Fisher CW 30 Hardware Installation Guide

Product Information Package

pg

PIP-CW_30 Upgrade Kit
Mar., 2007

CW_30 Hardware

ControlWave_30
HARDWARE INSTALLATION GUIDE

For u

rade of the 3330 DPC

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

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

These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or main­tenance. Should problems arise that are not covered sufficiently in the text, the pur­chaser is advised to contact Bristol for further information.

EQUIPMENT APPLICATION WARNING

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

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note
the following: The party sending such materials is responsible to ensure that the
materials returned to Bristol are clean to safe levels, as such levels are defined and/or
determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Bristol and save Bristol harmless from any liability or
damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic in­struments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by
exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude
and duration of the ESD, this can result in erratic operation or complete failure of the
equipment. Read supplemental document S14006 at the back of this manual for
proper care and handling of ESD-sensitive components.

Bristol 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

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

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

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

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

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

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

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

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

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

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

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

or oral warranties beyond those set forth herein.

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

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

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

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

REMEDIES

How to return material for Repair or Exchange

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

You can easily obtain a RA number by:

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

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

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

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

C. Mail
Mail the form (GBU 13.01) to

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

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

with a RA number.

D. Phone

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

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

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

. A Bristol Repair Dept.

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

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

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

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

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

• Evaluate / Test / Verify Discrepancy

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

• Return to Customer

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

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

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

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

Model No./Part No. Description

Please be aware of the Non warranty standard charge:

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

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

Range/Calibration S/N
Reason for return

: Failure Upgrade Verify Operation Other

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

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

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

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

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

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

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

repaired returned replaced scrapped?

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

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

repaired returned replaced scrapped?

returned replaced scrapped?
returned replaced *see below?

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

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

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

phone_____________________

____________________________________________________________________________________________________

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

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

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

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

• Minimize installation, start-up and maintenance costs.

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

• Know your system.

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

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

6200.

A Few Words About Bristol Inc.

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

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

Getting Additional Information

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

Help Files / Release Notes

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

Contacting Bristol Inc. Directly

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

Our main phone numbers are:

[phone]
[phone] (FAX)

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

Telephone Support - Technical Questions

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

For technical questions about TeleFlow products call [phone].

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

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

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

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

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

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

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

You can e-mail the Communication Technology Group at:

[e-mail]

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

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

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

Visit our Site on the World Wide Web

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

Training Courses

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

PIP-CW_30 Upgrade Kit

Hardware Installation Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

SECTION 1 – ControlWave_30 INTRODUCTION...................................... 1

SECTION 2 – ControlWave PROGRAMMING ENVIRONMENT......................... 1

SECTION 3 – PHYSICAL DESCRIPTION ............................................ 3

3.1 CW_30 CPU Board Overview............................................................................................ 3

3.1.1 CW_30 CPU Board Serial Comm. Port Connectors......................................................... 6

3.1.2 CW_30 CPU Board Ethernet Ports .................................................................................. 6

3.1.2.1 Ethernet CPU Engine 10/100Base-T Connectors ............................................................ 6

3.1.3 CW_30 CPU Board Memory.............................................................................................. 8

3.1.4 CW_30 CPU Board Configuration Jumpers..................................................................... 8

3.1.5 CW_30 CPU Board Configuration Switches .................................................................... 9

3.1.6 CW_30 CPU Board LEDs ................................................................................................ 10

3.2 CW_30 Communication Board (CB) Overview .............................................................. 12

3.2.1 Setting CB Board DIP Switches ..................................................................................... 12

3.2.2 Setting CB Board Configuration Jumpers ..................................................................... 15

3.2.3 CB Board LED Indicators ............................................................................................... 16

3.2.4 CB Board Communication Port Information ................................................................. 17

SECTION 4 – ControlWave_30 CONFIGURATION.................................. 18

4.1 Step 1 - Hardware Configuration ................................................................................... 18

4.2 Step 2 - Software Installation on the PC Workstation .................................................. 23

4.3 Step 3 - Establish Communications using either LocalView or Netview,

and Run the Flash Configuration Utility ....................................................................... 23

4.4 Step 4. - Create an Application-specific Control Strategy in

ControlWave Designer..................................................................................................... 23

4.5 Step 5 - Create Application Specific Web Pages OPTIONAL) ...................................... 24

4.6 Step 6 - Create an Open BSI Network Containing the CW_30,

or add the CW_30 to an Existing Open BSI Network ................................................... 25

4.7 Step 7 - Download the Application-specific Control Strategy

into the CW_30 DPC........................................................................................................ 25

SECTION 5 – OPERATIONAL DETAILS........................................... 25

5.1 Downloading the Application Load................................................................................. 26

5.2 Upgrading CW_30 Firmware.......................................................................................... 26

5.2.1 Using LocalView to Upgrade CW_30 Firmware ............................................................ 26

5.2.2 Using Hyperterminal to Upgrade CW_30 Firmware .................................................... 30

5.2.3 Remote Upgrade of CW_30 Firmware............................................................................ 32

5.3 Core Updump ................................................................................................................... 32

SECTION 6 – GENERAL SERVICE NOTES ........................................ 33

6.1 Extent of Field Repairs.................................................................................................... 33

6.2 Disconnecting RAM Battery ........................................................................................... 33

PIP-CW_30 Upgrade Kit Contents / 0 - 1

PIP-CW_30 Upgrade Kit

Hardware Installation Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

SECTION 6 – GENERAL SERVICE NOTES (Continued) ............................ 33

6.3 Maintaining Backup Files............................................................................................... 34

SECTION 7 – WINDIAG DIAGNOSTICS ........................................... 34

7.1 Diagnostics Using WINDIAG ......................................................................................... 36

7.1.1 Communication Diagnostic Port Loop-back Tests......................................................... 36

7.1.2 Serial Comm. Port External Loop-back Test Procedure ............................................... 36

7.1.3 Ethernet Port Diagnostics............................................................................................... 38

7.1.3.1 10/100Base-T (RJ-45 – Twisted Pair) Port Hardware Setup ........................................ 39

7.1.3.2 Ethernet Port Diagnostic Test Execution ...................................................................... 39

7.1.3.3 Loop-back Out Twisted Pair Test RUN Button ............................................................. 40

7.1.3.4 Return Hardware Address Test RUN Button................................................................ 40

7.1.3.5 Ethernet Port Diagnostic Error/Failure Messages........................................................ 40

SECTION 8 – DISPLAY/KEYPAD ASSEMBLY OPERATION ......................... 40

8.1 Operation of the Dual-button/Display/Keypad Assembly ............................................. 41

SECTION 9 – CW_30 SPECIFICATIONS ........................................... 44

9.1 CW_30 CPU Board Specifications .................................................................................. 44

9.1.1 CPU Board Communication Port Specifications ........................................................... 44

9.1.2 CPU Board 3.3V Power Supply Specifications............................................................... 44

9.1.3 CPU Board Environmental Specifications ..................................................................... 45

9.2 CW_30 Communication Board (CB) Specifications ....................................................... 45

9.2.1 CB Board Connectors ...................................................................................................... 45

9.2.2 CB Board Communication Port Specifications .............................................................. 45

9.2.3 CB Board 3.3V Power Supply Specifications ................................................................. 45

9.2.4 CB Board Environmental Specifications........................................................................ 45

APPENDICES

4 X 20 DISPLAY-KEYBOARD ASSEMBLY..........................................................Appendix DKA

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

REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS

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

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

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

ACCOL Translator User Guide ............................................................................... D5086

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

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

ControlWaveMICRO Quick Setup Guide ................................................................ D5124

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

0 - 2 / Contents PIP-CW_30 Upgrade Kit

ControlWave_30

HARDWARE INSTALLATION GUIDE

SECTION 1 - ControlWave_30 INTRODUCTION

DPC 3330 can be field upgraded to become a ControlWave_30 DPC (herein referred to as
CW_30) by utilizing the hardware provided in an installation kit. Upgrade will require
removal of the standard DPC 3330 CPU and Comm./ECOM Boards and then adding the

CW_30 CPU (CPU) and CW_30 Communication (CB) Boards provided in the upgrade kit.

ControlWave® products have been designed and integrated as a highly adaptable, high

performance Distributed Open Controller family with exceptional networking capability
that provides a complete Process Automation Management Solution. The CPU and CB
Boards were designed with an emphasis on providing high performance with low power
consumption and scalability.

The CPU Module utilizes Sharp’s LH7A400 System-on-Chip Advanced RISC Machine
(ARM) microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC)
Core. In addition to the microprocessor and control logic, the CPU Board includes two com­munication ports that can be individually configured for RS-232 or RS-485 operation, 1MB
of battery backed Static RAM (SRAM), 4MB of Synchronous Dynamic RAM (SDRAM),
512kB Boot/Downloader FLASH, 16MB simultaneous read/write FLASH, an I/O Bus
Connector, up to two optional Ethernet ports.

In addition to Idle and Watchdog LEDs, there are six status LEDs located on the CPU
Board that will display run time status information. Two LEDs are also provided for each
Comm. Port.

CW_30 Distributed Process Controllers provide the following key features:

• ARM processor provides exceptional performance and low power consumption

• Ten independently configurable asynchronous serial communication ports (RS-

232/RS-485) and one 3-wire serial RS-232 Utility Port

• Up to two optional Ethernet ports (10/100Base-T)

• Optional Expansion Comm. Modules with/without built-in modem

• Wide temperature range: (-40 to +70°C) (-40 to 158°F)

• Utilizes existing DPC 3330 Chassis, Power Supply and I/O Boards

• RS-232/RS-485 Comm. Ports provided with LED status Indicators

• Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,

300mA-hr lithium coin cell battery located on the CPU Board Ass’y.

• Class I, Div. 2 Hazardous Location approval

SECTION 2 - ControlWave PROGRAMMING ENVIRONMENT

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

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 1

The ControlWave programming environment consists of a set of integrated software tools
which allow a user to create, test, implement, and download complex control strategies for
use with Bristol’s CW_30 Distributed Process Controller.

The tools that make up the programming environment are:

• ControlWave Designer load building package offers several different methods for
generating and debugging control strategy programs including function blocks, ladder
logic, structured languages, etc. The resulting process control load programs are fully
compatible with IEC 61131-3 standards. Various communication methods are offered,
including TCP/IP, serial links, as well as communication to Bristol’s Open BSI soft­ware and networks.

• The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,

allows you to define process I/O modules in the CW_30 and configure the individual
mapping of I/O points for digital and analog inputs and outputs.

• The ACCOL3 Firmware Library, which is imported into ControlWave Designer, in-

cludes a series of Bristol specific function blocks. These pre-programmed function blocks
accomplish various tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as PID control.

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

real-time data access to any OPC [Object Linking and Embedding (OLE) for Process
Control] compliant third-party software packages.

• A series of Configuration Controls are available for setting up various aspects of the
system such as historical data storage, system security, and soft switches. Additional
Data Access Controls are also available for retrieval of real-time data values and
communication statistics. The configuration controls and the data access controls utilize
ActiveX technology and are called through a set of fixed Web pages, compatible with
Microsoft® Internet Explorer. Alternatively, developers can place the controls in third­party ActiveX compatible containers such as Visual BASIC or Microsoft® Excel.

• User-defined Web Pages - If desired, user-defined web pages can be stored within a
PC to provide a customized human-machine interface (HMI).

• Flash Configuration Utility – Parameters such as the BSAP local address, IP ad­dress, etc. are set using the Flash Configuration Utility, accessible via Open BSI
LocalView or NetView.

Note: DPC 3330s that are upgraded with “CW_30 Hardware,” must have their
ACCOL application load converted to an IEC 61131 ControlWave Program Load.
This is accomplished via the ACCOL Translator (see User Guide D5086).

Pg. 2 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Figure 1 - ControlWave - Control Strategy Software Diagram

SECTION 3 - PHYSICAL DESCRIPTION

CW-30 Upgrade kits are comprised of the following major components:

• CW_30 CPU Board (CPU) Overview (Section 3.1)

• CW_30 Communication Board (CB) Overview (Section 3.2)

3.1 CW_30 CPU Board Overview

The multilayer CPU Board provides CW_30 CPU, I/O monitor/control, memory and
communication functions. CW_30 CPU Boards operate over an extended temperature range
with long-term product reliability.

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 3

CW_30 CPU Boards are based on a 32-bit ARM9TDMI RISC Core Processor. The CPU
Board is specified to operate on CW_30 (+12Vdc or +24Vdc systems) and with a system
clock speed of 150 MHz. In addition to the microprocessor and control logic, the CPU Board
includes two independently (DIP-Switch) configurable communication ports (RS-232/RS-

485) (COM5 & COM6), up to two optional Ethernet ports (10/100Base-T), CPU Memory

consists of 1MB of battery backed Static RAM (SRAM), 512kB Boot/Downloader FLASH
and 16MB simultaneous read/write FLASH.

CPU Boards are provided backup power via a coin cell socket that accepts a 3.0V, 300mA-hr
lithium battery. This 3.0V battery provides backup power for the real-time clock and the
system’s Static RAM (SRAM). Backup power is enabled when Configuration Jumper W3
(just below the battery) is installed in position 1 to 2.

If the 3.3Vdc that powers the unit goes out of specification, a supervisory circuit on the CPU
Board switches the battery voltage to the CPU’s SRAM and RTC.

The system SRAM is specified to have a standby current of 20:A for each part (1MB),
(40:A maximum) (plus 2uA for the RTC). For a system containing 2MB of system SRAM, a
worst-case current draw of 42:A allows a battery life of approximately 7142 hours.

A supervisory circuit is used to switch to battery power when VCC falls out of specification.
For maximum shelf life, the battery may be isolated from the circuit by removing the
Backup Enable Jumper W3 from position 1 to 2 and then installing it in position 2 to 3. If
the Real-time clock looses its battery backup a ControlWave Designer system variable bit
(_QUEST_DATE) is set. This bit can be used to post a message or alarm to the PC (see the
ControlWave Designer Programmer’s Handbook - D5125, System Variables

Section).

Basic CPU Board components and features are summarized as follows:

• LH7A400 System-on-Chip 32-bit ARM9TDMI RISC Core microprocessor

• Supports process control loads that are fully compatible with IEC 61131-3 standards

• 512KB FLASH Boot/Downloader, 29LV040B, 90 nS, 8-bit access

• 1MB SRAM, 3.3V, 256 x 16, 70 nsec., with Battery Back-up

• 4 MB SDRAM via two 1M x 16, 100MHz SDRAMs configured as a 1M x 32-bit array.

• 16MB simultaneous read/write FLASH, 90 nsec.

• 2 user configurable serial Comm. ports (RS-232/RS-485) (COM5 & COM6) (compatible

with existing 3330 communication cables)

• 2 optional Ethernet ports (10/100Base-T)

• I/O Bus Interface, control for up to 12 I/O Boards

• MAC address in serial EEPROM

• Spread Spectrum clock for lower EMI

• Serial Real Time Clock with battery backup

• 8-Position general-purpose switch bank plus a 4-Position recovery switch bank

• Coin cell socket accepts a 3.0V, 300mA-hr lithium battery

• Six Status LEDs, 6 Comm. Port LEDs plus Watchdog, Idle and Comm. Port LEDs

• 3-wire (RS-232) Utility Port: Provides compatibility with existing FLASH load cable

used with the 3330 CPU.

Pg. 4 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Figure 2 – CW_30 CPU Board Component Identification Diagram

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 5

3.1.1 CW_30 CPU Board Serial Comm. Port Connectors

The CPU Board supports up to two serial communication ports (COM5 and COM6). COM5
and COM6 are interconnected to a Comm. Interface Board Assembly that contains two
Female D-Type connectors (see Table 10 for Comm. Port D-type connector pin
assignments). The interface cable is connected to J5 on the CW_30 CCPU Board and P2 on
the Comm. Interface Board Assembly (Bristol Part No. 392574-01-2). Comm. Interface
Board Assembly Connector BIP1 supports Comm. Port 5 while connector BIP2 supports
Comm. Port 6. When configured for RS-485 operation Comm. Port 5 and Comm. Port 6
receivers are enabled by DTR the RS-485 driver is enabled by RTS. An eight position DIP­Switch (SW3) is assigned to Comm. Port 5 and another (SW4) is assigned to Comm. Port 6.
These switches provide user configuration of RS-485 port receiver biasing and termination
as well as 2-wire or 4-wire operation.

3.1.2 CW_30 CPU Board Ethernet Ports

Connection to the Ethernet can be established via one or two Ethernet Ports situated on the
CPU Board. Ethernet Ports utilize 10/100Base-T RJ45 modular connectors (J1 & J2) that
typically provide a twisted pair interface to an Ethernet Hub. Ethernet Port Jacks are
equipped with two LEDs that function as follows: yellow = TX, green = RX activity.

3.1.2.1 Ethernet CPU Engine 10/100Base-T Connectors J2 & J3

8-pin 10/100Base-T Connectors J2 and J3 typically provide connection to a twisted pair
Ethernet via an Ethernet Hub. Both ends of the Ethernet cable are equipped with modular
RJ45 connectors. A typical hub provides eight (8) 10/100Base-T RJ45 ports (with port 8
having the capability to link to another hub or to an Ethernet communication port. The
cable used between a CPU Module Expansion Board’s Ethernet 10/100Base-T connector
and an Ethernet Hub has a one-to-one wiring configuration as shown in Figure 4. Table 1
provides the assignment and definitions of 8-pin 10/100Base-T Connectors J2 & J3.

It is possible to connect two nodes in a point-to-point configuration without the use of a
Hub. However; the cable used must be configured such that the TX± Data pins are
connected to the RX± Data pins (swapped) at the opposite ends of the cable (see Figure 3).

The maximum length of one segment (CPU to Hub) is 100 meters (328 feet). The use of
Category 5 shielded cable is recommended.

Table 1 - Ethernet 10/100Base-T Connectors J2 & J3 Pin Assignments

Pin # Description Pin # Description

1TX+ Transmit Data+ 5 Not Connected
2TX- Transmit Data- 6RX- Receive Data­3RX+ Receive Data+ 7 Not Connected
4 Not Connected 8 Not Connected

Note: TX & RX are swapped at Hub’s.

Pg. 6 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Figure 3 - Point-to-Point 10/100Base-T Ethernet Cable

Figure 4 - Standard 10/100Base-T Ethernet Cable (CPU Board to Hub)

Figure 5 - 10/100Base-T Connector (P2) with Cable Configured for Loopback

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 7

3.1.3 CW_30 CPU Board Memory

Boot/downloader FLASH

Boot/download code is contained in a single 512Kbytes FLASH IC. 4-Position DIP-Switch
SW1’s position 3 allows start-up menu options to be displayed or boot-up from system
FLASH. If SW1-3 is closed (ON) when a reset occurs, the boot-up code will cause a recovery
menu to be sent out the Utility Port (on the CPU Board) to a terminal program running on
an external host computer. Note: Recovery Mode will also be initiated if CPU Board Switch

SW1 positions 1 and 2 are both set ON or OFF when a reset occurs.

FLASH Memory

The base version of the CPU Board has 16Mbytes of 3.3V, simultaneous read/write (DL)
FLASH memory. System Firmware and the Boot Project are stored here.

System Memory (SRAM)

The CPU Board has 1Mbyte of static RAM, implemented with two 256K x 16, 70
nanosecond asynchronous SRAMs. All random access memory retained data is stored in
SRAM. During power loss periods, SRAM is placed into data retention mode (powered by a
backup 3.0V lithium battery). SRAM’s operates at 3.3V and are packaged in a 44-pin
uTSOP. Critical system information that must be retained during power outages or when
the system has been disabled for maintenance is stored here. Data includes: Last states of
all I/O, historical data, retain variables and pending alarm messages not yet reported.

Synchronous Dynamic RAM (SDRAM)

The CW_30 CPU Board contains 4 Mbytes of Synchronous Dynamic RAM (SDRAM)
implemented with two 1M x 16, 100MHz Synchronous DRAMs. The running application is
stored here. This allows the system to run faster than it will from the FLASH memory.
SDRAM is not battery-backed.

3.1.4 CW_30 CPU Board Configuration Jumpers

CW_30 CPU Boards provide 18 User Configuration Jumpers that function as follows:

• W3 - Enable/Disable Battery Back-up Selection

1 to 2 = Enable Battery Back-up

2 to 3 = Disable Battery Back-up

• W5 - Status LED Enable/Disable Selection

1 to 2 = Enable Status LEDs
2 to 3 = Disable Status LEDs

• W8 - Serial Comm. Port Status LED Enable/Disable Selection

1 to 2 = Enable Serial Comm. Port Status LEDs
2 to 3 = Disable Serial Comm. Port Status LEDs

• W9 - BIP1 (Comm. Port 5) Configuration Selection Note: W10 through W13 ditto

1 to 2 = Set for RS-232 Operation
2 to 3 = Set for RS-485 Operation

• W14 - BIP1 (Comm. Port 5) DSR/DTR Control

1 to 2 = DSR on Pin-8 of D-type Connector
2 to 3 = DTR on Pin-8 of D-type Connector

Pg. 8 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

• W15 - BIP1 (Comm. Port 5) Control

1 to 2 = CTS Source is from Port
2 to 3 = RTS to CTS Loopback

• W16 - BIP2 (Comm. Port 6) Configuration Selection Note: W17 through W20 ditto

1 to 2 = Set for RS-232 Operation
2 to 3 = Set for RS-485 Operation

• W21 - BIP2 (Comm. Port 6) DSR/DTR Control

1 to 2 = DSR on Pin-8 of D-type Connector

2 to 3 = DTR on Pin-8 of D-type Connector

• W22 - BIP2 (Comm. Port 6) Control

1 to 2 = CTS Source is from Port
2 to 3 = RTS to CTS Loopback

• W23 - Power Good LED Control

1 to 2 = Enable Power Good LED
2 to 3 = Disable Power Good LED

3.1.5 CW_30 CPU Board Configuration Switches

Four user-configurable DIP Switches are provided on the CW_30 CPU Board. Eight-bit
DIP-Switch SW2 is provided for user configuration settings while four-bit DIP-Switch SW1
provides forced recovery functions. Eight-bit DIP-Switch SW3 provides loopback,
termination control, and receiver bias settings for the Comm. Port 5 when it has been
configured for RS-485 operation (via jumpers W9 through W13). Eight-bit DIP-Switch SW4
provides loopback, termination control, and receiver bias settings for Comm. Port 6 when it
has been configured for RS-485 operation (via jumpers W16 through W20).

Table 2 – CW_30 CPU Board (General Purpose Switch SW2) Assignments

Note: Except for SW2-4, ON = Factory Default

SW# Function Setting - (ON = Factory Default)

SW2-1 Watchdog Enable

SW2-2

SW2-3

SW2-4

SW2-5 SRAM Control

SW2-6

SW2-7 N/A

SW2-8 Enable WINDIAG

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

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

System Firmware
Load Control

ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Recovery Switch (SW1)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote downloading of System Firmware *
OFF = Disable remote downloading of System Firmware

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

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 9

Table 3 – CW_30 CPU Board (Switch SW1) Assignments CPU/System

Recovery Mode/Local Mode Control (Note: SW1-4 not used)

Switch Function Setting

SW1-1/2

SW1-3

* = Note: Only the CPU Board Switch SW1 settings listed in this table have been tested.

Recovery/Local Mode *

Force Recovery Mode *

Both ON or OFF = Recovery Mode
SW1 OFF & SW2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
OFF = Recovery Mode disabled

Table 4 – CW_30 CPU Board Switch SW3/SW4 Assignments

RS-485 Loopback & Termination Control (COM5 = SW3 & COM6 = SW4)

Switch

SW3/4-1 TX+ to RX+ Loopback/2-Wire ON - Only for Diagnostics
SW3/4-2
SW3/4-3 100 Ohm RX+ Termination ON - End Nodes Only
SW3/4-4

SW3/4-7 RX+ Bias (End Nodes/Node)

SW3/4-8

RS-485 Function

Switch ON

TX− to RX− Loopback/2-Wire

100 Ohm RX− Termination

RX− Bias (End Nodes/Node)

Setting

ON - Only for Diagnostics

ON - End Nodes Only
ON - 4-Wire = Both End Nodes

ON - 2-Wire = One End Node Only
ON - 4-Wire = Both End Nodes
ON - 2-Wire = One End Node Only

3.1.6 CW_30 CPU Board LEDs

CW_30 CPU Boards are equipped with 15 LEDs. Table 5 provides CPU Board LED

assignments. Table 6 provides definitions for the six Status LEDS.

Table 5 – Assignment of CW_30 CPU Board LEDs

LED Ref. Function Color LED Ref. Function Color

CR2 Utility Port TX Red CR8 Status 2 Red
CR3 Utility Port RX Red CR9 Status 3 Red
CR4 - Top COM5 (BIP1) TX Red CR10 Status 4 Red
CR4 ­Bottom
CR5 - Top COM6 (BIP2)TX Red CR12 Status 6 Red
CR5 ­Bottom
CR6 Power Good Green CR14 Idle Red
CR7 Status 1 Red

Note: Optional Ethernet Port Jacks are equipped with two LEDs that function as

follows: Yellow = TX, Green = RX activit

COM5 (BIP1) RX Red CR11 Status 5 Red

COM6 (BIP2) RX Red CR13 Watchdog Red

y.

Two red LEDs provide for the following status conditions when lit: WD (CR13 - Indicates a
Watchdog condition has been detected) & IDLE (CR14 - Indicates that the CPU has free
time at the end of its execution cycle. Normally, it should be ON most of the time. When the
Idle LED is OFF, it indicates that the CPU has no free time, and may be overloaded). The
green Power Good LED (CR6) is on when power is within specification. Six status LEDs
provide run time status codes.

Pg. 10 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit

Table 6

System Status Codes for Status LCDs CW_30 CPU Board (see Figure 6)

LED

6

CR12

0 0 0 0 0 0 00 Application Running
0 0 0 0 0 1 01 Unit in Diagnostic Mode
0 0 0 0 1 1 03 Unit Running Diagnostics
0 0 0 1 0 0 04 Flash XSUM Error
0 0 0 1 0 1 05 Error Initializing Application Device
0 0 0 1 1 1 07 Flash Programming Error
0 0 1 0 0 0 08 Using Factory Defaults *
0 0 1 0 0 1 09 Battery Failure Detected *
0 1 0 0 0 0 10 Waiting in Recovery Mode
0 0 1 0 1 0 0A Currently Loading the Boot Project
0 0 1 0 1 1 0B System Initialization in Progress
0 1 0 0 1 0 12 Error Testing SRAM
1 0 0 0 0 0 20 Application Loaded
1 0 1 0 0 0 28 Stopped at a Break Point
1 1 0 0 0 0 30 No Application Loaded
1 1 1 0 0 0 38 Running with Break Points
1 1 1 0 1 1 3B Waiting for Power-down (after NMI)
1 1 1 1 1 0 3E Waiting for Updump to be Performed
1 1 1 1 1 1 3F Unit Crashed (Watchdog Disabled)

* = Flashed at startup

LED

5

CR11

LED

4

CR10

LED

3

CR9

LED

2

CR8

LED

1

CR7

Status

In

Hex

Indication

Definition

Figure 6 – CW_30 CPU Status LED Hexi-decimal Codes

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 11

3.2 CW_30 Communication Board (CB) Overview

CW_30 Communication Boards provide either four or two (depopulated version of Four Port

CB) communication ports which utilize 9-pin, D-Type, female connectors. Up to 2 CBs can
be installed in a CW_30. CB Board communication ports are labeled as follows:

First 4-Port CB contains Ports 1, 2, 7, & 8 (resides in Communication Socket #1).
Second 4-Port CB contains Ports 3, 4, 9 & 10 (resides in Communication Socket #2).

First 2-Port CB Contains Ports 1 & 2 (resides in Communication Socket #1).
Second 2-Port CB Contains Ports 3 & 4 (resides in Communication Socket #2).

Standard 9-Pin D-Type Connectors are used in the two port version of the CB and dual
stacked D-Type Connectors are used on four port versions. When the DPC contains two 4­Port CBs, a maximum of ten ports are available (four on each CB and two on the CW_30
CPU Board). When two 2-Port CBs are installed in a CW_30 DPC, a maximum of six ports
are available (two on each CB assembly and two on the CW_30 CPU Board).

The communication ports can be configured for an RS-485 or RS-232 interface. The former
is required for BSAP network communications, while the latter is required for devices such
as a PC or printer. However; these ports can also be configured for other applications. For
example, port 1 can be configured to interface with a PC while ports 2, 3, 4, etc. can be
configured for use with options such as modems and printers. It should be noted that only 2-

Port CBs (Port 2) will support piggyback modems, and that RASCL "redundancy," and use
of a Hand Held Terminal aren’t supported.

3.2.1 Setting CB Board DIP Switches

The procedure for setting DIP switches is identical for the two different board versions
except that the 4-Port Communication Board contains four DIP switches while the 2-Port
CB contains two DIP switches. When an individual switch (toggle) is pressed to the right it
is set to its ON position (see Figure 7). Switches SW1 through SW4 control port
configuration and are assigned as follows:

SW1 - Controls Port 1/3
SW2 - Controls Port 7/9
SW3 - Controls Port 2/4
SW4 - Controls Port 8/10

Figure 7 - Enlarged View of SW1-SW4

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Figure 8 - CW_30 - 2-Port CB Board Component Identification Diagram

PIP-CW_30 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 13

Figure 9 - CW_30 - 4-Port CB Board Component Identification Diagram

Pg. 14 / Hardware Upgrade Installation Guide PIP-CW_30 Upgrade Kit