Fisher CW 35 Hardware Installation Guide

Product Information Package

GU

PIP-CW_35 Upgrade Kit

Mar., 2007

CW_35 & CW-31 Hardware

ControlWave_35 & ControlWave _31

HARDWARE INSTALLATION

For upgrade of the following 33XX Series Products:
3335 DPC & 3331 RIO

IDE

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 Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol to effectively and efficiently process your retu rn. 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. C 04/27/06

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_35 Upgrade Kit

ControlWave_35 & ControlWave_31

Hardware Installation Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

SECTION 1 – ControlWave_35/31 INTRODUCTION ................................... 1

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

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

3.1 CW_35/31 CPU Module Overview .................................................................................... 6

3.1.1 CW_35/31 CPU Board Serial Comm. Port Connectors.................................................... 8

3.1.2 CW_35/31 CPU Board Memory......................................................................................... 8

3.1.3 CW_35/31 CPU Board Configuration Jumpers................................................................ 9

3.1.4 CW_35/31 CPU Board Configuration Switches ............................................................. 10

3.1.5 CW_35/31 CPU Module LEDs......................................................................................... 11

3.1.6 CW_35/31 Expansion Board Ethernet Ports.................................................................. 13

3.1.6.1 Ethernet CPU Engine 10Base-T Connectors J1 & J2 ................................................... 13

3.2 CW_35 Communication Board (CB) Overview .............................................................. 15

3.2.1 Setting CB Board DIP Switches ..................................................................................... 18

3.2.2 Setting CB Board Configuration Jumpers ..................................................................... 18

3.2.3 CB Board LED Indicators ............................................................................................... 20

3.2.4 CB Board Communication Port Information ................................................................. 20

SECTION 4 – ControlWave_35/31 CONFIGURATION ............................... 21

4.1 Step 1 - Hardware Configuration ................................................................................... 21

4.2 Step 2 - Software Installation on the PC Workstation .................................................. 25

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

and Run the Flash Configuration Utility ....................................................................... 25

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

ControlWave Designer..................................................................................................... 26

4.5 Step 5 - Create Application Specific Web Pages OPTIONAL) ...................................... 27

4.6 Step 6 - Create an Open BSI Network Containing the CW_35/31,

or add the CW_35/31 to an Existing Open BSI Network .............................................. 27

4.7 Step 7 - Download the Application-specific Control Strategy

into the CW_35/31 DPC/RIO........................................................................................... 27

SECTION 5 – OPERATIONAL DETAILS........................................... 28

5.1 Downloading the Application Load................................................................................. 28

5.2 Upgrading CW_35/31 Firmware..................................................................................... 29

5.2.1 Using LocalView to Upgrade CW_35/31 Firmware ....................................................... 29

5.2.2 Using HyperTerminal to Upgrade CW_35/31 Firmware .............................................. 32

5.2.3 Remote Upgrade of CW_35/31 Firmware....................................................................... 34

5.3 Core Updump ................................................................................................................... 35

SECTION 6 – GENERAL SERVICE NOTES ........................................ 35

6.1 Extent of Field Repairs.................................................................................................... 35

6.2 Disconnecting RAM Battery ........................................................................................... 36

6.3 Maintaining Backup Files............................................................................................... 36

PIP-CW_35 Upgrade Kit Contents / 0 - 1

PIP-CW_35 Upgrade Kit

ControlWave_35 & ControlWave_31

Hardware Installation Guide

TABLE OF CONTENTS

SECTION TITLE PAGE #

SECTION 7 – WINDIAG DIAGNOSTICS ........................................... 36

7.1 Diagnostics Using WINDIAG ......................................................................................... 38

7.1.1 Communication Diagnostic Port Loop-back Tests......................................................... 38

7.1.2 Serial Comm. Port External Loop-back Test Procedure ............................................... 38

7.1.3 Ethernet Port Diagnostics............................................................................................... 40

7.1.3.1 10Base-T (RJ-45 – Twisted Pair) Port Hardware Setup ............................................... 41

7.1.3.2 Ethernet Port Diagnostic Test Execution ...................................................................... 41

7.1.3.3 Loop-back Out Twisted Pair Test RUN Button ............................................................. 42

7.1.3.4 Return Hardware Address Test RUN Button................................................................ 42

7.1.3.5 Ethernet Port Diagnostic Error/Failure Messages........................................................ 42

SECTION 8 – DISPLAY/KEYPAD ASSEMBLY OPERATION ......................... 42

8.1 Operation of the Dual-button Display/Keypad Assembly ............................................. 43

SECTION 9 – CW_35/31 SPECIFICATIONS ........................................ 46

9.1 CW_35/31 CPU Module Specifications ........................................................................... 46

9.1.1 CPU Module Communication Port Specifications .........................................................46

9.1.2 CPU Module 3.3V Power Supply Specifications ............................................................ 47

9.1.3 CPU Module Environmental Specifications................................................................... 47

9.2 CW_35 Comm. Board (CB) Specifications...................................................................... 47

9.2.1 CB Board Connectors ...................................................................................................... 47

9.2.2 CB Board Communication Port Specifications .............................................................. 47

9.2.3 CB Board 3.3V Power Supply Specifications ................................................................. 47

9.2.4 CB Board Environmental Specifications........................................................................ 48

APPENDICES

ControlWave_35 DISPLAY/KEYPAD (with 25 Keys) ASSEMBLY GUIDE......... 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_35 Upgrade Kit

ControlWave_35 & ControlWave_31

HARDWARE INSTALLATION GUIDE

SECTION 1 - ControlWave_35/31 INTRODUCTION

3335 DPC and 3331 RIOs can be field upgraded to become a ControlWave_35 DPC or
ControlWave_31 RIO (herein referred to as CW_35/31) by utilizing the hardware provided
in an installation kit. Upgrade will require removal of the standard DPC 3335/RIO 3331
CPU Module and Comm./ECOM Boards and then adding the CW_35/31 CPU Module
(CPUM) and CW_35 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 Module 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, and up to two optional Ethernet ports.

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

CW_35/31 DPC/RIOs provide the following key features:

• ARM processor provides exceptional performance and low power consumption

• Up to six 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) (one on CW_31)

• Optional Expansion Comm. Modules (2 Port or 4 Port)

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

• Utilizes existing DPC 3330/ RIO 3331 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_35 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_351 Distributed Process Controller or CW_31 Remote I/O Unit.

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_35 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,

includes 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 3335s or RIO 3331s that are upgraded with “CW_35/31 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_35 Upgrade Kit

Figure 1 - ControlWave - Control Strategy Software Diagram

SECTION 3 - PHYSICAL DESCRIPTION

CW_35 Upgrade kits are comprised of the following major components:

• CW_35 CPU Module (CPUM) Overview (Section 3.1)
CW_35 CPU Board

CW_35 LED Board
CW_35 Expansion Board (with 2 Ethernet Ports and a Display/Keypad Jack)

• CW_35 Communication Board (CB) Overview (Section 3.2)
2-Port CB or 4-Port CB

CW_31 Upgrade kits are comprised of the following major components:

• CW_35/31 CPU Module (CPUM) Overview (Section 3.1)
CW_35/31 CPU Board

CW_35/31 LED Board
CW_35/31 Expansion Board (with 1 Ethernet Port)

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 3

Figure 2A – CW_35 Front View

Showing PC Boards, Module Layout & LED Assignments

Pg. 4 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit

Figure 2B – CW_31 Front View

Showing PC Boards, Module Layout & LED Assignments

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 5

3.1 CW_35/31 CPU Module Overview

CW_35/31 CPU Modules (CPUM) provide CW_35/31 CPU, I/O monitor/control, memory

and communication functions. CW_35/31 CPU Modules operate over an extended
temperature range with long-term product reliability. Each CPUM consists of a CPU Board
(CPUB), a CPU LED Board and an Expansion Board (EB).

CW_35/31 CPUMs are based on a 32-bit ARM9TDMI RISC Core Processor. The CPU Board
is specified to operate on CW_35/31 (+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 Jumper configurable communication ports (RS-232/RS-485)
(COM5 & COM6), up to two optional 10/100Base-T Ethernet ports (two for CW_35 & one
for CW_31), 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. 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

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). A worst-case current draw of 42:A allows a
battery life of approximately 7142 hours.

Basic CPU Module 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 3335/3331 communication cables)

• 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

Section).

Pg. 6 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit

Note: Expansion Bd. Connectors J2 & J3 aren’t available on CW_31s

Figure 3 – CW_35/31 CPU Module Component Identification Diagram

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 7

• LEDs: CPUB has 4 Serial Comm. Port LEDs (two for each port) plus Power Good,

Utility Port TX and Utility Port RX LEDs; CPU LED Board has Six Status LEDs plus
Watchdog and Idle LEDs and the EB has TX and RX LEDs built into the Ethernet
Ports

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

used with the 3335 CPU.

3.1.1 CW_35/31 CPU Board Serial Comm. Port Connectors

The CPU Board supports up to two serial communication ports (COM5 and COM6). These
ports are supported by Female D-Type connectors (see Table 10 for Comm. Port D-type
connector pin assignments). Connector J1 (BIP1) supports Comm. Port 5 while connector J2
(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 DIP-Switch (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 (see Section 1.3.5). Configuration
Jumpers on the CPU Board RS-232/485 configuration and control of BIP1/BIP2
communication ports (see Section 3.1.4).

The following information is provided to support use of CPU Board Serial Comm. Ports:

• When configured for RS-232 operation, CPU Board Comm. Ports support RTS, DTR,
CTS, DCD and DSR modem control signals.

• RS-232 transceivers are enabled by the port’s DTR signal, i.e., when DTR goes high the
port becomes active.

• Each RS-232 transceiver has one active receiver while in the power-down mode
(disabled). DCD is connected to the active receiver.

• When configured for RS-485 operation, the CB Comm. Port receiver is enabled by DTR
while the driver is enabled by RTS.

• For RS-485 operation, an eight-position DIP switch (one per port) enables receiver
biasing and termination as well as two-wire and 4-wire selection.

3.1.2 CW_35/31 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 ON when a reset occurs, the boot-up code will cause a recovery menu to
be sent out the Utility Port 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

Pg. 8 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit

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_35/31 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.

3.1.3 CW_35/31 CPU Board Configuration Jumpers

CW_35/31 CPU Boards are provided with 18 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 - Power Good LED (CR1 on CPU Bd.) Enable/Disable Selection

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

• W6 - Status LEDs (on LED Bd.) Enable/Disable Selection

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

• W9 - Serial Comm. Port Status LEDs (on CPU Bd.) Enable/Disable Selection

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

• W10 -- BIP1 (Comm. Port 5) Configuration Selection Note: W11, W12, W13 & W16 ditto

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

• W14 - BIP1 (Comm. Port 5) Control

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

• W15 - 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

• W18 -- BIP2 (Comm. Port 6) Configuration Selection Note: W19, W20, W21 & W24 ditto

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

• W22 BIP2 (Comm. Port 6) Control

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

• W23 - 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

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 9

3.1.4 CW_35/31 CPU Board Configuration Switches

Four configuration DIP-Switches are provided on the 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 RS­485 operation (via jumpers W10 through W13 and W16). 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 W18 through W21 and W24).

Table 1 – CW_35/31 CPU Board (General Purpose Switch SW2) Assignments

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

Switch 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)

Table 2 – CW_35/31 CPU Board (Switch SW1) Assignments

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

Switch Function Setting

SW1-1/2

SW1-3 Force Recovery Mode

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

Recovery/Local 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 3 – CW_35/31 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

Pg. 10 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit

3.1.5 CW_35/31 CPU Module LEDs

CW_35/31 CPU Modules are equipped with up to 15 LEDs (plus 2 LEDs in each Ethernet

Jack). Table 4 provides CPU Module LED assignments. Table 5 provides definitions for the
six Status LEDS.

Table 4 – Assignment of CW_35/31 CPU Module LEDs

LED Ref. Function Color

CR1 Power Good Green CPU Bd. - Next to SW3 (Not User Viewable)
CR3 (1) - Right COM5 (BIP1) TX Red CPU Bd. - Card Edge (Top - Next to J1)
CR3 (2) - Left COM5 (BIP1) RX Red CPU Bd. - Card Edge (Top - Next to J1)
CR4 (3) - Right COM6 (BIP2)TX Red CPU Bd. - Card Edge (Bottom - Next to J2)
CR4 (4) - Left COM6 (BIP2) RX Red CPU Bd. - Card Edge (Bottom - Next to J2)
CR5 Utility Port TX Red CPU Bd. - Behind CR3/4 (Not User Viewable)
CR6 Utility Port RX Red CPU Bd. - Behind CR3/4 (Not User Viewable)
CR1 Status 1 Red LED Bd. - Bottom
CR2 Status 2 Red LED Bd.
CR3 Status 3 Red LED Bd.
CR4 Status 4 Red LED Bd.
CR5 Status 5 Red LED Bd.
CR6 Status 6 Red LED Bd.
CR7 Idle Red LED Bd.
CR8 Watchdog Red LED Bd. - Top

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

follows: yellow = TX, Green = RX activit

y.

Location

Two red LEDs provide for the following status conditions when lit: WD (CR18 on the LED
Board - Indicates a Watchdog condition has been detected) & IDLE (CR7 on the LED Board

- Indicates that the CPU has free time at the end of its execution cycle). Normally, the Idle

LED 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 (CR1 on the CPU
Board) is on when power is within specification. Six status LEDs provide run time status
codes.

Table 5 - System Status Codes for Status LCDs

CW_35/31 CPU Module LED Board (see Figures 4 & 5)

LED

LED

6

CR6

5

CR5

LED

4

CR4

LED

3

CR3

LED

2

CR2

LED

1

CR1

Status

In Hex

Indication
Definition

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 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 0 0 10 Waiting in Recovery Mode
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

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 11

Table 5 - System Status Codes for Status LCDs

CW_35/31 CPU Module LED Board (see Figures 4 & 5) (Continued)

LED

* = Flashed at startup

LED

6

CR6

5

CR5

LED

4

CR4

LED

CR3

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)

3

LED

2

CR2

LED

1

CR1

Status

In Hex

Indication
Definition

Figure 4 – CW_35/31 CPU Module LED Identification

(Note: EB Connectors J2 & J3 not available for CW_31s)

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Figure 5 – CW_35/31 CPU Status LED Hexi-decimal Codes

3.1.6 CW_35/31 Expansion Board Ethernet Ports

Connection to the Ethernet can be established via one or two Ethernet Ports situated on the
CPU Module’s Expansion Board (EB). 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. Note: Ethernet Port 2 isn’t available on CW_31 EBs.

3.1.6.1 Ethernet CPU Engine 10/100Base-T Connectors J1 & J2

8-pin 10/100Base-T Connectors J1 and J2 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 Convergence Expansion Board’s Ethernet 10/100Base-T
connector and an Ethernet Hub has a one-to-one wiring configuration as shown in Figure 7.
Table 6 provides the assignment and definitions of the 8-pin 10/100Base-T Connector P2.

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 13

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 6).

Table 6 - Ethernet 10/100Base-T Connector P2 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.

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

Figure 6 - Point-to-Point 10/100Base-T Ethernet Cable

Figure 7 - Standard 10/100Base-T Ethernet Cable (CPU Board to Hub)

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Figure 8 – 10/100Base-T Connector (P2) with Cable Configured for Loopback

3.2 CW_35 Communication Board (CB) Overview

Communication Boards (CB) provide either four or two communication ports that utilize 9­pin, D-Type, female connectors. These communication ports are compatible with existing
3335 Comm. Port cables. One CB can be installed in a CW_35. It should be noted that a CB
won’t fit into the first Comm. Slot, i.e., Chassis Slot 13 (see Figure 2). CB Board com­munication ports are labeled as follows:

4-Port CB contains Ports 3, 4, 9, & 10 (resides in Communication Socket #2).
2-Port CB Contains Ports 3 & 4 (resides in Communication Socket #2).

Note: The communication port numbering scheme is compatible with your

existing ACCOL application program.

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 a 4-Port
CB, a maximum of six serial Comm. ports are available (four on the CB and two on the
CW_35 CPU Board). When a 2-Port CBs is installed in a CW_35 DPC, a maximum of four
serial Comm. ports are available (two on the CB assembly and two on the CW_35 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 other RS-232 device. However; these ports can also be configured for other
applications. For example, port 3 can be configured to interface with a PC while ports 4, 5,
6, etc. can be configured for use with options such as modems. It should be noted that

internal chassis mounted modems, RASCL "redundancy," and use of a Hand Held Terminal
aren’t supported.

PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 15