Fisher ControlWave Redundant Controller Manuals & Guides

Instruction Manual

CI-ControlWaveRED
Oct., 2006

ControlWave RED

ControlWave Redundant Controller

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

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 Bristol for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for
whatever reason, may leave an operating process without protection. Depending upon
the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment
or provide alternate means of protection such as alarm devices, output limiting, fail­safe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional
in-formation is required, the purchaser is advised to contact Bristol .

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note
the following: The party sending such materials is responsible to ensure that the
materials returned to Bristol 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 Bristol and save Bristol harmless from any liability or
damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical 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 at the back of this manual for
proper care and handling of ESD-sensitive components.

Bristol 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

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

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

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

defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

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

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

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

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

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

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

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

or oral warranties beyond those set forth herein.

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

replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Water­town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incidental or consequential

damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.

REMEDIES

How to return material for Repair or Exchange

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

You can easily obtain a RA number by:

A. FAX
Completing the form (GBU 13.01) and faxing it to [phone]. A Bristol Repair

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

B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)

and sending it via E-Mail to [e-mail]
representative will return E-Mail (or other requested method) with a RA number.

C. Mail
Mail the form (GBU 13.01) to

Bristol Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

A Bristol Repair Dept. representative will return call (or other requested method)

with a RA number.

D. Phone

Calling the Bristol Repair Department at [phone]. A Bristol Repair Depart-

ment representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

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

. A Bristol Repair Dept.

Bristol Inc. Repair Authorization Form (off-line completion)

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

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

Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is

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

• Evaluate / Test / Verify Discrepancy

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

• Return to Customer

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

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

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

Part II Please complete Parts II & III for each unit returned

Model No./Part No. Description

Please be aware of the Non warranty standard charge:

• There is a $100 minimum evaluation charge, which is

applied to the repair if applicable (√ in “returned”
B,C, or D of part III below)

Range/Calibration S/N
Reason for return

: Failure Upgrade Verify Operation Other

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

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

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

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

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

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

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

repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,
would you like the product:

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

repaired returned replaced scrapped?

returned replaced scrapped?
returned replaced *see below?

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

that has the most knowledge of the problem is: ______________________________ phone_____________________

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

phone_____________________

____________________________________________________________________________________________________

Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: [phone] Fax: [phone] Form GBU 13.01 Rev. B 04/11/06

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

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

• Minimize installation, start-up and maintenance costs.

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

• Know your system.

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

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

6200.

A Few Words About Bristol Inc.

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

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

Getting Additional Information

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

Help Files / Release Notes

Many Bristol software products incorporate help screens. In addition, the software typically
includes a ‘read me’ release notes file detailing new features in the product, as well as other
information which was available too late for inclusion in the manual.

Contacting Bristol Inc. Directly

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

Our main phone numbers are:

[phone]
[phone] (FAX)

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

Telephone Support - Technical Questions

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

For technical questions about TeleFlow products call [phone].

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

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

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call [phone].

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

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

The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at [phone] or [phone].

You can e-mail the Communication Technology Group at:

[e-mail]

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

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

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

Visit our Site on the World Wide Web

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

Training Courses

Bristol’s Training Department offers a wide variety of courses in Bristol hardware and
software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at [phone] for course
information, enrollment, pricing, and scheduling.

CI-ControlWaveRED

ControlWave

Redundant Controller

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL DESCRIPTION ........................................................................................... 1-1

1.2 ControlWaveRED PROGRAMMING ENVIRONMENT............................................ 1-2

1.3 PHYSICAL DESCRIPTION........................................................................................... 1-4

1.3.1 CPU Modules .................................................................................................................1-4

1.3.1.1 CPU Module Connectors ............................................................................................... 1-7

1.3.1.2 CPU Module Switches ....................................................................................................1-8

1.3.1.3 CPU Module System Battery......................................................................................... 1-9

1.3.1.4 CPU Module LEDs and Port 80 Display .................................................................... 1-10

1.3.1.5 CPU Module Memory Summary.................................................................................. 1-10

1.3.2 Power Supply/Sequencer Module................................................................................. 1-11

1.3.2.1 PSSM Power Switch SW1 ............................................................................................ 1-13

1.3.2.2 PSSB Board Fuse.......................................................................................................... 1-13

1.3.2.3 PSSB Board Connectors ............................................................................................... 1-13

1.3.2.4 PSSM LEDs .................................................................................................................. 1-14

1.3.3 ControlWaveRED CPU & Comm. Redundancy Switch Module.............................. 1-14

1.3.3.1 CCRS Module Switches................................................................................................ 1-16

1.3.3.2 User Accessible CCRS Module Connectors ................................................................. 1-17

1.3.3.3 CCRS Module Status LEDs .........................................................................................1-17

1.3.4 ControlWaveRED Backplane ....................................................................................1-17

1.3.5 ControlWaveRED Chassis......................................................................................... 1-19

Section 2 - INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1

2.2 ControlWaveRED INSTALLATION SITE CONSIDERATIONS.............................. 2-2

2.2.1 Temperature & Humidity Limits .................................................................................. 2-2

2.2.2 Vibration Limits ............................................................................................................. 2-2

2.3 ControlWaveRED INSTALLATION/CONFIGURATION .........................................2-3

2.3.1 Mounting the ControlWaveRED Chassis ...................................................................2-6

2.3.1.1 ControlWaveRED Grounding ...................................................................................... 2-7

2.3.2 Power Supply/Sequencer Module (PSSM) Configuration............................................. 2-7

2.3.3 CPU Module Configuration............................................................................................ 2-8

2.3.3.1 CPU Module Switch Configuration ...............................................................................2-9

2.3.3.2 Communication Ports................................................................................................... 2-11

2.3.3.3 RS-232 & RS-485 Interfaces ........................................................................................2-12

2.3.3.4 Ethernet Ports .............................................................................................................. 2-17

2.3.4 Wire Connections.......................................................................................................... 2-18

2.3.4.1 Power Supply Wiring.................................................................................................... 2-19

2.3.4.1.1 Bulk Power Supply Current Requirements ................................................................2-19

2.3.4.1.2 Power Wiring ................................................................................................................ 2-20

2.3.4.1.3 Watchdog MOSFET Switch Wiring............................................................................. 2-21

2.3.4.2 CCRS Module Isolated On-Line Status Output Wiring ............................................. 2-21

2.3.5 Installation of the Lithium Backup Battery ............................................................... 2-22

CI-ControlWaveRED Contents / 0 - 1

CI-ControlWaveRED

ControlWave

Redundant Controller

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 2 - INSTALLATION (Continued)

2.3.6 Installation of the Bezel Assembly ..............................................................................2-23

2.4 OPERATIONAL DETAILS .......................................................................................... 2-24

2.4.1 Downloading the Redundant Project ........................................................................... 2-25

2.4.2 Upgrading ControlWave Firmware ........................................................................... 2-25

2.4.2.1 Using LocalView to Upgrade ControlWave Firmware .............................................2-26

2.4.2.2 Using Hyperterminal to Upgrade ControlWave Firmware...................................... 2-30

2.4.2.3 Remote Upgrade of ControlWave Firmware ............................................................. 2-34

2.4.3 Operation of the RUN/REMOTE/LOCAL Switch ....................................................... 2-34

2.4.4 Operation of the Reset Switch ..................................................................................... 2-35

2.4.5 Operation of the CCRSM A/B Primary Controller Select Switch ..............................2-35

2.4.6 Operation of the CCRSM A/B Enable Key Switch...................................................... 2-35

2.4.7 Soft Switch Configuration and Communication Ports ...............................................2-35

Section 3 - SERVICE

3.1 SERVICE INTRODUCTION ........................................................................................ 3-1

3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1

3.2.1 Accessing Modules For Testing...................................................................................... 3-1

3.2.2 Removal/Replacement of a Bezel Assembly .................................................................. 3-2

3.2.3 Removal/Replacement of a CPU Module (CPUM) ........................................................ 3-2

3.2.4 Replacing a Failed CPU while the other CPU Remains On-line ................................. 3-2

3.2.5 Removal/Replacement of a Power Supply/Sequencer Module (PSSM)........................ 3-7

3.2.6 Removal/Replacement of a CCRS Module (CCRSM).................................................... 3-7

3.3 TROUBLESHOOTING TIPS......................................................................................... 3-8

3.3.1 Power Supply/Sequencer Module (PSSM) Voltage Checks .......................................... 3-8

3.3.2 LED Checks .................................................................................................................... 3-9

3.3.3 Wiring/Signal Checks ................................................................................................... 3-10

3.4 GENERAL SERVICE NOTES..................................................................................... 3-11

3.4.1 Extent of Field Repairs................................................................................................. 3-11

3.4.2 Disconnecting RAM Battery ........................................................................................ 3-11

3.4.3 Maintaining Backup Files............................................................................................ 3-12

3.4.4 Port 80 Display POST Checks ..................................................................................... 3-12

3.5 WINDIAG DIAGNOSTICS .......................................................................................... 3-15

3.5.1 Diagnostics Using WINDIAG ...................................................................................... 3-17

3.5.1.1 Communications Diagnostic Port Loop-back Test...................................................... 3-18

3.5.1.2 COM 1, 2, 3, 4 Eternal Loop-back Test Procedure...................................................... 3-19

3.5.1.3 Ethernet Diagnostic Port Loop-back Test ................................................................... 3-20

3.5.1.4 Ethernet Port 1, 2 & 3 External Loop-back Test Procedure ...................................... 3-21

3.6 CORE UPDUMP........................................................................................................... 3-22

3.7 TROUBLESHOOTING REDUNDANCY PROBLEMS.............................................. 3-23

3.8 ControlWaveRED FUNCTIONALTESTS................................................................... 3-24

3.8.1 Basic Reset and Supervisory Power-Up Tests ............................................................ 3-25

3.8.2 Redundant Power Source & Supervisory Power-Up Tests ........................................ 3-25

3.8.3 Watchdog Mechanism Power-Up Tests ....................................................................... 3-25

0 - 2 / Contents CI-ControlWaveRED

CI-ControlWaveRED

ControlWave

Redundant Controller

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 3 - SERVICE (Continued)

3.8.4 Primary CPU Selection on Power-Up Tests................................................................ 3-26

3.8.5 Tests of Switchover from “Dead” Primary Selected Unit on Power-Up ....................3-26

3.8.6 Forced Primary CPU Selection on Power-Up Tests ................................................... 3-27

3.8.7 Normal Power-Up & Switchover Tests........................................................................ 3-28

3.8.8 Normal Power-Up & Forced Switchover Tests ...........................................................3-29

3.8.9 On-Line Relay Functional Tests .................................................................................. 3-30

3.8.10 CCRS Assembly Communication Ports Functional Tests.......................................... 3-31

3.8.10.1 Configuration for Port Tests............................................................................................... 3-31

3.8.10.2 Communication Port Switching Tests ............................................................................... 3-31

Section 4 - SPECIFICATIONS

4.1 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1

4.1.1 CPU Module Communication Ports............................................................................... 4-3

4.2 POWER SUPPLY/SEQUENCER MODULE ............................................................... 4-4

4.2.1 Input/Output Power Specs. ............................................................................................ 4-4

4.2.2 Power Supply Sequencer Specs. .................................................................................... 4-5

4.2.3 Power Supply Connectors............................................................................................... 4-5

4.3 BACKPLANE PCB ......................................................................................................... 4-6

4.4 CCRS MODULE SPECIFICATIONS............................................................................ 4-7

4.4.1 CCRS Module Communication Ports .......................................................................... 4-10

4.5 ENVIRONMENTAL SPECIFICATIONS.................................................................... 4-10

4.6 DIMENSIONS ..............................................................................................................4-11

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

REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS

WINDIAG - Windows Diagnostics for Bristol Controllers ...................................D4041A

Open BSI Utilities Manual ...................................................................................... D5081

ControlWave Quick Setup Guide............................................................................. D5084

Getting Started with ControlWave Designer.......................................................... D5085

Web_BSI Manual...................................................................................................... D5087

ControlWave Designer Reference Manual .............................................................. D5088

ControlWave Redundancy Setup Guide .................................................................. D5123

ControlWave Designer Programmer’s Handbook................................................... D5125

APPENDICES/SUPPLEMENTAL INSTRUCTION

MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z

Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW

Care and Handling of PC Boards and ESD-Sensitive Components .....................S14006

CI-ControlWaveRED Contents / 0 - 3

BLANK PAGE

Section 1

INTRODUCTION

1.1 GENERAL DESCRIPTION

ControlWave™ Redundant Controllers (ControlWaveRED) employ a modular hardware

architecture with a modern and rugged industrial design that in keeping with the rest of
the line of ControlWave Industrial Process Automation Controllers is both simple to
install and configure. ControlWave™ Redundant Controllers utilize dual CPUs that
communicate with the same physical remote I/O. One CPU is on line, while the other
functions as a "hot" backup. A CPU & Communications Redundancy Switch (CCRS) Module
included in the system provides arbitration between the two processors. Should the CCRS
Module detect a failure in the on-line unit, it will switch to the backup unit without
interrupting control and communication functions. Each ControlWaveRED CPU Module
utilizes an AMD Elan SC520 microprocessor running at 100 MHz and is powered by its own
Power Supply/Sequencer Module. Two Bezel Assembles are provided (one for each CPU &
PSSM pair).

Figure 1-1 - ControlWaveRED Assembly

At the heart of the system is the ControlWaveRED CPU & Communications Redundancy
Switch Module that provides for automatic or manual switching of the CPU Module that is

CI-ControlWaveRED Introduction / 1-1

communicating with the Remote I/O Rack or the I/O Expansion Rack being controlled. The
ControlWave™ CPU & Communications Redundancy Switch Module (CCRSM) also
provides for controlled switching of the four non-Ethernet communications ports associated
with the selected or ‘On-Line’ CPU Module. Each CPU Module can have two, three or four
RS-232 communication ports. Ports COM3 and COM4 (on the Secondary Communications
Board) can be individually factory configured for either RS-232 or RS-485 operation. Port
connections from the redundant CPU Modules (A & B) are routed to the front of the CPU &
Communications Redundancy Switch Module by means of two cable headers and custom
cabling.

ControlWave™ Redundant Controllers provide the following key features:

• Low power consumption

• Small size (supports panel-mount or 19-inch rack-mount installations)

• ControlWaveRED CPU Architecture compatible with IBM Personal Computers

with a system BIOS.

- BIOS FLASH - 512 Kbytes contained in a single IC

- FLASH Memory - 4 Mbytes to 64 Mbytes mounted in up to 4 48-pin TSOPs

- Memory (SRAM) - 2 Mbytes of soldered-down static RAM (SRAM) is implemented

with four 512K x 8 asynchronous SRAMs that are configured as a 1M x 16-bit
array. Each SRAM device operates at 3.3V and is packaged in a 32-pin TSOP. An
additional 2Mbytes of SRAM may be factory installed.

- SDRAM - 4Mbytes of on board Synchronous Dynamic RAM (SDRAM) (2 x

KM416S1120DT).

- Three 10/100Base-T Ethernet ports implemented via AMD Am79C973 Pcnet

FAST III Controllers. The built-in transceiver provides a full-duplex im­plementation with a RJ-45 10/100Base-T Connector (J4).

• ControlWaveRED CPU & Communications Redundancy Switch Module (CCRSM)
provides for automatic switching of the CPU Module and its four associated
communications ports whenever a defective CPU Module or associated PSSM is
detected.

• LED annunciation of the On-Line CPU and Power Supply/Sequencer Modules.

• A pluggable Terminal Block on the front of the CPU & Communications Redun-

dancy Switch Module provides dual pairs of isolated relay contacts that indicate the
on-line status of the ‘A’ and ‘B’ redundant controllers.

1.2 ControlWaveRED PROGRAMMING ENVIRONMENT

The ControlWaveRED programming environment uses industry-standard tools and
protocols to provide a flexible, adaptable approach for various process control applications
in the water treatment, wastewater treatment, and industrial automation business.

The ControlWaveRED programming environment consists of a set of integrated software
tools which allow a user to create, test, implement, and download complex control strategies
for use with Bristol Babcock’s ControlWave and ControlWaveRED Control-lers.

The tools that make up the programming environment are:

• ControlWave Designer load building package offers several different methods for

generating and debugging control strategy programs including function blocks, ladder
logic, structured languages, etc. The resulting process control load programs are fully
compatible with IEC 61131-3 standards. Various communication methods as offered,

1-2 / Introduction CI-ControlWaveRED

including TCP/IP, serial links, as well as communication to Bristol Babcock’s Open BSI
software and networks

.

Figure 1-2 - ControlWave - Control Strategy Software Diagram

• The I/O Configuration Wizard, 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.

• The Bristol Firmware Library (Bbifsb) which is imported into ControlWave

Designer, includes a series of Bristol Babcock specific function blocks. These pre­programmed function blocks accomplish various tasks common to most user
applications including alarming, historical data storage, as well as process control
algorithms such as PID control.

• The Bristol I/O Simulator allows the load program generated through ControlWave

Designer to be tested on a PC, with simulated analog and digital inputs and outputs.

CI-ControlWaveRED Introduction / 1-3

The I/O Simulator utilizes the identical IEC 61131 real time system used in the
ControlWaveRED controller; this allows initial I/O testing and debugging to be
performed in a safe, isolated environment, without the need for a running

ControlWaveRED controller and process I/O boards.

• The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows

real-time data access to any OPC compliant third-party software packages.

• A series of Configuration Controls are available for setting up various aspects of the

system such as historical data storage, system security, and soft switches. Additional
Data Access Controls are also available for retrieval of real-time data values and
communication statistics. The configuration controls and the data access 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 third­party ActiveX compatible containers such as Visual BASIC or Microsoft® Excel.

• User-defined Web Pages - If desired, user-defined web pages can be stored within a

PC to provide a customized human-machine interface (HMI).

1.3 PHYSICAL DESCRIPTION

ControlWave Redundant Controllers are comprised of the following major components:

• Two CPU Modules (see Section 1.3.1) & System Batteries (see Section 1.3.1.3)

• Two Power Supply/Sequencer Modules (PSSM) (see Section 1.3.2)

• CPU & Communications Redundancy Switch Module (CCRSM) (see Section 1.3.3)

• Backplane Assembly (1.3.4)

• Chassis Assembly (see Section 1.3.5)

1.3.1 CPU Modules

Each CPU Module houses a CPU Board and optionally, a Secondary Communications
Board (SCB). The CPU Board is a multilayer board that provides ControlWaveRED CPU,
I/O monitor/control, memory and communication functions. This board operates over an
extended temperature range with long-term product reliability.

ControlWaveRED CPU Boards are based on AMD’s Elan SC520 Microcontrollers. The
CPU operates at 2.5V with a system clock speed of 100 MHz. The Microcontroller is
packaged in a 388-pin Plastic Ball Grid Array. The base version of the CPU Board includes
two RS-232 communication ports, an Ethernet RJ-45 communication port, 2 Mbytes of
Static RAM (SRAM), 4 Mbytes of Synchronous Dynamic RAM (SDRAM), 512 kbytes of
BIOS in FLASH, 4 Mbytes simultaneous read/write FLASH (soldered down). Basic CPU
components and features are summarized as follows:

• 2.5V Core 3.3V I/O 66/100MHz AMD Elan SC520 Processor featuring:

Floating Point unit
16-KB write-back cache
Integrated PCI host bridge controller
DRAM controller (up to 256MB supported)
Standard PC/AT-compatible peripherals
Three general purpose timers
Watchdog timer
Software timer

1-4 / Introduction CI-ControlWaveRED

Synchronous serial interface
Flexible address decoding
Programmable I/O pins

• 512KB FLASH BIOS IC, 29LV040B, 90 nanosecond, 8-bit access

• 2MB SRAM, 3.3V, 512K x 8, soldered-down (factory upgradeable to 4Mbyte)

• 4MB simultaneous read/write FLASH, TSOP sites (factory upgradeable to 64Mbyte)

• Two 9 wire PC/AT compatible (RS-232) serial communications ports

• I/O Bus Interface capable of driving up to 8 slots

• 10/100Base-T Ethernet interface implemented by an AMD Pcnet Fast III Controller

• Port 80 diagnostic LED Display

• PC/104-Plus Expansion Connector

• 4Mbyte on board SDRAM - 2 x KM416S1120DT

• 3 position key-lock switch

• 3.6V, 950mA-hr Lithium ½ AA cell battery provides backup for the real-time clock,

CMOS RAM & System SRAM

Figure 1-3 - Block Diagram of ControlWave™ CPU Board

Figure 1-3 provides the CPU Module block diagram. The shaded components of Figure 1-3
are features that are only available on Secondary Comm. Boards.

CI-ControlWaveRED Introduction / 1-5

Figure 1-4 - ControlWaveRED CPU Module

Three basic versions of the dual CPU Modules are available (Note: All CPU boards have 2
RS-232 Ports and 1 Ethernet Port):

1-6 / Introduction CI-ControlWaveRED

CPU Bd. & SCB (SCB contains 2 RS-232 & 2 Ethernet Ports)
CPU Bd. & SCB (SCB contains 1 RS-232 (COM4), 1 RS-485 (COM3) & 2 Ethernet Ports)
CPU Bd. & SCB (SCB contains 2 RS-485 & 2 Ethernet Ports)

The BIOS is contained in a single 512 Kbyte uniform sector FLASH IC. This device resides
on the General Purpose (GP) bus, operates at 3.3V and is configured for 8-bit access.

The CPU Board contains four 48-pin TSOP sites that accept FLASH devices ranging in
density from 2 to 16 Mbytes. Units are factory configured for from 4 to 64 Mbytes of
industrial simultaneous read/write (SMR) FLASH memory. The FLASH memory is a linear
array of 16 Mbit parts configured for 32-bit, 16-bit or 8-bit read access (32-bit write access)
and is connected to the SDRAM bus.

The base version of the CPU Module has 2Mbyte of soldered-down static RAM, im­plemented with four 512K x 8 asynchronous SRAMs that are configured as a 1M x 16-bit
array. SRAM operate at 3.3V and are packaged in 32-pin TSOPs. An additional 2Mbyte of
SRAM may be factory added to raise the board total to 4Mbyte. SRAM is placed into data
retention mode (powered by a backup 3.6V lithium battery) when power is lost. The SRAM
supports 16-bit or 8-bit accesses and is connected to the GP bus.

CPU Modules contain 4Mbyte of SDRAM housed in 2 KM416S1120DTs ICs (U15 & U16).

1.3.1.1 CPU Module Connectors

The CPU Modules contain up to nine (9) user accessible connectors that function as follows
(see Table 1-1):

Table 1-1 - CPU Board Connector Summary

Ref. # Pins Function Notes

J1 132-pin I/OB Connector see Figure 4-1
J2 9-pin COM1 9-pin male D-sub see Figure 4-2 & Table 4-2
J2 8-pin COM3 RJ-45 (RS-232 or RS-485) * see Figure 4-3 & Table 4-3
J3 9-pin COM2 9-pin male D-sub see Figure 4-2 & Table 4-2
J3 9-pin COM4 9-pin male D-sub * see Figure 4-2 & Table 4-2
J4 8-pin Ethernet 10/100Base-T RJ-45 #1 see Figure 4-4 & Table 4-4
J5 8-pin Ethernet 10/100Base-T RJ-45 #2 * see Figure 4-4 & Table 4-4
J7 8-pin Ethernet 10/100Base-T RJ-45 #3 * see Figure 4-4 & Table 4-4
J10 3-pin Battery Connector see Figure 4-5

* = Located on Secondary Comm. Board

CPU Board Comm. Port Connectors J2, J3 and SCB Comm. Port Connector J3

The CPU Module supports up to three external 9-pin RS-232 serial ports (COM1, COM2
and COM4 (with COM4 located on the Secondary Communication Board - a PC/104 Plus
expansion option). COM1, COM2 and COM4 utilize standard 9-pin male D-sub connectors
and are PC/AT compatible ports. COM4 can also be factory configured for Isolated RS-485
operation instead of RS-232.

CPU Module Comm. Port Connector J2 (SCB)

8-pin RJ-45 connector J2 (COM3) is provided on the Secondary Communications Board and
is factory set for use as an Isolated RS-485 port or is factory set for use as a RS-232 port.

CI-ControlWaveRED Introduction / 1-7

This port is referenced as COM3. Note: COM3 will be configured for RS-485 operation
on SCB’s configured with one RS-232 and one RS-485 port.

Ethernet Port Connectors J4, J5 (SCB) and J7 (SCB)

Up to three Ethernet ports are supported via 8-pin RJ-45 connectors. The 10/100Base-T
Ethernet interfaces are implemented using AMD Am79C973 Pcnet - FAST III controllers.
These devices logically reside on the PCI bus and are wired for full bus-mastering
capability and provide a full-duplex implementation. The Ethernet Port associated with J4,
J5 (SCB) and J7 (SCB) are assigned as PCI devices 1, 2 and 3 respectively and are assigned
PCI interrupts A, B and C respectively.

CPU Board I/OB Connector J1

CPU Board I/O bus connector J1 provides a 132-pin interface between Backplane PCB slot
#2 (P2) or #4 (P4) and the CPU Module (CPUA or CPUB respectively).

CPU Board Battery Connector J10

CPU Board connector J10 provides a 3-pin interface to an external 3.6V Lithium Battery
that is a component of the CPU Module. The 3.6V, 950mA-hr lithium ½ AA cell battery
provides backup power for the real-time clock, CMOS RAM and the system’s Static RAM
(SRAM). Battery backup is enabled when CPU Module switch SW3-4 is set to the ON
position.

1.3.1.2 CPU Module Switches

Cutouts are provided in the CPU Module to provide user access to the configuration
switches. Two user configurable DIP switches are provided on the CPU Board; eight-bit DIP
switch SW1 is provided for user configuration settings while four-bit DIP switch SW3
provides battery back-up and forced recovery functions. The optional Secondary
Communications Board (SCB) has two eight position DIP switches (one per communications
port) that provide loopback control for RS-232 ports or loopback, termination control, and
receiver bias settings for isolated RS-485 ports.

The CPU Module’s RUN/REMOTE/LOCAL Switch is set via a removable key. This switch
can be identified by a removable key that allows the user to set the unit as follows: When
set to ‘RUN,’ this switch prevents the user from performing any ControlWave Designer
Debug/Program operations such as Start/Stop, download of application, etc. Use of the
‘LOCAL’ or ‘REMOTE’ setting depends on the type of network connection the Comm. Port
in question has been configured for, via ControlWave Designer (Port selection can be IP,
Serial or OpenBSI). If a Comm. Port has been configured for IP or OpenBSI (BSAP)
communications, it is considered a remote port and the RUN/REMOTE/LOCAL Switch
should be set to ‘REMOTE’ to receive a Debug or Program download. However, if the
Comm. Port in question has been configured for Serial communications, it is considered a
local port and the RUN/REMOTE/LOCAL Switch should be set to ‘LOCAL’ to receive a
Debug/Program download.

The Reset Switch allows the user to reset (stop and restart) the unit during maintenance
routines or as required.

1-8 / Introduction CI-ControlWaveRED

Table 1-2 - Assignment of CPU Bd. Switch SW1 - User Configurations

Switch Function Setting - (ON = Factory Default)

SW1-1

SW1-2

SW1-3

SW1-4

SW1-5 SRAM Control

SW1-6

SW1-7 Unit A/Unit B ON = CPU assigned as ‘A’ CPU - OFF = CPU assigned as ‘B’ CPU

SW1-8

Watchdog
Enable
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
(see Section 3.6)

Redundancy
Enable/Disable

Enable
WINDIAG

ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump via use of Run/Remote/Local Key Switch
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Redundancy Disabled
OFF = Redundancy Enabled

ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)

Table 1-3 - Assignment of CPU Bd. Switch SW3

Firmware Load Control/Recover Mode/Battery Enable

Switch Function Setting

SW3-1 Not Used

SW3-2

SW3-3 Force Recovery Mode

SW3-4 SRAM & RTC Battery Enable

* = Boot PROM version 06 or higher and System PROM version 4.7 or higher

System Firmware
Load Control *

ON = Disable remote download of System Firmware
OFF = Enable remote download of System Firmware
ON = Force recovery mode (via CW Console)
OFF = Recovery mode disabled
ON = Battery back-up enabled
OFF = Battery back-up disabled

Table 1-4 - SCB Port Switches SW1 = COM3 & SW2 = COM4

Loopback & Termination Control

Switch# RS-232 Function

Switch ON

1 DTR to DSR Loopback TX+ to RX+ Loopback ON - Only for Diagnostics
2 TXD to RXD Loopback TX- to RX- Loopback ON - Only for Diagnostics
3 N/A 100 Ohm RX+ Termination ON - End Nodes Only
4 N/A 100 Ohm RX- Termination ON - End Nodes Only
5 RTS to CTS Loopback N/A ON - Only for Diagnostics

6 N/A

7 N/A RX+ Bias (End Node) ON - End Nodes Only
8 N/A RX- Bias (End Node) ON - End Nodes Only

RS-485 Function

Switch ON

Slow Slew Rate - ON = Fast
OFF = Slow

Setting

ON/OFF - As required
Factory Default = ON

1.3.1.3 CPU Module System Battery

The CPU Board connects to an external battery via a three-pin connector (J10). This 3.6V,
950mA-hr lithium ½ AA cell (battery) provides backup for the real-time clock, CMOS RAM
(within the microprocessor), and the System SRAM.

CI-ControlWaveRED Introduction / 1-9

The system SRAM is specified to have a standby current of 50:A maximum for each part.
For a system containing 2MB of System SRAM, a worst-case current draw of 210:A allows
a battery life of approximately 4524 hours, while for a system containing 4MB of System
SRAM a worst-case current draw of 410:A allows a battery life of 2317 hours.

A supervisory circuit is used to switch to battery power when VCC falls below VCC-10%.
For maximum shelf life, the battery may be isolated from the circuit by setting switch SW3­4 (on the CPU Board) to the OFF position. If the Real-time clock looses its battery backup a
ControlWave Designer system variable bit (_QUEST_DATE) is set. This bit can be used to
post a message or alarm to the PC (see the ‘System Variables’ section of the ControlWave
Designer Programmer’s Handbook D5125).

1.3.1.4 CPU Module LEDs and Port 80 Display

All CPU Modules have eight (8) LEDs on the CPU Board. Units equipped with the optional
Secondary Communications Board (SCB) have eight (8) additional LEDs. Additionally, all
CPU Modules are provided with a Port 80 Display assembly consisting of two TI TIL311
Displays that are visible from the front of the CPU Module. The Port 80 LED Display
assembly provides POST codes during system boot as well as run time status indication.
During normal system operation, the Port 80 Display is powered down.

Figure 1-5 - CPU Module LEDs

1.3.1.5 CPU Module Memory Summary

A brief synopsis of CPU Module Memory is provided below.

Boot-Block FLASH BIOS

512 kbytes contained in a single IC. BIOS that runs the CPU Board is contained in this
device. The BIOS is contained in a single 512 kbyte Uniform Sector FLASH (USF) IC. This
device resides on the General Purpose (GP) bus, operates at 3.3V and is configured for 8-bit
access.

1-10 / Introduction CI-ControlWaveRED

Switch SW3-3 provides for forced update/recovery of the BIOS if SW3-3 has been set to the
ON position when a reset occurs. The boot-up code passes control to the built-in Recovery
Command Processor that communicates with the user via the recovery serial connection
and a terminal program running on an external host computer.

FLASH Memory

4 Mbytes to 64 Mbytes simultaneous read/write (non-volatile) FLASH mounted in up to 4
48-pin TSOPs. The System Firmware and the Boot Project are stored here. The FLASH
memory is a linear array of 16 Mbit parts configured for 32-bit, 16-bit or 8-bit read access
(32-bit write access) and is connected to the SDRAM bus. No hardware write protection is
provided for the FLASH array.

Static RAM Memory (SRAM)

2 Mbytes of soldered-down static RAM (SRAM) is implemented with four 512K x 8
asynchronous SRAMs that are configured as a 1M x 16-bit array. Each SRAM device
operates at 3.3V and is packaged in a 32-pin TSOP. An additional 2Mbytes of SRAM may
be factory installed. SRAM is placed into data retention mode (powered by a backup 3.6V
lithium battery) when power is lost. The SRAM supports 16-bit or 8-bit accesses and is
connected to the GP bus. Critical system information that must be retained during power
outages or when the system has been disabled for maintenance is stored here. Data in­cludes: Last states of all I/O, historical data, retain variables and alarm messages not yet
reported.

Synchronous Dynamic RAM (SDRAM)

4 Mbytes of on board Synchronous Dynamic RAM (SDRAM) (2 x KM416S1120DT). The run
application and a copy of system firmware are stored here. This allows the system to run
faster than it would from the FLASH memory. SDRAM is not battery-backed.

CMOS RAM

RAM internal to the CPU Module’s AMD Elan SC520 Microprocessor. This RAM data is
loaded from BIOS. 10 bytes are provided for RTC alarm and calendar parameters and 114
bytes are provided as configuration parameters.

1.3.2 Power Supply/Sequencer Module

Power Supply/Sequencer Modules (PSSM) plugs into the system’s Backplane Board
(Connector P1 and P3) via their Compact PCI (CPCI) type keyed 132-pin connector J1. The
front of the PSSM contains a system power switch, as well as two pluggable terminal blocks
for external input power and watchdog MOSFET switch connections. Three LEDs, visible
through the front panel, provide the following status conditions: PWRGOOD (power good:
green), MC (master clear active: red) and PWRFAIL (power fail: red)

PSSMs contain a DC to DC Converter that generates isolated +5Vdc for the CPU and CCRS
Modules and isolated +12Vdc for the CCRS Module. A piggy-back converter board provides
isolated +3.3Vdc required for CPU logic, memory and FLASH devices.

Also contained on the PSSM is the sequencer circuit that monitors the incoming power as
well as the isolated output supplies and has a reset/early power fail warning controller that
interfaces with the system CPU Module. Master Clear and Power Fail signals are
generated by the sequencer circuit when incoming power or the isolated supply voltages fall
below specified limits. Additionally, the sequencer circuit controls an on-board watchdog
MOSFET switch that will open when Master Clear is active or the CPU Module asserts the
Watchdog Bad signal.

CI-ControlWaveRED Introduction / 1-11

The power supply operates from bulk inputs of +10.6 to +20V or +20.7 to +30V (dc) with the
nominal input supply configuration (12V or 24V) factory set by on-board jumpers. A
supervisory circuit monitors the incoming power and the isolated supply voltages. The
isolated supplies are shut down when the incoming voltage drops below +10.6V for a +12V
system or +20.7V, for a +24V system.

Figure 1-6 - Power Supply/Sequencer Module

The circuit that drives the watchdog MOSFET switch is on the secondary (isolated) side of
the power supply. A solid state relay (SSR) actuates the watchdog hardware and is factory
enabled or disabled via an on-board jumper. When either /MC or /WDOGB is active, the on­board watchdog hardware will be OFF. /WDOGB is a signal generated by the CPU Module
when its hardware detects improper software operation.

The watchdog MOSFET switch is powered via the VI input of the terminal block and its
switched output is connected to the VO/NO output of the terminal block. The external
power source connected to the COM terminal must be referenced to the return point of the
input source that powers the PSSM (-VIN (PSGND)).

1-12 / Introduction CI-ControlWaveRED

Figure 1-7 - Power Supply/Sequencer Module Block Diagram

1.3.2.1 PSSM Power Switch SW1

Switch SW1 is used to connect input power to the PSSM circuitry via Controlled Power
MOSFETs when the ‘I’ side of the switch has been pressed to its actuated position. This will
turn the unit ON.

1.3.2.2 PSSB Board Fuse

The PSSM contains Fuse F1 that isn’t field replaceable. Slow Blow Fuse F1 is rated at 3A
for a +12V/24V system - protects the entire system.

1.3.2.3 PSSB Board Connectors

Connectors TB1, TB2 and J1 function as described below.

CI-ControlWaveRED Introduction / 1-13

PSSB Bd. Terminal Block Connector TB1
TB1 provides 2 watchdog MOSFET switch connections:

TB1-1 = VO - Watchdog MOSFET Switch Output
TB1-2 = VI - Watchdog MOSFET Switch Input
TB1-3 = Not Used with ControlWaveRED

PSSB Bd. Terminal Block Connector TB2

TB2 provides 5 input connections for bulk power:

TB2-1 = (+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
TB2-2 = (+VINF) Field Supply - Not Used
TB2-3 = (-VIN) (1st Supply Ground)
TB2-4 = (-VINF) (2nd Supply Ground) - Not Used
TB2-5 = Chassis Ground - CHASSIS (

)

PSSB Bd. Connector J1

Connector J1 is a 132-pin keyed CPCI type connector that interfaces Power, Ground and
Master Clear(s), power supply status (/PWR_FAIL) and watchdog status (/WDOGB) signals
to Connector P1 on the Backplane Board.

1.3.2.4 PSSM LEDs

Three LEDs, visible through the front panel, will provide status conditions PWRGOOD
(power good: green), MC (master clear active: red) and PWRFAIL (power fail: red). When
power is first applied or when the unit is reset, the red MC LED will illuminate for a short
period of time. The green PWRGOOD LED should be ON whenever the unit is running and
no power problems have been detected. The red PWRFAIL LED should only be ON when
power has dropped below acceptable levels.

1.3.3 ControlWaveRED CPU & Comm. Redundancy Switch Module

The CPU & Communications Redundancy Switch (CCRS) Module is a system module that
interfaces to a redundant pair of Power Supply/Sequencer and CPU modules via the
ControlWaveRED CPU & Communications Redundancy Backplane (CCRB). The CCRS
Module provides either automatic or manual selection of the primary controller CPU in the
case of hardware failure. The CCRS Module will also switch up to four serial
communications ports to the selected primary CPU of the redundant pair. Multiple power
sources within the CCRS ensure system viability. Backplane interconnects convey power,
power sequencing, watchdog hardware control, primary CPU selection and respective serial
communications port selection control for redundancy purposes.

CCRS Module hardware implements a front panel user interface, module/system status
indicators and selected (primary) CPU communication port switching to front panel
mounted 9-pin male D-type connectors. Triple replicated system logic circuitry and the
multiple CCRS Module power supply circuits provide a high level of tolerance to
miscellaneous hardware faults.

The CCRS Module transfers control of the process and communication from one CPU to the
other CPU in the event the first CPU fails. Redundancy is recommended for plants or
processes where a loss of control could result in damage or injury. The process of
transferring control from one CPU to the other CPU is referred to as fail-over. A fail-over
from one CPU to the other typically falls into one of two categories:

1-14 / Introduction CI-ControlWaveRED

Hardware failures - These could occur from a variety of causes:

• loose cable

• improper configuration, e.g. board not seated properly

• power supply failure (no power for CPU)

• individual board or component breakdown

Software failures - Possible causes include:

• application program running in the CPU ‘crashes’ as indicated by ‘FF’ on the display

• all tasks are suspended for more than a user-configurable number of milliseconds

• a task watchdog occurs (this option can be user enabled/disabled)

• user-created logic for detection of a particular failure is activated, triggering a

switchover via a REDUN_SWITCH function block

When redundant CPUs are used, these sorts of failures trigger a watchdog relay, and
cause a fail-over from the on-line CPU that failed to a standby backup CPU. The
standby CPU has been configured to be a nearly exact duplicate of the on-line CPU, so that
it can assume full control over the process previously controlled by the failed CPU, and
becomes the new on-line CPU.

Figure 1-8 - Perspective View of CPU & Comm. Redundancy Switch Module

CI-ControlWaveRED Introduction / 1-15

Figure 1-9 - Front View of CPU & Comm. Redundancy Switch Module

1.3.3.1 CCRS Module Switches

A/B Primary Controller Select Switch - 2-position - selects the primary controller, i.e.,

CPU A (UNIT A) or CPU B (UNIT B) at CCRS Module power up only

if the A/B Enabled
Mode Select Switch has been set in the automatic selection (centered) position. The
selected CPU Module will be chosen as the primary system controller if the CCRS Module’s
logic determines it is ready for on-line duty. Otherwise, the alternate CPU will be selected if
it is OK.

A/B Enable Key Switch - 3-position - used to determine whether the primary CPU
selection is forced to CPU A (UNIT A) or CPU B (UNIT B) or is automatically selected
(Center). Forced primary selection is useful for diagnostic purposes, where a failed CPU
Module may be placed on-line for debugging.

1-16 / Introduction CI-ControlWaveRED

1.3.3.2 User Accessible CCRS Module Connectors

Front of CCRS Module (see Figures 1-8 and 1-9):

Connector J1 - Switched COM1 Port - 9-pin D-Type Male RS-232 - represents COM1 of the

selected CPU Module.

ConnectorJ2 - Switched COM2 Port - 9-pin D-Type Male RS-232 - represents COM2 of the

selected CPU Module.

Connector J3 - Switched COM3 Port - 9-pin D-Type Male RS-232/485 - represents COM3 of

the selected CPU Module.

Connector J4 - Switched COM4 Port - 9-pin D-Type Male RS-232/485 - represents COM4 of

the selected CPU Module.

Connector J5 - CPU A Comm. Ports Interface Cable Header - 2 x 25 Male, Shrouded &

Polarized

Connector J6 - CPU B Comm. Ports Interface Cable Header - 2 x 25 Male, Shrouded &

Polarized

Connector J7 - Isolated On-Line Status Outputs - 4-pin pluggable (Screw Clamp) - Provides

A & B pairs of relay driven Normally Open (NO) & Common (COM) outputs

Rear of CCRS Module:

Connector J1 - CCRS/CCRB Slot A 50-pin Ribbon Cable Header - Interface to Backplane

REDSWA Connector P5.

Connector J2- CCRS/CCRB Slot B 50-pin Ribbon Cable Header - Interface to Backplane

REDSWB Connector P6.

1.3.3.3 CCRS Module Status LEDs

UNIT A ON-LINE LED - Green - ON means CPUA is on line
UNIT A FAIL LED - Red - ON means CPUA has failed - If blinking means CCRS Slot

A cable is not attached or is defective

UNIT B ON-LINE LED - Green - ON means CPUB is on line
UNIT B FAIL LED - Red - ON means CPUB has failed - If blinking means CCRS Slot

B cable is not attached or is defective

POWER SYSTEM STATUS LEDs A & B - Red/Green
ON Green means Power is good
ON Red means Power is defective

1.3.4 ControlWaveRED Backplane

The ControlWaveRED Backplane provide for the interconnection of the Power Sup­ply/Sequencer Modules (PSSMs), CPU Modules and the CPU & Communications
Redundancy Switch Module (CCRSM). PSSM and CPU module slot connections are im­plemented with Compact PCI (CPCI) type connectors. Connections to the CPU &
Communications Redundancy Switch Module are implemented via two 50-pin ribbon cable
headers. The two ribbon cables connected between the Backplane and the rear of the
CCRSM accommodate the interconnection of PSSMA & PSSMB provided regulated logic
power, regulated relay power and Master Clear A/B signals, CPUA and CPUB provided
Watch Dog A/B signals, and CCCRSM provided On-Line/BackupA and On-Line/BackupB
control signals.

CI-ControlWaveRED Introduction / 1-17

Figure 1-10 - ControlWaveRED Backplane Assembly

Figure 1-11 - Backplane PCB Block Diagram

1-18 / Introduction CI-ControlWaveRED

Isolated power (+ 3.3V, +5V, +12V, -12V and PCOM) from the associated PSSM is con­nected to the CPU. The power supply monitor/sequencer circuit (within the PSSM) provides
/MC and PWR_FAIL signals to the CPU thus providing properly timed early warning of low
input or supply voltages followed by a CPU reset to support the WARM START CPU
function. The watchdog circuitry on the PSSM is controlled by CPU signal /WDOGB.

Connectors P1 through P4 are equipped with connector coding devices. These color-coded
devices are physically unique to ensure that only the correct module type can be installed.
Modules are equipped with mating connector coding devices (yellow for PSSM and blue for
CPU) that provide the service technician with a quick visual indication of the backplane
slot(s) where the module in question can physically reside.

1.3.5 ControlWaveRED Chassis

The ControlWaveRED Backplane PCB and the modules that comprise the system are
housed in a Stainless Steel Chassis. Any ControlWaveRED Chassis can be panel/wall
mounted. ControlWaveREDs can also be mounted to a 19-inch equipment rack by using
BBI supplied Filler Panels. ControlWaveRED Chassis are factory shipped with only the
CCRSM and ribbon cables installed. The Chassis assembly also contains a Ground Lug that
accommodates up to a #4 AWG Ground Wire. Grounding the unit is accomplished by
connecting a ground wire between the Ground Lug and a known good Earth Ground.

Figure 1-12 - ControlWaveRED Chassis and Comm. Cabling Diagram

CI-ControlWaveRED Introduction / 1-19

Two special communication cable assemblies provide for interconnection of CPUA’s and
CPUB’s Comm. Ports with the CPU & Communications Redundancy Switch Module.

1-20 / Introduction CI-ControlWaveRED

Section 2

INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS

ControlWave Redundant Controllers are not furnished in a closed or sealed housing. The

modules that comprise the system are housed in a Stainless Steel Chassis. The Chassis can
be panel or wall mounted. Mounting in a 19-inch equipment rack is possible with the use of
a Bristol supplied Filler Panel. Use in Class I, Division 2, Groups A, B, C and D hazardous
areas will require the selection of an appropriate enclosure that meets the NEMA Type 3X
or 4X specification.

Figure 2-1 - ControlWaveRED - Mounting Diagram

CI-ControlWaveRED Installation & Operation / 2-1

Figure 2-2 - ControlWaveRED Rack Mount Filler Panel Dimensions

2.2 ControlWaveRED INSTALLATION SITE CONSIDERATIONS

Check all clearances when choosing an installation site. Make sure that the Control-
WaveRED Controller will be accessible for wiring and service. To install the

ControlWaveRED Chassis, see Section 2.3.1.

2.2.1 Temperature & Humidity Limits

ControlWaveRED Controllers have been designed to operate over a -40°F to +158°F (-40°C

to +70°C) temperature range (with storage at up to +185°F (+85°C)) and a 15% to 95% Non­condensing Relative Humidity range. Make sure that the ambient temperature and
humidity at the measuring site remains within these limits. Operation beyond these ranges
could cause output errors and erratic performance. Prolonged operation under extreme
conditions could also result in failure of the unit.

2.2.2 Vibration Limits

Check the mounted enclosure, panel or equipment rack for mechanical vibrations. Make
sure that the ControlWaveRED Controller is not exposed to a level of vibration that
exceeds those given in the specifications. The ControlWaveRED’s vibration limits are 1g
for 10 - 150 Hz & .5g for 150 - 2000 Hz.

2-2 / Installation & Operation CI-ControlWaveRED

2.3 ControlWaveRED INSTALLATION/CONFIGURATION

ControlWaveRED Controllers are shipped from the factory fully assembled and consisting

of the following components:

Chassis Assembly - (with two CCRS interface ribbon cables) and the CCRSM.
Power Supply/Sequencer Module A
CPU Module A & Bezel - (with special Comm. cable)
Power Supply/Sequencer Module B
CPU Module B & Bezel - (with special Comm. cable)

Overview of Configuration

An overview of the eight (8) steps required to configure a ControlWaveRED Controller are
provided below. Also see the ControlWave Redundancy Setup Guide

Step 1. Initial Hardware Installation & Configuration

This involves unpacking the ControlWaveRED hardware, mounting the chassis, installing
external power source wiring, wiring the Isolated On-line Status Outputs, making proper
ground connections, connecting a communication cable to the PC workstation and setting
CPU Module switches (to enable the backup batteries). To install and configure the
ControlWaveRED Controller to receive its application load follow steps 1 through 13
below:

1. Remove the Chassis from its carton and install it at its assigned work site (see

Section 2.3.1).

2. Install a ground wire between the Chassis Ground Lug and a known good Earth

Ground (see Section 2.3.1.1).

3. Remove CPU Module A from Chassis slot # 2 and set Switch SW3-4 ON to enable

the backup battery. Replace CPU Module A into Chassis slot # 2. All other Switches
are factory configured (see Section 2.3.3 for CPU Switch settings).

4. Remove CPU Module B from Chassis slot # 4 and set Switch SW3-4 ON to enable

the backup battery. Replace CPU Module B into Chassis slot # 4. All other Switches
are factory configured (see Section 2.3.3 for CPU Switch settings).

5. Install Watchdog MOSFET Switch wiring to each PSSM Module (see Section

2.3.4.1.3).

6. Connect Bulk DC Power to the ControlWaveRED’s PSSM Modules but don’t apply

power at this time (see Sections 2.3.4.1 through 2.3.4.1.2).

7. Install the Bezels so that each one covers its associated PSSM and CPU Modules

(see Section 2.3.6).

8. Install the special serial communications cable between the four serial com-

munications ports on CPU Module A and connector J5 on the front (left) of the
CCRSM. Install the special serial communications cable between the four serial
communications ports on CPU Module B and connector J6 on the front (right) of the
CCRSM.

9. Connect COMM. Port 2 of the ControlWaveRED’s CCRSM to a COMM. Port of a

PC (typically PC COMM. Port 1

10. Set the CCRSM’s A/B Enable Key Switch to either the ‘A’ or ‘B’ position.

11. Set the selected CPU’s RUN/REMOTE/LOCAL Switch to the LOCAL position (see

Section 2.4.3).

12. Install an Ethernet cable between one of the Ethernet Ports on CPU Module A and

an Ethernet Hub. Install an Ethernet cable between the same Ethernet Hub and the

- D5123.

CI-ControlWaveRED Installation & Operation / 2-3

Ethernet Port on CPU Module B with the same designation, i.e., Ethernet Port 1
(E1), Ethernet Port 2 (E2) or Ethernet Port 3 (E3). Or install a direct point-to-point
Ethernet cable (see Figure 2-13) between CPU A and CPU B Ethernet Ports of the
same designation.

13. Apply power to the ControlWaveRED Controller by setting the Power Switch on

both PSSM Modules to the ‘I’ position. After receiving the application load (see

Steps 2. through 7. and Section 2.4.1), you must perform Step 8. before the
ControlWaveRED Controller will be ready for on line operation. Note: The CPU
that wasn’t selected (via the CCRSM’s A/B Enable Key switch in step 10)
will automatically receive its application load via an Ethernet side-load.

Step 2. Software Installation on the PC Workstation

ControlWave Designer software must be installed on the PC workstation. This is ac-

complished by installing the ControlWave Designer Package from the Open BSI CD
ROM.

If you will be including the ControlWaveRED in an Open BSI network that requires
Netview software, you should also install the Open BSI Network Edition.

For information on minimum system requirements and more details of the installation, see
the installation procedure in Chapter 2 of the Open BSI Utilities Manual (document #
D5081).

If you have an older version of ControlWave Designer already installed:

Beginning with ControlWave Designer Version 3.3, the copy protection key (dongle) is
NOT required. Prior to installing ControlWave Designer 3.3 or newer, you MUST remove
the hardware dongle from the parallel port of your PC workstation. Otherwise, when you
subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will
limit the available system resources.

IMPORTANT:

When you start ControlWave Designer, you will be reminded to register the software.
Unregistered software can only be used for a maximum of 30 days. For more information on
the registration process, see Chapter 2 of the Open BSI Utilities Manual (document#
D5081).

Step 3. Establish Communications using either LocalView or NetView, and Run

the Flash Configuration Utility

Communications must be established with the ControlWaveRED using either LocalView
or NetView.

Once communications have been established, the Flash Configuration Utility must be run,
in order to configure user account parameters, and to configure the ControlWaveRED
communication ports. An overview of this process (‘Establishing Communications’) is in­cluded in the ControlWave Redundancy Setup Guide (document # D5123). Detailed infor­mation on the Flash Configuration Utility, and LocalView is included in Chapter 5 of the
Open BSI Utilities Manual (document # D5081). NetView is described in Chapter 6 of
D5081.

2-4 / Installation & Operation CI-ControlWaveRED

Step 4. Create a Redundant Project or use the Sample Redundant Project in

ControlWave Designer

At this point, use ControlWave Designer to create a redundant project, or use the sample
redundant project provided on the Open BSI CD-ROM (RDNSAMPLE.ZWT).

For general help on creating ControlWave projects, see the ControlWave Quick Setup Guide
(document # D5084) and the Getting Started with ControlWave Designer Manual (document
# D5085).

For details about configuring the redundancy status variables in the project, see the
‘Testing the Redundant Setup’ section of the ControlWave Redundancy Setup Guide
(document # D5123).

NOTE:

From this point on, the order of steps may be varied, somewhat,
depending upon the requirements of the user's application.

Step 5. Create Application-Specific Web Pages (OPTIONAL)

The ControlWaveRED Controller supports a set of standard web pages for configuration
purposes (stored on a PC). These web pages also provide access to communication statistics
maintained in the controller.

Optionally, additional user-created web pages may be created to allow a customized
human-machine interface. A series of ActiveX controls for data collection and configuration
are provided on the Open BSI CD which can be included as part of these user-created web
pages. For information on the ActiveX controls, see the Web_BSI Manual (document #
D5087).

You can use whichever HTML creation package you want to create the pages, however, all
ControlWave related web pages (whether standard or user-created) must be viewed within
Microsoft® Internet Explorer. Web pages are stored on a PC workstation.

Step 6. Create an Open BSI Network Containing the ControlWaveRED Unit, or

ADD the ControlWaveRED unit to an Existing Open BSI Network

In order for the ControlWaveRED Controller to function as part of a Bristol network, it is
necessary to include it in the Bristol network.

If no Bristol network exists:

You will need to start Open BSI’s NetView software on the PC workstation in order to
define a Bristol network. A series of software wizards are used to define a Network Host
PC, a network, and the RTUs (controllers) belonging to the network. Finally,
communication lines must be specified which handle the address assigned to the
ControlWaveRED Controller. Chapters 3 and 4 of the Open BSI Utilities Manual
(document # D5081) include ‘quick start’ examples for performing these steps. More
detailed information is included in the NetView chapter (Chapter 6) of the same
manual.

CI-ControlWaveRED Installation & Operation / 2-5

If a Bristol network already exists:

You will need to add the ControlWaveRED Controller to the existing network using
Net-View’s RTU Wizard. Chapter 6 of the Open BSI Utilities Manual (document #
D5081) includes different sub-sections depending upon whether you are adding the unit
to a BSAP network, or an IP network.

NOTE: When configuring the ControlWave Redundant Controller in NetView, it

should be defined as a single RTU that has two IP addresses. See
‘Communications Redundancy’ in the ‘Additional Configuration’ section
of the ControlWave Redundancy Setup Guide (document # D5123).

Step 7. Download Your Redundant Project Into the ControlWaveRED Unit

Either ControlWave Designer or the Open BSI 1131 Downloader allows you to download
your completed redundant project into the ControLWaveRED unit. Users must download
the project into the boot project area of FLASH memory.

To download the application load, see Section 2.4.1.

Step 8. Final Hardware Installation & Configuration

To complete the hardware installation of the ControlWaveRED Controller follow steps 1
through 6 below:

1. Shut off power at PSSM A and PSSM B.

2. Install serial communication port connections (required for the application) between
the D-Type connectors on the CCRSM and the remote device, i.e., Process
Automation Controller, PC, etc. (see Sections 2.3.3.2 and 2.3.3.3).

3. Install Ethernet connections to CPU Module A and CPU Module B as required for

your application (see Section 2.3.3.4).

4. Install field wiring between the CCRSM’s Isolated On-Line Status Output connector

(J7) and the associated field device (see Section 2.3.4.2).

5. Set the RUN/REMOTE/LOCAL Switch to RUN position (see Section 2.4.3).

6. Apply power to the ControlWaveRED Controller by setting the Power Switch on

both PSSM Modules to the ‘I’ position.

2.3.1 Mounting the ControlWaveRED Chassis

ControlWaveREDs can be mounted to a panel or a wall. Mounting in a 19-inch equipment

rack is possible with the use of a BBI supplied Filler Panel. Mounting hole patterns are
provided in Figures 2-1 and 2-2. ControlWaveRED units are factory shipped with the End
Plates configured for rack mounting. A Rack Mount Extension must be added to either side
to accommodate 19-inch rack mounting. When mounting one of these units to a panel or
wall, it is to be positioned in accordance with the following restrictions:

- The End Plates must be removed, rotated 180° and then reinstalled to accommodate

panel or wall mounting. Hole patterns and dimensions are provided in Figure 2-1.

- The unit must be positioned so that the front of the assembly is visible and the unit is

accessible for service, i.e., installing an option or replacement of the Lithium Battery,
or installation/removal of any module.

- ControlWaveRED CPU and PSSM Modules should not be installed until the unit’s

Chassis has been mounted and grounded at a designated work site.

2-6 / Installation & Operation CI-ControlWaveRED

2.3.1.1 ControlWaveRED Grounding

ControlWaveRED Chassis are provided with a Ground Lug that accommodates up to a #4

AWG wire size. A ground wire must be run between the Chassis Ground Lug and a known
good Earth Ground. The cases of the various ControlWaveRED Modules are connected to
Chassis Ground when they have been installed and secured via their Captured Panel
Fasteners. As an extra added precaution, it is recommended that a #14 AWG wire be run
from PSSM Power Connector TB2-5 (Chassis Ground) to the same known good Earth
Ground. The following considerations are provided for the installation of Control-
WaveRED system grounds:

• Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is recommended

that stranded copper wire is used and that the length should be as short as possible.

• This ground wire should be clamped or brazed to the Ground Bed Conductor (that is

typically a stranded copper AWG 0000 cable installed vertically or horizontally).

• The wire ends should be tinned with solder prior to insertion into the Chassis Ground

Lug. Note: Use a high wattage Soldering Iron.

• The ground wire should be run such that any routing bend in the cable has a minimum

radius of 12-inches below ground and 8-inches above ground.

• Supplement Guide S1400CW - Site Considerations for Equipment Installation,

Grounding & Wiring provides additional information on grounding and Isolation.

2.3.2 Power Supply/Sequencer Module (PSSM) Configuration

Each Power Supply/Sequencer Module (PSSM) must be in place prior to the installation of
its associated CPU Module, i.e., installed in slot # 1 for PSSMA or slot # 3 for PSSMB (see
Figures 2-4 & 2-5). Power and Watchdog wiring can be performed at this time, however; for
safety reasons and to prevent accidental damage to the user’s bulk DC Power Supply(s), it
is recommended that pluggable Terminal Block connectors TB1 and TB2 (associated with
each PSSM) are not connected to the PSSMs until the CPU Modules have been wired, and
hardware configured. Section 2.3.4.1.3 provides details on Watchdog Connector TB1 wiring
and Section 2.3.4.1.2 provides details on DC Power Connector TB2 wiring.

Figure 2-3 - ControlWaveRED Prior to Installation of PSSMs

CI-ControlWaveRED Installation & Operation / 2-7

Figure 2-4 - PSSMs Installed in ControlWaveRED Slots #1 and #3

Figure 2-5 - PSSMs & CPUMs Installed in ControlWaveRED Slots #1 through #4

2.3.3 CPU Module Configuration

To configure the CPU Modules, DIP Switches must be set (see Section 2.3.3.1) and Com­munication Ports must be wired (see Sections 2.3.3.2 through 2.3.3.4). The CPU Modules
reside in slot # 2 and slot # 4 (see Figure 2-5).

2-8 / Installation & Operation CI-ControlWaveRED

2.3.3.1 CPU Module Switch Configuration

ControlWave CPU Module DIP Switches are factory configured for redundancy operation

with System A assigned to the PSSMA and CPUA (installed in slots # 1 & 2 respectively)
and with System B assigned to the PSSMB and CPUB (installed in slots # 3 & 4
respectively). CPUs leave the factory with the backup battery disabled. Set Switch SW3-4
(on both CPUs) to the ON position to enable the backup battery. Tables 2-1 and 2-2 provide
an overview of switch settings.

Table 2-1 - CPU Bd. Switch SW1 - User Configurations

Switch Function Setting - (Bold = Factory Default)

SW1-1 Watchdog

Enable

SW1-2

SW1-3

SW1-4

SW1-5 SRAM Control

SW1-6

SW1-7 Unit A/Unit B

SW1-8

Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6

Redundancy
Enable/Disable

Enable
WINDIAG

ON = Watchdog circuit is enabled

OFF = Watchdog circuit is disabled

ON = Write to Soft Switches and FLASH files

OFF = Soft Switches, configurations and FLASH files are locked

ON = Use Soft Switches (configured in FLASH)

OFF = Ignore Soft Switch Configuration and use factory defaults

ON = Core Updump Disabled

OFF = Core Updump Enabled (use Run/Remote/Local Switch)

ON = Retain values in SRAM during restarts

OFF = Force system to reinitialize SRAM
ON = Redundancy Disabled

OFF = Redundancy Enabled
ON = CPU assigned as ‘A’ CPU - OFF = CPU assigned as ‘B’ CPU
ON = Normal Operation (don’t allow WINDIAG to run test)

OFF = Disable boot project (allow WINDIAG to run test)

SW1-1 set OFF will disable the system from entering a watchdog state when a crash or
system hangup occurs. Setting SW1-1 OFF prevents the system from automatically
restarting. - Factory Set ON

SW1-2 set OFF prevents changing the Soft Switches, other configurations and FLASH files,
i.e., these items are locked. To change Soft Switch, configuration and FLASH files SW1-2
must be set to the ON position (see Section 2.4.7). - Factory Set ON

SW1-3 set OFF forces the use of Soft Switches as set per factory default (see Section 2.4.7).
For use of user defined Soft Switches, SW1-3 must be set to the ON position. Note: If both

SW1-3 and SW1-8 are set OFF (closed), communication ports COM1 through COM4 will be
set to 9600 bps operation. - Factory Set ON

SW1-4 set OFF and used in conjunction with a properly sequenced Run/Remote/Local
Switch will cause the ControlWaveRED CPU to perform a Core Updump (see Section

3.6). - Factory Set ON

SW1-5 set OFF forces the ControlWaveRED CPU to reinitialize SRAM when the unit
recovers from a low power or power outage condition. When set ON, the contents of SRAMS
will be retained and utilized when the system restarts. - Factory Set ON

SW1-6 set ON will disable the redundancy feature of the ControlWaveRED but will allow
the CPU to run as the forced application controller. Set SW1-6 to the OFF position for
normal operation. When it is necessary to run a non-redundant application (because of a
defective CCRS Module or the other redundant system’s PSSM or CPU, or while
troubleshooting, etc.) place SW1-6 to the ON position. - Factory Set OFF

CI-ControlWaveRED Installation & Operation / 2-9

SW1-7 set OFF will assign the CPU to System ‘B.’ Place SW1-7 to the ON position when it
is desired to utilize the CPU in System ‘A.’ Note: System ‘A’ CPU must reside in Slot #2 and

System ‘B’ CPU must reside in Slot #4. - Factory Set - CPUA ON - CPUB OFF

Figure 2-6 - CPU Module Switches SW1 & SW3

SW1-8 set OFF prevents the ‘Boot Project’ from running and places the unit into diagnostic
mode. SW1-8 must be set OFF to run the WINDIAG program resident on the local PC (see
Section 3.5). When SW1-8 has been set ON, diagnostics are disabled. SW1-8 must be set to
the ON position for normal system operation, i.e. for the Boot project to run. Note: If both

SW1-3 and SW1-8 are set OFF (closed), communication ports COM1 through COM4 will be
set to 9600 bps operation. - Factory Set ON

Table 2-2 - CPU Bd. Switch SW3

Firmware Load Control/Recovery Mode/Protect/Battery Enable

Switch Function Setting

SW3-1 Not Used

SW3-2

SW3-3 Force Recovery Mode

SW3-4 SRAM & RTC Battery Enable

* = Boot PROM version 06 or higher and System PROM version 4.7 or higher

System Firmware
Load Control *

ON = Disable remote download of System Firmware
OFF = Enable remote download of System Firmware
ON = Force recovery mode (via CW Console)
OFF = Recovery mode disabled
ON = Battery back-up enabled
OFF = Battery back-up disabled

Table 2-5 in Section 2.3.3.3 provides SCB Port Switches SW1 (COM3) and SW4 (COM4) RS­232 & RS-485 communication port settings.

2-10 / Installation & Operation CI-ControlWaveRED

2.3.3.2 Communication Ports

A ControlWaveRED Controller can be configured as a Master node on either a MODBUS
network or a BSAP network. Up to seven communication ports are contained on the
ControlWaveRED CPU Module and are designated as follows:

COM1 - Port 1: CPU Bd. J2, PC/AT 9-Pin Male D-Sub - RS-232
COM2 - Port 2: CPU Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232
COM3 - Port 3: SCB Bd. J2, 8-Pin RJ-45 - RS-232/RS-485
COM4 - Port 4: SCB Bd. J3, PC/AT 9-Pin Male D-Sub - RS-232/RS-485
Ethernet Port 1: CPU Bd. J4, 8-Pin RJ-45 - Twisted Pair 10/100Base-T
Ethernet Port 2: SCB Bd. J5, 8-Pin RJ-45 - Twisted Pair 10/100Base-T
Ethernet Port 3: SCB Bd. J7, 8-Pin RJ-45 - Twisted Pair 10/100Base-T

Communication Ports 1 through 4 support asynchronous operation. Communication Ports
COM1 and COM2 support RS-232 operation while COM3 and COM4 are individually
factory configured per order for RS-232 or RS-485 operation. RS-232 and RS-485 Ports are
protected to ±8KV ESD (Contact). Ethernet and RS-485 Ports are isolated to 500Vdc.

Any of the four non-Ethernet communication ports can be configured for local com­munications, i.e., connected to a PC loaded with ControlWave Designer and OpenBSI soft­ware.

Each CPU Module contains four serial communications ports that are connected to the CPU &
Comm. Redundancy Switch Module via a special communications cable (see Figure 2-8).

Note: Comm. Port 3 will be configured for RS-485 operation on SCB’s configured
with one RS-232 and one RS-485 port.

Figure 2-7 - CPU Module Component Identification Diagram

CI-ControlWaveRED Installation & Operation / 2-11

Figure 2-8 - Redundant Communication Cables Connection Diagram

The connections for the CCRSM 9-pin, RS-232/485 interfaces are shown in Figure 2-9, while the
corresponding pin labels are provided in Table 2-3.

2.3.3.3 RS-232 & RS-485 Interfaces

Communications ports (COM1 & COM2) support RS-232 communications only. RS-232 or
RS-485 communications can be provided by communications ports COM3 and COM4. These
connectors are summarized below. Note: All four serial communications ports on the
CCRSM use PC/AT 9-Pin Male D-Sub connectors.

CPU Bd. J2 - 9-Pin Male D-Sub - RS-232 - COM1 - CCRSM J1 (Port 1)
CPU Bd. J3 - 9-Pin Male D-Sub - RS-232 - COM2 - CCRSM J2 (Port 2)
SCB Bd. J2 - 8-Pin RJ-45 - RS-232/RS-485 - COM3 - CCRSM J3 (Port 3)
SCB Bd. J3 - 9-Pin Male D-Sub - RS-232/RS-485 - COM4 - CCRSM J4 (Port 4)

RS-232 Ports

An RS-232 interface supports point to point half-duplex and full-duplex communications (20
feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWaveRED utilize MODBUS or BSAP protocol, while full-duplex is supported by
the Point to Point (PPP) protocol. ControlWaveRED RS-232 ports utilize the “null modem”

2-12 / Installation & Operation CI-ControlWaveRED

cable (Figure 2-9A) to interconnect with other devices such as a PC, printer, a

ControlWave unit, a ControlWave I/O Expansion Rack, a ControlWaveLP, etc. when the
ControlWaveRED is communicating using the full-duplex PPP protocol. The half-duplex

cable shown in Figure 2-9A is utilized when the ControlWaveRED Controller is connected
to a ControlWaveLP, a ControlWave I/O Expansion Rack, a ControlWave, etc. The “null
modem” cable may be used for full-duplex communications (PPP protocol) when a
ControlWaveRED Controller is connected to a PC. If communicating with a Bristol series
3305, 3310, 3330 or 3335 RTU/DPC, one of the cables shown in Figure 2-9B must be used.
Refer to Figure 2-9C to connect a ControlWaveRED to either a modem or radio.

An illustration of the CPU and CCRSM’s male 9-pin D-type connectors is provided in
Figure 2-10. Table 2-3 provides the connector pin assignments for CCRSM ports 1 through

4. The connector pin assignments for CPU Module Communications Port 3 is provided in
Chapter 4 (see Figure 4-3 and Table 4-3).

Note: The following facts regarding ControlWaveRED RS-232 serial communications

ports should be observed when constructing communications cables:

• DCD must be high to transmit

• CTS must be high to transmit

• When port is set for full-duplex operation - RTS is always ON

• DTR is always high (when port is active)

• When port is set for half-duplex operation - CTS must go low after RTS goes low

RS-485 Ports
ControlWave Controllers can use an RS-485 configured port for local network

communications to multiple nodes up to 4000 feet away. Since this interface is intended for
network communications, Table 2-4 provides the appropriate connections for wiring the
master, 1st slave, and nth slave. Essentially, the master and the first slave transmit and
receive data on opposite lines; all slaves (from the first to the "nth") are paralleled (daisy
chained) across the same lines. The master node should be wired to one end of the RS-485
cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used. Note:
Only half-duplex RS-485 networks are supported.

Table 2-3 - CCRSM: COM1 through COM4 Connector Pin Assignment

Pin # Signal

RS-232

1 DCD Data Carrier Detect Input N/A
2 RXD Receive Data Input RXD- Receive Data - Input
3 TXD Transmit Data Output TXD- Transmit Data - Output
4 DTR Data Terminal Ready Output TXD+ Transmit Data + Input
5 GND Signal/Power Ground ISOGND Isolated Ground
6 DSR Data Set Ready Input RXD+ Receive Data + Output
7 RTS Request To Send Output N/A
8 CTS Clear To Send Input N/A
9 RI Ring Indicator * N/A

Description:

RS-232 Signals

Signal

RS-485

Description:

RS-485 Signals

Note: RS-485 Signals in Table 2-3 are only available on COM3 & COM4. * RI

signal

is not available on COM3.

CI-ControlWaveRED Installation & Operation / 2-13

Figure 2-9 - Communication Port RS-232 Cables Wiring Diagrams

2-14 / Installation & Operation CI-ControlWaveRED

Figure 2-10 - Male DB9 9-Pin Connector (CPUM: COM1, COM2 & COM4)

(CCRSM: COM1 - COM4)

Table 2-4 - RS-485 Network Connections

(see Tables 2-3 & 4-3 for ControlWave RS-485 Port Pin # Assignments)

From

Master

TXD+ RXD+ RXD+

TXD- RXD- RXD-

RXD+ TXD+ TXD+

RXD- TXD- TXD-

ISOGND ISOGND ISOGND

To 1st

Slave

To nth

Slave

Note: Pins 1, 2, 3, 4 & 9 of Bristol Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485
Comm. Ports are assigned as follows: 1 = TXD+, 2 = TXD-, 3 = RXD+, 4 = RXD- & 9 =
ISOGND.

To ensure that the “Receive Data” lines are in a proper state during inactive transmission
periods, certain bias voltage levels must be maintained at the master and most distant
slave units (end nodes). These end nodes also require the insertion of 100-Ohm terminating
resistors to properly balance the network. Secondary Communication Board switches must
be configured at each node to establish proper network performance. This is accomplished
by configuring SCB Switch SW1 (Comm. Port 3) and/or SCB Switch SW2 (Comm. Port 4) so
that the 100-Ohm termination resistors and biasing networks are installed at the end nodes
and are removed at all other nodes on the network (see Table 2-5).

Table 2-5 - SCB Port Switches SW1 = COM3, SW2 = COM4

Loopback & Termination Control

Switch RS-232 Function

Switch ON

1 DTR to DSR Loopback TX+ to RX+ Loopback ON - Only for Diagnostics
2 TXD to RXD Loopback TX- to RX- Loopback ON - Only for Diagnostics
3 N/A 100 Ohm RX+ Termination ON - End Nodes Only
4 N/A 100 Ohm RX- Termination ON - End Nodes Only
5 RTS to CTS Loopback N/A ON - Only for Diagnostics

6 N/A

7 N/A RX+ Bias (End Node) ON - End Nodes Only
8 N/A RX- Bias (End Node) ON - End Nodes Only

RS-485 Function

Switch ON

Slow Slew Rate - ON = Fast
OFF = Slow

Setting

ON/OFF - As required
Factory Default = ON

CI-ControlWaveRED Installation & Operation / 2-15

Figure 2-11 - Secondary Comm. Bd. Switches SW1 (COM3) & SW2 (COM4)

2-16 / Installation & Operation CI-ControlWaveRED

2.3.3.4 Ethernet Ports

ControlWaveRED CPU Modules can contain from one to three Ethernet Ports. Each Port

utilizes a 10/100Base-T RJ-45 modular connector that typically provides a shielded twisted
pair interface to an Ethernet Hub. Each CPU will have a user selected Ethernet Port
which, in addition to standard process communications will accommodate redundant CPU
“Side Load” communications. Note: A dedicated, point-to-point Ethernet com-

munications line may be used for redundant “Side Load” communications in lieu
of a standard Ethernet connection. It is via this Side Load communication scheme that

the secondary CPU monitors the Primary CPU’s activity. ControlWaveRED Ethernet Port
assignment is provided below.

Ethernet Port 1: CPU Bd. J4, 8-Pin RJ-45 - Shielded Twisted Pair 10/100Base-T
Ethernet Port 2: SCB Bd. J5, 8-Pin RJ-45 - Shielded Twisted Pair 10/100Base-T
Ethernet Port 3: SCB Bd. J7, 8-Pin RJ-45 - Shielded Twisted Pair 10/100Base-T

A typical Ethernet Hub provides eight (8) 10/100Base-T RJ-45 Ports (with Port 8 having the
capability to link to another Hub or to an Ethernet communications port). Both ends of the
twisted pair Ethernet cable are equipped with modular RJ-45 connectors. These cables have
a one-to-one wiring configuration as shown in Figure 2-14. Table 2-6 provides the as­signment and definitions of the 8-pin 10/100Base-T connectors.

Figure 2-12 - RJ-45 Connector (Ethernet Ports) J2 (CPU), J5 & J7 (SCB)

It is possible to connect two nodes in a point-to-point configuration without the use of a
Hub. However, the cable used must be configured such that the TX+/- Data pins are con­nected to the RX+/- Data pins (swapped) at the opposite ends of the cable (see Figure 2-13).

CI-ControlWaveRED Installation & Operation / 2-17

Figure 2-13 - 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.

Figure 2-14 - Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)

Table 2-6 - Ethernet 10/100Base-T CPU Module Pin Assignments

Pin # Description Pin # Description

1 Transmit Data+ (Output) 5 Not Connected
2 Transmit Data- (Output) 6 Receive Data- (Input)
3 Receive Data+ (Input) 7 Not Connected
4 Not Connected 8 Not Connected

Note: TX & RX are swapped at Hub’s.

2.3.4 Wire Connections

ControlWaveRED Controllers utilize compression-type terminals that accommodate up to

#14 AWG wire. A connection is made by inserting the wire’s bared end (1/4” max) into the

2-18 / Installation & Operation CI-ControlWaveRED

clamp beneath the screw and securing the screw. The wire should be inserted fully so that
no bare wires are exposed to cause shorts. If using stranded wire, tin the bare end with
solder to prevent flattening and improve conductivity.

2.3.4.1 Power Supply Wiring

ControlWaveRED PSSMs utilize compression-type terminals that accommodate up to #14

AWG wire. Allow some slack in the wires when making terminal connections. The slack
makes the connections more manageable and minimizes mechanical strain on the terminal
blocks.

Figure 2-15 - PSSM Wire Routing Diagram

2.3.4.1.1 Bulk Power Supply Current Requirements

ControlWaveRED Controllers are equipped with either a 12Vdc or 24Vdc Power Supply

Sequencer Module (PSSM). The maximum current required for the +12Vdc or +24Vdc bulk
power supply used with a particular ControlWaveRED Controller are provided as follows:

CI-ControlWaveRED Installation & Operation / 2-19

Bulk +12/24Vdc Supply Current = Current of CPU + PSSM + Backplane + CCRSM

This summation will accommodate steady state as well as power up in-rush current draw.

Note: When two bulk power supplies are required, the first supply (VIN) (see Fig. 2-16)

must be rated to handle 2 Amps.

Table 2-7 and 2-8 provide detailed steady state current requirements for each Control-
WaveRED module.

Table 2-7 - Power Requirements for Bulk 12Vdc Power Supply

COMPONENTS SYSTEM NOTES

CPU/SCB, CHASSIS,
PSSM
CCRSM B = 140mA

A = 1050mA CPU w/Ethernet SCB w/Ethernet

Table 2-8 - Power Requirements for Bulk 24Vdc Power Supply

COMPONENTS SYSTEM NOTES

CPU/SCB, CHASSIS,
PSSM
CCRSM B = 40mA

A = 650mA CPU w/Ethernet SCB

w/Ethernet

2.3.4.1.2 Power Wiring

DC Power is interconnected to the PSSM via Connector TB2. One Bulk DC Power Supply
can be connected to each ControlWaveRED PSSM or both can share the same supply. The
Bulk DC supply (nominally +12Vdc or +24Vdc) connected to TB2-1 (+VIN) is converted,
regulated and filtered by the PSSM to produce +5Vdc, +3.3Vdc, +12Vdc and -12Vdc
(optional). This PSSM circuit is fused at 3A and is referred to as the LOGIC Supply since
these voltages are used for CPU, communications and I/O logic.

The operating range of the LOGIC Supply is +10.6 to +20.0 Vdc (nominal +12Vdc input
source) or +20.7 to +30.0 Vdc (nominal +24Vdc input source).

PSSM Connector TB2 provides 5 input connections for bulk power as follows:

TB2-1 = (+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
TB2-2 = (+VINF) Not Used
TB2-3 = (-VIN) (1st Supply Ground)
TB2-4 = (-VINF) (2nd Supply Ground) - Not Used
TB2-5 = Chassis Ground - CHASSIS (

)

Figure 2-16 - PSSM TB2 Typical Wiring Schemes

2-20 / Installation & Operation CI-ControlWaveRED

2.3.4.1.3 Watchdog MOSFET Switch Wiring (see Figures 2-15, 2-16 & 2-17)

The circuit that drives the Watchdog MOSFET switch is on the secondary side of the power
supply. A solid state relay (SSR) actuates the watchdog hardware and is factory enabled or
disabled via an on-board jumper. When either the Master Clear or Watchdog Bad signal are
active, the on-board watchdog hardware will be OFF. Watchdog Bad is a signal generated

by the CPU Module when its hardware detects improper software operation.

The watchdog MOSFET switch is powered via the VI input of the terminal block (TB1-2)
and its switched output is connected to the VO output of the terminal block (TB1-1). The
external power source connected to the VI terminal must be referenced to the return point
of the input source that powers the PSSM [-VIN or PSGND (TB2-3)].

PSSM Connector TB1 provides 3 Watchdog MOSFET switch connections as follows:

MOSFET Connections:

TB1-1 = VO - Watchdog MOSFET Switch Output
TB1-2 = VI - Watchdog MOSFET Switch Input
TB1-3 = Not Used with ControlWaveRED

(see Figures 2-15 & 2-17)

Figure 2-17 - Watchdog MOSFET Switch Field Wiring

2.3.4.2 CCRS Module Isolated On-Line Status Output Wiring

CCRSMs utilize compression-type terminals that accommodate up to #14 AWG wire. Allow
some slack in the wires when making terminal connections. The slack makes the
connections more manageable and minimizes mechanical strain on the terminal blocks.

CCRSMs are provided with isolated relay circuitry that provides output status signals
representing the redundancy control states of CPU Module A & B. These isolated on-line
status outputs provide an on-line (ONLINE) and a common (COM) lead point that can
handle up to 30Vdc (max) from a field powered device. The isolated relay switch

associated with the CPU Module that is on-line will be closed while the relay
switch associated with the standby CPU Module will be open.

CCRS Module Terminal Block Connector J7 provides isolated on-line status output
connections as follows:

Isolated On-Line Status Output Connections:

CI-ControlWaveRED Installation & Operation / 2-21

(see Figure 2-18)

J7-1 = A_ONLINE - Switch Output (associated with CPU Module A)
J7-2 = A_ONLINE - Common connection (associated with CPU Module A)
J7-3 = B_ONLINE - Switch Output (associated with CPU Module B)
J7-4 = B_ONLINE - Common connection (associated with CPU Module B)

Figure 2-18 - CCRS Module - Isolated On-Line Status Outputs - Field Wiring

2.3.5 Installation of the Lithium Backup Battery (see Figures 2-5 & 2-19)

The 3.6V Lithium backup battery located on the CPU Module connects to CPU Board
connector J10. This 950mA-hr lithium ½ AA cell battery is provided with a three-wire
connector (2-wires used). The battery provides backup for the real-time clock, CMOS RAM
and the system SRAM. A supervisory circuit is used to switch to battery power when VCC
falls below VCC - 10%. The Battery PCB provides a regulated +2.5Vdc to the CPU Module.

The system SRAM has a standby current draw of 50uA maximum for each part. For a unit
containing 2MB of SRAM, a worst-case current draw of 210uA allows a battery life of
approximately 4524 hours, while for a unit containing 4MB of SRAM, a worst-case current
draw of 410uA results in a battery life of approximately 2317 hours.

CPU Board Switch SW3-4 must be set to the ON position to enable the battery. For
maximum shelf life, the battery may be isolated from the circuit by moving CPU Board
Switch SW3-4 to the OFF position.

The CPU Module is shipped with the Lithium backup battery installed. To remove the
Lithium backup battery, the Battery Retaining Clip must be removed from the Battery
Holder Assembly (see Figure 2-19). Once the replacement battery has been installed into

2-22 / Installation & Operation CI-ControlWaveRED

the Battery Holder Assembly on the Battery Backup PCB Assembly, the Battery Retaining
Clip can be easily snapped back into place.

Note:
If the lithium battery is removed when power is off, CPU Switch SW3-4 should be
set OFF for over a minute or power should remain off for at least a minute.

- or -

CPU Switch SW1-5 MUST be set OFF for the next Boot.

Figure 2-19 - Lithium Backup Battery Removal Diagram

2.3.6 Installation of the Bezel Assembly (see Figures 2-1, 2-5 & 2-20)

Each Bezel Assembly covers the front of a PSSM and CPU Module and provides the
following functions:

• It can be removed or its Terminal Door opened to access the PSSM and CPU modules.

• Bundled wires and cables are routed downward between the modules and the Bezel.

CI-ControlWaveRED Installation & Operation / 2-23

Figure 2-20 - Bezel Assembly

The appropriate Bezel Assembly is shipped with the CPU Module and should be installed
whenever the unit is operational (except during service). The Bezel is secured to the
Chassis by two snaps. To remove the Bezel assembly, gently grasp its sides and pull out
and away from the Chassis.

Installation of the Bezel Assembly requires that its snaps be aligned with their mating
holders on the Chassis. Once the Bezel has been properly positioned on the Chassis, a slight
push should snap it into place.

2.4 OPERATIONAL DETAILS

ControlWaveRED Process Automation Controllers are shipped from the factory with firm-

ware that allows the unit to be configured in conjunction with an IEC 61131 application
program. This section provides information as follows:

- Steps required to download the application load and place the unit into ‘Run’ mode.

- Steps required to download system firmware.

- Operation of the CPU Module’s Reset Switch

- Operation of the CPU Module’s RUN/REMOTE/LOCAL Switch

- Operation of the CCRS Module’s A/B Primary Controller Select Switch

- Operation of the CCRS Module’s A/B Enable Key Switch

- Soft Switch Configurations and Communication Ports

Operational details on ControlWaveRED LEDs, the PORT 80 Display and use of the BBI
WINDIAG program for fault isolation are provided in Chapter 3.

2-24 / Installation & Operation CI-ControlWaveRED

2.4.1 Downloading the Redundant Project

A ControlWaveRED Controller must receive its configured redundant project before it can be
placed into operation. This will require connection of one of the ControlWaveRED unit’s CPU
Modules (via the CCRSM’s A/B Enable Key Switch) to a PC running Windows 98™/Windows
NT™ (4.0 or higher) and equipped with ControlWave Designer software & OpenBSI software.
Configuration of the redundant project load must be performed by an individual familiar with
the various programming tools. The following software user documentation is referenced:

Getting Started with ControlWave Designer Manual - D5085
ControlWave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Web_BSI Manual - D5087
ControlWave Redundant Setup Guide - D5123

This download can be initiated, i.e., from ControlWave Designer, or from the OpenBSI 1131
Downloader for ControlWave Nodes.

1. Set the selected CPU’s RUN/REMOTE/LOCAL Switch (Key Operated) as follows:

- If the PC is connected to a ControlWaveRED’s Comm. Port that has been configured
as an IP or OpenBSI Network Port, set the CPU’s RUN/REMOTE/LOCAL Switch to
the ‘REMOTE’ position.

- If the PC is connected to a ControlWaveRED’s Comm. Port that has been configured
as a Serial Port, set the CPU’s RUN/REMOTE/LOCAL Switch to the ‘LOCAL’ position.

Note: From the factory, COM1 defaults to 115.2 kbd (RS-232) using the Internet Point

to Point Protocol (PPP). Don’t connect COM1 to a PC unless the PC’s RS-232
port in question has been configured for PPP.

2. Once the ControlWaveRED redundant project has been defined and communications

and configuration parameters have been set, perform the download into the boot project
area (see ‘Testing the Redundant Setup’ in Document # D5123).

3. After the download has been completed set the CPU’s RUN/REMOTE/LOCAL Switch to

the RUN position and the CCRSM’s A/B Enable Key Switch to its center (Auto Selection)
position.

2.4.2 Upgrading ControlWave Firmware

ControlWave Process Automation Controller CPUs ship from the factory with system

firmware already installed. If an upgrade of the system firmware is required, use one of the
procedures below to download the new or replacement firmware from the PC.

Upgrade of system firmware via LocalView FLASH Mode requires OpenBSI 5.1 (or newer).
If you have an older version of OpenBSI, FLASH upgrades are to be performed via
HyperTerminal. Connect of one of the ControlWaveRED unit’s CPU Modules (via the
CCRSM’s A/B Enable Key Switch) to a PC running Windows™ 2000 (Service Pack 3 or newer)
or Windows™ XP Professional.
You will need a binary (*.BIN) system firmware file, and that file should be defined in the
Flash Master File (FLASH.MST). A sample Flash Master File is shown, below:
cwp0410.bin Firmware - Release 04.1

Upgrade of an unattended ControlWave RED can be accomplished from a remote PC. This
capability is introduced in Section 2.4.2.3.

CI-ControlWaveRED Installation & Operation / 2-25

2.4.2.1 Using LocalView to Upgrade ControlWave Firmware

NOTE

Both ControlWave CPUs must be set to Recovery Mode ENABLE (ON) prior to
performing the FLASH upgrade, then set to Recovery Mode DISABLE (OFF) after
the upgrade. This is accomplished via CPU Switch SW3-3. Also set Switch SW1-3
(OFF) on both CPUs to ignore soft switch configuration and use factory defaults;
set SW1-3 on both CPUs (ON) after the upgrade.

A null modem cable (see Figure 2-9) must be connected to ControlWave CPU Port COM1
(via J1 of the CPU & Communications Redundancy Switch Module) and to any RS-232 port
on the associated PC. The PC’s RS-232 port used for this purpose must be set to run at

115.2 Kbaud.

Set the A\ENABLED/B Switch on the CPU & Communications Redundancy Switch Module
to the ‘A’; or the ‘B’ position. Apply power to the ControlWaveRED by turning both PSSM’s
ON/OFF Switch to the ON (‘I’) position. The resident BIOS will initialize and test the
hardware, this process is referred to as POST (Power On Self Test).

A status of the POST progress is displayed on the Port 80 display. Unless there is a problem
these codes will scroll at a fast rate and won’t be discernable. Successful completion is
indicated with an 86 on the Port 80 display.

Follow the procedure below to upgrade the Firmware in both CPUs. If not already running,
apply power to the associated PC.

Start LocalView, Choose FLASH, Enter A Name, Click on [Create]

Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView. The
New View Mode dialog box will appear (see Figure 2-21).

"Mode"
Choose 'Flash' for the mode.

Figure 2-21 - Local View - New View Mode Menu

2-26 / Installation & Operation CI-ControlWaveRED

"Name"
Enter a name for the View Mode File in the "Name" field.

"Location"

If you want to store the View Mode File in a directory other than that shown in the

"Location" field, enter the new location there, or use the [Browse] push button to find
the directory.

When the "Mode", "Name", and "Location" have been specified, click on the [Create] push
button to activate the Communication Setup Wizard (see Figure 2-22).

Step 1 - Communication Setup

Complete the fields in the Communication Setup Wizard as described, below.

Figure 2-22 - Communication Setup: Step 1 Menu

"What port would you like to use?"

Specify the PC port you would like to use; this would be the port on the PC which will be
connected to the serial cable, e.g. COM1:, COM2:, etc.

"Would you like to use auto baud rate detection?" / "What baud rate would you like
to use?"

If you know which baud rate to use, answer no for auto baud detection, and specify the
baud rate. If you do not know which baud rate to use, choose auto baud detection.

CI-ControlWaveRED Installation & Operation / 2-27

[Advanced Parameters]

See the ‘Advanced Communication Parameters Dialog Box’ section, later in this chapter
for details on this.

Click on the [Next] pushbutton to activate the next wizard (see Figure 2-23).

Step 2 - Flash RTU Setup

In the Flash RTU Setup Wizard (see Figure 2-23), complete the fields as described, below:

"What is the type of the RTU?"

Use the list box to select the type of controller you are connected to. In this case, you
should only choose from among the ControlWave-series options:

Select this option: For this type of unit:

ControlWave

ControlWave Process Automation Controller or
ControlWave Redundant Controller

"What is the local address of the RTU that you would like to connect to?"

Select the BSAP local address of the ControlWave unit (from 1 to 127) using the list

box provided.

"If you are flashing a redundant pair, specify the time to wait before start
downloading:?"

Enter the time (from 1 to 30 seconds) in the time box (if no time is entered, default = 0).

Allow enough time for both processors to settle down (Hex Code 86 should be displayed
on both Port 80 Displays).

Click on the [Next] push button to activate the Flash Data Setup Wizard.

Figure 2-23 - Flash RTU Setup Menu

Step 3 - Flash Data Setup

Complete the fields in the Flash Data Setup Wizard (see Figure 2-24), as described, below:

"Please enter the name of the binary file to Flash"

To upgrade system firmware, you must specify the path and name of a binary (*.BIN)

file on your hard disk containing the firmware. Normally, the contents of the various

2-28 / Installation & Operation CI-ControlWaveRED

available BIN files are described in a Flash Master File (see box at bottom of the dialog
box). If you have specified a Flash Master File, double-click on the description of the
binary file you want to download to the RTU. Its path and name will be copied into this
field. (If you do NOT have a Flash Master File, type the path and name of the binary file
directly into this field.)

"Location of Flash Master File"

Specifies the location of the Flash Master File (FLASH.MST). The contents of the
FLASH Master File will be displayed in the box at the bottom of the dialog box, and
may be used to select binary files for FLASH downloading. (See above). If necessary, you
can use the [Browse] push button to locate the FLASH Master File.

Figure 2-24 - Flash Data Setup Menu

Figure 2-25 - Local View Downloading System Firmware Menu

CI-ControlWaveRED Installation & Operation / 2-29

Click on [Finish] to install the specified BIN file in FLASH memory at the RTU.

Once the Flash download has begun, you will NOT be allowed to shut down LocalView,
unless you cancel the download, or it has been completed.

The progress of the Flash download will be displayed in the window. Any mismatch in file
versions, or if the type of .BIN file does not match the type of RTU, the download will be
aborted.

Advanced Communication Parameters Dialog Box

Figure 2-26 - Local View Advanced Communication Parameters Menu

“What is the Link Level Timeout Period”

This defines the maximum amount of time (in seconds) that Open BSI will wait to

receive a response to any one data link transaction. If 0 is entered as the link timeout
period, the system will use a default timeout calculated based on the baud rate of the
line.

"Would you like to use RTS/CTS signals?"

If your communication line uses Ready to Send (RTS) / Clear to Send (CTS) signals (not

to be confused with ControlWave variables used for this purpose), click on 'Yes'.

"Front Pad", "Back Pad"

These fields specify the number of null characters to insert at the beginning (front) or

ending (back) of a message. Null characters may be useful in situations where there
may be a momentary delay, which could cause the start of a message to be missed, for
example, while a radio link is being activated. To determine the delay caused by null
packing, perform the following calculation:

seconds of delay = (number of null characters x 10) / baud rate

2.4.2.2 Using HyperTerminal to Upgrade ControlWave Firmware

A null modem cable (see Figure 2-9) must be connected to ControlWave CPU Port COM1
(via J1 of the CPU & Communications Redundancy Switch Module) and to any RS-232 port
on the associated PC. The PC’s RS-232 port used for this purpose must be set to run at

115.2 Kbaud. On both CPUs, set CPU Switch SW3 position 3 to ON (ON = Force Recovery).

2-30 / Installation & Operation CI-ControlWaveRED

Set the A\ENABLED/B Switch on the CPU & Communications Redundancy Switch Module
to the ‘A’; or the ‘B’ position and apply power to the ControlWaveRED. After both Port 80
Displays stabilize with a Status Code of 86, follow the procedure below to upgrade the
Firmware in both CPUs. If not already running, apply power to the associated PC.

1. Apply power to the ControlWaveRED by turning both PSSM’s ON/OFF Switch to the

ON (‘I’) position. The resident BIOS will initialize and test the hardware, this process is
referred to as POST (Power On Self Test).

A status of the POST progress is displayed on the Port 80 display. Unless there is a
problem these codes will scroll at a fast rate and won’t be discernable. Successful
completion is indicated with an 86 on the Port 80 display and with the cold start menu
being displayed on the PC’s screen. Detection of a fault will be indicated by a 2-digit code on
the Port 80 display. Refer to Section 3.4.4 for POST Status Code definition.

2. If not already running, apply power to the associated PC.

3. Start the HyperTerminal program on the PC. Note: HyperTerminal is a Windows 95 (or

newer) application utility program. If using HyperTerminal for the first time, set the
communications properties (for the PC Port being utilized) via the Properties Menu as
follows: Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop bits: = 1, and Flow
control: = None and then click OK.

4. From the HyperTerminal Recovery Mode menu (Figure 2-27), press the ‘F’ key, to enter
FLASH download. A message will be displayed warning that the FLASH is about to be
erased; press the ‘Y’ key at the prompt. The screen will display dots as the flash devices are
being erased; this could take a few minutes.

Figure 2-27 - HyperTerminal Recovery Mode Menu

CI-ControlWaveRED Installation & Operation / 2-31

Figure 2-28 - HyperTerminal FLASH Download Menu

(Ready to Download) - (Transfer/Send File Selected)

5. When the FLASH is ready for download the letter C will be displayed on the screen. In
the HyperTerminal command bar click on Transfer and then Send File…(see Figure 2-

28). In the Send File Dialog Box (see Figure 2-29), select “1KXmodem” for the protocol,
enter the filename of the appropriate .bin file in the format “CWPxxxxx.bin” (where
xxxxx varies from release to release). Click on the Send button to start the download
(see Figures 2-29 and 2-30). When the HyperTerminal Recovery Mode Menu of Figure 2­27 appears, the download has completed.

Figure 2-29 - HyperTerminal Flash Download

(Send File Dialog Box - Enter Filename)

2-32 / Installation & Operation CI-ControlWaveRED

Figure 2-30 - HyperTerminal FLASH Download

(Download in Process)

6. Close the HyperTerminal program. The null modem cable connected between the
ControlWaveRED and the PC can be removed if desired.

7. On both CPUs, set Switch SW3 position 3 to OFF (OFF = Recovery Mode Disabled). Switch
Power OFF and then ON again via both PSSM’s ON/OFF Switch.

Once the ControlWave is running its application load, status codes posted to the Port 80
Display have a different meaning than the Port 80 POST Status Codes (see Section 3.4.4
for POST Status Codes). The PORT 80 Display is disabled during normal running
operation to save power. These Port 80 Running Status (Hex) Codes are listed in Table 2-

11.

Table 2-9 - PORT 80 - Running Status Codes

Hex Code Definition Notes

00 No Application
01 Application Loaded
10 Application Loaded - BPTs Set Break Point(s) Set
11 Application Running Display Blank
12 Running with BPT Break Point in Debug

1D Currently Loading the Boot Project

51 System Initialization in Progress

86* Recovery Mode SW3-3 = ON

BA Standby - Valid Standby (can take over) Watchdog LED OFF
BC Standby - Connected to Master Watchdog LED ON
BD Standby - Not connected to Master Watchdog LED ON
BF Battery Fail (flashed at startup) Check S3-4
CA Hot Card Replacement in Progress

CI-ControlWaveRED Installation & Operation / 2-33

Table 2-9 - PORT 80 - Running Status Codes (Continued)

Hex

Code

CF Invalid Firmware Checksum Detected Unit Stopped

D0 Diagnostic Mode SW1-8 =OFF
D1 Running Diagnostic

DE User Application has failed to start Invalid I/O Driver

F0 NPX Error Unit Stopped
F1 Waiting for Power-down (after NMI)

CPU Bd. Switch SW1-3 Set OFF

FA

FC Waiting for Alt. Watchdog Timer Unit Stopped

FD Waiting for Updump

FE FLASH Programming Error

FF Unit Crashed Unit Stopped

Ignore Soft Switch Configuration - Use
factory defaults

Definition Notes

Flashes for 1 second
At startup

Core Dump in process
or waiting to start

* Not an actual Running Status Code - SW3-3 should be OFF

Note: If the STANDBY CPU’s Port 80 Display is not posting a Running Status Code of ‘BA’

when the ONLINE CPU goes off line (looses power, is shut off, etc.) it won’t switch
over to become the online unit.

2.4.2.3 Remote Upgrade of ControlWave Firmware

It is possible to download system firmware into an unattended remote ControlWave RED.
This function can only be accomplished if CPU Board Switch SW3-2 (associated with the
unit in question) is set in the OFF position (factory default). The procedure for performing a
remote download of system firmware is discussed in Appendix J of the Open BSI Utilities
Manual (document D5081). Note: Remote upgrade of ControlWave RED Firmware

requires Boot PROM version 4.7 or higher and System PROM version 4.7 or
higher.

2.4.3 Operation of the RUN/REMOTE/LOCAL Switch

The CPU Module’s RUN/REMOTE/LOCAL Switch is set via a removable key. The CPU
Module’s RUN/REMOTE/LOCAL Switch can be identified by a removable key that allows
the user to set the unit as follows: When set to ‘RUN,’ this switch prevents the user from
performing any ControlWave Designer Debug/Program operations such as Start/Stop,
download of application, etc. Use of the ‘LOCAL’ or ‘REMOTE’ setting depends on the type
of network connection the Comm. Port in question has been configured for (Port selection
can be IP, Serial or OpenBSI). If a Comm. Port has been configured for IP or OpenBSI
(BSAP) communications, it is considered a remote port and the RUN/REMOTE/LOCAL
Switch should be set to ‘REMOTE’ to receive a download. However; if the Comm. Port in
question has been configured for Serial communications, it is considered a local port and
the RUN/REMOTE/LOCAL Switch should be set to ‘LOCAL’ to receive a download. Note:

When the RUN/REMOTE/LOCAL Switch has been set to the ‘LOCAL’ position,
communications via any ControlWave Comm. Port is possible, i.e., via either a local or
remote Comm. Port. However; when the RUN/REMOTE/LOCAL Switch has been set to the
‘REMOTE’ position, only communications with a Comm. Port that has been configured as a
remote Comm. Port is possible.

2-34 / Installation & Operation CI-ControlWaveRED

The key used to set the RUN/REMOTE/LOCAL Switch may be removed or inserted while
the RUN/REMOTE/LOCAL Switch is in any position.

2.4.4 Operation of The Reset Switch

The CPU Module’s Reset Switch is a momentary button that allows the operator to reset
(stop and restart) the CPU Module in question when the unit is being tested via WINDIAG.
Never use this switch during normal operation.

2.4.5 Operation of the CCRSM A/B Primary Controller Select Switch

The CCRSM A/B Primary Controller Select Switch is a two position toggle switch that is
used to select the primary controller, i.e., CPU A (UNIT A) or CPU B (UNIT B) at CCRS
Module power up only
selection (centered) position. The selected CPU Module will be chosen as the primary
system controller if the CCRSM’s logic determines it is ready for on-line duty. Otherwise,
the alternate CPU will be selected if it is OK.

if the A/B Enabled Mode Select Switch has been set in the automatic

2.4.6 Operation of the CCRSM A/B Enable Key Switch

The A/B Enable Key Switch has three positions and is used to determine whether the
primary CPU selection is forced to CPU A (UNIT A) or CPU B (UNIT B) or is
automatically selected (Center). Forced primary selection is useful for diagnostic purposes,
where a failed CPU Module may be placed on-line for debugging.

2.4.7 Soft Switch Configuration and Communication Ports

Firmware defined soft switches that control many default settings for various system
operating parameters such as BSAP Local Address, EBSAP Group Number, four (4)
communication port parameters, etc., can be viewed and, if desired, changed via
‘Configuration Web Pages’ in Microsoft Internet Explorer via the Flash Configuration
Utility. When connecting the ControlWaveRED to the PC (local or network) for the first
time you should be aware of the communication port default parameter settings provided
below (see Figures 2-5 through 2-9). Note: Communication port factory defaults can be
enabled anytime by setting CPU Board Switch SW1-3 to the OFF position.

COM1: From the factory, COM1 (originating on the CPU Bd.) defaults to 115.2 kbps (RS-

232) using the Internet Point to Point Protocol (PPP). Note: ControlWave Port

COM1 will be configured for RS-232 operation (at 9600 bps) by setting CPU
Switches SW1-3 and SW1-8 OFF. This will prevent the boot project from running
and places the unit into diagnostic mode. To test COM1 using the WINDIAG

program, it must not otherwise be in use and CPU Switch SW1-8 must be set to
the OFF position. Connection to a PC requires the use of an RS-232 “Null Modem”
cable (see Figure 2-9).

COM2: From the factory, COM2 (originating on the CPU Bd.) defaults to 9600 bps, 8-bits,

no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM2 using the WINDIAG program, it must not otherwise be in use and CPU
Switch SW1-8 must be set to the OFF position. It is recommended that an RS-232
“Null Modem” cable be connected between COM2 and the PC (typically COM1)
(see Figure 2-9).

CI-ControlWaveRED Installation & Operation / 2-35

COM3: When factory set for RS-232 or RS-485 operation, COM3 (originating on the SCB)

defaults to 9600 bps, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer
protocol operation. This port utilizes an RJ-45 female connector (see Figures 2-7, 2­9D and 4-3 and Table 4-3). To test COM3 using the WINDIAG program, it must
not otherwise be in use and CPU Switch SW1-8 must be set to the OFF position.
Connection to a PC depends on the type of communications port jack utilized by
the PC.

If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a

special “Null Modem” cable equipped with RJ-45 male plugs and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 392843­01-3 connected to two Bristol “RJ45 to DB9 Adapter” cables P/N 392844-01-0 (see
Figures 2-9A & 2-9D), to interconnect the PC to COM3.

If the PC’s RS-232 Port utilizes the standard 9-pin D-type male connector, the use

of the Bristol “Null Modem” cable P/N 392843-01-3 (see Figure 2-9A) and one
Bristol “RJ45 to DB9 Adapter” cable P/N 392844-01-0 (see Figure2-9D) will be
required. This RS-232 network, consisting of two cables, connects to COM3 of the
ControlWave with an 8-pin RJ-45 male connector and to the PC (typically COM1)
with a 9-pin D-type female connector.

If RS-485 communications is required an RS-485 cable can be assembled using the

connections provided in Table 2-4.

COM4: When factory set for RS-232 or RS-485 operation, COM4 (originating on the SCB)

defaults to 9600 bps, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer
protocol operation. To test COM4 using the WINDIAG program, it must not
otherwise be in use and CPU Switch SW1-8 must be set to the OFF position. In
lieu of the use of COM2, an RS-232 “Null Modem” cable (see Figure 2-9) can be
connected between COM4 and the PC (typically COM1) or an RS-485 cable (see
Tables 2-3 & 2-4) can be connected between COM4 and the PC’s RS-485 Port.

Others: Any of the three optional Ethernet Ports can be connected directly or via a network

to a PC equipped with an Ethernet Port (see Figures 2-7, 2-8 and 2-12 through 2-

14). If not configured with an address, the ControlWaveRED uses DHCP (by
default) to obtain an IP address.

2-36 / Installation & Operation CI-ControlWaveRED

Section 3

SERVICE

3.1 SERVICE INTRODUCTION

This section provides general, diagnostic and test information for the ControlWaveRED
Controller.

The service procedures described herein will require the following equipment:

1. PC with null modem interface cable & Bristol Software

2. Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 3-9)

3. Loop-back plug, 9-pin female D-Sub (for RS-485) (see Figure 3-11)

4. Loop-back plug, 8-pin RJ-45 male (for RS-232) (see Figure 3-9)

5. Loop-back plug, 8-pin RJ-45 male (for RS-485) (see Figure 3-11)

6. Loop-back plug, 8-pin RJ-45 male (for twisted pair Ethernet) (see Figure 3-12)

7. Ohmmeter or Continuity Tester (see Section 3.8.9)

The following test equipment can be used to test the Power Supply/Sequencer Module
(PSSM):

1. DMM (Digital Multimeter): 5-1/2 digit resolution

2. Variable DC Supply: Variable to 30Vdc @ 2.5A (with vernier adjustment)

When ControlWaveRED Controllers are serviced on site, it is recommended that any
associated processes be closed down or placed under manual control. This precaution will
prevent any processes from accidentally running out of control when tests are conducted.

Warning

Harmful electrical potentials may still be present at the field wiring terminals
even though the ControlWaveRED’s power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or perform any
wiring operations until all the associated supply sources are turned off and/or
disconnected.

Warning

Always turn off the any external supply sources used for externally powered
I/O circuits, before changing any modules.

3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES

This section provides information on accessing ControlWaveRED modules for testing, in­stallation and removal procedures.

3.2.1 Accessing Modules For Testing

Testing and replacement of ControlWaveRED Controller modules should only be
performed by technically qualified persons. Familiarity with the disassembly and test
procedures described in this manual are required before starting. Any damage to the
ControlWaveRED Controller resulting from improper handling or incorrect service
procedures will not be covered under the product warranty agreement. If these procedures

CI-ControlWaveRED Service / 3-1

cannot be performed properly, the unit should be returned to Bristol (with prior
authorization from Bristol Inc.) for factory evaluation and repairs. All Modules (PSSM,
CPU & CCRSM) are factory sealed to prevent tampering; if the seal is broken by other than
Bristol Babcock personnel, the warranty is void.

3.2.2 Removal/Replacement of a Bezel Assembly

Before a CPU Module can be removed, the associated Bezel Assembly (that covers the
PSSM and the CPUM) must be removed from the Chassis.

1. Set the CCRSM’s A/B Enabled Mode Select Switch to either the ‘A’ or ‘B’ position as

required, to force the other CPU to take control. Remove the Comm. Cable from the
four Comm. Ports on the CPU Module. Grasp the sides of the Bezel Assembly and
gently pull it off the Chassis.

2. To replace the Bezel Assembly, align the Bezel’s two snaps (one near the top and one

near the bottom) with their receptacles on the Chassis (centered between the
PSSM’s and CPUM’s Captured Panel Fastener holes).

3.2.3 Removal/Replacement of a CPU Module (CPUM)

1. Remove the applicable Bezel Assembly (see section 3.2.2).

2. If the entire unit is to be serviced, place any critical control processes under manual

control. Shut down the PSSM unit (associated with the applicable CPUM) by setting
the PSSM’s Power Switch to the ‘O’ position.

3. Loosen the two Captured Panel Fasteners that secure the CPU Module to the

Chassis and then carefully slide the CPU Module out of the front of the Chassis.

4. To replace the CPU Module, the Power Supply/Sequencer Module must be installed

(see Section 3.2.5). Carefully align the CPU Module with ControlWaveRED Slot 2
or slot 4 (as required) and insert the unit into the Chassis. When the assembly is
fully seated (CPU Module Connector J1 has mated with Backplane Connector
P2/P4), turn the module’s Captured Panel Fasteners (clockwise) to secure CPU
Module to the Chassis thus establishing a low resistance path between the CPU
Module and Chassis Ground. Make sure that the module’s Captured Panel
Fasteners are snug but don’t over-tighten them.

3.2.4 Replacing a Failed CPU while the other CPU Remains On-line

If you have a ControlWave Redundant Controller fully installed and running a plant or
process, and one of its CPU Modules fails, you can use the following procedure to replace
the failed board, while still allowing the other CPU Module to control the plant/process.

WARNING

If performing this procedure in a Class 1 Div 2 hazardous environment, be sure to turn OFF
the power to the Power Supply Sequencing Module (PSSM) of the affected unit, prior to
removing a failed PSSM or CPU Module. (See steps 1 to 3 of this procedure.)

In addition, any time a maintenance procedure such as this is performed on a controller
connected to a ‘live’ plant or process, adequate safeguards must be taken to ensure that
manual backup systems are available and ready should the control system fail during the
maintenance procedure.

3-2 / Service CI-ControlWaveRED

1. First, check to see that a power problem is not the actual cause of the failure of this

particular CPU. To do this, check the POWER SYSTEM STATUS LEDS (A and B)
on the CCRS (see Figure 3-6). They must both be lit GREEN. In addition, the two
LEDs labeled ‘FAIL’ must NOT be blinking. If this is NOT the case, check cable
connections between the CCRS Module and the Communications Redundancy Back­plane (CCRB).

Finally, open the bezel door of each Power Supply Sequencer Module (PSSM), and

verify that the PWRGOOD LED is lit, and that the MC and PWRFAIL LEDs are
NOT lit.

If all of these LED checks indicate there are no power problems, continue with step 2

of this procedure, otherwise, stop and correct the power problems first, and see if
they solve the failed CPU problem.

2. Take the A/B Enabled key switch on the CCRS out of automatic mode, and switch it

to the currently on-line operating CPU (A or B), in other words:

• If the ‘A’ CPU failed, turn the key switch to ‘B’.

• If the ‘B’ CPU failed, turn the key switch to ‘A’.

This will allow control of the process/plant to be maintained during the repair
procedure.

3. Power OFF the failed unit. (The power switch is located underneath the bezel door

on the Power Supply Sequencer Module (PSSM)).

4. Save the current ControlWave configuration parameters and soft switch settings of

the on-line CPU in a file on your PC. If, by chance, you already have this
information saved, you can skip to Step 5, otherwise continue with this step. There
are two ways to do this: You can save the information in a Flash Configuration
Profile (*.FCP) file, or you can save the information in your NETDEF file. For this

procedure, we will cover the FCP method only, because using the NETDEF method
has certain variations depending upon how you are communicating with the
ControlWave.

Saving Configuration Parameters and Soft Switch Settings into an FCP File:

a. Plug a cable from your PC/laptop into a configured serial port on-the CCRS panel

and establish communications with the on-line CPU using either NetView or
LocalView. Start the Flash Configuration Utility (see Figure 3-1).

b. Sign on, and leave the Flash Configuration Utility running.
c. Click on [Load From RTU]. This loads the current flash configuration and soft

switch settings into the Flash Configuration Utility. Click on [Close] after the
transfer is complete.

d. To save the current flash configuration and soft switch settings to an (*.FCP) file

on your PC, click on the [Write Profile] button, then specify the path and name
you want to use for this *.FCP file. Next, click on [Save].

CI-ControlWaveRED Service / 3-3

e. If practical to do so, leave the Flash Configuration Utility running, because it

will be needed later in step 12.

f. Disconnect the cable from the serial port on the CCRS.

Figure 3-1 - FLASH Configuration Utility Menu

5. Disconnect the four Serial Comm. cables and any Ethernet cables from the failed

CPU Module. For details on these cables, see Sections 2.3.3.3 & 2.3.3.4.

6. Remove the Bezel Assembly of the failed CPU Module (See Section 3.2.2 for

information on removing the Bezel Assembly)

7. Remove the failed CPU Module and set it aside (See Section 3.2.3 for information on

removing the CPU Module).

8. Unpack the new (spare) CPU Module, and set its switches to match exactly those on

the failed CPU Module, except for the following changes:

• Disable redundant operation by setting switch SW1-6 to ON.

• Disable the boot project from running by setting switch SW1-8 to OFF. (This puts

this CPU in diagnostic mode.)

9. Insert the new CPU Module in the slot where the failed Module had been, but do

NOT put in the bezel assembly at this time.

10. Connect the cable from your PC locally into serial port COM2 of the new CPU

Module (do NOT connect through the CCRS).

11. Apply power to the CPU Module. It should come up with an indication of “D0“ on the

display, indicating that it is in diagnostic mode.

12. On the PC, start the Flash Configuration Utility (if not already running) and sign

on. (Since this is a new CPU, you must use ‘SYSTEM’ and ‘666666’ to sign on).

3-4 / Service CI-ControlWaveRED

13. Click on [Read Profile] and select whichever Flash Configuration Profile (*.FCP)

file contains the flash parameters and soft switch settings for this ControlWave
(the file you saved in Step 4), then click on [Open]. A status message should appear
saying ‘Flash configuration profile has been read successfully’.

14. Click on [Save to RTU], and the contents of the FCP file will be copied to the new

CPU board, effectively setting the configuration parameters and soft switches.

15. Click on [Close] at the end of the transfer.

16. You will be asked whether or not you want to save these parameters to the NETDEF

file. This is optional. If you are in NetView, you can do this. If you choose this option
while in LocalView, the parameters will NOT be permanently saved unless you are
in ‘Configure’ mode. Answer [Yes] or [No] as desired.

17. You will see a message box warning you that certain parameters are only activated

when the unit is powered OFF and back ON. Click on [OK]. Then click on [Close] to
exit the Flash Configuration Utility.

18. Turn power to the newly installed CPU Module OFF.

19. Disconnect the serial cable from the newly installed CPU Module.

20. Remove the newly installed CPU Module again.

21. Change switches on the CPU Module as follows:

• Re-enable redundant operations by setting switch SW1-6 to OFF.

• Re-enable the boot project by setting switch SW1-8 to ON. (This disables

diagnostic mode.)

22. Now that the switches are set properly, put the CPU Module back in its slot, and

install the Bezel Assembly.

23. Re-connect the four Serial Communication cables and any Ethernet cables, which

were removed in step 5, to the CPU Module.

24. Apply power to the new CPU. The new parameters will be activated, and the on-line

CPU will perform a side-load to update the new CPU Module. If the update is
successful, ‘BA’ will appear on the display of the newly installed CPU Module.

25. Turn the A/B Enabled key switch to the center position. This puts the controller

back into automatic mode. The unit can now operate redundantly again.

Variations on Steps 4 and 13 of this Procedure - Saving Flash Configuration
Parameters in the NETDEF File

In the procedure, above, we used the Flash Configuration Profile (FCP) file to save flash
configuration parameters and soft switch settings. Instead, we could have saved this
information in the NETDEF file for this network. This method, however, varies depending
upon whether you are communicating via LocalView or NetView.

CI-ControlWaveRED Service / 3-5

If communicating via NetView:

If communicating via NetView, this method is straightforward, since you will already have
chosen a NETDEF file in order to communicate.

In the Flash Configuration Utility, choose [Load From RTU] to call up the flash
parameters and soft switch settings from the on-line ControlWave.

Click on [Close] at the conclusion of the transfer, then click on [Save to NetDef] and all of
this information will be saved in your current NETDEF file.

Later, in Step 13, when configuring the new CPU Module, choose [Load From NetDef] to
call the information up, instead of [Read Profile].

If communicating via LocalView

If communicating via LocalView, in order to make use of the actual NETDEF file, you
MUST choose ‘Configure Mode’ when starting LocalView. Otherwise, LocalView will use its
own temporary NETDEF file, which will automatically disappear on program exit. For full
details on using LocalView in ‘Configure Mode’ please refer to Chapter 5 of the Open BSI
Utilities Manual (document# D5081).

If using LocalView to save
data in a NETDEF file, you
MUST choose ‘Configure’
mode.

Figure 3-2 - Choosing ‘Configure Mode’ when Starting LocalView

In addition, when setting up LocalView communications, you must check the “Use an
existing configuration (.NDF) file” box, then use the [Browse] button to locate the

NETDEF file containing this ControlWave controller. Finally, choose the node name of the
controller from the list box (see Figure 3-3).

The remaining portions of this method are similar to using NetView:

In the Flash Configuration Utility, choose [Load From RTU] to call up the flash
parameters and soft switch settings from the on-line ControlWave. Click on [Close] at the
end of the transfer, then click on [Save to NetDef] and all of this information will be saved
in the NETDEF file you selected.

Later, in Step 13, when configuring the new CPU Module, choose [Load From File] to call
the information up, instead of [Read Profile].

3-6 / Service CI-ControlWaveRED

Figure 3-3 - Selecting ‘Use an existing configuration (.ndf) File’

Check this box, then specify the
NETDEF file which contains this
ControlWave

Specify the node name of the
ControlWave, as specified in
the NETDEF file.

(on IP RTU Setup Menu - Step 2 of 2)

3.2.5 Removal/Replacement of a Power Supply/Sequencer Module (PSSM)

1 Remove the applicable Bezel Assembly (see Section 3.2.2).
2 Remove the associated CPU Module (see Section 3.2.3 or 3.2.4).

3. Unplug the PSSM’s modular connectors TB1 (Power) and TB2 (Watchdog).

4. Loosen the two Captured Panel Fasteners that secure the PSSM to the Chassis and

then carefully slide the PPSM out of the front of the Chassis.

5. To replace the PSSM, the CPU Module must be removed. Carefully align the PSSM

with ControlWaveRED Slot 1 or Slot 3 (as required) and insert the unit into the
Chassis. When the assembly is fully seated (PSSM Connector J1 has mated with
Backplane Connector P1/P3), turn the module’s Captured Panel Fasteners
(clockwise) to secure the Power Supply/Sequencer Module to the Chassis thus
establishing a low resistance path between the PSSM and Chassis Ground. Make
sure that the module’s Captured Panel Fasteners are snug but don’t over-tighten
them.

6. Replace the CPU Module (see Section 3.2.3 or 3.2.4) and apply power.

3.2.6 Removal/Replacement of a CCRS Module (CCRSM)

1. Place any critical control processes under manual control. Shut down both PSSM

units by setting their Power Switches to the ‘O’ position.

2. Disconnect the Comm. Cable Assemblies from CCRSM connectors J5 and J6.

3. Loosen the four Captured Panel Fasteners that secure the CCRSM to the Chassis

and then carefully slide the CCRSM out of the front of the Chassis.

4. Remove the ribbon cables from connectors P5 (Slot A) and P6 (Slot B) on the

Backplane Board. Carefully eject both Cable End Connectors by simultaneously
actuating both Eject Tabs on the Cable Headers.

5. To replace the CCRS Module, follow steps 4 through 2 in reverse order and then

apply power to both PSSMs.

CI-ControlWaveRED Service / 3-7

3.3 TROUBLESHOOTING TIPS

3.3.1 Power Supply/Sequencer Module (PSSM) Voltage Checks

Only one bulk power source can be connected to a PSSM. Both PSSMs may share the same
power source or they may be discretely powered (see Figure 3-4):

TB2-1 = (+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
TB2-2 = (+VINF) Field Supply Input - Not Used
TB2-3 = (-VIN) (1st Supply Ground)
TB2-4 = (-VINF) (2nd Supply Ground) Internally connected to TB2-3 - Not Used
TB2-5 = Chassis Ground - CHASSIS (

)

Figure 3-4 - Power Supply/Sequencer Module’s TB1, TB2 & LED Designations

Bulk supply voltages can be checked at TB2 using a voltmeter or multimeter. PPSM’s are
factory configured for use with a nominal 12Vdc or 24Vdc bulk power supply. The
maximum and minimum input power switchpoints can be tested with the use of a Variable
dc Power Supply connected between TB2-1 (+) and TB2-3 (-). By increasing the input
voltage (starting at +10.6Vdc or +20.7Vdc) for +12V or +24V units respectively, you can
determine the point at which the unit will turn on, i.e., the point at which the green
PWRGOOD LED on the PSSM comes ON (Vt+). By decreasing the input voltage (starting at
+20Vdc or +30Vdc) for +12V and +24V units respectively, you can determine the point at
which the unit turns off, i.e., the point at which the green PWRGOOD LED on the PSSM
goes OFF (Vt-). If the value of the bulk power supply’s +12Vdc or +24Vdc output approaches
the value of Vt+ or Vt- it should be replaced by one with the correct +12V or +24V output.

3-8 / Service CI-ControlWaveRED

3.3.2 LED Checks

All ControlWaveRED Modules contain light emitting diodes (LEDs) that provide
operational and diagnostic functions. A brief synopsis of the individual module LEDs is
provided as follows:

PSSM: 3 LEDs: 1 MC LED, 1 PWRFAIL LED & 1 PWRGOOD LED
CPUM: 2 LEDs per Comm. Port = 4; 2 LEDs per Ethernet Port = 2
1 Idle LED, 1 Watchdog LED & the Port 80 LED Display Assembly
SCB: 2 LEDs per Comm. Port = 4; 2 LEDs Per Ethernet Port = 4
CCRSM: 6 LEDs: 1 UNIT A ON-LINE LED, 1 UNIT A FAIL LED, 1 UNIT B ON-LINE

LED , 1 UNIT B FAIL LED, 1 POWER SYSTEM STATUS A LED & 1 POWER
SYSTEM STATUS B LED

ControlWaveRED Module LED designations and functions are provided in Table 3-1.

Table 3-1 - LED Assignment

Module

PSSM MC Red ON 2msec after PWR_FAIL goes low *
PSSM PWRFAIL Red ON = Bulk or Regulated Power out of Specs. *
PSSM PWRGOOD Green ON = Normal operation - all supplies O.K. *
CPUM CR1 - WATCHDOG Red ON = Watchdog Condition - OFF = Normal
CPUM CR2 - IDLE Red ON = CPU Idle
CPUM CR3 - COMM 1 RX Red ON = RX Activity (Top-Left - see Fig 3-5)
CPUM CR3 - COMM 1 TX Red ON = TX Activity (Top-Right -see Fig 3-5)
CPUM CR3 - COMM 2 RX Red ON = RX Activity (Bottom-Left - see Fig 3-5)
CPUM CR3 - COMM 2 TX Red ON = TX Activity (Bottom-Right -see Fig 3-5)
CPUM CR8 - ENET Port 1 Red/Green ON Red = Data Collision (Left - see Fig 3-5)
CPUM CR8 - ENET Port 1 Red/Green ON Green = Receiving Data (Left -see Fig 3-5)
CPUM CR8 - ENET Port 1 Red/Green ON Red = Transmitting Data (Right - see Fig 3-5)
CPUM CR8 - ENET Port 1 Red/Green ON Green = Link O.K. (Right -see Fig 3-5)
SCB CR2 - COMM 3 RX Red ON = RX Activity (Top-Left - see Fig 3-5)
SCB CR2 - COMM 3 TX Red ON = TX Activity (Top-Right -see Fig 3-5)
SCB CR2 - COMM 4 RX Red ON = RX Activity (Bottom-Left - see Fig 3-5)
SCB CR2 - COMM 4 TX Red ON = TX Activity (Bottom-Right -see Fig 3-5)
SCB CR4 - ENET Port 2 Red/Green ON Red = Data Collision (Left - see Fig 3-5
SCB CR4 - ENET Port 2 Red/Green ON Green = Receiving Data (Left -see Fig 3-5)
SCB CR4 - ENET Port 2 Red/Green ON Red = Transmitting Data (Right - see Fig 3-5)
SCB CR4 - ENET Port 2 Red/Green ON Green = Link O.K. (Right -see Fig 3-5)
SCB CR5 - ENET Port 3 Red/Green ON Red = Data Collision (Left - see Fig 3-5)
SCB CR5 - ENET Port 3 Red/Green ON Green = Receiving Data (Left -see Fig 3-5)
SCB CR5 - ENET Port 3 Red/Green ON Red = Transmitting Data (Right - see Fig 3-5
SCB CR5 - ENET Port 3 Red/Green ON Green = Link O.K. (Right) (see Fig 3-5)
CPUM PORT 80 DISPLAY Red LED Matrix Status Codes (see Fig 3-5) **
CCRSM UNIT A ON-LINE Green ON = CPUA is on line
CCRSM UNIT A FAIL Red ON = CPUA has failed

CCRSM UNIT B ON-LINE Green ON = CPUB is on line

LED

Name

LED

Color

Function

Blinking Red = System A Backplane Cable is not
attached or has failed.

CI-ControlWaveRED Service / 3-9

Table 3-1 - LED Assignment (Continued)

Module

CCRSM UNIT B FAIL Red ON = CPUB has failed

CCRSM POWER SYSTEM A

STATUS

CCRSM POWER SYSTEM B

STATUS

* = see Figure 3-4, ** = see Sections 2.4.2 & 3.4.4

LED

Name

LED

Color

Blinking Red = System B Backplane Cable is not
attached or has failed.

Red/Green ON Green = All 3.3Vdc Pwr. Sources, i.e., V1, V2

& V3 are O.K.
ON Red = One or more of the Pwr. Sources V1, V2
and V3 are defective

Red/Green ON Green = +12VA and +12VB are good and

remaining logic 3.3V Pwr. Source V4 is O.K.
ON Red = Pwr. Source V4 is defective or +12VA or
+12VB is defective.

Function

Figure 3-5 - CPU Module Port & LED Designations

3.3.3 Wiring/Signal Checks

Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check
wiring for continuity, shorts & opens. Check I/O signals at their respective Terminal Blocks
(see Table 3-2).

Table 3-2 - I/O Field Wiring - Terminal Block Reference List

I/O Subsystem Figures Notes

Watchdog Ckt. 2-16 & 2-17 See Section 2.3.4.1.3
On-Line Status 2-18 See Section 2.3.4.2

3-10 / Service CI-ControlWaveRED

Figure 3-6 - CCRS Module LED Designations

3.4 GENERAL SERVICE NOTES

Certain questions or situations frequently arise when servicing the Bristol Controllers.
Some items of interest are provided in Sections 3.4.1 through 3.4.4.

3.4.1 Extent of Field Repairs

Field repairs to ControlWaveREDs are strictly limited to the replacement of complete
modules. ControlWaveRED Modules are sealed and employ a tamper indicator.
Disassembly of a ControlWaveRED Module constitutes tampering and will violate the
warranty. Defective ControlWaveRED Chassis or Modules must be returned to Bristol
Babcock for authorized service.

3.4.2 Disconnecting RAM Battery

ControlWaveRED CPU Lithium RAM batteries can be replaced while power is on. If the

RAM battery is disconnected when the power is off, the unit will still execute its FLASH­based application load (Boot Project) upon power-up, but all of the current process data will
be lost. Upon power-up, the unit will act as though it had just been booted and it will revert
back to the initial values specified in its application load. The battery may be disabled by
setting CPU Switch SW3 position 4 to the OFF position.

CI-ControlWaveRED Service / 3-11

Note:
If the lithium battery is removed when power is off, CPU Switch SW3-4 should be
set OFF for over a minute or power should remain off for at least a minute.

- or -

CPU Switch SW1-5 MUST be set OFF for the next Boot.

3.4.3 Maintaining Backup Files

It is essential to maintain a backup disk of each application load file to guard against an
accidental loss of process configuration data. Without a backup record, it will be necessary
to reconfigure the entire application load; that can be a very time consuming procedure.
Always play it safe and keep backup copies of your operating system loads. A copy of the
application load can be loaded into ControlWaveRED FLASH memory or saved to a PC’s
Hard Drive as a ZIP file.

3.4.4 Port 80 Display POST Checks

At start-up, by applying power or by depressing the momentary contact (RESET) switch
(SW4), the resident BIOS will initiate and test the hardware; this process is referred to as
POST, i.e., Power On Self Test.

The status of the POST progress (typically too fast to discern) is posted to the CPU
Module’s Port 80 Display. Successful POST completion is indicated with an 86 on the port
80 Display if the unit is in Recovery Mode. Detection of a fault will be indicated by a 2-digit
code on the Port 80 Display (see Table 3-3).

Table 3-3 - Port 80 POST Status Codes

Hex Code Definition

00 POST beginning.
01 CPU register test about to start.
02 NMIs are disabled; delay starts.
03 power-on delay finished.
04 kbd BAT done; reading kbd SYS bit.
05 disabling shadowing & cache.
06 calcing ROM cksum, wait kbd ctrllr.
07 cksum okay, kbd ctrllr free.
08 verifying BAT cmd to kbd ctrllr.

09 issuing kbd ctrllr cmd byte.
0A issuing kbd ctrllr data byte.
0B issuing pin 23, 24 blocking & unblocking.
0C issuing kbd ctrllr NOP cmd next.
0D testing CMOS RAM shutdown register.
0E checking CMOS cksum, updating DIAG byte.
0F initializing CMOS (if req’d every boot).

10 init CMOS status reg for date/time.

11 disabling DMA, interrupt ctrllrs.

12 disabling Port B, disabling video display.

13 init board, start auto-mem detect.

14 starting timer tests.

15 testing 8254 T2, for spkr, part B.

Note: See Table 2-9 for Running Status Codes.

3-12 / Service CI-ControlWaveRED

Table 3-3 - Port 80 POST Status Codes (Continued)

Hex Code Definition

16 testing 8254 T1, for refresh.
17 testing 8254 To, for 18.2 Hz.
18 starting memory refresh.

19 testing memory refresh.
1A testing 15usec refresh ON/OFF time.
1B testing base 64KB memory.
1C testing data lines.
1D currently loading the Boot Project

20 testing address lines.

21 testing parity (toggling).

22 base 64KB mem read/write test.

23 system init before vector table init.

24 init vector table.

25 reading 8042 for turbo switch setting.

26 initiating turbo data.

27 any init after vector table init is next.

28 setting monochrome mode.

29 setting color mode.
2A toggle parity before optional video ROM.
2B init before video ROM check.
2C control passed to video ROM.
2D video ROM returned control.
2E checking for EGA/VGA adapter found.
2F no EGA/VGA found, r/w test of video.

30 looking for video retrace signal.

31 retrace failed, checking alt. Display.

32 alt found, checking video retrace signal.

33 compare switches w/actual adapter type.

34 setting display mode.

35 check ROM BIOS data area at seg 40h.

36 setting cursor for power-on msg.

37 displaying power-on message.

38 save cursor position.

39 display BIOS ident. String.
3A display “Hit <DEL> to …” msg.

40 preparing vm test. vrfy from display.

41 preparing descriptor tables.

42 enter virtual mode for memory test.

43 enable inits for diagnostics mode.

44 init data for checking wraparound at 0:0.

45 checking for wrap, find total memory size.

46 write extended memory test patterns.

47 write conventional memory test patterns.

48 finding low memory size from patterns.

49 finding high memory size from patterns.
4A check ROM BIOS data area again.
4B check for <DEL>, clear low mem for soft reset.
4C clearing ext mem for soft reset.
4D saving memory size.
4E on cold boot, display 1st 64KB memtest.
4F on cold boot, test all of low memory.

50 adjust memsize for 1K usage.

CI-ControlWaveRED Service / 3-13

Table 3-3 - Port 80 POST Status Codes (Continued)

Hex Code Definition

51 system initialization in progress.
52 prepare for shutdown to real-mode.
53 saved regs & memsize, entering real-mode.
54 shutdown successful, restoring codepath.
55 disabling A20 line.
56 checking ROM BIOS data area again.
57 checking ROM BIOS data area some more.
58 clear the “Hit <DEL>” message.
59 test DMA page register.
60 verify from display memory (???).
61 test DMA0 base register.
62 test DMA1 base register.
63 checking ROM BIOS data area again.
64 checking ROM BIOS data area some more.
65 programming DMA ctrllrs 0 & 1
66 initializing INT ctrllrs 0 & 1.
67 starting keyboard test.
80 issuing reset cmd & clring output buffer
81 check for stuck keys & issue test cmd.
82 initializing circular buffer.
83 check for locked keys.
84 check for memsize mismatch.
85 check for pswd or bypass setup.
86 pswd checked. Do pgming before setup.
87 call the setup module.
88 back from setup, clr screen.
89 display power-on screen message.

8A display “Wait…” message.
8B do system & video BIOS shadowing.
8C load standard setup params into BIOSDATA.
8D check and initialize mouse.
8E check floppy disks.
8F configure floppy drives.

90 check hard disks.
91 configure IDE drives.
92 checking ROM BIOS data area again.
93 checking ROM BIOS data area some more.
94 setting base & ext mem sizes.
95 memsize adjusted for 1K, verifying disp mem.
96 initialization before calling C800h.
97 call ROM BIOS extension at C800h.
98 processing after extension returns.
99 configuring timer data area, printer base addr.

9A configuring serial port base addrs.
9B initialization before coprocessor test.
9C initializing the coprocessor.
9D processing after coprocessor initialized.
9E check ext kbd, kbdID, numlock settings.
9F issue keyboard ID command next.
A0 kbd ID flag reset.
A1 do cache memory test.
A2 display any soft errors.

3-14 / Service CI-ControlWaveRED

Table 3-3 - Port 80 POST Status Codes (Continued)

Hex Code Definition

A3 set keyboard typematic rate.
A4 program memory wait states.
A5 clear screen.
A6 enable parity and NMIs.
A7 initialization before calling E000h.
A8 call ROM BIOS extension at E000h.
A9 processing after extension returns.
B0 display system config. Box.
B1 test low memory exhaustively.
B2 test extended memory exhaustively.
B3 enumerate PCI space.

Note: Once the unit is running its application load, status codes posted to the

Port 80 Display have a different meaning than the Port 80 POST Status
Codes. The PORT 80 Display on the ONLINE unit is disabled during normal
running operation while that of the STANDBY unit should display Hex
Code ‘BA’ (Backup Available). Port 80 Running Status (Hex) Codes are
listed in Table 2-9. Once the system is running its application load the
STANDBY CPU’s Port 80 Display must be posting a Running Status Code of
‘BA’ when the ONLINE CPU goes off line (looses power, is shut off, etc.), or
it won’t switch over to become the ONLINE unit.

3.5 WINDIAG DIAGNOSTICS

Bristol’s WINDIAG software is a diagnostic tool used for testing ControlWaveRED CPU
memory, communications ports, etc., for proper performance. The ControlWaveRED must
be communicating with a PC equipped with Bristol’s WINDIAG program. CPU Module con­figuration switch SW1-8 must be set to the OFF (Closed) position to enable diagnostics.
Communication between the ControlWaveRED (with/without application loaded) and the
PC can be made via a Local or Network Port with the following restrictions:

• CPU Board Switch SW1-8 must be OFF (closed) to run the WINDIAG program. Setting

SW1-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into
diagnostic mode.

• Any ControlWaveRED communication port can be connected to the PC provided their

port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to 9600
bps operation).

• The ControlWaveRED communication port to be tested using the WINDIAG program

must be configured for 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave
Designer protocol operation. This can be accomplished via user defined Soft Switches, or
for ports COM2, COM3 and COM4, by setting CPU Board Switch SW1-3 OFF (closed).

• Communication port COM1 is only forced to 9600 bps operation when CPU Switches

SW1-3 and SW1-8 have both been set OFF (closed). COM1 can also be set to 9600 bps
operation via user defined Soft Switches.

• Setting CPU Board Switches SW1-3 and SW1-8 OFF (closed) prevents the ‘Boot Project’

from running, places the unit into diagnostic mode and forces communication ports
COM1 through COM4 to operate at 9600 baud.

COM1: From the factory, COM1 (originating on the CPU Bd.) defaults to 115.2 kbd (RS-232)

using the Internet Point to Point Protocol (PPP). Note: ControlWaveRED Port

CI-ControlWaveRED Service / 3-15

COM1 will be configured for RS-232 operation (at 9600 bps) by setting CPU
switches SW1-3 and SW1-8 OFF (closed). This will prevent the boot project from
running and places the unit into diagnostic mode. To test COM1 using the

WINDIAG program, it must not otherwise be in use and CPU Switch SW1-8 must
be set to the OFF position. Connection to a PC requires the use of an RS-232 “Null
Modem” cable (see Figure 2-9).

COM2: From the factory, COM2 (originating on the CPU Bd.) defaults to 9600 bps, 8-bits,

no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM2using the WINDIAG program, it must not otherwise be in use and CPU
Switch SW1-8 must be set to the OFF position. It is recommended that an RS-232
“Null Modem” cable be connected between COM2 and the PC (typically COM1)
(see Figure 2-9).

COM3: When factory set for RS-232 or RS-485 operation, COM3 (originating on the SCB)

defaults to 9600 bps, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer
protocol operation. This port utilizes an RJ-45 female connector (see Figures 2-7
through 2-9D and Table 2-4). To test COM3using the WINDIAG program, it must
not otherwise be in use and CPU Switch SW1-8 must be set to the OFF position.
Connection to a PC depends on the type of communications port jack utilized by
the PC.

If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a

special “Null Modem” cable equipped with RJ-45 male plugs and wired like the
null modem cable of Figure 9A, or use Bristol “Null Modem” cable P/N 392843-01-3
connected to two Bristol “RJ45 to DB9 Adapter” cables P/N 392844-01-0 (see
Figures 2-9A & 2-9D), to interconnect the PC to COM3.

If the PC’s RS-232 Port utilizes the standard 9-pin D-type male connector, the use

of the Bristol “Null Modem” cable P/N 392843-01-3 (see Figure 2-9A) and one
Bristol “RJ45 to DB9 Adapter” cable P/N 392844-01-0 (see Figure2-9D) will be
required. This RS-232 network, consisting of two cables, connects to COM3 of the
ControlWaveRED with an 8-pin RJ-45 male connector and to the PC (typically
COM1) with a 9-pin D-type female connector.

If RS-485 communications is required, an RS-485 cable can be assembled using the

connections provided in Table 2-5.

COM4: When factory set for RS-232 or RS-485 operation, COM4 (originating on the SCB)

defaults to 9600 bps, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer
protocol operation. To test COM4 using the WINDIAG program, it must not
otherwise be in use and CPU Switch SW1-8 must be set to the OFF position. In
lieu of the use of COM2, either an RS-232 “Null Modem” cable (see Figure 2-9) can
be connected between COM4 and the PC (typically COM1) or an RS-485 cable (see
Tables 2-3 & 2-4) can be connected between COM4 and the PC’s RS-485 Port.

Others: Any of the three optional Ethernet Ports can be connected directly or via a network

to a PC equipped with an Ethernet Port (see Figures 1-5 and 2-12 through 2-14). If
not configured with an address, the ControlWaveRED uses DHCP (by default) to
obtain an IP address.

To use the WINDIAG program place any critical process (associated with the
ControlWaveRED unit in question) under manual control. WINDIAG cannot be run while

3-16 / Service CI-ControlWaveRED

the ControlWaveRED application is running. Set the CPU Modules Switches SW1-3 and
SW1-8 to the OFF (closed) position. Perform steps 1 through 6 below.

1. Start the OpenBSI NetView Program. A menu similar to Figure 3-7 will appear.

2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI

Tools, then select Utilities Programs and then select Diagnostics.

Figure 3-7 - Netview Startup Menu - Example with Multiple Networks

3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 3-8 will

appear.

4. Select the module to be tested. Enter any prompted parameters. WINDIAG will

perform the diagnostics and display pass/fail results.

5. After all diagnostic testing has been performed, exit the WINDIAG program and then

exit the Netview Program if there aren’t any other units to be tested.

When you close the Netview program you will be prompted as to whether or not you

want to close the OpenBSI program; select Yes.

6. Set the ControlWaveRED CPU Switch SW1-8 to the ON (Open) position. The

ControlWaveRED should resume normal operation.

3.5.1 Diagnostics Using WINDIAG

All Controllers Modules except the Power Supply/Sequencer Module can be tested using the
WINDIAG program. From WINDIAG’s Main Diagnostics Menu (see Figure 3-8) the
following diagnostic tests can be performed:

CI-ControlWaveRED Service / 3-17

CPU & Peripherals Diagnostic: Checks the CPU Module (except for RAM & PROM).
PROM/RAM Diagnostic: Checks the CPU’s RAM and PROM hardware.
Communications Diagnostic: Checks Comm. Ports 1 through 4 - The External loop-back

tests require the use of a loop-back plug.

Ethernet Diagnostics: Checks Ethernet Ports 1 through 3 - The Loop-back Out

Twisted Pair tests require the use of a loop-back plug.

Figure 3-8 - WINDIAG Main Diagnostics Menu

3.5.1.1 Communications Diagnostic Port Loop-back Test

WINDIAG’s Communications Diagnostic Menu (see Figure 3-10) provides for selection of
the communication port to be tested (1 through 4). Depending on the type of network (RS­232 or RS-485) and the port in question, a special loop-back plug is required as follows:

Ports 1, 2 & 4 set-up for RS-232 use a 9-pin female D-type loop-back plug (see Fig. 3-9).
Port 4 set-up for RS-485 use a 9-pin female D-type loop-back plug (see Fig. 3-11).
Port 3 set-up for RS-232 use an 8-pin male RJ-45 loop-back plug (see Fig. 3-9).
Port 3 set-up for RS-485 use an 8-pin male RJ-45 loop-back plug (see Fig. 3-11).

This group of tests verifies the correct operation of the Communication Interface. COM1,
COM2, COM3 and COM4 can be tested with this diagnostic. The ControlWaveRED com­munication port that is connected to the PC (local or network and used for running these
tests) can’t be tested until diagnostics have been established via one of the other ports, i.e.,
to test all ControlWaveRED communication ports (via WINDIAG), communications with
the PC will have to be established twice (each time via a different port). It should be noted
that the ControlWaveRED communication port that is connected to the PC (RS-232, RS­485 or Ethernet) must be good for WINDIAG to run the Communications Diagnostics.

3-18 / Service CI-ControlWaveRED

Figure 3-9 - RS-232 Loop-back Plugs

Figure 3-10 - WINDIAG’s Communications Diagnostic Menu

3.5.1.2 COM 1, 2, 3, 4 External Loop-back Test Procedure

1. Connect an external loop-back plug to the CPU Port to be tested, i.e., J2 of CPU for Port

1, J3 of CPU for Port 2, J2 of SCB for Port 3, or J3 of SCB for Port 4 (see Figures 3-9
through 3-11).

CI-ControlWaveRED Service / 3-19

Figure 3-11 - RS-485 Loop-back Plugs

2. Type "1," "2," "3," or "4" for the port to test.

3. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5.

4. Click on RUN button next to External loop-back.

 Test responses:

a) Success - All sections of test passed
b) Failure - TXD RXD Failure

- CTS RTS Failure

 Execution time < 5 sec.

3.5.1.3 Ethernet Diagnostic Port Loop-back Test

WINDIAG’s Ethernet Diagnostic Menu (see Figure 3-13) provides for selection of the
Ethernet communication port to be tested (1 through 3). A special loop-back plug is
required to perform the Ethernet loop-back test (see Figure 3-12).

Figure 3-12 - RJ-45 Ethernet Loop-back Plug

3-20 / Service CI-ControlWaveRED

If a ControlWaveRED Ethernet port is connected to the PC (and used for running these
tests), it can’t be tested until diagnostics have been established via one of the other ports,
i.e., to test all ControlWaveRED communication ports (via WINDIAG), communications
with the PC will have to be established twice (each time via a different port. It should be
noted that the ControlWaveRED communication port that is connected to the PC (RS-232,
RS-485 or Ethernet) must be good for WINDIAG to run the Communications Diag-nostics.

This test configures the Ethernet to transmit and receive via the twisted pair port. Test
frames are transmitted and compared against received frames.

Figure 3-13 - WINDIAG’s Ethernet Diagnostic Menu

3.5.1.4 Ethernet Port 1, 2 & 3 External Loop-back Test Procedure

1. Connect an external RJ-45 Ethernet loop-back plug (see Figure 3-16) into the Ethernet

Port to be tested, i.e., J4 of CPU for Port 1, J5 of SCB for Port 2, or J7 of SCB for Port 3.

2. Type "1," "2," or "3" for the port to test.

3. Click on the "RUN" button next to the Loop-back out twisted pair test.

CI-ControlWaveRED Service / 3-21

4. Click on RUN button next to External loop-back.

• Test responses:

a) Success - All sections of test passed

b) Xmit Error
c) Rx Error
d) Buffer Compare Failure

3.6 CORE UPDUMP

In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for
evaluation by Bristol, Inc. engineers; this may be the case when the unit fails for no
apparent reason. This upload is referred to as a ‘Core Updump.’ A Core Updump may be
required if the ControlWaveRED Controller repeatedly enters a ‘Watchdog State’ thus ill
effecting system operation. A Watchdog State is entered when the system crashes, i.e., a
CPU timeout occurs due to improper software operation, a firmware glitch, etc. In some
cases the Watchdog State may reoccur but may not be logically reproduced.

‘Crash Blocks’ (a function of firmware provided for watchdog troubleshooting) are stored in
CPU RAM. The user can view and save the ‘Crash Blocks’ by viewing the Crash Block
Statistic Web Page (see Chapter 4 of the Open BSI Technician’s Toolkit - D5087). Crash
Block files should be forwarded to Bristol for evaluation. If additional information is
required to evaluate the condition, a Core Updump may be requested by Bristol. Once the
file generated by the Core Updump has been forwarded to Bristol, it will be evaluated and
the results will be provided to the user.

Follow the five steps below to preserve the ‘failed state’ when the unit ‘crashes,’ i.e., enters
a Watchdog State and to perform a Core Updump.

1. Set CPU Module Switch SW1-1 OFF (Disable Watchdog Timer). If SW1-4 is ON, set it

OFF (Enable Core Updump).

2. Wait for the error condition (typically FF on Port 80 Display).

3. Connect the ControlWaveRED’s Comm Port 1(on the CPU & Communications
Redundancy Switch Module) to a PC using a Null Modem Cable (see Figure 2-9).

4. Operate the CPU Module’s RUN/REMOTE/LOCAL Switch as follows:

Note: Perform each step in less than 1 second.

Turn RUN/REMOTE/LOCAL Switch to RUN
Turn RUN/REMOTE/LOCAL Switch to REMOTE
Turn RUN/REMOTE/LOCAL Switch to LOCAL
Turn RUN/REMOTE/LOCAL Switch to REMOTE
Turn RUN/REMOTE/LOCAL Switch to LOCAL

5. Start the PC’s HyperTerminal Program (at 115.2kbaud) and generate a receive using
the 1KX-Modem protocol. Save the resulting Core Updump in a file to be forwarded to
Bristol for evaluation.

When the ‘active unit’ of a ControlWaveRED has failed, it will not recover but forces the
Watchdog Relay so that the ‘standby unit’ takes over. Once the Core Updump has
completed, set the failed unit’s CPU Switch SW1-1 ON (Watchdog Circuit Enabled) and
SW1-4 ON (Normal Run Mode), if required and then power cycle the failed ControlWave
unit to receive the “side load,” and to become a valid standby unit.

3-22 / Service CI-ControlWaveRED

3.7 TROUBLESHOOTING REDUNDANCY PROBLEMS

There are several conditions, which can prevent the redundancy set-up from functioning.
Some relate to configuration errors in the redundancy set-up itself, others relate to
conditions, which cause the Standby to not be ready to take over if a failure occurs.

Some of the possible conditions that prevent redundancy from working include:

• A/B unit DIP switches set improperly. These need to be set to opposite values; i.e. one

CPU must be the "A" unit, and the other must be the "B" unit; you must never have two
"A" units or two "B" units.

• Switch settings must be correct. See Section 2.3.3.1 earlier in this manual, for details.

• Insufficient memory available in the backup unit.

• Mismatch between the "A" and "B" unit (or between boot project in the standby unit and

executing project in the on-line unit) with respect to Port configuration parameters,
historical parameters, soft switch parameters, IP routing parameters, or application
parameters. Any time an update is made to Flash parameters in the on-line unit, the
same changes should be saved to the backup, or a mismatch will exist the next time the
units are booted. NOTE: It is possible to configure system variables, which allow certain
mismatches to exist, without preventing redundant operation (errors are treated as
warnings.) See the [Ignore] button in the ‘Redundancy’ page of the System Variable
Wizard.

• A mismatch in Historical configuration or data (audit/ archive) can result in the standby

unit, never being ready to take over for the on-line unit. This would be indicated by the
on-line unit operating correctly, but the standby unit continuously cycling through the
sequence ‘BD’, ‘BC’, ‘BA’, ‘BD’. To correct this problem, the procedure, shown below,
must be followed:

PROCEDURE FOR CORRECTING HISTORICAL CONFIGURATION/DATA MIS­MATCHES

Indication: Standby unit never stays at ‘BA’, it continually cycles through ‘BD’, ‘BC’, ‘BA’

and back to ‘BD’.

Note: For this procedure, we are assuming “A” is the on-line unit, and “B” is the

standby; if the converse is true, reverse the letters.

Note: The sequence shown herein is critical; the steps must be performed in the order

shown.

Step # Unit A – Online Unit Unit B – Standby Unit

1.

2.

3.

4.

• Power OFF this unit.

• Power OFF this unit.

• Power ON this unit (it should now go

on-line).

• Start the Flash Configuration Utility

(from within LocalView/NetView).

• On the ‘Archives’ page, remove all of

the archive files.

CI-ControlWaveRED Service / 3-23

Step # Unit A – Online Unit Unit B – Standby Unit

• On the ‘Audit’ page, set the number

of alarms and events both to 0.

• Then choose [Save to Rtu]. DO NOT

save changes to the NETDEF file.

• Exit the Flash Configuration utility.

5.

6.

7.

8.

9.

10.

11.

12.

• Power ON this unit.

• Start the Flash Configuration

Utility.

• Choose [Load From RTU].

• Power OFF this unit, but leave

the Flash Configuration Utility
running.

• Verify that the “B” unit is OFF.

(See Step 10.)

• Power ON the “A” unit.

• Power OFF this unit.

• Power ON this unit. It should go on-

line, with a clear historical system.

• Choose [Save to Rtu]. This

effectively transfers the historical
configuration, but not the data.

• Power OFF this unit.

• Power ON this unit, it will receive a

side-load of all data from the on-line
unit.

• ‘BA’ (without repeated cycles of ‘BD’,

‘BC’) indicates success.

3.8 ControlWaveRED FUNCTIONAL TESTS

Tests provided herein allow the user to verify the proper functionality of the ControlWave
RED. Note: The ControlWaveRED must be running a valid redundant Control­Wave project.

• Basic Reset and Supervisory Power-Up Test (Sections 3.8.1)

• Redundant Power Source and Supervisory Power-Up Tests (Section 3.8.2)

• Watchdog Mechanism Power-Up Tests (Section 3.8.3)

• Primary CPU Selection on Power-Up Tests (Section 3.8.4)

• Tests of Switchover from ‘Dead’ Primary Selected Unit on Power-Up (Section 3.8.5)

• Forced Primary CPU Selection on Power-Up Tests (Section 3.8.6)

• Normal Power-Up and Switchover Tests (Section 3.8.7)

• Normal Power-Up and Forced Switchover Tests (Section 3.8.8)

• On-Line Relay Functional Tests (Section 3.8.9)

• Communication Ports Functional Tests (Section 3.8.10)

3-24 / Service CI-ControlWaveRED

3.8.1 Basic Reset and Supervisory Power-Up Tests

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF

Turn External Supply Power ON
A & B Power System Status LED’s should initially be RED
After approximately 1 second, both Power System Status LED’s should change to
GREEN

3.8.2 Redundant Power Source & Supervisory Power-Up Tests

Initial conditions:

Resume from last test; Both Power System Status LED’s should be GREEN

Turn PSSM A OFF
A Power System Status LED should change to RED
Turn PSSM A ON
A Power System Status LED should change to GREEN
Turn PSSM B OFF
B Power System Status LED should change to RED
Turn PSSM B ON
B Power System Status LED should change to GREEN

3.8.3 Watchdog Mechanism Power-Up Tests

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON
A & B Fail LED’s should initially be RED
After both CPU’s go through self-test, the primary CPU should go on-line (On-Line
LED = GREEN), and the backup unit should be side loaded from the primary (Display
= BD -> BC -> BA); both A & B Fail LED’s should go OFF
Turn PSSM A OFF; If CPU A was previously on-line, then CPU B should go on-line
when PSSM A is turned off; If CPU B was previously on-line, it will remain on-line
A Fail LED should change to RED; B Fail LED should remain off
Turn PSSM A ON
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should change to OFF; B Fail LED should remain off
Turn PSSM B OFF; CPU A should go on-line
B Fail LED should change to RED; A Fail LED should remain off
Turn PSSM B ON
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should change to OFF; A Fail LED should remain off

CI-ControlWaveRED Service / 3-25

3.8.4 Primary CPU Selection on Power-Up Tests

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = GREEN,
B On-Line LED = OFF
After CPU A completes self-test, the A Fail LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = OFF, B On-Line
LED = ON
After CPU B completes self-test, B Fail LED should go OFF
After CPU A completes self-test, it should be side loaded from the primary CPU (B); (A
CPU Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF

3.8.5 Tests of Switchover from “Dead” Primary Selected Unit on Power-Up

Initial conditions: PSSM A switch = OFF; PSSM B switch = ON; Ext Supply

Pwr = OFF; A/B Primary Switch = A; A/B Enabled Switch = AUTO (center

position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = ON, B On-Line
LED = OFF
A Fail LED remains RED as PSSM A is off
CPU B should complete self-test, but cannot be side loaded from the primary CPU (A)
because A is powered down; CPU B should display BD; B Fail LED should remain
RED

After a time delay of 13 seconds, the CCRS will attempt to bring CPU B on­line:

B On-Line LED should change to ON & A On-Line LED should change to OFF
CPU B should run its self-test; After B completes self-test, B Fail LED should go OFF
(CPU B is now on-line); A Fail LED should remain RED & A On-Line LED should
remain OFF
Restore CPU A
Turn PSSM A ON
Initially: A Fail LED = RED; A On-Line LED should remain OFF
After CPU A completes self-test, it should be side loaded from the primary CPU (B);

3-26 / Service CI-ControlWaveRED

(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF

Initial conditions: PSSM A switch = ON; PSSM B switch = OFF; Ext Supply

Pwr = OFF; A/B Primary Switch = B; A/B Enabled Switch = AUTO (center

position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = OFF, B On-Line
LED = ON
B Fail LED remains RED as PSSM B is off
CPU A should complete self-test, but cannot be side loaded from the primary CPU (B)
because B is powered down; CPU A should display BD; A Fail LED should remain RED

After a time delay of 13 seconds, the CCRS will attempt to bring CPU A on­line:

A On-Line LED should change to ON & B On-Line LED should change to OFF
CPU A should run its self-test; After A completes self-test, A Fail LED should go OFF
(CPU A is now on-line); B Fail LED should remain RED & B On-Line LED should
remain OFF
Restore CPU B
Turn PSSM B ON
Initially: B Fail LED = RED; B On-Line LED should remain OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF

3.8.6 Forced Primary CPU Selection on Power-Up Tests

Initial conditions: PSSM A switch = ON; PSSM B switch = ON; Ext Supply

Pwr = OFF; A/B Primary Switch = A; A/B Enabled Switch = B (right position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = OFF, B On-Line
LED = ON
After CPU B completes self-test, B Fail LED should go OFF
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF
Turn PSSM B OFF
B Fail LED should go ON and B On-Line LED should remain ON
Turn PSSM B ON
After CPU B completes self-test, B Fail LED should go OFF
B On-Line LED should remain ON

CI-ControlWaveRED Service / 3-27

Initial conditions: PSSM A switch = ON; PSSM B switch = ON; Ext Supply

Pwr = OFF; A/B Primary Switch = B; A/B Enabled Switch = A (left position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = ON, B On-Line
LED = OFF
After CPU A completes self-test, A Fail LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF
Turn PSSM A OFF
A Fail LED should go ON and A On-Line LED should remain ON
Turn PSSM A ON
After CPU A completes self-test, A Fail LED should go OFF
A On-Line LED should remain ON

3.8.7 Normal Power-Up & Switchover Tests

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = GREEN, B On­Line LED = OFF
After CPU A completes self-test, the A Fail LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF
Turn PSSM A OFF
B On-Line LED should change to GREEN, A On-Line LED should change to OFF & A
Fail LED should change to RED
Turn PSSM A ON
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF
Turn PSSM B OFF
A On-Line LED should change to GREEN, B On-Line LED should change to OFF & B
Fail LED should change to RED
Turn PSSM B ON
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON

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Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = OFF, B On-Line
LED = GREEN
After CPU B completes self-test, the B Fail LED should go OFF
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF
Turn PSSM B OFF
A On-Line LED should change to GREEN, B On-Line LED should change to OFF & B
Fail LED should change to RED
Turn PSSM B ON
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF
Turn PSSM A OFF
B On-Line LED should change to GREEN, A On-Line LED should change to OFF & A
Fail LED should change to RED
Turn PSSM A ON
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF

3.8.8 Normal Power-Up & Forced Switchover Tests

Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = GREEN, B On­Line LED = OFF
After CPU A completes self-test, the A Fail LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF
Change A/B Enabled Switch to B (right position): Force Switchover to B
B On-Line LED should change to GREEN, A On-Line LED should change to OFF & A
Fail LED should change to RED
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF
Change A/B Enabled Switch to A (left position): Force Switchover to A
A On-Line LED should change to GREEN, B On-Line LED should change to OFF & B
Fail LED should change to RED
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF

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Initial conditions:

PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center position)

Turn External Supply Power ON
Initially: A Fail LED = RED, B Fail LED = RED; A On-Line LED = OFF, B On-Line
LED = GREEN
After CPU B completes self-test, the B Fail LED should go OFF
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF
Change A/B Enabled Switch to A (left position): Force Switchover to A
A On-Line LED should change to GREEN, B On-Line LED should change to OFF & B
Fail LED should change to RED
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(CPU B Display = BD -> BC -> BA)
B Fail LED should go OFF and B On-Line LED should remain OFF
Change A/B Enabled Switch to B (right position): Force Switchover to B
B On-Line LED should change to GREEN, A On-Line LED should change to OFF & A
Fail LED should change to RED
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(CPU A Display = BD -> BC -> BA)
A Fail LED should go OFF and A On-Line LED should remain OFF

3.8.9 On-Line Relay Functional Tests

The CCRS Module has two sets of isolated relay contacts that indicate (by being closed)
which of the pair of CPU modules is currently on-line. Terminal block plug J7 on the CCRS
panel gives access to the relay contacts for test using the following procedure. Refer to
Figure 3.3 for connector and pin identification. An ohmmeter or continuity indicator may be
used to check relay status.

Initial conditions: PSSM A switch = ON; PSSM B switch = ON; Ext Supply Pwr

= OFF; A/B Primary Switch = A; A/B Enabled Switch = A (left position)

Check continuity between J7-1 & J7-2; there should be continuity indicating CPU A is
on-line
Check continuity between J7-3 & J7-4; there should be no continuity indicating CPU B
is not on-line

Turn External Supply Power ON
A On-Line LED should be ON
Check continuity between J7-1 & J7-2; there should be continuity indicating CPU A is
on-line
Check continuity between J7-3 & J7-4; there should be no continuity indicating CPU B
is not on-line

Change A/B Enabled Switch to B (right position): Force Switchover to B
B On-Line LED should be ON
Check continuity between J7-1 & J7-2; there should be no continuity indicating CPU A

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is not on-line
Check continuity between J7-3 & J7-4; there should be continuity indicating CPU B is
on-line

3.8.10 CCRS Assembly Communication Ports Functional Tests

3.8.10.1 Configuration for Port Tests

CPU modules A and B must be configured to run diagnostics prior to using the following
procedure (see Section 3.5). SW1-8 on each must be set to the “OFF” position to enable
diagnostics.

An RS232 cable must be connected between CCRS port COM1 (J1) and the PC configured
with ControlWave diagnostics (WINDIAG) and Open BSI Tools. Successful interaction
between the diagnostic tools and the testing of remaining ports COM2 Æ COM4 will serve
as test validation of COM1 switching through the CCRS. Refer to Sections 3.5.1.1 & 3.5.1.2
for required setup. (Note: PC connection to CCRS COM1 is preferable in the tests described
here).

Ports COM1 and COM 2 are always RS232 level, while COM3 and COM4 may be either
RS232 or RS485 dependent on the hardware assembly chosen. In the tests that follow,
utilize the appropriate loopback plugs and CCRS –> CPU cables based on the type of port to
be tested.

The CCRS module will switch the communication ports of the CPU currently on-line to the
set of connectors on its front panel. During first pass testing, the CCRS A/B Enabled switch
should be placed in the “A” position to force CPU A on-line and to run the serial com
diagnostics via interaction with the Open BSI Tools. When ports COM2, 3 and 4 have been
successfully tested, the switch should be moved to the “B” position and all tests should be
repeated for on-line CPU B.

3.8.10.2 Communication Port Switching Tests

Reference Section 2.3 and Figure 2-8

Establish communication between Open BSI Tools (NetView or LocalView) and the
selected CCRS CPU on port COM1
Bring up diagnostics (WINDIAG) and select the Communications Diagnostic test
Select the port to be tested (B = COM2, C = COM3, D = COM4), the number of passes
(enter “25”) and the Baud Rate (select 38.4 Kbps). Place the required loopback plug on
the port under test and click on the “RUN” button in the diagnostic window. If the port
paths are properly switched and all hardware is functional, the status display will
contain the message “Success” and the diagnostic should run for 25 passes before the
status message displays “Idle”.
Repeat the tests for all ports
Repeat all of the above after the alternate CPU is placed on-line with the A/B Enabled
switch

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