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