Be sure that these instructions are carefully read and understood before any operation is
attempted. Improper use of this device in some applications may result in damage or injury. The
user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions for further information.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may
leave an operating process without protection. Depending upon the application, this could result in
possible damage to property or injury to persons. It is suggested that the purchaser review the
need for additional backup equipment or provide alternate means of protection such as alarm
devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches,
etc. If additional information is required, the purchaser is advised to contact Remote Automation
Solutions.
RETURNED EQUIPMENT WARNING
When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions 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 Remote Automation Solutionsand save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions 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 gr ounded 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 for proper care and handling of ESD-sensitive components.
Before You Begin
Thank you for choosing ControlWave Micro!
We hope you will find ControlWave Micro to be the best solution
for your process automation needs.
From the start, we 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 Micro Process Automation Controller, is a true PLC/RTU hybrid, incorporating
the best features of both types of devices.
ControlWave Micro 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.
ControlWave Micro Quick Setup Guide
Stay Safe!
WARNING –
SHOCK
HAZARD
WARNING –
EXPLOSION
HAZARD
Throughout your configuration activities, please be aware of the
following items:
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.
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:
Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
Because ControlWave Micro is sometimes used in Class I Division 2
hazardous locations, where there could be explosive vapors or other
dangerous substances, you MUST observe and follow all regulations
and warnings about proper installation, use, and repair in these
environments. Failure to follow these instructions could result in an
explosion, injury, or death.
Carefully review ALL warnings in the CI-ControlWave Micro
hardware manual, especially those from Underwriter’s Laboratories
(see Appendix A of CI-ControlWave Micro).
Revised Aug-2015 Before You Begin iii
ControlWave Micro Quick Setup Guide
How to use this guide
This guide is intended to help you get “up-and-running” with a
minimal amount of effort. Chapter 1 talks about setting up the
hardware, and the remaining chapters talk about installing and
using ControlWave Designer software, and about how to configure
certain parameters.
See this: For information on:
Chapter 1
Chapter 2
Chapter 3
Chapter 4
This guide does NOT, however, tell you everything you need to
know about setting up and configuring a ControlWave Micro. We
have included references throughout this book to other places in
the documentation set, where you can get more details on a
particular subject.
If you need help…
If you're having problems setting up and configuring your
ControlWave, please call our technical support team.
The technical support phone number in the U.S. is: 1-800-5379313; for international numbers use this link:
Note: Depending upon how you order it, your ControlWave
Micro may ship from the factory already assembled, or as a
separate housing and modules you must install yourself. If
you order it pre-assembled, you can omit those portions of
this chapter that discuss installation of individual modules.
Hardware setup involves unpacking the ControlWave Micro
hardware, mounting the housing, installing I/O modules, wiring
I/O terminations, making proper ground connections, connecting a
communication cable to the PC workstation and setting switches.
The figure, below, shows the base housing with the Power Supply
Sequencer Module (PSSM – two different models shown), CPU
Module, and six I/O modules with bezels installed. Your unit may
have different options. The full hardware installation process is
described in detail in Chapter 2 and Chapter 3 of CI-ControlWave Micro. An overview of the steps is included, below:
Figure 1-1. ControlWave Micro with two different PSSM types shown
Revised Aug-2015 Setting up the Hardware 1-1
ControlWave Micro Quick Setup Guide
1. Remove the base housing from its carton and install it at its
assigned work site. (See Section 2.2 of CI-ControlWave
Micro.)
2. Remove any expansion housing units from their cartons, and
attach them to the base housing. (See Section 2.2 of CIControlWave Micro.)
3. Remove the Power Supply Sequencer Module (PSSM) from its
carton. (See Section 2.3 of CI-ControlWave Micro.) Set
jumpers based on your power DC power requirements (see
Section 2.3.3 of CI-ControlWave Micro). Install the PSSM into
base housing slot 1, that is, the first slot from the left end of the
installed unit.
4. Remove the CPU module from its carton. (See Section 2.4 of
CI-ControlWave Micro.) Enable the backup battery by
installing backup battery board jumper JP8 onto pins 1 and 2.
(See Section 2.4.1 of CI-ControlWave Micro.) Now, you must
set CPU module DIP Switches.
Notes:
CPU Module DIP Switches must be configured before the
CPU module has been installed into the base housing. (See
Section 2.4.2 of CI-ControlWave Micro.)
For the initial configuration activities described in this manual,
we recommend you leave the CPU switch settings in their
default positions, as set at the factory as follows:
o Switch bank SW1: all switches in the OFF position.
o Switch bank SW2: all switches in the ON position, except
for SW2-4, which should be OFF.
5. Install the CPU module into base housing slot 2, which is the
second slot from the left end of the installed unit.
6. For the configuration activities, described in this manual, we
will use RS-232 serial communication port 2 (Comm Port 2) on
the ControlWave Micro, which is configured by default for
9600 baud. (For more information on RS-232 serial
communication ports see Section 2.4.3 of CI-ControlWave Micro).
7. Plug one end of an RS-232 null modem cable into one of your
PC communication ports.
Note: See Figure 2-17 in CI-ControlWave Micro for a wiring
diagram of an RS-232 null modem cable.
8. Plug the other end of the RS-232 null modem cable into serial
communication port 2 (Comm Port 2) of the ControlWave
Micro.
1-2 Setting Up the Hardware Revised Aug-2015
ControlWave Micro Quick Setup Guide
9. If you purchased any Expansion Communication Module(s),
you can remove them from their cartons, configure them, and
install them now, otherwise, skip to the next step. (See Section
2.5 of CI-ControlWave Micro for information on Expansion
Communication Modules.) The first expansion communication
module must reside in ControlWave Micro base housing slot
#3. If you have a second expansion communication module, it
must reside in ControlWave Micro base housing slot #4.
Note: You cannot install Expansion Communication Module(s) in
the expansion housing, only in the base housing.
10. Remove any I/O Modules from their cartons and install them
into the appropriate housing slots. (See Chapter 3 of CIControlWave Micro). See the table, below for information on
which slots to use.
Table 1-1. Housing Slots Which Can Hold I/O Modules
Housing Type Slots which can hold I/O Modules
3-slot base housing
4-slot base housing
8-slot base housing
2-slot expansion
housing
4-slot expansion
housing
8-slot expansion
housing
Slot 3 if not occupied by an expansion
communication module
Slot 3 and Slot 4 (if they are not occupied by
expansion communication modules)
Slot 3 and Slot 4 (if they are not occupied by
expansion communication modules), Slot 5, Slot
6, Slot 7, Slot 8
Both slots
All 4 slots
All 8 slots
Note: In ControlWave Designer’s I/O Configurator, you must
enter the I/O slot number for each I/O module and configure
the module. The I/O Slot number is not the same as the
housing slot number. The housing slots which hold the
power supply and CPU boards are not considered to be I/O
slots, so the first I/O slot (I/O slot 1) is typically the third
housing slot (housing slot 3).
11. Install I/O wiring to each I/O module (see Chapter 3 of CI-
ControlWave Micro).
12. Install a ground wire between the housing ground lug and a
known good Earth ground (See Section 2.2.3 of CIControlWave Micro.)
13. Install Watchdog /MOSFET Switch wiring (see Section 2.3.7
of CI-ControlWave Micro). (OPTIONAL - perform this step
only if you want to use this feature.)
Revised Aug-2015 Setting up the Hardware 1-3
ControlWave Micro Quick Setup Guide
S
n
14. Connect bulk DC power to the ControlWave Micro’s PSSM
module (see Section 2.3.6 of CI-ControlWave Micro).
15. Install the bezel(s) so the I/O modules are covered. (See
Section 2.6 of CI-ControlWave MICRO.)
16. Turn the RUN/REMOTE/LOCAL key switch to the LOCAL
position or set the PSSM’s Mode Switch to Local mode, which
is SW1-1 on PSSM UP (Open) and SW1-2 on PSSM DOWN
(Closed).
17. Apply power to the ControlWave Micro controller.
18. When the ControlWave Micro completes its power-on
sequence, status LEDs 5 and 6 on the PSSM module should be
ON. (This indicates the ControlWave Micro does not have any
application program loaded. If you see other LEDs lit, see
Table 5-2 of manual CI-ControlWave Micro which has a list of
LED status codes and their meanings. Figure 5-5 of CI-ControlWave Micro shows how the various LED patterns
correspond to the status codes.
Typical Configuratio
Chassis Ground
+ VIN
- VIN
CHASSI
Figure 1-3. PSSM LEDs on Initial Power-Up
You hardware is ready! Now you can install ControlWave
Designer software on the PC to create a project which you can
download into the ControlWave Micro.
Note: This chapter outlines the basic steps in installing
ControlWave Designer software. For more detailed
instructions, see Chapter 2 of the OpenBSI Utilities Manual
(D5081).
2.1 Recommended Requirements for the OpenBSI Workstation:
To run ControlWave Designer your PC workstation must meet the
following minimum system requirements:
1 GHz processor
at least 200 MB free disk space for use by OpenBSI
512 MB RAM (more recommended)
CD-ROM drive
VGA Monitor (minimum 256 colors 800x600). Optimal screen
resolution for OpenBSI web pages is 1024 x 768.
Mouse
Communication cable(s) to connect the PC to the ControlWave
Micro.
Microsoft® Windows® 2003 Server, 2008 Server, XP
Professional, 7.0, or Vista. OpenBSI only supports 32-bit
operating systems. We recommend you install the latest
available service pack for your operating system.
Note: Emerson only tests OpenBSI and ControlWave Designer
on the following platforms: Windows™ XP Professional,
Windows Vista/7.0 and Windows™ 2003/2008 Server
including both dual core, and dual-core dual-processor
computers.
Microsoft® Internet Explorer Version 5 or newer (Required for
ControlWave web pages).
Note: If you use Microsoft® Windows XP Service Pack 2 (or
newer), you must change default operating system settings
for certain OpenBSI features to work. Please see the Using OpenBSI with Microsoft® Windows XP Service Pack 2
notes in Chapter 2 of the OpenBSI Utilities Manual
(D5081).
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.
Note: You must log in with Windows administrative privileges to
install the software.
2.3 Installing the ControlWave Designer Software
1. Log into the workstation with administrative privileges.
2. Insert the OpenBSI CD-ROM in your CD-ROM drive.
3. 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.
4. A screen reminds you to close all other programs, and warns
you that older OpenBSI versions will be removed. Click Next.
5. A license agreement screen opens. Review the agreement,
using the scroll bar to bring it into view. Click I accept the
terms of the license agreement to proceed. Then click Next.
6. Now you must choose the installation directory on your
computer for OpenBSI.. The default directory is \Program
Files\Bristol\OpenBSI. Either accept the default or click
Browse to specify a new directory. Then click Next.
7. On the next screen, use the check-boxes to select whichever
package(s) you want to install. As a minimum, you must
choose ControlWave Designer with ACCOL III.
9. On the next screen you can specify the user files folder. The
system stores user files such as ControlWave projects, recipes,
and network files in sub-folders of this folder. Note: If User
Account Control (UAC) is enabled in Windows, you must have
write access to this folder. The default is C:\OpenBSI. Use the
default or use Browse to specify a different user files folder.
When finished click Next.
10. This is your last opportunity to make any changes prior to
starting the installation. If you want to make changes, you can
click Back to go back to earlier pages. If you want to read the
printed release notes for this version of OpenBSI, check the
View the Release Notes box.
11. If you are ready to perform the installation, click Install, and
the installation process starts. Be patient, as it may take several
minutes to install all of the different utilities, depending upon
which you choose.
12. When the installation completes, re-boot your computer when
prompted. This must be done in order for OpenBSI to function
properly. If you choose not to re-boot now, you must do so
before running OpenBSI. Click Finish, and the installation will
be complete, and re-boot will proceed, if you chose to do it
now.
After re-boot, an “OpenBSI Tools” menu selection is added to
your Windows Start Programs menu through which you can
access the various OpenBSI utilities. If you prefer, you can
create Windows shortcuts to the tools to provide access
through icons on the desktop. See your Windows
documentation for information on how to do this.
Now, let's create a very simple project to run in your ControlWave
Micro. 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.
3.1 Connect the PC Workstation to the ControlWave Micro
1. Plug one end of a null modem cable into your PC serial port.
2. Plug the other end of the cable into one of the RS-232 serial
communication ports on the ControlWave Micro.
Note: Later in this chapter, you’ll need to know the baud rate of
the ControlWave Micro serial port. See Table 4-1 in CIControlWave Micro for details on factory default baud rates
If this is the very first time ControlWave Designer has been started on
Caution
this particular computer, you will be reminded to register the
software. Otherwise, the software can only be used for a maximum of
60 days. For more information on the registration process, see
Chapter 2 of the OpenBSI Utilities Manual (D5081).
Revised: Aug-2015 Creating a Simple Project 3-1
ControlWave Micro Quick Setup Guide
3.3 Open a New Project
1. Click File>New Project
2. Double-click on the CWMicro icon to select a CWMicro
template.
Click File > New Project
Figure 3-1. Create a New Project
Double-click on “CWMicro”
Figure 3-2. CWMicro Template
The left window pane of ControlWave Designer fills with a
structure called the project tree.
3.4 Insert a new logical program organization unit (POU).
Right click Logical POUs in the project tree, and choose Insert >
Program from the pop-up menus.
3-2 Creating a Simple Project Revised: Aug-2015
ControlWave Micro Quick Setup Guide
Right-click on “Logical POUs” in
the project tree, then choose “Insert
> Program”.
Figure 3-3. Choose Program POU
3.5 Name the POU, and specify it as a program in ladder (LD).
1. Enter the name “SIMPLE”.
2. Choose "Program" as the type. (If not already chosen.)
3. Choose "LD" as the language.
4. Click OK.
Enter a “Name” for the program.
Choose “Program” as the “Type.”
Specify “LD” as the language.
When finished, click “OK.”
Figure 3-4. Insert dialog box
3.6 Create a Contact Network
1. Double-click on the third SIMPLE item in the project tree (the
code window).
Revised: Aug-2015 Creating a Simple Project 3-3
ControlWave Micro Quick Setup Guide
2. Click in the right-most window pane.
Three new items show in the in project tree. Double-click on the third
SIMPLE item in the project tree, then click in the right window pane.
Figure 3-5. Project Tree
3. Click the “Network” icon.
Click the “Network” icon and a network of one
contact and one coil shows in the right window pane.
Double-click the C000 contact to call up the Contact/Coil Properties dialog box.
Figure 3-6. Creating a Contact Network
Note: You may need to scroll through the right pane to view the
rest of the network.
3-4 Creating a Simple Project Revised: Aug-2015
3.7 Define the “WATER_LOW” variable.
1. Double-click on the “C000” contact to call up the Contact/Coil
Properties dialog box (see Figure 3-6).
2. Enter the variable name “WATER_LOW” in place of “C000”
in the "Name" field, then click OK.
ControlWave Micro Quick Setup Guide
Enter a variable name “WATER_LOW” then click “OK.”
Figure 3-7. Contact/Coil Properties dialog box
New name for the contact
Figure 3-8. Assigning a Name to a Contact
Revised: Aug-2015 Creating a Simple Project 3-5
ControlWave Micro Quick Setup Guide
then click the Paralle
3.8 Insert a parallel contact below, and define the “DRAIN_OPEN”
variable
1. Click the WATER_LOW contact, then click the Parallel icon.
This adds a new contact called “C002” below the
WATER_LOW contact we defined earlier.
Click the WATER_LOW contact,
l icon
…this adds a parallel branch contact below.
Figure 3-9. Adding a Parallel Branch
2. Double-click on the new contact “C002” to call up the Contact/
Coil Properties dialog box.
Double-click the C002 contact to call up the
Contact/Coil Properties dialog box.
Figure 3-10. Calling Up the Contact/Coil Properties dialog box
3. Enter “DRAIN_OPEN” in place of “C002” in the Name field
of the Contact /Coil Properties dialog box, then click OK.
3-6 Creating a Simple Project Revised: Aug-2015
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