1-5V or 4-20mA)
o 1-to-2 Installed = 4-20mA analog input
o 2-to-3 Installed = 1-5V analog input
JP6: AI2 input type (1-5V or 4-20mA)
o 1-to-2 Installed = 4-20mA analog input
o 2-to-3 Installed = 1-5V analog input
JP7: AI3 input type (1-5V or 4-20mA)
o 1-to-2 Installed = 4-20mA analog input
o 2-to-3 Installed = 1-5V analog input
3.2.2 Setting DIP Switches on the Process I/O Board
The Process I/O board includes a single switch bank (SW1) to configure
the frequency for the high speed counters (HSC), the source current for
discrete inputs/counters, and the analog output.
Table 3-2. Process I/O Module Switch SW1
SW1 Function Mode
SW1-1
SW1-2
3-2 I/O Configuration and Wiring Revised Nov-2013
Frequency for High Speed Counter1 (HSC1)
Frequency for High Speed Counter2 (HSC2)
OFF = 10 kHz (high speed)
ON = 300 Hz (low speed)
OFF = 10 kHz (high speed)
ON = 300 Hz (low speed)
ControlWave Corrector Instruction Manual
SW1 Function Mode
SW1-3
SW1-4
DI/HSC 2mA source current
AO configuration
OFF = disabled
ON = enabled
Note: This switch affects
all DIs and HSCs.
OFF = current
ON = voltage
Figure 3-1. Process I/O Board Component Identification Diagram
Revised Nov-2013 I/O Configuration and Wiring 3-3
ControlWave Corrector Instruction Manual
Caution
3.3 I/O Wiring
Power down the ControlWave Corrector before you perform I/O wiring.
Shut down any processes the ControlWave Corrector may be managing
(or switch them over manually or handle with another controller).
Perform any hardware configuration (wiring, jumper configuration, and
installation) only when the ControlWave Corrector is powered down.
Before any I/O connections can become operational, you must use
ControlWave Designer to configure and then download the application
(project).
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:
Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
The ControlWave Corrector uses card edge terminal blocks to
accommodate field wiring. You route the wires into the
enclosure/chassis through a 0.75 inch conduit fitting.
ControlWave Corrector I/O uses compression-type terminals that
accommodate up to #16 AWG wire. Insert the wire’s bared end (approx.
¼” max) into the clamp beneath the screw and secure the wire. To
prevent shorts, ensure that no bare wire is exposed. If using standard
wire, tin the bare end with solder to prevent flattening and improve
conductivity. Allow some slack in the wires when making terminal
connections. Slack makes the wires more manageable and helps
minimize mechanical strain on the terminal blocks.
Shielding and
Grounding
Use twisted-pair, shielded and insulated cable for I/O signal wiring to
minimize signal errors caused by electromagnetic interference (EMI),
radio frequency interference (RFI), and transients.
When using
shielded cable, ground all shields at only one point in the appropriate
system. This prevents circulating ground current loops that can cause
signal errors.
3-4 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 3-2. Process I/O Board Wiring Diagrams
Revised Nov-2013 I/O Configuration and Wiring 3-5
ControlWave Corrector Instruction Manual
3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board
Process I/O Board terminal block connector TB2 provides interface to
four dedicated non-isolated discrete inputs DIs – DI1 through DI4. In
addition, terminal block connector TB3 provides two additional points
that can serve as either discrete inputs or discrete outputs (DI5 and DI6
when wired as inputs).
Table 3-3. Non-Isolated DI General Characteristics
Type Number
Discrete Inputs
(DI)
Wiring
See Figure 3-2 for wiring diagrams.
Supported
4 on TB2
(optionally
2 on TB3)
Characteristics
Supports dry contact inputs pulled
internally to 3.3 Vdc when field input is
open.
Source current for DI1 to DI4 of either
60 μA or 2 mA based on switch SW1-
3 setting. See Table 3-2.
Source current for DI5 to DI6 of either
200 μA or 2.2 mA based on switch
SW1-3 setting. See Table 3-2.
15 ms input filtering
Software Configuration
To use data from these DIs you must include a CWM_EIO board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this board.
Note: You must specify whether a discrete input/output is a DI or a
DO in ControlWave Designer’s I/O Configurator by
configuring a DI pin or a DO pin.
3-6 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O Board
Process I/O Board terminal block connector TB3 provides interface to
two dedicated non-isolated discrete outputs DOs – DO1 and DO2. In
addition, terminal block connector TB3 provides two additional points
that can serve as either discrete inputs or discrete outputs (DO3 and
DO4 when wired as outputs).
Table 3-4. Non-Isolated DO General Characteristics
Wiring
Type Number
Supported
Discrete Outputs
(DO)
2 to 4 (on
TB3)
See Figure 3-2 for wiring diagrams.
Characteristics
Supports 30V operating range. Can
sink 400 mA max at 30Vdc (open
drain).
Maximum output frequency of 20Hz.
Surge protection between signal and
ground.
Software Configuration
To use data from these DOs you must include a CWM_EIO board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this board.
Note: You must specify whether a discrete input/output is a DO or a
DI in ControlWave Designer’s I/O Configurator by
configuring a DO pin or a DI pin.
Revised Nov-2013 I/O Configuration and Wiring 3-7
ControlWave Corrector Instruction Manual
3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board
Process I/O Board terminal block connector TB6 provides interface to
three single-ended analog inputs (AIs).
Table 3-5. Non-Isolated AI General Characteristics
Type Number
Analog
Inputs (AI)
Supported
3 (on TB6)
Characteristics
Jumper-selectable using JP5, JP6, and
JP7 for either 4-20mA or 1-5V operation.
Jumper JP4 determines whether AI field
power comes from system power (bulk
input supply applied to TB1-3 and TB1-4
on the CPU/System Controller Board) or
the external loop power source connected
to TB7-3 and TB7-4 on the Process I/O
board.
2 Hz low pass filter for each AI.
Surge Suppression.
Self calibrating.
Setting Jumpers
Wiring
Software
Configuration
See Section 3.2.1 for details on setting jumpers.
Each AI includes three terminals (field power, AI# and DGND). See
Figure 3-2 for wiring diagrams. If using the ControlWave Loop Power
Supply, see document PIP-ControlWave-LS.
Notes:
You must connect cable shields associated with AI wiring to the
ControlWave Corrector chassis ground.
Multiple shield terminations require you to supply a copper ground
bus. You must connect the ground bus to the ControlWave
Corrector chassis ground lug using up to a #4 AWG wire size. The
ground bus must accommodate a connection to a known good Earth
ground (in lieu of a direct connection from the ControlWave
Corrector chassis ground) and to all AI cable shields.
Use an appropriate terminal lug for shield wires and secure them to
the copper bus using industry rugged hardware (screw/bolt, lock
washer and nuts).
To use data from these AIs you must include a CWM_EIO board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this board.
3-8 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board
Process I/O Board terminal block connector TB7 provides interface to a
single analog output (AO).
Table 3-6. Non-Isolated AO General Characteristics
Type Number
Supported
Analog
Output
(AO)
1 (on TB7)
Characteristics
Supports either 4-20mA or 1-5V operation.
Selection using jumper JP1 and switch SW1-
4.
Jumper JP3 determines whether AO field
power comes from system power (nominally
12 or 24V from bulk input supply applied to
TB1-3 and TB1-4 on the CPU/System
Controller Board) or from an external 24V
power source (+11 to +30Vdc connected to
TB7-3 and TB7-4) such as the ControlWave
Loop Power Supply.
Maximum external load you can connect to a
4-20mA output is 250 ohms for an external
11V power source or 650 ohms for an
external 24V power source.
Maximum external load current for the 1-5V
output is 5 mA (with an external 11 to 30 V
power source.)
Factory-calibrated.
Setting
Jumpers
Wiring
Software
Configuration
See Section 3.2.1 for details on setting jumpers.
See Figure 3-2 for wiring diagrams. If using the ControlWave
Loop Power Supply, see document PIP-ControlWave-LS.
Note: If your ControlWave Corrector uses 6V bulk power,
you must provide external power for the AO.
To use data from this AO you must include a CWM_EIO board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That
same manual includes an I/O Mapping section that describes, for
advanced users, the I/O map for this board.
Revised Nov-2013 I/O Configuration and Wiring 3-9
ControlWave Corrector Instruction Manual
3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Board
CPU/System Controller Board connector TB5 provides interface to two
internally sourced open collector pulse counter/discrete inputs (Pulse1
and Pulse2) with a 1 second scan rate. Pulse counters act like high speed
counters but cannot function with contact relays because they lack
contact debounce circuitry.
Table 3-7. Non-Isolated Pulse Counter/Discrete Inputs General
Characteristics
Wiring
Type Number
Supported
Pulse Counter /
Discrete Inputs
2 on TB5 of
CPU/Syste
m Controller
board
Pulse counter/discrete inputs are field driven by open collector circuits
and are sourced for 3.3V (internally) with a 200μA source current. See
Figure 3-3 for information on the open collector wiring arrangement.
Characteristics
Signal conditioning circuitry provides
20 microsecond filtering.
Surge suppression.
Maximum input frequency for each
pulse counter/discrete input circuit is
10 KHz.
Figure 3-3. Pulse Input Wiring Diagram
If the pulse counter inputs come from a turbine meter through the
optional TeleCounter (pulser) assembly (mounted to the base of the
enclosure) the wiring diagram shown in Figure 3-4 is utilized (factory-
installed).
3-10 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 3-4. TeleCounter Wiring Diagram
ISProx Module
DO
Term. Blk.
P2
1
2
DO
Term. Blk.
P3
DO2
1
2
Input Power
Term. Blk.
P1
VDD
1
GND
2
DO1
Red
Black
Oran ge
Yellow
CPU/System
Controller
Board
TB1- 3 (Po wer In +)
TB5-3 (GND)
TB5- 1 (PU LSE 1)
TB5- 2 (PULSE 2)
Figure 3-5. ISProx Wiring Diagram (see PIP-ISProx)
Revised Nov-2013 I/O Configuration and Wiring 3-11
ControlWave Corrector Instruction Manual
When a ControlWave Corrector is equipped with an optional ISProx
assembly, (mounted on the inside of the unit’s Front Cover), the wiring
diagram shown in Figure 3-5 is utilized (factory installed).
Software Configuration
To use data from these pulse counter/discrete inputs you must include
a CWM_ECPU board in your ControlWave project using
ControlWave Designer’s I/O Configurator, and then configure it. See
the ControlWave Designer Programmer's Handbook (D5125) for more
information. That same manual includes an I/O Mapping section that
describes, for advanced users, the I/O map for this board. To read a DI
value, look at the appropriate offset for the _STATE variable for the
board.
3-12 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on TB4 of Process I/O Board
Process I/O Board connector TB4 provides interface to two internally
sourced single-ended high speed counter/discrete inputs (HSC1 and
HSC2).
Table 3-8. Non-Isolated High Speed Counter/Discrete Inputs General
Characteristics
Type Number
High Speed
Counter /
Discrete Inputs
Supported
2 on TB4
of Process
I/O board
Characteristics
Surge suppression and signal
conditioning.
HSCs can use dry contacts or open
collector field circuits.
High speed counter switch-selectable
frequency of 10kHz or 300Hz.
Sourced from 3.3Vdc and switch
selectable for a source current of
200μA (switch SW1-3 = OFF) or
2.2mA (switch SW1-3 = ON). Note:
These switches affect all DIs and
HSCs.
Wiring
Switch Settings
Software Configuration
See Figure 3-2 for wiring diagrams.
See Table 3-2 for details on setting switches.
To use data from these high speed counter/discrete inputs you must
include a CWM_EIO board in your ControlWave project using
ControlWave Designer’s I/O Configurator, and then configure it. See
the ControlWave Designer Programmer's Handbook (D5125) for more
information. That same manual includes an I/O Mapping section that
describes, for advanced users, the I/O map for this board. To read a DI
value, look at the appropriate offset for the _STATE variable for the
board.
Revised Nov-2013 I/O Configuration and Wiring 3-13
ControlWave Corrector Instruction Manual
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board
CPU/System Controller Board connector TB6 provides connection to a
3-wire 100 ohm platinum bulb RTD (using the DIN 43760 curve).
Wire the RTD according to Table 3-9 and Figure 3-6 and Figure 3-7. In
this configuration, the return lead connects to the RTD- terminal and the
two junction leads (Sense and Excitation) connect to the RTD+ and
RTD EXC terminals.
Never ground the RTD cable shield at both ends or allow it to come in
Caution
contact with metallic/conductive conduit because multiple ground paths
can cause RTD input errors.
Table 3-9. RTD Connections to CPU/System Controller Board
Connector TB6
TB6 Pin Signal Function
1 RTD EXC Reference
2 RTD+ Sense
3 RTD- Return
Figure 3-6. 3-Wire RTD Temperature Input Wiring
Installing the RTD
Probe
To install the RTD probe, screw the fitting body into the thermowell
with a 7/8” open-end wrench. While you apply pressure against the
sheath to force the tip of the RTD probe into the bottom of the
thermowell (so that the probe tip is in contact with the bottom of the
thermowell), tighten the 9/16” nut using an open-end wrench against
the 7/8” fitting body.
3-14 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 3-7. RTD Probe Installation/Removal Diagram
Software Configuration
To use data from the RTD you must include a CWM_ECPU board in
your ControlWave project using ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this module.
Revised Nov-2013 I/O Configuration and Wiring 3-15
ControlWave Corrector Instruction Manual
3.3.8 Connections to a Bristol Model 3808 Transmitter
You can connect a Bristol 3808 transmitter (digital) to the ControlWave
through either an RS-232 or RS-485 port. Communication schemes and
cable lengths determine the type of communication port you need to
use. In general RS-232 communications require that you place the 3808
transmitter within 25 feet of the ControlWave Corrector (local
communications). You can use RS-485 communications to reach
transmitters up to 4000 feet away (remote communications).
Figure 3-8 details RS-232 wiring connections required between the
ControlWave Corrector and the 3808 transmitter.
Figure 3-8. 3808 Transmitter to ControlWave Corrector RS-232 Comm. Cable Diagram
Figure 3-9 details RS-485 wiring connections required between the
ControlWave Corrector and the 3808 transmitter.
Note: For loopback and termination control, use switch SW3 on the
CPU/System Controller board to configure COM3. See Table 2-
3.
3-16 I/O Configuration and Wiring Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 3-9. 3808 Transmitter to ControlWave Corrector RS-485 Comm. Cable
You can connect up to two 3808 transmitters to a ControlWave
Corrector using a half-duplex RS-485 network. See Figure 3-10 for an
illustration of this type of network.
Figure 3-10. ControlWave Corrector to 3808s - RS-485 Network Diagram
Revised Nov-2013 I/O Configuration and Wiring 3-17
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Chapter 4 – Operation
This chapter provides general operational details for using the
ControlWave Corrector.
In This Chapter
4.1 Powering Up/Powering Down the ControlWave Corrector .............. 4-1
4.2 Communicating with the ControlWave Corrector ............................ 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 Corrector ................. 4-3
4.3 Creating and Downloading an Application (ControlWave Project) .. 4-3
4.4 Creating and Maintaining Backups .................................................. 4-4
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ............ 4-4
4.4.2 Saving Flash Configuration Parameters (*.FCP) ................. 4-6
4.4.3 Backing up Data ................................................................... 4-7
ControlWave Corrector Instruction Manual
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave Corrector is situated in a hazardous location,
turn off power before servicing or replacing the unit and before
installing or removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
See Appendix A for details on Class I Division 2 usage of this device.
4.1 Powering Up/Powering Down the ControlWave Corrector
The ControlWave Corrector receives power either from a solar panel
and user-supplied battery or from an external bulk power supply
attached using connector TB1 on the CPU/System Controller board. It
can also receive power through alternate connector TB2 on the same
board. Chapter 2 includes instructions for wiring power to the
ControlWave Corrector. See Figure 2-3 for the location of these
connectors.
Power Up
To apply power to the ControlWave Corrector, plug in connectors TB1
and optionally TB2 on the CPU/System Controller board. If your
ControlWave project resides in flash memory, the project will load into
SRAM and begin execution. Depending upon the setting of the SRAM
control switch, retain variable values may load as well.
Revised Nov-2013 Operation 4-1
ControlWave Corrector Instruction Manual
Caution
When you disconnect power from the ControlWave Corrector, your
running control strategy is erased from SRAM, as is any process data not
stored in retention mode. When configured for retention and the backup
battery remains good, SRAM stores the last states of all I/O points,
audit/archive data not residing in FLASH, the values of all variables
marked RETAIN, the values of variables stored in the static memory area,
and any pending unreported alarm messages.
Power Down
To remove power from the ControlWave Corrector, unplug connectors
TB1 and TB2 from the CPU/System Controller board.
4.2 Communicating with the ControlWave Corrector
You communicate to the ControlWave Corrector by connecting a cable
between a port on your PC workstation and one of the ControlWave
Corrector ports.
The port at the PC workstation must match the configuration of the
ControlWave Corrector port.
4.2.1 Default Comm Port Settings
As delivered from the factory, ControlWave Corrector communication
ports have default settings. Table 4-1 details these defaults.
Table 4-1. Default Comm Port Settings
Port PCB Default Configuration
COM1 CPU RS-232; 115.2 Kbps using BSAP or ControlWave Designer
protocol. Note: The local port at the bottom of the door is
factory-wired to COM1.
COM2 CPU RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM3 CPU RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol. Intended for use with Bristol
3808 transmitters. You use jumpers W12 through W16 to
configure COM3 for either RS-232 or RS-485
Note: You can re-enable the factory communication settings at any
time by setting CPU module switch SW2-3 to OFF.
Ethernet
Using an optional Ethernet port (located on the 33MHz versions of the
CPU module), you can connect either directly or through a network to a
PC equipped with an Ethernet port. The default IP address and mask
for the Ethernet port is:
ETH1 IP Address: 10.0.1.1 IP Mask: 255.255.255.
4-2 Operation Revised Nov-2013
4.2.2 Changing Port Settings
You change port settings (baud rate, port type, IP address, and so on)
using the Flash Configuration utility.
You must establish communications with the ControlWave device using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.
Note: For detailed information on using the Flash Configuration utility,
see Chapter 5 of the OpenBSI Utilities Manual (D5081).
ControlWave Corrector Instruction Manual
Caution
When you change the baud rate for a port, the baud rate changes as
soon as you write the flash file changes to the RTU, and do not require
a reset. For this reason, you should not change baud rate for the active
port on which you are communicating, or communications will
immediately stop due to the baud rate mismatch between the PC port
and the controller port. If this happens accidentally, you can use CPU
switch settings as discussed in the notes in Section 4.2.1 to restore
defaults and re-establish communications.
4.2.3 Collecting Data from the ControlWave Corrector
OpenBSI utilities such as DataView, Data Array Save/Restore and
Harvester allow you to collect real time data (values of variables, array
values, alarm messages) and historical data (audit records, archive files)
from the ControlWave. See the OpenBSI Utilities Manual (D5081) for
details. SCADA software such as OpenEnterprise can then present this
data to an operator in the form of graphical displays and reports.
4.3 Creating and Downloading an Application (ControlWave Project)
Most Corrector users purchase the ControlWave gas flow measurement
application (ControlWave project) which ships pre-installed in the
Corrector when it leaves the factory.
You can, however, create your own project using PC-based
ControlWave Designer software. Instructions for creating a
ControlWave project are beyond the scope of this manual. Please refer
to the following sources for information:
Getting Started with ControlWave Designer (D5085)
ControlWave Designer Programmer’s Handbook (D5125)
ControlWave Designer online help
You must connect the Corrector to a PC running ControlWave Designer
software and OpenBSI software.
Note: You can download an application either from ControlWave
Designer or from the OpenBSI 1131 Downloader.
Revised Nov-2013 Operation 4-3
ControlWave Corrector Instruction Manual
1. Connect a serial cable between your PC and COM1 of the
ControlWave Corrector.
2. Define the ControlWave project in ControlWave Designer, and
set communication and configuration parameters.
3. Download the project according to instructions in the
Downloading section of the ControlWave Designer
Programmer's Manual (D5125).
4.4 Creating and Maintaining Backups
You should always maintain a current backup of each ControlWave
project and keep it in a safe place, preferably in a location physically
separate from the controller.
The reason we recommend you keep backup files is that if a disaster
occurs that damages or destroys your ControlWave hardware (flood,
lightning strike, etc.) you don’t want to also lose its control strategy
software programs. Otherwise, when the unit is repaired or replaced,
you’d have to create a new ControlWave project from scratch, which
might take a lot longer than replacing a few damaged modules.
Caution
Always maintain a backup copy of your ControlWave project in a safe
place.
Anytime you modify your ControlWave project, be sure to create a new
backup of the new project.
Notes:
You may find it useful to maintain more than one backup copy in
case the backup media itself fails, for example, a CD-ROM becomes
unreadable because it melted in the sun or a thumb drive fails
because someone spilled coffee on it.
If you don’t keep more than one backup copy, it’s a good idea to
periodically test your backup copy to verify that the media has not
failed.
4.4.1 Creating a Zipped Project File (*.ZWT) For Backup
Note: The .zwt file is a complete backup of your entire project
including code, comments and graphics. It may be stored on your
PC or removable storage media. It may also be downloaded and
archived to ControlWave Flash memory where it may be
uploaded at a later time for editing.
With your current ControlWave project open in ControlWave Designer,
perform the following steps:
1. Click File > Save Project As / Zip Project As.
4-4 Operation Revised Nov-2013
ControlWave Corrector Instruction Manual
Figure 4-1. Saving a Backup of Your Project
2. In the “Save/Zip project as” dialog box, specify a project name in
the File name field. In Figure 4-1 we chose the name mynewproj.
3. In the Save as type field, choose Zipped Project Files (*.zwt).
4. In the Zip Options area, select which additional files you want to
include in the zwt file. Other than increasing the file size of the zwt,
it doesn’t hurt to check any or all of these options.
Zip Option Description
Zip User-Libraries
Zip Frontend-Code If you selected Zip User-Libraries you
Zip FW-Libraries
Zip Pagelayouts
If you created your own user-defined
functions or function blocks, you must
select this to preserve them.
should also select this option to include
compiled code for libraries in your zip file.
Otherwise, you need to re-compile your
user libraries with the project when you
unzip the zwt.
This includes firmware libraries, such as
ACCOL3.FWL in your zwt.
This includes pagelayout information for
printing your project, as well as graphical
elements used in certain 1131 languages.
5. Click Zip and a progress bar displays the percent complete of the
zipping process.
6. When the zip process completes, you’ll see a message box reporting
successful completion. Click OK.
Revised Nov-2013 Operation 4-5
ControlWave Corrector Instruction Manual
7. Copy the resulting zwt file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the project, just open the zwt
file in ControlWave Designer, load libraries as needed, then compile
the project and download it into the ControlWave.
4.4.2 Saving Flash Configuration Parameters (*.FCP)
You must establish communications with the ControlWave Corrector
using NetView, LocalView, or TechView before you can run the Flash
Configuration utility.
Note: For detailed information on using the Flash Configuration utility,
see Chapter 5 of the OpenBSI Utilities Manual (D5081).
1. Start the Flash Configuration utility. To do this in NetView or
LocalView, right-click on the icon for this ControlWave and
choose RTU > RTU Configuration Parameters.
To do this in TechView, click Operations > Access Flash
Parameters or click the Access Flash icon .
2. Depending upon how your system is configured, the Flash
Configuration – Loading Options dialog box may open. If it
does, choose Load from device and wait for the utility to
retrieve all parameters from the ControlWave Corrector, then
skip to step 4, otherwise, just proceed to step 3.
3. Click and wait for the utility to retrieve all
parameters from the ControlWave.
4. Click and specify a name for your FCP file,
then click Save. When the status line indicates successful
completion, your FCP file in done.
5. Copy the resulting FCP file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the FCP parameters to the
controller, establish communications with the unit, start the
4-6 Operation Revised Nov-2013
4.4.3 Backing up Data
You can back up certain types of data and restore it if needed. There are
other types of data that you can only collect, but you cannot restore.
If you have certain variables that represent tuning parameters
(setpoints, for example) you can use tools such as the OpenBSI
DataView recipe feature to save those values to a recipe file on the
PC, and then restore them at a later time. See Chapter 8 of the
OpenBSI Utilities Manual (D5081).
You can store the contents of read/write data arrays using the
OpenBSI Data Array Save/Restore utility. See Chapter 13 of the
OpenBSI Utilities Manual (D5081).
You can collect alarms, and historical data (audit records, archive
files) but you cannot restore alarms or historical data.
ControlWave Corrector Instruction Manual
Flash Configuration utility, and load the FCP file using the Read
from FCP button, then choose the Write to RTU button.
Revised Nov-2013 Operation 4-7
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ControlWave Corrector Instruction Manual
Chapter 5 – Service and Troubleshooting
This chapter provides general diagnostic and test information for the
ControlWave Corrector as well as some common maintenance
procedures.
In This Chapter
5.1 Upgrading Firmware ........................................................................ 5-2
5.2 Removing or Replacing Components .............................................. 5-6
5.2.1 Accessing Modules for Testing ............................................ 5-6
5.2.2 Removing/Replacing the CPU/System Controller Board and the
Process I/O Board .............................................................. 5-6
5.2.3 Removing/Replacing the Primary Battery System ............... 5-7
5.2.4 Removing/Replacing the Backup Battery ............................ 5-8
5.2.5 Enabling / Disabling the Backup Battery .............................. 5-9
5.2.6 Removing/Replacing the Case-Mounted Radio or Modem . 5-9
5.2.7 Removing/Replacing the GPT Transducer ........................ 5-10
5.2.8 Removing/Replacing the TeleCounter (Pulser) Assembly . 5-10
5.3 General Troubleshooting Procedures ........................................... 5-11
5.3.1 Common Communication Configuration Problems ............ 5-11
5.3.2 Checking LEDs ................................................................... 5-12
5.3.3 Checking LCD Status Codes ............................................. 5-12
5.3.4 Wiring/Signal Checks ......................................................... 5-12
5.4 WINDIAG Diagnostic Utility ........................................................... 5-13
5.4.1 Available Diagnostics ......................................................... 5-14
5.5 Core Updump ................................................................................ 5-17
5.6 Calibration Checks ......................................................................... 5-18
Equipment
You need the following equipment to perform the procedures described
in this chapter:
To run diagnostics software:
PC with WINDIAG software, and either OpenBSI LocalView,
NetView, or TechView for communications
Null modem interface cable
Loop-back plug (See Figure 5-6 and Figure 5-7.)
To perform firmware upgrades:
Null modem interface cable
PC with the following software:
o OpenBSI LocalView
o OpenBSI System Firmware Downloader and either NetView,
LocalView, or TechView for communications.
o HyperTerminal (included in Windows®)
To replace the SRAM backup battery:
Tweezers or needle-nose pliers
Miscellaneous other equipment:
Needle-nose pliers
Revised Nov-2013 Service & Troubleshooting 5-1
ControlWave Corrector Instruction Manual
Screw drivers
Anti-seize compound (when replacing GPT/MVT)
Note: When you service a ControlWave Corrector on site, we
recommend that you close down (or place under manual control)
any associated processes. This precaution prevents any processes
from accidentally running out of control when you conduct tests.
Caution
Harmful electrical potentials may still exist at the field wiring terminals
even though the ControlWave Corrector power source may be turned
off or disconnected. Do not attempt to unplug termination connectors
or perform any wiring operations until you verify that all associated
power supply sources are turned off and/or disconnected.
Always turn off any external supply sources for externally powered I.O
circuits before you change any modules.
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave Corrector is situated in a hazardous location,
turn off power before servicing or replacing the unit and before
installing or removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
See Appendix A for details on Class I Division 2 usage of this device.
5.1 Upgrading Firmware
The ControlWave Corrector ships from the factory with system
firmware already installed. If you need to upgrade the system firmware
(stored in Flash memory) to acquire new functionality or restore
firmware, you can use one of several methods.
System
Firmware
Downloader
Use this tool to download system firmware to an unattended remote
ControlWave Corrector. To use this utility, you must set CPU/System
Controller board switch SW2-6 ON (the factory default position).
Note: For further information and detailed use instructions, refer to
Appendix J of the OpenBSI Utilities Manual (D5081).
LocalView
One of the standard OpenBSI utilities, LocalView requires OpenBSI
version 5.1 (or newer). If you have an older version of OpenBSI, use
HyperTerminal.
Note: For further information and detailed use instructions, refer to the
Flash Mode section of Chapter 5 of the OpenBSI Utilities
Manual (D5081).
5-2 Service & Troubleshooting Revised Nov-2013
ControlWave Corrector Instruction Manual
HyperTerminal
HyperTerminal is a communications utility program included with
Microsoft® Windows® XP.
Notes:
If you are using a version of OpenBSI older than 5.1, or do not have
OpenBSI software, you can only perform a firmware upgrade using
HyperTerminal.
While HyperTerminal is included in Microsoft® Window® XP,
some newer versions of Window® do not include it.
The screens shown here may appear different depending upon the
version of HyperTerminal you use.
HyperTerminal requires *.BIN files; newer ControlWave firmware
upgrade files use *.CAB files. In cases such as those, you should use
the Remote System Firmware Downloader.
1. Connect a null modem cable between COM1 of the
ControlWave Corrector and any RS-232 port on the associated
PC.
2. Click Start > Programs > Accessories > Communications >
HyperTerminal
3. If using HyperTerminal for the first time, set the communication
properties (for the PC port) via the Properties Menu as follows:
Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop
bits: = 1, and Flow control: = None and then click OK.
4. Set CPU/System Controller board switch SW1-3 ON (ON =
Force Recovery).
5. Apply power; to the ControlWave Corrector. The resident BIOS
initializes and tests the hardware, this process is referred to as
POST (Power On Self Test). Unless there is a problem, the LCD
display should show RECOV. If you see a different status code,
see Section 5.3.2.
6. From the HyperTerminal Mode menu (Figure 5-1), press the F
key to enter FLASH download. A message warns that the
FLASH is about to be erased; press the Y key at the prompt. The
screen displays dots as the system erases the flash memory; this
could take a few minutes.
Revised Nov-2013 Service & Troubleshooting 5-3
ControlWave Corrector Instruction Manual
Figure 5-1. HyperTerminal Mode Menu
7. When the FLASH is ready for download, HyperTerminal
repeatedly displays the letter C on the screen. In the
HyperTerminal menu bar click Transfer > Send File (see
Figure 5-2).
Figure 5-2. HyperTerminal (Ready to Download)
8. In the Send File dialog box (see Figure 5-3), select 1KXmodem
for the protocol, enter the filename of the appropriate .bin file in
the format “E1Sxxxxx.bin” or “E3Sxxxxxx.bin” (where E1S
refers to 14 MHz CPUs, and E3S refers to 33 MHz CPUs and
5-4 Service & Troubleshooting Revised Nov-2013
ControlWave Corrector Instruction Manual
xxxxx varies from release to release) and click Send to start the
flash upgrade (see Figure 5-4). When you see the
HyperTerminal Mode Menu again, it means the download has
completed.
9. Exit HyperTerminal and power down the ControlWave. If
desired, you can disconnect the null modem cable between the
ControlWave Corrector and the PC.
10. Set switch SW1-3 to the OFF position (OFF = Recovery Mode
Disabled).
11. Restore power to the ControlWave.
Figure 5-3. Send File dialog box
CWEXP01
E1S0410.bin
Figure 5-4. HyperTerminal (Download in Progress)
Revised Nov-2013 Service & Troubleshooting 5-5
ControlWave Corrector Instruction Manual
5.2 Removing or Replacing Components
This section provides information on accessing ControlWave Corrector
components for testing, as well as removal/replacement procedures.
Field repairs to the ControlWave Corrector are strictly limited to the
Caution
replacement of complete boards. Replacing board components
constitutes tampering and violates the product warranty. Return
defective boards or housings to the factory for authorized service.
5.2.1 Accessing Modules for Testing
Only technically qualified personnel should test and/or replace
ControlWave Corrector components. Read completely the disassembly
and test procedures described in this manual before starting. Any
damage to the ControlWave Corrector resulting from improper handling
or incorrect service procedures is not covered under the product
warranty agreement. If you cannot properly perform these procedures,
obtain authorization and then return the device to the factory for
evaluation and repairs.
5.2.2 Removing/Replacing the CPU/System Controller Board and the Process I/O Board
Use this procedure to remove or replace the CPU/System Controller
board and the Process I/O board.
1. If the ControlWave Corrector is running, place any critical
control processes under manual control.
2. Open the cover and shut down the ControlWave Corrector by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3. Disconnect all removable card edge connectors from the
CPU/System Controller board and the Process I/O board. Label
or otherwise identify them so you can easily re-connect them
later.
4. If present, disconnect the display/keypad from connector J2 on
the CPU/System Controller board.
5. Loosen the upper and lower locking tabs and rotate them so you
can remove the boards together. Carefully slide the boards
toward the front of the unit and unplug the GPT cable from the
CPU/System Controller board connector P1.
6. If you need to replace either the CPU/System Controller board
or Process I/O board, you need to separate the two boards. Use a
pair of needle-nosed pliers to squeeze the pair of tabs associated
with each of the six nylon mounting posts, while gently pulling
the CPU/System Controller board away from the Process I/O
board. Carefully unplug the boards from their interface
5-6 Service & Troubleshooting Revised Nov-2013
ControlWave Corrector Instruction Manual
connectors. Align the replacement boards with each other and
press them together so that the interface connectors and
mounting posts properly mate; then squeeze together so that the
mounting post tabs capture the CPU/System Controller board.
7. To install the replacement boards, power must be off. Align the
Process I/O board with the upper and lower guides so that the
CPU/System Controller board is on the right side. Slide the
boards (assembly) into the unit, making sure to re-connect the
GPT cable to CPU/System Controller board connector P1 before
you fully insert the assembly.
8. Rotate the upper and lower locking tabs to secure the boards.
9. Replace all cables removed in steps 3 through 6.
10. Apply power and test the unit.
5.2.3 Removing/Replacing the Primary Battery System
Notes:
The primary battery system attaches to the inside of the battery
cover/radio mounting plate.
Make sure the replacement battery is fully charged before you install
it.
1. If the ControlWave Corrector is running, place any critical
control processes under manual control.
2. Open the cover and shut down the ControlWave Corrector by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3. Remove the battery wires from the CPU/System Controller
board connector TB1 (unplugged in step 2) making sure they
don’t contact each other.
4. Loosen the four screws that secure the battery cover/radio
mounting plate to the one-piece mounting bracket.
5. Slide the battery cover/radio mounting plate towards the top of
the unit so that its slots clear the mounting screws, and remove
it. If a radio or modem is present, carefully set the battery
cover/radio mounting plate to one side.
6. Carefully remove the primary battery system (with cables
attached).
7. To replace the primary battery system, reverse the steps you
performed from step 6 to step 3.
8. Apply power and test the unit.
Revised Nov-2013 Service & Troubleshooting 5-7
ControlWave Corrector Instruction Manual
5.2.4 Removing/Replacing the Backup Battery
Note: The CPU/System Controller board draws power from the battery
only if the board loses power. The system SRAM has a standby
current draw of 20 μA maximum for each part plus 2 μA for the
real time clock. For a ControlWave Corrector containing 2MB
of SRAM, a worst-case current draw of 42 μA allows a battery
life of approximately 9000 hours. This means you should not
need to replace a battery until the ControlWave Corrector has
been in service for an extended period (normally many years).
The CPU/System Controller board accommodates a 3 V, 300 mA
lithium coin cell backup battery housed in a coin-cell socket (S1).
supervisory circuit on the CPU switches to battery power when the
regulated 3.3 Vdc falls out of specification. The battery then provides
backup power for the real-time clock (RTC) and the system SRAM on
the CPU/System Controller board.
Note: If the backup battery is working properly, the _BAT_OK system
variable is set ON; if the battery fails, this is OFF. The Ram
Backup Battery Status shows on the Station Summary page in
the standard measurement application. If the real-time clock
loses its battery backup, the ControlWave system variable
_QUEST_DATE turns ON. You can monitor this to generate an
alarm. See the System Variables section of the ControlWave
Designer Programmer's Handbook (D5125) for more
information. See the ControlWave Flow Measurement
Applications Guide (D5137) for information on the standard
measurement application.
A
Caution
5-8 Service & Troubleshooting Revised Nov-2013
You lose SRAM contents when you remove the backup battery.
If you replace a backup battery, wait at least one minute before repowering the system. This enables the SRAM to completely discharge.
After you install the new battery, ensure that you have placed jumper
W3 on pins 1-2 (to enable the battery).
ControlWave Corrector Instruction Manual
Removing /
Replacing the
Backup Battery
1. If the ControlWave Corrector is running, place any critical control
processes under manual control.
2. Remove power from the ControlWave Corrector.
3. Remove the CPU/System Controller board assembly from the
housing.
To remove the lithium battery, gently pry up the tab holding the battery
in the coin cell socket and remove the battery with a pair of tweezers or
needle-nosed pliers. Install the replacement battery.
4. Replace the CPU/System Controller board assembly in the housing.
5. Re-connect power to the ControlWave Corrector.
6. Once the battery has been replaced, the unit executes its Flash-
based application (“boot project”) at power-up, but all of the
current process data is lost. At power-up, the ControlWave
Corrector acts as though it had just been booted and reverts back to
the initial values specified in its application.
5.2.5 Enabling / Disabling the Backup Battery
For maximum shelf life, the CPU/System Controller board ships
from the factory with the installed lithium backup battery disabled.
You must enable it when you install the CPU/System Controller
board.
Enabling
Disabling
To enable the battery, install jumper W3 on pins 1-2.
For maximum shelf life, you can isolate the battery from the circuit by
placing jumper W3 on pins 2-3.
5.2.6 Removing/Replacing the Case-Mounted Radio or Modem
1. If the ControlWave Corrector is running, place any critical
control processes under manual control.
2. Open the cover and shut down the ControlWave Corrector by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3. Disconnect (unplug/unscrew) all power and interface connectors
from the radio/modem.
4. Disconnect the antenna cable from the radio.
5. Loosen the four screws that secure the battery cover/radio
mounting plate to the one-piece mounting bracket.
6. Slide the battery cover/radio mounting plate towards the top of
the unit, and remove it with the radio/modem installed.
7. Remove the mounting screws from the inner side of the battery
cover/radio mounting plate to remove the radio/modem. Note: If
the unit has a Bristol 9600 bps PSTN modem you also have to
Revised Nov-2013 Service & Troubleshooting 5-9
ControlWave Corrector Instruction Manual
remove four screws that mount it to a plate which in turn mounts
to the radio/modem mounting plate.
8. Replace the radio/modem, reversing the steps from 7 to 3.
9. Apply power and test the unit.
5.2.7 Removing/Replacing the GPT Transducer
1. If the ControlWave Corrector is running, place any critical
control processes under manual control.
2. Open the cover and shut down the ControlWave Corrector by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
3. Remove the ControlWave Corrector from its installation site and
take it to a repair area that supports proper ESD (electrostatic
discharge) control.
4. Remove the 4mm Hex cap screw from the mounting collar and
slowly pull out the GPT transducer. Carefully unplug the cable
from the GPT transducer.
5. Prior to installation of a replacement GPT, make sure that the
GPT O-ring seal is in place. Reverse the instructions from step 4
through step 1.
5.2.8 Removing/Replacing the TeleCounter (Pulser) Assembly
1. Configure the replacement TeleCounter assembly.
2. If the ControlWave Corrector is running, place any critical
control processes under manual control.
3. Open the cover and shut down the ControlWave Corrector by
disconnecting the power at the CPU/System Controller assembly
terminal TB1 (and if applicable, TB2).
4. Remove the ControlWave Corrector from its installation site and
take it to a repair area that supports proper ESD (electrostatic
discharge) control.
5. Disconnect the TeleCounter interface wiring from the
CPU/System Controller board and the Process I/O board.
6. Remove the four (4) screws which secure the TeleCounter
assembly to the base of the ControlWave Corrector.
7. While securing the ControlWave Corrector assembly, remove
the nuts that secure the base of the TeleCounter assembly to the
turbine meter and remove the TeleCounter.
8. While securing the ControlWave Corrector assembly, install the
replacement TeleCounter assembly (with top gasket) to the base
of the unit such that the wiring harness runs through the large
5-10 Service & Troubleshooting Revised Nov-2013
hole at the base of the unit’s housing. Install and tighten the four
screws that secure the TeleCounter to the bottom of the
ControlWave Corrector’s housing.
9. Install a new gasket to the top of the turbine meter and mount
the ControlWave Corrector. When mating the Corrector to the
turbine meter, it is essential that the input shaft of the
TeleCounter and the opening of the output shaft of the turbine
meter mate properly. Be careful not to damage the mating
surfaces. Once you align the surfaces, install and tighten the
mounting washers and nuts.
10. Connect the replacement TeleCounter wires to the CPU/System
Controller board.
5.3 General Troubleshooting Procedures
This section presents some procedures to troubleshoot problems with
the Corrector.
ControlWave Corrector Instruction Manual
5.3.1 Common Communication Configuration Problems
If serial communications do not function, it is often due to one of the
following issues:
Baud rate mismatch – the baud rate at both ends of the
communication line must match. If communications fail during a
download of a new flash configuration profile (FCP) file, you may
have changed the baud rate of the active communication line, since
baud rate changes occur immediately on FCP download. You can
always re-establish factory default baud rates for communication
ports by powering down the unit, and then setting CPU switch SW2-
3 to OFF and restoring power.
Incorrect BSAP local address – this address must be an integer from
1 to 127 and must be unique on this particular BSAP communication
line. You set the BSAP local address using the flash configuration
utility. If this ControlWave is a BSAP slave node, and the range of
addresses defined for the BSAP master port end of the
communication line does not encompass the local BSAP address
defined for this ControlWave, BSAP communications will not
function.
Incorrect EBSAP Group number – if you use expanded BSAP the
EBSAP group number must be correct; if you are not using EBSAP,
the group number must be 0.
If IP communications do not function, it is often due to incorrect IP
addresses or masks. Check to see that the IP address you defined for the
ControlWave is compatible with the range of IP addresses defined for
the communication line on which the unit resides. Also check that the IP
address of the default gateway is correct.
Revised Nov-2013 Service & Troubleshooting 5-11
ControlWave Corrector Instruction Manual
5.3.2 Checking LEDs
The ControlWave Corrector includes two red light emitting diodes
(LEDs) that provide operational and diagnostic functions.
You must open the chassis door to view these LEDs.
Table 5-1. LEDs on CPU/System Controller Board
LED Color Description
WD (CR1 right) RED ON = Watchdog condition – program crash; OFF = Normal operation
IDLE (CR1 left) RED ON = CPU has free time at end of execution cycle. Should be on
frequently.
OFF = CPU overloaded. Note: The idle LED may also be off if you
disabled it - see Table 2-1 in Chapter 2.
5.3.3 Checking LCD Status Codes
The following codes may appear on the LCD display:
Table 5-2. LCD Display Status Codes
LCD
Display
Blank Application Running
DIAG Unit in Diagnostic Mode
R DIAG Unit Running Diagnostics
FWXSUM Flash XSUM Error
DEVERR Error Initializing Application Device
FLASH Flash Programming Error
FACT Using Factory Defaults
BATT Battery Failure Detected
STRTUP Currently Loading the Boot Project
INIT System Initialization in Progress
RECOV Waiting in Recovery Mode
RAMERR Error Testing SRAM
STOP Application Loaded
HALT Stopped at a Break Point
NO APP No Application Loaded
BREAKP Running with Break Points
POWERD Waiting for Power-down (after NMI)
UPDUMP Waiting for Updump to be Performed
NOTRUN Unit Crashed (Watchdog Disabled)
Indication
Definition
5.3.4 Wiring/Signal Checks
Check I/O field wires at the card edge terminal blocks and at the
field device.
Check wiring for continuity, shorts and opens.
Check I/O signals at their respective terminal blocks.
5-12 Service & Troubleshooting Revised Nov-2013
5.4 WINDIAG Diagnostic Utility
ControlWave Corrector Instruction Manual
Caution
The ControlWave Corrector cannot execute your control strategy while
it runs diagnostic routines; place any critical processes controlled by
the ControlWave Corrector under manual control before starting this
procedure.
WINDIAG is a software-based diagnostic tool you use to test the
performance of I/O, CPU memory, communication ports, and other
system components. .
WINDIAG is a PC-based program, so the ControlWave Corrector must
be attached to and communicating with a PC running WINDIAG.
Establish communication between the ControlWave Corrector
(with/without an application loaded) and the PC with a local or network
port under the following conditions:
Set CPU module switches SW2-3 to OFF and SW2-8 to OFF.
Turning these switches off sets all serial ports on the ControlWave
Corrector to 9600 baud in preparation for diagnostic testing and
prevents the boot project from running and also places the
ControlWave Corrector in diagnostic mode.
Connect any ControlWave Corrector serial communication port to
the PC provided their port speeds match. Use a null modem cable to
connect RS-232 ports between the ControlWave Corrector and the
PC; use an RS-485 cable to connect the RS-485 port of the
ControlWave Corrector and the PC. See Chapter 2 for information
on cables.
Reserve the port running a diagnostic test for exclusive use; you
cannot use that port for any other purpose during testing.
Follow these steps:
1. Start OpenBSI communications using NetView, TechView, or
LocalView, and select the RTU you want to test.
2. Select Start >Programs > OpenBSI Tools >Common Tools >
Diagnostics. The Main Diagnostics menu (Figure 5-5) opens.
Revised Nov-2013 Service & Troubleshooting 5-13
ControlWave Corrector Instruction Manual
Figure 5-5. WINDIAG Main Diagnostics Menu
3. Select the component to be tested. See Section 5.4.1 for a
description of the tests. Enter any prompted parameters (slot #,
etc.). WINDIAG performs the diagnostics and displays pass/fail
results.
After performing all diagnostic testing, exit WINDIAG.
4. Set switches SW2-3 and SW2-8 on the CPU module to ON. The
ControlWave Corrector should resume normal operation.
5.4.1 Available Diagnostics
WINDIAG’s Main Diagnostics Menu (see Figure 5-5) provides the
following diagnostic selections:
Option Tests
CPU & Peripherals Checks the CPU/System Controller board except
Analog Output Checks the AO on the Process I/O board.
High Speed Counter Checks HSCs on the Process I/O board and
Prom/Ram Checks the SRAM and FLASH memory.
Analog Input Checks AIs on the Process I/O board.
Communications Checks serial communication ports COM1,
Discrete I/O Checks DIs and DOs on the Process I/O board.
EEPROM Checks the EEPROM.
Keyboard & Display Checks the optional display/keypad hardware.
for memory.
Pulse Counter inputs on the CPU/System
Controller board.
COM2, and COM3. The External loop-back tests
require the use of a loop-back plug.
5-14 Service & Troubleshooting Revised Nov-2013
ControlWave Corrector Instruction Manual
Port Loop-back
Test
WINDIAG allows you to select the communication port to test.
Depending on the type of network (RS-232 or RS-485) and the port in
question, a special loop-back plug is required:
Port 1 - RS-232 uses a 9-pin female D-type loop-back plug (see
Figure 5-6).
Figure 5-6. COM1 & COM2 RS-232 Loop-back Plug/Wires
Port 2 - RS-232 use loop-back wires (see Figure 5-6).
Port 3 - RS-232 use loop-back wires (see Figure 5-7).
Figure 5-7. COM3 RS-232 & RS-485 Loop-back Wires
Note: You can configure RS-485 loopback by setting CPU/System
Controller board switches SW3-1 & SW3-2 ON.
Port 3 - RS-485 use loop-back wires or CPU Switch SW3 (see
Figure 5-7).
These tests verify the correct operation of the communication ports.
Note: You cannot test a communications port while you are using it.
Revised Nov-2013 Service & Troubleshooting 5-15
ControlWave Corrector Instruction Manual
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
Test Procedure
Use this procedure to test the communication ports.
1. Connect an external loop-back plug to the port on the CPU you
want to test. Valid ports are: COM1, COM2, or COM3.
2. Select Communications on the WINDIAG Main Diagnostics
Menu. The Communications Diagnostic screen opens:
Figure 5-8. Communications Diagnostic Menu
3. Enter 5 in the Number of Passes field.
4. Select a port to test (click to display all available ports).
Note: The port you select must correlate to the port on which you
placed the loop-back plug in step 1.
5. Select 115200 or ALL ASYNC as the baud rate (click to
display all available rates).
6. Click RUN to start the test. At the completion of the test (which
generally takes about 5 seconds), any failed results appear in the
Status field to the right of the RUN button: For example:
TXD RXD Failure
CTS RTS Failure
7. Click Return to Menu to display the WINDIAG Main Menu.
5-16 Service & Troubleshooting Revised Nov-2013
5.5 Core Updump
ControlWave Corrector Instruction Manual
In some cases—such as when a ControlWave Corrector fails for no
apparent reason—you can upload a copy of the contents of SRAM and
SDRAM to a PC for support personnel and service engineers to
evaluate. This upload is called a “core updump.”
A core updump may be required if the ControlWave Corrector
spontaneously enters a watchdog state that affects all system operation.
This occurs when the system crashes as a result of a CPU timeout
(resulting from improper software operation, a firmware glitch, and so
on). In some cases, the watchdog state can recur but you cannot
logically reproduce the conditions.
The CPU’s RAM contains “crash blocks,” a firmware function provided
specifically for watchdog troubleshooting. You can view and save the
crash blocks by viewing the Crash Block Statistic Web Page (see the
Web_BSI Manual, D5087). On request, you can forward crash block
files to our technical support personnel. If they need additional
information to evaluate the condition, the technical support group may
request a core updump. Once the core updump process generates a file,
you can forward that file to the support personnel for evaluation and
resolution.
Use the following steps to preserve the “failed state” condition at a
system crash and perform a core updump:
1. Set switch SW2-1 on the CPU/System Controller board to OFF
(Disable Watchdog Timer). Set switch SW2-4 to OFF (Enable
Core Updump).
Note: The factory default setting for switch SW2-4 is OFF.
2. Wait for the error condition (typically“NOTRUN” on the LCD
display).
3. Connect the ControlWave Corrector’s Comm Port 1 to a PC
using a null modem cable.
4. Set the ControlWave Corrector for Recovery Mode by setting
both SW1-1 and SW1-2 to either the ON position or both to
the OFF position..
5. Start the PC’s HyperTerminal program (at 115.2 kbaud) and
generate a receive using the 1KX-Modem protocol. Save the
resulting core updump in a file so you can forward it later to the
technical support group.
By setting the CPU/System Controller board switches SW2-1 and SW2-
4 both off before the ControlWave Corrector fails you prevent the
Corrector from automatically recovering from the failure and enable it
to wait for you to take a core updump.
Once you complete the core updump, set the CPU/System Controller
Revised Nov-2013 Service & Troubleshooting 5-17
ControlWave Corrector Instruction Manual
board’s switch SW2-1 to ON (Watchdog Enabled) and SW2-4 to ON
(Core Updump Disabled).
Additionally, set switch SW1-1 to OFF and SW1-2 to ON.
With these switches set, power up the ControlWave Corrector and begin
standard operations.
5.6 Calibration Checks
The AO and AI on the Process I/O board are self-calibrating.
To calibrate the MVT/GPT and the RTD, use TechView software. See
the TechView User’s Guide (D5131) for more information.
5-18 Service & Troubleshooting Revised Nov-2013
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