s
Part Number D301415X012
Document Number D5084
August 2015
ControlWave®
Process Automation Controller
Quick Setup Guide
Remote Automa tio n Solution
www.EmersonProcess.com/Remote
Be sure that these instructions are carefully read and understood before any operation is
attempted. Improper use of this device in some applications may result in damage or injury. The
user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions 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 Solutions and 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!
We hope you will find ControlWave 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 Process Automation
Controller, is a true PLC/RTU hybrid, incorporating the best
features of both types of devices.
ControlWave 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 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 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 hardware
manual, especially those from Underwriter’s Laboratories (se e
Appendix A of CI-ControlWave).
Revised Aug-2015 Before You Begin iii
ControlWave 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. 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:
http://www2.emersonprocess.com/enUS/brands/remote/systems_and_software/supportnet/support_contacts/Pa
ges/support_contacts.aspx
Setting up the hardware.
Software installation.
Creating a ControlWave project in
ControlWave Designer.
Setting up RTU parameters.
Alternatively, log into SupportNet at this link:
http://www3.emersonprocess.com/remote/support/support_login.html
iv Before You Begin Revised Aug-2015
Contents
ControlWave Quick Setup Guide
Chapter 1 – Setting up the Hardware 1-1
Chapter 2 – Installing ControlWave Designer Software on the PC 2-1
2.1 Recommended Requirements for the OpenBSI Workstation: .................................................. 2-1
2.2 Before You Begin the Software Installation .............................................................................. 2-2
2.3 Installing the ControlWave Designer Software ......................................................................... 2-2
Chapter 3 – Creating a Simple Project in Ladder Language (LD) 3-1
3.1 Connect the PC Workstation to the ControlWave ..................................................................... 3-1
3.2 Start ControlWave Designer: .................................................................................................... 3-1
3.3 Open a New Project .................................................................................................................. 3-2
3.4 Insert a new logical program organization unit (POU). ............................................................. 3-2
3.5 Name the POU, and specify it as a program in ladder (LD). .................................................... 3-3
3.6 Create a Contact Network ......................................................................................................... 3-4
3.7 Define the “WATER_LOW” variable. ........................................................................................ 3-5
3.8 Insert a parallel contact below, and define the “DRAIN_OPEN” variable ................................. 3-6
3.9 Define the START_PUMP variable: .......................................................................................... 3-7
3.10 Create a task, and associate the program with that task: ......................................................... 3-8
3.11 Compile the program: .............................................................................................................. 3-11
3.12 Download the project into the ControlWave ............................................................................ 3-11
3.13 Test the logic of the program in Debug Mode ......................................................................... 3-17
Chapter 4 – Configuring RTU Parameters 4-1
4.1 Starting the Flash Configuration Utility ...................................................................................... 4-1
4.1.1 Method 1: Starting from within LocalView ..................................................................... 4-1
4.1.2 Method 2: Starting from within NetView (ControlWave Already in a Network) ............. 4-3
4.1.3 Method 3: Starting from within TechView ..................................................................... 4-4
4.2 Using the Flash Configuration Utility ......................................................................................... 4-7
4.2.1 Flash Configuration Utility Buttons ................................................................................ 4-9
4.3 Setting Soft Switches .............................................................................................................. 4-14
4.3.1 Saving Changes When You Finish ............................................................................. 4-15
4.4 Setting Up a BSAP Slave Port ................................................................................................ 4-15
4.4.1 Saving Changes When You Finish ............................................................................. 4-17
4.5 Setting Up an Ethernet Port .................................................................................................... 4-17
4.5.1 Recommended Ranges for IP Addresses ................................................................... 4-18
4.5.2 Other Port Types: ........................................................................................................ 4-19
4.5.3 Saving Changes When You Finish ............................................................................. 4-19
4.6 Setting IP Parameters ............................................................................................................. 4-20
4.6.1 Saving Changes When You Finish ............................................................................. 4-21
4.7 Configuring Usernames and Passwords ................................................................................. 4-22
4.7.1 Adding a New User ..................................................................................................... 4-22
4.7.2 Modifying the Privileges of an Existing User ............................................................... 4-25
4.7.3 Deleting an Existing User ............................................................................................ 4-25
4.7.4 Saving Changes When You Finish ............................................................................. 4-25
4.8 What’s Next? ........................................................................................................................... 4-26
Appendix A – Troubleshooting Tips A-1
Revised Aug-2015 Contents v
This page is intentionally left blank
Chapter 1 – Setting up the Hardware
80
)
Note: Depending upon how you order it, your ControlWave 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 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 a ControlWave in a ten-slot housing. The
housing includes eight I/O slots. The unit has four serial ports and
three Ethernet ports. Your unit may have different options. The full
hardware installation process is described in detail in Chapter 2
and Chapter 3 of CI-ControlWave. An overview of the steps is
included, below:
ControlWave Quick Setup Guide
Bezel
(Plastic bezel covers the
power supply sequencer
module in slot 1 and CPU
module in slot 2.)
Serial Port COM1
Chassis
Serial Port COM2
Ethernet Port 1
Bezel Door
(for access to po wer
switch and PSSM
LEDs
Port
Display
RUN/REMOTE/LOCAL Key switch
Serial Port COM3 (Optional)
Serial Port COM4 (Optional)
Ethernet Port 3
(Optional)
Ethernet Port 2 (Optional)
Chassis
Local I/O
Modules
(install in chassis
slots 3 to 10)
Figure 1-1. ControlWave with Eight I/O Modules
Revised Aug-2015 Setting up the Hardware 1-1
ControlWave Quick Setup Guide
y
a
t
1. Remove the housing from its carton and install it at its assigned
2. Remove the Power Supply Sequencer Module (PSSM) from its
3. Remove the CPU module from its carton and configure CPU
work site. (See Section 2.2.1 and 2.2.3 of CI-ControlWave.)
carton and install it into slot 1, which is the first slot from the
left end of the installed unit. (See Section 2.3.2 of CI-
ControlWave.)
module DIP switches. (See Section 2.4 and 2.4.1 of CI-
ControlWave.)
Reset
Switch
Comm.
Port 1 (J2)
Lithium
Battery
3.6V
950mA-hr
½ AA Cell
Comm.
Port 2 (J3)
Ethernet
Port 1 (J4)
Enlarged detail
of CPU switch
banks
(CAPITALIZED entry
indicates ON position)
Bootproject ENABLE / disable
Redundancy DISABLE / enable
static memory RETAIN / initialize
Updump DISABLE / enable
Soft switches USE / ignore
Soft switches write UNLOCK / lock
Watchdog circuit ENABLE/disable
UNIT A / unit B
Port 80
Display
Run/
Remote/
Local
Key Switch
SW1
SW1
SW3
SW3
Leave all SW3
CPU switches
in default 'OFF'
position, excep
for #4.
ENABLE/disable battery backup
recovery mode ENABLE/disable
Unused
Unused
(CAPITALIZED entry
indicates ON position)
B
default, SW1
switches should
ll be 'ON'
Figure 1-2. Configuring CPU Module DIP Switches
1-2 Setting Up the Hardware Revised Aug-2015
ControlWave Quick Setup Guide
Notes:
For the initial configuration activities described in this manual,
we recommend you leave most of the CPU switch settings in
their default positions, as set at the factory:
o Switch bank SW1: all switches in the ON position.
o Switch bank SW3: all switches in the OFF position, except
for SW3-4, which you should set ON to enable the backup
battery when the ControlWave is ready to be put into
service. If the ControlWave not going to be installed for an
extended period of time, you can leave this off to avoid
draining the battery.
4. Install the CPU module into slot 2 of the housing, which is the
second slot from the left end of the installed unit.
5. For the configuration activities, described in this manual, we
will use RS-232 serial communication port 2 (Comm Port 2) on
the ControlWave, which is configured by default for 9600
baud. (For more information on RS-232 serial communication
ports see Section 2.4.2 of CI-ControlWave).
Plug RS-232
null modem
cable into
COM2
Figure 1-3. Plugging a Cable into COM2
6. Plug one end of an RS-232 null modem cable into one of your
PC communication ports.
Note: See Figure 2-15 in CI-ControlWave for a wiring diagram
of an RS-232 null modem cable.
7. Plug the other end of the RS-232 null modem cable into serial
communication port 2 (Comm Port 2) of the ControlWave.
Revised Aug-2015 Setting up the Hardware 1-3
ControlWave Quick Setup Guide
8. Remove any I/O modules from their cartons and install them
Note: In ControlWave Designer’s I/O Configurator, you must
9. Install a ground wire between the housing ground lug and a
10. Install Watchdog relay/MOSFET switch wiring (see Section
into the appropriate housing slots. I/O modules reside in slots 3
through 6, or 3 through 10 for units supporting 4, or 8 I/O
modules respectively. Install I/O wiring to each I/O module.
(See Section 3.3 of CI-ControlWave.)
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).
known good Earth ground (See Section 2.2.4 of CI-
ControlWave.)
2.3.7 of CI-ControlWave). (OPTIONAL - perform this step
only if you want to use this feature.)
11. Connect bulk DC power and field power to the ControlWave’s
PSSM module. (See Section 2.3.5 of CI-ControlWave.)
Figure 1-4. Wiring for Bulk DC Power (TB1) and Field Power (TB2)
1-4 Setting Up the Hardware Revised Aug-2015
ControlWave Quick Setup Guide
12. Turn the RUN/REMOTE/LOCAL key switch to the LOCAL
position.
Turn RUN/RE MOTE/LOCAL
key switch to the 'LOCAL'
position. (Illustration shows
it in 'RUN' position)
Figure 1-5. Setting the RUN/REMOTE/LOCAL Switch
13. Install the bezel so that it covers the PSSM and CPU modules.
(See Section 2.5 of CI-ControlWave.)
14. Open the bezel door, and apply power to the ControlWave
controller by setting the power switch on the PSSM module to
the “1” position. When the ControlWave completes its poweron sequence, the code “00” shows on the Port 80 display. The
“00” code indicates the ControlWave does not have any
application program loaded. A list of possible status codes is
included in Table 5-3 and Table 5-4 of CI-ControlWave.
Note: One code you may encounter is “86” which indicates the
unit is set for recovery mode (switch SW3-3 is ON) which
allows a field upgrade of system firmware.
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.
Revised Aug-2015 Setting up the Hardware 1-5
This page is intentionally left blank
ControlWave Quick Setup Guide
Chapter 2 – Installing ControlWave Designer Software
on the PC
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.
Microsoft® Windows® 2003 Server, 2008 Server, XP
Professional, 7.0, or Vista. 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).
Revised Aug-2015 Installing ControlWave Designer 2-1
ControlWave Quick Setup Guide
2.2 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.
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.
Figure 2-1. Selecting Software Packages
2-2 Installing ControlWave Designer Revised Aug-2015
ControlWave Quick Setup Guide
8. Once you make your choices, click Next.
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.
a Simple Project in Ladder Lan guage (LD)
Revised Aug-2015 Installing ControlWave Designer 2-3
This page is intentionally left blank
ControlWave Quick Setup Guide
Chapter 3 – Creating a Simple Project in Ladder
Language (LD)
Now, let's create a very simple project to run in your ControlWave.
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
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.
Note: Later in this chapter, you’ll need to know the baud rate of
the ControlWave serial port. See Table 4-1 in CI-
ControlWave for details on factory default baud rates for
the ControlWave serial ports.
3.2 Start ControlWave Designer:
Click Start>Programs>OpenBSI Tools> ControlWave
Tools>ControlWave Designer
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 Quick Setup Guide
3.3 Open a New Project
1. Click File>New Project
2. Double-click on the ControlWave icon to select a
Click File > New Project
Figure 3-1. Create a New Project
ControlWave template.
Double-click on “ControlWave”
Figure 3-2. ControlWave 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 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
Revised: Aug-2015 Creating a Simple Project 3-3
ControlWave Quick Setup Guide
3.6 Create a Contact Network
1. Double-click on the third SIMPLE item in the project tree (the
code window).
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
3-4 Creating a Simple Project Revised: Aug-2015
Loading...