Quick Setup Guide
D5121
December, 2006
ControlWave LP Quick Setup Guide
ControlWave LP
www.EmersonProcess.com/Bristol
THIS PAGE INTENTIONALLY LEFT BLANK
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, Inc. 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, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional information is required, the purchaser is advised to contact Bristol, Inc..
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol, Inc. for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure
that the materials returned to Bristol, Inc. 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, Inc. and save
Bristol, Inc. harmless from any liability or damage which Bristol, Inc. 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.
Thank you for choosing ControlWave LP!
We hope you will find ControlWave LP to be the best solution for your process automation
needs.
From the start, Bristol designed this unit to merge the simplicity and modularity of a
programmable logic controller, with the full communication and programming capabilities of a
remote process controller. The result - the ControlWave Low Powered (LP) Controller, is a
true PLC/RTU hybrid, incorporating the best features of both types of devices.
ControlWave LP features a low-power, modular design, which supports all five IEC 61131-3
programming languages: ladder logic (LD), sequential flow chart (SFC), function block diagram
(FBD), structured text (ST), and instruction list (IL). A full suite of PC-based configuration
wizards and programming tools is provided.
Before You Begin
This guide is intended to help you get ‘up-and-running’ with a minimal amount of effort. It does
NOT, however, tell you everything you need to know about setting up and configuring a
ControlWave LP. We have included references throughout this book to other places in the
documentation set, where you can get more details on a particular subject.
Throughout your configuration activities, please be aware of the following items:
Shock Hazard! Always follow accepted safety guidelines. As with all electronic devices,
improper installation, grounding, or usage can cause an electrical shock. If you have any doubts
about how to install, ground, and use this product safely, please consult a qualified electrician.
Electrostatic Discharge (ESD) - Sensitive electronic devices such as this can be damaged by
electrostatic discharge. Please follow accepted ESD guidelines.
If You Need Help…
If you're having problems setting up and configuring your ControlWave LP, please call our
ControlWave Application Support team at (860) 945-2394 or (860) 945-2286 for assistance.
Help is available Monday through Friday 8:00 AM to 4:30 PM Eastern Time, excluding
holidays, and scheduled factory shutdowns.
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Table of Contents
Part 1
Setting Up the Hardware................................................................................................................. 8
Installing ControlWave Designer Software on the PC................................................................. 12
Creating a Simple Project in Ladder Language (LD)................................................................... 14
Part 2
Establishing Comunications with LocalView / NetView.............................................................29
Using the Flash Configuration Utility........................................................................................... 32
Setting Soft Switches.................................................................................................................... 37
Configuring Communication Ports............................................................................................... 38
Setting Up A BSAP Slave Port.............................................................................................. 38
Setting Up an Ethernet Port.................................................................................................... 40
Recommended Ranges for IP Addresses ............................................................................... 41
Other Port Types:................................................................................................................... 42
Configuring IP Parameters............................................................................................................ 43
Configuring User Accounts and Privileges................................................................................... 45
Adding A New User............................................................................................................... 45
Modifying the Privileges of an Existing User........................................................................ 48
Deleting An Existing User ..................................................................................................... 48
When You Have Finished Making Security Changes............................................................ 48
What's Next?................................................................................................................................. 49
Appendix A - Troubleshooting Tips...........................................................................................A-1
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6
Part 1
This part of the manual discusses the initial steps necessary to set up an all NEW ControlWave
LP, and start to use it.
• Setting up the Hardware
This section gives you a quick overview of how to set the switches, and where to connect the
cable between the ControlWave LP and the PC. References are included to the hardware
manual for details of the individual steps.
• Installing ControlWave Designer on the PC
This section provides instructions for installing ControlWave Designer software on your PC.
ControlWave Designer is the software which allows you to create an application-specific
program (called a project) that will execute inside the ControlWave LP.
• Creating a Simple Project in Ladder Language (LD)
This section shows how to create a very simple program in ladder language (LD) which is
one of the five IEC 61131-3 languages supported by ControlWave. In addition, this section
also discusses how to compile the program, and download it into the ControlWave LP.
7
Setting up the Hardware
P
h
Hardware Configuration
Setting Up the Hardware
The ControlWaveLP comes pre-assembled, but does NOT include an enclosure. It comprises
three boards, the CPU board, the Fixed Multifunction I/O Board (FMI/OB), and the Power
Supply/Sequencer Board (PSSB). The FMI/OB board is on top, the PSSB board is in the middle,
and the CPU board is on the bottom, attached to the mounting panel.
ower switc
Serial Ports
COM1
COM2
COM3
COM4
COM5
Ethernet
Port
(optional)
CPU board
Status LEDs
switch banks
Hardware setup involves unpacking the ControlWave LP, mounting the unit, wiring I/O
terminations, making proper ground connections, connecting a communication cable to the PC
workstation and setting switches. The full installation process is described in detail in Chapter 2
of CI-ControlWaveLP. An overview of the steps is included, below:
1. Remove the unit from its carton and install it at its assigned work site. (see Section 2.2 of CI-
ControlWaveLP).
2. Configure the jumpers on the Fixed Multi-Function Input / Output Board (FMI/OB). (See
Section 2.3.2 of CI-ControlWaveLP).
8
Setting up the Hardware
2
S
3. Configure CPU Module Switches (See Section 2.3.3 of CI-ControlWaveLP).
SW
W4
NOTE: For the initial configuration activities described in this manual, we recommend you leave
all CPU switch settings in their default positions, as set at the factory:
• Switch bank SW4: all switches in the ON position.
• Switch bank SW2: Switches SW2-1, SW2-2, and SW2-3 in the OFF position, and
SW2-4 in the ON position. (SW2-1 and SW2-2 are unused. SW2-3 should only be
ON when performing a system firmware upgrade. SW2-4 should always be ON.)
SW5 - UNUSED - IGNORE
(NOTE: ON state shown
in CAPITAL LETTERS)
Not Used
Not Used
Recovery Mode Disable / ENABLE
ALWAYS LEAVE THIS SWITCH ON
Watchdog Disable/ENABLE
Flash Files and Soft Switches Lock/UNLOCK
Soft Switches Ignore / USE
Core Updump / NORMAL RUN
SRAM Clear / RETAIN
Unused (leave ON)
Unused (leave ON)
Bootproject Disable / ENABLE
SW2-1 and SW2-2 are
unused and should be
left OFF. SW2-3 is only
turned ON when upgrading
system firmware, otherwise
is must be OFF. SW2-4
MUST always be left ON.
ALL SW4 switches
should be left ON.
SW5 is currently UNUSED.
9
Setting up the Hardware
4. For the configuration activities, described in this manual, we will use Serial Communication
Port 2 (COM2) on the ControlWave LP, which is configured by default for 9600 baud. (For
more information on communication ports see Section 2.3.4 of CI-ControlWaveLP).
• Plug one end of an RS-232 null modem cable1 into one of your PC communication ports.
• Plug the other end of the RS-232 null modem cable into Serial Communication Port 2
(COM2) of the ControlWave LP.
Plug RS232 Null Modem
Cable into COM Port 2
5. Install I/O wiring to each I/O Module (see Section 2.4.1 through 2.4.4 of CI-
ControlWaveLP).
6. Install Watchdog Relay/MOSFET Switch wiring (see Section 2.4.5 of CI-ControlWaveLP).
(OPTIONAL - perform this step only if you want to use this feature.)
1
For a wiring diagram of an RS-232 null modem cable, see Figure 2-5 in the CI-ControlWaveLP manual.
10
Setting up the Hardware
)
pp
(
)
7. Connect Bulk DC Power to the ControlWave LP’s PSSB Board (see Section 2.4.6 of CI-
ControlWaveLP).
Connect Unit Ground Wire to:
1. Conductive Mounting Panel
2. User Supplied Ground Lug
3. User Supplied Ground Bus
8. Connect the unit to a known good Earth Ground (see Section 2.2.3 of CI-ControlWaveLP).
9. Apply power to the ControlWave LP controller by setting the Power Switch on the PSSB
Module to the ‘1’ position. When the ControlWaveLP completes its power-on sequence,
status LEDs 1 to 6 should all be OFF. If this is NOT the case, please see Table 2-15 in CIControlWaveLP for information on what the status LED pattern means.2
You are now ready to install ControlWave Designer software on the PC to create a project which
can be downloaded into the ControlWave LP.
TB2 V+ 10.6-30VDC Input
TB2 V- PSGND
TB2 CHASSIS (Chassis ground)
Unit Ground Wire (#14 AWG
Power Supply Ground
That is connected to a
known good
Earth Ground!!!
via
#4 AWG
Stranded Co
er Wire
2
Table 2-15 in CI-ControlWaveLP shows the normal status LED patterns you are most likely to see. In addition,
Section 3.3.4 of CI-ControlWaveLP covers Power On Self-Test (POST) status codes, most of which are not seen
unless there is an error prior to completion of the power up. One POST code you may encounter is "86" (LEDs 2
and 3 lit) which indicates that the unit has been set for recovery mode (switches SW2-3 and SW2-4 are ON) to allow
a field upgrade of system firmware
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Installing ControlWave Designer Software on the PC
y
nstalling ControlWave LP Designer Software on the PC
For more detailed explanations of software installation options, see Chapter 2 of the Open BSI
Utilities Manual (document# D5081).
Recommended Requirements for the Open BSI Workstation:
133 MHz Pentium® CPU (Pentium 4 or higher CPU recommended) PC workstation with:
• at least 85 MB free disk space
• 32 MB RAM (more recommended)
• CD ROM drive
• VGA Monitor (minimum 256 colors 800x600). Optimal screen resolution when using Bristol
web pages is 1024 x 768.
• Mouse
• Microsoft® Windows™ 2000 (Service Pack 3 or newer required) or XP Professional. We
recommend you install the latest available service pack for your operating system. NOTE:
Open BSI/ControlWave Designer is currently tested on the following platforms only:
Pentium 4 with Windows™ XP Professional, Windows™ 2000, and Windows™ 2003
Server. Open BSI/ControlWave Designer software has NOT been tested on dual core
processors or hyper-threaded processors.
• Microsoft® Internet Explorer Version 5 or newer (Required for configuration web pages
used by ControlWave users).
• Microsoft® Access and ODBC - Windows™ 2000 version or newer
• RS-232 null modem cable (required to connect the PC to the ControlWave LP)
Before You Begin the Software Installation
ControlWave Designer software is installed from within Windows™. We recommend that all
other Windows™ application programs you have running should be shut down before beginning
installation.
If
ou are installing under Windows™ NT, you must be logged on with administrative privileges.
IMPORTANT
IMPORTANT - Remove Older Versions Prior to Installation
Before installing this kit on a computer which already has Open BSI 3.22 (or earlier versions) you
MUST first remove the previous version(s) of Open BSI.
To remove the older kits or components, use the Add/Remove programs option from the Windows™
Control Panel. When files have been removed, use Windows™ Explorer to browse the Open BSI
installation directory (usually \OPENBSI) and manually delete any remaining .EXE, .DLL, or .OCX
files.
12
Installing ControlWave Designer Software on the PC
Installing the ControlWave Designer Software
1. Insert the Open BSI CD-ROM in your CD ROM drive.
2. If your CD-ROM drive has autorun enabled, skip to the next step. Otherwise, use
Windows™ Explorer to locate the file BROWSER.EXE in the root directory of the CD.
Double-click on BROWSER.EXE. When the CD browser screen appears, choose the
“Install OpenBSI’’ option.
3. A screen reminding you to close all other programs, and warning you that older Open
BSI versions will be removed, will appear. Click on [Next>].
4. A license agreement screen will appear. Review the agreement, using the scroll bar to
bring it into view. Click on “I accept the terms of the license agreement” in order to
proceed. Then click on [Next>].
A list of available software packages will be
displayed similar to the one shown, at right. Choose
“ControlWave Designer with ACCOL III” as well
as any other packages you want to install then click
on [Next>].
5. Now, you can specify, if desired, different directories for storage of data and
configuration files. Otherwise, leave the directories at their default settings.
6. Now, click on [Next>]. This is your last opportunity to make any changes prior to
starting the installation. If you want to make changes, you can use the [<Back] button to
go back to earlier pages. If you are ready to perform the installation, click on the
[Install>] button, and the installation process will begin. Be patient, as it may take
several minutes to install all of the different utilities, depending upon which you have
chosen. When the installation has completed, you will be prompted to re-boot your
computer, which must be done in order for the software to run properly. If you don’t
choose to do it now, you should do it before starting ControlWave Designer.
7. Click on [Finish], and the installation will be complete, and re-boot will proceed, if you
chose to do it now.
Once installation is complete, an ‘OpenBSI Tools’ menu selection will be added to your
Windows Start Programs menu through which you can access ControlWave Designer.
At this point, you can begin the initial configuration activities for your new ControlWave LP.
13
Creating a Simple Project in Ladder Language (LD)
Creating a Simple Project in Ladder Language (LD)
Now, let's create a VERY simple project to run in your ControlWave LP. Let's say we have a
water tank - when the water level in the tank goes below a certain level, a WATER_LOW signal
is turned ON, and as a result, a START_PUMP signal needs to be turned ON to refill the tank.
Similarly, we want to issue a START_PUMP signal any time the drain valve for the tank is open.
Our project is so simple, we aren't going to handle turning off the pump, or what happens if the
tank overflows; we just want to show how either of two conditions cause the pump to be started.
NOTE: We won't be defining the I/O for this project; we're keeping it as simple as possible.
Step 1. Start ControlWave Designer:
• Click on StartÆProgramsÆOpenBSI ToolsÆControlWave Designer
IMPORTANT: If this is the very first time ControlWave Designer has been started on this
particular computer, you will be reminded to register the software. Otherwise, the software
can only be used for a maximum of 30 days. For more information on the registration
process, see Chapter 2 of the Open BSI Utilities Manual (document# D5081).
Step 2. Open a new project:
• Click on FileÆNew Project
• Double-click on the ControlWave icon.
• The left-window pane of ControlWave
Designer will be filled with a structure
called the project tree.
14
Creating a Simple Project in Ladder Language (LD)
Step 3. Insert a new logical program organization unit (POU).
• Right click on "Logical POUs" in the
project tree, and choose "Insert" and
“Program” from the pop-up menus.
Step 4. Name the POU, and specify it as a program in ladder language (LD).
• Enter the name ‘SIMPLE’.
• Choose "Program" as the
type. (If not already chosen.)
• Choose "LD" as the language.
• Click on [OK].
15
Creating a Simple Project in Ladder Language (LD)
Step 5. Create a Contact Network
• Double-click on the third SIMPLE item in the project tree (the code window).
• Click in the right-most window pane.
• Click on the ‘Contact Network’ icon.
Click on the 'Contact Network' icon and a
network of one contact and one coil will appear
in the right window pane.
Double-click on the C000 contact to call
up the Contact/Coil Properties dialog box.
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