Honeywell WEB/CP-202-XPR, WEB/CP-202-XPR-GW, WEB/CP-602-XPR-GW, WEB/CP-602-XPR Installation Instructions Manual

WEB/CP-202-XPR and
WEB/CP-602-XPR Controllers

INSTALLATION INSTRUCTIONS

This document covers the mounting and wiring of the WEB/CP-202-XPR and WEB/CP-602-XP
controllers. It assumes that you are an engineer, technician, or service person who is performing
control system installation. Instructions in this document apply to the following products:

Model Description

a

WEB/CP-202-XPR
WEB/CP-602-XPR

WEB/CP-202-XPR-GW
WEB/CP-602-XPR-GW

a

WEB/CP-202-XPR models: PowerPC® 405EP processor @250 MHz, 64MB Flash,
128MB SDRAM

b

WEB/CP-602-XPR models: PowerPC 440 processor @ 524 MHz, 128MB Flash,
256MB DDR RAM

Base unit including two Ethernet ports, one RS-232 port, one
RS-485 port, integral power supply for 24Vac/dc input, and

b

16 onboard I/O points (8 universal inputs, 4 digital outputs,
4 analog outputs).

a

WEB/CP-202-XPR or WEB/CP-602-XPR with a factory
installed wireless GPRS modem module and a SIM card for

b

use on the Wyless Network.

M29982

NOTE: Not covered in this document is the NiagaraAX™ software installation and configuration required for a functioning unit.

Refer to the JACE NiagaraAX Install and Startup Guide, GPRS Modem Option - Engineering Notes, and NiagaraAX
NRIO Guide documents for this information

.

These are the main sections in this document:

Product Description ......................................... 2

Preparation ....................................................... 4

Precautions ...................................................... 5

Mounting ........................................................... 6

Board Layout ................................................... 11

About Expansion Options ............................. 12

Wiring Summary ............................................ 13

Earth Ground and 24V Input Power ............. 14

I/O Wiring ........................................................ 15

Nrio16Module (Software) Representation .... 19

External 12V Backup Battery ........................ 22

Wiring to Remote I/O Modules ...................... 23

Power Up and Initial Checkout ..................... 23

Also included in this document are several appendixes:

About LEDs ........................................................................ 25

Maintaining the WEB/CP-202-XPR and WEB/CP-602-XPR

Controllers ......................................................................... 27

Replacement Parts ............................................................ 28

Replacing the WEB/CP-202-XPR or WEB/CP-602-XPR

Controller ........................................................................... 29

Returning a Defective Unit ................................................ 31

Certifications ...................................................................... 32

95-7775-01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

M29983

WIRING AREA IS UNDER

RIGHT COVER

KNOCKOUTS AT BOTTOM
(2; ONE FOR 24V POWER)

2 SCREWS AT
TOP AND BOTTOM
SECURE THE
RIGHT COVER

CONTROLLER
BOARD

COMM
OPTION SLOT (1)

NIMH BACKUP
BATTERY PACK

INTEGRAL
24V INPUT
POWER SUPPLY

2 SCREWS

NEAR TOP AND

BOTTOM SECURE

THE LEFT COVER

LEFT

COVER

GROUNDING
TERMINAL
STRIP

UNIVERSAL
INPUT
TERMINALS (8)

RS-485 AND
15V POWER
OUT

DIGITAL
OUTPUT
TERMINALS (4)

ANALOG
OUTPUT
TERMINALS (4)

RIGHT

COVER

REAR

MOUNTING

KEYHOLE (1)

REAR WIRING

KNOCKOUTS (6)

STATUS LEDS (10)

LOWER MOUNTING TABS (2)

BOTTOM TOP

REMOVABLE SHIELD COVERS THE 24V POWER INPUT WIRING TERMINALS.

1

1

SIM CARD SLOT

2

2

RIGHT COVER MUST BE REMOVED FIRST, THEN LEFT COVER CAN BE REMOVED.

3

SEE FIG. 15 ON PAGE 22 FOR I/O TERMINALS AND CONTROLLER PORTS DETAILS.

12V EXTERNAL

SLA BATTERY

RS-232 PORT
(RJ-45)

OPTION
CARD
AREA

ETHERNET
LAN PORTS (2)

3

PRODUCT DESCRIPTION

The WEB/CP-202-XPR and WEB/CP-602-XPR controllers are embedded controller/servers for remote monitoring and control
applications. Included are 16 points of on-board I/O with removable screw terminals, a built-in power supply (24 Vac or 24 Vdc
input), an optional onboard GPRS modem, and one expansion slot for a communications option card. Flash memory is used for
storage, and an integral NiMH battery provides shutdown/database backup and real-time clock support for power loss scenarios.

Designed for use in commercial environments, the controllers run the Niagara
supervision, and network management solutions for wide variety of networked field devices. NiagaraAX-3.4.51 or later is
required.

Packaging and Features

The WEB/CP-202-XPR and WEB/CP-602-XPR have a plastic chassis designed for wall mounting by using three (3) screws; one
in a rear keyhole slot, and two into lower mounting tabs. Vents at the top and bottom of the unit allow cooling by air convection.
The front cover is split in two halves, each secured by two screws, where the right cover overlaps the left cover. The right side
provides access to all wiring terminals, including controller communications ports, I/O point terminals, and 24V power input
terminals. See Fig. 1 for the location of important features.

AX

Framework® to provide integrated control,

95-7775—01 2

Fig. 1. Features of the WEB/CP-202-XPR and WEB/CP-602-XPR controllers.

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

The wiring area under the right cover provides knockouts at the back, bottom and top holes, and a grounding terminal strip. For
wiring ease, the controller uses removable screw terminal blocks, using 0.2 in. (5mm) spacing. Typically, the left-side cover needs
removal only if replacing the NiMH battery pack, installing a SIM card in the onboard GPRS modem (if model so equipped), or if
installing an option card on the controller. One option card is supported, to provide additional communications, e.g. LonWorks
FTT-10, or another RS-232 port. Controller models are available with a pre-installed GPRS modem, which does not consume the
option card slot.

Sixteen (16) integral I/O points include eight (8) universal inputs (UIs), compatible with 0 to 10 Vdc, 4 to 20 mA, dry contacts,
pulsing dry contacts, or Type 3 thermistor sensors. Four (4) digital outputs with Form-A relay contacts provide on/off control of
loads up to 30 Vac or Vdc, at 0.5A maximum. Four (4) 0 to 10 Vdc analog outputs provide analog control of loads at 2.5K ohm
minimum, or 4 mA drain maximum.

Ten (10) LEDs are visible atop the left cover, indicating the state of each of the four digital outputs, along with the status of the
controller, Ethernet, and wireless options (if installed). For GPRS equipped models, a GSM/GPRS quad-band antenna can be
mounted on the left side. A rechargeable NiMH battery pack is included inside the unit. Separate terminals support an external
12 V sealed lead-acid (SLA) backup battery, if desired.

®

The controllers use a PowerPC processor with Flash memory for storage and have either SDRAM or DDR RAM. TCP/IP access
is via two standard Ethernet ports, and two serial ports (RS-232, RS-485) are also standard. The controllers use the QNX
operating system, along with the IBM J9 JVM. For a complete listing, see the next section “Technical Specifications.”

®

RTOS

Technical Specifications

WEB/CP-202-XPR and WEB/CP-602-XPR Platforms

• WEB/CP-202-XPR models:

— PowerPC 405EP @ 250 MHz processor.
— 128 MB SDRAM and 64 MB Serial Flash.

• WEB/CP-602-XPR models:

— PowerPC 440 @ 524 MHz processor.
— 256 MB DDR RAM and 128 MB Serial Flash.

• Real-time clock.

• Two (2) Ethernet ports; 10/100 Mbps with RJ-45 connectors.

• One (1) RS-232 port using an RJ-45 connector.

• One (1) isolated RS-485 / 15 Vdc power on a 6-position connector. Usable as a standard non-powered isolated RS-485 port
on 3 terminals, or to support remote I/O modules – available in a later release.
(A maximum of three IO-16-REM-H modules on the WEB/CP-202-XPR controller is recommended, due to platform resource
considerations).

• One (1) available comm option card slot for a communications option card, such as LonWorks FTT-10, an additional RS-232
port, or two more isolated RS-485 ports.

• One (1) USB port for future use (WEB/CP-602-XPR models only).

• LEDs on front of unit to monitor controller power, system status, and digital output states.

Onboard I/O Points

• 16 total points of I/O, using removable screw terminals with spacing of 0.2 in. (5mm) centers for all inputs and outputs, in
connector blocks of 6 or more screws each.

• 8 Universal Inputs (UI), with the following types supported:
— Type 3 (10K) Thermistors; Thermistor Sensor Range -23.3 to 115.5°C (-10 to 240°F).

Input accuracy is in the range of ± 2% of span. Other types may be supported by entering custom non-linear curve inter-

polation points for each unique non-linear input.
— 0 to 10 Vdc; accuracy is ± 2% of span, without user calibration.
— 4 to 20 mA current loop; accuracy is ± 2% of span, without user calibration. Self-powered or board-powered sensors

accepted; uses an external resistor for current input (four provided, mounted by installer on input terminal connections).
— Dry contact; 3.3 V open circuit, 300 uA short-circuit current.
— Pulsing dry contact, at rate up to 20 Hz; 50% duty cycle.

• 4 Digital Outputs (DO), using Form A relay contacts; suitable for on/off control only (no floating control). Maximum load voltage
is 30 Vdc or Vac; with 0.5 A maximum current rating per contact.

• 4 Analog Outputs (AO), providing 0 to 10 Vdc signal, at 4 mA drain maximum (controlled load must have resistance of
2500 ohms or higher).

3 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

Power Input

• Integrated power supply for 24 V input, using either a dedicated, external, Class-2, 24 Vac transformer or a 24 Vdc power
supply, 40 W maximum.

• Includes integral rechargeable NiMH backup battery pack, for short duration AC power fail operation.

• Connection for external, rechargeable, 12V sealed lead-acid battery, for continuous system operation over longer power
outages. Provides trickle charge and monitoring support to customer-supplied battery.

GPRS Modem (WEB/CP-202-XPR-GW and WEB/CP-602-XPR-GW only)

• Factory-installed GSM cellular modem using GPRS (General Packet Radio Service) data technology.
An LED on the front left cover indicates modem status.

• Uses GSM/GPRS quad-band SMA coax-mounted stub antenna, mounted on left side of unit. If needed, an extension SMA
coax cable can be used to the antenna, or another external antenna used instead.

Operating System

• QNX RTOS, IBM J9 Java® Virtual Machine.

•JACE

®

(Java Application Control Engine) NiagaraAX software (AX-3.4.51 or later required).

Chassis and Enclosure

• Plastic wall mount chassis, with two removable front covers secured by screws.

• Cooling by internal air convection.

• Dimensions: 12.625 in. (320.7mm) tall

• Weight: Net 2.1 lbs. (0.95 kg), Gross 3 lbs. (1.36 kg)

x 7.5 in. (190.5mm) wide x 2.25 in. (57.2mm) deep.

Environment

• Operating temperature range: 0 to 50°C (32 to 122°F).

• Storage temperature range: 0 to 70°C (32 to 158°F).

• Relative humidity range: 5% to 95% at 25°C (77°F), non-condensing.

Agency Listings

• UL 916

• C-UL listed to Canadian Standards Association (CSA) C22.2 No. 205-M1983 “Signal Equipment”

• CE, FCC part 15 Class A

• BTL B-BC BACnet Building Controller listed when the BACnet driver is installed and configured

PREPARATION

Unpack the controller and inspect the package contents for damaged or missing components. If damaged, notify the appropriate
carrier at once and return any damaged components for immediate repair or replacement. See “Returning a Defective Unit” on
page 31.

Additional information applies, as follows:

• Included in this Package

• Material and Tools Required

Included in this Package

Included in this package you should find the following items:

• The controller, with both cover halves fastened.

• These WEB/CP-202-XPR and WEB/CP-602-XPR Installation Instructions, form 95-7775.

• A hardware bag containing the following items:
— Two (2) 7-position screw terminal blocks, for UIs (universal inputs).
— Three (3) 6-position screw terminal blocks, one for AOs (analog outputs), one for DOs (digital outputs),

one for RS-485/15V power to optional remote modules (3 terminals RS-485, 3 for power).
— One (1) 2-position screw terminal block for external 12V sealed lead-acid battery (not provided).
— A GSM/GPRS coax-mounted stub antenna (for units ordered with integral GPRS modem).

• If a WEB/CP-202-XPR-GW or WEB/CP-602-XPR-GW model controller, a SIM card provisioned by the Wyless Group.

95-7775—01 4

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

CAUTION

WARNING

WARNING

Material and Tools Required

The following supplies and tools are typically required for installation:

• Suitable tools and fasteners for mounting unit and accessories.
— #1 Phillips screwdriver used to remove and replace cover screws.
— #2 Phillips screwdriver used to install optional communications card.
— Small flat-blade screwdriver used for making wiring connections to removable screw terminal plugs.

• To power the unit, either one of the following:
— UL listed, Class 2, 24 Vac transformer, rated at minimum of 40 VA. Note that a dedicated transformer is required (does not

also power additional equipment).

— 24 Vdc power supply, capable of supplying at least 1.5 A (36 W).

• (Optional) One or two 12V sealed-lead-acid (SLA) rechargeable backup batteries, with wire harness for connecting to the
2-position connector on the unit. Should be sized as required by the system. See “External 12V Backup Battery” on page 22.

Related Documentation

For more information on configuring and using the T-x02-XPR-24 controller, consult the following documents:

• JACE NiagaraAX Install and Startup Guide

• GPRS Modem Option - Engineering Notes

• IO-16-REM-H Installation and Configuration Instructions (form 95-7768)

• NiagaraAX Nrio Guide

• NiagaraAX User Guide

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.

They alert readers to 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 24Vac or 24Vdc circuit powers the controller. 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.

5 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

CAUTION

NiMH Battery Precautions

Observe the following NiMH (Nickel Metal Hydride) battery precautions:

Overcharging, short-circuiting, reverse charging, mutilation, or incineration of the cells and the batteries must
be avoided to prevent one or more of the following occurrences:

Release of toxic materials, release of hydrogen and/or oxygen gas, rise in surface temperature.

If a cell or battery has leaked or vented, replace it immediately using protective gloves.

If and when necessary, these cells or batteries must be replaced with identical new ones from the same
manufacturer. If a cell or a battery to be replaced is connected with other cells or batteries in series, it is
recommended that the other cells or batteries be replaced with new ones at the same time.

Reverse polarity installation of the cell or the battery in the end product must be avoided.

Static Discharge Precautions

Static charges produce voltages high enough to damage electronic components. Circuitry within the controller is sensitive to
static discharge. Follow these precautions when installing or servicing the unit:

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.

MOUNTING

NOTE: This product is intended for indoor use only. The unit should not be exposed to ambient conditions outside of the range

of 0°C (32°F) to 50°C (122°F), or relative humidity outside the range of 5 to 90% at 25°C (77°F), non-condensing. Refer
to the “Environment” section on page 4 for further details on storage specifications.

NOTE: Before mounting the unit:

1. Remove any wiring knockouts needed. See Locate and remove chassis knockouts on page 9.

2. Install the SIM card for the integral GPRS modem (if applicable). See Inserting a SIM card and attaching GPRS
antenna on page 10.

3. Install any option card (if applicable). See About Option Cards on page 12.

Mount the controller in a location that allows clearance for wiring, servicing, and removal of covers. Additional mounting
information applies, as follows:

• Environmental Requirements

• Physical Mounting

Environmental Requirements

Note the following requirements for the controller mounting location:

• If mounting 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, plus dissipation from any other devices installed in the same enclosure.
This is especially important if the controller is mounted inside an enclosure with other heat producing equipment.

• 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, spark igniters, and variable frequency drives.

95-7775—01 6

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

7.75 (197)

39.4 (100)

2.125 (54)

12.03 (306)

0.59 (15)

2 x

0.225 (5.7)

5.9 (150)

R. 0.1 (2.54)

0.433 (11)

0.41 (10.4)

M29987

1a

1b

2a

2b

3

3/32 (2.4)

10.16 (258)

Physical Mounting

• For proper cooling, mount the controller vertically, with the two screw mounting tabs at the bottom of the unit. It is not
necessary to remove the covers before mounting.

• Dimensions of the rear keyhole slot and lower mounting tabs are shown in Fig. 2, along with a step-by-step wall mounting
procedure.

NOTE: Install one panhead screw (intended for the rear keyhole slot) into the wall first, then hang the controller on that screw.

Then use screws in the two lower tabs to secure. See Fig. 2.

Fig. 2. WEB/CP-202-XPR or WEB/CP-602-XPR controller wall mounting dimensions in inches (mm) and details.

To mount unit on wall.

1. For the rear center keyhole slot, install a pan head screw into the wall (1a in Fig. 2). Do not tighten completely. Leave the
back of the screw head about 3/32 in. (2.4mm) from the wall (1b in Fig. 2).

2. Position the unit over the screw (2a in Fig. 2), entering the screw head into the keyhole slot in the back of the unit.

3. Pressing the unit against the wall, slide it down so the screw is captured by the slot (2b in Fig. 2).

4. Level the unit, and install a screw into each of the two lower mounting tabs (3 in Fig. 2).

7 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

RIGHT COVER REMOVAL

REMOVE AND RETAIN

TOP AND BOTTOM SCREWS (2)

24 V POWER WIRING SHIELD

(SEE WARNING ABOVE)

LEFT COVER REMOVAL

M28865

REMOVE AND
RETAIN
TOP AND
BOTTOM
SCREWS (2)

Removing and Replacing the Covers

The controller has two plastic covers, each is secured by two #1 phillips head screws:

• Right cover — Must be removed first, provides access to all wiring terminals (controller and I/O wiring).

• Left cover — Remove only to install a SIM card (if a model with GPRS modem), install an option card, or to replace the
controller’s NiMH battery pack.

See Fig. 3 for locations of the screws that secure each of the two covers.

Remove 24V power before removing power wiring shield, before making any wiring terminations, or before
removing the left cover!

To remove the right cover:

1. Using a #1 Phillips screwdriver, remove the two screws in the right cover as shown in Fig. 3, left.

Carefully set the screws aside to reuse.

2. Slide the cover towards the right to disengage.

3. Lift the right cover away from the unit, and set aside. Replace by simply reversing this procedure.

To remove the left cover:

1. Remove the right cover as described above.

2. Using a #1 Phillips screwdriver, remove the two screws as shown in Fig. 3, right.

Carefully set the screws aside to reuse.

3. Lift the left cover away from the unit, and set aside. Replace by simply reversing this procedure.

95-7775—01 8

Fig. 3. Controller cover removal.

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

FRONT RIGHT COVER REMOVED

KNOCKOUTS: QTY 5; 0.954 (24) DIA.

GROUNDING TERMINAL STRIP

UNIVERSAL
INPUTS (UI)

RS-485 / 15VDC

POWER OUT

DIGITAL

OUTPUTS (DO)

ANALOG

OUTPUTS (AO)

RS-232

KNOCKOUT: ONE (1)

0.46 (11.7) WIDE x 1.25 (31.7) HIGH

M28866

24 V POWER AND EARTH GROUND

(SHIELD REMOVED)

REMOVING CHASSIS KNOCKOUTS

1a

1b

2

Locate and remove chassis knockouts

The WEB/CP-202-XPR or WEB/CP-602-XPR has six (6) wiring knockouts on the back of the plastic chassis (see Fig. 4):

• Five (5) round, 0.945 in. (24 mm) diameter, for general wiring of controller terminals and I/O points.

• One (1) oval, 0.46 in. (11.7 mm) wide x 1.25 in. (31.7 mm) high, for wiring 24V input power and ground.

NOTE: In addition to these rear knockouts, there are two wiring holes, 0.845 in. (21.5 mm) for general wiring—one on the top

Remove the appropriate knockouts, as needed, before mounting to the wall. Note that the shielded 24V power input wiring area
has a hole on the bottom side, as well as an oval-shaped knockout on the rear of the chassis. If necessary, install any conduit or
cable clamps to knockout holes.

Locate and remove chassis knockouts.

1. To remove a rear knockout:

2. Remove the right-side cover (see Removing and Replacing the Covers on page 8).

Fig. 4. Wiring knockout details.

side, one on the bottom side. The top hole has an associated “U-shaped knockout” atop the right cover. Also, an
additional wiring hole is at the bottom 0.865 in. (22 mm), available for wiring 24V input power and ground. Usage of
wiring knockouts and holes will vary by installation.

a. Hold the unit with its knockout side on flat work surface, as shown in Fig. 4 (1a).
b. From the back, wedge a straight-blade screwdriver into the knockout edge, and twist to pry open as shown in

Fig. 4 (1b).

Press up each opened knockout with your finger and thumb as shown in Fig. 4 (2), then twist and remove.

9 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

A

Inserting a SIM card and attaching GPRS antenna

For any controller ordered with the integral GPRS modem, you must insert a SIM card in its SIM card socket for GPRS operation.
You must remove both covers to access the socket. Given the tight working area, this is easiest to do before mounting the unit.

NOTE: A controller ordered without the integral GPRS modem does not have the circuit board with the SIM card socket

installed in the controller. In this case, you skip the remainder of this section.

INSERT WITH

NGLED CORNER

UP AND TO THE

LEFT AS SHOWN

INSERT

A

SIM CARD
INTO
SOCKET

SIM CARD

SIM CARD SOCKET

AREA

OF

DETAIL

B

LEDS

FULLY SEAT
SIM CARD
INTO
SOCKET

GPRS ANTENNA
ATTACHES TO
LOWER JACK

OPTIONAL GPRS ANTENNA EXTENSION
KIT ALLOWS MOUNTING ANTENNA UP
TO 6.5 FT. (2M) AWAY FROM UNIT

M28867

Fig. 5. Inserting SIM in the WEB/CP-202-XPR-GW or WEB/CP-602-XPR-GW SIM card socket, attaching antenna

(GPRS factory equipped units only).

NOTE: The lower antenna jack is for the integral GPRS modem, where the antenna attaches using a standard SMA coax

connector. Note the GPRS antenna is not interchangeable with one for the upper Sedona/Jennic antenna jack (future
use), which uses a “reverse polarity SMA” type connector.

Inserting a SIM card and mounting the GPRS stub antenna.

1. Remove both covers (see Removing and Replacing the Covers on page 8).

2. Locate the SIM card socket near the upper left corner of the controller, above the LEDs (Fig. 5).

3. Orient the SIM with its angled corner up, foil connectors facing the socket (writing side towards metal shield as shown in

Fig. 5, and slide down fully into the socket connector.

4. Replace the left cover, then the right cover (see Removing and Replacing the Covers on page 8).

5. To attach the GPRS antenna, simply insert it into the SMA coax jack on the left side (lower jack) and finger tighten the

knurled nut, as shown in Fig. 5.

6. Optionally, order and install the GPRS antenna extension kit (part H-GPRS-CBL-EXT), which includes the cable and
antenna bracket. This lets you mount the GPRS antenna up to 6.5 feet (2m) away from the unit.

95-7775—01 10

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

L

NG

M28868

LEDS (SERIAL, TX, RX) FOR:

S2: RS-485

S1: RS-232 PORT OR SERIAL OPTION CARD
LIKE T-NPB-MDM DIALUP MODEM, IF INSTALLED

EARTH TO GROUNDING

TERMINALS

EARTH
GROUNDING
TERMINALS
(FOR CABLE
SHIELD WIRES)

UNIVERSAL INPUTS (8)
USING TWO TERMINAL
BLOCKS WITH AVAILABLE
V+ SENSOR

ACCEPTS:
10K THERMISTOR,
0 TO 10 VDC,
4 TO 20 MA,
DRY CONTACTS,
PULSE CONTACTS

ANALOG OUTPUTS (4)
0 TO 10 VDC

GND

V +

UI4

UI3

UI2

UI1

GND

UI8

UI7

UI6

UI5

GND

GND

V +

GND

AO4

AO3

AO2

AO1

GND

RS-232 COM1 (RJ45)

3C4

NO4

NO3

NO2

NO1

1C2

P+

P

–

PB

–

S

+

–

+

TRIDIUM-2/6
SERIES OPTION
CARD AREA
INCLUDING
SOCKET
HEADER (LEFT)
AND BLANKING
PLATE (RIGHT).
SEE ABOUT
OPTION CARDS
ON PAGE 12.

LEDS (10):

N

GND

L

DIGITAL RELAY OUTPUTS (4)
FORM A RELAY TYPE

15 VDC; BB OUT
(SUPPORTS REMOTE IO MODULES)

FOR EXTERNAL 12V BACKUP BATTERY

RS-485 COM2

EARTH GROUND AND 24 VAC OR VDC INPUT
SEE EARTH GROUND AND 24V INPUT POWER ON PAGE 14.

24 V POWER SUPPLY

(INPUT 24 VAC OR 24 VDC)

NIMH BATTERY PACK

NIMH

BATTERY

CONNECTOR

(KEYED)

STATUS

BEAT

LAN1 (PRI)

LAN2 (SEC)

FUTURE USE

DO4

DO3

DO2

DO1

GPRS

SEE
ABOUT LEDS
ON PAGE 25.

1

LED COLORS: = GREEN, = YELLOW.

1

1

K4K2K1LED2LED1 K3

S1TX

S1RX

S2TX

S2RX

X1

BOARD LAYOUT

Fig. 6 shows the location of the option card slot, LEDs, I/O terminals, communications ports and other controller features. For a
side view of communications ports and other features, see Fig. 15 on page 20.

Fig. 6. WEB/CP-202-XPR and WEB/CP-602-XPR main board layout details.

11 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

ABOUT EXPANSION OPTIONS

The WEB/CP-202-XPR and WEB/CP-602-XPR controllers provide for field-installable expansion with these kinds of options:

• Option card—Install on connectors inside the controller’s base unit. See About Option Cards.

• Remote I/O modules—To wire to the controller’s 6-pin RS-485/Power connector. See About Remote I/O Modules on page

13.

About Option Cards

The controller has one (1) available option slot to accept a custom option card, from among the WEBs-AX 2xx/6xx series options
cards (30-pin, 2 row connector). See Fig. 4. on page 9. Installing an option card is recommended before mounting the unit. See

Installing an Option Card.

Power to the controller must be OFF, and all LEDs out, when installing or removing an option card, or else
damage will occur! Be sure to properly align pins when plugging an option card into the connector.

Table 1 lists the supported models of communications option cards for a WEB/CP-202-XPR or WEB/CP-602-XPR controller.

Table 1. T-x02-XPR-24 option cards.

Model Description Note

NPB-LON

NPB-2X-RS485 Dual, optically-isolated, RS-485 adapter with

NPB-RS232 Single port RS-232 adapter, with a DB-9M

NPB-MDM 56Kbps Auto-dial/Auto-answer Modem with one

NPB-GPRS-W-XPR GSM cellular modem card using GPRS

FTT-10A LON
2-position removable screw-terminal connector
plug.

two 3-position removable screw-terminal
connector plugs.

connector. Uses its own on-board UART.
Supports baud rates up to 115200.

RJ-11 connector for phone line.
This option is not supported if the unit has the
integral GPRS modem.

(General Packet Radio Service), with onboard
socket for SIM card, and a Wyless SIM.
Kit includes a coax cable and an external
antenna with bracket.
This option is not supported if the unit has the
integral GPRS modem.

®

(LonWorks) adapter with a

Port operates in the hosted NiagaraAX station as LON1.

AX

Ports operate in the hosted Niagara
and COM8.

Port operates in the hosted Niagara

Operates as COM1. This disables the RS-232 base
serial port (RJ-45 connector) on the T-x02-XPR-24
during normal operation.
If a NPB-MDM is installed, and the “mode jumper” (see
Fig. 4 on page 9) is put in “Serial Shell” position, the
unit’s base RS-232 port becomes active immediately
following a reboot. This allows an RS-232 connection to
the “serial shell” for debugging purposes. To re-enable
the modem, you must put the mode jumper back in the
“Normal” position, and reboot again.

In general, ordering a WEB/CP-202-XPR or
WEB/CP-602-XPR with the onboard GPRS modem
(WEB/CP-202-XPR-GW, WEB/CP-602-XPR-GW) is
recommended over installing this GPRS modem option
card kit.
A special mounting and wiring document covers
installation. See the NPB-GPRS-W-XPR Modem Option
Installation Sheet.

station as COM7

AX

station as COM7.

Installing an Option Card

For complete details, see the mounting and wiring instructions document that accompany the specific option card. The following
procedure provides a basic set of steps:

Mounting an option card in a WEB/CP Controller:

1. Remove power from the controller and wait for all LEDs to turn off. See the previous WARNI NG on this page.

2. Remove both covers. See Removing and Replacing the Covers on page 8.

3. Locate and remove the blanking plate for the option slot (see Fig. 4. on page 9).

Retain the blanking plate in case the option card must be removed at a later date.

95-7775—01 12

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

4. Carefully insert the pins of the option card into the socket headers of the option card slot.
The mounting holes on the option board should line up with the standoffs on the base board. If they do not, the connector is
not properly aligned. Press until the option card is completely seated.

5. Place the custom end plate that came with the option card over the connector(s) of the option card.

6. With the mounting holes aligned with the standoffs, place the two screws through the end plate, and into the standoffs on

the controller’s base board. Using a screwdriver, hand tighten these screws.

7. Replace both covers on the controller.

About Remote I/O Modules

The WEB/CP-202-XPR and WEB/CP-602-XPR have an integral 6-pin connector to support remote I/O modules. The connector
provides both 15 Vdc power and RS-485 communications to modules on that connected trunk, and is located below the 6­position Digital Output (DO) I/O connector (see Fig. 6. on page 11).

Each remote I/O module has a DIN-mount base, and provides two (2) 6-pin connectors that allow you to “chain” multiple modules
together into one assembly. Table 2 lists the currently available modules.

NOTE: The maximum number of IO-16-REM-H modules supported varies by platform, as follows:

• 3 maximum IO-16-REM-H modules if a WEB/CP-202-XPR.

• 15 maximum IO-16-REM-H modules if a WEB/CP-602-XPR.

NOTE: Note that the actual maximum number of supported IO-16-REM-H modules may be less, as resource usage varies with

each application database

Table 2. Remote I/O modules compatible with the WEB/CP-202-XPR AND WEB/CP-602-XPR.

Model Description Notes

IO-16-REM-H Remote I/O RS-485 Module

DIN-mountable RS-485 comm module that provides
16 points I/O, with I/O point types as noted.

Provides the following I/O points:

• 8 - Universal Inputs (UIs).

• 4 - Digital Outputs (DOs), SPST-relay type.

• 4 - Analog Outputs, 0–10Vdc type.

Wiring is covered in a separate document, see the

IO-16-REM-H Installation and Configuration
Instructions.

WIRING SUMMARY

See Fig. 6. on page 11 to locate connectors and other components on the controller.

Make connections to the controller in the following order:

1. Install any option board (LON, RS-485, RS-232) in the available option slot. See Installing an Option Card on page 12 for
general procedures. For complete details, refer to the specific documentation that accompanied the option.

2. If applicable, insert the SIM card for the unit’s GPRS modem, and attach the GPRS antenna if not already attached (see
Inserting a SIM card and attaching GPRS antenna on page 10).

3. After mounting, wire earth ground and 24V power (circuit de-energized). See Earth Ground and 24V Input Power on

page 14.

4. Wire I/O points to the controller’s I/O terminals and earth ground terminal strip (for cable shield wires). See I/O Wiring on
page 15 for more details.

5. Connect communications cables. See Communications Wiring on page 20 for ports available on the controller base unit.
For ports on any installed option board (LON, RS-485, RS-232, modem) see the specific mounting and wiring guide for any
additional details.

6. Apply power to the unit. See Power Up and Initial Checkout on page 23.

13 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

EARTH GROUND AND 24V INPUT POWER

After mounting the unit, wire earth ground and 24 Vac or 24 Vdc to the terminals under the power input shield.

NOTE: If powering from a 24V transformer, do not power any other equipment with it. Otherwise, conducted noise problems

may result. Do not ground either side of the transformer’s 24V secondary.

Disconnect power from the 24V input source before making wiring terminations. Do not reconnect power until
other wiring is complete.
Note this device has no power-on switch. See Power Up and Initial Checkout on page 23.

RIGHT COVER REMOVED.
REMOVE SHIELD TO WIRE
THE EARTH GROUND AND
24 V POWER.

REAR KNOCKOUT

OR LOWER HOLE

REAR KNOCKOUT

OR LOWER HOLE

LINE VOLTAGE

(MAINS)

DEDICATED 24 VAC

TRANSFORMER WITH

NEITHER SIDE OF

SECONDARY TIED

TO EARTH GROUND

G

N

H

24 VAC 24 VDC

OR

14 AWG

MINIMUM

–

+

24 VDC POWER SUPPLY
(POLARITY NOT CRITICAL)
NEITHER SIDE OF
SECONDARY TIED
TO EARTH GROUND

EARTH
ROUND

REPLACE SHIELD

AFTER WIRING THE

EARTH GROUND

AND 24 V POWER

Fig. 7. Wire Earth Ground and 24 Vac or 24Vdc to power input terminals.

Wiring earth ground and 24V power to controller power supply.

1. If not already removed, remove the right cover. See Removing and Replacing the Covers on page 8.

2. Remove the shield over the 3-position terminal block (see Fig. 7, left) and carefully set it aside.

3. Route 24V power and ground wiring either through the rear (oval) knockout, or thought the hole directly below the

3-position terminal block.
a. Wire nearby earth ground to the “G” (ground) terminal, using 14 AWG or larger wire.
b. Wire 24V power to the “N” (neutral) and “L” (line) terminals.

4. Replace the shield over the 3-position terminal block.
If wiring is through the back oval knockout, install an end plug into the hole below the terminal block (see Fig. 7, right).

5. Replace the right cover when finished with all wiring.

INSTALL
BOTTOM PLUG
IF WIRING
THROUGH
BACK (OVAL)
KNOCKOUT

M28869

NOTE: After connecting earth ground to the “G” terminal, earth ground is available on the 10-position grounding terminal strip,

located near the top of the wiring area. See Fig. 6 on page 11.
Use this 10-position strip for terminating the shield (drain) wire on shielded cables that connect I/O sensors and remote
communications ports.

95-7775—01 14

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

I/O WIRING

The WEB/CP-202-XPR and WEB/CP-602-XPR controllers have 16 on-board I/O points that include:

• Eight (8) Universal Inputs that support analog inputs (temperature, resistance, voltage, and current) and digital inputs (contact
closure, pulse count).

• Eight (8) Outputs that include 4 analog outputs (0 to 10 Vdc) and 4 relay (24 Vac/dc, 0.5A max.) digital outputs.

See Fig. 8. for location of I/O terminals.

WEB/CP-202-XPR and WEB/CP-602-XPR

EARTH GROUND TERMINAL STRIP
(FOR CABLE SHIELD WIRE TERMINATIONS)

UNIVERSAL INPUTS (UI) 1 TO 8

UI8

GND

UI6
UI7

GND

UI5
V +

UI4

GND

UI3

GND

UI2
UI1
V +

ANALOG OUTPUTS (AO) 1 TO 4

AO4
GND
AO2
AO3
GND
AO1

DIGITAL RELAY
OUTPUTS (NO) 1 TO 4

NO4
NO3
3C4
NO2
1C2
NO1

M28870

Fig. 8. Input and Output terminal locations on the WEB/CP-202-XPR and WEB/CP-602-XPR controllers.

Inputs

Each of the 8 universal inputs (UI) can support any one of the following:

• Thermistor Type-3 10K ohm (also see CAUTION on page 16)

• Resistive 0 to 100K ohms

• 0 to 10 Vdc

• 4 to 20 mA

• Binary Input (Contacts or Pulse)

Thermistor

Inputs support 10K Thermistor temperature sensors. Input accuracy is in the range of ±1% of span. By default, conversion is for
a standard Type 3 thermistor sensor, with a sensor range of -10 to 135°F (23.3 to 57.2°C). Using a conversion type of “Tabular
Thermistor,” you can specify a different thermistor response curve, by importing a thermistor curve .xml file. Currently, the kitIo
module contains an xml folder with thermistor curves for a various thermistor temperature sensors. You can also edit and export
(for reuse) customized thermistor curve xml files. See the NiagaraAX NRIO Guide for details.

Fig. 9 on page 16 shows the wiring diagram for a Thermistor sensor.

15 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

CAUTION

M28872

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

CUT AND TAPE
SHIELD WIRE
BACK AT SENSOR

SHIELD

USE POINT: VoltageInputPoint
CONVERSION: Linear

0 TO 10 VDC SENSOR
(SELF POWERED SENSOR)
RANGE: 0 TO 10 VDC
INPUT IMPEDANCE: > 5K OHMS

GND

V +

UI4

UI3

UI2

UI1

GND

+

–

0 TO 10

VDC

USE POINT: ThermistorInputPoint

SHIELD

CUT AND TAPE
SHIELD WIRE

UI4

GND

UI3

UI2

GND

UI1

V +

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

BACK AT THERMISTOR

10K THERMISTOR

M28871

Fig. 9. Thermistor sensor wiring diagram.

Resistive 0 to 100K ohms

Inputs can read a resistive signal within a range from 0 to 100,000 ohms. Wiring is the same as shown for a Thermistor
temperature sensor (Fig. 9.). Resistive signals require a ResistiveInputPoint.

UI inputs provide optimum resistive-to-temperature resolution in the 10K ohm range. For a sensor with a range
far from 10K ohms (such as a 100-ohm or 1000-ohm sensor), resolution is so poor as to be unusable! To
successfully use such a sensor, install a transmitter that produces a Vdc or mA signal, and then wire the
transmitter to the UI according to the 0 to 10 Vdc or 4 to 20 mA instructions.

0 to 10 Vdc

Inputs support self-powered 0 to 10 Vdc sensors. Input impedance is greater than 5K ohms. 0 to 10 volt accuracy is ±2% of span,
without user calibration. Fig. 10. shows the wiring diagram for a 0 to 10 Vdc sensor.

Fig. 10. 0 to 10 Vdc sensor wiring diagram.

4 to 20 mA

Inputs support self-powered or controller-powered 4 to 20 mA sensors. The input requires an external 499 ohm resistor for
current input (four resistors are supplied). For controller-powered sensors, the controller’s two V+ terminals supply 24 Vdc, at up
to 80 mA combined. Input accuracy is ±2% of span, without user calibration.

Fig. 11 on page 17 shows wiring used for a self-powered sensor (top) and a 2-wire controller-powered sensor (bottom).

95-7775—01 16

R

UI4

GND

UI3

UI2

GND

UI1

V +

499 OHM RESISTOR

(SUPPLIED WITH UNIT)

UI4

GND

UI3

UI2

GND

UI1

V +

SHIELD

SHIELD

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

CUT AND TAPE
SHIELD WIRE
BACK AT SENSOR

–

4 TO 20 mA SENSOR
(SELF POWERED)

i

RANGE: 4 TO 20 mA

+

USE POINT: VoltageInputPoint
CONVERSION: 500 Ohm Shunt
SECONDARY CONVERSION: LINEA

CUT AND TAPE
SHIELD WIRE
BACK AT SENSOR

–

4 TO 20 mA SENSOR

i

(CONTROLLER POWERED)
RANGE: 4 TO 20 mA

+

M28873

Fig. 11. 4 to 20 mA sensor wiring diagram.

A 4 to 20 mA sensor requires a VoltageInputPoint, using conversion type 500 Ohm Shunt, and secondary conversion type
Linear.

Binary Input

Inputs support both pulse contacts and normal dry (equipment status) contacts.

• Pulse contacts may have a change-of-state (COS) frequency of up to 20 Hz with a 50% duty cycle.
Note: Minimum dwell time must be > 25ms.
(Contacts must remain open at least 25ms and be closed at least 25ms.)

• Standard dry contacts must have a 1 Hz. (or less) COS frequency, with minimum dwell time > 500ms.
(Contacts must remain open at least 500ms and be closed at least 500ms.)

Both types of dry contacts support 3.3 Vdc open circuits or 330 µA short-circuit current.

Fig. 12 on page 18 shows the wiring diagram. For a pulse contact, use the CounterInputPoint in the station database.
For other dry contacts, use the BooleanInputPoint.

17 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

M28874

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

CUT AND TAPE
SHIELD WIRE
BACK AT DEVICE

SHIELD

USE POINT: CounterInputPoint

PULSE
RANGE: 20 Hz, 50% DUTY CYCLE
MINIMUM DWELL TIME: > 25 ms

GND

V +

UI4

UI3

UI2

UI1

GND

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

CUT AND TAPE
SHIELD WIRE
BACK AT DEVICE

SHIELD

DRY CONTACTS

GND

V +

UI4

UI3

UI2

UI1

GND

USE POINT: BooleanInputPoint

Fig. 12. Binary input wiring diagram.

Outputs

The controller has four (4) 0 to 10 volt Analog Outputs and four (4) Digital Relay Outputs. See Fig. 8. on page 15 for location of
the output terminals.

Analog Outputs

Analog outputs (AO) are referenced by the terminals labeled An and GND (ground). Each AO can supply a maximum of 4 mA
over the entire 0 to 10 Vdc range. The minimum input impedance of a device controlled by an AO must be greater than 2500
ohms. Typical wiring for an AO is shown in Fig. 13.

For each AO, use a VoltageOutputWritable in the station database.

SHIELD

AO4

GND

AO3

AO2

GND

AO1

SHIELDED, TWISTED CABLE,

200 FEET (61 M) MAXIMUM

CUT AND TAPE
SHIELD WIRE
BACK AT DEVICE

USE POINT: VoltageOutputWritable

0 TO 10 VDC DEVICE

INPUT IMPEDANCE:

> 2500 OHMS

COMMON (–)

INPUT (

+)

M28875

Digital Relay Outputs

Each digital relay output is rated at 24 Vac or Vdc at 0.5A. Relay outputs have MOV (metal oxide varistor) suppressors to support
inductive-type loads such as heavy-duty relay coils.

95-7775—01 18

Fig. 13. Analog output wiring diagram.

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

Relays are not rated for AC mains (line level) powered loads – 24V @ 0.5A is the maximum switched load. Use an
external 24V transformer or a 24 Vdc power supply to power loads.

Use a RelayOutputWritable in the station for each output. Fig. 14 shows an example wiring diagram.

24 VDC POWER SUPPLY

24 VAC TRANSFORMER

(SEE PREVIOUS WARNING)

AC LINE (MAINS)

24 VAC

24 VDC

NO4

3C4

NO3

NO2

1C2

NO1

1

THE TWO COMMON TERMINALS (3C4, 1C2) ARE ISLOATED FROM EACH OTHER.
IF POWERING PILOT LOADS FROM A SINGLE 24 V SOURCE, YOU CAN JUMPER THEM TOGETHER AS SHOWN.

1

Fig. 14. Relay output wiring diagram.

NOTE: The two common DO terminals (2C1, 3C4) are isolated from each other. This is useful if controlled loads 1 and 2 are

powered from a different circuit/source than loads 3 and 4.

An LED status indicator for each relay output (K1–K4) is visible on the left cover, and also on the board. Under normal operation,
an On status indicates that the load is powered. See About LEDs on page 25 for more details.

24 VAC LOADS

2

1

3

USE POINT: RelayOutputWritable

M28876

Nrio16Module (Software) Representation

In the NiagaraAX station interface to the WEB/CP-202-XPR or WEB/CP-602-XPR, the controller’s onboard I/O is modeled in the
station’s M2mIoNetwork (copied from the nrio palette), under a child Nrio16Module “device level” component. This
Nrio16Module has a default name of “LocalIo16”.

4

• If there are no remote I/O modules (IO-16-REM-H) this is the only Nrio network needed in the station.
The M2mIoNetwork has a fixed “Port Name” property of COM3, and a “Trunk” property of 1.

• If any remote I/O modules are connected to the controller’s RS-485 port, the station needs an additional NrioNetwork, with a
“Port Name” property of COM2, and “Trunk” property of 2. For more details, see the
see

Wiring to Remote I/O Modules on page 23

WEB/CP-202-XPR, due to platform resource considerations.
After remote I/O modules are discovered and added to the station under this separate NrioNetwork (each as one as an

Nrio16Module), the serial status LEDs for the controller’s RS-485 port (S2TX, S2RX) continually flash, reflecting polling
activity. See About LEDs on page 25 for more details. Also, the “STATUS” LED on each remote I/O module lights solid green.

NOTE: Any time a remote I/O module’s status LED is not lit solid green, all of its outputs are in “fail-safe” state (all relay outputs

OFF, and all AOs are at a 0-volt level).
Blinking of a remote I/O module’s status LED occurs for two reasons, shown at different rates:

- Rapid flash (low duty cycle), meaning the unit is unconfigured. Discovery and addition to the station database is
required.

- Equal time on and off (50% duty cycle), meaning the unit is configured, but currently offline with the controller. Check
RS-485 wiring between the controller and remote I/O module.

NiagaraAX NRIO Guide. For wiring details,

. Note that a maximum of three IO-16-REM-H modules is recommended for a

19 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

M28877

RIGHT SIDE
COVER
REMOVED

RS-485

COM2

RS-232
(RJ-45)

COM1

OPTION SLOT

CONNECTOR AREA

(SEE ABOUT

OPTION CARDS

ON PAGE 12)

SEC

SECONDARY

ETHERNET

(RJ-45)

USB PORT
WEB/CP-602-XPR
ONLY
(FUTURE USE)

UNIVERSAL
INPUTS
(8 TOTAL)

PRI
PRIMARY
ETHERNET
(RJ-45)

EXTERNAL 12V

12V + P BATT. OUT (PB)

15V PS + OUT (PB+)

15V PS - OUT (PB-)

RELAY
OUTPUTS (4)

ANALOG

OUTPUTS (4)

EARTH GROUND
TERMINALS (10)

S + –

For both local and remote I/O, each input or output used requires a special NiagaraAX Remote Input/Output (Nrio) point to be
added in the station database. These components act as the station interface to the physical I/O points. The Nrio points you need
for each input or output type are noted in previous wiring sections in boldface.

For Nrio software details, see the NiagaraAX NRIO Guide in Workbench online Help, or the same document in PDF.

COMMUNICATIONS WIRING

Communications ports on the controller are alongside the edge of the controller board, accessible with the right cover removed
(Fig. 15). Communications port types include Ethernet and Serial.

NOTE: Prior to connecting cables, provide strain relief for them to prevent damage to the controller.

Fig. 15. Controller communications ports and other connectors.

Ethernet

Two, female 10/100 Mbps Ethernet connections are provided on the controller. These are RJ-45 connectors labeled PRI and
SEC. Use a standard Ethernet patch cable for connecting to a hub or Ethernet switch.

The controller’s factory-default IP address for PRI (NET1) is
matches the last digit in the controllers’s serial number, and the subnet mask is
By default, SEC (NET2) on the unit is disabled.

Refer to the JACE NiagaraAX Install and Startup Guide for details on changing IP address.

NOTE: Typically, you only use PRI (primary port), unless you have a specific application for isolating a driver’s network traffic to

a separate LAN, using SEC. Do not use SEC as the primary port.

Serial

There are two “RS” serial ports on the controller’s base board. Each has a UART capable of operation up to 115,200 baud.

• An RS-232 port uses an RJ-45 socket connector, and operates as COM1.

• An isolated RS-485 port is on three terminals of a 6-position screw-terminal connector, and operates as COM2 (by default).

95-7775—01 20

192.168.1.12n, where the last numeral n in the address

255.255.255.0.

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

NOTES:

1. An additional serial port may be added with an option card in Option Slot 1, such as an NPB-RS232 card (port oper­ates as COM7) or NPB-2X-RS485 card—note this option actually adds two serial ports, which operate in the control­ler as COM7 and COM8.

2. If a dialup modem option card (NPB-MDM) is installed, this effectively disables the onboard RS-232 port, and the
modem operates as COM1. Note that this option card is not supported if the controller is equipped with the

onboard GPRS modem.

RS-232

RS-232 serial port connections can be made to the female (socket) RJ-45 connectors using an 8-conductor flat “silver satin”
stranded cable with standard male (plug) RJ-45 connectors. Connect the flat satin cable (maximum distance 50 feet) through the
enclosure knockout nearest the port. This “straight-through” cable is then connected to a socket-to-socket type RJ-45 to DB-9
adapter.

The controller is a serial DTE device, such another DTE device (PC, for example) requires a “null modem” adapter (part number
H10148, optional item). If connecting the controller to a DCE device (modem, for example), a straight-through adapter may be
used. Table 3 on page 21 provides pinouts for both types of RJ-45 to DB-9 adapters.

NOTES:

1. Silver satin cable is not standard Ethernet UTP cable, in which the pairs are twisted around each other. The twisting
of the pairs may cause undesirable effects on the serial communication, therefore we recommend the use of flat sil­ver satin cable instead. Note that flat silver satin cable is unshielded. If installing this cable in a noisy electrical envi­ronment, run the cable through conduit.

2. If you need a temporary serial shell connection from your PC to the controller, and you have the necessary RJ-45 to
DB-9 null modem adapter (part number H10148), but you have no silver satin cable, you can substitute an ordinary
Ethernet patch cable. However, using silver satin cable is recommended for any permanent RS-232 connection, for
reasons mentioned above.

3. If rebooted with the mode jumper in the “Serial Shell” position (see Fig. 6 on page 11), the RS-232 port provides
“system shell” access. See the JACE NiagaraAX Install and Startup Guide for related details about system shell.
Note that if a dialup modem option card (NPB-MDM) is installed, this modem is disabled during this “serial shell”
access. NPB-MDM operation resumes only after putting the mode jumper back to the “Normal” position, and then
rebooting the controller.

Table 3. RJ-45 to DB-9 adapter pinouts.

RJ-45 and DB-9

Pinout References Type of Adapter

Null Modem

RJ-45 SOCKET (FEMALE)

(for connecting to
another DTE device)
Part number 10148

18

Straight-through

(for connecting to

DB-9 SOCKET (FEMALE)

15

96

M28878

a DCE device)

RJ-45

Socket Pin Signal

5 DCD Data carrier detect 1

3 TXD Transmit data 2

6 RXD Receive data 3

8 DSR Data set ready 4

4 GND Ground 5

1 DTR Data terminal ready 6

7 CTS Clear to send 7

2 RTS Request to send 8

— not used on the controller 9

5 DCD Data carrier detect 1

6 RXD Receive data 2

3 TXD Transmit data 3

1 DTR Data terminal ready 4

4 GND Ground 5

8 DSR Data set ready 6

2 RTS Request to send 7

7 CTS Clear to send 8

— not used on the controller 9

DB-9

Socket Pin

21 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

RS-485

An RS-485, optically isolated port is available on 3 pins of a 6-position connector, and operates by default as COM2. As shown in
Fig. 15 on page 20, the screw terminals are minus (–), plus (+), and shield. Wire in a continuous multidrop fashion to other
RS-485 devices, meaning “minus to minus,” “plus to plus,” and “shield to shield.” Connect the shield to earth ground at one end
only, such as at the controller. For wiring to one or more remote I/O modules (IO-16-REM-H), see Wiring to Remote I/O
Modules on page 23.

NOTE: If enabled to do so, the controller’s RS-485 port can be alternatively used as a Sedona/Jennic IPv6 wired connection. In

that case, COM2 is unavailable to NiagaraAX. However, note at the time of this document, the released
WEB/CP-202-XPR controller does not include the onboard Jennic module.

EXTERNAL 12V BACKUP BATTERY

The controller provides a 2-position connector for support of an external 12V sealed lead-acid (SLA) type rechargeable battery
(part number 712BNP). Usage is optional. For more details, see Backup Battery on page 25.

WEB/CP-202-XPR, WEB/CP-602-XPR

NOTE:

CONTROLLER TERMINALS BT+ AND BT- SUPPLY CHARGING VOLTAGE
AT 200mA MAXIMUM. THIS TRICKLE CHARGES THE CONNECTED SLA BATTERY BACKUP.

NOTE - MINIMUM WIRE SIZE:

• 18AWG (1.0m m) for up to 4 ft. (1.22m )

• 16AWG (1.29 mm) for up to 12 ft. ( 3.66 m).

+

PS

PS

BB

RS-485 –

RS-485

485 GND

BT

BT

–

+

–

+

15 VDC POWER AND BACKUP BATTERY
PASSED THROUGH 6-POSITION CONNECTOR.

–

1 2V SEAL ED L EAD ACI D

+

BAC KUP B ATTE RY(IE S)

712BNP

M28879

Fig. 16. Sealed lead-acid backup battery connection on the WEB/CP-202-XPR or WEB/CP-602-XPR.

95-7775—01 22

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

PS

–

PS

+

BB

RS-485

–

RS-485 +

485 GND

PS

–

PS

+

BB

PS

–

PS

+

BB

PS

–

PS

+

BB

–

+

S

–

+

S

–

+

S

POWER SUPPLY (15V) AND 12V BACKUP BATTERY IS
WIRED TO REMOTE IO MODULES USING A 3-CONDUCTOR
WITH SHIELD CABLE.

USE THE SHORTEST WIRING ROUTE POSSIBLE FOR
POWER WIRING. STAR, TEE, BUS AND LOOP
TOPOLOGIES ARE ALL PERMISSIBLE.

USE STANDARD VOLTAGE DROP CALCULATIONS FOR DISTANCE
AND WIRE GAGE TO ENSURE THAT VOLTAGE AT THE FURTHEST
REMOTE MODULE IS NO LESS THAN 11.5 VDC.
FOR LONGER RUNS, AN AUXILIARY POWER SOURCE MAY BE
REQUIRED FOR THE REMOTE MODULES.

CONNECT SHIELD WIRE TO

GROUND AT ONE END ONLY.

RS-485 COMMUNICATIONS IS DAISY-CHAINED TO

REMOTE IO MODULES USING A SHIELDED TWISTED-PAIR CABLE.

CONNECT RS-485 SHIELD WIRE TO

GROUND AT ONE END ONLY.

NOTE:
A MAXIMUM OF THREE REMOTE IO-16-REM-H
MODULES IS RECOMMENDED FOR THE
WEB/CP-202-XPR, DUE TO PLATFORM RESOURCE
CONSIDERATIONS.

IO-16-REM-H IO-16-REM-H

WEB/CP-202-XPR, WEB/CP-602-XPR

M28880

WIRING TO REMOTE I/O MODULES

Wiring to remote I/O modules (IO-16-REM-H) typically provides both 15 Vdc power and 12V battery backup to the modules,
along with RS-485 communications. See Fig. 17.

Fig. 17. RS-485 cabling between WEB/CP-202-XPR and WEB/CP-602-XPR and remote I/O modules.

For related information, see the IO-16-REM-H Installation and Configuration Instructions document.

POWER UP AND INITIAL CHECKOUT

Following all mounting and wiring (I/O Wiring, Communications Wiring, External 12V Backup Battery, Wiring to Remote I/O
Modules), perform the following:

Initial power up and checkout

1. Apply Power.

2. Check the Status LEDs.

Also see the section About the Backup Batteries on page 24.

23 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

Apply Power

The WEB/CP-202-XPR and WEB/CP-602-XPR controllers do not include an on/off switch. To apply power, you simply energize
the 24 Vac transformer (or 24 Vdc power supply) wired to the 3-position power input terminals. If remote I/O modules are wired to
the unit, they are also typically powered by the controller as well.

Check the Status LEDs

When power is applied, the (top) green LED STATUS will light. This indicates that the system is OK and that power is applied.
Once the controller boots, the yellow BEAT (heartbeat) LED under it will begin a steady blink, with a typical rate of about 1 Hz.
Blinking should begin within 30 seconds after power is applied.

If after applying power, the STATUS LED goes out, or if the yellow BEAT LED comes on (steady) and stays lit longer than two
minutes, contact Systems Engineering for technical assistance. Also see About LEDs on page 25.

About the Backup Batteries

The WEB/CP-202-XPR and WEB/CP-602-XPR controllers can have two different backup batteries:

• The standard on-board NiMH battery pack, and

•An optional external, sealed lead-acid, rechargeable Backup Battery (or batteries)

For continuous system operation during loss of primary AC power, unless power loss is only a few seconds, both batteries should
be installed. Station alarms are generated if either battery is uncharged or unable to hold a sufficient charge, as well as whenever
primary power is lost. You should always investigate any alarm related to backup batteries.

NiMH battery pack

NOTE: See NiMH Battery Precautions on page 6.

A custom 10-cell NiMH (nickel metal hydride) battery pack is mounted inside the controller, under the cover atop a metal shield
plate (see Fig. 1 on page 2). This battery allows the controller to continue station operation (only) through very short power
bumps, meaning a few seconds in duration. If a longer outage occurs, the NiMH battery provides enough run time for the unit to
backup data and then shutdown. Typically, this process takes about one minute. Shutdown occurs automatically, after data is
backed up to on-board flash memory.

Upon startup (boot), a test of the NiMH battery is performed. A system alarm is generated if the NiMH battery voltage level is
found to be bad. A charge is also initiated upon startup, which lasts from 3 hours minimum, and can range up to 18 hours if the
battery is completely discharged.

During this NiMH battery charge period, neither the NiMH battery or the external Backup Battery (if installed) is tested. After the
startup NiMH charge period, a periodic test occurs of the NiMH battery and the external sealed lead acid backup battery. The
appropriate battery alarm is generated is either battery is found to be bad.

NOTES:

1. If the last NiMH battery test was “bad,” upon loss of primary power, the controller performs an immediate shutdown,
backing up data and powering off (including expansion modules).

2. A NiMH battery characteristic is to lose charge if not left in charge mode (trickle charge). Leaving the battery uncon­nected, or in the unit powered off will cause the battery to fully discharge in a matter of weeks. Note that in the case
of a new controller, the battery pack ships from the factory completely discharged. Therefore, allow at least 18 hours
for the battery to charge if it has not been in a powered unit.

Replace the NiMH battery pack approximately every three years, or more often if the unit is in a high temperature environment.
For more information on the use and replacement of the battery, refer to Required NiMH Battery Maintenance on page 27.

95-7775—01 24

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

Backup Battery

The optional sealed lead-acid backup battery is an external, 12V, rechargeable battery (or multiple batteries) sized to operate the
system during loss of primary power for some duration, typically four (4) hours. The current load includes the controller, as well as
power to attached remote I/O expansion modules.

Connect the backup battery to the controller using a 2-position connector (see Fig. 16 on page 22).

Whenever primary-powered, the controller supplies a constant “trickle” charge to this battery, at 200mA maximum.

NOTE: Use the 712BNP Sealed Lead Acid Backup Battery.

Providing the controller platform is so configured, at startup (boot), a test of the backup battery is performed, as well as a periodic
test. A system alarm is generated if a battery test deems the backup battery to be bad. If the backup battery has tested good,
upon loss of primary power the system operates from this backup battery power until the charge level of the on-board NiMH
battery pack reaches 0. Note that both batteries discharge in parallel. However, as the sealed lead-acid backup battery capacity
is much greater, the NiMH battery pack discharges much slower than if these backup batteries were bad or not present.

NOTE: If the backup battery test was “bad,” upon loss of primary power, the controller performs an immediate shutdown,

backing up data and powering off (including expansion modules).

Replace the sealed lead-acid backup batteries approximately every three (3) years, or more often if the unit is in a high
temperature environment.

ABOUT LEDS

The WEB/CP-202-XPR and WEB/CP-602-XPR provide a number of LEDs, most of which are visible on the left cover. Fig. 18
shows LED locations, along with following descriptions.

1

STATUS

ETHERNET

RELAY OUT

(FUTURE USE)

BEAT

PRI

SEC

GPRS

K4

K3

K2

K1

1

LED COLORS: = GREEN, = YELLOW

SERIAL PORT LEDS

COM1 (RS-232)

S1TX
S1RX

1

COM2 (RS-485)

S1TX
S1RX

NOTE:
TO CHECK THE FOUR
SERIAL PORT LEDS,
REMOVE THE RIGHT COVER.

M28881

Fig. 18. LEDs on the WEB/CP-202-XPR and WEB/CP-602-XPR.

Status

The green STATUS LED is located on the cover. The status LED should remain lit whenever the controller is powered, or else be
blinking during the boot sequence. If the status LED does not light while power is applied, contact System Engineering for
technical support.

25 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

Beat

The yellow heartbeat BEAT LED is located on the cover. Following boot-up, the heartbeat LED blinks about once per second. If
the heartbeat LED stays on constantly, does not light, or blinks very fast (more than once per second), contact System
Engineering for technical support.

Ethernet

A green activity LED for each of the two LAN ports (PRImary for LAN1, SECondary for LAN2) is located on the cover under the
STATUS and BEAT LEDs, and operate as follows.

• Off – No Ethernet link is made

• On – Ethernet link is present, but no activity on the LAN

• Blinking – Ethernet link is present with data activity on the LAN.

Relay Out

Each of the four relay outputs has an associated green LED on the cover, “K4” to “K1” (from top-to-bottom). Under normal
operation, each digital status LED indicates activity as follows:

• Off – relay open / no current flows.

• On – relay closed / load current flows.

Therefore, an On status indicates that the load is powered.

(Future Use) JENNIC

The green JENNIC LED provides status for the onboard Sedona/Jennic wireless module, and is visible on the cover. (Sedona/
Jennic module not included in the current product release. Currently, this LED should remain Off without activity).

GPRS

The GPRS LED provides status of the onboard GPRS modem (for controller models so equipped), and is visible on the cover. It
flashes various LED patterns based on the state of the modem. This LED is directly under control of the modem itself, versus
Niagara

Upon initial power up, the GPRS LED pattern is typically 600ms On and 600ms Off, and may change depending on various
modem state changes. If the controller does not have the integral GPRS modem, this LED should remain Off without activity.

AX

software.

Serial

LEDs for the two serial ports are located on the controller’s main board, near the Analog Output terminals (Fig. 18 on page 25).
Board markings S1 and S2 correspond to the software configuration of the COM1 and COM2 ports. LEDs show the transmit (TX)
and receive (RX) activity for the two serial ports.

You must remove the right cover to see the serial port LEDs. See Removing and Replacing the Covers on page 8.

• The yellow TX (transmit) LED indicates that the controller is sending data out the serial port over a communications line to a
connected device.

• The green RX (receive) LED indicates that the controller is receiving data from a connected device.

These LEDs provide a fixed on-time when data is detected on the port. If the receive LED is on constantly, this indicates a
problem with the communications channel, such as a shorted wire or reversed wiring.

NOTE: If the RS-485 port is connected to configured remote I/O modules (IO-16-REM-H), during normal operation the COM2

LEDs both continuously flash about 3 times a second, indicating ongoing polling.

95-7775—01 26

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

CAUTION

MAINTAINING THE WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

This section provides information on the following topics:

• Cleaning

• Required NiMH Battery Maintenance

• Replacement Parts

• Replacing the WEB/CP-202-XPR or WEB/CP-602-XPR Controller

• Returning a Defective Unit

Cleaning

If dust or metal filings are present inside the unit, clean with vacuum or compressed air. Otherwise, no cleaning inside the unit is
required. Optionally, if the covers become dirty, you can wipe them with a damp cloth and mild detergent.

Required NiMH Battery Maintenance

NOTE: See NiMH Battery Precautions on page 6.

Battery life expectancy is a function of its discharge cycles (the number of discharges and their depth) and the ambient
temperature of the battery during normal operation. In most applications, the NiMH battery should see relatively few discharges.
Therefore, ambient temperature has more to do with determining the life expectancy of the battery than does any other factor. If
the controller is installed in a conditioned space, this battery should provide dependable service for approximately three years
(average). In an environment where the operating temperature is higher (that is, 50°C or 122°F), you should only expect the
battery to last approximately one year.

The NiMH battery in the controller is fully discharged when factory shipped. Additionally, NiMH batteries lose charge over time if
not kept trickle-charged (for more details, see NiMH battery pack on page 24). Therefore, even a new unit (or replacement
battery) will require up to 18 hours of powered operation before it can provide reliable backup power (is at full charge).

The controller monitors the NiMH battery and periodically loads the battery to test its ability to maintain battery-backed functions.
Investigate any battery trouble message, and check the battery connections to the unit. Replace the battery as required. To order
a new battery, see Standard Replacement Parts on page 29. See the next section, Replacing the NiMH Battery, for a
replacement procedure.

Replacing the NiMH Battery

The replacement NiMH battery is an assembly, that is a custom battery pack mounted on a bracket, with an attached cable and
connector plug (see Fig. 19 on page 28). To replace the battery, you must remove power to the unit and remove both covers.

Use only NiMH battery packs approved for use with the WEB/CP-202-XPR and WEB/CP-602-XPR controllers.

Replacing NiMH battery assembly in a WEB/CP-202-XPR or WEB/CP-602-XPR.

AX

1. Backup the controller’s configuration to your PC using the appropriate Niagara

2. Remove all power from the controller, including disconnecting any sealed lead-acid battery. Wait for LED activity to stop—

after a couple of minutes, all LEDs on the unit should be off.

3. Remove both covers. See Removing and Replacing the Covers on page 8.
At this point you have access to the NiMH battery assembly (Fig. 19 on page 28).

software tool (for example, Workbench).

27 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

UNPLUG BATTERY CONNECTOR

FROM MAIN CONTROLLER BOARD

NOTE:
DISPOSE OF THE USED
NIMH BATTERY PROPERLY.
SEE BATTERY DISPLOSAL
ON PAGE 31.

Fig. 19. Replacing NiMH battery pack in WEB/CP-202-XPR or WEB/CP-602-XPR.

REMOVE THE THREE PHILLIPS HEAD
SCREWS AND LIFT ASSEMBLY AWAY

INSTALL REPLACEMENT BATTERY ASSEMBLY
AND REPLUG THE CONNECTOR INTO THE
CONTROLLER BOARD

M28882

4. Unplug the NiMH battery from the main board connector (see Fig. 19).

5. Remove the three Phillips head screws fastening the battery bracket, and set aside.

Remove the NiMH battery assembly.

6. Plug the battery connector plug of the replacement battery assembly into the NiMH battery connector on the controller’s
main board. The connector is keyed; you cannot plug the battery in reversed.

7. Set the replacement battery/bracket assembly in place, with the three mounting holes aligned with the standoffs on the
controller board.

8. Place the three screws through the holes in the bracket and into the standoffs. Use a Phillips head screwdriver to hand
tighten these screws.

9. Replace the covers.

10. Restore power to the controller and verify normal operation.

Battery Disposal

Please dispose of the used NiMH battery in accordance with local, state, and federal regulations.

Do not incinerate or mutilate the battery, as this may cause it to burst or release toxic materials.

If regulations specify returning the old battery to a recycling center, but no acceptable recycling center can be found, please
return the old NiMH battery pack to Tridium

®

for proper disposal.

REPLACEMENT PARTS

Servicing the WEB/CP-202-XPR or WEB/CP-602-XPR may call for replacement parts. There are three categories of parts:

• Non-replaceable Parts

• Standard Replacement Parts

• New Replacement Unit

95-7775—01 28

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

WARNING

CAUTION

Non-replaceable Parts

Fuse

The controller contains a non-user replaceable fuse, soldered on the main circuit board. This fuse provides protection from
internal shorts or connection to incorrect power supplies. If the fuse circuitry is suspect, contact your regional Tridium office for
technical support. See Returning a Defective Unit on page 31.

Standard Replacement Parts

Standard replacement parts are listed in Table 4 and can be ordered from stock without restriction. Standard replacement parts
cannot be returned for credit and should be disposed of in an appropriate manner.

Table 4. Standard Replacement Parts for WEB/CP-202-XPR or WEB/CP-602-XPR.

Part Number Description

H11393 NiMH Battery Pack Assembly; see Replacing the NiMH Battery on page 27.

H11364 Hardware Bag for WEB/CP-202-XPR or WEB/CP-602-XPR containing removable screw terminal

connector blocks (two 7-position, three 6-position, one 2-position).

H11166 Replacement right-angle GSM/GPRS quad-band SMA coax-mounted stub antenna.

H-GPRS-CBL-EXT 6.56 feet (2m) SMA-type coax extension cable with mounting bracket. See Fig. 2 on page 7.

H10148 Adapter; RJ-45 to DB-9 null modem for onboard RS-232 serial port to connect to DTE device.

H10180 Silver satin patch cable; 4 feet (used between adapter and serial port).

H10181 Silver satin patch cable; 10 feet (used between adapter and serial port).

H10182 Silver satin patch cable; 25 feet (used between adapter and serial port).

712BNP External 12 Vdc sealed lead acid backup battery.

New Replacement Unit

To replace an entire unit, order and install a new WEB/CP-202-XPR or WEB/CP-602-XPR. If the faulty controller is still in
warranty, you may receive credit by returning it to Tridium. Contact Tridium for a return authorization (RMA) number before

shipping any item for return credit. See Returning a Defective Unit on page 31, for more details.

NOTE: Before ordering a new replacement unit, it is strongly recommended that you contact your normal technical support

resource to eliminate the possibility of a software issue or mis-configuration problem.

REPLACING THE WEB/CP-202-XPR OR WEB/CP-602-XPR CONTROLLER

Before replacing, power to the controller must be OFF, and all LEDs out! In addition, power must be removed to
any I/O devices wired back to the controller. Failure to do so may result in electrical shock or equipment damage.

Before handling circuit boards, discharge any accumulated static by touching a nearby grounded object. For
details, see “Static Discharge Precautions” section on page 6.

To replace a controller with a new replacement unit, proceed as follows:

Replacing a controller.

1. If possible, use the appropriate Niagara

2. Disconnect power to the controller, including the disconnection of an external 12V battery, if used. The unit should power

down automatically. Wait for all LEDs to remain off.

3. Disconnect all power to any I/O devices wired to the controller.

AX

software tool to back up the controller’s configuration to your PC.

29 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

NOTE: Typically, if I/O wiring is routed through rear knockouts, you must remove it from the controller’s screw terminal blocks,

so that the wiring can pass through the knockouts. In this case, it is extremely important to remove all related power
sources, in order to prevent electrical shock and equipment damage.

4. Remove both covers. See Removing and Replacing the Covers on page 8.

5. Note positions of all communications and other wiring cables going to the controller. Label cables and wires to avoid mis-

connection later, when re-terminating to the replacement controller.

6. Unplug all Ethernet, serial, LON, and I/O connectors from the controller. If needed, remove wiring from I/O terminal blocks,
carefully labeling conductors for proper re-termination.

7. Remove all cable shield wire terminations to the earth grounding terminal strip.

8. Remove the AC line and neutral (mains) and earth ground terminations from the 3-position screw terminal block.

9. Loosen any conduit clamps to the unit.

10. Remove the two mounting screws in the lower mounting tabs.

11. Slide the unit up for the top mounting screw to clear the keyhole slot, and move the unit away from the wall, working the

cables and wiring out through the wiring holes and knockouts.
Free the unit from all wiring and place on a flat work surface.

12. If applicable, remove any option card installed in the old controller, and install the card into the replacement controller. See
Installing an Option Card on page 12 for more details.

13. Reroute the removed power, communications, and I/O wiring through the knockouts and wiring holes in the replacement

controller (as done previously), and position the unit in place on the wall.
Place it over the top mounting screw and slide down to hook into the keyhole slot.

14. Replace the two mounting screws in the lower mounting tabs.

15. Tighten any conduit clamps on the unit.

16. Reconnect the earth ground wire and the AC line and neutral wires (mains) to the 3-position terminal block in the unit.

17. Replace the left cover and metal shield over the AC/earth ground terminals.

18. As needed, reconnect any I/O wiring to terminal blocks, and re-plug I/O terminal blocks onto the replacement controller

board.

19. Reconnect all Ethernet, serial, and LON wiring to the controller.

20. Reconnect all cable shield wire terminations to the earth grounding terminal strip.

21. If power was disconnected to remote I/O devices wired to the controller, restore that power.

22. Restore power to the unit. It should boot up as a new unit. See Check the Status LEDs on page 24.

23. Replace the right cover. See Removing and Replacing the Covers on page 8.

24. Using the Niagara

AX

platform tools, re-commission the controller, and install the saved station database. For more details,

see the JACE NiagaraAX Install and Startup Guide.

95-7775—01 30

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

RETURNING A DEFECTIVE UNIT

NOTE: If the defective unit is under warranty, please follow return instructions provided in this section.

If the unit is out of warranty, please discard any replaced part.

• Do not return an out-of-warranty controller to Tridium.

For proper credit on an in-warranty unit, ship the defective unit to Tridium within 30 days.

Prior to returning the unit, contact one of the following Tridium offices to obtain a return authorization (RMA) number and other
instructions. Please provide:

• Product model • Serial number • Nature of the defect • Purchase order number to secure RMA

United States

Phone: [phone], ext. 11 E-mail for RMA: [e-mail]

Return to:

Tridium, Inc.
2256 Dabney Road, Suite C
Richmond, VA 23230
Attn: Return Department RA# ________

Asia/Pacific

Phone: [phone] Fax: [phone]

Address:

Tridium Asia Pacific Pte Ltd E-mail for technical support: [e-mail]
17 Changi Business Park Central 1
Honeywell Building Attn: Mr Lim Hoon Chat, Engineering Mgr.
Singapore 486073
Attn: Return Department RA# __________

Sales: (Australia/Asia Pacific):

Phone: [phone] E-mail: [e-mail]

31 95-7775—01

WEB/CP-202-XPR AND WEB/CP-602-XPR CONTROLLERS

CERTIFICATIONS

Federal Communications Commission (FCC)

This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the
instruction manual, may cause interference with radio communications. It has been tested and found to comply with the limits for
a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection
against such interference when operated in a commercial environment. Operation of this equipment in a residential area may
cause interference, in which case, users at their own expense will be required to take whatever measures may be required to
correct the interference. Any unauthorized modification of this equipment may result in the revocation of the owner's authority to
continue its operation.

Canadian Department of Communications (DOC)

This Class A digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations.

Cet appareil numerique de la classe A respecte toutes les exigencies du Reglement sur le material broilleur du Canada.

CE Declaration of Conformity

Date: February, 2009

Application of Council Directive: 89/336/EEC, 92/31/EEC, 73/23/EEC, 93/68/EEC

Manufacturer: Tridium Inc.

3951 Westerre Parkway, Suite 350
Richmond, Virginia 23233
United States of America

Manufacturer’s Representative: Steve Fey, President, Tridium Inc.

Product Model Numbers: WEB-202-XPR, WEB-202-XPR-GW, WEB-602-XPR, WEB-602-XPR-GW, CP-202-XPR,

CP-202-XPR-GW, CP-602-XPR, and CP-602-XPR-GW

Type of Equipment: Electrical Equipment for Measurement, Control, and Laboratory Use

EMS Standards Applied: Standard Description Criteria Met

CISPR 16-2-3:2006 Radiated Emissions - Class A Complies
IEC 61000-4-2 Electrostatic Discharge Immunity PASS Class B
IEC 61000-4-3 Radiated Electromagnetic Field Immunity PASS Class A
IEC 61000-4-4 Electrical Fast Transient / Burst Immunity PASS Class B
IEC 61000-4-6 Conducted Radio-Frequency Immunity PASS Class A
IEC 61010-1:2001

rev. 9/19/03

Safety requirement for electrical equipment
For measurement, control, and laboratory use

PASS

PowerPC® is a registered trademark of International Business Machines Corporation.

®

JACE

and JAVA® are registered trademark of Sun Microsystems, Inc.
LON® and LonWorks® are registered trademarks of Echelon Corporation.
Niagara
Tridium® and Niagara Framework® are registered trademarks of Tridium, Inc.
QNX

Automation and Control Solutions

Honeywell International Inc.

1985 Douglas Drive North

Golden Valley, MN 55422

Honeywell Limited-Honeywell Limitée

35 Dynamic Drive

Toronto, Ontario M1V 4Z9

customer.honeywell.com

AX

™ and the Niagara logo are trademarks of Tridium, Inc.

®

is a registered trademark of QNX Software Systems, Ltd.

® U.S. Registered Trademark
© 2010 Honeywell International Inc.
95-7775—01 M.S. 04-10
Printed in U.S.A.