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ControlWave Micro Process Automation Controller (CI-ControlWave Micro)
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Fisher ControlWave Micro Process Automation Controller (CI-ControlWave Micro) Manuals & Guides

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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
1.1Scope of the Manual ................................................................................................................. 1-2
1.2Physical Description .................................................................................................................. 1-2
1.3Housings ................................................................................................................................... 1-4
1.4CPU Module .............................................................................................................................. 1-4
1.5Power Supply/ Sequencer Module (PSSM) .............................................................................. 1-7
1.6Expansion Communications Modules ....................................................................................... 1-9
1.7I/O Modules ............................................................................................................................... 1-9
1.8Software Tools ........................................................................................................................ 1-10
1.9Secure Gateway ...................................................................................................................... 1-13
Chapter 2 – Installation 2-1
2.1Site Considerations ................................................................................................................... 2-1
2.1.1Class I, Div 2 Installation Considerations ...................................................................... 2-2
2.2Installation Overview ................................................................................................................. 2-2
2.2.1Unpacking Components ................................................................................................ 2-3
2.2.2Mounting the Housing ................................................................................................... 2-8
2.2.3Grounding the Housing ................................................................................................. 2-9
2.3Power Supply/Sequencer Module (PSSM) ............................................................................. 2-10
2.3.1General Information about the PSSM ......................................................................... 2-10
2.3.2PSSM Installation Overview ........................................................................................ 2-12
2.3.3Setting Jumpers on the PSSM .................................................................................... 2-12
2.3.4Setting Mode Switch SW1 on the PSSM .................................................................... 2-13
2.3.5General Wiring Guidelines .......................................................................................... 2-13
2.3.6Wiring a Bulk DC Power Supply to the PSSM ............................................................ 2-14
2.3.7Wiring an External Alarm or Annunciator to the Watchdog Connector (OPTIONAL) . 2-15
2.4CPU Module ............................................................................................................................ 2-17
2.4.1Setting Jumpers on the CPU Module .......................................................................... 2-19
2.4.2Setting DIP Switches on the CPU Module .................................................................. 2-20
2.4.3Connections to RS-232 Serial Port(s) on CPU or ECOM Modules ............................ 2-23
2.4.4Connections to RS-485 Serial Port(s) on CPU or ECOM Modules ............................ 2-26
2.4.5Connections to Ethernet Port(s) on the CPU Module ................................................. 2-29
2.5Expanded Communications Module (ECOM) ......................................................................... 2-31
2.5.1RS-232 Ports ............................................................................................................... 2-32
2.5.2RS-485 Ports ............................................................................................................... 2-32
2.5.3Modem Port (Type 1 ECOM only) ............................................................................... 2-33
2.6Bezels ...................................................................................................................................... 2-36
2.7Optional Display/Keypads ....................................................................................................... 2-37
Chapter 3 – I/O Modules 3-1
3.1Module Placement .................................................................................................................... 3-2
3.2Wiring ........................................................................................................................................ 3-2
3.2.1Local Termination .......................................................................................................... 3-3
3.2.2Remote Termination ...................................................................................................... 3-3
3.2.3Shielding and Grounding ............................................................................................... 3-4
3.3Isolated Digital Input (DI) Module .............................................................................................. 3-6
3.4Isolated Digital Output (DO) Module ....................................................................................... 3-11
3.5Non-isolated Digital Input/Output (DI/O) Module .................................................................... 3-15
3.6Non-isolated Analog Input/Output & Analog Input Module ..................................................... 3-18
3.7Non-isolated High Speed Counter (HSC) Input Module ......................................................... 3-22
Revised Aug-2015 Contents iii
ControlWave Micro Instruction Manual
3.8Isolated Analog Input (AI) Module ........................................................................................... 3-26
3.9Isolated Analog Output (AO) Module ...................................................................................... 3-30
3.10Non-isolated Mixed I/O (MI/O) Module ................................................................................... 3-33
3.11Isolated Vac Digital Input Module ........................................................................................... 3-39
3.12Relay Isolated Vac/Vdc Digital Output Module ....................................................................... 3-41
3.13Isolated Digital Input/Output (DI/O) Module ............................................................................ 3-43
3.14Isolated Resistance Temperature Device (RTD) Input Module .............................................. 3-46
3.15Isolated Low Level Analog Input (LLAI) Module ..................................................................... 3-49
3.16Non-isolated HART®/BTI Interface Module ............................................................................. 3-54
Internally Sourced Transmitters ............................................................................................. 3-58
Externally Sourced Transmitters ............................................................................................ 3-59
3.17IEC62591 Interface Module .................................................................................................... 3-62
Chapter 4 – Operation 4-1
4.1Powering Up/Powering Down the ControlWave Micro ............................................................. 4-1
4.2Setting the Operating Mode (Run/Remote/Local Switch or Mode Switch) ............................... 4-2
4.3Communicating with the ControlWave Micro ............................................................................ 4-3
4.3.1Default Comm Port Settings ......................................................................................... 4-3
4.3.2Changing Port Settings ................................................................................................. 4-4
4.3.3Collecting Data from the ControlWave Micro ................................................................ 4-5
4.4Creating and Downloading an Application (ControlWave Project) ........................................... 4-5
4.5Creating and Maintaining Backups ........................................................................................... 4-6
4.5.1Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-7
4.5.2Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-8
4.5.3Backing up Data ............................................................................................................ 4-9
Chapter 5 – Service and Troubleshooting 5-1
5.1Upgrading Firmware .................................................................................................................. 5-2
5.2Removing or Replacing Components ....................................................................................... 5-5
5.2.1Accessing Modules for Testing ..................................................................................... 5-5
5.2.2Removing/Replacing the Bezel ..................................................................................... 5-6
5.2.3Removing/Replacing the CPU Module ......................................................................... 5-6
5.2.4Removing/Replacing the PSSM .................................................................................... 5-6
5.2.5Removing/Replacing an I/O Module ............................................................................. 5-7
5.2.6Removing/Replacing the Backup Battery ..................................................................... 5-7
5.2.7Enabling / Disabling the Backup Battery ....................................................................... 5-9
5.3General Troubleshooting Procedures ....................................................................................... 5-9
5.3.1Checking LEDs ............................................................................................................. 5-9
5.3.2Checking Wiring/Signals ............................................................................................. 5-16
5.3.3Common Communication Configuration Problems ..................................................... 5-17
5.4WINDIAG Diagnostic Utility ..................................................................................................... 5-17
5.4.1Available Diagnostics .................................................................................................. 5-20
5.5Core 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
1.1Scope of the Manual ........................................................................ 1-2
1.2Physical Description ........................................................................ 1-2
1.3Housings .......................................................................................... 1-4
1.4CPU Module .................................................................................... 1-4
1.5Power Supply/ Sequencer Module (PSSM) .................................... 1-7
1.6Expansion Communications Modules ............................................. 1-9
1.7I/O Modules...................................................................................... 1-9
1.8Software Tools ............................................................................... 1-10
1.9Secure 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
This page is intentionally left blank
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
2.1Site Considerations .......................................................................... 2-1
2.1.1Class I, Div 2 Installation Considerations ............................. 2-2
2.2Installation Overview ........................................................................ 2-2
2.2.1Unpacking Components ....................................................... 2-3
2.2.2Mounting the Housing .......................................................... 2-8
2.2.3Grounding the Housing ........................................................ 2-9
2.3Power Supply/Sequencer Module (PSSM) ................................... 2-10
2.3.1General Information about the PSSM ................................ 2-10
2.3.2PSSM Installation Overview ............................................... 2-12
2.3.3Setting Jumpers on the PSSM ........................................... 2-12
2.3.4Setting Mode Switch SW1 on the PSSM ........................... 2-13
2.3.5General Wiring Guidelines ................................................. 2-13
2.3.6Wiring a Bulk DC Power Supply to the PSSM ................... 2-14
2.3.7Wiring an External Alarm or Annunciator to the Watchdog
2.4CPU Module .................................................................................. 2-17
2.4.1Setting Jumpers on the CPU Module ................................. 2-19
2.4.2Setting DIP Switches on the CPU Module ......................... 2-20
2.4.3Connections to RS-232 Serial Port(s) on CPU or ECOM .. 2-23
2.4.4Connections to RS-485 Serial Port(s) on CPU or ECOM .. 2-26
2.4.5Connections to Ethernet Port(s) on the CPU Module ........ 2-29
2.5Expanded Communications Module (ECOM) ............................... 2-31
2.5.1RS-232 Ports ...................................................................... 2-32
2.5.2RS-485 Ports ...................................................................... 2-32
2.5.3Modem Port (Type 1 ECOM only) ...................................... 2-33
2.6Bezels ............................................................................................ 2-36
2.7Optional 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
2-2 Installation Revised Aug-2015
ControlWave Micro Instruction Manual
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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ControlWave Micro Instruction Manual
Figure 2-2. 3-Slot Base Housing
Figure 2-3. 4-Slot Base Housing
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ControlWave Micro Instruction Manual
Figure 2-4. 8-Slot Base Housing
Figure 2-5. 2-Slot Expansion Housing
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ControlWave Micro Instruction Manual
Figure 2-6. 4-Slot Expansion Housing
Figure 2-7. 8-Slot Expansion Housing
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ControlWave Micro Instruction Manual

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).
2-8 Installation Revised Aug-2015

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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ControlWave Micro Instruction Manual

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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ControlWave Micro Instruction Manual
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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ControlWave Micro Instruction Manual
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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ControlWave Micro Instruction Manual
JP5: Three-position Field Voltage Shutdown Trip Point Selection
Jumper
o 1-to-2 Installed = +12V Bulk Supply Field Voltage Shutdown
Trip Point Selected
o 2-to-3 Installed = +24V Bulk Supply Field Voltage Shutdown
Trip Point Selected. (default)
2.3.4 Setting Mode Switch SW1 on the PSSM
The version of the PSSM shown in Figure 2-10 has a DIP switch that
controls whether the PSSM operates in Local Mode or Recovery Mode.
Local Mode is the normal operating mode for the ControlWave Micro, and is the factory default. We recommend you use the factory default unless you have a reason to use Recovery Mode.
Only use Recovery Mode during system firmware upgrades or core
updumps. See Chapter 5 for more information on these subjects. Table 2-1 lists the SW1 settings:
Switch position Mode
Both switches set to right (Open) or both switches set to left (Closed)
Upper switch (SW-1) set to right (Open) and lower switch (SW-2) set to left (Closed)
Note: Only the PSSM SW1 switch settings listed in the table have
been tested.

2.3.5 General Wiring Guidelines

ControlWave Micro PSSMs use compression-type terminals that
accommodate up to #14 AWG wire. When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the wire. To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and improve conductivity.
Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize mechanical strain on the terminal blocks.
Table 2-1. PSSM Switch SW1
Activates Recovery mode, used for firmware upgrades or core updumps.
Activates Local mode, used for normal operation. (This is the factory default)
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ControlWave Micro Instruction Manual

2.3.6 Wiring a Bulk DC Power Supply to the PSSM

Caution
At this time you can also connect power and watchdog wiring. However; for safety reasons and to prevent accidental damage to the your bulk DC power supply, do not connect the pluggable terminal block connectors TB1 and TB2 to the PSSM until after you install, wire, and configure the CPU module.
Follow the instructions in Section 2.3.5 General Wiring Guidelines when wiring connections.
You can connect one bulk DC power supply (nominally either +12 Vdc or +24 Vdc) to the PSSM. The PSSM then converts, regulates, and filters the power to +3.3 Vdc. For safety, the PSSM circuit has a 3A fuse.
The ControlWave Micro PSSM’s operating range is +10.7 to +30.0 Vdc (with nominal +12Vdc input source) or +21.7 to +30.0 Vdc (with a nominal +24Vdc input source).
Use the following formula to determine the maximum current required for the +12 Vdc or +24 Vdc bulk power used with a particular ControlWave Micro:
Bulk + 12/24 Vdc Supply Current = CPU* + Sum of all ECOM modules and I/O modules.
Refer to Table 2-2 for ControlWave Micro bulk power requirements.
Table 2-2. Bulk Power Requirements
Component
CPU, backplane, and PSSM (with Ethernet)
CPU, backplane, and PSSM (without Ethernet)
Any backplane 2 mA 4 mA PSSM 3.2 mA 6.4 mA Non-isolated AI/AO Module 2.8 mA + (47.2 mA – VEXT) 5.6 mA + (47.2 mA – VEXT) Isolated DI Module 104 mA 208 mA Isolated DO Module 13 mA 26 mA Non-isolated DI/DO Module 12 mA 24 mA Non-isolated HSC Module 5 mA 10 mA Isolate5.3 mA d AI Module 113 mA + (24.5 mA/loop) 192 mA + (49 mA/loop) Isolated AO Module 10 mA + (22.5 mA/I loop) or
10 mA + (5.3 mA/E loop @ 5 mA)
Non-isolated Mixed I/O module (with optional AO)
Isolated VAC DI module 5 A 10 mA Isolated VAC/DC DO module 10 mA 20 mA Isolated DI/DO module 83.1 mA 166.2 mA
8.3 mA + (24.3 mA – VEXT) 16.67 mA + (24.3 mA – VEXT)
Bulk 24 Vdc
Power Supply
50 mA 100 mA
45 mA 90 mA
19 mA + (10.5 mA/E loop @ 5 mA)
Bulk 12 Vdc
Power Supply
19 mA + (45 mA/I loop) or
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ControlWave Micro Instruction Manual
Component
HART/BTI module 250 mA 500 mA Isolated RTD module 13.5 mA 27 mA Isolated LLAI module 26.3 mA 52.5 mA ECOM without modem/radio 22 mA 45 mA ECOM with modem 56 mA 112 mA
ECOM with FreeWave radio* ECOM with modem and FreeWave
radio
*
Bulk 24 Vdc
Power Supply
272 mA 545 mA 306 mA 612 mA
Bulk 12 Vdc
Power Supply
* FreeWave radio no longer available
Terminal Block
Connector TB1
Unplug removable connector TB1 from the PSSM and wire DC power
to the connector. We recommend you do not plug the connector back
into the PSSM until the CPU module is already installed in the housing.
TB1 provides three input connections for bulk power:
TB1-1: (+VIN) (+10.7V to +30V dc for +12V supply) (+21.7V to
+30V dc for +24V supply)
TB1-2 = (-VIN) (Supply Ground - PSGND) TB1-3 = Chassis Ground - CHASSIS ( )
Figure 2-11 shows the typical wiring at the PSSM’s TB1 block.
Figure 2-11. PSSM TB1 Wiring
Note
: 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 used for the base housing.
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog Connector (OPTIONAL)
Caution
At this time you can also connect power and watchdog wiring. However; for safety reasons and to prevent accidental damage to the your bulk DC power supply, do not connect the pluggable terminal block connectors TB1 and TB2 to the PSSM until after you install, wire, and configure the CPU module.
Follow the instructions in Section 2.3.5 General Wiring Guidelines when wiring connections.
The version of the PSSM shown in Figure 2-9 includes an optional
watchdog connector. The purpose of the watchdog connector is to
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ControlWave Micro Instruction Manual
trigger an external alarm or annunciator if the ControlWave Micro enters a “watchdog” condition in which the CPU cannot control your process.
A watchdog condition occurs when:
A watchdog timer expires. This happens if the ControlWave project
execution halts unexpectedly – “program crash.”
The controller powers up but is not yet running the ControlWave
project.
The CPU module detects that the regulated 3.3 Vdc or 1.8 Vdc
supplies are out of specification.
A MOSFET switch activates the watchdog connector whenever a watchdog condition occurs.
Terminal Block Connector TB2
You must power the watchdog connector (TB2) from an external power supply. Unplug removable connector TB2 from the PSSM and wire
power to the connector. We recommend you do not plug the connector
back into the PSSM until the CPU module is already installed in the housing.
TB2 provides two watchdog MOSFET switch connections:
TB2-1 = VI - Watchdog MOSFET Switch Input TB2-2 = VO - Watchdog MOSFET Switch Output
The VI input on TB2 powers the watchdog switch; its switched output connects to the VO output on the same terminal block. You must reference the external power source connected to the VI terminal to the return point of the input source powering the PSSM (which is either –
VIN or PSGND on TB2). See Figure 2-12.
Figure 2-12. Watchdog MOSFET Switch Wiring
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2.4 CPU Module

ControlWave Micro Instruction Manual
The CPU module, which controls the ControlWave Micro and handles memory and communication functions, can only be installed in Slot #2 of the ControlWave Micro backplane.
Note: Do not confuse the CPU module (which has communication
components) with the Expansion Communication module
(ECOM), which does not have a CPU component or a battery backup but does have additional communication components.
Identify the carton holding the CPU module and remove it from that carton. The CPU module has several different configurations, each of which have on-board communications components:
CPU with two RS-232 serial ports, and one RS-485 serial port (see
Figure 2-13)
CPU with two RS-232 serial ports, one RS-485 serial port, and one
Ethernet port (see Figure 2-14)
CPU with one RS232 serial port, one RS-485 serial port, and two
Ethernet ports (see Figure 2-15)
Figure 2-13. CPU Module with Three Serial Ports
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ControlWave Micro Instruction Manual
Figure 2-14. CPU Module with Three Serial Ports and One Ethernet Port
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ControlWave Micro Instruction Manual
Figure 2-15. CPU Module with Two Serial and Two Ethernet Ports

2.4.1 Setting Jumpers on the CPU Module

Each CPU module contains a number of jumpers (labeled with JPn) when n in the jumper number. See Figure 2-13, Figure 2-14, or Figure 2-15) to locate the jumpers.
Note: When present, jumpers 1, 2, 3, 5, 6, and 9 (JP1, JP2, JP3, JP5,
JP6, and JP9) are reserved for factory use only. Do not alter these jumpers from their factory settings.
Jumper 4 (JP4) enables the Idle and Status LEDs on the PSSM. It
comes enabled from the factory. (We recommend you leave these LEDs enabled during initial installation and setup. If power conservation is an issue, you can disable these LEDs by removing the jumper.)
Jumper 7 (JP7) enables the Communication Port Status LEDs on the
CPU module. It comes enabled from the factory. We recommend you leave these LEDs enabled during initial installation and setup. If power conservation is an issue, you can disable these LEDs by removing the jumper.
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ControlWave Micro Instruction Manual
Note: For maximum shelf life, the CPU module ships from the
factory with the installed lithium backup battery disabled. You must enable it when you install the CPU module by placing JP8 on pins 1-2.
Jumper 8 (JP8) enables/disables the lithium backup battery on the
CPU module.
Pins 1-2: Enables the CPU module’s backup battery.
Pins 2-3: Disables the CPU module’s backup battery (Factory
Jumper 10 (JP10) specifies how COM1 is enabled.
Pins 1-2: Enables COM1 whenever DCD is active. (Factory
Pins 2-3: Enables COM1 whenever you connect a cable to the
Jumper 11 (JP11) when present, specifies how COM2 is enabled.
Pins 1-2: Enables COM2 whenever DTR is ON. (Factory
default)
default)
port.
default)
Pins 2-3: Port is always enabled. This setting can be used to
control external radios that feature DTR sleep modes.

2.4.2 Setting DIP Switches on the CPU Module

Before you install the CPU module, you must determine the settings for
three banks of DIP switches. Refer to Figure 2-13, Figure 2-14, or Figure 2-15 for the location of the DIP switch banks on each CPU module. Refer to Tables 2-3 through 2-5 for DIP switch setting values.
Note: Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF.
Table 2-3. CPU Module Switch SW1
SW1 Setting Function Mode
1 2 3
4
N/A Not currently used. N/A Not currently used. Force
Recovery Mode
N/A Not currently used.
Enables recovery mode. Values are:
ON (enables recovery mode) OFF (disables recovery mode). – This is the factory default.
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Table 2-4. CPU Module Switch SW2
SW2 Setting Function Mode
1
2
3
4
5
6
7
Watchdog Enable
Lock/Unlock Soft Switches
Use/Ignore Soft Switches
Core Updump Causes the ControlWave Micro to perform a core updump,
SRAM Control Manages SRAM contents following a low power situation
System Firmware
N/A Not currently used.
Controls whether the system enters a watchdog state when a crash or system hangup occurs and automatically restarts. Values are:
ON (Enables watchdog circuit; factory default) OFF (Disables watchdog circuit and prevents automatic
restart) Controls the ability to modify soft switches, other
configurations, and flash files. Values are:
ON (Unlocks soft switches and flash files; factory default). OFF (Locks soft switches, configurations, and flash files)
Controls the use of soft switches. Values are: ON (Enable user-defined soft switches configured in flash memory; factory default) OFF (Disable soft switch configuration and use factory defaults)
Note: Setting both switch 3 and switch 8 to OFF (closed)
provided you have set the PSSM mode switch to Recovery mode or properly sequenced the Run/Remote/Local switch on the PSSM. Values are:
ON (Disables core updump; factory default) OFF (Core updump via PSSM Run/Remote/Local switch
or PSSM mode switch SW1)
or a power outage. Values are:
ON (Retain values in SRAM during restarts; factory default) OFF (Reinitialize SRAM) – Data in SRAM lost during
power outage or re-start. Allows a remote download of system firmware (on units
equipped with boot PROM version 4.7 or higher and system PROM version 4.7 and higher). Values are:
ON (Enable remote download of system firmware; factory default) OFF (Disable remote download of system firmware)
ControlWave Micro Instruction Manual
sets all serial communication ports to 9600 bps operation. All serial communication ports must be set at 9600 bps before WINDIAG can perform communication tests.
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ControlWave Micro Instruction Manual
SW2 Setting Function Mode
8
Enable WINDIAG
Notes:
Table 2-5 describes switch settings for the RS-485 port. You may
want to review Section 2.4.4 Connections to RS-485 Serial Port(s)
before you set these switches.
Table 2-5 applies to the following switches:
o SW3 on CPU Module – controls COM3
o SW1 on Type 1 ECOM Module – controls COM5/COM9
Suspends normal operation and allows diagnostic routines. Values are: ON (Permits normal system operation, including the boot project, and disables the WINDIAG diagnostics from running; factory default) OFF (Allow WINDIAG to run test; disable boot project and normal system operation.)
Note: Setting both switch 8 and switch 3 to OFF (closed)
sets all communication ports to 9600 bps operation. All serial communication ports must be set at 9600 bps before WINDIAG can perform communication tests.
Switch
Setting
1 2 3 4 5 6
7 8
o SW1 on Type 2 ECOM Module – controls COM6/COM10
o SW2 on Type 2 ECOM Module – controls COM7/COM11
Table 2-5. RS-485 Configuration Switch
Function Mode
TX+ to RX+ Loopback TX- to RX- Loopback 100 Ohm RX+ Termination 100 Ohm RX- Termination N/A Not currently used Slew Rate (ISO485 Only)
RX+ Bias (End Node) RX- Bias (End Node)
ON (only for diagnostics or 2-wire) ON (only for diagnostics or 2-wire) ON (End nodes only) ON (End nodes only)
ON (Slow rate enabled) OFF (Fast rate enabled)
Note: On CPU module, not currently used. ON (End nodes only)
ON (End nodes only)
After you configure the jumpers and DIP switches, slide the CPU module into slot #2 (the second slot from the left) of the base housing
(see Figure 2-2, Figure 2-3 or Figure 2-4).
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ControlWave Micro Instruction Manual
2.4.3 Connections to RS-232 Serial Port(s) on CPU or ECOM Modules
An RS-232 port provides point-to-point, half-duplex and full-duplex communications (for a maximum of 20 feet using data quality cable).
Your CPU module includes either one or two RS-232 ports.
If you require additional RS-232 ports, you can purchase an optional expansion communication module that can include either one (ECOM Type 1) or two (ECOM Type 2) RS-232 ports. The ControlWave Micro can support up to two expansion communication modules, for a total of up to four additional RS-232 ports beyond those on the CPU module. Expansion communication modules reside in slot #3 and slot #4.
RS-232 COM
Port Names and
Connectors
RS-232 COM ports are assigned names based on their location in the ControlWave Micro.
If the CPU module has two RS-232 ports and one RS-485 port (as in
Figure 2-13), the RS-232 ports are COM1 and COM2.
If the CPU module has one RS-232 port and one RS-485 port (as in
Figure 2-15), the RS-232 port is COM1.
Table 2-6. RS-232 Connectors on CPU
Connector Name # Pins Function Notes
J3 COM1 9-pin 9-pin male D-sub (RS-232) See Figure 2-13, Figure 2-14
Figure 2-15, Figure 2-16 & Table 2-8
J4 COM2 9-pin 9-pin male D-sub (RS-232) See Figure 2-13, Figure 2-14
Figure 2-16 & Table 2-8
If you have an ECOM module with one RS-232 port, this is COM4
if the module is in slot #3 or COM8 if the module is in slot #4.
If you have an ECOM module with two RS-232 ports, those ports
are COM4 and COM5, respectively, if the ECOM module is in slot #3, or COM8 and COM9, respectively, if the ECOM module is in slot #4.
Table 2-7. RS-232 Connectors on Expansion Communications Modules
Connector Name #
Pins
J4 COM4 (when in slot 3)
COM8 (when in slot 4)
J5 COM5 (when in slot 3)
COM9 (when in slot 4)
9-pin 9-pin male D-sub (RS-
9-pin 9-pin male D-sub (RS-
Function Notes
See Figure 2-16, Figure 2-23,
232)
232)
Figure 2-24 & Table 2-8 See Figure 2-16, Figure 2-24 &
Table 2-8 Only available on ECOM Type
2 models.
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ControlWave Micro Instruction Manual
RS-232 COM
Port Cables
For the ControlWave Micro, half-duplex communications use Modbus or BSAP protocol, while full-duplex communications use point-to-point
protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 2-
17) to connect with other devices (such as a PC, a printer, another
ControlWave [except the CW_10/30/35]) when the ControlWave Micro uses the full-duplex PPP protocol.
Note: You can configure the ControlWave Micro as either a master or
slave node on a Modbus or BSAP network.
Figure 2-16 illustrates the CPU module’s male 9-pin D-type connector. Use the content provided in Table 2-8 to determine pin assignments for
the COM1 and COM2 ports and the expansion communication ports COM4/5 and COM8/9.
Figure 2-16. Male DB9 9-Pin Connector
Table 2-8. RS-232 Port Connector Pin Assignment
Pin
1 DCD Data Carrier Detect Input 2 RXD Receive Data Input 3 TXD Transmit Data Output 4 DTR Data Terminal Ready Output 5 GND Signal/Power Ground 6 DSR Data Set Ready Input 7 RTS Request to Send Output 8 CTS Clear to Send Input 9 N/A
RS-232
Signal
RS-232 Description
Use the “null modem” cable for full-duplex (PPP protocol) communications when connecting a ControlWave Micro to a PC. (See
top part of Figure 2-17.)
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ControlWave Micro Instruction Manual
)
Figure 2-17. Full-duplex and Half-duplex Cable
Use the half-duplex cable (shown in the bottom part of Figure 2-17)
when connecting the ControlWave Micro to another ControlWave series unit (again, with the exception of the CW_10/30/35).
When communicating with a Network 3000 series RTU 3305, RTU 3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of
the cables shown in Figure 2-18.
3305/3310/3330/3335/CW_10/30/35
9-Pin Male
“D” Connector
P1
1 = DTR
6 = CTS
5 = RTS
2 = TXD 7 = DCD
4 = RXD 9= GND
To P2 Pin-1 To P2 Pin-2
To P2 Pin-4
To P2 Pin-3 To P2 Pin-5
3305/3310/3330/3335/CW_10/30/35
9-Pin Male
“D” Connector
P1
1 = DTR 6 = CTS
7 = DCD
5 = RTS
2 = TXD
4 = RXD 9 = GND
To P2 Pin-2
To P2 Pin-3 To P2 Pin-5
CW Micro
9-Pin Female
“D” Connector
P2
1 = DCD
2 = RXD 3 = TXD 4 = DTR 5 = GND
CW Micro
9-Pin Female
“D” Connector
P2
2 = RXD 3 = TXD
5 = GND
7 = RTS 8 = CTS
1 = DCD
7 = RTS 8 = CTS
4 = DTR
Full-duplex
Cable
(PPP Protocol
Half-duplex
Cable
Figure 2-18. Full-duplex and Half-duplex Cable
When interfacing to the COM3 port of a ControlWave, or the COM5 or
COM6 port a ControlWaveEXP unit, use the cable presented in Figure 2-19 along with the cable shown in Figure 2-17 or Figure 2-18.
Revised Aug-2015 Installation 2-25
ControlWave Micro Instruction Manual
(
)
RS-232 Cable
Guidelines
P1
CW
(COM3)
or
CWEXP
(COM5/6)
(Looking into Connector Intf. Side of P1)
8-Pin RJ45
Plug
Pin 1 (Wht/Grn Stripe) to Pin 1 = DCD Pin 2 (Wht/Blu Stripe) to Pin 6 = DSR/RX+ Pin 3 (Blu/Wht Stripe) to Pin 2 = RXD/RX ­Pin 4 (Grn/Wht Stripe) to Pin 7 = RTS Pin 5 (Wht/Org Stripe) to Pin 3 = TXD/TX­Pin 6 (Wht/Brn Stripe) to Pin 8 = CTS Pin 7 (Orn/Wht Stripe) to Pin 4 = DTR/TX+ Pin 8 (Brn/Wht Stripe) to P in 5 = GND
Looking into Wire Terminal Side of P2
P2
9-Pin Male
“D” Connector
Figure 2-19. Full-duplex and Half-duplex Cable
Observe the following guidelines when constructing RS-232 communication cables:
Ensure that DCD is high to transmit (except when dialing a modem) Verify that each RS-232 transceiver has one active receiver while
disabled (in power down mode); connect the DCD signal to the active receiver.
Set CTS to high to transmit. If the port is set for full-duplex operation, RTS is always ON. Ensure that DTR is always high when port is active; DTR enables
RS-232 transceivers.
Note: Control DTR using the PORTCONTROL function block and
the _Pn_AUTO_DTR system variable in your ControlWave
project. If you turn DTR off through these mechanisms, the
port remains off, even though hardware is fully configured.
When port is set for half-duplex operation, CTS must go low after
RTS goes low.
All RS-232 comm ports support RTS, DTR, CTS, DCD, and DSR
control signals.
All RS-232 comm port I/O signals are protected by surge protectors.
2.4.4 Connections to RS-485 Serial Port(s) on CPU or ECOM Modules
The RS-485 port supports local network communications to multiple nodes up to 4000 feet away.
Your CPU module includes one RS-485 port.
If you require additional RS-485 ports, you can purchase an optional expansion communication module that includes one or two RS-485 ports. The ControlWave Micro can support up to two expansion communication modules, for a total of up to four additional RS-485 ports beyond the one on the CPU module. Expansion communication modules reside in slot #3 and slot #4.
RS-485 COM
Port Names and
RS-485 COM ports are assigned names based on their location in the ControlWave Micro.
Connectors
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ControlWave Micro Instruction Manual
The CPU module’s RS-485 port is COM3. If you have a Type 1 ECOM module in slot #3, its RS-485 port is
COM5. If you have a Type 1 ECOM module in slot #4, its RS-485 port is COM9.
If you have a Type 2 ECOM module in slot #3, its RS-485 ports are
COM6 and COM7. If you have a Type 2 ECOM module in slot #4, its RS-485 ports are COM10 and COM11.
Table 2-9 provides the connector assignments for CPU port COM3; Table 2-10 shows the assignments for ECOM1 port COM5/9; and Table 2-11 shows assignments for ECOM2 ports COM6/10 and 7/11.
Table 2-9. RS-485 Connectors on CPU
Connector Name # Pins Function Notes
J4 or J5 depending on CPU type
COM3 9-pin 9-pin male D-sub (RS-485) See Figure 2-13 (connector J5)
or Figure 2-15 (connector J4), and Table 2-12.
Table 2-10. RS-485 Connectors on Type 1 Expansion Communications Modules
Connector Name # Pins Function Notes
J5 COM5 (when in slot 3)
COM9 (when in slot 4)
9-pin 9-pin male D-sub
(RS-485)
See Figure 2-23 & Table 2-12 Only available on ECOM Type
2 models.
Table 2-11. RS-485 Connectors on Type 2 Expansion Communications Modules
Connector Name # Pins Function Notes
J6 COM6 (when in slot 3)
COM10 (when in slot
4)
J7 COM7 (when in slot 3)
COM11 (when in slot
4)
9-pin 9-pin male D-sub
(RS-485)
9-pin 9-pin male D-sub
(RS-485)
See Figure 2-24 & Table 2-12
See Figure 2-24 & Table 2-12
RS-485 COM
Port Cables
Figure 2-16 illustrates the CPU module’s male 9-pin D-type connector. Use the content provided in Table 2-12 to determine pin assignments for
the COM3 port on the CPU, and COM5/9, COM6/10, and COM7/11 expansion communication ports.
Revised Aug-2015 Installation 2-27
ControlWave Micro Instruction Manual
Pin RS-485 Signal RS-485 Description
1 N/A 2 RXD– Receive Data – Input 3 TXD– Transmit Data – Output 4 TXD+ Transmit Data + Output 5 GND/
6 RXD+ Receive Data + Input 7 N/A 8 N/A 9 N/A
Since the RS-485 port is intended for network communications, refer to
Table 2-13 for the appropriate connections for wiring the master, first slave, and nth slave.
Table 2-12. RS-485 Port Connector Pin Assignment
Ground/Isolated Ground
ISOGND
Essentially, the master and the first slave transmit and receive data on
opposite lines; all slaves (from the first to the nth) are paralleled (daisy-
chained) across the same lines. Wire the master node to one end of the RS-485 cable run using a 24-gauge paired conductor cable (such as a Belden 9843).
Note: ControlWave Micros support only half-duplex RS-485
networks.
Table 2-13. RS-485 Network Connections
From Master To First Slave To nth Slave
TXD+ RXD+ RXD+ TXD– RXD– RXD– RXD+ TXD+ TXD+ RXD– TXD– TXD–
GND/ISOGND GND/ISOGND GND/ISOGND
To ensure that the “Receive Data” lines are in a proper state during inactive transmission periods, you must maintain certain bias voltage levels at the master and most distant slave units (end nodes). These end nodes also require the insertion of 100Ω terminating resistors to properly balance the network.
You must also configure switches at each node to establish proper network performance. Accomplish this by configuring switches listed so that the 100Ω termination resistors and biasing networks are installed at the end nodes and are removed at all other nodes on the network. You
2-28 Installation Revised Aug-2015
ControlWave Micro Instruction Manual
enable receiver biasing and termination (as well as 2-wire or 4-wire selection) using an 8-position DIP switch located on the CPU and
ECOM modules. See Table 2-5 in Section 2.4.2 Setting DIP Switches on the CPU Modules for information on RS-485 termination and loopback
control switch settings.
2.4.5 Connections to Ethernet Port(s) on the CPU Module
Caution
The RJ45 Ethernet ports are located on the CPU module. The PSSM also has one RJ45 port for the optional Display/Keypad. Never connect Ethernet to the Display/Keypad port or damage to the PSSM will result.
ControlWave Micros can support up to two Ethernet ports. These use a 10/100Base-T RJ-45 modular connector that provides a shielded twisted pair interface to an Ethernet hub. Two LEDs per port provide transmit and receive status indications:
Port assignments are:
Ethernet Port 1: CPU Bd. J6, 8-Pin RJ-45 - Shielded Twisted Pair
10/100Base-T
Ethernet Port 2: CPU Bd. J5, 8-Pin RJ-45 - Shielded Twisted Pair
10/100Base-T
A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with port 8 having the capability to link either to another hub or to an Ethernet communications port). Both ends of the Ethernet twisted pair cable are equipped with modular RJ-45 connectors.
18
Looking into
receptacle
Figure 2-20. RJ-45 Ethernet Connector
These cables have a one-to-one wiring configuration as shown in Figure 2-21. Table 2-14 provides the assignment and definitions of the 8-pin
10/100Base-T connectors.
Figure 2-21. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)
Revised Aug-2015 Installation 2-29
ControlWave Micro Instruction Manual
Table 2-14. Ethernet 10/100Base-T CPU Module Pin Assignments
Pin Description
1 Transmit Data+ (Output) 2 Transmit Data– (Output) 3 Receive Data+ (Input) 4 Not connected 5 Not connected 6 Receive Data– (Input) 7 Not connected 8 Not connected
Note: You can swap TX and RX at the hub.
You can connect two nodes in a point-to-point configuration without using a hub. However, you must configure the cable so that the TX+/­Data pins connect to the RX+/- Data pins (swapped) at the opposite
ends of the cable (see Figure 2-22).
Figure 2-22. Point-to-Point 10/100Base T Ethernet Cable
The maximum length of one segment (CPU to hub) is 100 meters (328 feet). The use of Category 5 shielded cable is recommended.
2-30 Installation Revised Aug-2015
ControlWave Micro Instruction Manual

2.5 Expanded Communications Module (ECOM)

ControlWave Micros can support up to two optional expanded
communications modules (ECOMs) which you can install only in slots #3 or #4 (in place of I/O modules). ECOMSs do not have a CPU
component.
Two Types of
ECOM Modules
There are two types of ECOM module:
Type 1 Expansion Communications Module (ECOM1) with one RS-
232 port, one RS-485 serial port, and an optional modem port (see
Figure 2-23)
Type 2 Expansion Communications Module (ECOM2) with two
RS-232 serial ports and two RS-485 serial ports (see Figure 2-24)
Identify the carton holding the ECOM module(s) and remove the module from that carton.
Figure 2-23. Type 1 ECOM with Two Serial Ports and a Modem
Revised Aug-2015 Installation 2-31
ControlWave Micro Instruction Manual
g
T
LED
Re c eiv e LEDs Comm. Port 4/8
Comm. Port 4/8
RS-232
Comm. Port 5/9
Comm. Port 5/9
RS-232
Comm. Port 6/10
Comm. Port /10
6
RS-485
Comm. Port 7/11
rans mit
CR1
J4
CR2
J5
CR3
J6
CR4
s
1-2 Installed = LEDs Enabled
W1
2-3 installed = LEDs Disabled
1
W1
W2
&
W3
1
Comm. Port 6/10 RS-485 Network
Configuration
W2 for Comm. Port 4/8
1
1-2 Installed = Loopback Disabled 2-3 installed = RTS/CTS Loopback
W3 for Comm. Port 5/9
- for Factory Use ONLY
J2
N
O
5678
1234
SW1
P1
T1
Isolation
Transformers
Isolated RS-485
T2
for
2
Comm. Port /11
7
RS-4 85
If In Slot #3 - Comm. Port Assignments = 4, 5, 6 & 7 If in Slot #4 - Comm. Port Assi
Figure 2-24. Type 2 ECOM with Two RS-232 and Two RS-485 Ports
Detailed Technical
Specifications

2.5.1 RS-232 Ports

2.5.2 RS-485 Ports

N
J7
nments = 8, 9, 10 & 11
O
5678
1234
SW2
Comm. Port 7/11
RS-485 Network
Configuration
For detailed technical specifications, please see document CWMICRO:COM available on our website http://www.emersonprocess.com/remote/D301673X012.pdf.
Type 1 ECOMs include one RS-232 port. Type 2 ECOMs include two RS-232 ports. For information on connecting to these ports, including
cabling information, see Section 2.4.3.
Type 1 ECOMs include one RS-485 port. Type 2 ECOMs include two RS-485 ports. For information on connecting to these ports, including
cabling information, see Section 2.4.4.
2-32 Installation Revised Aug-2015
ControlWave Micro Instruction Manual
When connecting a ControlWave Micro to an external modem, use the
cable configuration in Figure 2-25.
Figure 2-25. Full-duplex and Half-duplex Cable
Figure 2-26. ECOM Modem Installation

2.5.3 Modem Port (Type 1 ECOM only)

You can mount an optional 56Kb PSTN Hayes-type modem on a Type
1 ECOM (see Figure 2-26).
The ControlWave Micro then assigns the modem COM7 (if in slot #3) or COM11 (if in slot #4).
You can configure the MultiTech model MT9234SMI modem module for publicly switched telephone network (PSTN) operation. You can
Revised Aug-2015 Installation 2-33
ControlWave Micro Instruction Manual
also clock DTE/DCE serial data into (transmit) or out of (receive) the modem at rates up to 115.2 kHz.
The factory supplies the modem pre-installed or in kit form with all required hardware. You install it on the ECOM1 module and then use the Ports page in the Flash Configuration utility (in NetView, LocalView, or TechView) to assign ports. Configure a profile for the modem using AT commands submitted using a terminal emulation program (such as HyperTerminal). Users typically use AT commands only when checking the modem’s active or stored profile or when reconfiguring a modem (to turn auto answer on or off, etc.).
Prior to shipment from the factory, the MultiTech modems are pre­configured using the following steps:
1. Connect pin Enable modem setup by setting jumper JP2 on the
ECOM to 2-3.
2. Connect via HyperTerminal (Parameters = 9600, 8, N, 1, None)
to ECOM port C1 using the null modem cable (see Figure 2-17).
3. Send Factory Default = AT&F0
PSTN
Connections
4. Disable Flow Control = AT&K0
5. Set baud rate using AT Command: AT$SB9600, or whatever
baud rate you require.
6. Write to Memory. = AT&W
7. Disable setup mode. Park JP2 (no connection)
Note: You can reconfigure the modem using AT commands and a
terminal program (like HyperTerminal). Connect pins 2 and 3 of JP2 with a suitcase jumper, and use a null modem cable (see
Figure 2-17) to connect the PC to the modem (COM4 or COM8).
Figure 2-27 shows a publicly switched telephone network (PSTN)
using a single master and three remote ControlWave Micros (each
equipped with a PSTN modem). This application requires only one
remote connection.
Use a cable with standard telephone connectors (RJ11s) on each end. Plug one end of the cable into the RJ11 connector jack on the ECOM and the end into a RJ11 wall jack. The telephone company provides the necessary subscriber loops at its central system along with the phone numbers for each destination.
Caution
2-34 Installation Revised Aug-2015
Connect only one modem on each drop. If you attempt to parallel two or more modems across a single drop, an impedance mismatch occurs, adversely affecting the signal. Modems cannot provide reliable communications under these conditions.
ControlWave Micro Instruction Manual
Figure 2-27. PTSN Field Connections for ControlWave Micros
Figure 2-28. Phone Cord Wiring
The 56K PSTN modem is FCC-approved for use with public telephone lines. However, before you place a modem in operation, check the following items to make sure you meet all FCC requirements:
Connections to party line service are subject to state tariffs. Connections to telephone company-provided coin service (central
office implemented systems) are prohibited.
The equipment compliance information is summarized as follows:
o Complies with Part 68 FCC Rules.
Revised Aug-2015 Installation 2-35
ControlWave Micro Instruction Manual
o Contains device with FCC Registration Number: AU7-USA-
o Ringer Equivalence Number (REN): 0.3B
Note: The sum of all the RENs on your telephone lines should
Make any direct connections to PSTN lines through standard plugs
and jacks as specified in the FCC rules. The PSTN line connector plugs into J1 on the modem. Notify your telephone company that the
jack (connector) required for your device is one of the following:
o USOC: RJ11C or o USOC: RJ11W
Note: The jack provided on the Modem (J1) is a 6-pin TLECO RJ-
25814-M5-E
be less than five in order to assure proper service from the telephone company. In some cases, a sum of five may
not be usable on a given line.
11. The connections to the modem are pin 3 PSTN-Tip, and
pin 4 PSTN-Ring.

2.6 Bezels

After the telephone company has installed the above jack, connect
the modem to your equipment by inserting the appropriate equipment interface RJ11 plug into the modem and wall connector.
Bezels are blue plastic covers (see Figure 2-29) that protect an adjacent
pair of I/O modules and provide an easy way for you to route wiring. The factory provides bezels with each order. Install bezels over I/O modules whenever the ControlWave Micro is operational; remove the bezels for maintenance procedures.
Bezels attach to the module covers of two adjacent I/O modules. Hooks
on the bezels (see Figure 2-29) attach to notches in the upper and lower
portions of the module covers. Align the hooks on the bezel with the notches on the I/O module covers and slide the bezel down. To remove the bezel, grasp its sides and gently squeeze them, and pull up and then away from the I/O modules.
2-36 Installation Revised Aug-2015
ControlWave Micro Instruction Manual
Figure 2-29. Bezel Assembly

2.7 Optional Display/Keypads

The ControlWave Micro supports two optional display/keypads:
A 2-button keypad (shown in the left of Figure 2-30) A 25-button keypad (shown in the right Figure 2-30)
Figure 2-30. Optional 2-Button and 25-Button Keypads
Revised Aug-2015 Installation 2-37
ControlWave Micro Instruction Manual
Both keypads use the same 4-line by 20-character LCD displays. You connect the keypad to the ControlWave Micro using a cable, one end of which has an RJ-45 jack (connected into the RJ-45 equipped with two plugs. This cable connects between the RJ-45 display jack (J1) on the PSSM Board and RJ-45 jack (J1) on the remote Display/Keypad assembly. A potentiometer, provided on the keypad, allows you to set the contrast of the LCD display.
Note: For further information on the installation and use of the
optional keypads, refer to the ControlWave Display/Keypad Manual (D5135).
2-38 Installation Revised Aug-2015
Chapter 3 – I/O Modules
This chapter discusses the placement and wiring for I/O modules for the ControlWave Micro. The chapter begins with some general instructions on module installation that are common to most I/O modules. The balance of the chapter includes specific details for configuring and wiring each type of I/O module.
In This Chapter
3.1Module Placement ........................................................................... 3-2
3.2Wiring ............................................................................................... 3-2
3.3Isolated Digital Input (DI) Module .................................................... 3-5
3.4Isolated Digital Output (DO) Module .............................................. 3-10
3.5Non-isolated Digital Input/Output (DI/O) Module ........................... 3-14
3.6Non-isolated Analog Input/Output & Analog Input Module ............ 3-17
3.7Non-isolated High Speed Counter (HSC) Input Module ................ 3-21
3.8Isolated Analog Input (AI) Module ................................................. 3-25
3.9Isolated Analog Output (AO) Module ............................................. 3-29
3.10Non-isolated Mixed I/O (MI/O) Module .......................................... 3-32
3.11Isolated Vac Digital Input Module .................................................. 3-38
3.12Relay Isolated Vac/Vdc Digital Output Module .............................. 3-40
3.13Isolated Digital Input/Output (DI/O) Module................................... 3-42
3.14Isolated Resistance Temperature Device (RTD) Input Module ..... 3-45
3.15Isolated Low Level Analog Input (LLAI) Module ............................ 3-48
3.16Non-isolated HART
3.17IEC62591 Interface Module ........................................................... 3-61
ControlWave Micro Instruction Manual
®
/BTI Interface Module ................................... 3-53
Installation
Installing any I/O module in the ControlWave Micro involves the same basic steps:
1. Remove the I/O module and associated I/O module cover from the
shipping carton.
Note: Modules normally ship from the factory completely
assembled.
2. Align the I/O module with its intended slot on the base or expansion
housing and slide the module into the housing. Make sure the module snaps into the appropriate securing notches on the housing.
3. Wire and plug the local or remote cable assemblies into the
appropriate module connectors.
4. After installing and wiring two I/O modules into adjacent slots in
the housing, cover the modules with a protective bezel. The bezels snap on and off for maintenance.
5. Using a PC running the ControlWave Designer and OpenBSI
software, configure the ControlWave Micro to accept the new I/O modules and download the revised ControlWave project.
Revised Aug-2015 I/O Modules 3-1
ControlWave Micro Instruction Manual
Note: This step is beyond the scope of this manual. Refer to the
ControlWave Designer Programmer’s Handbook (D5125) for further instructions.
Caution
Power down the ControlWave Micro before you install or remove any I/O module. Shut down any processes the ControlWave Micro may be managing (or switch them over manually or handle with another controller). Perform any hardware configuration (wiring, jumper configuration, and installation) only when the ControlWave Micro is powered down.
Before any I/O modules can become operational, you must use ControlWave Designer to configure and then download the application (project).
Do not install any modules in the base or expansion housings until you have mounted and grounded those housings at the designated installation site.
To ensure safe use of this product, please review and follow the instructions in the following supplemental documentation:

3.1 Module Placement

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)

3.2 Wiring

You can place I/O modules in the base or expansion housing:
3-slot base housing: supports one I/O module in slot 3. 4-slot base housing: supports up to two I/O modules in slots 3 and 4. 8-slot base housing: supports up to six I/O modules in slots 3
through 8.
2-slot expansion housing: supports up to two I/O modules. 4-slot expansion housing: supports up to four I/O modules. 8-slot expansion housing: supports up to eight I/O modules.
Note: Some modules have placement restrictions. Note these in the
individual descriptions.
With a few exceptions (noted in the module descriptions), I/O modules support either “local termination” (field wiring connected directly to the module’s removable terminal blocks) or “remote termination” (field wiring connected to the remote headers under the module’s cover and routed to a DIN-rail mounted terminal assembly and then to field devices).
3-2 I/O Modules Revised Aug-2015
ControlWave Micro I/O modules use compression-type terminals that accommodate up to #14 AWG wire. Insert the wire’s bared end (approx. ¼” max) into the clamp beneath the screw and secure the wire. To prevent shorts, ensure that no bare wire is exposed. If using standard wire, tin the bare end with solder to prevent flattening and improve conductivity. Allow some slack in the wires when making terminal connections. Slack makes the wires more manageable and helps minimize mechanical strain on the terminal blocks.

3.2.1 Local Termination

For I/O modules equipped with local terminal blocks, install the field wiring between the I/O module’s removable terminal block connectors and field devices (see Figure 3-1). (consult with the field device manufacturer for recommendations). Leave some slack and plan for wire routing, identification, and maintenance. Route the bundled wires out through the bottom of the I/O module assembly between the terminal block and the terminal housing.
ControlWave Micro Instruction Manual
Use AWG 14 or smaller wire
Figure 3-1. Module Wiring: Local Termination

3.2.2 Remote Termination

For I/O modules that support remote terminations, install cables between the module’s remote headers and the remote DIN-rail mounted terminal block assemblies (see Figure 3-2). Install field wiring between the DIN-rail mounted terminal bock assembly and field devices (see the wiring diagrams associated with each I/O module description).
Revised Aug-2015 I/O Modules 3-3
ControlWave Micro Instruction Manual
Use AWG 14 or smaller wire (consult with the field device manufacturer for recommendations) for remote terminations. Leave some slack and plan for wire routing, identification, and maintenance. Route the cables running between the I/O module and the DIN-rail mounted terminal blocks out through the bottom of the I/O module assembly via the bezel assembly.
Figure 3-2. Module Wiring: Remote Termination

3.2.3 Shielding and Grounding

Use twisted-pair, shielded and insulated cable for I/O signal wiring to minimize signal errors caused by electromagnetic interference (EMI), radio frequency interference (RFI), and transients. When using shielded cable, ground all shields at only one point in the appropriate system. This prevents circulating ground current loops that can cause signal errors.
3-4 I/O Modules Revised Aug-2015

3.3 Isolated Digital Input (DI) Module

Isolated DI modules provide 16 isolated digital inputs. For 24V DI modules you can individually configure inputs for either externally sourced inputs or internally powered (dry contact) applications.
Table 3-1. Isolated DI Module General Characteristics
Type Number
Supported
Digital Inputs (DI)
A DI module consists of an isolated digital input printed circuit board (PCB) with either two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination). Each DI module also includes 19 configuration jumpers and a module cover. The DI PCB connects to the backplane using a 36­pin gold-plated card-edge connector.
16
ControlWave Micro Instruction Manual
Characteristics
Each DI supports/ includes:
Nominal input voltage of 12V or 24Vdc Nominal input current of 5 mA 30 ms input filtering
Dedicated LED on module turns ON
when DI is ON. (not available on all module versions)
Detailed Technical
Specifications
Configurations
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Isolated Digital Input (DI) modules (general part number 396571-XX- X) come in different configurations. See Table 3-2 to see the variations.
Table 3-2. Isolated DI Module Configurations
Part Number Termination Connector Notes
396571-02-6 24V local Includes LED
daughterboard.
396571-04-2: 24V remote Includes LED
daughterboard.
396571-07-7 12V local
Does NOT support internal power source.
Includes LED daughterboard.
Figure 3-3, Figure 3-4, and Figure 3-5 show wiring for the DI module.
Isolation
Surge suppressors and optocouplers electrically isolate the DI field circuitry from the module’s bus interface circuitry. 24V input modules configured for use in dry contact applications contain a +21 Vdc isolated power supply powered by the output of the +VIN power
Revised Aug-2015 I/O Modules 3-5
ControlWave Micro Instruction Manual
source originating on the Power Supply/Sequencer module (PSSM).
Setting Jumpers
Set configuration jumpers W1 through W19 according to Table 3-3. Use jumper W19 (see Figure 3-3) to enable or disable the +21 Vdc field power supply.
Note:
Jumpers W1 through W12 and W15 through W19 only apply to
24V DI Modules.
Table 3-3. Jumper Assignments: Isolated DI Module
Jumper Purpose Description
WI Configures DI1 Pins 2-3 & 4-5 installed = External Power DI
Pins 1-2 & 3-4 installed = Internal Source DI
W2-W12 Configures DI2 through DI12
(respectively)
W13 Enables LEDs Pins 1-2 installed = allows hardware to enable LEDs
W14 Programs Serial EEPROM
W15 Configures DI13 Same as W1
W16 Configures DI14 Same as W1
W17 Configures DI15 Same as W1
W18 Configures DI16 Same as W1
W191
1 You must install a jumper on pins 1-2 of W19 to configure any DI for internally sourced operation.
Enables VIN Pins 1-2 enable VIN
Same as W1
Pins 2-3 installed = allows software to enable LEDs
Reserved for factory use only
Pins 2-3 disable VIN
Wiring the Module
Figure 3-3 shows field wiring assignments associated with locally terminated DI modules; Figure 3-4 shows field wiring assignments associated with remotely terminated DI modules. Figure 3-5 shows an optional remote termination module with built-in discrete relay module that supports input from 120 Vac DIs. The special remote termination module (with built-in discrete relay module) interfaces with an externally sourced DI module.
3-6 I/O Modules Revised Aug-2015
ControlWave Micro Instruction Manual
Figure 3-3. Isolated DI Module (Local Termination)
Figure 3-4 shows the wiring assignments associated with a DIN-rail
mounted terminal block assembly for a DI module associated with either internally sourced or externally powered operation. Figure 3-5 shows the wiring assignments associated with a DIN-rail mounted terminal block assembly for a DI module associated with relay isolated 120 Vac operation.
Revised Aug-2015 I/O Modules 3-7
ControlWave Micro Instruction Manual
Figure 3-4. Isolated DI Module (Remote Termination, Internally Sourced or Externally Powered)
Note:
Fuses F0 to F7 are 1/8 A; F+ is a 2A fuse.
3-8 I/O Modules Revised Aug-2015
ControlWave Micro Instruction Manual
Figure 3-5. Isolated DI Module (Remote Termination, Internally Sourced or Externally Powered with
and without Fuses)
Software Configuration
To use data from an isolated DI module you must add a CWM_DI16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
Revised Aug-2015 I/O Modules 3-9
ControlWave Micro Instruction Manual

3.4 Isolated Digital Output (DO) Module

Isolated DO modules provide 16 DOs to control signaling functions. DO modules consist of a DO PCB with either two 10-point terminal
block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination). DO modules also include two configuration jumpers, an LED board with 16 status LEDs (one for each point), and a cover assembly. The DO PCB connects with the backplane using a 36-pin gold-plated card-edge connector.
Table 3-4. Isolated DO Module General Characteristics
Type Number
Supported
Digital Outputs (DO)
16
Characteristics
Each DO supports/ includes:
Optically isolated open source
MOSFET with surge suppression that is capable of handling 500mA at 30V.
Dedicated LED on module turns ON
when DO is ON.
Detailed Technical
Specifications
Configurations
Isolation
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
The isolated Digital Output (DO) module (general part number
396572-XX-X) comes in two possible configurations, see Table 3-5:
Table 3-5. Isolated DO Module Configurations
Part Number Termination Connector Notes
396572-02-2 local
396572-04-9 remote Includes LED
Includes LED daughterboard.
daughterboard.
Surge suppressors and optocouplers electrically isolate the DO field circuitry MOSFETs from the module’s bus interface circuitry.
DO modules provide a total of 16 DOs with surge protection. Each DO uses an open source MOSFET that is capable of driving up to 31Vdc at up to 500mA. A 500Vdc MOV to chassis and a 31Vdc MOV (across output) are provided to protect each DO. The maximum operating frequency is 20 Hz.
Outputs set OFF on
Power-up
An on-board DO load register stores output data. At power-up the load register clears and sets all outputs to “off.”
Setting Jumpers
3-10 I/O Modules Revised Aug-2015
DO modules contain two configuration jumpers (W1 and W2), which function as follows:
ControlWave Micro Instruction Manual
Table 3-6. Jumper Assignments: Isolated DO Module
Jumper Purpose Description
WI Configures DI1 Pins 1-2 installed = Manually enables status LEDs
Pins 2-3 installed = Software enables status LEDs
See Figure 3-6 for the location of this jumper.
W2 Programs serial EEPROM
Reserved for factory use only
Wiring the Module
Figure 3-6 shows field wiring assignments associated with a locally terminated DO module; Figure 3-7 shows field wiring assignments associated with remotely terminated DO modules. Figure 3-8 shows a remote termination module with built-in discrete relay modules.
Figure 3-6. Isolated DO Module (Local Termination)
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ControlWave Micro Instruction Manual
Figure 3-7 shows the terminal block assignments for a remotely terminated DIN-rail mounted open source isolated DO module. Figure 3-8 shows the terminal block assignments for a remotely terminated DIN-rail mounted relay isolated 24 Vdc DO module.
Figure 3-7. Isolated DO Module (Remote Termination)
Note:
Fuses F0 to F7 are 1/8 A; F+ is a 2A fuse.
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ControlWave Micro Instruction Manual
Figure 3-8. Isolated DO Module (Remote Termination with Relay Isolated with 24 Vdc)
Software Configuration
To use data from an isolated DO module you must add a CWM_DO16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
Revised Aug-2015 I/O Modules 3-13
ControlWave Micro Instruction Manual

3.5 Non-isolated Digital Input/Output (DI/O) Module

Non-isolated DI/O modules consist of a digital input/output PCB with either two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination). The DI/O module also includes 14 configuration jumpers, an LED board with 16 status LEDs (one for each point), and a cover assembly. The DI/O module connects with the backplane using a 36-pin gold-plated card-edge connector.
Non-isolated DI/O modules contain field interface circuitry for up to 12 digital inputs and four digital outputs.
Table 3-7. Non-Isolated DI/DO Module General Characteristics
Type Number
Digital Inputs (DI)
Digital Outputs (DO)
Supported
12
4
Characteristics
Each DI supports/ includes:
Internally sourced DI operation for dry
contacts pulled internally to 3.3Vdc when field input is open.
Surge suppressor
Signal conditioning
Filter time of 15 ms
Jumper to configure source current for
either 2 mA or 60 uA
Dedicated LED on module turns ON
when DI is ON.
Each DO supports/ includes:
Open drain MOSFET provides 100mA
at 30Vdc to an externally powered device.
Surge suppressor Current sink to ground of DI/DO
module
Dedicated LED on module turns ON
when DO is ON.
Detailed Technical
Specifications
Configurations
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
The non-isolated DI/O module (general part number 396567-XX-X) comes in several different configurations. See Table 3-8.
Table 3-8. Non-Isolated DI/O Module Configurations
Part Number Termination Connector Notes
396567-02-9
396567-04-5:
local Includes LED
daughterboard.
remote Includes LED
daughterboard.
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ControlWave Micro Instruction Manual
Setting Jumpers
DI/O modules provide 12 individually field configurable DIs and 4 non-configurable externally powered DOs.
Using configuration jumpers W1 through W12, you can set each DI individually to provide either a 2 mA or 60 uA source current. Table 3-9 details jumper settings.
Table 3-9. Jumper Assignments: Non-isolated DI/O Module
Jumper Purpose Description
W1-W12 Configures DI1 through DI12
(respectively)
W13 Enables LEDs Pins 1-2 installed = allows manual enabling of LEDs
W14 Programs Serial EEPROM
Pins 1-2 installed = 2mA Source Current Pins 2-3 installed = 60uA Source Current
Pins 2-3 installed = allows software enabling of LEDs
Reserved for factory use only
Wiring the Module
Figure 3-9 shows the terminal block assignments for a locally terminated DI/O module. Figure 3-10 shows the terminal block assignments for a DIN-rail mounted remotely terminated DI/O module.
Figure 3-9. Non-isolated DI/O Module (Local Termination)
Revised Aug-2015 I/O Modules 3-15
ControlWave Micro Instruction Manual
Figure 3-10. Non-isolated DI/O Module (Remote Termination)
Software Configuration
To use data from a non-isolated DI/O module you must add a CWM_MD board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
3-16 I/O Modules Revised Aug-2015
ControlWave Micro Instruction Manual

3.6 Non-isolated Analog Input/Output & Analog Input Module

Non-isolated Analog Input/Output (AI/O) modules support six externally sourced 4–20mA or 1–5 Vdc single-ended analog inputs and optionally, two independently configurable 4–20 mA or 1–5 Vdc analog outputs. Non-isolated Analog Input (AI) modules are identical to
AI/O modules but have a depopulated AO section.
AI/O modules consist of an AI/O PCB with two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination), 12 configuration jumpers, and a cover assembly. The AI/O module connects with the backplane using a 36-pin gold-plated card-edge connector.
Table 3-10. Non-Isolated AI/O and AI Module General Characteristics
Type Number
Analog Inputs (AI)
Analog Outputs (AO)
Supported
6 on AI/O
Module
6 on AI Module
2 on AI/O
Module
None on AI
Module
Characteristics
Each AI supports/includes:
Jumper to configure input for either 4–
20mA or 1–5 Vdc
Signal conditioning that provides 2 Hz
low pass filter
Transorb for surge suppression
Analog to Digital converter
Each AO supports/includes:
Jumper to configure output for either 4–
20mA or 1–5 Vdc
maximum external load to the 4–20mA
output of either 250 ohms with an external 11V power source or 650 ohms with an external 24V power source.
maximum external load current to the
1–5 Vdc output is 5 mA with an external 11-30 V power source.
AO operation requires an 11–30Vdc
power source connected to the VEXT terminal of the AI/O module.
Detailed Technical
Specifications
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Configurations
Each non-isolated AI/O module (general part number 396568-XX-X) consists of a PCB with six AIs, 2 AOs, and comes with a module cover. There are two configurations:
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ControlWave Micro Instruction Manual
Table 3-11. Non-Isolated AI/O Module Configurations
Part Number Termination
396568-01-7: 396568-02-5:
Each non-isolated AI module (general part number 396569-XX-X) consists of a PCB with six AIs and comes with a module cover. There are two configurations:
Table 3-12. Non-Isolated AI Module Configurations
Part Number Termination Connector Notes 396569-01-3: 396569-02-1:
Notes
Connector
local
remote
local
remote
Cable Shields
Connect cable shields associated with AI wiring to the ControlWave Micro’s housing ground. Multiple shield terminations require that you supply a copper ground bus (up to a #4 AWG wire size) and connect it to the housing’s ground lug.
This ground bus must accommodate a connection to a known good earth ground (in lieu of a direct connection from the ground lug) and to all AI cable shields. Shield wires should use an appropriate terminal lug. Secure them to the copper bus using industry rugged hardware
Setting Jumpers
(screw/bolt, lock washer, and nuts).
AI/O and AI modules have jumpers you can use to configure each of the six AIs. You can individually configure AIs for 1–5 Vdc or 4–20 mA operation. See Table 3-13.
Table 3-13. Jumper Assignments: Non-isolated AI/O and AI Module
Jumper Purpose Description
JP1-JP6 Configures AI1 through AI6
(respectively)
JP71
JP81
JP91
JP101
JP1 Configures ISP Connector
W1 Programs Serial EEPROM
1 Configuration for JP7 and JP9 must match (that is, both 1-5 V or 4-20mA)
Configuration for JP8 and JP10 must match (that is, both -5 V or 4-20mA)
AO1 Field Output Pins 1-2 installed = 4-20 mA AO
AO2 Field Output Pins 1-2 installed = 4-20 mA AO
AO1 Calibration Test Pins 1-2 installed = 1-5 V AO
AO2 Calibration Test Pins 1-2 installed = 1-5 V AO
Pins 1-2 installed = 4-20 mA AI Pins 2-3 installed = 1-5 V AI
Pins 2-3 installed = 1-5 V AO
Pins 2-3 installed = 1-5 V AO
Pins 2-3 installed = 4-20 mA AO
Pins 2-3 installed = 4-20 mA AO
Reserved for factory use only Reserved for factory use only
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ControlWave Micro Instruction Manual
Wiring the Module
Figure 3-11 shows field wiring assignments associated with the locally terminated AI/O and AI modules. Figure 3-12 shows field wiring assignments associated with remotely terminated AI/O and AI modules.
Figure 3-11. Non-isolated AI/O and AI Module Configuration (Local Termination)
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ControlWave Micro Instruction Manual
Figure 3-12. Non-isolated AI/O and AI Modules (Remote Termination)
Software Configuration
To use data from a non-isolated AI/O module you must add a CWM_MA board in ControlWave Designer’s I/O Configurator, and then configure it. To use data from a non-isolated AI module you must add a CWM_AI6 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for these modules.
3-20 I/O Modules Revised Aug-2015
ControlWave Micro Instruction Manual

3.7 Non-isolated High Speed Counter (HSC) Input Module

Non-isolated High Speed Counter (HSC) Input modules provide up to four inputs. You can individually configure HSC module inputs for either a 10 KHz (high speed) or 300 Hz (low speed) input, and as a 16­bit high speed counter
HSC modules consist of a HSC PCB with two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination), 14 configuration jumpers, an LED daughter board with four status LEDs (one for each point), and a cover assembly. The HSC PCM connects with the backplane using a 36-pin gold-plated card-edge connector.
Table 3-14. High Speed Counter Module General Characteristics
Type Number
High Speed Counter Inputs (HSC)
Supported
4
Characteristics
Each HSC supports/includes:
Jumper to configure point as either a
low speed input (300 Hz) or a high speed input (10 KHz).
Jumper to configure HSC current.
Bandwidth limiting
Surge suppression
Field inputs can be driven by signals or
relay contacts.
LED status indicator
Detailed Technical
Specifications
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Configurations
The non-isolated HSC module (general part number 396570-XX-X) has the following configurations:
Table 3-15. High Speed Counter Module Configurations
Part Number Termination Connector Notes 396570-05-4: 396570-06-2:
local
remote
Setting Jumpers
HSC modules support up to four HSC inputs. Configure the HSC jumpers (W1 through W14) according to Table 3-16.
Table 3-16. Jumper Assignments: Non-isolated HSC Module
Jumper Purpose Description
W1 – W4 Configures HSC1 through
HSC4 (respectively)
Pins 1-2 installed = Enables 300 Hz (low speed input) Pins 2-3 installed = Enables 10 KHz (high speed input)
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ControlWave Micro Instruction Manual
Jumper Purpose Description
W5 Programs Serial EEPROM
W6 Enables LEDs Pins 1-2 installed = Enables LEDs manually
W7 & W8 Controls HSC1 Current Pins 1-2 installed = Enables additional 2 mA load
W9 & W10 Controls HSC2 Current Pins 1-2 installed = Enables additional 2 mA load
W11 & W12 Control HSC3 Current Pins 1-2 installed = Enables additional 2 mA load
W13 & W14 Controls HSC4 Current Pins 1-2 installed = Enables additional 2 mA load
Reserved for factory use only
Pins 2-3 installed = Enables LEDs via software
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
Wiring the Module
Figure 3-13 shows field wiring assignments for the locally terminated HSC module; Figure 3-14 shows field wiring assignments for the remotely terminated HSC module.
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ControlWave Micro Instruction Manual
Figure 3-13. Non-isolated HSC Module (Local Termination)
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ControlWave Micro Instruction Manual
Note: Fuses F0, F2, F4, and F6 are 1/8 A.
Figure 3-14. Non-isolated HSC Module (Remote Termination)
Software Configuration
To use data from a high speed counter module you must add a CWM_HSC4 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
3-24 I/O Modules Revised Aug-2015

3.8 Isolated Analog Input (AI) Module

Isolated AI modules support eight 4–20 mA, 1–5 Vdc, or 0–10 Vdc differential analog inputs.
AI modules consist of an AI PCB with two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination), eight configuration jumpers, and a module cover assembly. The AI PCB connects with the backplane using a 36-pin gold-plated card-edge connector.
Table 3-17. Isolated Analog Input (AI) Module General Characteristics
Type Number
Supported
Analog Inputs (AI)
8
ControlWave Micro Instruction Manual
Characteristics
Each AI supports/includes:
Jumpers to configure input for either
isolated 4–20mA, isolated 1–5 Vdc, isolated 0–10 Vdc, or non-isolated internally powered 4-20mA current loop operation.
AIs configured as isolated inputs have
a common mode range of 180V
Analog input circuitry isolated from bus
interface
Cable Shields
Detailed Technical
Specifications
Configurations
Connect cable shields associated with AI wiring to the ControlWave Micro’s housing ground. Multiple shield terminations require that you supply a copper ground bus (up to a #4 AWG wire size) and connect it to the housing’s ground lug.
This ground bus must accommodate a connection to a known good earth ground (in lieu of a direct connection from the ground lug) and to all AI cable shields. Shield wires should use an appropriate terminal lug. Secure them to the copper bus using industry rugged hardware (screw/bolt, lock washer, and nuts).
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
The isolated Analog Input (AI) module (general part number 396604- XX-X) has the following configurations:
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ControlWave Micro Instruction Manual
Table 3-18. Isolated Analog Input Module Configurations
Part Number Termination Connector Notes 396604-03-0 396604-04-8
local
remote
Setting Jumpers
AI modules have jumpers you can use to configure each of the eight AIs. You can individually configure AI for 4–20 mA, 1–5 Vdc, or 0– 10 Vdc isolated operation or internally sourced 4–20 mA non-isolated operation. See Table 3-19 for settings.
Table 3-19. Jumper Assignments: Isolated AI Module
Jumper Purpose Description
W1 – W8 Configures AI1 through AI8
(respectively)
W9 Programs Serial EEPROM
Voltage Input AIs use two dual-pin jumpers Isolated Current AIs use three dual-pin connectors Internally sourced AIs use four dual-pin jumpers
See Figure 3-15 and Figure 3-16 for examples of how to
use these jumpers.
Reserved for factory use only
Wiring the Module
Figure 3-15 shows terminal assignments for a locally terminated AI module; Figure 3-16 shows terminal assignments for a remotely terminated AI.
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ControlWave Micro Instruction Manual
2
2
TB1
TB2
P3
P4
+AI
-AI
Shield
Internally Sourced
Chassis Ground
Field
TB2
1
2
AI#1 (Example)
4-20mA AI
Wiring Diagram
P1
FIELD
CIRCUIT RY
P3
P4
+AI1
-AI1
+AI2
-AI2
+AI3
-AI3
+AI4
-AI4 ISOGND ISOGND
+AI5
-AI5
+AI6
-AI6
+AI7
-AI7
+AI8
-AI8 ISOGND ISOGND
Chassis Gro und
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
+AI
-AI
Shield
Field
TB
AI #1 ( Exampl e)
Externally
Powered
0-10Vdc AI
Wiring Diagram
TB1
}
TB2
}
1
FIEL D
CIRCUITRY
_
+
+AI
-AI
Shield
Chassis Ground
Field
TB
1
2
AI #1 (Exam ple)
Externally
Powered
4-20mA AI
Wiring Diagram
FIEL D
CIRCUIT RY
Figure 3-15. Isolated AI Module (Local Termination)
Chassis Ground
-AI
Shield
Field
TB
+AI
AI #1 (Exam ple)
Externally
Powered
1-5Vdc AI
Wiring Diagram
1
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ControlWave Micro Instruction Manual
Note: Fuses F0, F2, F4, and F6 are 1/8 A.
Figure 3-16. Isolated AI Module (Remote Termination)
Software Configuration
To use data from an isolated analog input module you must add a CWM_AI8 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
3-28 I/O Modules Revised Aug-2015

3.9 Isolated Analog Output (AO) Module

AO modules support four independently configurable 4–20 mA or 1–5 Vdc isolated analog outputs. Analog output circuitry is electrically isolated from the CPU power system.
AO modules consist of an AO PCB with two 10-point terminal block assemblies (TB1 and TB2 for local termination) or two 14-pin mass termination headers (P2 and P3 for remote termination), four configuration jumpers, and a module cover. The AO PCB connects to the backplane using a 36-pin gold-plated card-edge connector.
ControlWave Micro Instruction Manual
Detailed Technical
Specifications
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Configurations
The isolated Analog Output module (general part number 396603-XX­X) has the following configurations:
Table 3-20. Isolated Analog Output Module Configurations
Part Number Termination Connector Notes 396603-01-7 396603-02-5
local
remote
Setting Jumpers
AO modules have jumpers you can use to configure each of the four AOs. You can individually configure each AO for 4–20 mA or 1–5 Vdc isolated operation. See Table 3-21.
Table 3-21. Jumper Assignments: Isolated AO Module
Jumper Purpose Description
JP1 Configures AO1 Pins 1-2 installed = Voltage output
Pins 2-3 installed = Current output
JP2 Configures AO2 Pins 1-2 installed = Voltage output
Pins 2-3 installed = Current output
JP3 Configures AO3 Pins 1-2 installed = Voltage output
Pins 2-3 installed = Current output
JP4 Configures AO4 Pins 1-2 installed = Voltage output
Pins 2-3 installed = Current output
Wiring the Module
Figure 3-17 shows field wiring assignments for a locally terminated AO module. Figure 3-18 shows field wiring assignments for a remotely terminated AO module.
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ControlWave Micro Instruction Manual
Figure 3-17. Isolated AO Module (Local Termination)
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ControlWave Micro Instruction Manual
Note: Fuses F0, F2, F4, and F6 are 1/8 A.
Figure 3-18. Isolated AO Module (Remotely Terminated)
Software Configuration
To use data from an isolated analog output module you must add a CWM_AO4 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
Revised Aug-2015 I/O Modules 3-31
ControlWave Micro Instruction Manual

3.10 Non-isolated Mixed I/O (MI/O) Module

Non-isolated Mixed I/O (MI/O) modules provide up to six individually field configurable DI/Os, four AIs, two HSC Inputs and, optionally, one AO.
MI/O modules consist of an MI/O PCB with two 10-point terminal block assemblies (TB1 and TB2 for local termination) or two 14-pin mass termination headers (P2 and P3 for remote termination), 28 configuration jumpers, and a module cover. The MI/O PCB connects to the backplane using a 36-pin gold-plated card-edge connector.
Note: I/O circuitry is identical to circuitry used on other I/O modules.
HSC inputs have surge suppression, bandwidth limiting and 20 microsecond (50kHz) filtering. You can individually field-configure HSC inputs for 2mA or 200uA (low power) operation. Each input of the HSCI Module is configured as a 16-bit high-speed counter.
Detailed Technical
Specifications
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Optional AO
Optionally, certain configurations of MI/O modules can also support one externally powered (VEXT = 11–30 Vdc) analog output.
AO circuitry consists of a 12-bit resolution Digital-to-Analog Converter (DAC).
Configurations
The non-isolated Mixed I/O (MI/O) module (general part number 396630-XX-X) has the following configurations:
Table 3-22. Mixed I/O Module Configurations
Part Number I/O Included Termination
Connector 396897-01-0 396897-02-9
396897-03-7 396897-04-5
4AI, 2HSC, 6DI/DO local includes LED daughterboard
4AI, 2HSC, 6DI/DO
& 1AO (on daughterboard)
4AI, 2HSC, 6DI/DO remote includes LED daughterboard
4AI, 2HSC, 6DI/DO
& 1AO (on daughterboard)
local includes LED daughterboard
remote includes LED daughterboard
Notes
Setting Jumpers
MI/O modules have 28 jumpers you can use to configure each input or output. See Table 3-23.
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ControlWave Micro Instruction Manual
Table 3-23. Jumper Assignments: Non-isolated MI/O Module
Jumper Purpose Description
1
W1
W2 Configures optional AO for
W3 Enables DI/DO status LEDs Pins 1-2 installed = Enables LEDs manually
W4 Enables HSC status LEDs Pins 1-2 installed = Enables LEDs manually
W5 & W6 Controls HSC1 Current Pins 1-2 installed = Permits additional 2 mA load
W7 & W8 Controls HSC2 Current Pins 1-2 installed = Permits additional 2 mA load
W9 & W10 Configures HSC1 and HSC2
W11-W16 Configures DI1 through DI6
W17-W22 Select DI/O1 through DI/O6
W23-W26 Configures AI1 through AI4
W272
W28 Enables HSC Circuitry Pins 1-2 installed = Enable (power) HSC circuit
1 W1 jumper located on optional AO daughterboard. 2 Set W27 always to pins 2-3.
Configures optional AO for voltage or current output
voltage or current output
debounce (respectively)
current (respectively)
points (respectively)
(respectively)
Selects AO Voltage Pins 1-2 installed = N/A
Pins 1-2 installed = Sets AO for current output Pins 2-3 installed = Sets AO for voltage output
Pins 1-2 installed = Sets AO for voltage output Pins 2-3 installed = Sets AO for current output
Pins 2-3 installed = Enables LEDs via software
Pins 2-3 installed = Enables LEDs via software
Pins 2-3 installed = Permits 200 uA source; no 2 ma load
Pins 2-3 installed = Permits 200 uA source; no 2 ma load
Pins 1-2 installed = Enables HSC debounce Pins 2-3 installed = Disabled HSC debounce
Pins 1-2 installed = Sets 2 mA source current Pins 2-3 installed = Sets 60 uA source current
Pins 1-2 installed = Sets digital input operation Pins 2-3 installed = Sets digital output operation
Pins 1-2 installed = 4–20 mA AI (250Ω resistor in) Pins 2-3 installed = 1–5 Vdc AI
Pins 2-3 installed = External Field Voltage (TB2-9)
Pins 2-3 installed = Disable HSC circuit
Wiring the Module
Figure 3-19 shows field wiring assignments for a locally terminated MI/O module. Figure 3-20 shows field wiring assignments for a remotely terminated MI/O module.
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ControlWave Micro Instruction Manual
Figure 3-19. Non-isolated MI/O Module (Local Termination)
Figure 3-20. Non-isolated MI/O Module (Remote Termination)
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ControlWave Micro Instruction Manual
Figure 3-21 shows terminal block assignments for remote termination. Figure 3-22 shows a wiring diagram for mixed I/O for local
termination. Figure 3-23 shows a wiring diagram for mixed I/O for remote termination.
Note: Fuses F1 to F6 are ¼ A; fused F7 to F15 are 1/8 A.
Figure 3-21. MI/O Module (Remote Termination)
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ControlWave Micro Instruction Manual
Figure 3-22. MI/O Module Wiring (Local Termination)
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ControlWave Micro Instruction Manual
Figure 3-23. MI/O Module Wiring (Remote Termination)
Software Configuration
To use data from a mixed I/O module you must add a CWM_MIX board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
Revised Aug-2015 I/O Modules 3-37
ControlWave Micro Instruction Manual

3.11 Isolated Vac Digital Input Module

Isolated Vac DI modules provide eight isolated DIs, which can interface to field-powered devices providing 110 Vac or 220 Vac.
Table 3-24. Isolated Vac DI Module General Characteristics
Type Number
Supported
Isolated Digital Inputs (DI)
Vac DI modules consists of a DI PCB with two 10-point terminal block assemblies (for local termination), one configuration jumper, an LED daughterboard with eight status LEDs (one for each point), and a module cover. The Vac DI PCB connects with the backplane using a 36­pin gold-plated card-edge connector.
8
Characteristics
Each DI supports/includes:
Nominal field powered input voltage of
110Vac or 220Vac
Nominal input current of 12mA @
120Vac
30 ms input filtering
LED that turns ON when DI is ON.
Detailed Technical
Specifications
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Configuration
The isolated Vac DI module is available in a single configuration (part number 396686-01-0):
Isolation
Optocouplers electrically isolate the module’s DI field circuitry from the module’s bus interface circuitry.
Setting Jumpers
Vac DI module has one jumper which enables the DI status LEDs. See
Table 3-25.
Table 3-25. Jumper Assignments: Isolated Vac DI Module
Jumper Purpose Description
W1 Enables DI status LED Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
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ControlWave Micro Instruction Manual
Wiring the Module
Figure 3-24 shows field wiring assignments for a locally terminated Vac DI module.
Figure 3-24. Isolated Vac DI Module Wiring (Local Termination)
Software Configuration
To use data from an Isolated Vac Digital Input module you must add a CWM_DI16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
Revised Aug-2015 I/O Modules 3-39
ControlWave Micro Instruction Manual

3.12 Relay Isolated Vac/Vdc Digital Output Module

Caution
You cannot install a relay isolated Vac/Vdc DO module in slot #1 of any expansion housing.
Relay isolated Vac/Vdc DO modules provide a total of eight isolated DOs to control signaling functions. The DOs do not have surge protection (this is a customer-provided feature, if necessary).
Table 3-26. Relay Isolated Vac/Vdc DO Module Characteristics
Type Number
Supported
Relay Isolated Digital Outputs (DO)
8
Characteristics
Each DO supports/includes:
A pair of Normally Open (NO) relay
contacts capable of handling a maximum operating load of 6A at 240 Vac or 5A at 30Vdc.
Output relay provides 500 Vdc
electrical isolation for the DO.
Maximum operating frequency of 360
operations per hour (under rated load).
LED that turns ON when DO is ON.
Detailed Technical
Specifications
Isolation
Configuration
Setting Jumpers
Isolated Vac/Vdc DO modules consist of a DO PCB with two 10-point terminal block assemblies (for local termination), one configuration jumper, an LED daughterboard with eight status LEDs (one for each point), and a module cover. The DO PCB connects with the backplane using a 36-pin gold-plated card-edge connector.
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
Relays electrically isolate the Vac/Vdc DO field circuitry from the module’s bus interface circuitry. An onboard DO load register stores output data. At power up the DO load register clears and sets all outputs to “off.”
The relay isolated Vac/Vdc DO module is available in a single configuration (part number 396687-01-6).
The Vac/Vdc DO module has one jumper which enables the DI status LEDs. See Table 3-27.
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ControlWave Micro Instruction Manual
A
A
2
Table 3-27. Jumper Assignments: Isolated Vac DI Module
Jumper Purpose Description
W1 Enables DO status LED Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
Wiring the Module
Figure 3-25 shows field wiring assignments for a locally terminated relay isolated Vac/Vdc DO module.
DO3
LED Board Connector
TB1
TB2
A Relay Isolated Vac/Vdc DO Module
cannot be installed into Sl ot #1 of a
2
1
P2
39
Control MICRO
I/O Expansion Chassis!
1
W1 LED Enable 1-2 = Enable LEDs Manually 2-3 = Enable LEDs via Software
NOTE:
Wave
P1
DO3
DO1 DO2
DO5 DO6 DO7 DO8
DO4
C/DC
DO Module
LED
ssignments
NO_IN1
NO_OUT1 NO_IN2 NO_OUT2 N/C N/C NO_IN3 NO_OUT3 NO_IN4 NO_OUT4
NO_IN5 NO_OUT5 NO_IN6 NO_OUT6
N/C
N/C NO_IN7 NO_OUT7 NO_IN8 NO_OUT8
DO1
DO5
DO2
DO6
DO4
DO8
DO7
1 2
3 4 5
TB1
6 7 8 9 10
1 2 3 4 5
TB
6 7 8 9 10
Figure 3-25. Relay Isolated Vac/Vdc DO Module Wiring (Local Termination)
Software Configuration
FIELD
AC/DC DO MODULE
CIRCUITRY
NO_IN1
NO_OUT1
1
2
Field
TB
To use data from a Relay Isolated Vac/Vdc Digital Output module you must add a CWM_DO16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
Revised Aug-2015 I/O Modules 3-41
ControlWave Micro Instruction Manual
3.13 Isolated Digital Input/Output (DI/O) Module
Isolated Digital I/O modules provide four isolated DOs that are externally powered and twelve isolated DIs.
Table 3-28. Isolated (DI/O) Module Characteristics
Type Number
Isolated Digital Outputs (DO)
Isolated Digital Inputs (DI)
Supported
4
12
Characteristics
Each isolated DO supports/includes:
Externally powered. Supports 500mA
maximum load (nominally powered
from a 10Vdc supply [30Vdc max]_
Surge protection.
Open source MOSFET drives up to
31Vdc at up to 500mA.
500Vdc MOV to chassis and 31Vdc
MOV (across output) protect each DO.
Maximum operating frequency of 20
Hz.
Each isolated DI supports/includes:
Jumper allows externally powered
single end inputs or internally sourced
dry contact operation.
Nominal input voltage of 24Vdc.
Nominal input current of 5mA.
30 ms filtering.
Detailed Technical
Specifications
Configuration
Isolation
Isolated DI/O modules consist of a DI/O PCB with two 10-point terminal block assemblies (for local termination), 14 configuration jumpers, an LED daughterboard with 16 status LEDs (one for each point), and a module cover. The isolated DI/O PCB connects with the backplane using a 36-pin gold-plated card-edge connector.
For detailed technical specifications, please see our website http://www.emersonprocess.com/remote.
The isolated DI/O module is available in a single configuration (part number 396804-01-2).
Surge suppressors and optocouplers electrically isolate the DI field circuitry from the module’s bus interface circuitry.
When configured for use in dry contact applications, all DIs use a built­in +21Vdc field power supply. This is an isolated supply powered by the output of the +VIN power source originating on the PSSM. Use jumper W15 to enable or disable the +21Vdc field power supply.
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ControlWave Micro Instruction Manual
Each of the four DO circuits contain an optically isolated open source MOSFET with surge suppressor and are capable of handling 500mA @ 30V.
Use jumper W15 to enable power for DIs that are configured for internal power. The nominal input voltage is 24Vdc at 5mA.
Setting Jumpers
The isolated DI/O module has 15 jumpers you can use to configure inputs and outputs. See Table 3-29.
Table 3-29. Jumper Assignments: Isolated Vac DI Module
Jumper Purpose Description
W1 Configures DI1 Pins 2-3 & 4-5 installed = Permit external power DI
Pins 1-2 & 3-4 installed = Permit internal source DI
W2-W12 Configures DI2 through DI12
(respectively)
W13 Enables DI/O status LED Pins 1-2 installed = Enables LEDs manually
W14 Programs serial EEPROM
W151
1 Place configuration jumper on pins 1-2 if you configure any DI for internally sourced operation.
Enables VIN Pins 1-2 installed = Enable VIN
Pins 2-3 & 4-5 installed = Permit external power DI Pins 1-2 & 3-4 installed = Permit internal source DI
Pins 2-3 installed = Enables LEDs via software
Reserved for factory use only
Pins 2-3 installed = Disable VIN
Wiring the Module
Figure 3-26 shows field wiring assignments for a locally terminated isolated DI/O module.
Revised Aug-2015 I/O Modules 3-43
ControlWave Micro Instruction Manual
Figure 3-26. Isolated DI/O Module Wiring (Local Termination)
Software Configuration
To use data from an Isolated Digital Input/Output module you must add a CWM_MD board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
3-44 I/O Modules Revised Aug-2015
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