Honeywell WEB-645, CP-645 Installation Instructions Manual
Put Bar Code Here
62-0432-01
WEB-645, CP-645
Network Controller
INSTALLATION INSTRUCTIONS
ABOUT THIS GUIDE
This document covers the installation instructions of the Honeywell WEB-645 and CP-645 controllers. It assumes that you are an
engineer, technician, or service person who has performed control system installations. Instructions in this document apply to the
following products:
Model Description Ports/Notes
WEB-645-AX
WEB-645I-AX
CP-645-AX
CP-645I-AX
For complete specifications, please refer to the product data sheet for the WEB-645-AX and CP-645-AX controller.
JACE controller with various communication ports, mounted in a
metal enclosure. Has a pre-wired power transformer and
rechargeable 12V backup battery. (WEB-645-AX, CP-645-AX are for
U.S. installations, WEB-645I-AX, CP-645I-AX are for International
installations).
Controller uses an NPM6E processor module with a PowerPC
440EP CPU, 256MB DDR RAM, 128MB Serial Flash, 512KB Boot
Flash, 512KB Static RAM (SRAM), and runs the QNX Real-time
Operating System, and the Oracle Hotspot Java Virtual Machine.
Can host either a WEB R2 station (WEBs 2.301.535 or later) or a
WEB-AX station (WEB-AX 3.6.49 or later) for WEB products and CPAX Station (CP-AX 3.6.49 or later) for CP products, depending on
license.
Regardless of release, WEBs host (platform) configuration requires
WEB-AX Workbench 3.6.49 or later. If hosting an R2 station, the
existing R2 WEB Java Desktop Environment (JDE), build 2.301.535
or later, is used to access the controller’s running station.
2 -Ethernet 10/100 Mbit/s ports
(RJ-45 connectors).
4 - RS-485 ports, optically isolated, 3position connectors.
1 - LonWorks FTT-10A port, 2-position
connector.
2 - RS-232 port (RJ-45 connectors).
The LON port and all RS-485 ports
use pluggable screw terminal
connectors.
NOTE: Not covered in this document is the WEB-AX-R2 or WEB-AX software installation and configuration required for
a fully functioning unit. See the “Related Documentation” section below. The content of this documentation
equally applies to CP-645-AX product.
Related Documentation
For software details on configuring and using the WEB-645-AX controller, consult the following documents:
• Retrofit Board WEBs R2 Install & Startup Guide (if WEBs R2)
• JACE WEBs-AX Install and Startup Guide (if WEBs-AX)
• JACE Data Recovery Service (SRAM Support) - Engineering Notes (if WEBs-AX)
WEB-645, CP-645 NETWORK CONTROLLER
CAUTION
WARNING
WARNING
PREPARATION
Unpack the controller and inspect the package contents for damaged or missing items. If damaged, notify the appropriate carrier
and return for immediate repair or replacement.
Included in this Package
Included in this package you should find the following items:
• a WEB-645-AX controller.
— a hardware bag containing the following items:
— 3-position RS-485 screw terminal connector plug (quantity 4).
— 2-position LON screw terminal connector plug (quantity 1).
— if a WEB-645-AX, wire nuts (quantity 2).
• This NETWORK CONTROLLER WEB-645-AX Mounting and Wiring Guide document.
— Optional items (if ordered):
— RJ-45 to DB-9 adapter (for an RS-232 port).
— Silver satin patch cable (used between the adapter and a serial port).
Material and Tools Required
The following supplies and tools are used for installation:
• 1/4" (6mm) nut driver: used to remove the transformer shield, and also the enclosure door grounding wire. If installing an
option card (WEBs-AX units only), a #2 Phillips screwdriver.
• Small flat-blade screwdriver: used for LON and RS-485 connectors. Also for power terminals if a WEB-645I-AX (International)
model.
• Suitable tools, fasteners, and supplies for mounting the controller’s metal enclosure, and also for fastening electrical conduit.
NOTE: If removing or installing the circuit board from the enclosure, a 1/4-inch thin-walled socket is recommended (do
not use a nut driver). See “Replacing the WEB-645-AX circuit board,” page 15.
PRECAUTIONS
This document uses the following warning and caution conventions:
Cautions remind the reader to be careful. They alert readers to situations where there is a chance that the reader
might perform an action that cannot be undone, might receive unexpected results, or might lose data. Cautions
contain an explanation of why the action is potentially problematic.
Warnings alert the reader to proceed with extreme care in situations where there is a chance that the reader
might do something that can result in personal injury or equipment damage. Warnings contain an explanation of
why the action is potentially dangerous.
Safety Precautions
The following items are warnings of a general nature relating to the installation and start-up of the controller. Be sure to heed
these warnings to prevent personal injury or equipment damage.
• A 120Vac circuit powers the transformer in the unit. Disconnect power before installation or servicing to prevent
electrical shock or equipment damage.
• Make all connections in accordance with national and local electrical codes. Use copper conductors only.
• To reduce the risk of fire or electrical shock, install in a controlled environment relatively free of contaminants.
• This device is only intended for use as a monitoring and control device. To prevent data loss or equipment damage, do
not use it for any other purpose.
62-0432—01 2
WEB-645, CP-645 NETWORK CONTROLLER
CAUTION
Static Discharge Precautions
Static charges produce voltages high enough to damage electronic components. The JACE printed circuit board contains
components that are sensitive to static discharge. Follow these precautions when installing or servicing the system:
• Work in a static-free area.
• Discharge any static electricity you may have accumulated. Discharge static electricity by touching a known, securely
grounded object.
• Do not handle printed circuit boards (PCBs) without proper protection against static discharge. Use a wrist strap when
handling PCBs. The wrist strap clamp must be secured to earth ground.
WEEE (Waste of Electrical and Electronic Equipment)
Recycling of Electronic Products: (International Installations)
In 2006 the European Union adopted regulations (WEEE) for the collection and recycling of all waste electrical and electronic
equipment. It is no longer allowable to simply throw away such equipment. Instead, these products must enter the recycling
process. To properly dispose of this product, please take it to a local recycling center.
If a local recycling center cannot be found, please return it to one of these offices:
Tridium Europe Ltd
1, The Grainstore
Brooks Green Road
Coolham, West Sussex
RH13 8GR United Kingdom
Tridium Asia Pacific Pte Ltd
17 Changi Business Park Central 1
Honeywell Building
Singapore 486073
Tridium, Inc.
2256 Dabney Road, Suite C
Richmond, VA 23230
MOUNTING
Mount the controller in a location that allows clearance for wiring, servicing, and module removal. For mounting details refer to
Fig. 1. on page 4 (a drill template is provided on the last page of this document).
Pay attention to the following recommendations and precautions when mounting and installing the unit.
• This product is intended for indoor use only. The unit should not be exposed to ambient conditions outside of the range of 0ºC
(32º F) to 50ºC (122º F) and relative humidity outside the range 5% to 95% non-condensing (pollution degree 1).
If the controller is mounted inside an enclosure, that enclosure should be designed to keep the unit within its required operating
range considering a 20-watt dissipation by the controller. This is especially important if the controller is mounted inside an
enclosure with other heat producing equipment.
• Minimum clearance from the wall on which the unit is mounted is 0.2-inches (provided by the dimpled mounting feet). Ensure
that this space is not compromised and that airflow is not blocked behind the unit.
• Do not mount the unit:
— in an area where excessive moisture, corrosive fumes, or explosive vapors are present.
— where vibration or shock is likely to occur.
— in a location subject to electrical noise. This includes the proximity of large electrical contractors, electrical machinery, welding
equipment, and spark igniters.
• The unit is designed to be wall mounted with the battery situated towards the bottom of the unit. For proper airflow at
temperature extremes, do not mount the unit oriented in any other way.
3 62-0432—01
WEB-645, CP-645 NETWORK CONTROLLER
.438" (11.1 mm)
.406"
(10.3 mm)
.218"
(5.5 mm)
1.88" (48 mm)
1.20" (31 mm)
0.16" (4 mm)
0.96"
(24 mm)
2.50"
(64 mm)
1.00"
(25 mm)
Min.
1.00"
(25 mm)
Min.
2.00"
(51 mm)
Min.
15.6"
(396 mm)
Min.
2.00"
(51 mm)
Min.
0.221"
(5.6 mm)
Dia.
2.0"
(51 mm)
2.0"
(51 mm)
2.0"
(51 mm)
3.0"
(76 mm)
2.25"
(57 mm)
2.25"
(57 mm)
9.84"
(250 mm)
11.6"
(295 mm)
0.72"
(18 mm)
5.94"
(151 mm)
9.75"
(248 mm)
1.52"
(39 mm)
11.8" (300 mm)
1/2" (13mm)
Mount This
End Up
Mounting Surface
Conduit Knockout (typ. of 7)
Minimum Clearance Area
Keyhole
Detail
Minimum
Mounting is summarized in the following sections:
• Removing and replacing the enclosure door
• Lift the door away from the unit. When installation is finished, replace the door and grounding wire in the reverse fashion
Enclosure knockouts and mounting notes
62-0432—01 4
Fig. 1. WEB-645-AX mounting details.
WEB-645, CP-645 NETWORK CONTROLLER
1
2
3
Removing and replacing the enclosure door
The WEB-645-AX’s cover (door) is removable. A knurled-edge, slotted-head screw secures the door closed.
NOTE: For a more secure installation, use a padlock in the security tab that protrudes through the door.
Remove or replace the enclosure door.
Removing the enclosure door allows more light inside the unit, and makes mounting and wiring easier.
1. Loosen the cover screw and open the enclosure door about half way.
2. If the grounding wire near the bottom is fastened to the screw post on the inside of the door, use a 1/4" (6mm) nut driver to
unfasten it from the door. Set the nut aside to reuse later.
Screw post on
inside of enclosure
1
door.
Green grounding
2
wire with eyelet.
1/4" Keps nut to
secure grounding
wire to post.
3
3. Slide the door towards the top of the unit, until the hinge tabs on the door clear the hinge slots on the enclosure.
4. Lift the door away from the unit.
When installation is finished, replace the door and grounding wire in the reverse fashion Enclosure knockouts and mounting
notes
NOTE: The WEB-645-AX’s enclosure has seven 1/2" (13mm) knockouts: one on top (for AC line power), two on the left
side, and four on the bottom (typically used for RS-485 cabling or other communications cabling). As needed,
locate and remove the necessary knockouts and install the necessary conduit or cable clamps in the knockout
holes. (This may easiest to do before mounting the controller to the wall).
Mounting the controller.
1. With the controller’s enclosure door opened or removed, position the controller on the wall in the location where you are
installing it.
2. Make sure that the location provides the necessary minimum clearances around the controller’s enclosure (left and right
sides, top and bottom). See Fig. 1. on page 4.
3. Carefully mark the mounting hole locations, and remove the controller.
4. Drill the needed pilot holes in the wall. For example, if using wall anchors you might drill 5/16" holes.
5. Mount the controller to the wall using the appropriate fasteners.
6. As needed, install wiring conduit to the controller’s enclosure.
See “Board Layout,” page 6 and “Wiring Summary,” page 7 for further details.
5 62-0432—01
WEB-645, CP-645 NETWORK CONTROLLER
LON LEDs
Primary Ethernet
LAN1 port (RJ-45)
See “Ethernet” on
page 8
RS-485 LEDs
(2 each port)
Secondary Ethernet
LAN 2 port (RJ-45)
LEDs:
LAN2 (SEC)
LAN1 (PRI)
BEAT
STATUS
See “LEDs on
NPM6E processor
module” on page 10
NPM6E processor
module
RS-485 ports
COM3 and COM4
See “RS-485” on
page 8.
Option card
connector/area
See “Option
Card Installation
(WEBs-AX units
only)” on page
12
Power
Connector
RS-485 ports
COM5 and COM6
See “RS-485” on
page 8.
RS-232 ports
COM1 and COM2
(RJ-45)
See “RS-232” on
page 8.
RS-232 LEDs
(2 each port)
S
+
–
S
+
–
S
+
–
S
+
–
Serial Shell jumper
Normal
Serial Shell
See “Serial Shell
mode” on page 11
LON port
See “LonWorks
(LON),” page 9
RS-485 Bias
Jumpers
(4-pin bias header for
each RS-485 port)
See “RS-485 port
biasing” on page 11
BOARD LAYOUT
Refer to Fig. 2 for the location of communication ports, LEDs, and other features of the WEB-645-AX controller.
Fig. 2. WEB-645-AX board layout details.
62-0432—01 6
Loading...