Fisher ControlWave Micro Process Automation Controller (CI-ControlWave Micro) Manuals & Guides
s
Instruction Manual
Doc Number CI-ControlWave Micro
Part Number D301392X012
August 2015
ControlWave® Micro
Process Automation Controller
Remote Automa tio n Solution
www.EmersonProcess.com/Remote
Be sure that these instructions are carefully read and understood before any operation is
attempted. Improper use of this device in some applications may result in damage or injury. The
user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions for further information.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may
leave an operating process without protection. Depending upon the application, this could result in
possible damage to property or injury to persons. It is suggested that the purchaser review the
need for additional backup equipment or provide alternate means of protection such as alarm
devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches,
etc. If additional information is required, the purchaser is advised to contact Remote Automation
Solutions.
RETURNED EQUIPMENT WARNING
When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions are clean to safe levels, as such levels are
defined and/or determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions may incur or suffer due
to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be gr ounded in
accordance with OSHA rules and regulations pertaining to "Design Safety Standards for Electrical
Systems," 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are in agreement
with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that
include electrically operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an
electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this
can result in erratic operation or complete failure of the equipment. Read supplemental document
S14006 for proper care and handling of ESD-sensitive components.
ControlWave Micro Instruction Manual
Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual ................................................................................................................. 1-2
1.2 Physical Description .................................................................................................................. 1-2
1.3 Housings ................................................................................................................................... 1-4
1.4 CPU Module .............................................................................................................................. 1-4
1.5 Power Supply/ Sequencer Module (PSSM) .............................................................................. 1-7
1.6 Expansion Communications Modules ....................................................................................... 1-9
1.7 I/O Modules ............................................................................................................................... 1-9
1.8 Software Tools ........................................................................................................................ 1-10
1.9 Secure Gateway ...................................................................................................................... 1-13
Chapter 2 – Installation 2-1
2.1 Site Considerations ................................................................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ...................................................................... 2-2
2.2 Installation Overview ................................................................................................................. 2-2
2.2.1 Unpacking Components ................................................................................................ 2-3
2.2.2 Mounting the Housing ................................................................................................... 2-8
2.2.3 Grounding the Housing ................................................................................................. 2-9
2.3 Power Supply/Sequencer Module (PSSM) ............................................................................. 2-10
2.3.1 General Information about the PSSM ......................................................................... 2-10
2.3.2 PSSM Installation Overview ........................................................................................ 2-12
2.3.3 Setting Jumpers on the PSSM .................................................................................... 2-12
2.3.4 Setting Mode Switch SW1 on the PSSM .................................................................... 2-13
2.3.5 General Wiring Guidelines .......................................................................................... 2-13
2.3.6 Wiring a Bulk DC Power Supply to the PSSM ............................................................ 2-14
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog Connector (OPTIONAL) . 2-15
2.4 CPU Module ............................................................................................................................ 2-17
2.4.1 Setting Jumpers on the CPU Module .......................................................................... 2-19
2.4.2 Setting DIP Switches on the CPU Module .................................................................. 2-20
2.4.3 Connections to RS-232 Serial Port(s) on CPU or ECOM Modules ............................ 2-23
2.4.4 Connections to RS-485 Serial Port(s) on CPU or ECOM Modules ............................ 2-26
2.4.5 Connections to Ethernet Port(s) on the CPU Module ................................................. 2-29
2.5 Expanded Communications Module (ECOM) ......................................................................... 2-31
2.5.1 RS-232 Ports ............................................................................................................... 2-32
2.5.2 RS-485 Ports ............................................................................................................... 2-32
2.5.3 Modem Port (Type 1 ECOM only) ............................................................................... 2-33
2.6 Bezels ...................................................................................................................................... 2-36
2.7 Optional Display/Keypads ....................................................................................................... 2-37
Chapter 3 – I/O Modules 3-1
3.1 Module Placement .................................................................................................................... 3-2
3.2 Wiring ........................................................................................................................................ 3-2
3.2.1 Local Termination .......................................................................................................... 3-3
3.2.2 Remote Termination ...................................................................................................... 3-3
3.2.3 Shielding and Grounding ............................................................................................... 3-4
3.3 Isolated Digital Input (DI) Module .............................................................................................. 3-6
3.4 Isolated Digital Output (DO) Module ....................................................................................... 3-11
3.5 Non-isolated Digital Input/Output (DI/O) Module .................................................................... 3-15
3.6 Non-isolated Analog Input/Output & Analog Input Module ..................................................... 3-18
3.7 Non-isolated High Speed Counter (HSC) Input Module ......................................................... 3-22
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ControlWave Micro Instruction Manual
3.8 Isolated Analog Input (AI) Module ........................................................................................... 3-26
3.9 Isolated Analog Output (AO) Module ...................................................................................... 3-30
3.10 Non-isolated Mixed I/O (MI/O) Module ................................................................................... 3-33
3.11 Isolated Vac Digital Input Module ........................................................................................... 3-39
3.12 Relay Isolated Vac/Vdc Digital Output Module ....................................................................... 3-41
3.13 Isolated Digital Input/Output (DI/O) Module ............................................................................ 3-43
3.14 Isolated Resistance Temperature Device (RTD) Input Module .............................................. 3-46
3.15 Isolated Low Level Analog Input (LLAI) Module ..................................................................... 3-49
3.16 Non-isolated HART®/BTI Interface Module ............................................................................. 3-54
Internally Sourced Transmitters ............................................................................................. 3-58
Externally Sourced Transmitters ............................................................................................ 3-59
3.17 IEC62591 Interface Module .................................................................................................... 3-62
Chapter 4 – Operation 4-1
4.1 Powering Up/Powering Down the ControlWave Micro ............................................................. 4-1
4.2 Setting the Operating Mode (Run/Remote/Local Switch or Mode Switch) ............................... 4-2
4.3 Communicating with the ControlWave Micro ............................................................................ 4-3
4.3.1 Default Comm Port Settings ......................................................................................... 4-3
4.3.2 Changing Port Settings ................................................................................................. 4-4
4.3.3 Collecting Data from the ControlWave Micro ................................................................ 4-5
4.4 Creating and Downloading an Application (ControlWave Project) ........................................... 4-5
4.5 Creating and Maintaining Backups ........................................................................................... 4-6
4.5.1 Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-7
4.5.2 Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-8
4.5.3 Backing up Data ............................................................................................................ 4-9
Chapter 5 – Service and Troubleshooting 5-1
5.1 Upgrading Firmware .................................................................................................................. 5-2
5.2 Removing or Replacing Components ....................................................................................... 5-5
5.2.1 Accessing Modules for Testing ..................................................................................... 5-5
5.2.2 Removing/Replacing the Bezel ..................................................................................... 5-6
5.2.3 Removing/Replacing the CPU Module ......................................................................... 5-6
5.2.4 Removing/Replacing the PSSM .................................................................................... 5-6
5.2.5 Removing/Replacing an I/O Module ............................................................................. 5-7
5.2.6 Removing/Replacing the Backup Battery ..................................................................... 5-7
5.2.7 Enabling / Disabling the Backup Battery ....................................................................... 5-9
5.3 General Troubleshooting Procedures ....................................................................................... 5-9
5.3.1 Checking LEDs ............................................................................................................. 5-9
5.3.2 Checking Wiring/Signals ............................................................................................. 5-16
5.3.3 Common Communication Configuration Problems ..................................................... 5-17
5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-17
5.4.1 Available Diagnostics .................................................................................................. 5-20
5.5 Core Updump .......................................................................................................................... 5-24
Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1
Appendix D – Modem Installation D-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1
Index IND-1
iv Contents Revised Aug-2015
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Micro hybrid controller (called the “ControlWave Micro” or “Micro”
throughout the rest of this manual). For information about the software
used with the Micro, refer to the ControlWave Micro Quick Setup Guide
(D5124), the ControlWave Designer Programmer’s Handbook (D5125),
and the online help in ControlWave Designer.
This chapter details the structure of this manual and provides an
overview of the ControlWave Micro and its components.
In This Chapter
1.1 Scope of the Manual ........................................................................ 1-2
1.2 Physical Description ........................................................................ 1-2
1.3 Housings .......................................................................................... 1-4
1.4 CPU Module .................................................................................... 1-4
1.5 Power Supply/ Sequencer Module (PSSM) .................................... 1-7
1.6 Expansion Communications Modules ............................................. 1-9
1.7 I/O Modules...................................................................................... 1-9
1.8 Software Tools ............................................................................... 1-10
1.9 Secure Gateway ............................................................................ 1-13
ControlWave Micro Instruction Manual
Features
ControlWave products have been designed and integrated as a highly
adaptable, high performance distributed open controller family with
exceptional networking capability that provides a complete process
automation management solution for the natural gas, water, and
wastewater industries. The ControlWave Micro was designed with an
emphasis on providing high performance with low power consumption,
scalability, and modularity.
Base housings are available with backplanes that support one, two or six
I/O modules. Optional expansion housings attach to either the 4- or 8slot base housing and support two, four, or eight I/O modules.
Note: The 3-slot base housing does not include a plug-in connection to
any expansion housings.
ControlWave Micros have the following key features:
Exceptional performance and low power consumption through use
of the ARM microprocessor
Small size (enabling panel- or wall-mount installations)
One or two RS-232 and one RS-485 asynchronous serial
communication ports
One or two optional 10/100 MB Ethernet ports
Optional Expansion Communication modules (ECOMs) with
optional built-in modem and/or radio
Revised Aug-2015 Introduction 1-1
ControlWave Micro Instruction Manual
3-, 4- and 8-slot base housings with 2-, 4-, or 8-slot I/O expansion
housings
Wide operating temperature range: (–40 to +70C) (–40 to 158F)
Variety of I/O modules (including mixed I/O) for cost-effective
small RTU applications
LED status indicators on the CPU, PSSM, and I/O modules
Lithium coin cell battery (located on the CPU module) provides
battery backup for the real-time clock and the system’s static RAM
(SRAM)
CE and Class I, Division 2 Hazardous Location approvals
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Chapter 2
Installation
Chapter 3
I/O Modules
Chapter 4
Operation
Chapter 5 Service and
Troubleshooting
1.2 Physical Description
Each ControlWave Micro has a printed circuit board (PCB) backplane
mounted in an aluminum housing, a Power Supply/Sequencer Module
(PSSM), a CPU module, and—depending on the backplane and housing
size—from zero to six I/O modules. See Figure 1-1 Expansion housings
(in 2-, 4-, or 8-slot configurations) attach to the base housing and enable
you to add up to eight more I/O modules.
Provides an overview of the hardware and
general specifications for the ControlWave
Micro.
Provides information on the base and expansion
housings, the Power Supply/Sequencer module
(PSSM), the CPU module, the Expanded
Communications module (ECOM), and related
peripherals such as the optional keypad.
Provides general information and wiring
diagrams for the I/O modules.
Provides information on day-to-day operation of
the ControlWave Micro.
Provides information on service and
troubleshooting procedures.
You can insert optional expansion communication modules (ECOMs) in
slots #3 and #4 of the base housing in place of I/O modules.
Refer to the following sections in this chapter or to other chapters in this
manual for further information:
Base and expansion housings (chassis) with backplanes (see Section
1.3 and Chapter 2)
1-2 Introduction Revised Aug-2015
ControlWave Micro Instruction Manual
Power Supply/Sequencer module (PSSM) (see Section 1.5 and
Chapter 2)
CPU module (see Section 1.4 and Chapter 2)
One or more I/O modules (see Section 1.7 and Chapter 3)
Optional Expansion Communication modules (ECOMs) (see Section
1.6 and Chapter 2)
Peripheral components (such as keypad) (see Chapter 2)
Figure 1-1 shows an 8-slot base housing with PSSM and CPU modules
installed.
Figure 1-1. 8-slot Base Housing (without 6 I/O Modules
Revised Aug-2015 Introduction 1-3
ControlWave Micro Instruction Manual
1.3 Housings
ControlWave housings (whether base or expansion) are gold irriditeplated aluminum designed either for wall, DIN rail, or panel-mounting.
They contain the printed circuit board (PCB) backplane that provides
connections for the PSSM, the CPU module, any ECOMs, and any I/O
modules.
Base
Expansion
1.4 CPU Module
Three base housings are available:
3-slot base backplane supports one PSSM, one CPU, and one I/O
module.
4-slot base backplane supports one PSSM, one CPU, and two I/O
modules.
8-slot base housing supports one PSSM, one CPU, and up to six I/O
modules.
You can substitute one or two ECOMs for I/O modules in slots 3 and 4
(if present) of the base housing.
Three optional expansion housings enable you to add two, four, or
eight I/O modules. However, you cannot install ECOMs in an
expansion housing.
Note: For complete technical details on housings, refer to the
ControlWave Micro technical specification (CWM).
The CPU (central processing unit) module houses the multi-layer PCB,
which contains the ControlWave Micro CPU, I/O monitor/control,
memory, and communication functions.
The CPU module includes:
Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core,
operating at 1.8V with a system clock speed of 33 MHz and 150
MHz.
one or two RS-232 communication ports,
one RS-485 communication port
zero, one, or two 10/100baseT Ethernet ports
2 MB of battery backed Static RAM (SRAM),
64MB of Synchronous Dynamic RAM (SDRAM),
512KB boot/downloader Flash,
16MB simultaneous read/write Flash memory
transmit (TX) and receive (RX) LEDs for each communication port
configuration DIP switches (described in Chapter 2.)
1-4 Introduction Revised Aug-2015
ControlWave Micro Instruction Manual
CPU Module
Configurations
Number of
RS-232
Ports
2 1 0 left side of Figure 1-2
2 1 1 right side of Figure 1-2
1 1 2 Figure 1-3
Note: Do not confuse the CPU module (which has communication
The CPU module has several basic configurations, all of which
have an on-board backup battery and different combinations of
communications ports:
Table 1-1. CPU Module Configurations
Number of
RS-485
Ports
Number of
Ethernet Ports
See Figure
components) with the Expansion Communication module
(ECOM), which does not have a CPU component or a battery
backup but does have additional communication components.
Figure 1-2. CPU Module with Three Serial Ports (left) and One Ethernet Port (right)
Revised Aug-2015 Introduction 1-5
ControlWave Micro Instruction Manual
Figure 1-3. CPU Module with Two Serial and Two Ethernet Ports
CPU Backup Battery
CPU Memory
CPU modules have a coin cell socket that accepts a 3.0V, 220 mA-hr
lithium battery. This battery provides backup power for the real-time
clock and the system’s Static RAM (SRAM).
There are several different types of memory used on the CPU module:
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The CPU module contains 16 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.
System Memory (SRAM)
The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by a lithium backup battery). Critical system information that must be
retained during power outages or when the system has been disabled for
1-6 Introduction Revised Aug-2015
maintenance is stored here. This includes the last states of all I/O points,
audit/archive historical data (if not stored in FLASH), the values of any
variables marked RETAIN, the values of any variables assigned to the
static memory area, and any pending alarm messages not yet reported.
SDRAM
The CPU module contains 64MB of synchronous dynamic random
access memory (SDRAM). SDRAM holds the running application
(ControlWave project) as well as a copy of system firmware and the
current values of any variables not marked RETAIN or stored in the
static memory area. This allows the system to run faster than it will
from the SRAM memory. SDRAM is not battery-backed.
1.5 Power Supply/ Sequencer Module (PSSM)
The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave Micro housing/backplane to all installed modules.
ControlWave Micro Instruction Manual
The PSSM operates from +10.7 to +30 Vdc or from +21.7 to +30 Vdc.
You configure the nominal input supply configuration (12V or 24V)
using configuration jumper switches on the PSSM.
The PSSM includes:
a wide input range Vin to 3.3V DC to DC Converter
1200 msec good power detection circuitry
Vin out-of-specifications detection circuitry
Watchdog output connector
Status LEDs
Vin 12-bit serial analog to digital converter
There are two versions of the PSSM currently available for the
ControlWave Micro. One version includes a keyed run/remote/local
switch (see Figure 1-4); the other version includes a mode switch (see
Figure 1-5). Chapter 2 includes instructions for setting these switches
and configuring the PSSM.
Revised Aug-2015 Introduction 1-7
ControlWave Micro Instruction Manual
Figure 1-4. PSSM (with Run/Local/Remote Switch)
Figure 1-5. PSSM (with Mode Switch)
Board Fuse
The PSSM is fused to protect the entire system using a 5x20mm slow
blow fuse F1 rated at 3 Amps.
1-8 Introduction Revised Aug-2015
1.6 Expansion Communications Modules
An optional Expansion Communications module (see Figure 1-6)
provides two additional serial communications ports and optionally a
piggy-backed dial-up modem. Two basic versions of the module are
available. Both serial communication ports support speeds of up to
115.2 KB. The top communication port (labeled C1) supports RS-232
operation while the second port (labeled C2) supports RS-485 operation.
Additionally, you can order the RS-485 port with isolation to 500 Vdc.
ControlWave Micro Instruction Manual
Figure 1-6. Expansion Communications (ECOM) Module
1.7 I/O Modules
The ControlWave Micro supports a wide array of factory-configured
I/O modules including analog I/O, digital I/O, high speed counter, and
several others for either local or remote field device wiring termination.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-7
shows a typical I/O module housing.
Configuration jumpers on I/O modules accommodate individual field
I/O user configuration. Terminations are pluggable and accept a
Revised Aug-2015 Introduction 1-9
ControlWave Micro Instruction Manual
maximum wire size of #14 AWG. All I/O modules have surge
protection that meets C37.90-1978 and IEC 801-5 specifications. Each
I/O module connects to the backplane using a 36-pin male card-edge
connector. All I/O modules are provided with two 10-point terminal
block assemblies (for local termination) or two 14-pin mass Termination
headers (for remote termination).
All digital (or discrete) I/O modules have individual point LED status
indicators that you can enable either with a jumper on the module or
through a software setting.
Figure 1-7. Two ControlWave Micro I/O Modules (with Bezel)
1.8 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
Micro. Figure 1-8 graphically presents the programming environment.
1-10 Introduction Revised Aug-2015
ControlWave Micro Instruction Manual
Figure 1-8. 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 Micro. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), the ControlWave Micro Quick Setup
Guide (document D5124), 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 modules in the
ControlWave and configure the individual mapping of I/O points for
digital and analog inputs and outputs. For information on the I/O
Configurator see
the ControlWave Designer Programmer’s
Handbook (document D5125).
Revised Aug-2015 Introduction 1-11
ControlWave Micro 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.
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).
For information on individual function blocks, see
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. 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 using serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
1-12 Introduction Revised Aug-2015
1.9 Secure Gateway
ControlWave Micro Instruction Manual
For enhanced data security when using an IP/Ethernet connection,
Emerson Remote Automation Solutions recommends adding an
industrial router with VPN and firewall security. Recommended
solutions include the MOXA EDR‐810, the Hirschman Eagle One, or
the Phoenix mGuard rs4000 (or equivalents). An example of how to
install one of these devices to the RTU can be found in the Emerson
Remote Automation Solutions MOXA® Industrial Secure Router
Installation Guide (part number D301766X012). For further
information, contact your Local Business Partner or the individual
vendor’s website.
Revised Aug-2015 Introduction 1-13
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Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
Micro, considerations for installation, and instructions for setting
switches and jumpers on the CPU, PSSM, and ECOM modules.
In This Chapter
2.1 Site Considerations .......................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ............................. 2-2
2.2 Installation Overview ........................................................................ 2-2
2.2.1 Unpacking Components ....................................................... 2-3
2.2.2 Mounting the Housing .......................................................... 2-8
2.2.3 Grounding the Housing ........................................................ 2-9
2.3 Power Supply/Sequencer Module (PSSM) ................................... 2-10
2.3.1 General Information about the PSSM ................................ 2-10
2.3.2 PSSM Installation Overview ............................................... 2-12
2.3.3 Setting Jumpers on the PSSM ........................................... 2-12
2.3.4 Setting Mode Switch SW1 on the PSSM ........................... 2-13
2.3.5 General Wiring Guidelines ................................................. 2-13
2.3.6 Wiring a Bulk DC Power Supply to the PSSM ................... 2-14
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog
2.4 CPU Module .................................................................................. 2-17
2.4.1 Setting Jumpers on the CPU Module ................................. 2-19
2.4.2 Setting DIP Switches on the CPU Module ......................... 2-20
2.4.3 Connections to RS-232 Serial Port(s) on CPU or ECOM .. 2-23
2.4.4 Connections to RS-485 Serial Port(s) on CPU or ECOM .. 2-26
2.4.5 Connections to Ethernet Port(s) on the CPU Module ........ 2-29
2.5 Expanded Communications Module (ECOM) ............................... 2-31
2.5.1 RS-232 Ports ...................................................................... 2-32
2.5.2 RS-485 Ports ...................................................................... 2-32
2.5.3 Modem Port (Type 1 ECOM only) ...................................... 2-33
2.6 Bezels ............................................................................................ 2-36
2.7 Optional Display/Keypads.............................................................. 2-37
ControlWave Micro Instruction Manual
Connector (OPTIONAL) ................................................... 2-15
2.1 Site Considerations
When choosing an installation site, check all clearances. Ensure that the
ControlWave Micro is accessible for wiring and service.
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)
Revised Aug-2015 Installation 2-1
ControlWave Micro Instruction Manual
Specifications
for Temperature,
Humidity and
Vibration
Caution
2.1.1 Class I, Div 2 Installation Considerations
See document CWMICRO available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave Micro. This document is available on our website
at: http://www.emersonprocess.com/remote/D301671X012.pdf.
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 Micro is not
exposed to a level of vibration that exceeds that provided in the
technical specifications.
Placement of the ControlWave Micro in Class 1, Division 2 (Group A, B,
C, and D) hazardous locations requires that you select an appropriate
enclosure that meets NEMA Type 3X or 4X specifications.
WARNING
Underwriters Laboratories (UL) lists the ControlWave Micro as non-
incendive and suitable only for use in Class I, Division 2, Group A, B,
C, and D hazardous locations and non-hazardous locations. Read this
chapter and Appendix A carefully before you install a ControlWave
Micro 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).
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave Micro 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.
2.2 Installation Overview
Installing a ControlWave Micro involves several general steps:
1. Unpacking, assembling, and configuring the hardware
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2. Installing PC-based software (ControlWave Designer)
3. Establishing communications
4. Creating an application-specific control strategy (ControlWave
project).
5. Creating application-specific web pages (optional)
6. Adding the ControlWave Micro to an OpenBSI network
7. Downloading the application-specific ControlWave project into the
ControlWave Micro
Note: Steps 2 through 7 require that you install and use ControlWave
Designer software on your PC. This manual focuses on hardware
installation and preparation. Software installation and
configuration is beyond the scope of this manual. Refer to the
ControlWave Micro Quick Setup Guide (D5124) for material
related to software installation and use.
2.2.1 Unpacking Components
Packaging
Depending upon how you order it, the ControlWave Micro may arrive
pre-assembled, or in a number of separate boxes. If you did not order it
pre-assembled, you must identify, unpack, and assemble the
components. Unless otherwise noted, you can place modules in any slot
in a base or expansion housing.
Note: Do not install modules in the base or expansion housings until
you have mounted and grounded those housings at the
designated installation site.
Delivered boxes may include:
Housing assemblies (3-, 4- or 8-slot base housings and 2-, 4-, or 8-
slot expansion housings)
Power Supply/Sequencer module (PSSM)
Note: The PSSM must reside in slot #1 in the base housing.
CPU module
Note: The CPU module must reside in slot #2 in the base housing.
Expansion Communication Module (ECOM).
Note: The first ECOM must reside in slot #3 in the base housing; a
second ECOM can reside in slot #4 in the base housing.
I/O Modules
Note: There are many different types of I/O modules available.
Chapter 3 contains detailed instructions on each I/O module.
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ControlWave Micro Instruction Manual
One or more bezel assemblies; each bezel covers two I/O modules.
Housing
The base housing (or chassis) for the ControlWave Micro is an openfaced aluminum assembly. In use, you install a blue plastic cover
(“bezel”) over each pair of installed I/O modules, as shown in Figure
2-1.).
Figure 2-1. 8-Slot Base Housing with Bezel
Keyed cutouts in the housing’s rear wall (see Figure 2-2 through Figure
2-7) permit wall or panel mounting. The base housing has the following
components:
Built-in guides on the top and bottom of the housing permit easy
installation and removal of modules
Built-in ground lug (on right bottom corner of housing)
Printed circuit board (PCB) attached to interior back of housing
provide seating and electrical interface for modules
Built-in interface connector (available only on 4-slot and 8-slot
housings) for expansion housings.
Composed of aluminum (plated with gold irridite), the base housing has
three configurations (3-slot, 4-slot, or 8-slot backplane). Optional I/O
expansion housings (also gold irridite-plated aluminum) accommodate
additional I/O modules in three configurations (2-slot, 4-slot, or 8-slot
backplanes), and can be either wall- or panel-mounted or rack mounted
with a DIN-rail. Refer to Figure 2-2 through Figure 2-7 for dimensional
drawings of the three base housings and three expansion housings.
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Figure 2-2. 3-Slot Base Housing
Figure 2-3. 4-Slot Base Housing
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Figure 2-4. 8-Slot Base Housing
Figure 2-5. 2-Slot Expansion Housing
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Figure 2-6. 4-Slot Expansion Housing
Figure 2-7. 8-Slot Expansion Housing
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2.2.2 Mounting the Housing
You can mount base or expansion housings to a panel or a wall. When
mounting one of these units to a panel or wall, place it according to the
following guidelines:
Ensure that the front of the ControlWave Micro is visible and
accessible for service (for example, so you can easily install or
remove modules).
Use the mounting holes provided in the base and expansion
housings (see Figure 2-2 through Figure 2-7).
Remove the base housing and any applicable expansion housings from
their cartons and install them at the assigned work site.
Note: If you are attaching an expansion housing to a 4-slot or 8-slot
base housing, remove the three bus terminators JP2, JP3, and
JP4 (see Figure 2-8) from the backplane on the 4-slot or 8-slot
base housings. You also may need to remove the paper label
over the connector on the right back edge of the base housing.
JP2, JP3, &
JP4 jumpers
Figure 2-8. JP2, JP3, and JP4 Jumpers on Base Housing
Face the housings and mount the base housing on the left and the
expansion housing on the right so that the connector on the right back
edge of the base housing (P10) seats firmly with the connector on the
left back edge of the expansion housing (P9).
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2.2.3 Grounding the Housing
ControlWave Micro Instruction Manual
Caution
Do not install any modules in the base or expansion housings until you
have mounted and grounded those housings at the designated
installation site.
Base housings have a ground lug (see Figure 2-2 through Figure 2-7)
that accommodates up to a #4 AWG wire size. Once you have installed
the base and any expansion housings, you must run a ground wire
between the base housing ground lug and a known good earth ground.
Note: After you install the PSSM in the base housing, as an added
precaution we recommend that you run a #14 AWG wire from
the TB1-3 power connection (Ground) to the same known good
earth ground.
Additional grounding guidelines include:
Use stranded copper wire (#4 AWG) for the base housing to earth
ground, and keep the length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Tin the wire ends with solder (using a high-wattage soldering iron)
prior to inserting the wire into the base housing ground lug.
Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.
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2.3 Power Supply/Sequencer Module (PSSM)
Before we actually configure the PSSM and install it in the housing,
we’re going to discuss some general information about how it works.
2.3.1 General Information about the PSSM
The Power Supply/Sequencer module (PSSM) plugs into slot #1 (first
slot from the left) on the ControlWave Micro’s backplane using
connector P1, a 44-pin female non-keyed header (see Figure 2-2, Figure
2-3 and Figure 2-4).
Currently, we offer the PSSM in two configurations:
PSSM with Run/Remote/Local Switch & Display Interface (model
396657-01-0, Revision A and above) (see Figure 2-9)
PSSM with Mode Switch SW1 & Display Interface (model 396657-
02-8 without Watch Dog, Revision A and above) (see Figure 2-10)
Note: In addition to these two PSSM versions, you can optionally
substitute a System Controller Module (SCM) for the PSSM.
Since the SCM is designed primarily for use in ControlWave
EFM models, we won’t discuss the SCM in this manual. See CI-
ControlWave EFM for more information on the SCM.
Figure 2-9. PSSM with Run/Remote/Local Switch, Display Interface, and Watchdog Connector
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Figure 2-10. PSSM Module with Mode Switch, Display Interface, and without Watchdog Connector
Two terminal blocks (see Figure 2-9) provide external input power and
watchdog connector switch connections. Two red LEDs on the PSSM’s
front panel enable you to monitor the status of the watchdog (WD) and
Idle (IDLE) circuits.
Note: The Idle LED is usually on, indicating when the CPU has free
time at the end of its execution cycle. If the LED is off, it
indicates the CPU has no free time and may be overloading.
Six additional LEDs provide system status codes (see Chapter 5).
PSSMs contain a DC-to-DC converter that generates a +3.3 Vdc supply
for the entire unit (that is, the CPU and various I/O modules that plug
into the backplane).
Power
Supply
An auxiliary +5 Vdc regulator powers low power detection circuitry
and sequencer timing circuitry.
The power supply operates from +10.7 to +30 Vdc or from +21.7 to +30
Vdc. You can configure the nominal input supply configuration (12V or
24V) using configuration jumper switches on the PSSM PCB. See
Figure 2-9 and Figure 2-10.
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Watchdog
Switch
PSSMs optionally include a watchdog metal oxide semiconductor fieldeffect transistor (MOSFET) switch connector. The purpose of the
watchdog connector is to trigger an external alarm or annunciator if the
ControlWave enters a “watchdog” condition in which the CPU cannot
control your process. This occurs on power-up before the ControlWave
project starts, if the unit is reset, if the ControlWave project “crashes”
or if the system loses power. See Section 2.3.7.
2.3.2 PSSM Installation Overview
There are several steps you need to follow when you install the PSSM.
1. Identify the carton holding the PSSM and remove it from that carton.
See Section 2.2.1.
2. Set jumpers on the PSSM based on whether your external DC bulk
power supply provides +12V or +24V. See Section 2.3.3.
3. If your PSSM includes a mode switch (SW1) set it according to
Section 2.3.4.
4. Slide the PSSM into slot #1 of the housing.
5. Unplug terminal block connector TB1 from the PSSM and wire it to
an external bulk DC power supply. See Section 2.3.6.
6. If you want to use the watchdog connector TB2, unplug it from the
PSSM and wire it to an external annunciator or similar device
according to instructions in Section 2.3.7.
7. After you configure and install the CPU module in slot #2 re-connect
terminal blocks to their connectors to apply power to the unit.
2.3.3 Setting Jumpers on the PSSM
The PSSM has three jumpers which you set based on whether your
bulk DC power supply will provide +12V or +24V. See Figure 2-9 or
Figure 2-10 to locate the jumpers on your version of the PSSM.
JP2: Three-position Power Fail Trip Point Selection Jumper:
o 1-to-2 Installed = Choose this to select +12V Bulk Supply
Power Fail Trip Point
o 2-to-3 Installed = Choose this to select +24V Bulk Supply
Power Fail Trip Point (default)
JP4: Three-position Power Supply Shutdown Trip Point Selection
Jumper:
o 1-to-2 Installed = Choose this to select +12V Bulk Supply
Shutdown Trip Point.
o 2-to-3 Installed = Choose this to select +24V Bulk Supply
Shutdown Trip Point. (default)
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