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Emerson Bristol ControlWave Express, Instruction Manual

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ControlWave Express Instruction Manual (CI-ControlWave Express)

  

Revised Mar-2011 

Installation 

2-15 

 

Figure 2-5. Male DB9 9-Pin Connector

 

Table 2-6. RS-232 COM1 and COM2 Port Connector Pin Assignment 

 

Pin  

RS-232 

Signal 

 

RS-232 Description 

1 

DCD 

Data Carrier Detect Input 

2 

RXD 

Receive Data Input 

3 

TXD 

Transmit Data Output 

4 

DTR 

Data Terminal Ready Output 

5 GND 

Power 

Ground 

6 

DSR 

Data Set Ready Input 

7 

RTS 

Request to Send Output 

8 

CTS 

Clear to Send Input 

9  

N/A 

 

Use the “null modem” cable for full-duplex (PPP protocol) 
communications when connecting a ControlWave Express to a PC. (See 
top part of 

Figure 2-6

.) 

 

Table 2-7. RS-232 COM1 (J11) Alternate Connector Pin Assignment 

 

Pin  

RS-232 

Signal 

 

RS-232 Description 

1 GND 

Power 

ground 

2 

RXD 

Receive data input 

3 

TXD 

Transmit data output 

 

Summary of Contents for Bristol ControlWave Express

Page 1: ...www EmersonProcess com Remote Instruction Manual CI ControlWave Express Part D301386X012 March 2011 ControlWave Express ControlWave Express Remote Terminal Unit Remote Automation Solutions ...

Page 2: ...turning any equipment to RAS for repairs or evaluation please note the following The party sending such materials is responsible to ensure that the materials returned to RAS are clean to safe levels as such levels are defined and or determined by applicable federal state and or local law regulations or codes Such party agrees to indemnify RAS and save RAS harmless from any liability or damage whic...

Page 3: ...r operation Emerson offers a full schedule of classes conducted by full time professional instructors Classes are offered throughout the year at various locations By participating in our training your personnel can learn how to install calibrate configure program and maintain your Emerson products and realize the full potential of your system For information or to enroll in any class go to http ww...

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Page 5: ...net Port on the CPU System Controller Board 2 21 2 4 Optional Display Keypads 2 22 Chapter 3 I O Configuration and Wiring 3 1 3 1 I O Options 3 1 3 2 Process I O Board 3 2 3 2 1 Setting Jumpers on the Process I O Board 3 2 3 2 2 Setting DIP Switches on the Process I O Board 3 2 3 3 I O Wiring 3 4 3 3 1 Non Isolated Discrete Inputs DI on TB2 and TB3 of Process I O Board 3 6 3 3 2 Non Isolated Discr...

Page 6: ...5 5 5 2 1 Accessing Modules for Testing 5 5 5 2 2 Removing Replacing the CPU System Controller Board and the Process I O Board 5 5 5 2 3 Removing Replacing the Backup Battery 5 6 5 2 4 Enabling Disabling the Backup Battery 5 7 5 3 General Troubleshooting Procedures 5 8 5 3 1 Checking LEDs 5 8 5 4 WINDIAG Diagnostic Utility 5 12 5 4 1 Available Diagnostics 5 13 5 5 Core Updump 5 16 5 6 Calibration ...

Page 7: ...manufacturing Typical process inputs used by the ControlWave Express are pressure flow level temperature and frequency input typically used for positive displacement PD turbine or ultrasonic meters In some cases inputs may also be derived from external multivariable transmitters using either the BSAP or Modbus protocols When mounted in a suitable enclosure you can operate the ControlWave Express i...

Page 8: ...nd setting CPU jumpers and switches Chapter 3 I O Configuration Provides general information on wiring the process I O points Chapter 4 Operation Provides information on day to day operation of the ControlWave Express Chapter 5 Service and Troubleshooting Provides information on service and troubleshooting procedures 1 2 Physical Description The ControlWave Express consists of a CPU System Control...

Page 9: ...U I O monitor control memory and communication functions The CPU System Controller board includes Sharp LH7A400 System on Chip ARM microprocessor with 32 bit ARM9TDMI Reduced Instruction Set Computer RISC core with a system clock speed of either 14 MHz or 33 MHz two RS 232 communication ports one communication port configurable by jumpers as either RS 232 or RS 485 optional 10 100baseT Ethernet po...

Page 10: ... ohm platinum bulb Uses DIN 43760 curve 33MHz low power 12V or 24Vdc No Yes Yes No 33MHz 12V or 24Vdc Yes No No Yes same as ultra low power Note Each of the variants shown in Table 1 1 may be ordered with or without special gas calculation firmware CPU Backup Battery The CPU System Controller board has a coin cell socket that accepts a 3 0V 300 mA hr lithium battery This 3 0V battery provides back...

Page 11: ...ive historical data if not stored in FLASH the values of any variables marked RETAIN the values of any variables assigned to the static memory area and any pending alarm messages not yet reported 1 4 Power Options You can power the ControlWave Express by a user supplied rechargeable 6 12V lead acid battery used in conjunction with a solar panel other user supplied battery systems bulk nominal 6Vdc...

Page 12: ...ch allow you to create test implement and download complex control strategies for use with the ControlWave Express Figure 1 2 graphically presents the programming environment Figure 1 2 ControlWave Programming Environment The tools which make up the programming environment include ControlWave Designer is your load building package It offers several different methods for you to create control strat...

Page 13: ...ork of ControlWave controllers download files to the controllers and collect data from the network OpenBSI also exports data from the network to a SCADA host package such as OpenEnterprise For information on configuring OpenBSI communications see the OpenBSI Utilities Manual document D5081 OpenBSI Harvester is a special add on package that allows scheduled data collections from large networks For ...

Page 14: ...chronous Asynchronous Protocol BSAP ControlWave supports communications using Internet Protocol IP You can use an Ethernet port or use a serial port with serial IP using Point to Point Protocol PPP Other supported protocols include Modbus Allen Bradley DF1 CIP DNP3 and Hex Repeater See the ControlWave Designer online help for details and restrictions ...

Page 15: ...the Ethernet Port on the CPU System Controller Board 2 4 2 22 Optional Display Keypads 2 1 Site Considerations When choosing an installation site check all clearances Ensure that the ControlWave Express is accessible for wiring and service If present make sure the optional display keypad is accessible and visible The ControlWave Express comes in an enclosure chassis that you can mount to a panel o...

Page 16: ...ure that the ambient temperature and humidity at the installation site remains within these specifications Operation beyond the specified ranges could cause output errors and erratic performance Prolonged operation under extreme conditions could also result in failure of the unit Check the mounted enclosure panel or equipment rack for mechanical vibrations Make sure that the ControlWave Express is...

Page 17: ...tion of components may impair suitability for use in Class I Division 2 Group A B C and D environments When the ControlWave Express is situated in a hazardous location turn off power before servicing or replacing the unit and before installing or removing I O wiring Do not disconnect equipment unless the power is switched off or the area is known to be non hazardous 2 2 Installation Overview Insta...

Page 18: ...on Software installation and configuration is beyond the scope of this manual Refer to the Getting Started with ControlWave Designer Manual D5085 and the ControlWave Designer Programmer s Handbook D5125 for material related to software installation and use 2 2 1 Unpacking Components Packaging Depending upon how you order it the ControlWave Express may arrive pre assembled or in a number of separat...

Page 19: ...lWave Express Revised Mar 2011 Installation 2 5 I O power and communication cabling enters the unit through a slot on the left side of the removable card edge cover Refer to Figure 2 2 for mounting dimensions Figure 2 2 ControlWave Express Dimensions ...

Page 20: ...n grounding see the ControlWave Grounding Supplement S1400CW Additional grounding guidelines include Use stranded copper wire 4 AWG to earth ground and keep the length as short as possible Clamp or braze the ground wire to the ground bed conductor typically a stranded copper AWG 0000 cable installed vertically or horizontally Using a high wattage soldering iron crimp and solder the wire end you wi...

Page 21: ...onfiguration Options Switch Recovery Mode COM Status LEDs 1 O N 2 3 4 O N 1 2 3 4 5 6 7 8 Receive LED Transmit LED TXD GND DCD RXD DTR DSR RTS CTS TXD TXD GND GND DCD RXD RXD Input Input Output Output Output Input Input Input Input Output Output Output Input Input DTR DSR RTS CTS RTD Input 1 2 3 RTD CAUTION Damage WILL occur to the CPU if the Ethernet network is connected to connector J2 RTD EXC R...

Page 22: ...D status ON Enable all LEDs OFF Disable all LEDs except watchdog WD Table 2 2 CPU System Controller Board Switch SW2 SW2 Setting Function Mode 1 Watchdog Enable Controls whether the system enters a watchdog state when a crash or system hangup occurs and automatically restarts Values are ON Enables watchdog circuit factory default OFF Disables watchdog circuit and prevents automatic restart 2 Lock ...

Page 23: ...ly used 8 Enable WINDIAG Suspends normal operation and allows diagnostic routines Values are ON Permits normal system operation including the boot project and disables the WINDIAG diagnostics from running factory default OFF Allow WINDIAG to run test disable boot project and normal system operation Note Setting both switch 8 and switch 3 to OFF closed sets all communication ports to 9600 bps opera...

Page 24: ...e backup battery by setting jumper W3 to position 1 2 W3 Enable disable battery backup selection o 1 to 2 Installed Enable battery backup o 2 to 3 Installed Disable battery backup W5 Power supply shut down selection o 1 to 2 Installed 12 24V power supply shut down hysteresis o 2 to 3 Installed 6V power supply shut down hysteresis W6 Power supply shut down selection o 1 to 2 Installed 12V power sup...

Page 25: ...ntrolWave Express terminal blocks use compression type terminals that accommodate up to 16 AWG wire When making a connection insert the bare end of the wire approx max into the clamp adjacent to the screw and secure the screw To prevent shorts ensure that no bare wire is exposed If using standard wire tin the bare end with solder to prevent flattening and improve conductivity Allow some slack in t...

Page 26: ...process I O board 14 mA 33 MHz CPU with Ethernet and LCD display keypad Not Supported without process I O board 80 mA without process I O board 47 mA Note If your ControlWave Express includes an external modem or radio contact the radio modem manufacturer for power consumption specifications Caution If your ControlWave Express is configured to use a solar panel to charge a 7AH 6V or 12V battery fo...

Page 27: ... at connections TB1 1 and TB1 2 TB1 connections are TB1 1 Solar Power IN Power from a 1W 6V 5W 6V or 5W 12V solar panel internally wired to recharge a user supplied battery Not available on units with Ethernet TB1 2 Ground GND TB1 3 Primary Power Power from a user supplied nominal 6Vdc 12Vdc or 24Vdc power supply depending upon the CPU type TB1 4 Ground GND TB1 5 Auxiliary Power Out for an externa...

Page 28: ... 232 Connectors Connector Name Pins and Type Notes J4 COM1 9 pin male D type Choice of active connector for COM1 determined by jumper W18 J11 COM1 3 pin male Choice of active connector for COM1 determined by jumper W18 TB3 COM2 8 pin terminal block TB4 COM3 5 pin terminal block This port can be configured as either RS 232 or RS 485 See Section 2 3 6 for more information RS 232 COM1 COM2 Port Cable...

Page 29: ...Input 3 TXD Transmit Data Output 4 DTR Data Terminal Ready Output 5 GND Power Ground 6 DSR Data Set Ready Input 7 RTS Request to Send Output 8 CTS Clear to Send Input 9 N A Use the null modem cable for full duplex PPP protocol communications when connecting a ControlWave Express to a PC See top part of Figure 2 6 Table 2 7 RS 232 COM1 J11 Alternate Connector Pin Assignment Pin RS 232 Signal RS 232...

Page 30: ... TXD 6 DSR 7 RTS 8 CTS 4 DTR 2 RXD 1 DCD 5 GND 1 2 3 4 5 6 7 8 or or vice versa 3 TXD 2 RXD 7 RTS 8 CTS 4 DTR 1 DCD 5 GND To P2 Pin 2 To P2 Pin 3 To P2 Pin 4 To P2 Pin 5 To P2 Pin 1 or vice versa CW 9 Pin Female D Connector P1 3 TXD 7 RTS 8 CTS 4 DTR 2 RXD 1 DCD 5 GND TB3 COM2 P2 or J4 COM1 P2 3 TXD 7 RTS 8 CTS 4 DTR 2 RXD 1 DCD 5 GND 1 2 3 4 5 6 7 8 Figure 2 6 Full duplex and Half duplex Cable Us...

Page 31: ...To P2 Pin 1 3 TXD 7 RTS 8 CTS 4 DTR 2 RXD 1 DCD 5 GND P2 P2 P2 3 TXD 7 RTS 8 CTS 4 DTR 2 RXD 1 DCD 5 GND 1 2 3 4 5 6 7 8 or 3 TXD 6 DSR 7 RTS 4 DTR 2 RXD 1 DCD 5 GND 8 CTS 1 2 3 4 5 6 7 8 Figure 2 7 Full duplex and Half duplex Cable Refer to Figure 2 8 when using COM2 of the ControlWave Express to connect with an external modem or external radio PL Modem or Radio Intf Cable PSTN Modem Intf Cable T...

Page 32: ...nd Half duplex Cable RS 232 Cable Guidelines Observe the following guidelines when constructing RS 232 communication cables Ensure that DCD is high to transmit except when dialing a modem Verify that each RS 232 transceiver has one active receiver while disabled in power down mode connect the DCD signal to the active receiver Set CTS to high to transmit If the port is set for full duplex operation...

Page 33: ... Pin Signal Description 1 RXD Receive Data input Not applicable for RS 232 usage 2 RXD RXD Receive Data Input 3 TXD TXD Transmit Data Output 4 TXD Transmit Data Output Not applicable for RS 232 usage 5 Power Ground Ground When serving as an RS 485 port COM3 supports local network communications to multiple nodes up to 4000 feet away Since the RS 485 port is intended for network communications refe...

Page 34: ...t distant slave units end nodes These end nodes also require the insertion of 100Ω terminating resistors to properly balance the network You must also configure switches at each node to establish proper network performance Accomplish this by configuring switches listed so that the 100Ω termination resistors and biasing networks are installed at the end nodes and are removed at all other nodes on t...

Page 35: ...ace to an Ethernet hub A typical Ethernet hub provides eight 10 100Base T RJ 45 ports with port 8 having the capability to link either to another hub or to an Ethernet communications port Both ends of the Ethernet twisted pair cable are equipped with modular RJ 45 connectors 1 8 Looking into receptacle Figure 2 10 RJ 45 Ethernet Connector These cables have a one to one wiring configuration as show...

Page 36: ...pins swapped at the opposite ends of the cable see Figure 2 12 Figure 2 12 Point to Point 10 100Base T Ethernet Cable The maximum length of one segment CPU to hub is 100 meters 328 feet The use of Category 5 shielded cable is recommended 2 4 Optional Display Keypads The ControlWave Express supports two optional display keypads and a display without a keypad A 2 button keypad shown in the left of F...

Page 37: ...ble names on line 2 You connect the Display Keypad or Display to the ControlWave Express using a cable one end of which has an RJ 45 jack connected into the RJ 45 equipped with two plugs This cable connects between the RJ 45 display jack J2 on the CPU System Controller board and RJ 45 jack J1 on the remote Display or remote Display Keypad assembly A potentiometer provided on the keypad allows you ...

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Page 39: ...tput AO on TB7 of Process I O Board 3 3 5 Non 3 10 Isolated Pulse Counter Discrete Inputs on TB5 of CPU System Controller Board 3 3 6 Non 3 11 Isolated High Speed Counter HSC Discrete Inputs DI on TB4 of Process I O Board 3 3 7 3 12 Resistance Temperature Device RTD Inputs on CPU System Controller Board 3 3 8 3 14 Connections to a Bristol Model 3808 Transmitter 3 1 I O Options ControlWave Express ...

Page 40: ...iguration o 1 to 2 Installed external 24Vdc power o 2 to 3 Installed bulk input supply system power JP5 AI1 input type 1 5V or 4 20mA o 1 to 2 Installed 4 20mA analog input o 2 to 3 Installed 1 5V analog input JP6 AI2 input type 1 5V or 4 20mA o 1 to 2 Installed 4 20mA analog input o 2 to 3 Installed 1 5V analog input JP7 AI3 input type 1 5V or 4 20mA o 1 to 2 Installed 4 20mA analog input o 2 to ...

Page 41: ...s Instruction Manual CI ControlWave Express Revised Mar 2011 I O Configuration and Wiring 3 3 SW1 Function Mode SW1 4 AO configuration OFF current ON voltage Figure 3 1 Process I O Board Component Identification Diagram ...

Page 42: ... uses card edge terminal blocks to accommodate field wiring You route the wires into the enclosure chassis through a slot in the removable card edge cover ControlWave Express I O uses compression type terminals that accommodate up to 16 AWG wire Insert the wire s bared end approx max into the clamp beneath the screw and secure the wire To prevent shorts ensure that no bare wire is exposed If using...

Page 43: ...ControlWave Express Instruction Manual CI ControlWave Express Revised Mar 2011 I O Configuration and Wiring 3 5 Figure 3 2 Process I O Board Wiring Diagrams ...

Page 44: ...nput is open Source current for DI1 to DI4 of either 60 μA or 2 mA based on switch SW1 3 setting See Table 3 1 Source current for DI5 to DI6 of either 200 μA or 2 2 mA based on switch SW1 3 setting See Table 3 1 15 ms input filtering Wiring See Figure 3 2 for wiring diagrams Software Configuration To use data from these DIs you must include a CWM_EIO board in your ControlWave project using Control...

Page 45: ...aracteristics Discrete Outputs DO 2 to 4 on TB3 Supports 30V operating range Can sink 400 mA max at 30Vdc open drain Maximum output frequency of 20Hz Surge protection between signal and ground Wiring See Figure 3 2 for wiring diagrams Software Configuration To use data from these DOs you must include a CWM_EIO board in your ControlWave project using ControlWave Designer s I O Configurator and then...

Page 46: ...r AI and DGND See Figure 3 2 for wiring diagrams If using the ControlWave Loop Power Supply see document PIP ControlWave LS Notes You must connect cable shields associated with AI wiring to the ControlWave Express chassis ground Multiple shield terminations require you to supply a copper ground bus You must connect the ground bus to the ControlWave Express chassis ground using up to a 4 AWG wire s...

Page 47: ... ControlWave Loop Power Supply Maximum external load you can connect to a 4 20mA output is 250 ohms for an external 11V power source or 650 ohms for an external 24V power source Maximum external load current for the 1 5V output is 5 mA with an external 11 to 30 V power source Self calibrating Setting Jumpers See Section 3 2 1 for details on setting jumpers Wiring See Figure 3 2 for wiring diagrams...

Page 48: ...gnal conditioning circuitry provides 20 microsecond filtering Surge suppression Maximum input frequency for each pulse counter discrete input circuit is 10 KHz Wiring Pulse counter discrete inputs are field driven by open collector circuits and are sourced for 3 3V internally with a 200μA source current See Figure 3 3for information on the open collector wiring arrangement Figure 3 3 Pulse Input W...

Page 49: ...ncy of 10kHz or 300Hz Sourced from 3 3Vdc and switch selectable for a source current of 200μA switch SW1 3 OFF or 2 2mA switch SW1 3 ON Note These switches affect all DIs and HSCs Wiring See Figure 3 2 for wiring diagrams Switch Settings See Table 2 1 for details on setting switches Software Configuration To use data from these high speed counter discrete inputs you must include a CWM_EIO board in...

Page 50: ... 9 and Figure 3 4 and Figure 3 5 In this configuration the return lead connects to the RTD terminal and the two junction leads Sense and Excitation connect to the RTD and RTD EXC terminals Caution Never ground the RTD cable shield at both ends or allow it to come in contact with metallic conductive conduit because multiple ground paths can cause RTD input errors Table 3 9 RTD Connections to CPU Sy...

Page 51: ... thermowell tighten the 9 16 nut using an open end wrench against the 7 8 fitting body Figure 3 5 RTD Probe Installation Removal Diagram Software Configuration To use data from the RTD you must include a CWM_ECPU board in your ControlWave project using ControlWave Designer s I O Configurator and then configure it See the ControlWave Designer Programmer s Handbook D5125 for more information That sa...

Page 52: ... 25 feet of the ControlWave Express local communications You can use RS 485 communications to reach transmitters up to 4000 feet away remote communications Figure 3 6 details RS 232 wiring connections required between the ControlWave Express and the 3808 transmitter Figure 3 6 3808 Transmitter to ControlWave Express RS 232 Comm Cable Diagram Figure 3 7 details RS 485 wiring connections required be...

Page 53: ...ring 3 15 Figure 3 7 3808 Transmitter to ControlWave Express RS 485 Comm Cable You can connect up to two 3808 transmitters to a ControlWave Express using a half duplex RS 485 network See Figure 3 8 for an illustration of this type of network Figure 3 8 ControlWave Express to 3808s RS 485 Network Diagram ...

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Page 55: ...wn the ControlWave Express The ControlWave Express receives power either from a solar panel and user supplied battery or from an external bulk power supply attached using connector TB1 on the CPU System Controller board It can also receive power through alternate connector TB2 on the same board Chapter 2 includes instructions for wiring power to the ControlWave Express See Figure 2 3 for the locat...

Page 56: ...rolWave Designer protocol COM3 CPU RS 485 9600 baud 8 bits no parity 1 stop bit BSAP or ControlWave Designer protocol Intended for use with Bristol 3808 transmitters You use jumpers W12 through W16 to configure COM3 for either RS 232 or RS 485 Note You can re enable the factory comm settings at any time by setting switch 3 on the CPU module s SW3 to OFF Ethernet Using an optional Ethernet port loc...

Page 57: ...he ControlWave project in ControlWave Designer and set communication and configuration parameters 3 Download the project according to instructions in the Downloading section of the ControlWave Designer Programmer s Manual D5125 4 4 Creating and Maintaining Backups You should always maintain a current backup of each ControlWave project and keep it in a safe place preferably in a location physically...

Page 58: ... graphics It may be stored on your PC or removable storage media It may also be downloaded and archived to ControlWave Flash memory where it may be uploaded at a later time for editing With your current ControlWave project open in ControlWave Designer perform the following steps 1 Click File Save Project As Zip Project As Figure 4 1 Saving a Backup of Your Project 2 In the Save Zip project as dial...

Page 59: ...k Zip and a progress bar displays the percent complete of the zipping process 6 When the zip process completes you ll see a message box reporting successful completion Click OK 7 Copy the resulting zwt file to backup media CD ROM thumb drive etc If you ever need to restore the project just open the zwt file in ControlWave Designer load libraries as needed then compile the project and download it i...

Page 60: ...CP parameters to the controller establish communications with the unit start the Flash Configuration utility and load the FCP file using the Read from FCP button then choose the Write to RTU button 4 4 3 Backing up Data You can back up certain types of data and restore it if needed There are other types of data that you can only collect but you cannot restore If you have certain variables that rep...

Page 61: ...ilable Diagnostics 5 5 5 16 Core Updump 5 6 5 17 Calibration Checks Equipment You need the following equipment to perform the procedures described in this chapter To run diagnostics software PC with WINDIAG software and either OpenBSI LocalView NetView or TechView for communications Null modem interface cable Loop back plug See Figure 5 10 and Figure 5 11 To perform firmware upgrades Null modem in...

Page 62: ...ontroller board switch SW2 6 ON the factory default position Note For further information and detailed use instructions refer to Appendix J of the OpenBSI Utilities Manual D5081 LocalView One of the standard OpenBSI utilities LocalView requires OpenBSI version 5 1 or newer If you have an older version of OpenBSI use HyperTerminal Note For further information and detailed use instructions refer to ...

Page 63: ...trolWave Express The resident BIOS initializes and tests the hardware this process is referred to as POST Power On Self Test Unless there is a problem status LEDS show status code 10 LED 5 ON If you see a different status code see Section 5 3 1 6 From the HyperTerminal Mode menu Figure 5 1 press the F key to enter FLASH download A message warns that the FLASH is about to be erased press the Y key ...

Page 64: ...Hz CPUs and xxxxx varies from release to release and click Send to start the flash upgrade see Figure 5 4 When you see the HyperTerminal Mode Menu again it means the download has completed 9 Exit HyperTerminal and power down the ControlWave Express If desired you can disconnect the null modem cable between the ControlWave Express and the PC 10 Set switch SW1 3 to the OFF position OFF Recovery Mode...

Page 65: ...ly technically qualified personnel should test and or replace ControlWave Express components Read completely the disassembly and test procedures described in this manual before starting Any damage to the ControlWave Express resulting from improper handling or incorrect service procedures is not covered under the product warranty agreement If you cannot properly perform these procedures obtain auth...

Page 66: ...ently pulling the CPU System Controller board away from the Process I O board Carefully unplug the boards from their interface connectors Align the replacement boards with each other and press them together so that the interface connectors and mounting posts properly mate then squeeze together so that the mounting post tabs capture the CPU System Controller board 8 To install the replacement board...

Page 67: ...ving Replacing the Battery 1 If the ControlWave Express is running place any critical control processes under manual control 2 Remove power from the ControlWave Express 3 Remove the CPU System Controller board assembly from the housing 4 To remove the lithium battery gently pry up the tab holding the battery in the coin cell socket and remove the battery with a pair of tweezers or needle nosed pli...

Page 68: ...ting Procedures This section presents some procedures to troubleshoot problems with the Express 5 3 1 Checking LEDs The ControlWave Express includes light emitting diodes LEDs that provide operational and diagnostic functions These LEDs are visible through the chassis cover window Figure 5 5 ControlWave Express LEDs Figure 5 6 shows the various status LEDs on the CPU System Controller board s pigg...

Page 69: ...nd of execution cycle Should be on frequently OFF CPU overloaded STAn RED See Figure 5 7 and Table 5 1 for LED patterns and explanations TX1 RED Transmit activity on COM1 RX1 RED Receive activity on COM1 TX2 RED Transmit activity on COM2 RX2 RED Receive activity on COM2 TX3 RED Transmit activity on COM3 RX3 RED Receive activity on COM3 Receive GREEN Receive activity on Ethernet port Transmit YELLO...

Page 70: ...2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 STA6 STA5 STA4 STA3 STA2 STA1 Figure 5 7 CPU System Controller Board LED Patterns LED Hexadecimal Codes Table 5 2 LEDs on CPU System Controller Board and LCD Display Status Codes LED6...

Page 71: ...t a Break Point 1 1 0 0 0 0 30 NO APP No Application Loaded 1 1 1 0 0 0 38 BREAKP Running with Break Points 1 1 1 0 1 1 3B POWERD Waiting for Power down after NMI 1 1 1 1 1 0 3E UPDUMP Waiting for Updump to be Performed 1 1 1 1 1 1 3F NOTRUN Unit Crashed Watchdog Disabled In addition to the LEDs on the piggy back LED board the CPU System Controller board includes a watchdog LED WD CR1 right and an...

Page 72: ... 3 to OFF and SW2 8 to OFF Turning these switches off sets all serial ports on the ControlWave Express to 9600 baud in preparation for diagnostic testing and prevents the boot project from running and also places the ControlWave Express in diagnostic mode Connect any ControlWave Express serial communication port to the PC provided their port speeds match Use a null modem cable to connect RS 232 po...

Page 73: ...3 and SW2 8 on the CPU module to ON The ControlWave Express should resume normal operation 5 4 1 Available Diagnostics WINDIAG s Main Diagnostics Menu see Figure 5 9 provides the following diagnostic selections Option Tests CPU Peripherals Checks the CPU System Controller board except for memory Analog Output Checks the AO on the Process I O board High Speed Counter Checks HSCs on the Process I O ...

Page 74: ...Port Loop back Test WINDIAG allows you to select the communication port to test Depending on the type of network RS 232 or RS 485 and the port in question a special loop back plug is required Port 1 RS 232 uses a 9 pin female D type loop back plug see Figure 5 10 Figure 5 10 COM1 COM2 RS 232 Loop back Plug Wires Port 2 RS 232 use loop back wires see Figure 5 10 Port 3 RS 232 use loop back wires se...

Page 75: ...mplete testing on all other communication ports and verify their correct functioning you must reconnect using a now validated port and test the remaining untested port Test Procedure Use this procedure to test the communication ports 1 Connect an external loop back plug to the port on the CPU you want to test Valid ports are 2 Select Communications on the WINDIAG Main Diagnostics Menu The Communic...

Page 76: ...irmware glitch and so on In some cases the watchdog state can recur but you cannot logically reproduce the conditions The CPU s RAM contains crash blocks a firmware function provided specifically for watchdog troubleshooting You can view and save the crash blocks by viewing the Crash Block Statistic Web Page see the Web_BSI Manual D5087 On request you can forward crash block files to our technical...

Page 77: ... System Controller board switches SW2 1 and SW2 4 both off before the ControlWave Express fails you prevent the Express from automatically recovering from the failure and enable it to wait for you to take a core updump Once you complete the core updump set the CPU System Controller board s switch SW2 1 to ON Watchdog Enabled and SW2 4 to OFF Core Updump Enabled Additionally set switch SW1 1 to OFF...

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Page 79: ...power system solar panel and battery are not supplied by Emerson Process Management Remote Automation Solutions division and are therefore unrated see paragraph 2 Connection to the solar panel is approved as a nonincendive circuit so that Division 2 wiring methods are not required The nominal panel voltage must match the nominal battery voltage 6V or 12V 4 An optional RTD may be supplied with the ...

Page 80: ...4 COM3 5 pin terminal block RS 232 RS 485 RS 232 485 comm port For external network comm Refer to model spec and item 5 of this document CPU System Controller board TB5 4 pin terminal block pulse input interface Pulse input field wiring Field I O wiring connector is unrated use Div 2 wiring methods CPU System Controller board TB6 3 pin terminal block RTD interface Field wired Refer to item 4 of th...

Page 81: ...use Div 2 wiring methods Process I O board TB7 4 pin terminal block AO interface Analog output field wiring Field output wiring connector is unrated use Div 2 wiring methods Note These wires should only be installed removed when the item PCB in question is installed removed or when checking wiring continuity The area must be known to be nonhazardous before servicing replacing the unit and before i...

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Page 83: ...a Sheets This device includes certain components or materials which may be hazardous if misused For details on these hazards please contact the manufacturer for the most recent material safety data sheet Manufacturer General Description Emerson Part Number DURACELL http www duracell com 3V LITHIUM MANGANESE DIOXIDE BATTERY P N DL 2450 395620 01 5 ...

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Page 85: ... Programming Environment 1 6 2 1 ControlWave Express Component Identification 2 2 2 2 ControlWave Express dimensions 2 5 2 3 CPU System Controller Board Component I D Diagram 2 7 2 4 CPU System Controller Board TB1 TB2 Power Wiring 2 13 2 5 Male DB9 9 Pin Connector 2 15 2 6 Full duplex and Half duplex Cable 2 16 2 7 Full duplex and Half duplex Cable 2 17 2 8 Connection from an External Modem Radio...

Page 86: ... 4 2 J Jumpers CPU System Controller Board 2 10 Process I O Board 3 2 K Keypad Display 2 22 L LEDs Checking 5 8 disabling 2 8 LocalView 5 2 Loop back Test 5 14 5 15 M Material Safety Data Sheets MSDS how to obtain Z 1 Memory Boot FLASH 1 4 FLASH amount 1 5 SRAM amount 1 5 Mounting the housing 2 4 O Operator s keypad display 2 22 P Power connecting or disconnecting 4 2 wiring 2 11 Power connector T...

Page 87: ...2 Process I O Module Switch SW1 3 2 3 3 Non Isolated DI General Characteristics 3 6 3 4 Non Isolated DO General Characteristics3 7 3 5 Non Isolated AI General Characteristics 3 8 3 6 Non Isolated AO General Characteristics3 9 3 7 Non Isolated Pulse Counter Discrete Inputs General Characteristics 3 10 3 8 Non Isolated High Speed Counter Discrete Inputs General Characteristics 3 11 3 9 RTD Connectio...

Page 88: ...H RESPECT TO THIS MANUAL AND IN NO EVENT SHALL RAS BE LIABLE FOR ANY INCIDENTAL PUNITIVE SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PRODUCTION LOSS OF PROFITS LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL FUEL AND POWER AND CLAIMS OF THIRD PARTIES Bristol Inc Bristol Babcock Ltd Bristol Canada BBI SA de CV and the Flow Computer Divisi...

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