s
Instruction Manual
Part Number D301385X012
Document: CI-ControlWave EXP
August 2015
ControlWave®
I/O Expansion Rack
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.
ControlWave I/O Expansion Rack Instruction Manual
Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual ................................................................................................................. 1-2
1.2 Physical Description .................................................................................................................. 1-2
1.3 Housings ................................................................................................................................... 1-3
1.4 CPU Module .............................................................................................................................. 1-5
1.5 Power Supply/Sequencer Module (PSSM) ............................................................................... 1-6
1.6 I/O Modules ............................................................................................................................... 1-6
1.7 Secure Gateway ........................................................................................................................ 1-7
Chapter 2 – Installation 2-1
2.1 Site Considerations ................................................................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ...................................................................... 2-2
2.2 Installation Overview ................................................................................................................. 2-3
2.2.1 Unpacking Components ................................................................................................ 2-4
2.2.2 Color Coding of Slot Connectors .................................................................................. 2-5
2.2.3 Mounting the Housing ................................................................................................... 2-7
2.2.4 Grounding the Housing ............................................................................................... 2-11
2.3 Power Supply/Sequencer Module (PSSM) ............................................................................. 2-11
2.3.1 General Information about the PSSM ......................................................................... 2-11
2.3.2 PSSM Installation Overview ........................................................................................ 2-13
2.3.3 Setting Jumpers .......................................................................................................... 2-14
2.3.4 General Wiring Guidelines .......................................................................................... 2-16
2.3.5 Wiring a Bulk DC Power Supply to the PSSM ............................................................ 2-17
2.3.6 Hot-swapping a Power Supply .................................................................................... 2-20
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog Connector and Wiring the
Redundancy Control Input (OPTIONAL) ................................................................................ 2-21
2.3.8 Wiring Digital Inputs to indicate Power Supply Failure ............................................... 2-23
2.3.9 PSSM Specifications ................................................................................................... 2-24
2.4 CPU Module ............................................................................................................................ 2-25
2.4.1 Setting DIP Switches on the CPU Module .................................................................. 2-26
2.4.2 Connections to RS-232 Serial Port(s) ......................................................................... 2-29
2.4.3 Connections to RS-485 Serial Port on the Secondary Communication Board (SCB) 2-32
2.4.4 Connections to Ethernet Port(s) on the CPU Module ................................................. 2-34
2.5 Bezels ...................................................................................................................................... 2-35
Chapter 3 – I/O Modules 3-1
3.1 Module Placement .................................................................................................................... 3-3
3.2 Status LEDs .............................................................................................................................. 3-4
3.3 Wiring ........................................................................................................................................ 3-4
3.3.1 Local Termination .......................................................................................................... 3-5
3.3.2 Remote Termination ...................................................................................................... 3-6
3.3.3 Shielding and Grounding ............................................................................................... 3-6
3.4 Digital Input (DI) Modules .......................................................................................................... 3-8
3.5 Digital Output (DO) Modules ................................................................................................... 3-13
3.6 Analog Input (AI) Modules ....................................................................................................... 3-20
3.7 Analog Output (AO) Modules .................................................................................................. 3-25
3.8 Universal Digital Input (UDI) Modules ..................................................................................... 3-30
3.9 Isolated Resistance Temperature Device (RTD) Input Module .............................................. 3-36
3.10 Isolated Thermocouple Module ............................................................................................... 3-40
Issued Aug-2015 Contents iii
ControlWave I/O Expansion Rack Instruction Manual
Chapter 4 – Operation 4-1
4.1 Powering Up/Powering Down the ControlWave I/O Expansion Rack ...................................... 4-1
4.2 Communicating with the ControlWave I/O Expansion Rack ..................................................... 4-1
4.2.1 Default Comm Port Settings ......................................................................................... 4-1
4.2.2 Changing Port Settings ................................................................................................. 4-2
Chapter 5 – Service and Troubleshooting 5-1
5.1 Upgrading Firmware .................................................................................................................. 5-2
5.2 Removing or Replacing Components ....................................................................................... 5-5
5.2.1 Accessing Modules for Testing ..................................................................................... 5-5
5.2.2 Removing/Replacing the Bezel ..................................................................................... 5-5
5.2.3 Removing/Replacing the CPU Module ......................................................................... 5-6
5.2.4 Removing/Replacing the PSSM .................................................................................... 5-6
5.2.5 Removing/Replacing an I/O Module (Hot Swapping) ................................................... 5-7
5.2.6 Removing/Replacing the Backup Battery ................................................................... 5-12
5.3 General Troubleshooting Procedures ..................................................................................... 5-13
5.3.1 Common Communication Configuration Problems ..................................................... 5-13
5.3.2 Checking LEDs ........................................................................................................... 5-14
5.3.3 Checking Wiring/Signals ............................................................................................. 5-22
5.3.4 Port 80 Display Codes ................................................................................................ 5-22
5.3.5 Reset Switch ............................................................................................................... 5-26
5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-26
5.4.1 Available Diagnostics .................................................................................................. 5-28
5.5 Core Updump .......................................................................................................................... 5-32
Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations. A-1
Appendix B – Open MODBUS Interface B-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1
Index IND-1
iv Contents Issued Aug-2015
Chapter 1 – Introduction
The ControlWave I/O Expansion Rack provides additional I/O in a
separately mounted rack for an existing ControlWave process
automation controller.
This manual focuses on the hardware aspects of the ControlWave I/O
Expansion Rack. For information about the software used with the
ControlWave I/O Expansion Rack, refer to the ControlWave I/O
Expansion Rack Quick Setup Guide (D5122), the ControlWave
Designer Programmer’s Handbook (D5125), and the online help in
ControlWave Designer.
This chapter details the structure of this manual and provides an
overview of the I/O rack and its components.
In This Chapter
1.1 Scope of the Manual ........................................................................ 1-2
1.2 Physical Description ........................................................................ 1-2
1.3 Housings .......................................................................................... 1-3
1.4 CPU Module .................................................................................... 1-5
1.5 Power Supply/Sequencer Module (PSSM) ..................................... 1-6
1.6 I/O Modules...................................................................................... 1-6
1.7 Secure Gateway .............................................................................. 1-7
ControlWave I/O Expansion Rack Instruction Manual
Features
The ControlWave I/O expansion rack was designed with an emphasis
on providing high performance with low power consumption,
scalability, and modularity.
You can configure the ControlWave I/O expansion rack as a slave to a
ControlWave Process Automation Controller (CWPAC), ControlWave
Redundant Controller (CWRED), or a ControlWave Redundant I/O
Switch Unit (CWRED I/O). Communication to the rack can be via an
Ethernet connection, serial MODBUS, or Open MODBUS.
ControlWave I/O expansion racks have the following key features:
Low power consumption
Small size (enabling panel mount or 19 inch rack-mount
installations)
Two or three RS-232 ports
One or three 10/100 MB Ethernet ports
Options for additional communication ports
Housings to support four or eight I/O modules
Variety of I/O modules and support for hot swapping of I/O modules
Support for redundant operation with another ControlWave I/O
expansion rack
LED status indicators on the CPU, PSSM, and certain I/O modules
Revised Aug-2015 Introduction 1-1
ControlWave I/O Expansion Rack Instruction Manual
Port 80 display to present status codes
Battery backup for the real-time clock and the system’s static RAM
(SRAM)
Class I, Division 2 Hazardous Location approvals (Requires an
appropriate enclosure that meets NEMA Type 3X or 4X
specifications.)
1.1 Scope of the Manual
This manual contains the following chapters:
Chapter 1
Introduction
Chapter 2
Installation
Chapter 3
I/O Modules
Chapter 4
Operation
Chapter 5 Service and
Troubleshooting
1.2 Physical Description
Each ControlWave has a printed circuit board (PCB) backplane
mounted in a stainless steel housing, a Power Supply/Sequencer Module
(PSSM), a CPU module which may include an optional Secondary
Communication Board (SCB) and—depending on the backplane and
housing size—up to eight I/O modules.
Provides an overview of the hardware and
general specifications for the ControlWave.
Provides information on the housings, the
Power Supply/Sequencer module (PSSM), and
the CPU module.
Provides general information and wiring
diagrams for the I/O modules.
Provides information on day-to-day operation of
the I/O rack.
Provides information on service and
troubleshooting procedures.
Figure 1-1.
ControlWave I/O Expansion Rack with 8 I/O Modules
Refer to the following sections in this chapter or to other chapters in this
manual for further information:
Housings (chassis) with backplanes (see Section 1.3 and Chapter 2)
1-2 Introduction Revised Aug-2015
1.3 Housings
ControlWave I/O Expansion Rack Instruction Manual
Power Supply/Sequencer module (PSSM) (see Section 1.5 and
Chapter 2)
CPU module (see Section 1.4 and Chapter 2)
One or more I/O modules (see Section 1.6 and Chapter 3)
ControlWave housings are stainless steel designed for panel/wallmounting or for some versions, for mounting in a 19-inch equipment
rack. They contain the printed circuit board (PCB) backplane into which
you connect the PSSM, the CPU module, and any I/O modules.
The following housings are available:
6-slot backplane supports on PSSM, one CPU, and up to four I/O
modules.
10-slot housing supports one PSSM, one CPU, and up to eight I/O
modules. The 10-slot housing is suitable for mounting in a 19-inch
equipment rack.
Hot swap detection circuitry within the PSSM allows for the safe
insertion and removal of I/O modules while power is on.
Revised Aug-2015 Introduction 1-3
ControlWave I/O Expansion Rack Instruction Manual
Figure 1-2. ControlWave I/O Expansion Rack Housing Options
1-4 Introduction Revised Aug-2015
1.4 CPU Module
ControlWave I/O Expansion Rack Instruction Manual
Note: The ControlWave I/O Expansion Rack CPU does not accept a
downloadable ControlWave project (software application), it
only holds I/O modules. A separate ControlWave Process
Automation Controller runs the ControlWave project which must
reference the I/O points in the ControlWave I/O Expansion Rack.
The CPU (central processing unit) module houses the CPU board, and if
present the secondary communications board (SCB). The CPU module
provides I/O monitor/control, memory, and communication functions.
The CPU board includes:
Intel 386EX microprocessor running at 25 MHz
2 RS-232 communication ports
1 10/100baseT Ethernet port
2 MB of battery backed Static RAM (SRAM)
512 KB boot/downloader FLASH
32 MB simultaneous read/write FLASH memory
configuration DIP switches (described in Chapter 2)
Port 80 display to show status codes
You can order the CPU module with the optional secondary
communication board (SCB) for additional communication ports. See
CPU Module Configurations.
CPU Module
Configurations
The CPU module has two basic configurations, all of which have an
on-board backup battery and different combinations of
communications ports.
Table 1-1. CPU Module Configurations
Number of RS-232
Ports
2 (COM1 & COM2) 0 1 (ETH1) No SCB.
3 (COM1, COM2, COM4) 1 (COM3) 3 (ETH1,
CPU Backup
Battery
Number of RS-485
Ports
Number of
Ethernet
Ports
ETH2,
ETH3)
For this port count, 1
RS-232 (COM4), 1 RS485 (COM3), and 2
Ethernet ports (ETH2,
ETH3) reside on the
SCB.
The CPU module includes a 3.6V, 950 mA-hr lithium
This battery provides backup power for the real-time clock and the
system’s Static RAM (SRAM).
Notes
½ AA battery.
CPU Memory
There are several different types of memory used on the CPU module:
Revised Aug-2015 Introduction 1-5
ControlWave I/O Expansion Rack Instruction Manual
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The CPU module contains 32 MB of FLASH memory. The FLASH
memory holds the system firmware. The FLASH does not support
hardware write protection.
System Memory (SRAM)
The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by the CPU backup battery). Critical system information that must be
retained during power outages or when the system has been disabled for
maintenance is stored here. This includes the last states of all I/O points.
1.5 Power Supply/Sequencer Module (PSSM)
The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.
The PSSM operates from +22.2 to +30V (dc) and ships from the factory
with a nominal input supply configuration of 24V.
The PSSM includes:
ON/OFF system power switch(es) for each power supply board
Pluggable terminal block to connect the external power supply
Watchdog output connector to signal a watchdog failure to an
external device
Status LEDs
Chapter 2 includes instructions for installing and configuring the PSSM.
1.6 I/O Modules
The ControlWave I/O expansion rack supports analog input, analog
output, digital input, digital output, universal digital input, isolated
RTD, and isolated low level analog (thermocouple and mv) input
modules for either local or remote field device wiring termination.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-3
shows a typical I/O module housing.
Terminations are pluggable and accept a maximum wire size of #14
AWG. Each I/O module connects to the backplane using a 110-pin male
connector and to its associated terminal block assembly using a 44 pin
header.
1-6 Introduction Revised Aug-2015
ControlWave I/O Expansion Rack Instruction Manual
1.7 Secure Gateway
Figure 1-3. I/O Module (with door open)
For enhanced data security when using an IP/Ethernet connection,
Emerson Remote Automation Solutions recommends adding an
industrial router with VPN and firewall security. Recommended
solutions include the MOXA EDR‐810, the Hirschman Eagle One, or
the Phoenix mGuard rs4000 (or equivalents). An example of how to
install one of these devices to the RTU can be found in the Emerson
Remote Automation Solutions MOXA® Industrial Secure Router
Installation Guide (part number D301766X012). For further
information, contact your Local Business Partner or the individual
vendor’s website.
Revised Aug-2015 Introduction 1-7
This page is intentionally left blank
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
I/O Expansion Rack, considerations for installation, wiring instructions
for the PSSM module, and instructions for setting switches and jumpers
on the CPU module. For instructions on I/O installation, see Chapter 3.
In This Chapter
2.1 Site Considerations .......................................................................... 2-1
2.1.1 Class I, Div 2 Installation Considerations ............................. 2-2
2.2 Installation Overview ........................................................................ 2-3
2.2.1 Unpacking Components ....................................................... 2-4
2.2.2 Color Coding of Slot Connectors .......................................... 2-5
2.2.3 Mounting the Housing .......................................................... 2-7
2.2.4 Grounding the Housing ...................................................... 2-11
2.3 Power Supply/Sequencer Module (PSSM) ................................... 2-11
2.3.1 General Information about the PSSM ................................ 2-11
2.3.2 PSSM Installation Overview ............................................... 2-13
2.3.3 Setting Jumpers ................................................................. 2-14
2.3.4 General Wiring Guidelines ................................................. 2-16
2.3.5 Wiring a Bulk DC Power Supply to the PSSM ................... 2-17
2.3.6 Hot-swapping a Power Supply ........................................... 2-20
2.3.7 Wiring an External Alarm or Annunciator to the Watchdog
2.3.8 Wiring Digital Inputs to indicate Power Supply Failure ...... 2-23
2.3.9 PSSM Specifications .......................................................... 2-24
2.4 CPU Module .................................................................................. 2-25
2.4.1 Setting DIP Switches on the CPU Module ......................... 2-26
2.4.2 Connections to RS-232 Serial Port(s) ................................ 2-29
2.4.3 Connections to RS-485 Serial Port on the Secondary
2.4.4 Connections to Ethernet Port(s) on the CPU Module ........ 2-34
2.5 Bezels ............................................................................................ 2-35
ControlWave I/O Expansion Rack Instruction Manual
Connector and Wiring the Redundancy Control Input
(OPTIONAL) ..................................................................... 2-21
Communication Board (SCB) ........................................... 2-32
2.1 Site Considerations
When choosing an installation site, check all clearances. Ensure that the
ControlWave I/O expansion rack is accessible for wiring and service.
To ensure safe use of this product, please review and follow the
Caution
Revised Aug-2015 Installation 2-1
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)
ControlWave I/O Expansion Rack Instruction Manual
Specifications
for Temperature,
Humidity and
Vibration
2.1.1 Class I, Div 2 Installation Considerations
Caution
See document CWPAC available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave I/O Expansion Rack. This document is available
on our website at: http://www.emersonprocess.com/remote.
Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave is not
exposed to a level of vibration that exceeds that provided in the
technical specifications..
Placement of the ControlWave in Class 1, Division 2 (Group A, B, C, and
D) hazardous locations requires that you select an appropriate
enclosure that meets NEMA Type 3X or 4X specifications.
Underwriters Laboratories (UL) lists the ControlWave I/O Expansion
Rack as non-incendive and suitable only for use in Class I, Division 2,
Group A, B, C, and D hazardous locations and non-hazardous locations.
Read this chapter and Appendix A carefully before you install a
ControlWave in a hazardous location.
WARNING
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave I/O Expansion Rack is situated in a hazardous
location, turn off power before servicing or replacing the unit and
before installing or removing I/O wiring.
Do not connect or disconnect equipment unless the power is switched
off or the area is known to be non-hazardous.
2-2 Installation Revised Aug-2015
2.2 Installation Overview
Installing a ControlWave I/O Expansion Rack involves several general
steps, and includes not just the I/O expansion rack(s), but configuration
of its host ControlWave Process Automation Controller to reference the
I/O in the I/O expansion rack.
Unpacking, assembling, and configuring the hardware.
1.
a) Mount the housing (Section 2.2.3).
b) Install the PSSM in chassis slot 1 (Section 2.3.1).
c) Set CPU switches then install the CPU in chassis slot 2 (Section
d) Make communication port connections, including a connection
e) Install I/O modules in chassis slots 3 through 6 (or 3 through 10)
ControlWave I/O Expansion Rack Instruction Manual
2.4.1).
between your PC and the I/O rack (Sections 2.4.2, 2.4.3 and
2.4.4).
and wire the I/O modules to I/O devices (Chapter 3).
f) Install a ground wire between the chassis ground lug and a
known good earth ground (Section 2.2.4).
g) If required, install watchdog switch wiring and redundancy
control wiring (Section 2.3.7).
h) Connect bulk DC power to the PSSM module. (Section 2.3.5)
i) Install the bezel to cover the PSSM and CPU.(Section 2.5)
j) Plug an Ethernet cable from you network to one of the Ethernet
ports.
k) Open the bezel door and turn on the power on the PSSM
module.
l) Check the display; when the power on sequence finishes, it
should be blank.
2. Installing PC-based software (ControlWave Designer and
OpenBSI).
3. Establishing communication by connecting the PC to one of the I/O
rack’s communication ports.
4. Setting flash memory parameters in the I/O expansion rack(s).
5. Creating an application-specific control strategy (ControlWave
project) for the ControlWave host that references the I/O in the I/O
expansion rack.
6. Downloading the application-specific ControlWave project into the
ControlWave host controller.
Revised Aug-2015 Installation 2-3
ControlWave I/O Expansion Rack Instruction Manual
A
Note: Steps 2 through 6 require that you install and use ControlWave
Designer and OpenBSI software on your PC. This manual
focuses on hardware installation and preparation. Software
installation and configuration is beyond the scope of this
manual. Refer to the ControlWave I/O Expansion Rack Quick
Setup Guide (D5122) for material related to software
configuration.
ControlWave Process
utomation Controller
(HOST)
Ethernet cabling
ControlWave
Expansion I/O Rack
ControlWave
Expansion I/O Rack
Figure 2-1. ControlWave Process Automation Controller (PAC) with Two I/O Expansion Racks
2.2.1 Unpacking Components
Packaging
Depending upon how you order it, the ControlWave I/O Expansion
Rack may arrive pre-assembled, with all modules installed in the
housing, or as individual components in a number of separate boxes. In
the latter case, you must identify, unpack, and assemble the
components. Unless otherwise noted, you can place I/O modules in any
slot in a base or expansion housing.
Note: Do not install modules in the housing until you have mounted
and grounded the housing at the designated installation site.
Delivered boxes may include:
Housing assemblies
Power Supply/Sequencer module (PSSM)
Note: The PSSM must reside in slot #1 in the base housing.
CPU module
Note: The CPU module must reside in slot #2 in the base housing.
I/O Modules
2-4 Installation Revised Aug-2015
ControlWave I/O Expansion Rack Instruction Manual
Notes:
There are many different types of I/O modules available. Chapter
3 contains detailed instructions on each I/O module.
Universal Digital Input (UDI) modules can only reside in the first
four I/O slots. One or more bezel assemblies; each bezel covers
two I/O modules.
2.2.2 Color Coding of Slot Connectors
A color tab on each backplane connector matches the color on the
module which you can place in that slot.
PSSM goes in the first slot (Yellow tab)
CPU goes in the second slot (Blue tab)
I/O modules go in any other slot (Green tab)
Figure 2-2. Color Coded Board Connectors
Revised Aug-2015 Installation 2-5
ControlWave I/O Expansion Rack Instruction Manual
Figure 2-3. PSSM Installed in ControlWaveEXP Slot #1
Figure 2-4. PSSM & CPU (with SCB) Installed in Slot #1 & #2 (Respectively)
2-6 Installation Revised Aug-2015
ControlWave I/O Expansion Rack Instruction Manual
2.2.3 Mounting the Housing
ControlWave I/O expansion rack modules reside in a stainless steel
housing. No enclosure is provided.
You can install a ControlWave equipped with a 4-I/O module housing
on a wall or panel. See Figure 2-6 for mounting hole patterns for a 4-
I/O unit.
You can install a ControlWave I/O expansion rack equipped with an 8I/O module housing in a 19-inch equipment rack, a panel or a wall.
These units ship from the factory with the end plates configured for 19inch rack mounting. Remove the end plates, rotate them 180° and then
reinstall them to accommodate panel or wall mounting. See Figure 2-5
for hole patterns and dimensions.
When you install any of these units on a panel or wall, position it
according to the following restrictions:
Position the unit so that you can see the front of the assembly and so
it is accessible for service such as installing a module or replacing a
battery.
Do not install ControlWave modules until you mount the chassis
and ground it properly.
Revised Aug-2015 Installation 2-7
ControlWave I/O Expansion Rack Instruction Manual
Figure 2-5. 8-I/O Module ControlWave I/O Rack - Mounting Diagram
(dimensions in inches)
2-8 Installation Revised Aug-2015
ControlWave I/O Expansion Rack Instruction Manual
Figure 2-6. 4-I/O Module ControlWave - Mounting Diagram (dimensions in inches)
Revised Aug-2015 Installation 2-9
ControlWave I/O Expansion Rack Instruction Manual
Figure 2-7. 4-I/O Module ControlWave - Mounting Diagram
2-10 Installation Revised Aug-2015
ControlWave I/O Expansion Rack Instruction Manual
2.2.4 Grounding the Housing
Caution
Do not install any modules in the housing until you mount and ground
the housing at the designated installation site.
Housings have a ground lug that accommodates up to a #4 AWG wire
size. Once you install the housing, you must run a ground wire between
the housing ground lug and a known good earth ground.
When you install the various ControlWave modules into the housing
and secure them using the captured panel fasteners, this automatically
connects them to chassis ground.
Note: After you install the PSSM in the housing, as an added
precaution we recommend that you run a #14 AWG wire from
the TB2-3 power connection (chassis ground) to the same known
good earth ground.
Additional grounding guidelines include:
Use stranded copper wire (#4 AWG) for the housing to earth
ground, and keep the length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Tin the wire ends with solder (using a high-wattage soldering iron)
prior to inserting the wire into the housing ground lug.
Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.
2.3 Power Supply/Sequencer Module (PSSM)
Before we actually install the PSSM it in the housing, we’re going to
discuss some general information about how it works.
2.3.1 General Information about the PSSM
The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.
The PSSM is used in the following ControlWave models:
ControlWave Process Automation Controller
ControlWave I/O Expansion Rack
ControlWave Redundant Controller
The PSSM plugs into slot #1 (first slot from the left) on the
ControlWave’s backplane using connector J1.
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ControlWave I/O Expansion Rack Instruction Manual
The PSSM provides your ControlWave with dual power supplies for
operational redundancy.
Note: You can optionally purchase the PSSM with only a single power
supply installed, however, this configuration does not allow for
redundancy within the PSSM which is discussed throughout this
section.
The PSSM includes two independent power supplies. Should either
power supply fail, operations automatically continue using the second
supply, and you can “hot-swap” the failed power supply with a spare
unit without interrupting control operations. The PSSM also supports
hot swapping of I/O modules. However, you cannot replace the entire
PSSM itself without first turning off power to the ControlWave.
When used as part of a redundant system, the failure of one of the two
power supplies in a redundant power supply sequencer module would
not force a failover to the other controller. Only the loss of both power
supplies on the redundant power supply sequencer module would
trigger a failover.
Power
Supply
WARNING
Hot Swap of I/O
Modules
Hot Swapping of
Power Supplies
Watchdog
Switch
The PSSM ships from the factory configured for a nominal input supply
of 24Vdc.
Do not perform “hot swapping” in a Class I, Division 2 hazardous
location.
The PSSM supports “hot swapping” of I/O modules. This means you
can insert or remove an I/O module from the chassis while power is
live.
There is no support for “hot swapping” of the entire PSSM itself, or the
CPU module, however, if you have the dual power supply version, you
can hot swap a power supply on the PSSM. For information on hot
swapping of power supplies see Section 2.3.6.
PSSMs include a watchdog metal oxide semiconductor field-effect
transistor (MOSFET) switch connector. The purpose of the watchdog
connector is to trigger an external alarm or annunciator if the
ControlWave enters a “watchdog” condition in which the CPU cannot
control your process. This occurs on power-up before the ControlWave
project starts, if the unit is reset, if the ControlWave project “crashes”
or if the system loses power. See Section 2.3.7.
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ControlWave I/O Expansion Rack Instruction Manual
Redundancy
Control Input
The same terminal block (TB3) used for watchdog control also handles
a redundancy control line to a ControlWave Redundant I/O Switcher. If
this ControlWave I/O expansion rack is part of a redundant pair, and
the ControlWave Redundancy Switcher detects a watchdog failure in
the other ControlWave I/O rack, the redundancy control input sends
signals to this ControlWave I/O rack that it must take control. For more
information on how this works, see the ControlWave Redundancy
Setup Guide (D5123) and the ControlWave Redundant I/O and Control
Switch Unit Manual (CI-ControlWave REDI/O).
2.3.2 PSSM Installation Overview
There are several steps you need to follow when you install the PSSM.
1. Identify the carton holding the PSSM and remove it from that carton.
See Section 2.2.1.
2. If needed, set jumpers. See Section 2.3.3.
3. Slide the PSSM into slot #1 of the housing.
Slot 1
TB2
Power Supply
Module 1
Pin 7
TB3
Pin 1
Power Supply
Module 2
TB1
Figure 2-8. PSSM Installed in ControlWave Slot #1 of a ControlWave Controller
4. Tighten the captive panel fasteners to secure the PSSM in place.
5. Unplug terminal block connectors TB1 and TB2 from the PSSM and
wire them to an external bulk DC power supply. See Section 2.3.5.
6. If you want to use the watchdog connector TB3, or use this
ControlWave in a redundant system, unplug TB3 from the PSSM and
wire it to an external annunciator or similar device according to
instructions in Section 2.3.7.
7. After you configure and install the CPU module in slot #2 re-connect
terminal blocks to their connectors to apply power to the unit.
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ControlWave I/O Expansion Rack Instruction Manual
2.3.3 Setting Jumpers
Depending upon how you are using the PSSM, you may have to change
one or more jumpers from their factor default positions. See Table 2-1
for a list of the jumpers and their functions; see Figure 2-10 for jumper
locations.
Table 2-1. PSSM Jumpers
Jumper Position Description
JP1 1-2
2-3 Disables the watchdog circuitry.
JP2 1-2 Sets the PSSM as always the on-line unit.
2-3 Specifies that the PSSM is part of a redundant system.
JP3 1-2 Enables the 12V monitor.
2-3 Disables the 12V monitor.
Enables the watchdog circuitry. This is the default. Watchdog wiring is discussed
later in this document.
This is the default. Use this setting if the PSSM is not installed in a redundant
system.
Choose this position if the PSSM is installed:
In a ControlWave Redundant Controller or
In a ControlWave Controller that is part of a redundant pair or
In a ControlWave I/O Expansion Rack that is part of a redundant pair.
This is the default. When enabled, the PSSM reports a failure when voltage falls
below 12V and lights the PWR Down LED to indicate the failure.
When disabled, the PSSM does not report a failure if voltage falls below 12V.
If you need to change the jumper positions, unscrew the protective case
from the PSSM using a Phillips screwdriver (see Figure 2-9).
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ControlWave I/O Expansion Rack Instruction Manual
screws
Figure 2-9.Removing the Protective Case from the PSSM
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ControlWave I/O Expansion Rack Instruction Manual
Figure 2-10. Jumper Locations
Make the necessary adjustments to the jumpers according to Table 2-1.
When finished, re-attach the case by first aligning the protective case
with the screw holes, then inserting and tightening each screw.
2.3.4 General Wiring Guidelines
ControlWave PSSMs use compression-type terminals that
accommodate up to #14 AWG wire.
When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the wire.
To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.
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ControlWave I/O Expansion Rack Instruction Manual
2.3.5 Wiring a Bulk DC Power Supply to the PSSM
Caution
Operating
Range
One or Two
Power
Supplies
At this time you can also connect power and watchdog wiring. However;
for safety reasons and to prevent accidental damage to the your bulk DC
power supply, do not connect the pluggable terminal block connectors
TB1 and TB2 (or TB3) to the PSSM until after you install, wire, and
configure the CPU module.
Follow the instructions in Section 2.3.4 when wiring connections.
The ControlWave operates from +22.2 Vdc to +30.0 Vdc (with a
nominal +24Vdc input source).
You can connect one or two bulk DC power supplies (nominally +24
Vdc) to the PSSM. Use terminal blocks TB1 and TB2 to connect an
external bulk power supply to the PSSM.
The external bulk 24V DC power supply you connect to TB1-1 (+VIN)
provides system power to the ControlWave including the CPU boards,
communications and I/O boards (see Figure 2-11). The PSSM converts,
regulates, and filters the power to +5Vdc, +3.3Vdc, +12Vdc (optional)
and -12Vdc (optional).
+3.3 Vdc. For safety, this circuit has a 3A fuse.
The bulk DC supply you connect to terminal TB2-1 (+VINF) powers
the I/O field devices connected to the I/O modules. For safety, this
circuit has a 10A fuse.
Notes:
When you require two bulk power supplies, the first supply (VIN)
must be rated to handle 2 amps.
Be sure you route wires to the terminal block connectors so they do
not interfere with removal/replacement of the power supply
modules.
The fuses for the PSSM cannot be replaced in the field.
Figure 2-11. Wiring System Power to the PSSM
An external power supply (22.2 to 30V) connected to TB2 provides
field power to I/O boards, and any field devices (switches, relays, etc.)
powered through the I/O boards (see Figure 2-12).
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ControlWave I/O Expansion Rack Instruction Manual
Figure 2-12. Wiring Field Power to the PSSM
Calculating the
Maximum Current
Required
Max Bulk +24 Vdc Supply Current = CPU
where
CPU
Σ I/O Module
Use the following formula to determine the maximum current required
for the +24 Vdc bulk power used with a particular ControlWave I/O
Expansion Rack:
max_current
+ Σ I/O Module
max_current
:
max_current
max_current
refers to the maximum current required by the CPU (with or
without an SCB), backplane and the PSSM. This is 1A.
refers to the sum of the maximum current required by each
and every I/O module installed in the unit. The amount per
I/O module varies as follows:
16 AI Module 2A per module
8 AI Module 1A per module
8 AO Module 1A per module
16 DI Module 1A per module
32 DI Module 1A per module
16 DO Module See table (no surge current)
32 DO Module See table (no surge current)
6 UDI Module See table (no surge current)
4 RTD Module See table (no surge current)
6 LLAI Module See table (no surge current)
So, for example, if you have a ControlWave I/O rack with a 16AI
module, an 8AO module, and a 32DI module, the maximum current
draw is 1A for the CPU plus 2A for the 16AI module plus 1A for the
8AO module and 1A for the 32DI module, for a total of 5A.
Note: This calculation covers current draw during normal operation
(steady state) as well as the current draw during power-up inrush when the unit is first powered on. Power up in-rush current
can last up to 100 milliseconds and is higher than the current
draw required during normal operation.
Refer to Table 2-2 for ControlWave steady state and loop current
requirements for bulk power supplies.
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