Fisher ControlWave Redundant I/O and Comm Switch Unit (I/O Switcher) Manuals & Guides

Instruction Manual

CI-ControlWaveREDIO
Jan., 2008

ControlWave REDIO

ControlWave Redundant I/O
And Communications Switch Unit

Remote Automation Solutions

www.EmersonProcess.com/Remote

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

These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions division (RAS) for further information.

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

EQUIPMENT APPLICATION WARNING

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

RETURNED EQUIPMENT WARNING

When returning any equipment to RAS for repairs or evaluation, please note the following: The
party sending such materials is responsible to ensure that the materials returned to RAS 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 RAS and save RAS harmless from
any liability or damage which RAS 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.

Remote Automation Solutions

A Division of Emerson Process Management
1100 Buckingham Street, Watertown, CT 06795
Telephone [phone]

WARRANTY

A. Remote Automation Solutions (RAS) warrants that goods described herein and manufactured by RAS are

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

B. RAS 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 RAS 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 RAS consent, (iii) not installed,
maintained and operated in strict compliance with instructions furnished by RAS 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 RAS unless endorsed
herein in writing. Further, there are no warranties which extend beyond the description of the face hereof.

F. No agent of RAS is authorized to assume any liability for it or to make any written or oral warranties beyond

those set forth herein.

REMEDIES
A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost

to Buyer of any goods or parts found by Seller to be defective if Buyer notifies RAS 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 the RAS Watertown office, unless the RAS Watertown office
designates a different location, transportation prepaid, within thirty (30) days of the sending of such
notification and which upon examination by RAS proves to be defective in material and workmanship. RAS
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 RAS, the Buyer can arrange to have a RAS
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 n ot chargeable.

B. Under no circumstances will RAS 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 employees or other parties of goods sold under said agreement.

How to return material for Repair or Exchange

Before a product can be returned to Remote Automation Solutions (RAS) 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 RAS
Watertown 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 RAS Repair Dept. representative will

return the call (or other requested method) with a RA number.

B. E-MAIL
Accessing the form (GBU 13.01) via the RAS Web site (www.emersonprocess.c om/Bristol) and sending it

via E-Mail to [e-mail]

. A RAS Repair Dept. representative will return E-

Mail (or other requested method) with a RA number.

C. Mail
Mail the form (GBU 13.01) to

Remote Automation Solutions

A Division of Emerson Process Management
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

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

Calling the RAS Repair Department at [phone]. A RAS Repair Department representative will

record a RA number on the form and complete Part I, 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.

Remote Automation Solutions (RAS)

Repair Authorization Form (on-line completion)

(

Providing this information will permit Bristol, also doing business as Remote Automation Solutions (RAS) 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)

Bill to : Ship to:
Purchase Order: Contact Name:
Phone: Fax: E-Mail:

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)

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

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

: Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.) (Attach a separate sheet if necessary)

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

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

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

available

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

to the terms of warranty,, 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 RAS is unable to verify the discrepancy, would you like the product:

repaired returned replaced scrapped?

returned replaced scrapped?

returned replaced *see

below?

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

to contact that has the most knowledge of the problem is: phone

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

phone

Special Requests:
Ship prepaid to: Remote Automation Solutions, Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: [phone] Fax: [phone]

Form GBU 13.01 Rev. D 12/04/07

Emerson Process Management

Training

GET THE MOST FROM YOUR EMERSON

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. Emerson offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at various locations. By participating in our training, your personnel
can learn how to install, calibrate, configure, program and maintain your Emerson products
and realize the full potential of your system.

For information or to enroll in any class, go to http://www.EmersonProcess.com/Remote
click on “Training” or contact our training department in Watertown at [phone].

and

CI-ControlWaveREDIO

ControlWave Redundant I/O

and Communications Switch Unit

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION........................................................................................ 1-1

1.2 REDUNDANCY CONCEPTUALLY.............................................................................. 1-1

1.2.1 Redundant System Operation........................................................................................ 1-2

1.3 THEORY OF OPERATION ........................................................................................... 1-4

1.3.1 IORC Module Function .................................................................................................. 1-5

1.3.1.1 IORCM Functionality Overview .................................................................................... 1-6

1.3.1.2 IORCM Module Functional Details ............................................................................... 1-6

1.3.2 CWREDIO Power System .............................................................................................. 1-8

1.3.3 CWREDIO IORCM Control Logic.................................................................................. 1-8

1.3.3.1 IORCM LED Status Display Indicators ........................................................................ 1-9

1.3.3.2 CWREDIO IORCM Online Relays................................................................................. 1-9

1.3.3.3 Serial Communication Ports .......................................................................................... 1-9

1.3.3.4 Watchdog Inputs...........................................................................................................1-10

1.4 GENERAL DESCRIPTION ......................................................................................... 1-10

1.4.1 Overview of Local I/O and I/O Expansion Rack Redundancy Control Systems........ 1-11

1.4.1.1 Overview of the Local I/O Redundancy Control Systems........................................... 1-11

1.4.1.2 Overview of the I/O Expansion Rack Redundancy Control Systems......................... 1-11

1.4.2 Overview of the ControlWave Redundant I/O and Comm. Switch Unit .................1-14

1.4.3 Key System Features.................................................................................................... 1-14

1.5 PHYSICAL DESCRIPTION......................................................................................... 1-14

1.5.1 Chassis Assembly ......................................................................................................... 1-15

1.5.2 I/O Redundancy Backplane Assembly (IORB) ........................................................... 1-15

1.5.3 Power Supply/Monitor Modules (PSMM) .................................................................... 1-17

1.5.3.1 PSMM Power Switch SW1 ........................................................................................... 1-17

1.5.3.2 PSMM Board Fuse F1 .................................................................................................. 1-18

1.5.3.3 PSMM Board Connectors ............................................................................................. 1-18

1.5.3.4 PSMM LED ................................................................................................................... 1-18

1.5.4 I/O Redundancy Control Module (IORCM) .................................................................1-18

1.5.4.1 I/O Redundancy Control Module Connectors.............................................................. 1-19

1.5.4.2 I/O Redundancy Control Module Switches ................................................................. 1-20

1.5.4.3 I/O Redundancy Control Module LEDs ....................................................................... 1-21

1.5.5 I/O Redundancy Switch Modules (IORSM) ................................................................. 1-21

1.5.5.1 I/O Redundancy Switch Module Connectors............................................................... 1-23

1.5.5.2 Associated ControlWave I/O Modules........................................................................ 1-24

Section 2 - INSTALLATION & OPERATION

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

2.2 CWREDIO INSTALLATION SITE CONSIDERATIONS............................................ 2-2

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

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

2.3 CWREDIO INSTALLATION/CONFIGURATION .......................................................2-2

2.3.1 Mounting ControlWave Redundant I/O and Comm. Switch Units............................ 2-5

CI-ControlWaveREDIO Contents / 0 - 1

CI-ControlWaveREDIO

ControlWave Redundant I/O

and Communications Switch Unit

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 2 - INSTALLATION (Continued)

2.3.1.1 CWREDIO Grounding .................................................................................................... 2-5

2.3.1.2 Communication Ports.....................................................................................................2-5

2.3.1.3 RS-232 & RS-485 Interfaces .......................................................................................... 2-6

2.3.2 I/O Redundancy Switch Module Installation & Wiring ............................................. 2-11

2.3.2.1 Installation of I/O Redundancy Switch Modules ........................................................2-11

2.3.2.2 Wire Connections..........................................................................................................2-15

2.3.2.3 Shielding and Grounding ............................................................................................. 2-15

2.3.2.4 Digital Inputs................................................................................................................2-16

2.3.2.4.1 Digital Input Configurations........................................................................................2-17

2.3.2.5 Digital Outputs ............................................................................................................. 2-20

2.3.2.5.1 Digital Output Configurations..................................................................................... 2-20

2.3.2.6 Analog Inputs................................................................................................................ 2-24

2.3.2.6.1 Analog Input Configurations .......................................................................................2-25

2.3.2.7 Analog Outputs............................................................................................................. 2-26

2.3.2.7.1 Analog Output Configurations..................................................................................... 2-27

2.3.2.8 Universal Digital Input Modules ................................................................................. 2-29

2.3.2.8.1 Universal Digital Input Configurations ...................................................................... 2-30

2.3.3 Power Supply Wiring.................................................................................................... 2-32

2.3.3.1 Bulk Power Supply Current Requirements ................................................................2-32

2.3.3.2 Power Wiring ................................................................................................................ 2-34

2.3.3.3 Redundancy Control Field Wiring ............................................................................... 2-34

2.3.4 PSMM Cover ................................................................................................................. 2-36

2.4 OPERATIONAL DETAILS .......................................................................................... 2-36

2.4.1 Operation of IORC Module Switches........................................................................... 2-36

2.4.1.1 SW1 - Key Operated A/B ENABLE Mode Switch....................................................... 2-36

2.4.1.2 SW2 - A/B Primary Controller Select Switch.............................................................. 2-36

2.4.1.3 Forcing a Fail-over to the BACKUP (Standby) Unit via Program Control............... 2-36

2.4.1.4 Manually Forcing a Fail-over to the BACKUP (Standby) Unit ................................. 2-38

2.4.2 ControlWave Soft Switch Configuration and Communication Ports....................... 2-38

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 the I/O Redundancy Control Module ................................... 3-2

3.2.3 Removal/Replacement of a Power Supply/Monitor Module .........................................3-2

3.2.4 Removal/Replacement of a I/O Redundancy Switch Module ....................................... 3-2

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

3.3.1 Power Supply/Monitor Module (PSMM) Voltage Checks ............................................. 3-3

3.3.2 LED Checks .................................................................................................................... 3-4

3.3.3 Wiring/Signal Checks ..................................................................................................... 3-9

3.4 GENERAL SERVICE NOTES....................................................................................... 3-9

0 - 2 / Contents CI-ControlWaveREDIO

CI-ControlWaveREDIO

ControlWave Redundant I/O

and Communications Switch Unit

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 3 – SERVICE (Continued)

3.4.1 Extent of Field Repairs................................................................................................... 3-9

3.5 WINDIAG DIAGNOSTICS .......................................................................................... 3-10

3.5.1 Diagnostics Using WINDIAG ...................................................................................... 3-13

3.5.1.1 Communications Diagnostic Port Loop-back Test...................................................... 3-13

3.5.1.2 COM 1, 2, 3, 4 External Loop-back Test Procedure.................................................... 3-15

3.6 TROUBLESHOOTING REDUNDANCY PROBLEMS.............................................. 3-16

3.7 ControlWaveREDIO FUNCTIONAL TESTS............................................................ 3-17

3.7.1 Basic Reset and Supervisory Power-Up Tests ............................................................3-18

3.7.2 Redundant Power Source & Supervisory Power-Up Tests ........................................ 3-18

3.7.3 Watchdog Mechanism Power-Up Tests ....................................................................... 3-18

3.7.4 Primary CPU Selection on Power-Up Tests................................................................ 3-19

3.7.5 Tests of Switchover from “Dead” Primary Selected Unit on Power-Up .................... 3-19

3.7.6 Forced Primary CPU Selection on Power-Up Tests ...................................................3-20

3.7.7 Normal Power-Up & Switchover Tests........................................................................ 3-21

3.7.8 Normal Power-Up & Forced Switchover Tests ........................................................... 3-22

3.7.9 On-Line Relay Functional Tests .................................................................................. 3-22

3.7.10 I/O Redundancy Control Module Comm. Ports Functional Tests.............................. 3-23

3.7.10.1 Configuration for Port Tests ........................................................................................ 3-23

3.7.10.2 Communication Port Switching Tests......................................................................... 3-24

Section 4 - SPECIFICATIONS

4.1 ControlWave I/O REDUNDANCY CONTROL MODULE ........................................4-1

4.1.1 I/O Redundancy Control Module General Specifications ............................................. 4-1

4.2 POWER SUPPLY/MONITOR MODULE...................................................................... 4-3

4.2.1 Input Power Specs. .........................................................................................................4-3

4.2.2 Power Supply/Monitor Specs. ........................................................................................ 4-3

4.2.3 Power Supply Input Connector ..................................................................................... 4-3

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

4.4 ENVIRONMENTAL SPECIFICATIONS...................................................................... 4-5

4.5 DIMENSIONS ................................................................................................................ 4-5

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

REFERENCED BBI CUSTOMER INSTRUCTION MANUALS

ControlWave Process Automation Controller Instruction Manual...... CI-ControlWave

ControlWave I/O Expansion Rack Instruction Manual................ CI-ControlWaveEXP

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

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

APPENDICES/SUPPLEMENTAL INSTRUCTION

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

CI-ControlWaveREDIO Contents / 0 - 3

CI-ControlWaveREDIO

ControlWave Redundant I/O

and Communications Switch Unit

TABLE OF CONTENTS

REFERENCED BBI CUSTOMER SERVICE MANUALS (Continued)

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

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

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

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

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

0 - 4 / Contents CI-ControlWaveREDIO

Section 1

INTRODUCTION

1.1 GENERAL INTRODUCTION

This chapter provides an introduction and overview of the ControlWave® Redundant I/O
and Communications Switch Unit and redundant systems. The concept of redundancy,
theory of operation and general component/system description and physical component
descriptions are provided herein.

1.2 REDUNDANCY CONCEPTUALLY

Redundancy is a mechanism employed to prevent the loss of control over a process, and

minimize the loss of data, which can occur, if the ControlWave Controller should fail. It is
accomplished by using the ControlWave Redundant I/O and Communications Switch Unit
(CWREDIO). Redundancy is recommended for plants or processes where a loss of control
could result in damage, injury, or loss of production capability.

A ControlWave Redundant I/O and Comm. Switch Unit (CWREDIO) interfaces a pair of
ControlWave Process Automation Controllers or ControlWave I/O Expansion Racks
(which are identical except for CPU configuration switch settings and unique IP addresses).
The CWREDIO unit is housed in its own stainless steel chassis and utilizes an I/O
Redundancy Control Module (IORCM) to interface and switch process control between
CW_A/CWEXP_A and CW_B/CWEXP_B units.

Note: For the sake of simplicity the term CW will be used herein to mean either a

ControlWave or a ControlWave I/O Expansion Rack.

Figure 1-1 - Basic Redundancy Conceptual Diagram

I/O Redundancy Control Modules select one of the redundant CW units to serve as the
PRIMARY Controller while the other is selected as the hot BACKUP Controller. Although
field inputs (AIs, DIs and UDIs) are present at CW_A and CW_B, it is the PRIMARY
Controller that receives them and controls field outputs (AOs and DOs). The BACKUP
Controller is updated via a side-load from the PRIMARY Controller with historic,
configuration and process I/O data.

CI-ControlWaveREDIO Introduction / 1-1

The IORCM switches set control of the process and up to four communication ports from
one CW unit to the other in the event the unit (CW_A or CW_B) designated the PRIMARY
detects a failure and watchdogs. The process of transferring control from one CW unit to
the other is referred to as fail-over. A fail-over from one CPU to the other typically falls
into one of two categories:

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

• A loose cable

• Improper configuration, e.g. CW_A/CW_B board not seated properly

• Power supply failure at CW_A/CW_B (no power for CPU)

• Individual board or component breakdown at CW_A/CW_B

Software failures - Possible causes include:

• Application program running in the PRIMARY CPU ’crashes’, as indicated by an ’FF’

code on the display

• All tasks at the PRIMARY 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

These sorts of failures trigger a Watchdog Relay, and cause a fail-over from the PRIMARY
CW unit to the BACKUP CW unit. The BACKUP CW unit has been con-figured to be a
nearly exact duplicate of the PRIMARY CW unit, so it can assume full control over the
process when it becomes the new PRIMARY, i.e., the on-line CW unit.

ControlWave redundancy only handles a single point of failure i.e. either the "A" CW unit
can have a failure, or the "B" CW unit can have a failure. A failure of the "A" CPU, and the
"B" power supply, however, would disable the entire ControlWave Redundant I/O system,
even though the CWREDIO unit may be completely operational.

1.2.1 Redundant System Operation

Whenever the PRIMARY (on-line) ControlWave CPU receives a download of a new
ControlWave project file (boot project), that project is immediately transmitted to the
BACKUP (standby) ControlWave unit, and stored. This is known as a side-load. The boot

project is loaded into memory in the BACKUP CW unit but kept in the ’Stopped’ state. A
side-load also occurs at the initial startup of the BACKUP CW unit. Side-loads typically
occurs via Ethernet communications. It is not recommended to use RS-232 or RS-485 Ports
for this process.

Figure 1-2 - Redundant CW Side-load Diagram

1-2 / Introduction CI-ControlWaveREDIO

The PRIMARY ControlWave CPU is the only unit executing the project, communicating
with I/O boards and controlling the plant or process. The BACKUP ControlWave’s CPU
sits idle except for receiving updates from the on-line unit.

The updates from the PRIMARY unit to the BACKUP unit occur at the end of each task
execution cycle, unless:

• There have been no changes to process I/O output variables -and-

• The minimum update time

1

has not expired

1 The minimum update time is a configured value that may be used to limit the amount of traffic

between the on-line unit and the standby unit. Every time an update occurs the minimum update
timer is restarted. Unless process I/O output changes occur, any changes occurring during the time
prior to expiration of the configured update timer will not trigger an update to the standby unit.
Instead, they will be held until expiration of the timer, and the end of a task execution cycle. The
timer value is set via the _RDN_MIN_UPD system variable.

Updates between the PRIMARY unit, and the BACKUP unit, may consist of multiple
update messages, followed by a ‘commit’ message. Until the commit message is received,
the update messages are not applied to the BACKUP unit. This ensures that if the
PRIMARY unit fails before it sends the ‘commit’ message, that a partial update, e.g.
incomplete data, is not used. Instead, the BACKUP will discard the incomplete update
data, and start up using the last complete update that ended with a commit message.

In general, data is only transferred from the PRIMARY unit to the BACKUP unit if it has
changed. Among the types of data transferred are:

• Any changed process I/O variables

• All variables marked as RETAIN in the user’s project

• Any data in the static memory area (begins at address 3.100000)

• Certain function block parameters that are retained

• Changes to certain port configuration information, e.g., on-line baud rate changes, etc.

• Changes to user account definitions (usernames, passwords)

• Any newly generated alarms plus any changed alarm states from alarm function blocks

• Historical data (audit records, archive files)

Figure 1-3 - PRIMARY vs BACKUP CW Diagram

If a failure occurs at the PRIMARY unit, a Watchdog Relay is triggered, and the
CWREDIO’s I/O Redundancy Control Module (IORCM) will switch control to the BACKUP
CW’s CPU. The BACKUP CW now becomes the new on-line unit, i.e., the PRIMARY.

Note: Manually forced and program controlled fail-over are discussed in Chapter 2 –

Section 2.4.1.

CI-ControlWaveREDIO Introduction / 1-3

1.3 THEORY OF OPERATION

ControlWave Redundant I/O and Communications Switch Units (CWREDIO) interface to
two identical ControlWave (CW) Process Automation Controllers or two identical
ControlWave I/O Expansion Racks (CWEXP) to form a redundant control system. In this

system, one of the CWs or CWEXPs serves as the PRIMARY Controller and the other
serves as an automatically or manually switched BACKUP Controller that gets switched
over in the event of hardware failure or power loss at the PRIMARY.

Figure 1-4 ControlWave Redundant I/O and Communications Switch Unit

CWREDIOs consists of a Chassis with Backplane PCB, two Power Supply/Monitor Modules
(PSSM), an I/O Redundancy Control Module (IORCM) and from 1 to 8 I/O Redundancy
Switch Modules (IORSM). Operator interface for setup and control of the redundant system
is provided by the IORCM.

Note: From herein the term CW will imply ControlWave or ControlWave I/O Expansion

Rack.

CWREDIO’s I/O Redundancy Control Module circuitry provides the following system
functions:

• Operator Interface

• Automatic or Manual selection (switching) of the PRIMARY Controller

• Switching of serial communication ports 1 through 4 (associated with the selected

PRIMARY Controller of the pair)

• Switching of the output points of the various Output Modules (associated with the

selected PRIMARY Controller) to field terminations on matching I/O Redundancy
Switch Modules (IORSM) resident in the CWREDIO. Note: Field inputs are not

switched, but rather are supplied to both the PRIMARY and BACKUP CWs.

1-4 / Introduction CI-ControlWaveREDIO

1.3.1 IORCM Function

Front panel user interface, module/system status indicators and interconnections/switching
for serial communications from the selected PRIMARY CW serial communication ports to
CWREDIO front panel mounted field-accessed connectors are implemented by the IORCM.
Custom cabling provides I/O interface between each IORSM and Remotely Terminated I/O
Modules on the external CWs (PRIMARY and BACKUP). Process inputs (AI, DI, UDI) are
supplied to both the PRIMARY and BACKUP CWs and are never switched. Process
outputs are automatically switched from the selected CW unit at the IORSMs via IORCM
control.

Redundant circuitry is implemented to increase the reliability of the IORCM control logic.
Items not included in this implementation, or external signals or components that are not
part of this category are: external input/output signals, interface power (for display LEDs,
solid state relays, etc), relays and relay contacts, outputs of the voting circuitry and
interconnects.

Triple replicated system logic blocks and multiple logic power sources are used to provide a
high level of tolerance to miscellaneous hardware faults. The logic blocks monitor CW unit
status (CW watchdog signals), CWIORC module front panel settings (mode and primary
controller select switches) and internal control logic states, and generate on-line control
signals for both (redundant) external CW units.

The IORB implements system interconnections between the CWREDIO’s two Power Supply
Monitor Modules (PSMM), control logic on the IORC and IORS Modules. Separate logic and
relay power connections (+5.2Vdc (logic), +5.2Vdc (relay) from the same PSMM output
source are taken from each PSMM slot and carried to the IORCM slot. IORCM hardware
combines the sources to generate redundant logic (VCC_RED) and relay power
(RED_RLY_PWR) via ORing diodes, and passes these redundant sources through the IORB
for routing to all eight (8) IORSM slots. IORCM hardware also generates redundant A/B
system select signals (A/B I/O selection control), which are also routed through the IORB
for passage to all IORSM slots. Note: Logic power, relay power and A/B select signals

are only utilized by output version IORS Modules. An IORC Module also uses
relays to switch serial communication ports between the field and the selected
PRIMARY controller, i.e., CW_A or CW_B.

Two CWREDIO Control Panel Switches determine I/O redundancy modes of operation. The
key operated A/B ENABLE Mode Selection Switch selects one of three operating modes:
[FORCE] A, [AUTO SELECT] ENABLED or [FORCE] B. With this switch in [FORCE] A
position, all IORS output type modules are instructed to switch CW_A outputs to IORSM
mounted field terminations (regardless of CW_A watchdog signal status or IORCM logic
state). CW_B outputs are switched in a similar manner if this switch is in [FORCE] B
position. In [AUTO SELECT] ENABLED position, the source of I/O is based upon the
current online controller, which is selected according to logic algorithms embedded within
the IORC Module. The A/B Primary Selection Switch (examined at power up, only)
selects either CW_A or CW_B as PRIMARY Controller if the respective CW unit is ready
for on-line operation, i.e., corresponding watchdog signal is high (+24V), and the key
operated A/B Enabled Mode Selection Switch is in the ENABLED position.

CI-ControlWaveREDIO Introduction / 1-5

1.3.1.1 IORCM Functionality Overview

1. Automatically selects the external CW_A or CW_B units for PRIMARY and BACKUP
operation. Control is achieved based on the status of the watchdog signal cabled in from
each unit and control logic implemented within the IORC Module. Automatic CW
selection is prioritized based on the IORCM’s A/B PRIMARY Switch (at power up, only)
and the key operated A/B ENABLE Mode Selection Switch (when in the ENABLED
position only).

2. Forces selection of CW_A or CW_B as PRIMARY for control, based on the IORCM’s key

operated A/B ENABLE Mode Selection Switch when it is in the A or B positions
respectively (i.e. ignores the current watchdog state of the selected CW unit).

3. Generates individual external A_ONLINE and B_ONLINE control signals (as isolated

relay contact outputs) for the respective CW units. These signals are cabled to each CW
unit and select the PRIMARY Controller (i.e. the CW unit that is authorized to control
I/O and external communications).

4. Implements triple redundant voting circuits that select the PRIMARY CW unit based

on the criteria discussed in (1), (2) and (3) above (i.e. based on CW_A and CW_B
watchdog status, user controls and IORC Module algorithms).

5. Displays the status of the external CW_A and CW_B watchdog inputs.

6. Displays which CW unit is selected.

7. Displays the status of the triple redundant voting circuit power supplies, as well as that

of the non-voting logic supply and external redundant logic power and relay power
sources.

8. Guarantees single point fault tolerance on internal signals, power supplies and circuitry

to as great a degree as possible. Signals excluded from this category are external
watchdog signals.

1.3.1.2 IORCM Functional Details

Redundant circuitry is implemented to increase the reliability of the CWIORC control logic.
Items not included in this implementation, or external signals or components that are not
be part of this category are: external input/output signals, interface power (for display
LEDs, relay drivers, etc), relays and relay contacts, selector switches, outputs of the voting
circuitry, LED indicators and interconnects.

Determination of on-line and failure status for both external redundant CW units is
performed by triple replicated programmable logic devices whose outputs feed 2 of 3
majority voting blocks. The status determination of all 3 programmable logic blocks is
examined by majority voting logic, which generates final on-line and failure status signals
based on the two logic blocks in agreement. The majority voting logic adds fault tolerance to
the process by allowing for hardware failure in one of the determining logic blocks.

Multiple logic power sources are used to provide a high level of tolerance to miscellaneous
hardware faults. All IORCM hardware, except communication port switching relay coils,
are powered by multiple power supplies that generate +3.3Vdc. Three voltage regulators
generate +3.3Vdc sources that supply independent power to each of the system

1-6 / Introduction CI-ControlWaveREDIO

programmable logic blocks. An additional regulator, supplies most of the remaining board
hardware, and a fifth +3.3Vdc source is utilized to power IORCM front panel LED
indicators and supply supervisors. In the event of a fault condition, the circuit arrangement
prevents the offending source from taking down the remaining IORCM sources. A pair of
power supply monitors, also drive their respective power status LED’s, on the front panel to
indicate a failure in one of the supply groups.

System

Re dun dant V CC

Power Circuit ry

Pwr . Su ppli es:

+3.3V1, +3.3V2,
+3.3V3, +3.3V4,
+3.3V5

Triple

Redundant

A/B Select Log ic

W a tchog Input

Conditioning

W a t ch dog: CW_A PSSM

Watchdog: CW_B PS SM

TB1

C

Panel Swi tch es

W

I
O
R
B

Redundant

Power for

Re lays on

CWIO RC

and CWIORS

+3.3V1,2,3,4

VCC_RED

RED_RLY_PWR

Figure 1-5 - Block Diagram - CWREDIO I/O Redundancy Control Module

Input power to each IORCM +3.3Vdc supply group is derived by combining 2ea +5.2Vdc
logic sources via an independent set of ORing diodes (one set per +3.3Vdc group) for
redundancy reasons. These sources are generated by dual redundant power supplies
(PSMM) that are plugged into the system backplane (IORB).

The IORC Module is implemented as a front panel board and Logic/Power Supply Board set
that is interfaced to each other via complementary high reliability connectors.

A\ENABLE /B (SW1)

A/ B PRIMARY (SW2)

Online Status &

Communications

&

Relay Outputs

Status LEDs:

System
Vol tage

Supervisors

(2 each )

Power system moni tor re lay

A_ONLINE
B_ONLINE

CW_A COM1 - COM4

CW_ B COM1 - COM4

Fi e ld Com m . Po rt s

COM1 - COM4

J1 - J4

TB3

TB2

J5
J6

CI-ControlWaveREDIO Introduction / 1-7

1.3.2 CWREDIO Power System

The +5.2Vdc and relay supply voltages of the dual PSMM modules plugged into the IORB
are redundantly combined via ORing diodes on the IORC Module’s Logic Board to generate
VCC_RED and RED_RLY_PWR sources respectively. VCC_RED supplies transistor logic on
the IORC and IORS modules, and provides input voltage to the five, +3.3Vdc logic power
supplies located on the IORC Module’s Logic Board. Supplies +3.3V1, +3.3V2 & +3.3V3
power the triple redundant voting blocks. The +3.3V4 & +3.3V5 supplies power general
logic and LED indicators/voltage supervisors respectively. Each +3.3Vdc supply has an
input thermal switch to shutdown its circuit under fault conditions. Redundant source
RED_RLY_PWR powers communication and on-line status relays on the IORC Module’s
Logic Board, and relay circuits on output type IORS Modules.

1.3.3 CWREDIO IORCM Control Logic

Determination of on-line and failure status for both external redundant CW units is
performed by triple replicated programmable logic devices whose outputs feed 2 of 3
majority voting blocks. The majority voting logic adds fault tolerance to the process by
allowing for hardware failure in one of the determining logic blocks. Each programmable
logic device block monitors external CW status (via connected CW watchdog output signals
WDG_A, WDG_B), IORC Module front panel settings (A/B Enable Mode and Primary
Controller Select Switches) and internal logic states, and generates on-line control outputs
(via signals A_ONLINE and B_ONLINE) for both redundant CW units.

Watchdog hardware on the external CW units, from respective CPU through

special I/O

Redundancy Power Supply Sequencer Modules (IORED-PSSM), source their status to

IORC Module logic with +24Vdc level signals WDG_A and WDG_B via front panel terminal
block TB1. IORC Module logic returns back to each CW unit its on-line control command
with signals A_ONLINE and B_ONLINE via isolated relay contacts closures on front panel
terminal block TB2. In the event of IORCM logic power failure, A_ONLINE will be active
(on-line state/contact closed), while B_ONLINE will be inactive (backup state/contact open).

Two control panel switches determine I/O redundancy modes of operation. Key operated
A/B ENABLE Mode Switch selects one of three operating modes: [FORCE] A, [AUTO
SELECT] ENABLED or [FORCE] B. With this switch in [FORCE] A position, all CWIORS
output type modules are instructed to switch CW_A outputs to IORSM mounted field
terminations (regardless of CW_A watchdog signal status or IORCM logic state). CW_A
serial communication ports are also be switched to the front panel ports on the IORCM.
CW_B outputs and ports are switched in a similar manner if this switch is in [FORCE] B
position. In [AUTO SELECT] ENABLED position, the source of I/O is based upon the
current online (PRIMARY) Controller, external system watchdog status and logic
algorithms embedded within the IORC Module. The A/B PRIMARY Controller Select
Switch (examined at power up, only) selects either CW_A or CW_B as PRIMARY if the
respective CW unit is ready for on-line operation (i.e., corresponding watchdog signal is
high (+24V / WDOG OK)), and the A/B ENABLE Mode Select Switch is in the ENABLED
position.

The alternate (BACKUP) CW system is selected if the PRIMARY CW system fails (its
watchdog signal becomes low (0V/ WDOG FAILURE) and the alternate system is available
(its watchdog signal is high). Once selected, the alternate CW becomes PRIMARY and
remain selected (regardless of the state of the other CW unit) unless its watchdog changes
to failed status, and the A/B ENABLE Mode Switch is in the ENABLED position.

1-8 / Introduction CI-ControlWaveREDIO

IORCM control logic sets redundant signals A/BSEL1, A/BSEL2 & A/BSEL3 active (‘1’:
high) - based on the criteria discussed above) to cause all IORSM output type modules to
switch CW_A outputs to their respective IORSM terminations. Conversely, CW_B outputs
are switched if the select signals are inactive (‘0’: low). These select signals are processed by
2 of 3 voting circuits on the IORS Modules to insure fault tolerance.

1.3.3.1 IORCM LED Status Display Indicators (see Figure 1-10 and Table 1-2)

Six LED indicators are viewable on the front panel of the IORC module. These status

indicators are powered from an additional independent +3.3Vdc power source on the logic
board (+3.3V5), and display the status of the external CW racks under IORCM control and
the condition of the power sources used or generated on the IORCM.

• CW_A and CW_B watchdog status [A_FAIL (CR3), B_FAIL (CR4): Red LEDs]

• CW_A and CW_B online status [A_ONLINE (CR1), B_ONLINE (CR2): Green LEDs]

• Power System “A” Status (CR6): +3.3V1, +3.3V2, +3.3V3 (Triple replicated

programmable logic block power supplies): [Dual color LED indicators: Green = all OK,
Red = one or more of these supplies has failed]

• Power System “B” Status (CR5): VCC_RED, RED_RLY_PWR, +3.3V4 (Logic input, relay

and non-programmable logic power sources): [Dual color LED indicators: Green = all OK,
Red = one or more of these supplies has failed]

A pair of power supply monitors drives its respective power status LED on the front panel
to indicate a failure in one of the two supply groups. Group “A” includes the three
independent programmable logic block power sources, while group “B” includes the fourth
source that powers most remaining logic hardware, the fifth LED/power monitor source,
and the VCC_RED and RED_RLY_PWR supplies that power the IORCM logic and port
switching relays respectively.

1.3.3.2 CWREDIO IORCM Online Relays

Two sets of on-line relay contact outputs (A_ONLINE, B_ONLINE) are provided at IORCM
Control Panel Terminal Block TB2. These outputs are cabled to the external CW units,
where they are connected to input terminals of special I/O Redundancy Power Supply
Sequencer Modules (PSSM) in the respective CW systems. Each online relay contact circuit
uses two DPDT relays. The A_ONLINE circuit uses the normally closed versions of both ‘A’
and ‘B’ driven contacts connected in series (for fault tolerance). Conversely, CW_B online
circuit uses the normally open contact sets in the same arrangement as stated above for
CW_A. With CWIORSYS power not applied, the A_ONLINE contact circuit are closed to
indicate CW_A unit should be primary.

Another set of relay contacts is available to indicate power supply system status, at
Terminal Block TB3. This relay is energized if the power system is okay, and de-energized
if the power system has failed.

1.3.3.3 Serial Communication Ports

An interconnect/relay system is used to switch up to four RS232/RS485 serial
communications ports between the PRIMARY (selected) CW unit and field port connectors
on the CWREDIO Control Panel (J1 - J4). Two 50 pin connectors (J5 & J6) on the Control
Panel and custom cables are used to interconnect the communication port signals from the
CW_A and CW_B units. An A/B Select signal from IORCM logic drives the communications
relays to connect the appropriate ports of the online CW unit. For ports 1 and 2 (RS232

CI-ControlWaveREDIO Introduction / 1-9

only) the switched signals are DTR, TXD, and RTS. For ports 3 and 4 the RS232 switched
signals are RXD, DSR, DTR, TXD and GND, and in RS485 mode, the switched signals are
RX-, RX+, TX-, TX+ and ISOGND. Surge suppression for all communications signals is
provided.

1.3.3.4 Watchdog Inputs

System watchdog signals from external CW_A and CW_B units are cabled to Terminal
Block TB1 on the CWREDIO Control Panel. These watchdog inputs are passed on to the
IORCM Logic Board, where they are optically isolated and presented to the three
redundant voting circuits. The input circuitry is designed for +24Vdc level inputs, and
offers approximately 20 microseconds of delay filtering.

1.4 GENERAL DESCRIPTION

ControlWave™ Redundant I/O and Communications Switch Units (herein referred to as

CWREDIO) provide redundancy control for two identical ControlWave Process Automation
Controllers (CW) or two identical ControlWave I/O Expansion Racks (CWEXP) by
switching control of the CPU, four non-Ethernet communications ports and up to 8 remotely
terminated I/O Modules. CWREDIO units also provide field wiring termination for each of
the I/Os associated with the redundant ControlWaves or Control-WaveEXPs. CWREDIOs
employ scalable, modular hardware architecture with a modern and rugged industrial
design that is both simple to install and configure.

Definitions of acronyms used herein are provided to assist the reader:

• CW ControlWave Process Automation Controller (CW_A or CW_B) with up to

8 Remotely Terminated I/O Modules. Note: Rev. B or higher

ControlWave CPU Modules must be used and their firmware must be
Rev. 3.0 or higher.

• CWEXP ControlWave I/O Expansion Rack (CWEXP_A or CWEXP_B) with up to 8

Remotely Terminated I/O Modules. Note: Rev. B or higher

ControlWave/ControlWaveEXP CPU Modules must be used and their
firmware must be Rev. 4.10 or higher.

• CWREDIO ControlWave™ Redundant I/O and Communications Switch Unit

• IORB I/O Redundancy Backplane (part of CWREDIO)

• IORSM I/O Redundancy Switch Module (part of CWREDIO) - The system supports

up to 8 IORSMs. IORSMs are available as AORSM, DORSM, DIRSM,
AIRSM & UDIRSM versions. Note: Although 1-5V or 4-20mA AIs can

be connected to the appropriate Analog Input Redundancy Switch
Module (AIRSM), only 1-5V ControlWave AI Modules are supported
by redundant ControlWave Process Automation Controllers or
redundant ControlWave I/O Expansion Racks.

• IORCM I/O Redundancy Control Module (part of CWREDIO) - The IORC Module is

a two-board assembly that monitors and controls the selection of the
redundant ControlWaves (CPU, Communications and I/O).

• PSMM Power Supply/Monitor Module (part of CWREDIO) - Two PSMMs are

utilized.

CWREDIOs are used in two basic types of redundancy control systems, i.e., ControlWave
I/O redundancy (referred to as Local I/O redundancy) and I/O Expansion Rack redundancy.
Local I/O Redundancy Systems are comprised of two identical ControlWave units, a
CWREDIO, up to six external power supplies, cabling that ties each CW to the CWREDIO

1-10 / Introduction CI-ControlWaveREDIO

and field wiring. I/O Expansion Rack Redundancy Systems are comprised of two identical
ControlWave I/O Expansion Racks, a CWREDIO, up to six external power supplies and
cabling that ties each CWEXP to the CWREDIO. Note: The CW or CWEXP units used in

conjunction with the CWREDIO must be equipped with Remotely Terminated I/O
Modules.

1.4.1 Overview of the Local I/O and I/O Expansion Rack Redundancy
Control Systems

CWREDIO units support redundant operation of either ControlWave or ControlWave I/O
Expansion Racks. Local I/O redundancy control systems employ a pair of ControlWave
units while I/O Expansion Rack redundancy control systems employ a pair of ControlWave
I/O Expansion Racks.

1.4.1.1 Overview of the Local I/O Redundancy Control Systems

Each ControlWave Process Automation Controller (CW_A & CW_B) used in conjunction
with the Local I/O Redundancy Control System will have identical hardware including
Power Supply/Sequencer Modules, CPU Modules (Including Secondary Comm. Boards) and
remotely terminated I/O Modules. I/O Modules provide the circuitry necessary to interface
the assigned field I/O devices. Each ControlWave I/O Module is interconnected to their
associated I/O Redundancy Switch Module (IORSM) via discrete cable assemblies. A special
communications cable interfaces the four ControlWave CPU Module communication ports
to a 50-pin interface connector (J5 - CW_A or J6 - CW_B) on the ControlWave™
Redundant I/O and Communications Switch Unit’s I/O Redundancy Control Module
(IORCM) (see Figure 1-6).

A Local I/O Redundancy Control System can be part of a larger supervisory control and
data acquisition (SCADA) system or it may exist as it’s own autonomous control system,
i.e., as a free standing redundant system that is not part of a broader network.

1.4.1.2 Overview of the I/O Expansion Rack Redundancy Control Systems

Each ControlWave I/O Expansion Rack (CWEXP_A & CWEXP_B) used in conjunction
with the I/O Expansion Rack Redundancy Control System will have identical hardware
including Power Supply/Sequencer Modules, CPU Modules (Including Secondary Comm.
Boards) and remotely terminated I/O Modules. I/O Modules provide the circuitry necessary
to interface the assigned field I/O devices. Each ControlWave I/O Expansion Rack I/O
Module is interconnected to their associated I/O Redundancy Switch Module (IORSM) via
discrete cable assemblies. A special communications cable interfaces the four Control-
WaveEXP CPU Module communication ports to a 50-pin interface connector (J5 ­CWEXP_A or J6 - CWEXP_B) on the ControlWave™ Redundant I/O and Communications
Switch Unit’s I/O Redundancy Control Module (IORCM) (see Figure 1-7).

An I/O Expansion Rack Redundancy Control System can’t exist without higher level control
interface (Master Controller) since CWEXP CPUs are slave to either a ControlWave (CW)
or a ControlWave Redundant Controller (CWRED). Communications between the Master
Controller, CWEXP_A and CWEXP_B is via Ethernet connections. In general, one of three
types of Master Controllers can be used in conjunction with an I/O Expansion Rack
Redundancy System as follows:

• ControlWave Process Automation Controller (CW) - (Stand-alone or part of a larger

network).

CI-ControlWaveREDIO Introduction / 1-11

• ControlWave Redundant Controllers (CWRED) - (Stand-alone or part of a larger

network).

• ControlWave Redundant I/O and Communications Switch Unit (CWREDIO in a Local

I/O Redundancy System) - (Stand-alone or part of a larger network).

Figure 1-6 - Local I/O Redundancy System Diagram

1-12 / Introduction CI-ControlWaveREDIO

Figure 1-7 - I/O Expansion Rack Redundancy System Diagram

CI-ControlWaveREDIO Introduction / 1-13

1.4.2 Overview of the ControlWave Redundant I/O and Comm. Switch Unit

Each CWREDIO contains one Backplane Board mounted in a Chassis. The I/O Redundancy
Backplane (IORB) provides for the interconnection of the components that comprise the
ControlWave Redundant I/O and Comm. Switch Unit (CWREDIO). In addition to the
IORB, ControlWave Redundant I/O Comm. Switch Units are comprised of a I/O Redun­dancy Control Module (IORCM), two Power Supply/Monitor Modules (PSMM) and up to
eight I/O Redundancy Switch Modules (IORSM).

1.4.3 Key System Features

ControlWave Redundant I/O and Communications Units provide the following key

features:

• Supports panel-mount, wall-mount or 19-inch rack-mount installations

• Two RS-232 asynchronous serial ports (PC/AT 9-pin male D-sub connector)

• Two factory configured RS-232/485 asynchronous serial ports (PC/AT 9-pin male D-

sub connector)

• Design supports fully redundant ControlWave operation for each I/O point

• Design supports redundant ControlWave operation for full CPU Control, RS-

232/485 Communications and all I/O

• Redundant Power Supply/Monitor Boards

• Up to eight I/O Redundancy Switch Modules: Each CWREDIO supports up to 8

redundant I/O Modules as follows:

Discrete Input Modules - 16/32 (24V) DIs
Discrete Output Modules - 16/32 (Open Source) DOs
Analog Input Modules - 8/16 (1-5V) Isolated Voltage Input AIs*
Analog Output Modules - 4/8 (4-20mA) Current Output AOs
Analog Output Modules - 4/8 (1-5V) Voltage Output AOs

Universal Digital Input Modules - 6/12 (12V or 24V) Isolated UDIs (for
High/Low Speed Counting or Contact Closure operation)

* Note: Analog Input Redundancy Switch (AIRS) Modules that support 1-5V or 4-

20mA operation are available. The 4-20mA AIRS Module employs 250-Ohm
Resistors across each input to covert the signal from milliamperes to
volts.

1.5 PHYSICAL DESCRIPTION

CWREDIOs are comprised of the following major components:

One Chassis Assembly (see Section 1.5.1)
The Chassis Assembly used with the ControlWave™ Redundant I/O and Communications
Switch Unit (CWREDIO) accommodates 19” rack-mount or panel/wall-mount installations.

One I/O Redundancy Backplane Ass’y. (IORB) (see Section 1.5.2)
The IORB provides electrical interconnection and accommodates mounting for the two
Power Supply/Monitor Modules (PSMM), the I/O Redundancy Control Module (IORCM) and
up to eight I/O Redundancy Switch Modules (IORSM).

Two Power Supply/Monitor Modules (PSMM) (see Section 1.5.3) These DC-to-DC
Converters provide +5Vdc to the IORCM’s Logic Board.

1-14 / Introduction CI-ControlWaveREDIO

One I/O Redundancy Control Module (IORCM) (see Section 1.5.4)
Provides controlled switching (selection) of the ControlWave/ControlWaveEXP unit
(CPU, Communications Ports and I/O) that is acting as the redundant system PRIMARY
(on- line) Controller.

I/O Redundancy Switch Modules (IORSM) (see Section 1.5.5)
The system supports up to eight I/O Redundancy Switch Modules. IORS Modules are
available in AO, DO, DI, AI & UDI versions. Each Module provides interconnection for I/O
cabling of two identical (A/B) remotely terminated ControlWave I/O Modules. IORS
Modules may be equipped with a locally terminated Terminal Block Assembly or remotely
terminated Header Block Assembly. Note: Control Switching (A/B Select) is only

provided for output modules, i.e., for AORS and DORS Modules.

1.5.1 Chassis Assembly

The Backplane PCB and the modules that comprise the system are housed in a Stainless
Steel Chassis designed to accommodate redundant ControlWave/ControlWaveEXP
operation. Any ControlWave™ Redundant I/O and Communications Switch Unit
(CWREDIO) Chassis can be 19-inch equipment rack-mounted or panel/wall-mounted.
CWREDIO Chassis’ are factory shipped without any modules 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.

1.5.2 I/O Redundancy Backplane Assembly (IORB)

I/O Redundancy Backplane Assemblies (IORB) contain up to eleven (11) user accessible
connectors (see Table 1-1). Connector P3 is equipped with a connector-coding device. This
color-coded device is physically unique to ensure that only the correct Logic & Relay Board
connector (P2) is installed.

IORB Connectors J1 & J2

The I/O Redundancy Backplane (IORB) provides interconnection of two Power
Supply/Monitor Modules (PSMM) via 36-pin connectors J1 and J2. Redundant PSMMs
provide failsafe power, i.e., continuous power if one PSMM fails.

IORB Connector P3

IORB Connector P3 is a 132-pin (male) connector that accommodates connection to the I/O
Redundancy Control Module’s (IORCM) Logic & Relay Board. The IORCM Logic & Relay
Board connects to a piggy-back mounted IORCM Front Panel Board.

IORB Connectors J1 & J2

The ControlWave I/O Redundancy Backplane (IORB) provides interconnection of two
Power Supply/Monitor Modules (PSMM) via 36-pin connectors J1 and J2. Two PSMMs
provide failsafe power, i.e., continuous power if one PSMM fails.

IORB Connector P3

IORB Connector P3 is a 132-pin (male) connector that accommodates connection to the I/O
Redundancy Control Module’s (IORCM) Logic & Relay Board. The IORCM Logic & Relay
Board connects to a piggy-back mounted IORCM Front Panel Board.

CI-ControlWaveREDIO Introduction / 1-15

IORB Connectors P4 through P11
132-pin (male) IORB Connectors P4 through P11 accommodate connections to I/O Redun­dancy Switch Modules (IORSM) 1 through 8 respectively.

Figure 1-8 - ControlWave I/O Redundancy Backplane (CWIORB)

with CWPSMs Installed

1-16 / Introduction CI-ControlWaveREDIO

1.5.3 Power Supply/Monitor Modules (PSMM)

I/O Power Supply/Monitor Modules (PSMM) plug into the I/O Redundancy Backplane As­sembly (IORB) (Connectors J1 & J2) via their 36-pin Card edge connector. The front of each
PSMM contains a System Power Switch (SW1), as well as a pluggable 3-position Terminal
Block (TB1) for external input power and CHASSIS Ground connections. Each PSSM has
one LED, visible only when the Power Supply Cover Panel has been removed, that provides
the following status conditions: Lit GREEN = 5V power is good, OFF = 5V power below

4.9Vdc.

A relay is provided at Terminal Block (TB3), that remains energized while power is good,
but is de-energized if power fails. This relay could be used to trigger an external alarm in
the event of a power failure.

PSMMs are designed to operate from 20.0Vdc to 30.0Vd and accept a 24Vdc bulk source and
generate an isolated +5.2Vdc [regulated to 3.3Vdc (VCC) by the IORCM Logic Board] for
the IORCM PLDs and up to eight I/O Redundancy Switch Modules (IORSM).

Also contained on the PSMM is the supply monitor circuit that monitors the incoming
power as well as the isolated output supply voltages. The low limits for the bulk (incoming)
supply voltage is 20.0V. The supplies are enabled when the input voltage is above its low
limit. The monitor circuit for the isolated 5.2Vdc supply switches the status LED OFF when
the supply voltage drops below 4.9Vdc.

The nominal settings for the power supply are ON state above 20.7Vdc and OFF state
below 20.0Vdc. A supervisory circuit monitors the incoming power and the isolated supply
voltages. The isolated supplies are shut down when the incoming voltage drops below
+20.0Vdc.

Figure 1-9 - ControlWave I/O Power Supply/Monitor Board

1.5.3.1 PSMM Power Switch SW1

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

CI-ControlWaveREDIO Introduction / 1-17

1.5.3.2 PSMM Board Fuse F1

Each PSMM contains one replaceable fuse (F1). Slow Blow Fuse F1 is rated at 5A and
provides protection for the entire CWREDIO including DORSM field power.

1.5.3.3 PSMM Board Connectors

Pluggable connector TB1 and card edge connector P1 function as described below.

PSMM Bd. Terminal Block Connector TB1

TB1 accommodates input power and CHASSIS ground connections:

TB1-1 = (+VIN) (+20.7V to +30V dc for +24V Bulk Supply)
TB1-2 = (-VIN) (1st Supply Ground)
TB1-3 = Chassis Ground - CHASSIS (

PSMM Bd. Card Edge ConnectorP1

The 36-pin male card edge connector (P1) interfaces Power, Ground and CHASSIS Ground
signals to Connector J1 or J2 on the Backplane Board.

1.5.3.4 PSMM LED

One LED per PSSM, visible when the Power Supply Cover Panel has been removed, will
provide status conditions PWRGOOD (power good: green), and PWRDOWN (power down:
OFF). The LED should be ON (green) whenever the unit is running and no power problems
have been detected. The LED should only be OFF when the supply voltage for the isolated
power (+5.2Vdc) has dropped below 4.9Vdc, nominal.

)

1.5.4 I/O Redundancy Control Module (IORCM)

The I/O Redundancy Control Module (IORCM) is comprised of two printed circuit boards
(IORCM Panel PCB & the IORCM Logic & Relay PCB). In addition to the generation of A/B
select signals to each of the IORS Modules, the IORCM generates an ONLINE status signal
to CW_A and CW_B units that is derived from the WATCHDOG status signals of the CW_A
and CW_B units and the settings of the mode control switches (SW1 & SW2) on the IORCM
Panel PCB.

IORC Modules have been designed to provide the following functionality:

• Automatically select CW_A or CW_B racks upon power up when the A/B ENABLE Mode

Switch (SW1) has been set in the Enabled position. A/B selection is prioritized by the
settings on the A/B Primary Controller Select Switch (SW2). Allows fail-over to occur,
based on watchdog state.

• Force the selection of the CW_A or CW_B unit with IORCM Key Operated A/B ENABLE

Mode Switch (SW1) in A or B position regardless of the watchdog state of either
ControlWave/ControlWaveEXP unit.

• Generation of individual A_ONLINE and B_ONLINE external status signals.

• Single point fault tolerance on internal signals, power supplies and switches. Signals

that are not included are external watchdog signals.

1-18 / Introduction CI-ControlWaveREDIO

• Display the Power System status of PSMM#1 and PSMM#2 individually.

• Display the status of external watchdog inputs.

• Display the status of the selected online ControlWave/ControlWaveEXP unit, i.e.,

UNIT A or UNIT B.

1.5.4.1 I/O Redundancy Control Module Connectors

I/O Redundancy Control Modules (IORCM) contain eleven connectors (nine 9 user
accessible) (see Table 1-1).

IORCM Connector TB1

CW/CWEXP A/B isolated input watchdog signals used to establish master control are
connected to the IORCM at 4-pin connector TB1.

IORCM Connector TB2

IORCM Connector TB2 provides relay contact output signals A_ONLINE and B_ONLINE
for CW_A and CW_B PRIMARY (on-line MASTER) control selection.

IORCM Connector TB3

IORCM Connector TB3 provides relay contact output signals to indicate power system
status.

IORCM 9-Pin Male D-Type Connectors J1 through J4

IORCM male 9-pin D-Type connectors J1 and J2 are factory set for RS-232 operation and
represents COMM Port 1 and Comm Port 2 respectively of the ControlWave/Control-
WaveEXP selected as PRIMARY. J3 and J4 are male 9-pin D-Type connectors that
support factory configured RS-232 or RS-485 operation and represents COMM Port 3 and
Comm Port 4 respectively of the ControlWave/ControlWaveEXP selected as PRIMARY.

Table 1-1 - IORC Module User Accessible Connector Summary

(Unless Otherwise Noted Connectors are on the IORCM Panel Board)

Ref. # Pins Function Notes

TB1 4-pin A/B Watchdog Input Signals see Figure 1-10 & Table 4-3

TB2 4-pin

TB3 4-pin Power System Good / Failure see Figure 1-10 & Table 4-3
J1 9-pin D-Type COMM. Port 1 (RS-232) see Figure 4-1 & Table 4-2
J2 9-pin D-Type COMM. Port 2 (RS-232) see Figure 4-1 & Table 4-2

J3 9-pin

J4 9-pin

J5 50-pin CWA Comm Ports Interconnection see Figure 4-2
J6 50-pin CWB Comm Ports Interconnection see Figure 4-2

P1 110-pin

J1 110-pin

J2 110-pin

A_ONLINE & B_ONLINE
External Output Signals

D-Type COMM. Port 3 (RS-232 or
RS-485 - Factory Configured)
D-Type COMM. Port 4 (RS-232 or
RS-485 - Factory Configured)

Mates with J1 on CWIORC Logic
& Relay PCB.
CWIORC Logic & Relay Board –
Mates with P1 on Panel Board
CWIORC Logic & Relay PCB –
Connects to P3 on the CWIORB

see Figure 1-10 & Table 4-3

see Figure 4-1 & Table 4-2

see Figure 4-1 & Table 4-2

Not User Accessible

Not User Accessible

see Figures 2-3B & 4-4

CI-ControlWaveREDIO Introduction / 1-19

IORCM Connectors J5 and J6
IORCM 50-pin female connectors accommodate interconnection of COMM Ports 1

through 4 as follows: J5 mates witch Comm Ports 1 through 4 of CW_A
while J6 does the same for CW_B.

IORCM Panel/Logic & Relay Connector P1/J1
110-pin IORCM Logic & Relay Board connector J1 mates to IORCM Panel Board

connector P1 utilizing 5 rows of 22 pins marked A through E.

IORCM Logic/Backplane Connector J2
110-pin IORCM Logic & Relay Board connector J2 mates to IORB connector P3

utilizing 5 rows of 22 pins marked A through E.

1.5.4.2 I/O Redundancy Control Module Switches

A/B Primary Controller Select Switch (SW2) - 2-position - selects the PRIMARY

Con-troller, i.e., CPU A (Unit A) or CPU B (Unit B) at power up only if the
A/B ENABLE Mode Switch (SW1) has been set in the automatic selection
(centered) position. The selected unit will be chosen as the PRIMARY
System Controller if the I/O Redundancy Control Module (IORCM)
determines that it is ready for on-line duty. Otherwise, the alternate unit
will be selected if it is OK.

1-20 / Introduction CI-ControlWaveREDIO

TB3-1 = Normally Open - Closed if P ow er OK

)

c

TB3-2 = Normally Open - Closed if P ow er OK
TB3-3 = Normally Closed - Open if Power OK
TB3-4 = Normally Closed - Open if Power OK

4

TB3

{

CWIOR C Logi

1

& Rel a y Boa rd

Co mm. Intf.

Connector

for CW_A or

CWEXP_A

Po rt s 1 - 4

A/ B PRIMARY

Select

Sw itch SW2

C om m. Po rt 1

RS-232

J5

J6

A

B

PRIMARY

J1 J2

ENABLED

POWER

A

SYSTEM
STATUS

B

ON-LINE
FAIL

ON-LINE

FAIL

/BA\

SW1SW2

UNIT A

UNIT B

Co mm. Intf.

Connector

for CW_ B or

CWEXP_B

Po rt s 1 - 4

Key Operated

A/B ENABL E D

Sw i tch SW1

(Ke y Remove d

C om m. Po rt 2

RS-232

Note: If these

Components are

Present, Comm.

Port 3 = RS-485

C om m. Po rt 3

RS-232/485

Figure 1-10 - ControlWave I/O Redundancy Control Module

{

J3 J4

1144

{

TB2-1 = CW_A Online Co ntact Output
TB2-2 = CW_A Online Co ntact Output
TB2-3 = CW_B Online Contact Output

{

TB2-4 = CW_B Online Contact Output

{

{

TB1-1 = CW_A Watchdog + Input
TB1-2 = CW_A Watchdog - Input
TB1-3 = CW_B Watchdog + Input

{

TB1-4 = CW_B W atchdog - Input

Note: If these

Components are

Present, Comm.

Port 4 = RS-485

C om m. Po rt 4

RS-232/485

CI-ControlWaveREDIO Introduction / 1-21

A/B ENABLE Mode Switch (SW1) - 3-position (key operated) - used to determine
whether the PRIMARY unit selected is forced to Unit A or Unit B or is
automatically selected (Center). Forced primary selection is useful for diagnostic
purposes, where a failed Unit A or Unit B CPU Module may be placed on-line for
debugging. When set to the ENABLED position, Switch SW2 selects the PRIMARY
Controller; the alternate (BACKUP) Controller is selected if the PRIMARY
Controller goes into a watchdog state. Once selected, the alternate controller will
remain the PRIMARY (on-line MASTER) irrespective of the original PRIMARY
Controller’s state.

1.5.4.3 I/O Redundancy Control Module LEDs

IORC Modules are equipped with 6 status LEDs (see Table 1-2).

Note: These status indicators are powered from independent power source +3.3V5 on the

IORCM’s Logic Board, and display the status of the external CW units under
IORCM control and the condition of the power sources used or generated on the
IORCM.

Table 1-2 - IORC Module LEDs

LED

Name

CR1 - Unit A On-Line Green GREEN = CW_A is On-line as Primary Controller
CR2 - Unit B On-Line Green GREEN = CW_B is On-line as Primary Controller
CR3 - Unit A Fail Red RED = CW_A Watchdogged (failed)
CR4 - Unit B Fail Red RED = CW_B Watchdogged (failed)
CR5 - B Power
System Status

CR6 - A Power
System Status

LED

Color

Red
Green

Red
Green

Function

GREEN = +3.3V4, VCC_RED, RED_RLY PWR OK
RED = At least one of the above supplies has
failed
GREEN = =3.3V1, +3.3V2, +3.3V3 are OK
RED = At least one of the above supplies has
failed

1.5.5 I/O Redundancy Switch Modules (IORSM)

I/O Redundancy Switch Modules (IORSM) are connected to identical remotely terminated
I/O Modules housed in the two external ControlWave/ControlWaveEXP racks, i.e., CW_A
and CW_B. Each IORSM provides interconnection with the I/O field devices associated with
the redundant I/O Module pair. Each Output Redundancy Switch Module monitors the A/B
select signal from the Backplane (IORB) and drives on board relays or MOSFETS to select
the appropriate A/B ControlWave/ControlWaveEXP I/O Module. For Input Redundancy
Switch Modules, the external signals are routed to both external
ControlWave/ControlWaveEXP units without any switching mechanisms. Seven versions
of I/O Redundancy Switch Modules are offered:

• Analog Output RSMs contain reed relays to switch between ControlWave units.

• Digital Output RSMs use power MOSFETs to switch the field power supply source and

return.

• Externally Powered Digital Input RSMs have current limiting circuitry for each input.

DIRSM Current limiting circuitry provides protection of the ControlWave-
/ControlWaveEXP unit DI channel transorb and limits the current to a damaged
ControlWave/ControlWaveEXP DI Module when the channel fails shorted.

1-22 / Introduction CI-ControlWaveREDIO

• Internally Sourced Digital Input RSMs contain a diode/transorb arrangement. If a

transorb fails at the ControlWave/ControlWaveEXP unit, the diode will isolate the
channel.

• Analog Input RSMs are offered in two versions: Voltage Input and Current Input.

Voltage Input AIRSMs pass external 1 to 5 volt signals to both CW/CWEXP units.
Current Input AIRSMs have a 250-ohm resistor across each input. These 250-ohm
resistors convert a 4-20mA signal to a 1 to 5 V signal.

Note: The 4-20mA ControlWave Analog Input Module is NOT supported by the

redundancy system, i.e., CW/CWEXP units must be equipped with
Voltage Input AI Modules. Only Externally Powered AIs are supported.
In lieu of the use of the Current Input AIRSM, a 250-ohm resistor may be
placed across any or all Voltage Input AIRSM inputs.

• Universal Digital Input RSMs don’t protect against I/O card faults.

Figure 1-11 - I/O Redundancy Switch Module

1.5.5.1 I/O Redundancy Switch Module Connectors & LEDs

Each IORS Module is equipped with four connectors. Two upper panel connectors (J2 & J3)
provide interconnection between the associated CW_A and CW_B I/O Modules respectively.
A 110-pin connector (J1) mates with the associated Backplane Board connector, i.e., P4
through P11. A Terminal Block (for local terminations) or a Header Block (for remote

CI-ControlWaveREDIO Introduction / 1-23

terminations) is situated behind the IORS Module’s Terminal Housing Assembly and
accommodates field wiring to the associated field devices.

Two LEDs are provided on each IORSM. The top LED (green) represents B On-line Status
while the bottom LED (green) represents A On-line Status. The appropriate LED is lit
when the associated CW_A or CW-B is selected as the PRIMARY Controller.

1.5.5.2 Associated ControlWave I/O Modules

Five remotely terminated I/O Modules are available. Note: Redundant ControlWaves­/ControlWaveEXPs can’t be equipped with locally terminated I/O Modules. I/O
Modules are factory configured, encased, and factory sealed. A brief overview of each I/O
Module type is provided below. I/O Module specifications are covered in Section 4.5 of
Instruction Manual CI-ControlWave. ControlWave I/O Modules are connected to their
associated IORS Module via a discrete cable assembly equipped with four, 14-pin headers
(on the ControlWave/ControlWaveEXP I/O Module end) and a 62-pin header (on the
IORS Module end).

Analog Input Module

1-5 Vdc AI Modules are supported. Each module contains field interface circuitry for up to
16 or 8 analog inputs. Each AI Module consists of a Remote Terminal Board Assembly, an
Analog Input PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing
Assembly, as well as I/O assembly and mounting hardware.

Analog Output Module

AO Modules are factory configured to support either 4-20mA or 1-5 Vdc analog outputs.
Each module contains field interface circuitry for up to 8 or 4 analog outputs. Each AO
Module consists of a Remote Terminal Board Assembly, an Analog Output PCB (with a
daughter board when configured for 1-5V operation), an LED Housing Assembly, a
Terminal Housing Assembly, as well as I/O assembly and mounting hardware.

Digital Input Module

Digital Input (DI) Modules are factory configured to support either externally powered
source or dry contact DI applications. Each module contains field interface circuitry for up
to 32 or 16 discrete inputs with an input range of 24Vdc, a nominal input current of 5mA
and 30 millisecond input filtering. DI Modules consists of a Remote Terminal Board
Assembly, a Discrete Input PCB, an LED PCB, an LED Housing Assembly, a Terminal
Housing Assembly, as well as I/O assembly and mounting hardware.

Digital Output Module

Digital Output (DO) Modules provide a total of 32 or 16 DOs for control of signaling
functions. Each output contains an optically isolated open source MOSFET and surge
suppressor that are capable of handling 500mA @ 31V. DO Modules consists of a Remote
Terminal Board Assembly, a Discrete Input PCB, an LED PCB, an LED Housing Assembly,
a Terminal Housing Assembly, as well as I/O assembly and mounting hardware.

Universal Digital Input Module

Universal Digital Input (UDI) Modules provide a total of 12 or 6 inputs. Each input is
optically isolated from the field device. UDI Modules are factory configured with all inputs
set with debounce enabled or with all inputs set with debounce disabled. With debounce
enabled, spurious pulses caused by relay contact bounce are eliminated. Individual UDI
inputs can be customer configured for a polled input, interrupt on change of state (COS) or

1-24 / Introduction CI-ControlWaveREDIO

totalizer operation. Field inputs can be driven signals, open collector outputs or relay
contacts. The maximum input frequency is 10 kHz. For any input used as a totalizer, the
maximum totalized count before rollover is 65535 and the totalizer is not resetable through
software. UDI Modules consists of a Remote Terminal Board Assembly, a Universal Digital
Input PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as
well as I/O assembly and mounting hardware.

Figure 1-12 - ControlWave Redundant I/O and Communications Switch Unit

Block Diagram

CI-ControlWaveREDIO Introduction / 1-25

BLANK PAGE

Section 2

INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS

ControlWave Redundant I/O and Control Communications Units (CWREDIO) are not

furnished in an enclosure. The modules that comprise the system are housed in a Stainless
Steel Chassis designed to accommodate up to eight I/O Redundancy Switch Modules
(IORSM). Any CWREDIO can be panel/wall mounted. CWREDIO Chassis can mount to a
19” equipment rack in lieu of wall/panel mounting. Usage 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 - ControlWave (CWREDIO) - Mounting Diagram

CI-ControlWaveREDIO Installation & Operation / 2-1

2.2 CWREDIO INSTALLATION SITE CONSIDERATIONS

Check all clearances when choosing an installation site. Make sure that the CWREDIO will
be accessible for wiring and service. To install the CWREDIO Chassis, see Section 2.3.1.

2.2.1 Temperature & Humidity Limits

CWREDIOs 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 0% to 95% 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 CWREDIO is not exposed to a level of vibration that exceeds those given in
the specifications. The CWREDIO’s vibration limits are 1g for 10 - 150 Hz & .5g for 150 ­2000 Hz.

2.3 CWREDIO INSTALLATION/CONIGURATION

ControlWave Redundant I/O and Communications Switch Unit components are shipped

from the factory in separately boxed modules as follows:

• CWREDIO Chassis Assembly with I/O Redundancy Control Module (IORCM) and two

Power Supply/Monitor Modules (PSMMs) installed. Redundant Communication Cables
are provided in the shipping box.

• I/O Redundancy Switch Module (IORSM) - Two I/O Module Interface Cables are provided

with each IORSM. From 1 to 8 IORSMs are provided separately boxed for each
CWREDIO as follows:

AORSM - AO Redundancy Switch Module
AIRSM - AI Redundancy Switch Module
DORSM - DO Redundancy Switch Module
DIRSM - DI Redundancy Switch Module
UDIRSM - UDI Redundancy Switch Module

Overview of Configuration

An overview of the steps required to configure a ControlWave Redundant I/O and
Communications Switch Unit and the related redundant components is provided below.

Step 1. Hardware Configuration

This involves unpacking the CWREDIO hardware, mounting the chassis, configuring and
installing the various hardware modules, installing interconnect cables between each
ControlWave Process Automation Controller or each ControlWave I/O Expansion Rack
and the CWREDIO, wiring I/O terminations, making proper ground connections, and
wiring the ControlWave Power Supply/Monitor Modules (PSMMs) to bulk power supplies.
To install and configure the ControlWave Redundant I/O and Communications Switch
Unit follow steps 1 through 10 below:

2-2 / Installation & Operation CI-ControlWaveREDIO

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

2.3.1).

2. Remove the various CWREDIO Modules from their cartons and install them into their

designated slots (see Figure 2-6).

3. Connect the Redundant CW Communication Cables as follows: Connect one end of

Comm. Interface Cable A to Comm. Ports 1 through 4 of CW_A or CWEXP_A and the
other end to Comm. Interface Connector J5 of the I/O Redundancy Control Module
(IORCM) on the CWREDIO. Connect one end of Comm. Interface Cable B to Comm.
Ports 1 through 4 of CW_B or CWEXP_B and the other end to Comm. Interface
Connector J6 of the IORCM on the CWREDIO).

4. Connect network communications cables to the IORCM as follows (see Section 2.3.1.3):

Comm. Port 1 = J1 - RS-232
Comm. Port 2 = J2 - RS-232
Comm. Port 3 = J3 - RS-232 or RS-485 (factory configured per order)
Comm. Port 4 = J4 - RS-232 or RS-485 (factory configured per order)

5. Install I/O wiring to each IORSM (see Sections 2.3.2 through 2.3.2.8.1).

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

Ground (see Section 2.3.1.1).

7. Install switchover control wires (not provided) between IORCM pluggable terminal

block connectors TB1 and TB2 to CW_A and CW_B (or CWEXP_A and CWEXP_B)
Power Supply/Sequencer Module (PSSM) pluggable connectors TB1 respectively (see
Section 2.3.3.3).

8. Remove the Power Supply Panel Cover (secured via three screws) and connect Bulk

DC Power to the pluggable terminal block connector TB1 on each of the two PSMMs
(see Sections 2.3.3.1 & 2.3.3.2). Note: It is recommended that the pluggable

terminal block (TB1) associated with each PSMM are not connected until the
entire system has been wired and configured. When ready turn both PSMMs
to their ON position via SW1 ( ‘I’ pressed) on each PSMM.

9. Optionally connect terminal block connector TB3 to an external discrete input (DI) for

reporting on the ‘health’ of the power supply system.

10. Install the Power Supply Panel Cover removed in step 8. This item is secured to the
Chassis via three screws; two on top and one on the bottom.

11. Configure each of the ControlWave units (CW_A and CW_B) (or CWEXP_A and
CWEXP_B) associated with the redundancy system. Establish the side-load Ethernet
communication connections at CW_A and CW_B. Apply power to them by setting the
Power Switch on their PSSM Modules to the ‘I’ position. After receiving their
Application Loads (see Steps 2 below and Section 2.4.1 of CI-ControlWaveEXP and/or
CI-ControlWave), the redundancy I/O system will be ready for on line operation.

Step 2. Redundant ControlWave or Redundant ControlWaveEXP Configuration

Both ControlWaves, i.e., CW_A and CW_B (CWEXP_A and CWEXP_B), must be installed
and configured for redundant operation in the redundancy I/O system. Section 2.3 of
Instruction Manual CI-ControlWave details the seven steps required to configure the
ControlWave Process Automation Controllers; while Section 2.3 of Instruction Manual CI­ControlWaveEXP details the three steps required to configure the Control

Wave I/O

Expansion Racks. Note: Both ControlWaves (ControlWaveEXPs) must be identical

(except for IP Addresses and CPU Switch settings) and must be equipped with
Rev. B or higher CPU Boards that are running with ControlWave firmware (Rev.

4.10 or higher).

CI-ControlWaveREDIO Installation & Operation / 2-3

Figure 2-2 - Local I/O (ControlWave) Redundancy Diagram

(see Figure 1-7 for I/O Expansion Rack Redundancy Diagram)

2-4 / Installation & Operation CI-ControlWaveREDIO

2.3.1 Mounting ControlWave Redundant I/O and Comm. Switch Units

ControlWave Redundant I/O and Comm. Switch Units (CWREDIO) can be mounted to a

19-inch equipment rack, a panel or a wall. These CWREDIOs are factory shipped with the
End Plates configured for 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., removal, installation and maintenance of various modules,
field wiring and fuse replacement.

• Modules should not be installed until the CWREDIO’s Chassis has been mounted and

grounded at a designated work site.

2.3.1.1 CWREDIO Grounding

ControlWave Redundant I/O and Communications Switch Unit 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
I/O Redundancy Switch Modules (IORSM) are connected to Chassis Ground when they have
been installed and secured via their two Captured Panel Fasteners. As an extra added
precaution, it is recommended that a #14 AWG wire be run from both PSMM Board Power
Connectors (TB1-3 - Chassis Ground) to the same known good Earth Ground. The following
considerations are provided for the installation of CWREDIO 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.

2.3.1.2 Communication Ports

A ControlWave Process Automation Controller can be configured as a Master or Slave
node on a MODBUS network, a BSAP network, an Ethernet (using Internet Protocol) or a
network utilizing a custom third party protocol (see Bristol Manual D5125). A
ControlWave I/O Expansion Rack can be configured as a Slave to a host ControlWave on
a Serial MODBUS or Open MODBUS network or it may be connected to a ControlWave
via IP. The I/O Redundancy Control Module (IORCM) supplied with the CWREDIO
supports four communication ports.

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 IORCM communication ports (see Figure 2-3A/B) can be configured for local
communications, i.e., connected to a PC loaded with ControlWave Designer and OpenBSI

CI-ControlWaveREDIO Installation & Operation / 2-5

software. Connections for the 9-pin, RS-232/485 interface are shown in Figure 2-4, while the

corresponding pin labels are provided in Table 2-3.

2.3.1.3 RS-232 & RS-485 Interfaces

Communications Ports (COM1 & COM2) support RS-232 communications only. RS-232 or
RS-485 communications (one or the other - factory configured) can be provided by Comm.
Ports COM3 and COM4. These connectors are summarized below.

IORC Module J1 - 9-Pin Male D-Sub - RS-232 - COM1 - Port 1
IORC Module J2 - 9-Pin Male D-Sub - RS-232 - COM2 - Port 2
IORC Module J3 - 9-Pin Male D-Sub - RS-232/RS-485 - COM3 - Port 3
IORC Module J4 - 9-Pin Male D-Sub - RS-232/RS-485 - COM4 - Port 4

2-6 / Installation & Operation CI-ControlWaveREDIO

TB3-1 = Normally Open - Closed if P ow er OK

)

c

TB3-2 = Normally Open - Closed if P ow er OK
TB3-3 = Normally Closed - Open if Power OK
TB3-4 = Normally Closed - Open if Power OK

4

TB3

{

CWIOR C Logi

1

& Rel a y Boa rd

Co mm. Intf.

Connector

for CW_A or

CWEXP_A

Po rt s 1 - 4

A/ B PRIMARY

Select

Sw itch SW2

C om m. Po rt 1

RS-232

J5

J6

A

B

PRIMARY

J1 J2

ENABLED

POWER

A

SYSTEM
STATUS

B

ON-LINE
FAIL

ON-LINE

FAIL

/BA\

SW1SW2

UNIT A

UNIT B

Co mm. Intf.

Connector

for CW_ B or

CWEXP_B

Po rt s 1 - 4

Key Operated

A/B ENABL E D

Sw i tch SW1

(Ke y Remove d

C om m. Po rt 2

RS-232

Note: If these

Components are

Present, Comm.

Port 3 = RS-485

C om m. Po rt 3

RS-232/485

Figure 2-3A - IORC Module Component Identification Diagram (Front)

{

J3 J4

1144

{

TB2-1 = CW_A Online Co ntact Output
TB2-2 = CW_A Online Co ntact Output
TB2-3 = CW_B Online Contact Output

{

TB2-4 = CW_B Online Contact Output

{

{

TB1-1 = CW_A Watchdog + Input
TB1-2 = CW_A Watchdog - Input
TB1-3 = CW_B Watchdog + Input

{

TB1-4 = CW_B W atchdog - Input

Note: If these

Components are

Present, Comm.

Port 4 = RS-485

C om m. Po rt 4

RS-232/485

CI-ControlWaveREDIO Installation & Operation / 2-7

RS-232 Ports

d

d

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
associated ControlWave or ControlWaveEXP utilize MODBUS or BSAP protocol, while
full-duplex is supported by the Point to Point (PPP) protocol. RS-232 ports utilize the “null
modem” cable (Figure 2-4A) to interconnect with other devices such as a PC or another
ControlWave series unit (except CW_10/30/35) unit when the ControlWave or Control­WaveEXP is communicating using the full-duplex PPP protocol. The half-duplex cable
shown in Figure 2-4A is utilized when the CWREDIO port in question is connected to a
ControlWave series unit (except CW_10/30/35). If communicating with a Bristol series
3305, 3310, 3330, 3335 or CW_10/30/35 RTU/DPC, one of the cables shown in Figure 2-4B
must be used. Refer to Figure 2-4C to connect a ControlWave/ControlWaveEXP to either
a modem or radio via the CWREDIO’s IORCM. When connecting to ControlWave COM3
(Port 3) as an RS-232 port, the cable of Figure 2-4D must be utilized along with either a
DB9 Male to Female Adapter or the cable of Figure 2-4A.

J1

P1

J3

J4

J2

J5

IO R CM Logic & Relay Boar

IORCM

Panel Boar

Figure 2-3B - IORC Module Component Identification Diagram (Left Side)

2-8 / Installation & Operation CI-ControlWaveREDIO

An illustration of the IORCM’s male 9-pin D-type connectors is provided in Figure 2-5.
Table 2-1 provides the connector pin assignments for IORCM communication ports 1
through 4.

Note: The following facts regarding ControlWave I/O Expansion Rack RS-232 serial com-

munications ports should be observed when constructing communications cables:

• DCD must be high to transmit (except during Modem Dialing)

• 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

Table 2-1 - 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 - COM3/4

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

RS-485 Ports

CWREDIO units 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 2-2 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 24­gauge paired conductor cable, such as Belden 9843 should be used. Note: Only half-duplex

RS-485 networks are supported.

Table 2-2 - RS-485 Network Connections

(see Table 2-1 & Figure 3-12 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.

CI-ControlWaveREDIO Installation & Operation / 2-9

Figure 2-4 -Communication Port RS-232 Cable Wiring Diagrams

2-10 / Installation & Operation CI-ControlWaveREDIO

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. ControlWave/ControlWaveEXP 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 SW4 (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 2-3 below and Figure 2-11 in Section 2.3.3.3 of CI-ControlWave).

Figure 2-5 - Male DB9 9-Pin Connector Associated with COM1 through COM4

Table 2-3 - SCB Port Switches SW1 = COM3, SW4 = COM4

Loopback & Termination Control

SWITCH

#

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-232 Function

Switch ON

RS-485 Function

Switch ON

Slow Slew Rate - ON = Fast
OFF = Slow

Setting

ON/OFF - As required
Factory Default = ON

Closed = Switch set OFF

2.3.2 I/O Redundancy Switch Module Installation & Wiring

ControlWave Redundant I/O and Communications Switch Unit Chassis are support up to

8 I/O Redundancy Switch Modules (IORSM). IORSMs reside in slots 2 through 9. Figure 2-6
shows the ControlWave Redundant I/O and Communications Switch Unit Chassis slot
assignments.

IORSMs are configured per order and individually packaged. An IORSM will reside in one
of up to 8-I/O slots supported by Backplane Interface connectors P4 through P11.

2.3.2.1 Installation of I/O Redundancy Switch Modules

The ControlWave Redundant I/O and Communications Switch Unit must be shut down
prior to the installation (or removal) of any component. When adding one or more IORSMs
(along with ControlWave I/O Modules at CW_A/CWEXP_A and CW_B/CWEXP_B), the

CI-ControlWaveREDIO Installation & Operation / 2-11

application load in ControlWave Designer must be configured to accept the new I/O
Module(s) and then the new application load must be downloaded into both ControlWave
units before the new I/O Module(s) can become operational. For new site installations,
hardware configuration should take place with power disconnected until the entire unit has
been physically installed, configured and wired.

Perform steps 1 through 7 below for each IORSM. IORSMs are provided with a removable
Terminal Housing Assembly. This assembly has a door that swings downward to provide
access to the unit’s Terminal Handle which in turn is utilized to add in the removal of an
installed IORSM once the module’s Captured Panel Fasteners have been loosened.

1. Remove the IORSM from its shipping carton and remove the Terminal Housing

Assembly from the IORSM (see Figure 2-7).

2. Turn the Terminal Block’s Quarter Turn Fasteners (counterclockwise) and remove

the Terminal Block Assembly from the IORSM.

3. IORS Modules are available that support local terminations (field wiring connected

directly to the IORS Module’s Terminal Block PCB) or remote terminations (field
wiring connected to a remote DIN-rail mounted Terminal Block Assembly).

When installing wiring in conjunction with IORSMs that are equipped with a Local
Terminal Block PCB, install the field wiring between the IORSM’s Terminal Block
Assembly and field devices (see Figure 2-8). Use AWG 14 or smaller wire (consult
with the field device manufacturer for recommendations). Leave some slack and
plan for wire routing, identification, maintenance, etc. The bundled wires are to be
routed out through the bottom of the IORSM Assembly between the Terminal Block
Assembly and the Terminal Housing Assembly.

For IORSM that are equipped with a Remote Terminal Block Assembly, install the
cables between the IORS Module’s Terminal Block Assembly and the DIN-rail
mounted Terminal Block Assembly. Install the field wiring between the DIN-rail
mounted Terminal Block Assembly and field devices (see Figures 2-9, 2-11, 2-12, 2­17, 2-18, 2-20, 2-24 & 2-28). Use AWG 14 or smaller wire (consult with the field
device manufacturer for recommendations). Leave some slack and plan for wire
routing, identification, maintenance, etc. The cables that run between the I/O
Module and the DIN-Rail mountable Terminal Blocks are to be routed out through
the bottom of the IORSM Assembly between the Header Block and the Terminal
Housing Assembly. To provide access to the Header Block’s lower ¼ Turn Fastener,
cables associated with connectors P3 and P4 should be secured via a Tie Wrap to the
lower left side of the Header Block Assembly, while cables associated with
connectors P1 and P2 should be secured to the lower right side of the Header Block
Assembly via a second Tie Wrap (see Figure 2-9).

Refer to the following sections for I/O Module wiring information:

Section 2.3.2.4 = DI Module
Section 2.3.2.5 = DO Module
Section 2.3.2.6 = AI Module
Section 2.3.2.7 = AO Module
Section 2.3.2.8 = UDI Module

2-12 / Installation & Operation CI-ControlWaveREDIO

Figure 2-6 - CWREDIO Backplane Slot Assignments (PSMMs Installed)

CI-ControlWaveREDIO Installation & Operation / 2-13

Figure 2-7 - Terminal Housing Assembly Removal

4. Align the IORSM with the assigned I/O Slot and install the unit into the Chassis.
When the assembly is fully seated, turn the IORSM’s Captured Panel Fasteners
(clockwise) to secure the unit to the Chassis thus establishing a low resistance path
between the IORSM and Chassis Ground.

5. Install the Local or Remote Terminal Block Assembly (with wiring harness) onto the
IORSM (turning the Quarter Turn Fasteners (clockwise)).

6. Replace the module’s Terminal Housing Assembly.

as MS Word files that can be typeset by the user to provide wiring identification for
I/O Modules. These labels are available on the Bristol Babcock Web site
www.controlwave.com and can be affixed to the inside of the Term. Housing’s Door.

Note: Door Labels are available

7. Using a PC equipped with ‘ControlWave Designer’ and ‘OpenBSI’ software,

configure CW_A/CWEXP_A & CW_B/CWEXP_B to accept the new I/O Module (and
any other modules that have been added or removed) and then download the
application load into the ControlWave/ControlWaveEXP CPU’s System FLASH
and/or SDRAM (see Section 2.4.1). For new installations, this step can be skipped
until the unit has been wired and power applied.

2-14 / Installation & Operation CI-ControlWaveREDIO

Figure 2-8 - IORSM (Local Termination) Wire Routing

2.3.2.2 Wire Connections

ControlWave Redundant I/O and Communication Switch Units 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 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
standard wire, tin the bare end with solder to prevent flattening and improve conductivity.

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.

2.3.2.3 Shielding and Grounding

The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize
signal errors caused by electromagnetic interference (EMI), radio frequency interference
(RFI) and transients. When using shielded cable, all shields should only be grounded at one
point in the appropriate system. This is necessary to prevent circulating ground current
loops that can cause signal errors.

CI-ControlWaveREDIO Installation & Operation / 2-15

Figure 2-9 - IORSM (Remote Termination) Wire Routing

2.3.2.4 Digital Inputs (see Figures 2-10, 2-11, 2-12, 2-13 & 2-14)

ControlWave Digital Input (DI) Modules are factory-configured to support either

externally powered source or dry contact DI applications. Each module contains field
interface circuitry for up to 32 or 16 discrete inputs with an input range of 24Vdc, a

2-16 / Installation & Operation CI-ControlWaveREDIO

nominal input current is 5mA and 30 millisecond input filtering. DI Modules used in
conjunction with the Local I/O Redundancy System or I/O Expansion Rack Redundancy
System consists of a Header Block Assembly (remote), a Digital Input PCB, an LED PCB,
an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O assembly and
mounting hardware.

DI field circuitry is electrically isolated from the module’s bus interface circuitry by surge
suppressors and optocouplers. Modules configured for use in dry contact applications
contain a 21Vdc power supply. The 21Vdc field supply is derived from a control circuit and
an isolated power supply that is powered by the output of the hot swap control circuit,
which in turn is powered by the +VIN/-VIN supply interfaced from the
ControlWave’s/ControlWaveEXP’s Backplane.

Each DI PCB is connected to its associated Header Block Assembly via a 44-pin header and
to the ControlWave’s/ControlWaveEXP’s Backplane via a 110-pin connector.

2.3.2.4.1 Digital Input Configurations

Digital Input Modules are factory configured to support either 32/16 externally sourced DIs
or 32/16 internally sourced DIs. Modules configured for use in dry contact applications
contain a 21Vdc power supply. The nominal input voltage is 24Vdc @ 5mA.

Field wiring assignments associated with the locally terminated DIRS Modules and
remotely terminated DIRS Modules are provided in Figures 2-10 and 2-11 respectively. A
special remote termination module with built-in discrete relay module that supports input
from 120Vac DIs is also available (see Figure 2-12). The special remote termination module
(with built-in discrete relay module) is interfaced to an externally sourced DI Module.

Figure 2-10 - Local Terminal Block Assembly Assignments

for Internally Sourced DI Operation or Externally Powered DI Operation

CI-ControlWaveREDIO Installation & Operation / 2-17

Figure 2-11 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for Internally Sourced DI Operation or Externally Powered DI Operation

2-18 / Installation & Operation CI-ControlWaveREDIO

Figure 2-12 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for Relay Isolated 120Vac DI Operation

CI-ControlWaveREDIO Installation & Operation / 2-19

Figure 2-13 - Internally Sourced DI Module - Wiring Diagram

Figure 2-14 - Externally Powered DI Module - Wiring Diagram

2.3.2.5 Digital Outputs (see Figures 2-15, 2-16, 2-17 & 2-18)

ControlWave Digital Output (DO) Modules provide a total of 32 or 16 DOs for control of

signaling functions. Each output contains an optically isolated open source MOSFET and
surge suppressor that are capable of handling 500mA @ 31V. ControlWave DO Modules
used in conjunction with the Local I/O Redundancy System or I/O Expansion Rack
Redundancy System consists of a Header Block Assembly (remote), a Discrete Input PCB,
an LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O
assembly and mounting hardware.

DO field circuitry MOSFETs are electrically isolated from the module’s bus interface
circuitry by surge suppressors and optocouplers.

Output data is stored in an on board DO Load Register. Upon power up the DO Load
register is cleared and all outputs are set “off.”

Each DO PCB is connected to its associated Header Block Assembly via a 44-pin header
and to the ControlWave’s/ControlWaveEXP’s Backplane via a 110-pin connector

2.3.2.5.1 Digital Output Configurations

Digital Output Modules provide a total of 32 or 16 DOs with surge protection. Each DO
utilizes an open source MOSFET that is capable of driving up to 31Vdc at up to 500mA. A
500Vdc MOV to Chassis and a 31Vdc Transorb (across output) are provided to protect each
DO. The maximum operating frequency is 20 Hz.

.

2-20 / Installation & Operation CI-ControlWaveREDIO

Field wiring assignments associated with the locally terminated DORS Modules and
remotely terminated DORS Modules are provided in Figures 2-15 and 2-17 respectively. A
special remote termination module with built-in discrete relay modules is also available
(see Figure 2-18).

Figure 2-15 - Local Terminal Block Assembly Assignments

for Open Source Isolated DO Operation

Figure 2-16 - Open Source Isolated DO Module - Wiring Diagram

CI-ControlWaveREDIO Installation & Operation / 2-21

Figure 2-17 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for Open Source Isolated DO Operation

2-22 / Installation & Operation CI-ControlWaveREDIO

Figure 2-18 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for Relay Isolated 24Vdc DO Operation

CI-ControlWaveREDIO Installation & Operation / 2-23

2.3.2.6 Analog Inputs (see Figures 2-19 through 2-22)

Although the AIRSM supports connection to externally powered 4-20mA or 1-5 Vdc AIs,
only 1-5 Vdc type ControlWave AI Modules are supported by ControlWave Redundant I/O
and Communications Switch Units. The AIRSM that supports 4-20mA is similar to the 1­5V AIRSM but includes a discrete 250-ohm resistor across each input pair. The 250-ohm
resistor converts the 4-20mA input signal to a 1-5V signal. ControlWave 1-5V AI Modules
used in conjunction with Local I/O Redundancy System or I/O Expansion Rack Redundancy
System consists of a Header Block Assembly (remote), an Analog Input PCB, an LED PCB,
an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O assembly and
mounting hardware. Each Analog Input Module contains field interface circuitry for up to
16 or 8 analog inputs.

AI circuitry is electrically isolated from the module’s bus interface circuitry. On the isolated
side each AI signal is channeled through signal conditioning, surge suppression,
multiplexing and a 14-bit A to D converter. The bus interface circuitry consists of the
control logic to access A to D converters and multiplexers, static RAM (to store the latest
14-bit digitized data for each of the sixteen channels and the on board reference voltages)
and control logic to access the system bus.

The common mode range for 1-5V Analog Inputs is 31Vdc. For 4-20 mA Analog Inputs, all
inputs are referenced to the -AI the module. Each AI PCB is connected to its associated
Header Block Assembly via a 44-pin header and to the ControlWave’s/ControlWaveEXP
Backplane via a 110-pin connector.

Figure 2-19 - Local AI Module Terminal Block Assembly Assignments

2-24 / Installation & Operation CI-ControlWaveREDIO

2.3.2.6.1 Analog Input Configurations

ControlWave AI Modules (with either 16 or 8 AI) are offered with 1-5V isolated inputs.

Field wiring assignments associated with the locally terminated AIRSM are provided in
Figure 2-19. Field wiring assignments associated with remotely terminated AIRSMs are
provided in Figure 2-20.

Figure 2-20 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for 1-5V or 4-20mA AI Operation

CI-ControlWaveREDIO Installation & Operation / 2-25

Note:

Cable shields associated with AI wiring should be connected to the ControlWave Chassis
Ground. Multiple shield terminations will require a user supplied copper ground bus.
This ground bus must be connected to the ControlWave’s Chassis Ground Lug (using up to
a #4 AWG wire size) and must accommodate a connection to a known good Earth Ground
(in lieu of a direct connection from the Ground Lug) and to all AI cable shields. Shield
wires should use an appropriate Term. Lug and should be secured to the copper bus via
industry rugged hardware (screw/bolt, lockwasher and nuts).

Figure 2-21 - Externally Powered 4-20mA Current Loop AI - Wiring Diagram

Figure 2-22 - Externally Powered Isolated 1-5 Volt AI - Wiring Diagram

2.3.2.7 Analog Outputs (see Figures 2-23 through 2-26)

ControlWave AO Modules are factory configured to support either 4-20mA or 1-5 Vdc

analog outputs. Each module contains field interface circuitry for up to 8 or 4 analog
outputs. Each AO Module used in conjunction with the Local I/O Redundancy System or I/O
Expansion Rack Redundancy System consists of a Header Block Assembly (remote), an
Analog Output PCB (with a daughter board when configured for 1-5V operation), an LED
PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O assembly
and mounting hardware.

AO circuitry is electrically isolated from the module’s bus interface circuitry. On the
isolated side, each AO signal passes through one of two, 4-channel digital to analog con­verters (DAC) that drive voltage to current converters. The V to I circuits are powered by an
on board isolated 19V power supply and the DACs are powered by an isolated 5V supply.
Outputs are protected from transients with surge suppressors. Each AO PCB is connected

2-26 / Installation & Operation CI-ControlWaveREDIO

to its associated Header Block Assembly via a 44-pin header and to the Control-
Wave’s/ControlWaveEXP’s Backplane via a 110-pin connector.

The maximum external load that can be connected to the 4-20mA output is 650 ohms. The
maximum external load current for the 1-5V output is 5mA. An additional error (associated
with the voltage output mode) is caused by the voltage drop across an inductor. This error is
not compensated and is equal to the output current times two inductor resistances, e.g., 2.5
ohms x 2 x .005A = 25mV (or 0.625% of span).

2.3.2.7.1 Analog Output Configurations

ControlWave Analog Output Modules are factory configured to support either eight (8) 1-

5V or 4-20mA isolated outputs. Field wiring assignments associated with the locally
terminated AORS Modules are provided in Figures 2-23 while wiring assignments
associated with the remotely terminated AORS Modules are provided in Figure 2-24.

Figure 2-23 - Local AO Module Terminal Blocks Assembly Assignments

CI-ControlWaveREDIO Installation & Operation / 2-27

Figure 2-24 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for AO 4-20mA and 1-5V Operation

2-28 / Installation & Operation CI-ControlWaveREDIO

Figure 2-25 - 4-20mA Current Loop AO - Wiring Diagrams

Figure 2-26 - 1-5Vdc Voltage AO - Wiring Diagrams

2.3.2.8 Universal Digital Input Modules (see Figures 2-27 through 3-30)

ControlWave Universal Digital Input (UDI) Modules provide a total of 12 or 6 inputs. Each

input is optically isolated from the field device. UDI Module inputs are factory configured
with all inputs set with debounce enabled or with all inputs set with debounce disabled.
With debounce enabled, spurious pulses caused by relay contact bounce are reduced with
filters. Individual UDI inputs can be customer configured for a polled input or totalizer
operation. Field inputs can be driven signals, open collector outputs or relay contacts. The
maximum input frequency is 10 kHz. For any input used as a totalizer, the maximum
totalized count before rollover is 65535 and the totalizer is not resetable through software.
UDI Modules used in conjunction with the Local I/O Redundancy System or I/O Expansion
Rack Redundancy System consists of a Header Block Assembly (remote), a Universal Input
PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as
I/O assembly and mounting hardware.

ControlWave Universal Digital Input Module circuitry consists of signal conditioning
circuitry, 4-bit accumulators and a microcontroller. Signal conditioning circuitry includes
optocouplers, debounce circuitry and bandwidth limit circuitry. The microcontroller
monitors the inputs and maintains delays for each input that has been configured to be
polled.

Each input of the UDI Module can be configured as a polled input and/or as a low speed or
high speed counter.

CI-ControlWaveREDIO Installation & Operation / 2-29

UDI circuits with debounce disabled have two field inputs, SET and COM. When the
debounce circuitry is enabled (factory), a change of state on both the SET and RESET field
inputs is required to accumulate counts. The maximum input frequency is 10 kHz with a
nominal input current of 5mA.

Delay registers for signal conditioning allow individual inputs to utilize one of three
software selectable delays. The 20 usec delay is used for the 10 kHz input range required
for high speed counting. The 1 millisecond delay is required for low speed counter ap­plications. 30 millisecond delays are required for general purpose inputs or contacts where
contact bounce may be an issue.

2.3.2.8.1 Universal Digital Input Configurations

ControlWave UDI Modules provide a total of 12 or 6 UIs with surge protection. Each UDI

Module is capable of handling 24V inputs.

Each input is provided electrical isolation of 500Vdc to Chassis and 1500Vdc to system
logic. Each input is also protected with a 31dc Transorb (across input and to Field Common)
that meets the ANSI/IEEE standard C37.90-1978.

Field wiring assignments associated with the locally terminated UDIRS Modules and
remotely terminated UDIRS Modules are provided in Figures 2-27 and 2-28 respectively.

Figure 2-27 - Local UDI Terminal Block/Configuration Diagram

2-30 / Installation & Operation CI-ControlWaveREDIO

Figure 2-28 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments

for UDI Operation

CI-ControlWaveREDIO Installation & Operation / 2-31

Figure 2-29 - UDI (Debounce Enabled) Wiring Diagram

Figure 2-30 - UDI (Debounce Disabled) Wiring Diagram

2.3.3 Power Supply Wiring

ControlWave I/O Power Supply/Monitor Modules (PSMMs) 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 clamp adjacent to the screw and then securing the
screw. The wire should be inserted fully so that no bare wires are exposed to cause shorts.
If using standard wire, tin the bare end with solder to prevent flattening and improve
conductivity.

Allow some slack in the wires when making terminal connections. The slack makes the
connections more manageable and helps to minimize mechanical strain on the terminal
blocks.

2.3.3.1 Bulk Power Supply Current Requirements

ControlWave Redundant I/O and Communications Switch Units (CWREDIO) are equipped

with two 24Vdc ControlWave I/O Power Supply/Monitor Modules (PSMMs). The maximum
current required for the +24Vdc bulk power supply used with a particular CWREDIO can
be estimated as follows:

Bulk +24Vdc Supply Current = System Hardware + Sum of all AORSMs and DORSMs

This summation will accommodate steady state as well as power up in-rush current draw.
System hardware consists of the two PSMMs, the IORCM and the Chassis assemblies.
Table 2-4 provides the current requirements.

2-32 / Installation & Operation CI-ControlWaveREDIO

Note: When two bulk power supplies are required, the first supply (VIN) (see Fig. 2-32)

must be rated to handle 2 Amps.

Table 2-4 - Current Requirements for Bulk 24Vdc Power Supply

COMPONENTS

IORCM, CHASSIS, PSMMs 185mA 256mA
AORSM 3mA 103mA
DORSM 3mA 8mA

UNIT A

Master

UNIT B

Master

Figure 2-31 - PSMM Wire Routing Diagram

CI-ControlWaveREDIO Installation & Operation / 2-33

2.3.3.2 Power Wiring

DC Power is interconnected to a PSMM via Connector TB1. A discrete DC supply can be
connected to each PSMM, or they may use a shared Bulk DC supply. The Bulk DC supply
(nominally +24Vdc) connected to TB1-1 (+VIN) is converted, regulated and filtered by the
PSMM to produce a regulated +5.2Vdc power. Each PSMM contains 5A Fuse. The bulk DC
supply is connected to PSMM Terminal Block TB1-1 (+VIN) and TB1-2 (-VIN).

PSMM Connector TB1 provides 3 input connections for bulk power as follows:

TB1-1 = (+VIN) (+20.7V to +30V dc)
TB1-2 = (-VIN) (Supply Ground)
TB1-3 = Chassis Ground - CHASSIS (

)

Figure 2-32 - PSMM’s TB1 Typical Wiring Schemes

2.3.3.3 Redundancy Control Field Wiring (see Figure 2-33)

The circuit that drives Redundant Master Controller selection located on the I/O
Redundancy Control Module (IORCM). IORCM connectors TB1 and TB2 interface to
separate ControlWaves or ControlWaveEXPs. Basically the IORCM monitors the
Watchdog Bad signals from Controllers A and B and in conjunction with logic associated
with IORCM switches SW1 (A/B Enable Mode Key Switch) and SW2 (A/B Primary Select
Switch) it provides a relay driven signal to TB1 pin-3 (VR) of the Power Supply/Sequencer
Module in the selected Master ControlWave or ControlWaveEXP. Watchdog Bad is a

signal generated by a ControlWave series CPU Module when its hardware detects improper
software operation.

The ControlWave PSSM’s 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 PSMM [-VIN or PSGND
(TB2-3)].

2-34 / Installation & Operation CI-ControlWaveREDIO

Figure 2-33 - ControlWaveREDIO to ControlWave or ControlWaveEXP

Redundancy Control Field Wiring

I/O redundancy Control Module connectors TB1 and TB2 provide terminations for power,
ground, Controller A & B Watchdog Bad input signals and Redundant Unit Control output
signals as follows:

TB1-1 = VO - Watchdog MOSFET Switch Input from Controller A (from PSSM TB1-1)
TB1-2 = -VIN - Controller A Power Ground (PSSM TB2-2)
TB1-3 = VO - Watchdog MOSFET Switch Input from Controller B (from PSSM TB1-1)
TB1-4 = -VIN - Controller B Power Ground (PSSM TB2-2)
TB2-1 = VR - Redundant Unit Control Output to Controller A (to PSSM TB1-3)
TB2-2 = RLYPWR - +24Vdc Relay Power from external power source (to PSSM ‘A’ TB1-2)
TB2-3 = VR - Redundant Unit Control Output to Controller B (to PSSM TB1-3)
TB2-4 = RLYPWR - +24Vdc Relay Power from external power source (to PSSM ‘B’ TB1-2)
TB3 1-2 = Normally Open Contact – If power system OK, relay is energized and TB3 1-2 is
closed. If power system fails, relay is de-energized and TB3 1-2 is open.
TB3 3-4 = Normally Closed Contact – If power system OK, relay is energized and TB3 3-4 is
open. If power system fails, relay is de-energized and TB3 3-4 is closed.

CI-ControlWaveREDIO Installation & Operation / 2-35

2.3.4 PSMM Cover (see Figure 2-1)

The PSMM Cover is situated below the I/O Redundancy Control Module. It covers and
protects the two PSMMs and can be removed to access the PSM Modules. Bundled wires
and cables are routed downward between the PSM Modules and PSMM Cover. Three
screws secure the PSMM Cover to the Chassis; two on top and one on the bottom.

2.4 OPERATIONAL DETAILS

ControlWave Redundant I/O and Communications Switch Units are utilized with two
ControlWave Process Automation Controllers or with two ControlWave I/O Expansion

Racks which in turn are shipped from the factory with firmware that allows them to be
configured in conjunction with an IEC 61131 application program. This section provides
information as follows:

• Operation of the IORCM’s A/B Primary Select Switch (SW2)

• Operation of the IORCM’s Key Operated A/B ENABLE Mode Switch (SW1)

Operational details on ControlWave Redundant I/O and Communications Switch Unit
LEDs, are provided in Chapter 3 (see Section 3.3.2).

2.4.1 Operation of IORC Module Switches

Selection of the PRIMARY Controller, i.e., CW_A or CW_B is a function of the I/O
Redundancy Control Module (IORCM). IORCM switch (SW1 & SW2) settings and
Watchdog signals originating at CW_A and CW_B interact with IORCM control logic to
select the redundant ControlWave/ControlWaveEXP unit that acts as the PRIMARY
Controller.

2.4.1.1 SW1 - Key Operated A/B ENABLE Mode Switch

IORCM’s key operated A/B Enable Mode Switch (SW1) has three positions and is used to
determine whether the PRIMARY CPU selection is forced to CPU_A (A) or CPU_B (B) or is
automatically selected (ENABLED). Forced PRIMARY selection is useful for diagnostic
purposes, where a failed CPU Module may be placed on-line for debugging.

2.4.1.2 SW2 - A/B Primary Controller Select Switch

IORSM’s A/B Primary Controller Select Switch (SW2) is a two position toggle switch that is
used to select the PRIMARY Controller, i.e., Unit A’s CPU (A) or Unit B’s CPU (B) at
power up only
selection (centered) position. The selected redundant unit (A or B) will be chosen as the
PRIMARY System Controller if the IORSM’s logic determines it is ready for on-line duty.
Otherwise, the alternate CPU will be selected if it is OK.

2.4.1.3 Forcing a Fail-over to the BACKUP (Standby) Unit via Program Control

If desired, the user can trigger a redundant fail-over from On-line unit to the BACKUP
unit based on conditions detected in the software.

To do this, users must incorporate the REDUN_SWITCH function into their project.

if the A/B Enabled Select Switch (SW1) has been set in the automatic

2-36 / Installation & Operation CI-ControlWaveREDIO

Excerpts from a POU using the REDUN_SWITCH function block in structured text (ST) are
shown below. Comments appear in italics:

IF (SWITCHNOW) We are putting this at the top of the POU. If SWITCHNOW is TRUE a

fail-over occurs right at the top. This ensures that fail-over doesn’t occur
in the middle of the POU, which would cause all changes within that
execution cycle to be lost.

THEN
RDSTAT:=REDUN_SWITCH(SWITCHNOW);
SWITCHNOW:=FALSE;

;
ENDIF;
:
: the main body of the POU would appear here. Somewhere in here, a test to determine

whether a failure has occurred requiring a switchover must be made. The condition
causing the failure can be anything the user chooses.

FAILURE: =

some failure condition logic must be added here

:
:
IF (FAILURE) At the bottom of the POU, if the FAILURE condition, determined in the

main body is TRUE, then SWITCHNOW is set TRUE, so at the top of the
next execution cycle, the fail-over will occur.

THEN

SWITCHNOW:=TRUE;

ELSE

SWITCHNOW:=FALSE;
ENDIF
FAILURE:=FALSE;

In the structured text code, we use the REDUN_SWITCH function block, which takes the
format:

statuscode:=REDUN_SWITCH(ibEnable)

Whenever the ibEnable variable is TRUE, a fail-over will be attempted immediately.

Some other things you should be aware of when using the REDUN_SWITCH function
block:

• When using the REDUN_SWITCH function block, the condition that forces the fail-over,

in this case, the FAILURE variable, should be a local, non-retain variable. The reason for
this is that if the variable is retained, there is a possibility of repeated switchovers
between A and B since the same failure condition value would be transferred from the
PRIMARY (on-line) unit to the BACKUP (standby) unit, causing the new on-line unit to
try to fail back, and so on.

• Fail-over only occurs if there is a valid BACKUP (standby) unit and the key operated

A/B Enable Switch is in the ENABLED position.

• As soon as the REDUN_SWITCH function block executes with a TRUE ibEnable

variable, the fail-over process begins immediately, no additional lines of code in the task
are executed. For this reason, we recommend that the REDUN_SWITCH function block
always be placed at the very beginning of the POU, to prevent a switchover in the middle
of partial calculations, which would have to be discarded (see next item).

CI-ControlWaveREDIO Installation & Operation / 2-37

• Data updates to the BACKUP unit only occur at the end of a task’s cycle, therefore, if a

fail-over occurs somewhere during the task, no updates from that execution cycle will be
sent to the standby unit. For this reason, although you can have multiple program POUs
in your project, you may find it useful to confine all your program POUs to a single
executing task, since if you use multiple tasks and a fail-over occurs, the tasks could
become out of sync. This is because one or more tasks may not have completed an
execution cycle when the fail-over occurs, thereby resulting in incomplete updates to the

BACKUP unit; the updates for those tasks would be discarded.

2.4.1.4 Manually Forcing a Fail-over to the BACKUP (Standby) Unit

There are certain circumstances in which you might want to manually fail-over from the
PRIMARY (on-line) CPU to the BACKUP (Standby) CPU. The most common situation
would be if you need to perform some service or repair to the PRIMARY CPU, and
therefore, you need to take it 'off-line' and have the BACKUP take over while the service or
repair is being performed.

To force a manual fail-over, you can simply change the position of the A/B Enable key
switch on the IORCM to select the unit which is currently the BACKUP unit; it will then
become the new PRIMARY (on-line) unit.

Manually failing from "A" to "B"

If the "A" CPU is currently the PRIMARY CPU, and you want to manually fail-over to the
BACKUP CPU "B", move the A/B Enable Mode key switch on the IORCM to the "B"
position (right). The "B" CPU will now be the new PRIMARY unit.

Manually failing from "B" to "A"

If the "B" CPU is currently the PRIMARY CPU, and you want to manually fail-over to the
BACKUP CPU "A", move the A/B Enable Mode key switch on the IORCM to the "A"
position (left). The "A" CPU will now be the new PRIMARY unit.

Return the Key Operated A/B Enable Mode Switch to Automatic Mode

Once you have re-activated the controller which you were performing service on, we
recommend that you set the A/B Enable Mode key switch to the automatic position
("ENABLED"). This will allow an automatic fail-over back to the previous BACKUP
(standby) unit, if the current PRIMARY (on-line) unit should fail.

2.4.2 ControlWave 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 ControlWave/ControlWaveEXP to the PC (local or network)
for the first time you should be aware of the communication port default parameter settings
provided below. 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 defaults to 115.2 Kbaud (RS-232) using the Internet Point to

Point Protocol (PPP). Note: Port COM1 will be configured for RS-232 operation (at

2-38 / Installation & Operation CI-ControlWaveREDIO

9600 baud) 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 between CWREDIO Comm.
Port 1 and a PC requires the use of an RS-232 “Null Modem” cable (see Figure 2­4A).

COM2: From the factory, COM2 on the CPU Board defaults to 9600 baud, 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 OFF to the OFF position. Connection between CWREDIO
Comm. Port 2 and a PC requires the use of an RS-232 “Null Modem” cable (see
Figure 2-4A).

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

defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer
protocol operation. 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. An
RS-232 “Null Modem” cable (see Figure 2-4A) can be connected between COM3
and the PC or an RS-485 cable (see Tables 2-1 & 2-2) can be connected between
COM3 and the PC’s RS-485 Port.

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

defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/Control-Wave 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. An
RS-232 “Null Modem” cable (see Figure 2-4A) can be connected between COM4
and the PC or an RS-485 cable (see Tables 2-1 & 2-2) can be connected between
COM4 and the PC’s RS-485 Port.

Comm. Port Hardware Notes:

1. All CWREDIO Comm. Ports are equipped with 9-pin Male D-Sub connectors.

2. COM1, COM2 and COM4 of Redundant ControlWaves or ControlWaveEXPs

are equipped with 9-pin Male D-Sub connectors while COM3 is equipped with
an 8-pin RJ-45 jack.

3. When connecting a PC to COM1 through COM4 of the CWREDIO or directly to

COM1, COM2 or COM4 of a redundant ControlWave or redundant Control-
WaveEXP: If the PC is equipped with an RS-232 Port that utilizes an RJ-45
jack, the use of the Bristol “Null Modem” cable P/N 392843-01-3 (see Figure 2­4A) and one Bristol “RJ45 to DB9 Adapter” cable P/N 392844-01-0 (see
Figure2-4D) will be required.

4. When connecting a PC’s RS-232 Port directly to COM3 of a redundant

ControlWave or redundant ControlWaveEXP: 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 4A, or use Bristol “Null Modem” cable P/N 392843-01-3 connected to two
Bristol “RJ-45 to DB9 Adapter” cables P/N 392844-01-0 (see Figures 2-4A and
2-4D), to interconnect the PC directly to COM3 of a redundant CW or CWEXP.

5. When connecting a PC’s RS-232 Port directly to COM3 of a redundant

ControlWave or redundant ControlWaveEXP: If the PC is equipped with an
RS-232 Port that utilizes a standard 9-pin Male D-Sub connector, the use of the
Bristol “Null Modem” cable P/N 392843-01-3 (see Figure 2-4A) and one BBI

CI-ControlWaveREDIO Installation & Operation / 2-39

“RJ-45 to DB9 Adapter” cable P/N 392844-01-0 (see Figure 2-4D) will be
required. This RS-232 network, consisting of two cables, connects to COM3 of
the ControlWave/ControlWaveEXP with an 8-pin RJ-45 male connector to
the PC with a 9-pin D-type female connector.

6. If RS-485 communications is required an RS-485 cable can be assembled using
the connections provided in Tables 2-1 (for 9-pin D-Sub connectors), 2-2 (RS­485 network connections) and 2-3 (for 8-pin RJ-45 connectors).

2-40 / Installation & Operation CI-ControlWaveREDIO

Section 3

SERVICE

3.1 SERVICE INTRODUCTION

This section provides general, diagnostic and test information for the ControlWave
Redundant I/O and Communications Switch Unit (CWREDIO).

The service procedures described herein will require the following equipment:

1. PC with null modem interface cable & WINDIAG Software

2. Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 3-11)

1. Loop-back plug, 9-pin female D-Sub (for RS-485) (see Figure 3-12)

2. Ohmmeter or Continuity Tester (see Section 3.7.9)

The following test equipment can be used to test a Power Supply/Monitor Module:

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

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

When ControlWave Redundant I/O and Communications Switch Units 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 ControlWave Redundant I/O and Communications Switch
Unit’s power source(s) 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 CWREDIO modules for testing and instal­lation/removal procedures. Note CWREDIOs don’t support module Hot Swapping;

however, the I/O Modules resident in the redundant ControlWave’s or redundant
ControlWaveEXP’s may be Hot Swapped.

3.2.1 Accessing Modules for Testing

Testing and replacement of CWREDIO 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 CWREDIO resulting from
improper handling or incorrect service procedures will not be covered under the product

CI-ControlWaveREDIO Service / 3-1

warranty agreement. If these procedures cannot be performed properly, the unit should be
returned to Bristol Babcock (with prior authorization from Bristol Babcock) for factory
evaluation and repairs. All ControlWave Redundant I/O and Communications Switch Unit
Modules 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 the I/O Redundancy Control Module

The I/O Redundancy Control Module (IORCM) is secured to the Chassis by three Captured
Panel Fasteners.

1. Prior to removal of the IORCM, it is recommended that any associated processes be

closed down or placed under manual control. Turn both PSMs OFF.

1. Before disconnecting any cables from the IORCM make sure they are identified (so they

can be re-installed into their assigned location). Disconnect the communication cables
associated with CW_A/CWEXP_A and CW_B/CWEXP_B from IORCM Connectors J5
and J6 respectively. Disconnect the communication cables from J1 through J4 as
required. Unplug removable connectors TB1, TB2, and TB3.

3. Turn the IORCM’s three Captured Panel Fasteners counterclockwise until the unit can

be removed from the Chassis. Gently remove the IORCM from the Chassis.

4. To replace the IORCM, align the Logic & Relay Board’s Backplane Interface Connector

with Backplane Connector P3 and carefully insert the unit until its three Captured
Panel Fasteners (two near the top and one near the bottom) can be turned to secure the
unit. Turn the three Captured Panel Fasteners clockwise until the IORCM is fully
seated.

5. Re-install the connectors removed in step 2.

6. Reapply power to both PSMMs.

3.2.3 Removal/Replacement of a Power Supply/Monitor Module

1. Turn the PSM Cover’s three Quarter Turn Fasteners (two on top, one on the bottom)

counterclockwise until it can be removed from the Chassis and then remove it.

2. If the CWREDIO is running, and the PSSMs share a bulk power source, perform step 3.

If the CWREDIO is running and separate bulk power supplies are utilized shut off
power to the bulk supply associated with the failed PSSM and then perform step 3.

3. Unplug removable connector TB1 from the PSMM in question.

5. Turn the two Captured Panel Fasteners (associated with the PSMM in question)

counterclockwise until it can be removed from the Chassis and then remove it.

3. To replace a PSMM, align the unit with its assigned slot and Backplane connector (J1 or

J2) and carefully insert it until fully seated. Turn the PSMM’s Captured Panel
Fasteners Clockwise until they are snug. Re-install power connector TB1, and if
required, turn on power at the bulk power source. Turn the PSSM’s Power Switch to the
ON ‘I’ position and replace the PSM Cover securing it to the chassis via its three
Quarter Turn Fasteners.

3.2.4 Removal/Replacement of a I/O Redundancy Switch Module

1. Shut down or place under manual control all processes associated with the I/O

Redundancy Switch Module (IORSM) being removed.

2. Remove the CW_A/CWEXP_A and CW_B/CWEXP_B I/O Interface cables from their

respective IORSM connectors making sure that they are identified (so they can be re­installed into their assigned connectors).

3. Remove the Terminal Housing Assembly (see Figures 2-8 and 2-9).

3-2 / Service CI-ControlWaveREDIO

4. Turn the Terminal/Header Block’s Quarter Turn Fasteners (counterclockwise) and
remove the Terminal/Header Block Assembly (with wiring harness) from the IORSM.

5. Turn the IORSM’s Captured Panel Fasteners (counterclockwise) until it can be removed
from the Chassis. Remove the IORSM assembly in question from the Chassis. Note: To

ease IORSM removal, reinstall the Terminal Housing Assembly and (with
Terminal Door open) grasp the Terminal Handle and remove the IORSM.

4. If not already done, remove the Terminal/Header Block Assembly from the replacement

IORSM.

5. Install the replacement IORSM into the same I/O slot that the assembly in question was

removed from. When the assembly is fully seated, turn the Module’s Captured Panel
Fasteners (clockwise) to secure the unit to the Chassis.

6. Install the original Terminal/Header Block Assembly (with wiring harness) onto the

replacement IORSM (turning the Quarter Turn Fasteners (clockwise).

7. Replace the Terminal Housing Assembly.

8. Remove from manual control any processes associated with the IORSM.

3.3 TROUBLESHOOTING TIPS

3.3.1 Power Supply/Monitor Module (PSMM) Voltage Checks

One or two bulk power sources can be connected to the PSMM. PSMM connector TB1
provides 3 input terminal connections for bulk power (see Figure 3-1):

TB1-1 = (+VIN) (+20.7V to +30V dc for +24V supply)
TB1-2 = (-VIN) (Supply Ground)
TB1-3 = Chassis Ground - CHASSIS (

)

Figure 3-1 - Power Supply/Monitor Board Component Designations

Bulk supply voltages can be checked at TB1 using a voltmeter or multimeter. PSMM’s are
factory configured for use with a nominal 24Vdc bulk power supply. The maximum and
minimum input power switch points can be tested with the use of a Variable dc Power
Supply connected between TB1-1 (+) and TB1-2 (-). By increasing the input voltage
(starting at +20.7Vdc), you can determine the point at which the unit will turn on, i.e., the
point at which the green PWRGOOD LED on the PSMM comes ON (Vt+). By decreasing the
input voltage (starting at +30Vdc), you can determine the point at which the unit turns off,
i.e., the point at which the green PWRGOOD LED on the PSMM goes OFF (Vt-). If the

CI-ControlWaveREDIO Service / 3-3

value of the bulk power supply’s +24Vdc output approaches the value of Vt+ or Vt- it should
be replaced by one with the correct +24V output.

3.3.2 LED Checks

LEDs provide operational and diagnostic functions. A brief synopsis of the individual
ControlWave Redundant I/O and Communications Switch Unit LEDs is provided as
follows:

PSMM: 1 LED: PWRGOOD
IORCM: 6 LEDs: A Power System Status, B Power System Status, A Unit On-Line, A

Unit Fail, B Unit On-Line and B Unit Fail

IORSM: 2 LEDs: A On-Line Status and B On-Line Status

ControlWave Redundant I/O and Communications Switch Unit (CWREDIO) LED desig­nations and functions are provided in Table 3-1.

Module

PSMM1 PWRGOOD Green ON = Power Supply 1 Normal operation - O.K.
PSMM2 PWRGOOD Green ON = Power Supply 2 Normal operation - O.K.
IORCM CR1 - Unit A On-Line Green GREEN = CW_A is On-line as Primary Controller
IORCM CR2 - Unit B On-Line Green GREEN = CW_B is On-line as Primary Controller
IORCM CR3 - Unit A Fail Red RED = CW_A Watchdogged (failed)
IORCM CR4 - Unit B Fail Red RED = CW_B Watchdogged (failed)

IORCM

IORCM

IORSM
IORSM

All ControlWave/ControlWaveEXP Modules contain light emitting diodes (LEDs) that
provide operational and diagnostic functions. ControlWave and ControlWaveEXP LEDs
are discussed in instruction manuals CI-ControlWave and CI-ControlWaveEXP, respec­tively. A brief synopsis of the individual module LEDs is provided as follows:

PSSM: 3 LEDs: 1 MC LED, 1 PWRFAIL LED & 1 PWRGOOD LED
CPUB: 2 LEDs per Comm. Port = 4, 2 LEDs per Ethernet Port = 2
1 Idle LED, 1 Watchdog LED & the Port 80 Display Assembly
SCB: 2 LEDs per Comm. Port = 4, 2 LEDs/Ethernet = 4
AIM: 33 LEDs: 1 Status LED plus 2 LEDs per point x 16 = 32 AI LEDs
AOM: 2 LEDs: 1 FAIL LED & 1 GOOD LED
DIM: 33 LEDs: 1 Status LED plus 1 LED per point x 32 = 32 DI LEDs
DOM: 33 LEDs: 1 Status LED plus 1 LED per point x 32 = 32 DO LEDs
UDIM: 14 LEDs: 1 FAIL LED, 1 PASS LED plus 1 LED per point x 12 = 12 UI LEDs

Note: These status indicators are powered from an additional independent
+3.3Vdc power source on the IORSM’s Logic Board (+3.3V5), and display the
status of the external CW/CWEXP units under CWIORCM control and the
condition of the power sources used or generated on the CWIORCM.

Table 3-1 - CWREDIO LED Assignment

LED

Name

CR5 - B Power
System Status

CR6 - A Power
System Status

A On-Line Status
B On-Line Status

LED

Color

Red
Green

Red
Green

Green
Green

Function

GREEN = +3.3V4, VCC_RED, RED_RLY PWR OK
RED = At least one of the above supplies has
failed
GREEN = =3.3V1, +3.3V2, +3.3V3 are OK
RED = At least one of the above supplies has
failed
ON = System A I/O Module Selected

ON = System B I/O Module Selected

3-4 / Service CI-ControlWaveREDIO

ControlWave/ControlWaveEXP Module LED designations and functions are provided in
Table 3-2.

Table 3-2 - CW_A/CWEXP_A & CW_B/CWEXP_B LED Assignment

Module

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

AIM AI Bd. Status Red/Green

AIM

AIM

AOM AO Bd. Status Fail Red *** LED ON = AI Bd. Fail State/Bd. not recognized
AOM AO Bd. Status Pass Green *** LED ON = AI Bd. Normal or O.K. State

DIM DI Bd. Status Red/Green

DIM

DOM DO Bd. Status Red/Green

DOM

UIM UI Bd. Status Fail Red **** LED ON = UI Bd. Fail State/Bd. not recognized
UIM UI Bd. Status Pass Green **** LED ON = UI Bd. Normal or O.K. State

UIM

* = see Figure 3-1, ** = see Sections 2.4.2 & 3.4.4, *** = see Figure 3-4, **** = see Figure 3-7

RANGE (16 LEDs)
(1 Per Point)
RANGE (16 LEDs)
(1 Per Point)

INPUT (32 LEDs)
(1 Per Point)

OUTPUT (32 LEDs)
(1 Per Point)

INPUT (12 LEDs)
(1 Per Point)

LED

Name

LED

Color

Red

Green

Red

Red LED ON = Output is ON (see Fig 3-6)

Red

* and Figures Referenced to CI-ControlWave

ON Red = Fail State/Bd. not recognized
ON Green = Normal State (see Fig 3-3)
LED ON = Overrange or Underrange condition
(see Fig 3-3)
LED ON = In-range condition
(see Fig 3-3)

ON Red = DI Bd. Fail State/BD. not recognized
ON Green = DI Bd. Normal State (see Fig. 3-5)
LED ON = Input is present
LED OFF = Input is not present (see Fig 3-5)
ON Red = Fail State/Module not recognized
ON Green = Normal State (see Fig 3-6)

LED ON = Input activity on input is present
LED OFF = No activity on input (see Fig 3-7)

Function

CI-ControlWaveREDIO Service / 3-5

TB3-1 = Normally Open - Closed if Pow er OK

)

c

TB3-2 = Normally Open - Closed if Pow er OK
TB3-3 = Normally Closed - Open if Power OK
TB3-4 = Normally Closed - Open if Power OK

Co mm. Intf.

Connector

for CW_A or

CWEXP_A

Ports 1 - 4

J5 J6

TB3

{

4

1

POWER

A

SYSTEM
STATUS

B

ON-LINE

FAIL

ON-LINE

FAIL

UNIT A

UNIT B

CWIORC Logi

& Rel a y Bo ard

Co mm. Intf.

Connector

fo r C W _ B or

CWEXP_B

Ports 1 - 4

A/B PRIMARY

Select

Sw i tch SW 2

Com m. Port 1

RS-232

Note: If these
Component s ar e
Pr esent, Comm.

Port 3 = RS-485

C om m . Po rt 3

RS-232/485

{

A

B

PRIMARY

J1 J2

J3 J4

ENABLED

/BA\

SW1SW2

Key Operated

A/B ENABL ED

Sw i tch SW 1

(Key Removed

C om m . Po rt 2

RS-232

Note: If these

Component s ar e

{

Present, Comm.

Port 4 = RS-485

Comm. Po rt 4

RS-232/485

1144

{

TB2-1 = CW_A O nlin e Contact Outp ut
TB2-2 = CW_A O nlin e Contact Outp ut
TB2-3 = CW_B O nlin e Contact Output

{

Figure 3-2 - I/O Redundancy Control Module -

Connector, Port, Switch & LED Designations

3-6 / Service CI-ControlWaveREDIO

TB2-4 = CW_B O nlin e Contact Output

{

TB1-1 = CW_A Watchdog + Input
TB1-2 = C W_A Watchdog - Input
TB1-3 = CW_B Watchdog + Input

{

TB1-4 = CW_ B Watchdog - Input

Figure 3-3 - Analog Input (AI) Module LED Designations

Figure 3-4 - Analog Output (AO) Module LED Designations

CI-ControlWaveREDIO Service / 3-7

Figure 3-5 - Digital Input (DI) Module LED Designations

Figure 3-6 - Digital Output (DO) Module LED Designations

3-8 / Service CI-ControlWaveREDIO

Figure 3-7 - Universal Digital Input (UDI) Module 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 3-3).

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

I/O Subsystem Figures Notes

Discrete Inputs 2-10 through 2-14 See Section 2.3.2.4
Discrete Outputs 2-15 through 2-18 See Section 2.3.2.5
Analog Inputs 2-19 through 2-24 See Section 2.3.2.6
Analog Output 2-25 through 2-28 See Section 2.3.2.7
Universal Inputs 2-29 through 2-32 See Section 2.3.2.8
Watchdog Ckt. 2-35 See Section 2.3.2.3

3.4 GENERAL SERVICE NOTES

Certain questions or situations frequently arise when servicing the 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 ControlWave Redundant I/O and Communications Switch Units
(CWREDIO) are strictly limited to the replacement of complete modules. CWREDIO
Modules are sealed and employ a tamper indicator. Disassembly of a CWREDIO Module

CI-ControlWaveREDIO Service / 3-9

constitutes tampering and will violate the warranty. Defective CWREDIO Chassis or
Modules must be returned to an authorized service center.

3.5 WINDIAG DIAGNOSTICS

WINDIAG Software is a diagnostic tool used for testing ControlWave/-ControlWaveEXP
I/O Modules, CPU memory, communications ports, etc., for proper performance. The
ControlWave/ControlWaveEXP must be communicating with a PC equipped with
WINDIAG. ControlWave/ControlWaveEXP CPU Module configuration switch SW1-8
must be set to the OFF (Closed) position to enable diagnostics. Communication between the
ControlWave/ControlWaveEXP (with/without application loaded) and the PC can be
made via a Local or Network Port with the following restrictions:

• ControlWave/ControlWaveEXP 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 ControlWave/ControlWaveEXP communication port can be connected to the PC

provided their port speeds match. Many PCs have a COM1 port (typically RS-232 and
defaulted to 9600 bps operation).

• The ControlWave/ControlWaveEXP 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 ControlWave/-
ControlWaveEXP CPU Board Switch SW1-3 OFF (closed).

• Communication port COM1 is only forced to 9600 bps operation when ControlWave/-

ControlWaveEXP 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 ControlWave/ControlWaveEXP 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 defaults to 115.2 kbd (RS-232) using the Internet Point to

Point Protocol (PPP). Note: Port COM1 will be configured for RS-232 operation (at

9600 baud) 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 between CWREDIO Comm.
Port 1 and a PC requires the use of an RS-232 “Null Modem” cable (see Figure 2­4A).

COM2: From the factory, COM2 on the CPU Board defaults to 9600 baud, 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. Connection between CWREDIO Comm. Port 2
and a PC requires the use of an RS-232 “Null Modem” cable (see Figure 2-4A).

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

defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer
protocol operation. To test COM3 using the WINDIAG program, it must not

3-10 / Service CI-ControlWaveREDIO

otherwise be in use and CPU Switch SW1-8 must be set to the OFF position. An
RS-232 “Null Modem” cable (see Figure 2-4A) can be connected between COM3
and the PC or an RS-485 cable (see Tables 2-1 & 2-2) can be connected between
COM3 and the PC’s RS-485 Port.

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

defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/Control-Wave 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. An
RS-232 “Null Modem” cable (see Figure 2-4A) can be connected between COM4
and the PC or an RS-485 cable (see Tables 2-1 & 2-2) can be connected between
COM4 and the PC’s RS-485 Port.

Comm. Port Hardware Notes:

1. All CWREDIO Comm. Ports are equipped with 9-pin Male D-Sub connectors.

2. COM1, COM2 and COM4 of Redundant ControlWaves or ControlWaveEXPs

are equipped with 9-pin Male D-Sub connectors while COM3 is equipped with
an 8-pin RJ-45 jack.

1. When connecting a PC to COM1 through COM4 of the CWREDIO or directly to

COM1, COM2 or COM4 of a redundant ControlWave or redundant Control-
WaveEXP: If the PC is equipped with an RS-232 Port that utilizes an RJ-45
jack, the use of the “Null Modem” cable P/N 392843-01-3 (see Figure 2-4A) and
one “RJ45 to DB9 Adapter” cable P/N 392844-01-0 (see Figure2-4D) will be
required.

2. When connecting a PC’s RS-232 Port directly to COM3 of a redundant

ControlWave or redundant ControlWaveEXP: 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 4A, or use “Null Modem” cable P/N 392843-01-3 connected to two “RJ-45
to DB9 Adapter” cables P/N 392844-01-0 (see Figures 2-4A and 2-4D), to
interconnect the PC directly to COM3 of a redundant CW or CWEXP.

3. When connecting a PC’s RS-232 Port directly to COM3 of a redundant

ControlWave or redundant ControlWaveEXP: If the PC is equipped with an
RS-232 Port that utilizes a standard 9-pin Male D-Sub connector, the use of the
“Null Modem” cable P/N 392843-01-3 (see Figure 2-4A) and one “RJ-45 to DB9
Adapter” cable P/N 392844-01-0 (see Figure 2-4D) will be required. This RS­232 network, consisting of two cables, connects to COM3 of the
ControlWave/ControlWaveEXP with an 8-pin RJ-45 male connector to the PC
with a 9-pin D-type female connector.

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

the connections provided in Tables 2-1 (for 9-pin D-Sub connectors), 2-2 (RS­485 network connections) and 2-3 (for 8-pin RJ-45 connectors).

7.

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 CI-ControlWave - Figures 2-7, 2-12, 2­13 and 2-14 or CI-ControlWaveEXP - Figures 2-7, 2-10, 2-11 and 2-12). If not
configured with an address, the ControlWave/ControlWaveEXP uses DHCP (by
default) to obtain an IP address.

To use the WINDIAG program place any critical process (associated with the

Control­Wave/ControlWaveEXP unit in question) under manual control. WINDIAG cannot be run
while the ControlWave/ControlWaveEXP application is running. Set the ControlWave/-

CI-ControlWaveREDIO Service / 3-11

ControlWaveEXP 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 3-8 will appear.

Figure 3-8 - Netview Startup Menu - Example with Multiple Networks

2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI Tools,

then select Utilities Programs and then select Diagnostics.

3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 3-9 will

appear.

4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). 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 ControlWave/ControlWaveEXP
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 ControlWave/ControlWaveEXP CPU Switch SW1-8 to the ON (Open) position.

The ControlWave/ControlWaveEXP should resume normal operation.

3-12 / Service CI-ControlWaveREDIO

3.5.1 Diagnostics Using WINDIAG

All ControlWave/ControlWaveEXP Modules except the Power Supply/Sequencer Module
can be tested using the WINDIAG program. ControlWave Redundant I/O and Com­munication Switch Unit Modules are indirectly supported by the WINDIAG program.
ControlWave I/O Redundancy Switch Modules can be tested indirectly via WINDIAG, i.e.,
by running WINDIAG in conjunction with the associated ControlWave/ControlWaveEXP
I/O Module, all individual I/O points can be checked. The communication Ports on the

ControlWave I/O Redundancy Control Module can be checked along with the associated
ControlWave/ControlWaveEXP communication ports via WINDIAG’s Communication

Diagnostics. From WINDIAG’s Main Diagnostics Menu (see Figure 3-9) the following
diagnostic tests can be performed:

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 Diagnostic: Checks Ethernet Ports 1 through 3 - The Loop-back Out

Twisted Pair tests require the use of a loop-back plug.
Analog Output Diagnostic: Checks the Analog Output Module.
Analog Input Diagnostic: Checks the Analog Input Module.
Discrete I/O Diagnostic: Checks the DI Module and/or the DO Module.
High Speed Counter Diagnostic: Checks the Universal Digital Input Module

3.5.1.1 Communications Diagnostic Port Loop-back Test

WINDIAG’s Communications Diagnostic Menu (see Figure 3-11) 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:

If testing the Communications Port in question at the CWREDIO unit use a 9-pin female
D-Type loop-back plug (see Fig. 3-10).

If testing the Comm. Port in question at the ControlWave or ControlWaveEXP unit,
select an appropriate loopback plug as follows:

Ports 1, 2 & 4 set-up for RS-232 use a 9-pin female D-type loop-back plug (see Fig. 3-10).
Port 4 set-up for RS-485 use a 9-pin female D-type loop-back plug (see Fig. 3-12).
Port 3 set-up for RS-232 use an 8-pin male RJ-45 loop-back plug (see Fig. 3-10).
Port 3 set-up for RS-485 use an 8-pin male RJ-45 loop-back plug (see Fig. 3-12).

CI-ControlWaveREDIO Service / 3-13

Figure 3-9 - WINDIAG Main Diagnostics Menu

This group of tests verifies the correct operation of the Communication Interface. COM1,
COM2, COM3 and COM4 can be tested with this diagnostic. The ControlWave/Control-
WaveEXP communication port that is connected to the PC (directly or via the CWREDIO)
(local or network and used for running these tests) can’t be tested until diagnostics has
been established via one of the other ports, i.e., to test all communication ports (via
WINDIAG), communications with the PC will have to be established twice (each time via a
different port). It should also be noted that the ControlWave/ControlWaveEXP com­munication port that is connected to the PC (RS-232, RS-485 or Ethernet) must be good for
WINDIAG to run the Communications Diagnostics

Figure 3-10 - RS-232 Loop-back Plugs

3-14 / Service CI-ControlWaveREDIO

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 3-10 through
3-12).

Figure 3-11 - WINDIAG’s Communications Diagnostic Menu

Figure 3-12 - RS-485 Loop-back Plugs

CI-ControlWaveREDIO Service / 3-15

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.

3.6 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:

• Bulk Power loss at the CWREDIO unit (or a catastrophic failure at CWREDIO unit) will

result in the CWREDIO’s A_system relays closing and B_system relays opening. When
this occurs, CW_A becomes the on-line MASTER. CW_B can’t control the process since
its I/O and Comm. Ports 1 through 4 are switched out.

• 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 at CW_A and CW_B must be correct. See Section 2.3.3.1 of CI-

ControlWave, or CI-Control-WaveEXP for details.

• 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:

• CW_A and CW_B IP address are set the same. IP addresses at these units must be

different or side-loading and A/B unit data exchange can’t occur.

3-16 / Service CI-ControlWaveREDIO

PROCEDURE FOR CORRECTING CONFIGURATION MISMATCHES

Indication: Standby unit never stays at ‘BA’, it continually cycles through ‘BD’, ‘BC’, pos-

sibly ‘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.

• Power OFF this unit.

2.

3.

4.

5.

6.

• Power ON this unit.

7.

• Start the Flash Configuration

Utility.

• Choose [Load From RTU].

• Choose [Save to NetDef] and/or

[Write Profile].

• Power OFF this unit, but leave the

Flash Configuration Utility running.

8.

9.

10.

11.

• Verify that the “B” unit is OFF. (See

Step 10.)

• Power ON the “A” unit.

12.

• 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.

• 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.

• Power OFF this unit.

• Power ON this unit.

• Choose [Save to Rtu]. This effectively

transfers the historical configuration.

• 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.

3.7 ControlWaveREDIO FUNCTIONAL TESTS

Tests provided herein allow the user to verify the proper functionality of the ControlWave
REDIO.

• Basic Reset and Supervisory Power-Up Test (Section 3.7.1)

• Redundant Power Source and Supervisory Power-Up Tests (Section 3.7.2)

• Watchdog Mechanism Power-Up Tests (Section 3.7.3)

• Primary CPU Selection on Power-Up Tests (Section 3.7.4)

• Tests of Switchover from ‘Dead’ Primary Selected Unit on Power-Up (Section 3.7.5)

• Forced Primary CPU Selection on Power-Up Tests (Section 3.7.6)

CI-ControlWaveREDIO Service / 3-17

• Normal Power-Up and Switchover Tests (Section 3.7.7)

• Normal Power-Up and Forced Switchover Tests (Section 3.7.8)

• On-Line Relay Functional Tests (Section 3.7.9)

• Communication Ports Functional Tests (Section 3.7.10)

3.7.1 Basic Reset and Supervisory Power-Up Tests

Initial conditions:

PSMM A switch = ON; PSMM 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

3.7.2 Redundant Power Source & Supervisory Power-Up Tests

Initial conditions:

Resume from last test; Both Power System Status LED’s should be GREEN

Turn PSMM A OFF
A Power System Status LED should remain GREEN
Turn PSMM A ON
A Power System Status LED should remain GREEN
Turn PSMM B OFF
B Power System Status LED should remain GREEN
Turn PSMM B ON
B Power System Status LED should remain GREEN

3.7.3 Watchdog Mechanism Power-Up Tests

Initial conditions:

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

A/B Enabled Switch = AUTO (center position)

Ext. Supply Pwr for CW_A/CWEXP-A and CW_B/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
UNIT A & UNIT B Fail LED’s should initially be RED
After both redundant CPU’s go through self-test, the primary CPU should go on-line, the
appropriate ON_LINE LED should turn GREEN, the backup unit should be side loaded from
the primary and both UNIT A & UNIT B FAIL LED’s should go OFF
At CW_A/CWEXP-A, 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.
UNIT A FAIL LED should change to RED; UNIT B FAIL LED should remain OFF
At CW_A/CWEXP-A, turn PSSM A ON
After CPU A completes self-test, it should be side loaded from the primary CPU (B);
(A CPU Display = BD -> BC -> BA)
UNIT A FAIL LED should change to OFF; UNIT B FAIL LED should remain OFF
At CW_B/CWEXP-B, Turn PSSM B OFF; CPU A should go on-line
UNIT B FAIL LED should change to RED; UNIT A Fail LED should remain OFF
At CW_B/CWEXP-B, turn PSSM B ON
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(B CPU Display = BD -> BC -> BA)
UNIT B FAIL LED should change to OFF; UNIT A FAIL LED should remain OFF

3-18 / Service CI-ControlWaveREDIO

3.7.4 Primary CPU Selection on Power-Up Tests

Initial conditions:

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center position)

Ext. Supply Pwr for CW_A/CWEXP-A and CW_B/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
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 UNIT A FAIL LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A);
(B CPU Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and B ON-LINE LED should remain OFF

Initial conditions:

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center position)

Ext. Supply Pwr for CW_A/CWEXP-A and CW_B/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
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, UNIT 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)
UNIT A FAIL LED should go OFF and A ON-LINE LED should remain OFF

3.7.5 Tests of Switchover from “Dead” Primary Selected Unit on Power-Up

Initial conditions:

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center)

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = OFF; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
GREEN, UNIT B ON-LINE LED = OFF
A Fail LED remains RED as PSSM A is OFF
CPU B should complete self-test, but can’t be side loaded from the primary CPU (A) since A is
powered down; CPU B should display BD; UNIT B Fail LED should remain RED

The unit will attempt to bring CPU B on-line:

UNIT B ON-LINE LED should change to GREEN & UNIT A ON-LINE LED should change to
OFF
CPU B should run its self-test; After B completes self-test, UNIT B Fail LED should go OFF
(CPU B is now on-line); UNIT A Fail LED should remain RED & UNIT A ON-LINE LED
should remain OFF
Restore CPU A CPU
Turn PSSM A ON
Initially: UNIT A FAIL LED = RED; UNIT A ON-LINE LED should remain OFF
After CPU A completes self-test, it should be side loaded from the primary CPU (B); (A CPU
Display = BD -> BC -> BA)
UNIT A FAIL LED should go OFF and UNIT A On-Line LED should remain OFF

Initial conditions:

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center)

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = OFF;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

CI-ControlWaveREDIO Service / 3-19

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: A UNIT FAIL LED = RED, B UNIT FAIL LED = RED; A ON-LINE LED = OFF, B
ON-LINE LED = OFF
B FAIL LED remains RED as PSSM B is off
CPU B should complete self-test, but cannot be side loaded from the primary CPU (A) because
B is powered down; CPU A should display BD; UNIT A Fail LED should remain RED

The unit will attempt to bring CPU A on-line:

UNIT A ON-LINE LED should change to GREEN & UNIT B ON-LINE LED should change to
OFF
CPU A should run its self-test; After A completes self-test, UNIT A FAIL LED should go OFF
(CPU A is now on-line); UNIT B Fail LED should remain RED & UNIT B ON-LINE LED
should remain OFF
Restore B CPU
Turn PSSM B ON
Initially: UNIT B FAIL LED = RED; UNIT B ON-LINE LED should remain OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF

3.7.6 Forced Primary CPU Selection on Power-Up Tests

Initial conditions:

A/B Primary Switch = A; A/B Enabled Switch = B (right position)
PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF; A/B
CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
OFF, UNIT B ON-LINE LED = GREEN
After CPU B completes self-test, UNIT 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)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF
Turn PSSM B OFF
UNIT B FAIL LED should go ON and UNIT B ON-LINE LED should remain GREEN
Turn PSSM B ON
After CPU B completes self-test, UNIT B FAIL LED should go OFF
UNIT B On-Line LED should remain GREEN

Initial conditions:

A/B Primary Switch = B; A/B Enabled Switch = A (left position)
PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF; A/B
CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
GREEN, UNIT B ON-LINE LED = OFF
After CPU A completes self-test, UNIT A FAIL LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF
Turn PSSM A OFF
UNIT A FAIL LED should go ON and UNIT A ON-LINE LED should remain GREEN
Turn PSMM A ON
After CPU A completes self-test, UNIT A FAIL LED should go OFF
UNIT A ON-LINE LED should remain GREEN

3-20 / Service CI-ControlWaveREDIO

3.7.7 Normal Power-Up & Switchover Tests

Initial conditions:

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center position)

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
GREEN, B UNIT ON-LINE LED = OFF
After CPU A completes self-test, the UNIT A FAIL LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF
Turn PSSM A OFF
UNIT B ON-LINE LED should change to GREEN, UNIT A ON-LINE LED should change to
OFF & UNIT 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); (A CPU
Display = BD -> BC -> BA)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF
Turn PSSM B OFF
UNIT A ON-LINE LED should change to GREEN, UNIT B ON-LINE LED should change to
OFF & UNIT 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); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF

Initial conditions:

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center position)

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
OFF, UNIT B ON-LINE LED = GREEN
After CPU B completes self-test, the UNIT 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)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF
Turn PSSM B OFF
UNIT A ON-LINE LED should change to GREEN, UNIT ON-LINE LED should change to OFF
& UNIT 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); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF
Turn PSSM A OFF
UNIT B ON-LINE LED should change to GREEN, UNIT A ON-LINE LED should change to
OFF & UNIT 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); (A CPU
Display = BD -> BC -> BA)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF

CI-ControlWaveREDIO Service / 3-21

3.7.8 Normal Power-Up & Forced Switchover Tests

Initial conditions:

A/B Primary Switch = A; A/B Enabled Switch = AUTO (center position)

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
GREEN, UNIT B ON-LINE LED = OFF
After CPU A completes self-test, the UNIT A FAIL LED should go OFF
After CPU B completes self-test, it should be side loaded from the primary CPU (A); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF
Change A/B Enabled Switch to B (right position): Force Switchover to B
UNIT B ON-LINE LED should change to GREEN, UNIT A ON-LINE LED should change to
OFF & UNIT A FAIL LED should change to RED
After CPU A completes self-test, it should be side loaded from the primary CPU (B); (A CPU
Display = BD -> BC -> BA)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF
Change A/B Enabled Switch to A (left position): Force Switchover to A
UNIT A ON-LINE LED should change to GREEN, UNIT B ON-LINE LED should change to
OFF & UNIT B FAIL LED should change to RED
After CPU B completes self-test, it should be side loaded from the primary CPU (A); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF

Initial conditions:

A/B Primary Switch = B; A/B Enabled Switch = AUTO (center position)

PSMM A switch = ON; PSMM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Turn External Supply Power ON (at redundant units and CWREDIO)
Initially: UNIT A FAIL LED = RED, UNIT B FAIL LED = RED; UNIT A ON-LINE LED =
OFF, UNIT B ON-LINE LED = GREEN
After CPU B completes self-test, the UNIT 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)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF
Change A/B Enabled Switch to A (left position): Force Switchover to A
UNIT A ON-LINE LED should change to GREEN, UNIT B ON-LINE LED should change to
OFF & UNIT B FAIL LED should change to RED
After CPU B completes self-test, it should be side loaded from the primary CPU (A); (B CPU
Display = BD -> BC -> BA)
UNIT B FAIL LED should go OFF and UNIT B ON-LINE LED should remain OFF
Change A/B Enabled Switch to B (right position): Force Switchover to B
UNIT B ON-LINE LED should change to GREEN, UNIT A ON-LINE LED should change to
OFF & UNIT A FAIL LED should change to RED
After CPU A completes self-test, it should be side loaded from the primary CPU (B); (A CPU
Display = BD -> BC -> BA)
UNIT A FAIL LED should go OFF and UNIT A ON-LINE LED should remain OFF

3.7.9 On-Line Relay Functional Tests

The IORC 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 TB2 on the
IORCM panel gives access to the relay contacts for test using the following procedure. Refer

3-22 / Service CI-ControlWaveREDIO

to Figure 3.2 for connector and pin identification. An ohmmeter or continuity indicator may
be used to check relay status.

Initial conditions:

A/B Primary Switch = A; A/B Enabled Switch = A (left position)

PSMM A switch = ON; PSBM B switch = ON; Ext Supply Pwr = OFF;

CW/CWEXP_A PSSM A switch = ON; CW/CWEXP_B PSSM B switch = ON;

Ext. Supply Pwr for CW/CWEXP_A and CW/CWEXP_B = OFF

Check continuity between TB2-1 & TB2-2; there should be continuity indicating CPU A is on­line
Check continuity between TB2-3 & TB2-4; there should be no continuity indicating CPU B is
not on-line
Turn External Supply Power ON (at redundant units and CWREDIO)
UNIT A ON-LINE LED should be ON
Check continuity between TB2-1 & TB2-2; there should be continuity indicating CPU A is on­line
Check continuity between TB2-3 & TB2-4; 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
UNIT B ON-LINE LED should be ON
Check continuity between TB2-1 & TB2-2; there should be no continuity indicating CPU A is
not on-line
Check continuity between TB2-3 & TB2-4; there should be continuity indicating CPU B is on­line

3.7.10 I/O Redundancy Control Module Comm. Ports Functional Tests

3.7.10.1 Configuration for Port Tests

Associated 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 CWIORCM 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 through
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 (RS-232 or RS-485) and IORCM/PC cables based on
the type of port to be tested.

The IORC 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.

CI-ControlWaveREDIO Service / 3-23

3.7.10.2 Communication Port Switching Tests

Reference Section 3.5 through 3.5.1.1 for Assistance and Figure 3-2

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

3-24 / Service CI-ControlWaveREDIO