Fisher Manuals & Guides: ControlWave Redundant Controller Manuals & Guides

Instruction Manual

CI-ControlWaveRED
Oct., 2006

ControlWave RED

ControlWave Redundant Controller

www.EmersonProcess.com/Bristol

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this device in some applications may result in
damage or injury. The user is urged to keep this book filed in a convenient location for
future reference.

These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or main­tenance. Should problems arise that are not covered sufficiently in the text, the pur­chaser is advised to contact Bristol for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for
whatever reason, may leave an operating process without protection. Depending upon
the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment
or provide alternate means of protection such as alarm devices, output limiting, fail­safe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional
in-formation is required, the purchaser is advised to contact Bristol .

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol for repairs or evaluation, please note
the following: The party sending such materials is responsible to ensure that the
materials returned to Bristol are clean to safe levels, as such levels are defined and/or
determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Bristol and save Bristol harmless from any liability or
damage which Bristol may incur or suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic in­struments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by
exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude
and duration of the ESD, this can result in erratic operation or complete failure of the
equipment. Read supplemental document S14006 at the back of this manual for
proper care and handling of ESD-sensitive components.

Bristol 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

A. Bristol warrants that goods described herein and manufactured by Bristol are free

from defects in material and workmanship for one year from the date of shipment
unless otherwise agreed to by Bristol in writing.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from

defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited

to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part

thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written

or oral warranties beyond those set forth herein.

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or

replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Water­town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incidental or consequential

damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.

REMEDIES

How to return material for Repair or Exchange

Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify
proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very
important since the information permits the Bristol Repair Dept. to effectively and
efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX
Completing the form (GBU 13.01) and faxing it to [phone]. A Bristol Repair

Dept. representative will return call (or other requested method) with a RA number.

B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)

and sending it via E-Mail to [e-mail]
representative will return E-Mail (or other requested method) with a RA number.

C. Mail
Mail the form (GBU 13.01) to

Bristol Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

A Bristol Repair Dept. representative will return call (or other requested method)

with a RA number.

D. Phone

Calling the Bristol Repair Department at [phone]. A Bristol Repair Depart-

ment representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in­cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.

. A Bristol Repair Dept.

Bristol Inc. Repair Authorization Form (off-line completion)

(Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required

to receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________
Standard Repair Practice is as follows: Variations to this is

practice may be requested in the “Special Requests” section.

• Evaluate / Test / Verify Discrepancy

• Repair / Replace / etc. in accordance with this form

• Return to Customer

Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)
Bill to : Ship to:

Purchase Order: Contact Name:____________________________________
Phone: Fax: E-Mail:

Part II Please complete Parts II & III for each unit returned

Model No./Part No. Description

Please be aware of the Non warranty standard charge:

• There is a $100 minimum evaluation charge, which is

applied to the repair if applicable (√ in “returned”
B,C, or D of part III below)

Range/Calibration S/N
Reason for return

: Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,

Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________

3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due

to Bristol’s warranty clause, would you like the product:

repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,
would you like the product:

C. If product is deemed not repairable would you like your product:
D. If Bristol is unable to verify the discrepancy, would you like the product:

repaired returned replaced scrapped?

returned replaced scrapped?
returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact

that has the most knowledge of the problem is: ______________________________ phone_____________________

If we are unable to contact this person the backup person is: _________________________
Special Requests: ____________________________________________________________________________________

phone_____________________

____________________________________________________________________________________________________

Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795

Phone: [phone] Fax: [phone] Form GBU 13.01 Rev. B 04/11/06

Bristol

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

• Avoid Delays and problems in getting your system on-line

• Minimize installation, start-up and maintenance costs.

• Make the most effective use of our hardware and software.

• Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at three locations: Houston, Orlando and our Watertown, CT
headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol products and realize the full
potential of your system.

For information or to enroll in any class, contact our training department in Watertown at
[phone]. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

A Few Words About Bristol Inc.

For over 100 years, Bristol® has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Inc. instruments, controllers, and systems running year-in and
year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis­tance in using this product from the following sources:

Help Files / Release Notes

Many Bristol software products incorporate help screens. In addition, the software typically
includes a ‘read me’ release notes file detailing new features in the product, as well as other
information which was available too late for inclusion in the manual.

Contacting Bristol Inc. Directly

Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.

Our main phone numbers are:

[phone]
[phone] (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.

For technical questions about TeleFlow products call [phone].

For technical questions about ControlWave call [phone] or [phone].

For technical questions regarding Bristol’s OpenEnterprise product, call [phone]
or e-mail: [e-mail]

For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call [phone].

For technical questions about Network 3000 hardware, call [phone].

You can e-mail the Application Support Group at: [e-mail]

The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at [phone] or [phone].

You can e-mail the Communication Technology Group at:

[e-mail]

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed on the rear cover of
this manual) or to your Bristol-authorized sales representative.

Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office
covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol’s Training Department offers a wide variety of courses in Bristol hardware and
software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at [phone] for course
information, enrollment, pricing, and scheduling.

CI-ControlWaveRED

ControlWave

Redundant Controller

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL DESCRIPTION ........................................................................................... 1-1

1.2 ControlWaveRED PROGRAMMING ENVIRONMENT............................................ 1-2

1.3 PHYSICAL DESCRIPTION........................................................................................... 1-4

1.3.1 CPU Modules .................................................................................................................1-4

1.3.1.1 CPU Module Connectors ............................................................................................... 1-7

1.3.1.2 CPU Module Switches ....................................................................................................1-8

1.3.1.3 CPU Module System Battery......................................................................................... 1-9

1.3.1.4 CPU Module LEDs and Port 80 Display .................................................................... 1-10

1.3.1.5 CPU Module Memory Summary.................................................................................. 1-10

1.3.2 Power Supply/Sequencer Module................................................................................. 1-11

1.3.2.1 PSSM Power Switch SW1 ............................................................................................ 1-13

1.3.2.2 PSSB Board Fuse.......................................................................................................... 1-13

1.3.2.3 PSSB Board Connectors ............................................................................................... 1-13

1.3.2.4 PSSM LEDs .................................................................................................................. 1-14

1.3.3 ControlWaveRED CPU & Comm. Redundancy Switch Module.............................. 1-14

1.3.3.1 CCRS Module Switches................................................................................................ 1-16

1.3.3.2 User Accessible CCRS Module Connectors ................................................................. 1-17

1.3.3.3 CCRS Module Status LEDs .........................................................................................1-17

1.3.4 ControlWaveRED Backplane ....................................................................................1-17

1.3.5 ControlWaveRED Chassis......................................................................................... 1-19

Section 2 - INSTALLATION & OPERATION

2.1 INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1

2.2 ControlWaveRED INSTALLATION SITE CONSIDERATIONS.............................. 2-2

2.2.1 Temperature & Humidity Limits .................................................................................. 2-2

2.2.2 Vibration Limits ............................................................................................................. 2-2

2.3 ControlWaveRED INSTALLATION/CONFIGURATION .........................................2-3

2.3.1 Mounting the ControlWaveRED Chassis ...................................................................2-6

2.3.1.1 ControlWaveRED Grounding ...................................................................................... 2-7

2.3.2 Power Supply/Sequencer Module (PSSM) Configuration............................................. 2-7

2.3.3 CPU Module Configuration............................................................................................ 2-8

2.3.3.1 CPU Module Switch Configuration ...............................................................................2-9

2.3.3.2 Communication Ports................................................................................................... 2-11

2.3.3.3 RS-232 & RS-485 Interfaces ........................................................................................2-12

2.3.3.4 Ethernet Ports .............................................................................................................. 2-17

2.3.4 Wire Connections.......................................................................................................... 2-18

2.3.4.1 Power Supply Wiring.................................................................................................... 2-19

2.3.4.1.1 Bulk Power Supply Current Requirements ................................................................2-19

2.3.4.1.2 Power Wiring ................................................................................................................ 2-20

2.3.4.1.3 Watchdog MOSFET Switch Wiring............................................................................. 2-21

2.3.4.2 CCRS Module Isolated On-Line Status Output Wiring ............................................. 2-21

2.3.5 Installation of the Lithium Backup Battery ............................................................... 2-22

CI-ControlWaveRED Contents / 0 - 1

CI-ControlWaveRED

ControlWave

Redundant Controller

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 2 - INSTALLATION (Continued)

2.3.6 Installation of the Bezel Assembly ..............................................................................2-23

2.4 OPERATIONAL DETAILS .......................................................................................... 2-24

2.4.1 Downloading the Redundant Project ........................................................................... 2-25

2.4.2 Upgrading ControlWave Firmware ........................................................................... 2-25

2.4.2.1 Using LocalView to Upgrade ControlWave Firmware .............................................2-26

2.4.2.2 Using Hyperterminal to Upgrade ControlWave Firmware...................................... 2-30

2.4.2.3 Remote Upgrade of ControlWave Firmware ............................................................. 2-34

2.4.3 Operation of the RUN/REMOTE/LOCAL Switch ....................................................... 2-34

2.4.4 Operation of the Reset Switch ..................................................................................... 2-35

2.4.5 Operation of the CCRSM A/B Primary Controller Select Switch ..............................2-35

2.4.6 Operation of the CCRSM A/B Enable Key Switch...................................................... 2-35

2.4.7 Soft Switch Configuration and Communication Ports ...............................................2-35

Section 3 - SERVICE

3.1 SERVICE INTRODUCTION ........................................................................................ 3-1

3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1

3.2.1 Accessing Modules For Testing...................................................................................... 3-1

3.2.2 Removal/Replacement of a Bezel Assembly .................................................................. 3-2

3.2.3 Removal/Replacement of a CPU Module (CPUM) ........................................................ 3-2

3.2.4 Replacing a Failed CPU while the other CPU Remains On-line ................................. 3-2

3.2.5 Removal/Replacement of a Power Supply/Sequencer Module (PSSM)........................ 3-7

3.2.6 Removal/Replacement of a CCRS Module (CCRSM).................................................... 3-7

3.3 TROUBLESHOOTING TIPS......................................................................................... 3-8

3.3.1 Power Supply/Sequencer Module (PSSM) Voltage Checks .......................................... 3-8

3.3.2 LED Checks .................................................................................................................... 3-9

3.3.3 Wiring/Signal Checks ................................................................................................... 3-10

3.4 GENERAL SERVICE NOTES..................................................................................... 3-11

3.4.1 Extent of Field Repairs................................................................................................. 3-11

3.4.2 Disconnecting RAM Battery ........................................................................................ 3-11

3.4.3 Maintaining Backup Files............................................................................................ 3-12

3.4.4 Port 80 Display POST Checks ..................................................................................... 3-12

3.5 WINDIAG DIAGNOSTICS .......................................................................................... 3-15

3.5.1 Diagnostics Using WINDIAG ...................................................................................... 3-17

3.5.1.1 Communications Diagnostic Port Loop-back Test...................................................... 3-18

3.5.1.2 COM 1, 2, 3, 4 Eternal Loop-back Test Procedure...................................................... 3-19

3.5.1.3 Ethernet Diagnostic Port Loop-back Test ................................................................... 3-20

3.5.1.4 Ethernet Port 1, 2 & 3 External Loop-back Test Procedure ...................................... 3-21

3.6 CORE UPDUMP........................................................................................................... 3-22

3.7 TROUBLESHOOTING REDUNDANCY PROBLEMS.............................................. 3-23

3.8 ControlWaveRED FUNCTIONALTESTS................................................................... 3-24

3.8.1 Basic Reset and Supervisory Power-Up Tests ............................................................ 3-25

3.8.2 Redundant Power Source & Supervisory Power-Up Tests ........................................ 3-25

3.8.3 Watchdog Mechanism Power-Up Tests ....................................................................... 3-25

0 - 2 / Contents CI-ControlWaveRED

CI-ControlWaveRED

ControlWave

Redundant Controller

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 3 - SERVICE (Continued)

3.8.4 Primary CPU Selection on Power-Up Tests................................................................ 3-26

3.8.5 Tests of Switchover from “Dead” Primary Selected Unit on Power-Up ....................3-26

3.8.6 Forced Primary CPU Selection on Power-Up Tests ................................................... 3-27

3.8.7 Normal Power-Up & Switchover Tests........................................................................ 3-28

3.8.8 Normal Power-Up & Forced Switchover Tests ...........................................................3-29

3.8.9 On-Line Relay Functional Tests .................................................................................. 3-30

3.8.10 CCRS Assembly Communication Ports Functional Tests.......................................... 3-31

3.8.10.1 Configuration for Port Tests............................................................................................... 3-31

3.8.10.2 Communication Port Switching Tests ............................................................................... 3-31

Section 4 - SPECIFICATIONS

4.1 CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1

4.1.1 CPU Module Communication Ports............................................................................... 4-3

4.2 POWER SUPPLY/SEQUENCER MODULE ............................................................... 4-4

4.2.1 Input/Output Power Specs. ............................................................................................ 4-4

4.2.2 Power Supply Sequencer Specs. .................................................................................... 4-5

4.2.3 Power Supply Connectors............................................................................................... 4-5

4.3 BACKPLANE PCB ......................................................................................................... 4-6

4.4 CCRS MODULE SPECIFICATIONS............................................................................ 4-7

4.4.1 CCRS Module Communication Ports .......................................................................... 4-10

4.5 ENVIRONMENTAL SPECIFICATIONS.................................................................... 4-10

4.6 DIMENSIONS ..............................................................................................................4-11

Special Instructions for Class I, Division 2 Hazardous Locations .................Appendix A

REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS

WINDIAG - Windows Diagnostics for Bristol Controllers ...................................D4041A

Open BSI Utilities Manual ...................................................................................... D5081

ControlWave Quick Setup Guide............................................................................. D5084

Getting Started with ControlWave Designer.......................................................... D5085

Web_BSI Manual...................................................................................................... D5087

ControlWave Designer Reference Manual .............................................................. D5088

ControlWave Redundancy Setup Guide .................................................................. D5123

ControlWave Designer Programmer’s Handbook................................................... D5125

APPENDICES/SUPPLEMENTAL INSTRUCTION

MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z

Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW

Care and Handling of PC Boards and ESD-Sensitive Components .....................S14006

CI-ControlWaveRED Contents / 0 - 3

BLANK PAGE

Section 1

INTRODUCTION

1.1 GENERAL DESCRIPTION

ControlWave™ Redundant Controllers (ControlWaveRED) employ a modular hardware

architecture with a modern and rugged industrial design that in keeping with the rest of
the line of ControlWave Industrial Process Automation Controllers is both simple to
install and configure. ControlWave™ Redundant Controllers utilize dual CPUs that
communicate with the same physical remote I/O. One CPU is on line, while the other
functions as a "hot" backup. A CPU & Communications Redundancy Switch (CCRS) Module
included in the system provides arbitration between the two processors. Should the CCRS
Module detect a failure in the on-line unit, it will switch to the backup unit without
interrupting control and communication functions. Each ControlWaveRED CPU Module
utilizes an AMD Elan SC520 microprocessor running at 100 MHz and is powered by its own
Power Supply/Sequencer Module. Two Bezel Assembles are provided (one for each CPU &
PSSM pair).

Figure 1-1 - ControlWaveRED Assembly

At the heart of the system is the ControlWaveRED CPU & Communications Redundancy
Switch Module that provides for automatic or manual switching of the CPU Module that is

CI-ControlWaveRED Introduction / 1-1

communicating with the Remote I/O Rack or the I/O Expansion Rack being controlled. The
ControlWave™ CPU & Communications Redundancy Switch Module (CCRSM) also
provides for controlled switching of the four non-Ethernet communications ports associated
with the selected or ‘On-Line’ CPU Module. Each CPU Module can have two, three or four
RS-232 communication ports. Ports COM3 and COM4 (on the Secondary Communications
Board) can be individually factory configured for either RS-232 or RS-485 operation. Port
connections from the redundant CPU Modules (A & B) are routed to the front of the CPU &
Communications Redundancy Switch Module by means of two cable headers and custom
cabling.

ControlWave™ Redundant Controllers provide the following key features:

• Low power consumption

• Small size (supports panel-mount or 19-inch rack-mount installations)

• ControlWaveRED CPU Architecture compatible with IBM Personal Computers

with a system BIOS.

- BIOS FLASH - 512 Kbytes contained in a single IC

- FLASH Memory - 4 Mbytes to 64 Mbytes mounted in up to 4 48-pin TSOPs

- Memory (SRAM) - 2 Mbytes of soldered-down static RAM (SRAM) is implemented

with four 512K x 8 asynchronous SRAMs that are configured as a 1M x 16-bit
array. Each SRAM device operates at 3.3V and is packaged in a 32-pin TSOP. An
additional 2Mbytes of SRAM may be factory installed.

- SDRAM - 4Mbytes of on board Synchronous Dynamic RAM (SDRAM) (2 x

KM416S1120DT).

- Three 10/100Base-T Ethernet ports implemented via AMD Am79C973 Pcnet

FAST III Controllers. The built-in transceiver provides a full-duplex im­plementation with a RJ-45 10/100Base-T Connector (J4).

• ControlWaveRED CPU & Communications Redundancy Switch Module (CCRSM)
provides for automatic switching of the CPU Module and its four associated
communications ports whenever a defective CPU Module or associated PSSM is
detected.

• LED annunciation of the On-Line CPU and Power Supply/Sequencer Modules.

• A pluggable Terminal Block on the front of the CPU & Communications Redun-

dancy Switch Module provides dual pairs of isolated relay contacts that indicate the
on-line status of the ‘A’ and ‘B’ redundant controllers.

1.2 ControlWaveRED PROGRAMMING ENVIRONMENT

The ControlWaveRED programming environment uses industry-standard tools and
protocols to provide a flexible, adaptable approach for various process control applications
in the water treatment, wastewater treatment, and industrial automation business.

The ControlWaveRED programming environment consists of a set of integrated software
tools which allow a user to create, test, implement, and download complex control strategies
for use with Bristol Babcock’s ControlWave and ControlWaveRED Control-lers.

The tools that make up the programming environment are:

• ControlWave Designer load building package offers several different methods for

generating and debugging control strategy programs including function blocks, ladder
logic, structured languages, etc. The resulting process control load programs are fully
compatible with IEC 61131-3 standards. Various communication methods as offered,

1-2 / Introduction CI-ControlWaveRED

including TCP/IP, serial links, as well as communication to Bristol Babcock’s Open BSI
software and networks

.

Figure 1-2 - ControlWave - Control Strategy Software Diagram

• The I/O Configuration Wizard, accessible via a menu item in ControlWave Designer,

allows you to define process I/O modules in the ControlWave and configure the
individual mapping of I/O points for digital and analog inputs and outputs.

• The Bristol Firmware Library (Bbifsb) which is imported into ControlWave

Designer, includes a series of Bristol Babcock specific function blocks. These pre­programmed function blocks accomplish various tasks common to most user
applications including alarming, historical data storage, as well as process control
algorithms such as PID control.

• The Bristol I/O Simulator allows the load program generated through ControlWave

Designer to be tested on a PC, with simulated analog and digital inputs and outputs.

CI-ControlWaveRED Introduction / 1-3

The I/O Simulator utilizes the identical IEC 61131 real time system used in the
ControlWaveRED controller; this allows initial I/O testing and debugging to be
performed in a safe, isolated environment, without the need for a running

ControlWaveRED controller and process I/O boards.

• The OPC Server (Object Linking and Embedding (OLE) for Process Control) allows

real-time data access to any OPC compliant third-party software packages.

• A series of Configuration Controls are available for setting up various aspects of the

system such as historical data storage, system security, and soft switches. Additional
Data Access Controls are also available for retrieval of real-time data values and
communication statistics. The configuration controls and the data access controls utilize
ActiveX technology and are called through a set of fixed Web pages, compatible with
Microsoft® Internet Explorer. Alternatively, developers can place the controls in third­party ActiveX compatible containers such as Visual BASIC or Microsoft® Excel.

• User-defined Web Pages - If desired, user-defined web pages can be stored within a

PC to provide a customized human-machine interface (HMI).

1.3 PHYSICAL DESCRIPTION

ControlWave Redundant Controllers are comprised of the following major components:

• Two CPU Modules (see Section 1.3.1) & System Batteries (see Section 1.3.1.3)

• Two Power Supply/Sequencer Modules (PSSM) (see Section 1.3.2)

• CPU & Communications Redundancy Switch Module (CCRSM) (see Section 1.3.3)

• Backplane Assembly (1.3.4)

• Chassis Assembly (see Section 1.3.5)

1.3.1 CPU Modules

Each CPU Module houses a CPU Board and optionally, a Secondary Communications
Board (SCB). The CPU Board is a multilayer board that provides ControlWaveRED CPU,
I/O monitor/control, memory and communication functions. This board operates over an
extended temperature range with long-term product reliability.

ControlWaveRED CPU Boards are based on AMD’s Elan SC520 Microcontrollers. The
CPU operates at 2.5V with a system clock speed of 100 MHz. The Microcontroller is
packaged in a 388-pin Plastic Ball Grid Array. The base version of the CPU Board includes
two RS-232 communication ports, an Ethernet RJ-45 communication port, 2 Mbytes of
Static RAM (SRAM), 4 Mbytes of Synchronous Dynamic RAM (SDRAM), 512 kbytes of
BIOS in FLASH, 4 Mbytes simultaneous read/write FLASH (soldered down). Basic CPU
components and features are summarized as follows:

• 2.5V Core 3.3V I/O 66/100MHz AMD Elan SC520 Processor featuring:

Floating Point unit
16-KB write-back cache
Integrated PCI host bridge controller
DRAM controller (up to 256MB supported)
Standard PC/AT-compatible peripherals
Three general purpose timers
Watchdog timer
Software timer

1-4 / Introduction CI-ControlWaveRED

Synchronous serial interface
Flexible address decoding
Programmable I/O pins

• 512KB FLASH BIOS IC, 29LV040B, 90 nanosecond, 8-bit access

• 2MB SRAM, 3.3V, 512K x 8, soldered-down (factory upgradeable to 4Mbyte)

• 4MB simultaneous read/write FLASH, TSOP sites (factory upgradeable to 64Mbyte)

• Two 9 wire PC/AT compatible (RS-232) serial communications ports

• I/O Bus Interface capable of driving up to 8 slots

• 10/100Base-T Ethernet interface implemented by an AMD Pcnet Fast III Controller

• Port 80 diagnostic LED Display

• PC/104-Plus Expansion Connector

• 4Mbyte on board SDRAM - 2 x KM416S1120DT

• 3 position key-lock switch

• 3.6V, 950mA-hr Lithium ½ AA cell battery provides backup for the real-time clock,

CMOS RAM & System SRAM

Figure 1-3 - Block Diagram of ControlWave™ CPU Board

Figure 1-3 provides the CPU Module block diagram. The shaded components of Figure 1-3
are features that are only available on Secondary Comm. Boards.

CI-ControlWaveRED Introduction / 1-5

Figure 1-4 - ControlWaveRED CPU Module

Three basic versions of the dual CPU Modules are available (Note: All CPU boards have 2
RS-232 Ports and 1 Ethernet Port):

1-6 / Introduction CI-ControlWaveRED

CPU Bd. & SCB (SCB contains 2 RS-232 & 2 Ethernet Ports)
CPU Bd. & SCB (SCB contains 1 RS-232 (COM4), 1 RS-485 (COM3) & 2 Ethernet Ports)
CPU Bd. & SCB (SCB contains 2 RS-485 & 2 Ethernet Ports)

The BIOS is contained in a single 512 Kbyte uniform sector FLASH IC. This device resides
on the General Purpose (GP) bus, operates at 3.3V and is configured for 8-bit access.

The CPU Board contains four 48-pin TSOP sites that accept FLASH devices ranging in
density from 2 to 16 Mbytes. Units are factory configured for from 4 to 64 Mbytes of
industrial simultaneous read/write (SMR) FLASH memory. The FLASH memory is a linear
array of 16 Mbit parts configured for 32-bit, 16-bit or 8-bit read access (32-bit write access)
and is connected to the SDRAM bus.

The base version of the CPU Module has 2Mbyte of soldered-down static RAM, im­plemented with four 512K x 8 asynchronous SRAMs that are configured as a 1M x 16-bit
array. SRAM operate at 3.3V and are packaged in 32-pin TSOPs. An additional 2Mbyte of
SRAM may be factory added to raise the board total to 4Mbyte. SRAM is placed into data
retention mode (powered by a backup 3.6V lithium battery) when power is lost. The SRAM
supports 16-bit or 8-bit accesses and is connected to the GP bus.

CPU Modules contain 4Mbyte of SDRAM housed in 2 KM416S1120DTs ICs (U15 & U16).

1.3.1.1 CPU Module Connectors

The CPU Modules contain up to nine (9) user accessible connectors that function as follows
(see Table 1-1):

Table 1-1 - CPU Board Connector Summary

Ref. # Pins Function Notes

J1 132-pin I/OB Connector see Figure 4-1
J2 9-pin COM1 9-pin male D-sub see Figure 4-2 & Table 4-2
J2 8-pin COM3 RJ-45 (RS-232 or RS-485) * see Figure 4-3 & Table 4-3
J3 9-pin COM2 9-pin male D-sub see Figure 4-2 & Table 4-2
J3 9-pin COM4 9-pin male D-sub * see Figure 4-2 & Table 4-2
J4 8-pin Ethernet 10/100Base-T RJ-45 #1 see Figure 4-4 & Table 4-4
J5 8-pin Ethernet 10/100Base-T RJ-45 #2 * see Figure 4-4 & Table 4-4
J7 8-pin Ethernet 10/100Base-T RJ-45 #3 * see Figure 4-4 & Table 4-4
J10 3-pin Battery Connector see Figure 4-5

* = Located on Secondary Comm. Board

CPU Board Comm. Port Connectors J2, J3 and SCB Comm. Port Connector J3

The CPU Module supports up to three external 9-pin RS-232 serial ports (COM1, COM2
and COM4 (with COM4 located on the Secondary Communication Board - a PC/104 Plus
expansion option). COM1, COM2 and COM4 utilize standard 9-pin male D-sub connectors
and are PC/AT compatible ports. COM4 can also be factory configured for Isolated RS-485
operation instead of RS-232.

CPU Module Comm. Port Connector J2 (SCB)

8-pin RJ-45 connector J2 (COM3) is provided on the Secondary Communications Board and
is factory set for use as an Isolated RS-485 port or is factory set for use as a RS-232 port.

CI-ControlWaveRED Introduction / 1-7

This port is referenced as COM3. Note: COM3 will be configured for RS-485 operation
on SCB’s configured with one RS-232 and one RS-485 port.

Ethernet Port Connectors J4, J5 (SCB) and J7 (SCB)

Up to three Ethernet ports are supported via 8-pin RJ-45 connectors. The 10/100Base-T
Ethernet interfaces are implemented using AMD Am79C973 Pcnet - FAST III controllers.
These devices logically reside on the PCI bus and are wired for full bus-mastering
capability and provide a full-duplex implementation. The Ethernet Port associated with J4,
J5 (SCB) and J7 (SCB) are assigned as PCI devices 1, 2 and 3 respectively and are assigned
PCI interrupts A, B and C respectively.

CPU Board I/OB Connector J1

CPU Board I/O bus connector J1 provides a 132-pin interface between Backplane PCB slot
#2 (P2) or #4 (P4) and the CPU Module (CPUA or CPUB respectively).

CPU Board Battery Connector J10

CPU Board connector J10 provides a 3-pin interface to an external 3.6V Lithium Battery
that is a component of the CPU Module. The 3.6V, 950mA-hr lithium ½ AA cell battery
provides backup power for the real-time clock, CMOS RAM and the system’s Static RAM
(SRAM). Battery backup is enabled when CPU Module switch SW3-4 is set to the ON
position.

1.3.1.2 CPU Module Switches

Cutouts are provided in the CPU Module to provide user access to the configuration
switches. Two user configurable DIP switches are provided on the CPU Board; eight-bit DIP
switch SW1 is provided for user configuration settings while four-bit DIP switch SW3
provides battery back-up and forced recovery functions. The optional Secondary
Communications Board (SCB) has two eight position DIP switches (one per communications
port) that provide loopback control for RS-232 ports or loopback, termination control, and
receiver bias settings for isolated RS-485 ports.

The CPU Module’s RUN/REMOTE/LOCAL Switch is set via a removable key. This switch
can be identified by a removable key that allows the user to set the unit as follows: When
set to ‘RUN,’ this switch prevents the user from performing any ControlWave Designer
Debug/Program operations such as Start/Stop, download of application, etc. Use of the
‘LOCAL’ or ‘REMOTE’ setting depends on the type of network connection the Comm. Port
in question has been configured for, via ControlWave Designer (Port selection can be IP,
Serial or OpenBSI). If a Comm. Port has been configured for IP or OpenBSI (BSAP)
communications, it is considered a remote port and the RUN/REMOTE/LOCAL Switch
should be set to ‘REMOTE’ to receive a Debug or Program download. However, if the
Comm. Port in question has been configured for Serial communications, it is considered a
local port and the RUN/REMOTE/LOCAL Switch should be set to ‘LOCAL’ to receive a
Debug/Program download.

The Reset Switch allows the user to reset (stop and restart) the unit during maintenance
routines or as required.

1-8 / Introduction CI-ControlWaveRED

Table 1-2 - Assignment of CPU Bd. Switch SW1 - User Configurations

Switch Function Setting - (ON = Factory Default)

SW1-1

SW1-2

SW1-3

SW1-4

SW1-5 SRAM Control

SW1-6

SW1-7 Unit A/Unit B ON = CPU assigned as ‘A’ CPU - OFF = CPU assigned as ‘B’ CPU

SW1-8

Watchdog
Enable
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
(see Section 3.6)

Redundancy
Enable/Disable

Enable
WINDIAG

ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump via use of Run/Remote/Local Key Switch
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Redundancy Disabled
OFF = Redundancy Enabled

ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)

Table 1-3 - Assignment of CPU Bd. Switch SW3

Firmware Load Control/Recover Mode/Battery Enable

Switch Function Setting

SW3-1 Not Used

SW3-2

SW3-3 Force Recovery Mode

SW3-4 SRAM & RTC Battery Enable

* = Boot PROM version 06 or higher and System PROM version 4.7 or higher

System Firmware
Load Control *

ON = Disable remote download of System Firmware
OFF = Enable remote download of System Firmware
ON = Force recovery mode (via CW Console)
OFF = Recovery mode disabled
ON = Battery back-up enabled
OFF = Battery back-up disabled

Table 1-4 - SCB Port Switches SW1 = COM3 & SW2 = COM4

Loopback & Termination Control

Switch# RS-232 Function

Switch ON

1 DTR to DSR Loopback TX+ to RX+ Loopback ON - Only for Diagnostics
2 TXD to RXD Loopback TX- to RX- Loopback ON - Only for Diagnostics
3 N/A 100 Ohm RX+ Termination ON - End Nodes Only
4 N/A 100 Ohm RX- Termination ON - End Nodes Only
5 RTS to CTS Loopback N/A ON - Only for Diagnostics

6 N/A

7 N/A RX+ Bias (End Node) ON - End Nodes Only
8 N/A RX- Bias (End Node) ON - End Nodes Only

RS-485 Function

Switch ON

Slow Slew Rate - ON = Fast
OFF = Slow

Setting

ON/OFF - As required
Factory Default = ON

1.3.1.3 CPU Module System Battery

The CPU Board connects to an external battery via a three-pin connector (J10). This 3.6V,
950mA-hr lithium ½ AA cell (battery) provides backup for the real-time clock, CMOS RAM
(within the microprocessor), and the System SRAM.

CI-ControlWaveRED Introduction / 1-9

The system SRAM is specified to have a standby current of 50:A maximum for each part.
For a system containing 2MB of System SRAM, a worst-case current draw of 210:A allows
a battery life of approximately 4524 hours, while for a system containing 4MB of System
SRAM a worst-case current draw of 410:A allows a battery life of 2317 hours.

A supervisory circuit is used to switch to battery power when VCC falls below VCC-10%.
For maximum shelf life, the battery may be isolated from the circuit by setting switch SW3­4 (on the CPU Board) to the OFF position. If the Real-time clock looses its battery backup a
ControlWave Designer system variable bit (_QUEST_DATE) is set. This bit can be used to
post a message or alarm to the PC (see the ‘System Variables’ section of the ControlWave
Designer Programmer’s Handbook D5125).

1.3.1.4 CPU Module LEDs and Port 80 Display

All CPU Modules have eight (8) LEDs on the CPU Board. Units equipped with the optional
Secondary Communications Board (SCB) have eight (8) additional LEDs. Additionally, all
CPU Modules are provided with a Port 80 Display assembly consisting of two TI TIL311
Displays that are visible from the front of the CPU Module. The Port 80 LED Display
assembly provides POST codes during system boot as well as run time status indication.
During normal system operation, the Port 80 Display is powered down.

Figure 1-5 - CPU Module LEDs

1.3.1.5 CPU Module Memory Summary

A brief synopsis of CPU Module Memory is provided below.

Boot-Block FLASH BIOS

512 kbytes contained in a single IC. BIOS that runs the CPU Board is contained in this
device. The BIOS is contained in a single 512 kbyte Uniform Sector FLASH (USF) IC. This
device resides on the General Purpose (GP) bus, operates at 3.3V and is configured for 8-bit
access.

1-10 / Introduction CI-ControlWaveRED

Switch SW3-3 provides for forced update/recovery of the BIOS if SW3-3 has been set to the
ON position when a reset occurs. The boot-up code passes control to the built-in Recovery
Command Processor that communicates with the user via the recovery serial connection
and a terminal program running on an external host computer.

FLASH Memory

4 Mbytes to 64 Mbytes simultaneous read/write (non-volatile) FLASH mounted in up to 4
48-pin TSOPs. The System Firmware and the Boot Project are stored here. The FLASH
memory is a linear array of 16 Mbit parts configured for 32-bit, 16-bit or 8-bit read access
(32-bit write access) and is connected to the SDRAM bus. No hardware write protection is
provided for the FLASH array.

Static RAM Memory (SRAM)

2 Mbytes of soldered-down static RAM (SRAM) is implemented with four 512K x 8
asynchronous SRAMs that are configured as a 1M x 16-bit array. Each SRAM device
operates at 3.3V and is packaged in a 32-pin TSOP. An additional 2Mbytes of SRAM may
be factory installed. SRAM is placed into data retention mode (powered by a backup 3.6V
lithium battery) when power is lost. The SRAM supports 16-bit or 8-bit accesses and is
connected to the GP bus. Critical system information that must be retained during power
outages or when the system has been disabled for maintenance is stored here. Data in­cludes: Last states of all I/O, historical data, retain variables and alarm messages not yet
reported.

Synchronous Dynamic RAM (SDRAM)

4 Mbytes of on board Synchronous Dynamic RAM (SDRAM) (2 x KM416S1120DT). The run
application and a copy of system firmware are stored here. This allows the system to run
faster than it would from the FLASH memory. SDRAM is not battery-backed.

CMOS RAM

RAM internal to the CPU Module’s AMD Elan SC520 Microprocessor. This RAM data is
loaded from BIOS. 10 bytes are provided for RTC alarm and calendar parameters and 114
bytes are provided as configuration parameters.

1.3.2 Power Supply/Sequencer Module

Power Supply/Sequencer Modules (PSSM) plugs into the system’s Backplane Board
(Connector P1 and P3) via their Compact PCI (CPCI) type keyed 132-pin connector J1. The
front of the PSSM contains a system power switch, as well as two pluggable terminal blocks
for external input power and watchdog MOSFET switch connections. Three LEDs, visible
through the front panel, provide the following status conditions: PWRGOOD (power good:
green), MC (master clear active: red) and PWRFAIL (power fail: red)

PSSMs contain a DC to DC Converter that generates isolated +5Vdc for the CPU and CCRS
Modules and isolated +12Vdc for the CCRS Module. A piggy-back converter board provides
isolated +3.3Vdc required for CPU logic, memory and FLASH devices.

Also contained on the PSSM is the sequencer circuit that monitors the incoming power as
well as the isolated output supplies and has a reset/early power fail warning controller that
interfaces with the system CPU Module. Master Clear and Power Fail signals are
generated by the sequencer circuit when incoming power or the isolated supply voltages fall
below specified limits. Additionally, the sequencer circuit controls an on-board watchdog
MOSFET switch that will open when Master Clear is active or the CPU Module asserts the
Watchdog Bad signal.

CI-ControlWaveRED Introduction / 1-11

The power supply operates from bulk inputs of +10.6 to +20V or +20.7 to +30V (dc) with the
nominal input supply configuration (12V or 24V) factory set by on-board jumpers. A
supervisory circuit monitors the incoming power and the isolated supply voltages. The
isolated supplies are shut down when the incoming voltage drops below +10.6V for a +12V
system or +20.7V, for a +24V system.

Figure 1-6 - Power Supply/Sequencer Module

The circuit that drives the watchdog MOSFET switch is on the secondary (isolated) side of
the power supply. A solid state relay (SSR) actuates the watchdog hardware and is factory
enabled or disabled via an on-board jumper. When either /MC or /WDOGB is active, the on­board watchdog hardware will be OFF. /WDOGB is a signal generated by the CPU Module
when its hardware detects improper software operation.

The watchdog MOSFET switch is powered via the VI input of the terminal block and its
switched output is connected to the VO/NO output of the terminal block. The external
power source connected to the COM terminal must be referenced to the return point of the
input source that powers the PSSM (-VIN (PSGND)).

1-12 / Introduction CI-ControlWaveRED

Figure 1-7 - Power Supply/Sequencer Module Block Diagram

1.3.2.1 PSSM Power Switch SW1

Switch SW1 is used to connect input power to the PSSM circuitry via Controlled Power
MOSFETs when the ‘I’ side of the switch has been pressed to its actuated position. This will
turn the unit ON.

1.3.2.2 PSSB Board Fuse

The PSSM contains Fuse F1 that isn’t field replaceable. Slow Blow Fuse F1 is rated at 3A
for a +12V/24V system - protects the entire system.

1.3.2.3 PSSB Board Connectors

Connectors TB1, TB2 and J1 function as described below.

CI-ControlWaveRED Introduction / 1-13

PSSB Bd. Terminal Block Connector TB1
TB1 provides 2 watchdog MOSFET switch connections:

TB1-1 = VO - Watchdog MOSFET Switch Output
TB1-2 = VI - Watchdog MOSFET Switch Input
TB1-3 = Not Used with ControlWaveRED

PSSB Bd. Terminal Block Connector TB2

TB2 provides 5 input connections for bulk power:

TB2-1 = (+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
TB2-2 = (+VINF) Field Supply - Not Used
TB2-3 = (-VIN) (1st Supply Ground)
TB2-4 = (-VINF) (2nd Supply Ground) - Not Used
TB2-5 = Chassis Ground - CHASSIS (

)

PSSB Bd. Connector J1

Connector J1 is a 132-pin keyed CPCI type connector that interfaces Power, Ground and
Master Clear(s), power supply status (/PWR_FAIL) and watchdog status (/WDOGB) signals
to Connector P1 on the Backplane Board.

1.3.2.4 PSSM LEDs

Three LEDs, visible through the front panel, will provide status conditions PWRGOOD
(power good: green), MC (master clear active: red) and PWRFAIL (power fail: red). When
power is first applied or when the unit is reset, the red MC LED will illuminate for a short
period of time. The green PWRGOOD LED should be ON whenever the unit is running and
no power problems have been detected. The red PWRFAIL LED should only be ON when
power has dropped below acceptable levels.

1.3.3 ControlWaveRED CPU & Comm. Redundancy Switch Module

The CPU & Communications Redundancy Switch (CCRS) Module is a system module that
interfaces to a redundant pair of Power Supply/Sequencer and CPU modules via the
ControlWaveRED CPU & Communications Redundancy Backplane (CCRB). The CCRS
Module provides either automatic or manual selection of the primary controller CPU in the
case of hardware failure. The CCRS Module will also switch up to four serial
communications ports to the selected primary CPU of the redundant pair. Multiple power
sources within the CCRS ensure system viability. Backplane interconnects convey power,
power sequencing, watchdog hardware control, primary CPU selection and respective serial
communications port selection control for redundancy purposes.

CCRS Module hardware implements a front panel user interface, module/system status
indicators and selected (primary) CPU communication port switching to front panel
mounted 9-pin male D-type connectors. Triple replicated system logic circuitry and the
multiple CCRS Module power supply circuits provide a high level of tolerance to
miscellaneous hardware faults.

The CCRS Module transfers control of the process and communication from one CPU to the
other CPU in the event the first CPU fails. Redundancy is recommended for plants or
processes where a loss of control could result in damage or injury. The process of
transferring control from one CPU to the other CPU is referred to as fail-over. A fail-over
from one CPU to the other typically falls into one of two categories:

1-14 / Introduction CI-ControlWaveRED

Hardware failures - These could occur from a variety of causes:

• loose cable

• improper configuration, e.g. board not seated properly

• power supply failure (no power for CPU)

• individual board or component breakdown

Software failures - Possible causes include:

• application program running in the CPU ‘crashes’ as indicated by ‘FF’ on the display

• all tasks are suspended for more than a user-configurable number of milliseconds

• a task watchdog occurs (this option can be user enabled/disabled)

• user-created logic for detection of a particular failure is activated, triggering a

switchover via a REDUN_SWITCH function block

When redundant CPUs are used, these sorts of failures trigger a watchdog relay, and
cause a fail-over from the on-line CPU that failed to a standby backup CPU. The
standby CPU has been configured to be a nearly exact duplicate of the on-line CPU, so that
it can assume full control over the process previously controlled by the failed CPU, and
becomes the new on-line CPU.

Figure 1-8 - Perspective View of CPU & Comm. Redundancy Switch Module

CI-ControlWaveRED Introduction / 1-15

Figure 1-9 - Front View of CPU & Comm. Redundancy Switch Module

1.3.3.1 CCRS Module Switches

A/B Primary Controller Select Switch - 2-position - selects the primary controller, i.e.,

CPU A (UNIT A) or CPU B (UNIT B) at CCRS Module power up only

if the A/B Enabled
Mode Select Switch has been set in the automatic selection (centered) position. The
selected CPU Module will be chosen as the primary system controller if the CCRS Module’s
logic determines it is ready for on-line duty. Otherwise, the alternate CPU will be selected if
it is OK.

A/B Enable Key Switch - 3-position - used to determine whether the primary CPU
selection is forced to CPU A (UNIT A) or CPU B (UNIT B) or is automatically selected
(Center). Forced primary selection is useful for diagnostic purposes, where a failed CPU
Module may be placed on-line for debugging.

1-16 / Introduction CI-ControlWaveRED

1.3.3.2 User Accessible CCRS Module Connectors

Front of CCRS Module (see Figures 1-8 and 1-9):

Connector J1 - Switched COM1 Port - 9-pin D-Type Male RS-232 - represents COM1 of the

selected CPU Module.

ConnectorJ2 - Switched COM2 Port - 9-pin D-Type Male RS-232 - represents COM2 of the

selected CPU Module.

Connector J3 - Switched COM3 Port - 9-pin D-Type Male RS-232/485 - represents COM3 of

the selected CPU Module.

Connector J4 - Switched COM4 Port - 9-pin D-Type Male RS-232/485 - represents COM4 of

the selected CPU Module.

Connector J5 - CPU A Comm. Ports Interface Cable Header - 2 x 25 Male, Shrouded &

Polarized

Connector J6 - CPU B Comm. Ports Interface Cable Header - 2 x 25 Male, Shrouded &

Polarized

Connector J7 - Isolated On-Line Status Outputs - 4-pin pluggable (Screw Clamp) - Provides

A & B pairs of relay driven Normally Open (NO) & Common (COM) outputs

Rear of CCRS Module:

Connector J1 - CCRS/CCRB Slot A 50-pin Ribbon Cable Header - Interface to Backplane

REDSWA Connector P5.

Connector J2- CCRS/CCRB Slot B 50-pin Ribbon Cable Header - Interface to Backplane

REDSWB Connector P6.

1.3.3.3 CCRS Module Status LEDs

UNIT A ON-LINE LED - Green - ON means CPUA is on line
UNIT A FAIL LED - Red - ON means CPUA has failed - If blinking means CCRS Slot

A cable is not attached or is defective

UNIT B ON-LINE LED - Green - ON means CPUB is on line
UNIT B FAIL LED - Red - ON means CPUB has failed - If blinking means CCRS Slot

B cable is not attached or is defective

POWER SYSTEM STATUS LEDs A & B - Red/Green
ON Green means Power is good
ON Red means Power is defective

1.3.4 ControlWaveRED Backplane

The ControlWaveRED Backplane provide for the interconnection of the Power Sup­ply/Sequencer Modules (PSSMs), CPU Modules and the CPU & Communications
Redundancy Switch Module (CCRSM). PSSM and CPU module slot connections are im­plemented with Compact PCI (CPCI) type connectors. Connections to the CPU &
Communications Redundancy Switch Module are implemented via two 50-pin ribbon cable
headers. The two ribbon cables connected between the Backplane and the rear of the
CCRSM accommodate the interconnection of PSSMA & PSSMB provided regulated logic
power, regulated relay power and Master Clear A/B signals, CPUA and CPUB provided
Watch Dog A/B signals, and CCCRSM provided On-Line/BackupA and On-Line/BackupB
control signals.

CI-ControlWaveRED Introduction / 1-17

Figure 1-10 - ControlWaveRED Backplane Assembly

Figure 1-11 - Backplane PCB Block Diagram

1-18 / Introduction CI-ControlWaveRED