Fisher ControlWave Ethernet I/O Manuals & Guides

CI-ControlWave RI/OWave

Instr uction Manual

Issue: 08/2001

TM

Ethernet Distributed (Remote) I/O MODULES

Discrete I/O Modules:

Discrete Output Modules:

Discrete / Analog Modules:

Analog Input Modules:

Analog I/O Modules:

BB-8DI2-8DO2-H, BB-16DI2-H & BB-8CNT

BB-16DO2-H

BB-8DI2-8AI2-H & BB-4RTD-4DI2-U

BB-16AI2-H & BB-8INS-U

BB-8AI2-4AO2-H

Control

ControlWave Ethernet I/O

Wave

Bristol Babcock

NOTICE

Copyright Notice

The informatio n in this docume nt is subj ect to chan ge witho ut noti ce. Every e ffort has be en
made to supply comp lete and accurate informatio n. However, Bristol Babcock assu mes no
responsibility for any error s that may appear in this document.

Request for Additional Instructions

Additional copies of instruction manuals may be ordered from the address below per
attention of the Sales Order Processing Department. List the instruction book numbers or
give complete mo del number, serial o r software version num ber. Furnish a return a ddress
that includes the name of the person who will receive the material. Billing for extra copies
will be according to current pricing schedules.

TM

ControlWave
products mentioned in this document are for information only, and belong to their respective
companies, or trademark holders.

is a trademark of Bristol Babcock. Other trademarks or copy-righted

Copyright (c) 2001 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of
this manual may be reproduced in any form without the express written permission of
Bristol Babcock.

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this d evice in some app lications may re sult
in damage or injury. The user is urged to keep this book filed in a convenient
location for future reference.

These instructions may not cov er 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 Bristol Babcock for further information.

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 valv es, emerg ency shuto ffs, emerg ency switche s, etc.
If additional information is required, the purchaser is advised to contact Bristol
Babcock.

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol Babcock for repairs or evaluation,
please note the followin g: The party sending su ch mater ials is resp onsible to ensure
that the materials return ed to Bristol Babc ock are clean to safe leve ls, as such lev els
are defined and/or determined by applicable federal, state and/or local law
regulations or codes. Such party agrees to indemnify Bristol Babcock and save
Bristol Babcock harmless from any liability or damage which Bristol Babcock may
incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Sy stem s," 29 CFR, Part 1910, Subp art S, d ated : 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.

Bristol Babcock 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

A. Bristol warrants that goods described herein and manufactured by Bristol are free

from defects in material and workmanship for one year from the date of shipment
unless otherwise agreed to by Br istol in writing.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from

defects in material and wo rkmansh ip for a period to the e nd of th e orig inal warran ty
or ninety (90) days fr om the date of delivery of repaired goods, whichever is longer .

C. Warranties on goods sold by, but not manufactured by Bristol are expressly limited

to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part

thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in s ervice time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER WAR-

RANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION WAR­RANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY REP­RESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY BRIS­TOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE FACE
HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written

or oral warranties beyond those set forth herein.

REMEDIES

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or

replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol' s Watertown office, unless Bristol's Water­town office designa tes a different l ocation, transpo rtation prepai d, within thirty (3 0)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer doe s not w ish to sh ip the product ba ck to Bris tol, the Buye r can ar­range to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incident al or consequential damages

resulting from breach of any agreement relating to items included in this quotation
from use of the information herein or from the purchase or use by Buyer, its
employees or other parties of goods sold under s aid agreement.

How to return material for Repair or Exchange

Before a product can be returned to Bristol Babcock for repair, upgrade, exchange, or to
verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA
(Return Authorization) number and thus ensure an optimal lead time. Completing the form
is very important since the information permits the Bristol Babcock Repair Dept. to
effectively and efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX

Completing the form (GBU 13.01) and faxing it to [phone]. A BBI Repair
Dept. representative will return call (or other requested method) with a RA number.

B. E-MAIL

Accessing the form (GBU 13.01) via the Bristol Babcock Web site
(www.bristolbabcock.com) and sending it via E-Mail to [e-mail].
A BBI Repair Dept. representative will return E-Mail (or other requested method)
with a RA number.

C. Mail

Mail the form (GBU 13.01) to

Bristol Babcock Inc.

Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

A BBI Repair Dept. representative will return call (or other requested method) with
a RA number.

D. Phone

Calling the BBI Repair Department at [phone]. A BBI Repair Department
representative will record a RA number on the form and complete Part I, then send
the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in­cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.

Bristol Babcock Inc. Repair Authorization Form

(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to

receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________

Standard Repair Practice is as follow s: Variations to this is

practice may be requested in the “Special Requests” section.

• Evaluate / Test / Verify Discrepancy

• Repair / Replace / etc. in accordance with this form

Please be aware of the Non warranty standard cha r ge:

• There is a $100 minimum evaluation charge, which is
applied to the repair if applicable (√ in “retur ned” B,C,
or D of part III below)

• Return to Customer

Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)
Bill to : Ship to:

Purchase Order: Contact Name:____________________________________
Phone: Fax: E-Mail:

Part II Please complete Parts II & III f or each unit returned

Model No./Part No. Description
Range/Calibration S/N
Reason for return :

Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used:

Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________

3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due

to BBI’s warranty clause, would you like the product:

repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,

would you like the product:

C. If product is deemed not repairable would you like your product:
D. If BBI is unable to verify the discrepancy, would you like the product:

repaired returned replaced scrapped?

returned replaced scrapped?
returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that

has the most knowledge of the problem is: _______________________________ phone

If we are unable to contact this person the backup person is: _________________________

phone

Special Requests:

Ship prepaid to: Bristol Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: [phone] Fax: [phone]

Form GBU 13.01 Rev. A

Bristol Babcock

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

● Avoid Delays and problems in getting your system on-line

● Minimize installation, start-up and maintenance costs.

● Make the most effective use of our hardware and software.

● Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Babcock offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at four locations: Houston, Birmingham, Orlando and our Watertown,
CT headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol Babcock products and realize
the full potential of your system.

For information or to enroll in any class, contact our training department in Watertown at
[phone]. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

BLANK PAGE

A Few Words About Bristol Babcock

For over 100 years, Bristol7 has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Babcock instruments, controllers, and systems running year-in
and year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis­tance in using this product from the following sources:

Contacting Bristol Babcock Directly

Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.

Our main phone numbers are:

[phone]
[phone] (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol Babcock's Application Support Group can provide
telephone support for your technical questions.

For technical questions about TeleFlowÔ products call [phone].

For technical questions about ControlWave call [phone] or [phone].

For technical questions regarding Bristol’s OpenEnterprise product, call [phone] or
e-mail: [e-mail]

For technical questions regarding ACCOL products, Open BSI Utilities, as well as
Bristol's Enterprise Server

For technical questions about Network 3000 hardware, call [phone].

You can e-mail the Application Support Group at: [e-mail]

7

/Enterprise Workstation7 products, call [phone].

The Application Support Group also maintains a service area within our main web site.
Technical information, as well as software updates are available in this area. To access our
web site, go to: bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol Babcock hardware to radios, contact Communication
Technologies in Orlando, FL at [phone] or [phone].

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed below) or to your
Bristol-authorized sales representative.

Major U.S. Sales Offices Major International Sales Offices:

Watertown, CT [phone] Bristol Babcock Ltd (UK): (441) 562-820-001
Birmingham, AL [phone] Bristol of Canada: [phone]
Ontario, CA [phone] Bristol Babcock Asia Pacific 61 8-9455-9955
Farmington, NM [phone] BBI, S.A. de C.V. (Mexico) [phone]
Houston, TX [phone]
Richardson, TX [phone]

Please call the main Bristol Babcock number (860-945-2200) if you are unsure which office
covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Babcock and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Instruction Manual

ControlWave

Ethernet Distributed

(Remote) I/O Modules

Contents at a Glance:

Con tr ol

Wave Ethernet I/O

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

Section 9

General Information

Ethernet and RS485 Wiring Remote I/O, Ethernet I/O Expansion

Configuration Tools

Discrete I/O Modules

Discrete Output Module

Discrete / Analog Modules

Analog Input Modules

Analog I/O Module

Modbus Communications

Ethernet I/O modules

BB-232-SETUP and Windows Tools

BB-8DI2-8DO2-H, BB-16DI2-H, BB-8CNT

BB-16DO2-H

BB-8DI2-8AI2-H, BB-4RTD-4DI2-U

BB-16AI2-H, BB-8INS-U

BB-8AI2-4AO2-H

Scheme Configuration Notes

2

3

4

7

10

11

13

15

16

Supplements & Appendices

Special Instructions for Class I, Division 2 Hazardous Locations ......................... Appendix A

Class I, Division 2,

Groups A, B, C, and D

Hazardous Locations

CI-ControlWaveRI/O Table Of Contents 1

Section 1 General Information

Overview

General
Specifications

This manual will help you install and maintain Ethernet Remote I/O Modules and
gateways. In summary, wiring for power, communications and I/O is connected to each
module’s base. Then, setup choices are entered using the Remote I/O Tool Kit software
and the system will be ready to run. Shown below are some typical system configurations
using Ethernet I/O:

Ethernet Hub

RS 485

Control Wave Ethernet I/OControl Wave Ethernet I/OControl Wave Ethernet I/O

Distributed Ethernet and serial I/O

These general specifications apply to all Ethernet I/O modules. More detailed product
specifications may be found in the online help system of the Remote I/O Toolkit
configuration utility.

Supply Voltage 10 - 30 Vdc, 1.2 Watt typical per module

(48 mA @ 24 Vdc - varies by module and load).

RS485 Expansion Connect up to 32 Remote I/O modules using RS485
Ethernet Isolation 1200 Volts RMS (for 1 minute)

Operating Temperature -30 to 70 °C
Storage Temperature -40 to 85 °C
Humidity 5 to 95% (non-condensing)

Protocols Supported Open Modbus/TCP, Serial Modbus RTU & ASCII

Universal

Section 1 General Information 2

Section 2 Ethernet and RS485 Wiring

DC Power
Overview

Ethernet I/O modules can be powered from the same DC source that is used to power
your I/O devices. No separate power supply is required. Typically, 10 to 30 VDC power
is applied to terminals 24 and 25 on the base of each module. Refer to the upcoming
wiring diagram for each module for power connections.

RS485 Wiring
Guidelines

Screw Torque

The RS485 party-line consists of two wires and an isolated ground wire. It is
recommended that the ground wire be connected to all stations to provide a common
return. The RS485 port on all Ethernet I/O modules is isolated from its internal circuitry,
local power source, and I/O wiring to improve communications reliability. It is
recommended that only 32 Remote I/O modules be connected on any RS485 party-line,
and that the termination jumper be installed on the last module on each end of the RS485
network. Limiting the cabling to t wo network arms (segments) rad iating from the master
controller will yield the best signal results.

19 20 21 22 23
G + - T1 T2

First Node Middle Node End Node

All the screw terminals on the base should be tightened to a maximum of 3.48 in-lbs.

19 20 21 22 23
G + - T1 T2

19 20 21 22 23
G + - T1 T2

Section 2 Ethernet and RS485 Wiring 3

Section 3 Configuration Tools

BB-232-SETUP Remote I/O Setup Module

Operation

RS232 Wiring

This setup tool is recommended to initially configure each Ethernet Remote I/O module.
To use the setup module, simply unplug any Ethernet I/O module from its base and insert
the setup module into the base.

Note: Ethernet I/O “smart bases” allow hot swap of live modules -- an exclusive feature

that makes it permissible to configure Ethernet I/O modules in live systems.

The Ethernet I/O module configuration you created using the Remote I/O Tool Kit
program will be written into permanent memory in the module’s base. When the Ethernet
I/O module is reinserted into its base, the module will find and upload the configuration
information, instantly configure itself and begin scanning I/O.

Once an Ethernet I/O module has been configured with an appropriate station address and
IP address (Ethernet I/O only), modified configuration data can be downloaded through
the Ethernet port or RS485 port into the module base.

More information on the Remote I/O Setup Module can be found in the online help
system of the Remote I/O Toolkit.

Connect the setup module to your Windows PC using a standard BB ST-CABLE-PF
RS232 cable. Only the transmit (TD), receive (RD) and common return (GND) signals
are actively used. The RS232 port on this configuration tool is electrically isolated to
protect your computer in the event of field wiring errors. The setup module runs on the
DC power connected to terminals 17 and 18 of the mod ule base it is plugged into. No
other connections are required. (I/O wiring can be left undisturbed.)

RS232 Mode
Selection

This module always communicates to the host PC at 9600 baud, with no parity and eight
data bits. Be sure to select “Use Setup Module’s Settings” as the communication device
selection in the Remote I/O Tool Kit program.

Section 3 Configuration Tools 4

Remote I/O
Tool Kit

Ethernet I/O modules are configured using the Remote I/O Tool Kit software.
Configuration parameters are written over Ethernet, RS485 or RS232 (setup module only)
into permanent memory in the module’s base. Refer to the Remote I/O Tool Kit help for
details.

Here are the basic steps for configuring an Ethernet I/O module.

1. Connect DC power to the module.

2. Connect an Ethernet cable to the module. Use a straight-through cable if you are

connecting to an Ethernet hub or switch. Use a cross-wired cable if you are connecting
directly to a PC. Make sure the LNK LED on the module is on solid (not blinking).

3. Run the Remote I/O Tool Kit. You can use the Plug & Play Wizard to define the

parameters for the module. Be sure to do the following:

• Choose an IP address that is appropriate for your network. See the help file for

details.

• Enter in the serial number that is printed on a label on the module.

• Choose a station (slave) number for the module. This number must be unique

from other modules and the device to which you are interfacing.

• Select the appropriate RS232 or RS485 com parameters (protocol, baud rate, etc.)

to match the device to which you are interfacing.

4. Once you’ve complete d the wizard, save you r pro ject f ile. Go to the Dev ice
menu and choose the appropriate communication device. Then go to the
Operations menu an d select Load. This should set the IP address in the
module and then load down your other parameters.

If this load fails for some reason, here are some items to check:

• Make sure the LNK LED is on solid. If it is off or blinking then a typical cause is

a bad cable, a n incorrect cab le, or you are plugged into the wrong port o n your
hub/switch.

• Try to “ping” the module. Ping is a utility that comes with your PC. Start an

MSDOS prompt and type “ping” followed by the IP address of the gateway and
then hit <CR>. For example, “ping 10.1.0.1” (do not type the quotes). If you get
an “unknown command” error then you will need to install the TCP /IP Ethernet
protocol on your computer. If you get “destination unreachable” then make sure
the gateway’s IP address is valid with respect to the IP address and subnet mask
of your computer. If you get “request timeout” then check all the items above.

Note: Information on Ethernet networking can be found in the online help

system for the Remote I/O Toolkit.

5. Once you establish that you can communicate with the module from the Remote I/O
Tool Kit you then should attempt to communicate with your device using your
ControlWave master.

Section 3 Configuration Tools 5

Ethernet I/O
LEDs

Every Ethernet I/O module has a number of LEDs. These LEDs can be useful for system
diagnostics. These LEDs can be observed in the following states:

I/O Module
Status LED

Status LED
Wink Feature

ACT / LNK
LEDs

On, with a quick “OFF” BLINK (1.9 seconds ON, .1 seconds OFF) - The module is
configured and fully operational, but has not received a valid request from the host for a
time longer than the specified time out period. A communication time out has occurred.

Full ON - The module is configured, fully operational, and has received communication
from the host device before the timeout period expired. This is the desired LED

indication during system operation.
HALF BLINK (1 second ON, 1 second OFF) - The module is not adequately configured

and requires a download from the Remote I/O Tool Kit program.
Full OFF - There is no power to the module, or the status LED is being turned off

intentionally by the Remote I/O Tool Kit during the module loading operation.
Off, with a quick “ON” BLINK (1.9 seconds OFF, .1 seconds ON ) - The module failed

self-test at initialization. It will not attempt communication and should be replaced.

The “Status” LED of an I/O module can be intentionally winked (10 blinks/ second) by
the Remote I/O Tool Kit program to visually identify the module when other modules are
present.

The activity (ACT) LED on an Ethernet I/O module will flicker anytime there is traffic on
the Ethernet network, regardless of whom the network messages are intended for. The
link (LNK) LED will be ON whenever a valid link to another Ethernet device is detected.
The best troubleshooting tools for Ethernet I/O modules are the Status, ACT, and LNK
LEDs on each module. Each Ethernet I/O Status LED indicates the health of the module
and also the status of communication from the host device. You can use the Wink feature
to provide continuous transmission to an Ethernet I/O. Note that an Ethernet I/O module
does not send a reply in response to a Wink command.

Section 3 Configuration Tools 6

Section 4 Discrete I/O Modules

BB-8DI2-8DO2-H 8 Discrete Inputs and 8 Discrete Outputs
BB-16DI2-H 16 Discrete Inputs

BB-8DI2­8DO2
Overview

Wiring and
Jumpers

TPO Feature

This module provides one terminal for each input or output channel. All inputs may be
wired as sourcing or sinking. Outputs are wired in a sourcing (power switching)
configuration only. An input count feature uses analog input registers to accumulate the
positive transitions of each input. More information may be found in the on-line help in the
Remote I/O Tool Kit program.

Number of Channels 8 discrete inputs, 8 discrete o utputs (BB-8DI2-8DO2 only)
Input Voltage Range 12/2 4 VDC/VAC
Input Current @ 24Vdc 6. 7 mA
Output Voltage Range 10 – 30 VDC
Maximum Count Rate 100 Hz (6000 / minute) each input, plus selectable 2KHz

(120,000 / minute) mode for input 1 only

One wire from each sourcing field input should be bussed together and connected to
terminal 17 (DC +). One wire from each sourcing field output and/or or sinking field input
should be bussed together and connected to terminal 18 (DC GND). Refer to the wiring
diagram below. Set jumper W1 to match the wiring configuration of the inputs.

Time proportioned outputs pulse ON and OFF with a duty cycle proportional to an analog
value stored in an analog output register. TPO outputs are a low cost way to get smooth
proportional control of heaters and other process variables. Typically, TPO analog output
registers are assigned to the output of PID or other control logic in a ACCOL Workbench
or ControlWave Designer program. Use the Remote I/O Tool Kit to set pulse cycling as
fast as 10 mS or as slow (many minutes) as your system dynamics require. Each output
may be configured as a TPO or ordinary discrete output.

I/O Registers

Function Module Registers Modbus Registers
Discrete Inputs X0 – X7 10001 – 10008
Discrete Outputs Y0 – Y7 00001 – 00008
TPO Values AY0 – AY7 40001 – 40008
Counter Inputs AX0 – AX7 30001 – 30008

Section 4 Discrete I/O Modules 7

BB-16DI2-H High Density Discrete Input Module

BB-16DI2
Overview

Wiring and
Jumpers

I/O Registers

This module provides sixteen input channels. Inputs may be wired as all sourcing or
sinking. An input count feature uses analog input registers to accumulate the positive
transitions of each input. More information on this and other features may be found in the
on-line help supplied with the Remote I/O Tool Kit program.

Number of Channels 16 discrete inputs (connected to a common source)
Input Voltage Range 12/24 VDC/VAC
Input Current @ 24 VDC 6.7 mA

Positive DC or AC voltage must be applied to an input to indicate an ON condition. All
channels are referenced to a common return or supply, which is connected to the negative
side (ground) or positive side (DC+) of the DC power source. One wire from each
sourcing field input should be bussed together and connected to terminal 17 (DC +). One
wire from each sinking field input should be bussed together and connected to terminal 18
(DC GND). Refer to the wiring diagram below. Set jumper W1 to match the wiring
configuration of the inputs.

Function Module Registers Modbus Registers
Discrete Inputs X0 – X15 10001 – 10016
Counter Inputs AX0 – AX15 30001 – 30016

Section 4 Discrete I/O Modules 8

BB-8CNT High Speed Counter Module

BB-8CNT
Overview

Input Wiring

I/O Registers

This high-speed counter module has eight isolated circuits that accept pulse inputs from a
variety of sources, including quadrature and incremental encoders. Count values are
reported in 16 bit analog input registers or 32 bit long registers. The states of the counter
inputs are also reported as discrete inputs. Pulse rates up to 50 kHz are supported. The
counters may be reset by toggling discrete output bits. Counter modes are selected using
the Remote I/O Tool Kit program. More information on this and other features may be
found in the on-line help supplied with the Remote I/O Tool Kit program.

Number of Channels 8 discrete inputs, isolated
Input Voltage Range 12/24 VDC/VAC
Input Current @ 24 VDC 6.7 mA

Screw terminal assignments are shown below. For best noise immunity, connect input
signals using twisted wire pairs. To maintain the best differential noise rejection, do not
connect (-) screw terminals together at the I/O base. Positive DC voltage must be applied
to an input to indicate an ON condition. Refer to the wiring diagram below.

Any odd-numbered input can be gated by connecting a gating signal to the next highest
even-numbered input. For example, Input 2 can gate the counter for Input 1.

Function Module Registers Modbus Registers
Discrete Inputs X0 – X7 10001 – 10008
Counter Inputs AX0 – AX7 or LI0 – LI7 30001 – 30008

35001 – 35008

Resets Y0 – Y7 00001 – 00008

Section 4 Discrete I/O Modules 9

Section 5 Discrete Output Modules

BB-16DO2-H High Density Discrete Output Module

BB-16DO2
Overview

Wiring

TPO Feature

Sixteen discrete output channels each provide up to 1 Amp DC to motor contactors,
valves, and other loads. Inductive surge protection is provided. Each of the sixteen
outputs may optionally be configured as Time Proportioned Outputs that pulse ON at a
duty cycle proportional to an analog output register value. Typically these TPO outputs
are controlled by a PID loop or other process algorithm in a control program. More
information may be found in the on-line help supplied with the Remote I/O Tool Kit
program.

Number of Channels 16 discrete outputs connected to a common DC

source
Output Voltage Range 10 - 30 VDC
Max. Load per Output 1 Amp
Max. Load per Module 8 Amps
Max. Inrush Current 5 Amps (for 100 mS)

A single terminal is provided for each output channel. All outputs are powered from the
DC power terminal. All channels are referenced to a common return which is connected
to the negative side (ground) of the DC power source.

Time proportioned outputs pulse ON and OFF with a duty cycle proportional to an analog
value stored in an analog output register. TPO outputs are a low cost way to get smooth
proportional control of heaters and other process variables. Typically, TPO analog output
registers are assigned to the output of PID or other control logic in a ACCOL Workbench
or ControlWave Designer program. Use the Remote I/O Tool Kit to set pulse cycling as
fast as 10 mS or as slow (many minutes) as your system dynamics require. Each output
may be configured as a TPO or ordinary discrete output.

I/O Registers

Section 5 Discrete Output Module 10

Function Module Registers Modbus Registers
Discrete Outputs Y0 – Y15 00001 – 00016
TPO Values AY0 – AY15 40001 – 40016

Section 6 Discrete / Analog Modules

BB-8DI2-8AI2-H 8 Discrete Inputs and 8 4-20 mA Inputs

BB-8DI2-8AI2
Overview

Wiring and
Jumpers

Current
Shunts

Eight 4-20 mA inputs provide 14 bit analog measurements. Discrete inputs may be wired
as all sourcing or sinking. An input count feature uses analog input registers to
accumulate the positive transitions of each input. More information on this and other
features may be found in the on-line help supplied with the Remote I/O Tool Kit program.

Number of Channels 8 analog inputs (14 bit resolution), 8 discrete inputs
Input Range 4 - 20 mA (analog), 12/24 Vdc/Vac (discrete)
Analog Input Impedance 100 ohms Note: input voltage drop = 2 volts at 20 mA
DI Voltage Range 12/24 Vdc/Vac
Input Current @ 24 Vdc 6.7 mA

Positive DC or AC voltage must be applied to an input to indicate an ON condition. All
channels are referenced to a common return or supply, which is connected to the negative
side (ground) or positive side (DC+) of the DC power source. One wire from each
sourcing field input should be bussed together and connected to terminal 17 (DC +). One
wire from each sinking field input should be bussed together and connected to terminal 18
(DC GND). Refer to the wiring diagram below. Set jumper W1 to match the wiring
configuration of the discrete inputs. A single input terminal is provided for each analog
input channel. Care must be taken to externally provide a suitable instrumentation ground
for these single ended input circuits.

Precision 100 ohm current shunts, beneath the hinged access door in the wiring base, pass
current and maintain loop integrity even if the module is unplugged. A spare shunt is
provided and may be simply inserted in place of any shunt that open circuits as a result of
a current overload.

I/O Registers

Function Module Registers Modbus Registers
Analog Inputs AX0 – AX7 30001 – 30008
Discrete Inputs X0 – X7 10001 – 10008
Counter Inputs AX8 – AX15 30009 – 30016

Section 6 Discrete / Analog Modules 11

BB-4RTD-4DI2-U 4 RTD Inputs and 4 Discrete Inputs

BB-4RTD­4DI2
Overview

Wiring and
Jumpers

I/O Registers

Four RTD inputs provide 16 bit high-resolution analog measurements. Discrete inputs
may be wired as all sourcing or sinking. An input c o unt fea tur e use s ana lo g inp ut r egi ster s
to accumulate the positive transitions of each input. More information on this and other
features may be found in the on-line help supplied with the Remote I/O Tool Kit program.

Number of Channels 4 RTD inputs (16 bit resolution), 4 discrete inputs
RTD Input Type / Range 100 ohm platinum, -200 to 850 °°°°C
Discrete Input Range 12/24 VDC/VAC
Input Current @ 24 VDC 6.7 mA

See the wiring diagram below for RTD inputs. Discrete inputs need positive DC or AC
voltage applied to an input to indicate an ON condition. All channels are referenced to a
common return or supply, which is connected to the negative side (ground) or positive
side (DC+) of the DC power source. One wire from each sourcing field input should be
bussed together and connected to terminal 17 (DC +). One wire from each sinking field
input should be bussed together and connected to terminal 18 (DC GND). Refer to the
wiring diagram below. Set jumper W1 to match the wiring configuration of the discrete
inputs

Function Module Registers Modbus Registers
RTD Inputs AX0 – AX3 30001 – 30004
Discrete Inputs X0 – X3 10001 – 10004
Counter Inputs AX4 – AX7 30005 – 30008

Section 6 Discrete / Analog Modules 12

Section 7 Analog Input Modules

BB-16AI2-H High Density 4-20 mA Analog Input Module

BB-16AI2
Overview

Wiring

Current
Shunts

I/O Registers

Sixteen 4-20 mA inputs provide 14 bit high-resolution analog measurements. More
information may be found in the on-line help supplied with the Remote I/O Tool Kit
program.

Number of Channels 16 (14 bit resolution)
Input Range 4 - 20 mA
Input Impedance 100 ohms Note: input voltage drop = 2 volts at 20 mA

A single input terminal is provided for each measurement channel. Care must be taken to
externally provide a suitable instrumentation ground for these single ended input circuits.

Precision 100 ohm current shunts, beneath the hinged access door in the wiring base, pass
current and maintain loop integrity even if the module is unplugged. A spare shunt is
provided and may be simply inserted in place of any shunt that open circuits as a result of
a current overload.

Function Module Registers Modbus Registers
Analog Inputs AX0 – AX15 30001 – 30016

Section 7 Analog Input Modules 13

BB-8INS-U Instrumentation Analog Input Module

BB-8INS
Overview

BB-8INS
Wiring

4-20 mA
Input
Jumpers

Current
Shunts

Eight configurable inputs provide 16 bit high-resolution analog measurements. More
information may be found in the on-line help supplied with the Remote I/O Tool Kit
program.

Number of Channels 8 (16 bit resolution)
Input Range 0/4 - 20 mA, 62 mV to 10V, JKERTBCNS

thermocouples
Input Impedance (current) 100 ohms Note: input voltage drop = 2 volts at 20

mA

Input Impedance (other ranges) 200K Ohms

Two input terminals are provided for each measurement channel. Channel to channel
isolation is provided.

This module has a 4-20 mA input enable jumper for each channel. Set each jumper to
match the desired input as shown in the diagram below. The jumper setting must match
the range selection in the Remote I/O Tool Kit.

Precision 100 ohm current shunts, beneath the hinged access door in the wiring base, pass
current and maintain loop integrity even if the module is unplugged. A spare shunt is
provided and may be simply inserted in place of any shunt that open circuits as a result of
a current overload.

I/O Registers

Function Module Registers Modbus Registers
Analog Inputs AX0 – AX7 30001 – 30008

Section 7 Analog Input Modules 14

Section 8 Analog I/O Module

BB-8AI2-4AO2-H Combined Analog Input and Output Module

BB-8AI2-4AO2
Overview

Wiring

I/O Registers

This module combines eight 4-20 mA analog inputs and four 4-20 mA outputs. More
information may be found in the on-line help supplied with the Remote I/O Tool Kit
program.

Number of Analog Inputs 8 (14 bit resolution)
Input Range 4 - 20 mA
Input Impedance 100 ohms Note: input voltage drop = 2 volts at 20 mA
Number of Analog Outputs 4 (16 bit resolution)
Output Range 4 - 20 mA

A single input terminal is provided for each input and output channel. Care must be taken
to externally provide a suitable instrumentation ground for these input and output circuits.

Function Module Registers Modbus Registers
Analog Inputs AX0 – AX7 30001 – 30008
Analog Outputs AY0 – AY3 40001 – 40004

Section 8 Analog I/O Modules 15

Section 9

Modbus
Command
Support

Modbus Communications Scheme
Configuration Notes

Ethernet and RS-485 I/O Modules support the Modbus commands listed in Table 1 below
(see Modbus Function Codes) as described in AEG Modicon document Modicon Modbus
Protocol Reference Guide Number PI-MBUS-300 Rev. E (or higher). The modules
support only the command(s) that apply to their I/O type(s).

Extensions to commands 03 and 16 provide support for long integers and floating point
numbers. Two formats are supported: Daniel Extensions and Modicon Protocol.

Table 1

Registers versus Function Table (ACCOL & ControlWave Non I.P.)

Daniel
Extension
Support

ControlWave

Function

Codes

1 1.0 01 0XXXX Read Multiple Coil Outputs
2 2.0 02 1XXXX Read Multiple Coil Inputs
3 3.0 03 4XXXX Read Multiple Analog Outputs
4 4.0 04 3XXXX Read Multiple Analog Inputs
7 5.0 07 XXXXX Read Exception Coil
5 6.0 05 0XXXX Write Single Coil Output
6 7.0 06 4XXXX Write Single Analog Output*
8 8.0 15 0XXXX Write Multiple Coil Outputs
9 9.0 16 4XXXX Write Multiple Analog Outputs**

ACCOL

Function

Codes

Modbus

Function

Codes

Modbus

Registers

Description

1

* = For 16-bit Registers ONLY. ** = For 16-bit & 32-bit Registers.
1 = Not Supported

Note: For ControlWave use Custom Function Block if not using I.P.
Note: For ControlWaves implementing I.P. use the ControlWave I/O Configurator.
Note: Discrete Outputs are referred to as Coil Outputs under the Description column.

Ethernet and RS-485 I/O Modules can be configured to use Daniel Extensions or a pair of
registers when responding to Modbus commands from a Modbus master device. Daniel
Extension support is provided by some Modbus devices as a means of transferring 32-bit
registers. These extensions are detailed in the Daniel Industries document, Modbus
Communications 2500 Host-Slave Com-munications Number 3-9000-545 Rev. C (or
higher).

Ethernet and RS-485 I/O Modules can be configured to use Daniel Extensions or a pair of

Modbus
Slave
Operation

registers when responding to Modbus commands from a Modbus master device. Ethernet
High Speed Counter Modules do not support Daniel Extensions. The 32-bit registers in
the High Speed Counter Module are read as a pair of 16-bit registers only.

Modules acting as Modbus master stations. When Daniel Extension support is disabled,

Modbus
Master
Operation

Modbus data is transferred as a pair of analog registers. See the topic Transfer Longs and
Floats as a Pair of Analog Registers in the Modicon Modbus Protocol Reference Guide
for more information.

Section 9 Modbus Communications Scheme Configuration Notes 16

Modbus
Addressing

Access to different types of I/O is supported by the Modbus messaging protocol via
address ranges. Table 2 provides a list of Modbus address ranges assigned to various
types od I/O data. Table 3 provides a compilation of I/O Module setup information
required for Modbus communications configuration.

Table 2

I/O Module Addresses & Modbus Data Addresses

Data Type Module Address Module Data Address

Discrete Input 0000 to 9999 10001 to 20000
Discrete Output 0000 to 9999 00001 to 10000
Analog Input 0000 to 2999 30001 to 33000
Analog Output 0000 to 2999 40001 to 43000
Short Integer Input 0000 to 1999 33001 to 35000
Long integer Input 0000 to 1999 35001 to 37000
Floating Point Input 0000 to 2999 37001 to 40000
Short Integer Output 0000 to 1999 43001 to 45000
Long Integer Output 0000 to 1999 45001 to 47000
Floating Point Output 0000 to 2999 57001 to 50000

Examples: Modbus data address 10001 equates to module DI 0.

Modbus data address 30006 equates to module AI 5.

Table 3

I/O Module Memory Map - ACCOL/ControlWave Setup

I/O

Module

8DI/8DO DI

16DI DI

8CNT DI

16DO DO

8DI/8AI AI

4RTD/4DIRTD

16AI AI AX0 - AX15 30001 – 30016 4 4.0 1 to 16 1 to 16
8INS AI AX0 - AX7 30001 – 30008 4 4.0 1 to 8 1 to 8
8AI/4AO AI

I/O

Type

DO
TPO
CNT

CNT

CNT

Reset

TPO

DI
CNT

DI
CNT

AO

2

1

2

Module

Registers

X0 - X7
Y0 - Y7
AY0 - AY7
AX0 - AX7
X0 - X15
AX0 - AX15
X0 - X7
AX0 - AX7 or
L10 - L17
Y0 - Y7
Y0 - Y15
AY0 - AY15
AX0 - AX7
X0 - X7
AX8 - AX15
AX0 - AX3
X0 - X3
AX4 - AX7

AX0 - AX7
AY0 - AY3

Modbus
Register
Address

10001 - 10008
00001 - 00008
40001 - 40008
30001 - 30008
10001 - 10016
30001 - 30008
10001 - 10008
30001 - 30008
35001 - 35008
00001 - 00008
00001 - 00016
40001 – 40016
30001 – 30008
10001 – 10008
30009 – 30016
30001 – 30004
10001 – 10004
30005 – 30008

30001 – 30008
40001 – 4000443, 6, 9

CtrlWave
Function

Codes

2
1, 5, 8
3, 6, 9

4

2

4

2

4

3
1, 5, 8
1, 5, 8
3, 6, 9

4

2

4

4

2

4

ACCOL

Function

Codes

2.0

1.0, 6.0, 8.0

3.0, 7.0, 9.0

4.0

2.0

4.0

2.0

4.0

3.0

1.0, 6.0, 8.0

1.0, 6.0, 8.0

3.0, 7.0, 9.0

4.0

2.0

4.0

4.0

2.0

4.0

4.0

3.0, 7.0, 9.0

Count

1 to 8
1 to 8
1 to 8

1 to 8
1 to 16
1 to 16

1 to 8

1 to 8

1 to 8

1 to 8
1 to 16
1 to 16

1 to 8

1 to 8

1 to 8

1 to 4

1 to 4

1 to 4

1 to 8

1 to 4

Address

Range

1 to 8
1 to 8
1 to 8

1 to 8
1 to 16
1 to 16

1 to 8

1 to 8

1 to 8

1 to 8
1 to 16
1 to 16

1 to 8

1 to 8
9 to 16

1 to 4

1 to 4

5 to 8

1 to 8

1 to 4

Note 1: Count values are reported in 16-bit AI Registers or 32-bit long registers.
Note 2: When configured as TPO, each output will pulse ON at a duty cycle proportional to an

AO value stored in an AO Register.

Section 9 Modbus Communications Scheme Configuration Notes 17

Table 4 - PLC Formats Assigned to I/O Modules & I/O Types

I/O

Module

8DI/8DO DI

16DI DI

8CNT DI

16DO DO

8DI/8AI AI

4RTD/4DI RTD

16AI AI 16VU16
8INS AI 8VU16
8AI/4AO AI

I/O

Type

DO
TPO
CNT

CNT

CNT AX
CNT L
Resets

TPO

DI
CNT

DI
CNT

AO

(See PLC Formats – Modbus Master in the Gould

Modbus/Open Modbus Interface Section of the ACCOL II

8VL
8VL
8VU16
8VU16
16VL
16VU16
8VL
8VU16
8VU32
8VL
16VL
16VU16
8VU16
8VL
16VU16
4VU16
4VL
16VU16

8VU16
8VU16

PLC Formats

Custom Protocols Manual – D4066)

Reference
Documents

Software
Assistance

DI = Discrete Input DO = Discrete Output AI = Analog Input
AO = Analog Output CNT = Counter TPO = Time Proportional Output
RTD = Resistive Temperature Device
INS = Instrumentation AI - 16-bit high-resolution measurements per channel

ACCOL II Customs Protocols Manual - BBI doc. D4066
Getting Started with ControlWave Designer - BBI doc. D5085
Modicon Modbus Protocol Reference Guide - Modicon doc. PI-MBUS-300
Modbus Comm. 2500 Host-Slave Communications - Daniel Industries doc. 3-9000-545

ControlWave Designer - On-line Help - Custom Function Block
Remote I/O Toolkit - On-line Help

Section 9 Modbus Communications Scheme Configuration Notes 18

ControlWave Ethernet Distributed (Remote) I/O Modules

Special Instructions for Class I, Division 2 Hazardous Locations

1. The BBI ControlWave Ethernet Distributed (Remote) I/O Modules are listed by
Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I,
Division 2, Groups A, B, C and D hazardous locations or non-hazardous locations only.
Read this document carefully before installing a nonincendive ControlWave Ethernet
Distributed (Remote) I/O Module. In the event of a conflict between the ControlWave
Ethernet Distributed (Remote) I/O Modules User Manual (CI-ControlWaveRI/O) and
this document, always follow the instructions in this document.

2. Wiring must be performed in accordance with Class I, Division 2 wiring methods as
defined in Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations
within the United States, or as specified in Section 18-152 of the Canadian Electrical
Code for installation in Canada.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair

suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,
turn off power before servicing/replacing the unit and before installing or
removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the
power has been switched off or the area is known to be nonhazardous.

07/19/2000 Appendix A of CI-ControlWaveRI/O Page 1 of 1

BLANK PAGE

READER RESPONSE FORM

Please help us make our documentation more useful to you! If you have a complaint, a
suggestion, or a correction regarding this manual, please tell us by mailing this page with your
comments. We are dedicated to providing you correct, complete, and useful documentation.

DOCUMENT NUMBER: CI-ControlWaveRI/O
TITLE: ControlWave Ethernet Distributed remote I/O Modules - Customer Instruction

Manual

ISSUE DATE: AUG., 2001

COMMENT/COMPLAINT:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Mail this page to:
Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Attn: Technical Publications Group, Dept. 315

Customer Instruction Manual

CI-ControlWaveRI/O

(Issue: 4/2001)

Ethernet Distributed Remote I/O

Modules

Bristol Babcock Inc.

an FKI company

1100 Buckingham Street

Watertown, CT 06795

Telephone: [phone]