Emerson ControlWave EFM Instruction Manual
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Emerson ControlWave EFM Instruction Manual

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Instruction Manual
Doc Number CI-ControlWave EFM
Part Number D301383X012
December 2013
®
ControlWave
EFM
(Electronic Flow Meter)
Remote Automation Solutions
www.EmersonProcess.com/Remote

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  • Page 1 Instruction Manual Doc Number CI-ControlWave EFM Part Number D301383X012 December 2013 ® ControlWave (Electronic Flow Meter) Remote Automation Solutions www.EmersonProcess.com/Remote...
  • Page 2 These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process Management, Remote Automation Solutions for further information.

  • Page 3: Table Of Contents

    ControlWave EFM Instruction Manual Contents Chapter 1 – Introduction       Scope of the Manual ....................... 1-2     Physical Description ....................... 1-3     Housings and Enclosure ....................... 1-3     CPU Module ..........................1-4     System Controller Module (SCM) ..................1-6  ...
  • Page 4     Connections to a Bristol Model 3808 Transmitter ............. 3-20 Chapter 4 – Operation       Powering Up/Powering Down the ControlWave EFM ............4-1     Communicating with the ControlWave EFM ................ 4-2     4.2.1 Default Comm Port ...................... 4-2  ...

  • Page 5: Chapter 1 - Introduction

    Designer (D5085), the ControlWave Designer Programmer’s Handbook (D5125), and the online help in ControlWave Designer. For information on the flow measurement application used in the ControlWave EFM, see the ControlWave Flow Measurement Applications Guide (D5137). This chapter details the structure of this manual and provides an overview of the ControlWave EFM and its components.

  • Page 6: Scope Of The Manual

    1.1 Scope of the Manual This manual contains the following chapters: Chapter 1 Provides an overview of the hardware and general specifications for the ControlWave EFM. Introduction Chapter 2 Provides information on mounting the housing, Installation wiring power, configuring the CPU module and...

  • Page 7: Physical Description

    (whether base or expansion) are gold irridite-plated aluminum. They house the printed circuit board (PCB) backplane and all ControlWave EFM modules. The housing mounts to a fabrication panel on the inner rear wall of the enclosure. Two housings are available: ...

  • Page 8: Cpu Module

    ControlWave EFM Instruction Manual the enclosure’s right side secure the cover when you close it. A weatherproof communication connector, either a 9-pin male D-type connector or a circular 3-pin connector (the local port) mounts to the bottom of the enclosure and connects internally to RS-232 communication port 1 for local communications.
  • Page 9 ControlWave EFM Instruction Manual Figure 1-2. 33MHz CPU Module with Three Serial Ports (left), 150 MHz CPU Module with Three Serial Ports and One Ethernet Port (right) CPU Backup Battery CPU modules have a coin cell socket that accepts a lithium battery.

  • Page 10: System Controller Module (Scm)

    DC power supply (or an optional solar panel and lead acid battery combination) and then provides +3.3Vdc power and GND through the ControlWave EFM housing/backplane to all installed modules. The SCM also supplies switched field power to I/O module slots.

  • Page 11: Expansion Communications Modules

    ControlWave EFM Instruction Manual 1.6 Expansion Communications Modules Expansion Comm. Modules provide two additional serial communications ports and optionally the choice of a piggy-backed dial- line modem or piggy-backed 900 MHz Spread Spectrum radio (or both). The top port (labeled C1) supports RS-232 operation while the second one (labeled C2) supports RS-485 operation.

  • Page 12: I/O Modules

    14-pin mass Termination headers (for remote termination). Mixed I/O modules have two 10-point terminal blocks for local termination only. Figure 1-4. Two ControlWave EFM I/O Modules (with Bezel) Software Tools The ControlWave programming environment consists of a set of integrated software tools which allow you to create, test, implement, and download complex control strategies for use with the ControlWave.
  • Page 13 ControlWave EFM Instruction Manual Figure 1-5. 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 strategy programs that run in your ControlWave. You can use pre-made function blocks, ladder logic, or structured languages.

  • Page 14: Overview Of The Gas Flow Measurement Application

    Note: For detailed information on the gas flow measurement application and web pages refer to the ControlWave Flow Measurement Applications Guide (D5137). You can purchase the ControlWave EFM with a pre-programmed flow measurement application already loaded. 1-10 Introduction Revised Dec-2013...
  • Page 15 A station typically refers to a single flow computer and all its associated meter runs. Each meter run refers to measurement of natural gas through a single pipeline. The ControlWave EFM supports up to four meter runs. Meter runs can use orifice, turbine, or ultrasonic meters.
  • Page 16 ControlWave EFM Instruction Manual  AGA3-1992 with selectable AGA8 Gross or AGA8 Detail  AGA7/NX-19  AGA7 with selectable AGA8 Gross or AGA8 Detail  Auto-adjust AGA7/NX-19  Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail The application performs a complete flow calculation using the process variables every second.
  • Page 17 ControlWave EFM Instruction Manual 1.9.6 Energy Calculation The application offers the option of using a fixed volumetric heating value or calculating the energy content of the gas according to AGA Report No. 5. 1.9.7 Volume and Energy Integration The application integrates and accumulates volume and energy at the end of every calculation cycle.
  • Page 18 ControlWave EFM Instruction Manual  Any operator change to a configuration variable  Any change in the state of an alarm variable  A system restart  Certain other system events You can view audit records on-screen in the audit log.
  • Page 19  average heating value  flow time  uncorrected count ControlWave EFM maintains a daily historical log for each of up to four runs. Periodic Historical Data Log Each meter run maintains a periodic data log that holds one record for every log interval.
  • Page 20 ControlWave EFM Instruction Manual 1.9.11 Sampler and Odorizer Samplers are external devices which measure the quality of the gas stream. Because natural gas is odorless and colorless, devices called odorizers inject an additive to the gas stream that allows people to detect the presence of natural gas in the event of a gas leak.

  • Page 21: Chapter 2 - Installation

    2.1 Site Considerations When choosing an installation site, check all clearances. Ensure that the ControlWave EFM front cover (hinged on the left side) can be opened for wiring and service and that the LCD/keypad is visible and accessible to the on-site operator.

  • Page 22: Class I, Div 2 Installation Considerations

    Class I, Division 2, Group C, and D hazardous locations and non-hazardous locations. Read this chapter and Appendix A carefully before you install a ControlWave EFM in a hazardous location. Perform all power and I/O wiring for unrated circuits in accordance...
  • Page 23 ControlWave EFM Instruction Manual Figure 2-1. 4-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with D-Type Local Port) Revised Dec-2013 Installation...
  • Page 24 ControlWave EFM Instruction Manual Figure 2-2. 8-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with Circular Local Port) Installation Revised Dec-2013...

  • Page 25: Installation Overview

    Download the application-specific ControlWave project into the ControlWave EFM. Notes:  If you purchased the ControlWave EFM with the standard application already loaded, you do not need to create an application, or web pages, and the application is already downloaded for you.

  • Page 26: Unpacking Components

    (the first I/O slot); a second ECOM module (if you have one) must reside in slot #4 of the housing (the second I/O slot). Housing The housing (or chassis) for the ControlWave EFM is an open-faced gold irridite coated aluminum assembly. The eight slot housing has six I/O slots;...

  • Page 27: Mounting The Efm Housing

    ControlWave EFM Instruction Manual Figure 2-3. 8/4-Slot ControlWave EFM Housing - The 4-Slot Chassis is shown with ECOMs in Slots 3 & 4) 2.4 Mounting the EFM Housing  You must position the ControlWave EFM vertically with the transducer (MVT) at its base. Make sure clearances are adequate so...
  • Page 28 Circular Female Jack RTD Cable Assembly or Sealing Plug (4) Battery Ventilation Assembly 5” Liquid Tight Conduit Fitting or Plug (6) Ant. Cable Fitting, Polyphaser, Solderless Ground Lug (8) Multivariable Transducer Figure 2-4. ControlWave EFM Bottom View Installation Revised Dec-2013...
  • Page 29 ControlWave EFM Instruction Manual Figure 2-5. Side View of ControlWave EFM Mounted to a 2” Pipe Revised Dec-2013 Installation...
  • Page 30 ControlWave EFM Instruction Manual Figure 2-6. 4-Slot ControlWave EFM 2-10 Installation Revised Dec-2013...
  • Page 31 ControlWave EFM Instruction Manual Figure 2-7. 8-Slot ControlWave EFM - Base Chassis Assembly Dimensions Revised Dec-2013 Installation 2-11...
  • Page 32 ControlWave EFM Instruction Manual Figure 2-8. ControlWave EFM NEMA 3X Enclosure Dimensions 2-12 Installation Revised Dec-2013...

  • Page 33: Grounding The Housing

    ControlWave EFM Instruction Manual 2.4.1 Grounding the Housing The ControlWave EFM enclosure includes a ground lug. Once you have installed the unit, run a ground wire (#4 AWG max wire size) between the ground lug (see Figure 2-4) and a known good earth ground. As an added precaution, run a #14 AWG wire from SCM power connector TB1-3 (chassis ground) to the same known good earth ground.
  • Page 34 ControlWave EFM Instruction Manual Four bolts and nuts hold the two process flange assemblies in place. When you remove the bolts, you can reposition the flanges so that the connections can emanate from the front, rear or bottom of the transducer.

  • Page 35: Process Pipeline Connection (Meter Runs Without Cathodic Protection)

    2.4.4 Process Pipeline Connection (Meter Runs with Cathodic Protection) You can mount the ControlWave EFM directly on the pipeline (using a manifold block) or remotely on a vertical stand-alone two-inch pipe or on a wall. 2” Pipe-mounting Package...
  • Page 36 Figure 2-11. ControlWave EFM Remote Installation with Cathodic Protection Dielectric isolators are available and are always recommended as an added measure in isolating the ControlWave EFM from the pipeline even though the enclosure does provide some galvanic isolation from the pipeline and should not be affected by the cathodic protection or other EMF on the pipeline.

  • Page 37: System Controller Module (Scm)

    ControlWave EFM Instruction Manual from the EFM. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU 3140. This black tubing easily slips over the 2-inch pipe and then after uniform heating (with a rosebud torch) it electrically insulates and increases the strength of the pipe stand. See F1670SS-0a for information on PGI direct mount systems and manifolds.
  • Page 38 ControlWave EFM Instruction Manual WAT CHDOG LED JP5, JP6, JP7, JP8 & JP9 (Red) 1-to-2 Installed = 12V Bulk System CR27 2-to-3 Installed = 6V Bulk System IDLE LED (Red) CR26 Staus LEDs CR25 (Red) CR24 SW1 = Mode Switch Display Intf.

  • Page 39: Scm Installation Overview

    The SCM has a DIP switch that controls whether the SCM operates in Local Mode or Recovery Mode. Local Mode is the normal operating mode for the ControlWave EFM, and is the factory default. We recommend you use the factory default unless you have a reason to use Recovery Mode.

  • Page 40: General Wiring Guidelines

    ControlWave EFM Instruction Manual Table 2-1. SCM Switch SW1 Switch position Mode Both switches set to right (Open) or Activates Recovery mode, used for both switches set to left (Closed) firmware upgrades or core updumps. Upper switch (SW-1) set to right...

  • Page 41: Wiring A Bulk Dc Power Supply To The Scm

     Power requirements for the optional digital to relay I/O board, 21V power supply board, and the battery charger power manager board are provided in the ControlWave EFM product data sheet. Refer to Table 2-2 for ControlWave EFM bulk power requirements. Table 2-2. Bulk Power Requirements Bulk 12 Vdc...

  • Page 42: Using A Solar Panel And Lead Acid Battery To Power The Efm

    ControlWave EFM Instruction Manual Unplug removable connector TB1 from the SCM and wire DC power to Terminal Block the connector. We recommend you do not plug the connector back into Connector TB1 the SCM until the CPU module is already installed in the housing.
  • Page 43 ControlWave EFM Instruction Manual Note 2: Item D slots accommodate Tilt Angle Adjustment. NOTE 1: To Attach item C to item D: Slide two bolts (A) through the top and bottom Solar Panel (Centered) Channel Holes. Affix item C to item D via 2 sets of item A hardware as follows: Flat Washer, Lock Washer &...

  • Page 44: Installing The Lead Acid Battery And Solar Panel Harness

    ControlWave EFM Instruction Manual Table 2-3. Solar Panel Tilt Angle Tilt Angle Latitude 0-4° 10° from Horizontal 5-20° Add 5° to the Local Latitude 21-45° Add 10° to the Local Latitude 46-65° Add 15° to the Local Latitude 66-75° 80° from Horizontal...
  • Page 45 ControlWave EFM Instruction Manual Figure 2-15. Enclosure with Sealed Lead-acid Battery Installed Revised Dec-2013 Installation 2-25...

  • Page 46: Power Distribution Board (Optional)

    ControlWave EFM Instruction Manual 2.7 Power Distribution Board (Optional) If your ControlWave EFM includes any of the following optional components, it also requires the power distribution board.  21V Power Supply Board for external transmitters  Digital to Relay I/O Board ...
  • Page 47 Fuse F3 is rated at .5A and protects fused power output 1. F1 and F3 are provided for Class I, Div. 1 hazardous location use only, which does not apply to the ControlWave EFM. Figure 2-17. Power Distribution Board and Other Options - Snap Track Mounting...

  • Page 48: Power Supply (Optional)

    ControlWave EFM Instruction Manual 2.8 21V Power Supply (Optional) The 21V power supply is typically used to provide power to temperature and pressure transmitters (such as the Bristol 3508) that require higher than +12V but lower than +21.4V (± .8V) to operate.

  • Page 49: Cpu Module

    ControlWave EFM Instruction Manual 2.9 CPU Module The CPU module, which controls the ControlWave EFM and handles memory and communication functions, can only be installed in Slot #2 of the backplane. : Do not confuse the CPU module (which has communication...

  • Page 50: Setting Jumpers On The Cpu Module

    ControlWave EFM Instruction Manual Figure 2-20. CPU Module with Three Serial Ports and One Ethernet Port 2.9.1 Setting Jumpers on the CPU Module Each CPU module contains a number of jumpers (labeled with JPn) when n in the jumper number. See Figure 2-19 or Figure 2-20 to locate the jumpers.

  • Page 51: Setting Dip Switches On The Cpu Module

    ControlWave EFM Instruction Manual power conservation is an issue, you can disable these LEDs by removing the jumper. Note: For maximum shelf life, the CPU module ships from the factory with the installed lithium backup battery disabled. You must enable it when you install the CPU module by placing JP8 on pins 1-2.
  • Page 52 9600 bps before WINDIAG can perform communication tests. Core Updump Causes the ControlWave EFM to perform a core updump, provided you have set the SCM mode switch to Recovery mode. Values are: ON (Disables core updump; factory default)
  • Page 53 ControlWave EFM Instruction Manual Notes:  Table 2-7 describes switch settings for the RS-485 port. You may want to review Section 2.9.4 Connections to RS-485 Serial Port(s) before you set these switches.  Table 2-7 applies to the following switches: o SW3 on CPU Module –...

  • Page 54: Connections To Rs-232 Serial Port(S) On Cpu Or Ecom Modules

    If you require additional RS-232 ports, you can purchase an optional expansion communication module that can include either one (ECOM Type 1) or two (ECOM Type 2) RS-232 ports. The ControlWave EFM can support up to two expansion communication modules, for a total of up to four additional RS-232 ports beyond those on the CPU module.
  • Page 55 22) to connect with other devices (such as a PC, a printer, another ControlWave [except the CW_10/30/35]) when the ControlWave EFM uses the full-duplex PPP protocol. : You can configure the ControlWave EFM as either a master or Note slave node on a Modbus or BSAP network.
  • Page 56 Figure 2-22. Full-duplex and Half-duplex Cable Use the half-duplex cable (shown in the bottom part of Figure 2-22) when connecting the ControlWave EFM to another ControlWave series unit (again, with the exception of the CW_10/30/35). When communicating with a Network 3000 series RTU 3305, RTU 3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of the cables shown in Figure 2-23.
  • Page 57 Figure 2-25. Full-duplex and Half-duplex Cable If you use the local port circular connector see Figure 2-26, Figure 2-27 and Table 2-11. Figure 2-26. PC Connected to ControlWave EFM via D-Type Local Port (use Null Modem Cable P/N 392843-01-3) Revised Dec-2013...
  • Page 58 ControlWave EFM Instruction Manual Figure 2-27. PC Connected to ControlWave EFM via Circular Local Port (use Cable P/N 395402-01- 8 [10 foot cable] or P/N 395402-02-6 [25 foot cable]) Table 2-11. RS-232 Port (COM1) Connector Pin Assignment (COM1 Connectors – Circular Local Port &...

  • Page 59: Connections To Rs-485 Serial Port(S) On Cpu Or Ecom Modules

    If you require additional RS-485 ports, you can purchase an optional expansion communication module that includes one or two RS-485 ports. The ControlWave EFM can support up to two expansion communication modules, for a total of up to four additional RS-485 ports beyond the one on the CPU module.
  • Page 60 ControlWave EFM Instruction Manual Table 2-12. RS-485 Connectors on CPU Connector Name # Pins Function Notes and Figure 2- COM3 9-pin 9-pin male D-sub (RS-485) See Figure 2-19 Table 2-13. RS-485 Connectors on Type 1 Expansion Communications Modules Connector Name...
  • Page 61 ControlWave EFM Instruction Manual Since the RS-485 port is intended for network communications, refer to Table 2-16 for the appropriate connections for wiring the master, first slave, and nth slave. Essentially, the master and the first slave transmit and receive data on opposite lines;...

  • Page 62: Connections To Ethernet Port On The Cpu Module

    ControlWave EFM Instruction Manual 2.9.5 Connections to Ethernet Port on the CPU Module The RJ45 Ethernet port is located on the CPU module (150 MHz version Caution only). The SCM also has one RJ45 port for the optional Display/Keypad. Never connect Ethernet to the Display/Keypad port or damage to the SCM will result.
  • Page 63 ControlWave EFM Instruction Manual Table 2-17. Ethernet 10/100Base-T CPU Module Pin Assignments Description Transmit Data+ (Output) Transmit Data– (Output) Receive Data+ (Input) Not connected Not connected Receive Data– (Input) Not connected Not connected : You can swap TX and RX at the hub.

  • Page 64: Expanded Communications Module (Ecom)

    ControlWave EFM Instruction Manual 2.10 Expanded Communications Module (ECOM) ControlWave EFM can support up to two optional expanded communications modules (ECOMs) which you can install only in slots #3 or #4 (in place of I/O modules). ECOMSs do not have a CPU component.

  • Page 65: Ports

    ControlWave EFM Instruction Manual R eceive LEDs T ransmit LEDs Comm. P ort 4/8 1-2 Installed = LEDs Enabled 2-3 installed = LEDs Disabled W2 for Comm. Port 4/8 Comm. P ort 4/8 1-2 Installed = Loopback Disabled & RS -232 2-3 installed = RTS/CTS Loopback Comm.

  • Page 66: Modem Port (Type 1 Ecom Only)

    You can mount an optional 56Kb PSTN Hayes-type modem on a Type 1 ECOM (see Figure 2-34). The ControlWave EFM then assigns the modem COM7 (if in slot #3) or COM11 (if in slot #4). You can configure the MultiTech model MT9234SMI modem module for publicly switched telephone network (PSTN) operation.
  • Page 67 ControlWave EFM Instruction Manual also clock DTE/DCE serial data into (transmit) or out of (receive) the modem at rates up to 115.2 kHz. The factory supplies the modem pre-installed or in kit form with all required hardware. You install it on the ECOM1 module and then use the Ports page in the Flash Configuration utility (in NetView, LocalView, or TechView) to assign ports.
  • Page 68 ControlWave EFM Instruction Manual Figure 2-35. PTSN Field Connections for ControlWave Micros (and EFMs) Figure 2-36. Phone Cord Wiring The 56K PSTN modem is FCC-approved for use with public telephone lines. However, before you place a modem in operation, check the following items to make sure you meet all FCC requirements: ...

  • Page 69: Bezels

    I/O modules and provide an easy way for you to route wiring. The factory provides bezels with each order. Install bezels over I/O modules whenever the ControlWave EFM is operational; remove the bezels for maintenance procedures. Bezels attach to the module covers of two adjacent I/O modules. Hooks on the bezels (see Figure 2-37) attach to notches in the upper and lower portions of the module covers.

  • Page 70: Case Mounted Radio/Modem

    An alternative to using a Type 1 ECOM module with an integrated modem/radio is to order a case-mounted modem/radio. In this configuration, the ControlWave EFM ships from the factory with a user selected radio or modem installed within the enclosure (beneath the battery mounting bracket) or as a radio-ready unit, in other words, ready for field installation of a factory-supplied radio.
  • Page 71 Figure 2-38. Optional 2-Button and 25-Button Keypads Both keypads use the same 4-line by 20-character LCD displays. You connect the keypad to the ControlWave EFM using a cable, one end of which has an RJ-45 jack (connected into the RJ-45 equipped with two plugs).
  • Page 72 This page is intentionally left blank...

  • Page 73: Chapter 3 - I/O Modules

    Connections to a Bristol Model 3808 Transmitter ......3-20     Installation Installing any I/O module in the ControlWave EFM involves the same basic steps: Remove the I/O module and associated I/O module cover from the shipping carton. The cover snaps on or off to provide access to the unit’s I/O connectors.

  • Page 74: Module Placement

    I/O already defined. Refer to the ControlWave Designer Programmer’s Handbook (D5125) for further instructions. Power down the ControlWave EFM before you install or remove any I/O Caution module. Shut down any processes the ControlWave EFM may be managing (or switch them over manually or handle with another controller).

  • Page 75: Wiring

    I/O modules support local termination where field wiring connects directly to the module’s removable terminal blocks. ControlWave EFM I/O modules use compression-type terminals that accommodate up to #14 AWG wire. Consult with the field device manufacturer for recommendations if using smaller wire sizes. Insert the wire’s bared end (approx.

  • Page 76: Shielding And Grounding

    ControlWave EFM Instruction Manual module assembly between the terminal block and the terminal housing. All I/O wiring should be routed in/out of the enclosure through the 1” NPT conduit hub. Figure 3-2. Module Wiring: Local Termination 3.2.2 Shielding and Grounding...

  • Page 77: Non-Isolated Digital Input/Output (Di/O) Module

    ControlWave EFM Instruction Manual 3.3 Non-isolated Digital Input/Output (DI/O) Module Non-isolated DI/O modules consist of a digital input/output PCB with two 10-point terminal block assemblies for local termination. The DI/O module also includes 14 configuration jumpers, an LED board with 16 status LEDs (one for each point), and a cover assembly.
  • Page 78 ControlWave EFM Instruction Manual Jumper Purpose Description Pins 2-3 installed = allows software enabling of LEDs Programs Serial EEPROM Reserved for factory use only Wiring the Module Figure 3-3 shows the terminal block assignments for the locally terminated DI/O module.

  • Page 79: Non-Isolated Analog Input/Output & Analog Input Module

    ControlWave EFM Instruction Manual 3.4 Non-isolated Analog Input/Output & Analog Input Module Non-isolated Analog Input/Output (AI/O) modules support six externally sourced 4–20mA or 1–5 Vdc single-ended analog inputs and optionally, two independently configurable 4–20 mA or 1–5 Vdc analog outputs. Non-isolated Analog Input (AI) modules are identical to AI/O modules but have a depopulated AO section.
  • Page 80 ControlWave EFM Instruction Manual to the housing’s ground lug. This ground bus must accommodate a connection to a known good earth ground (in lieu of a direct connection from the ground lug) and to all AI cable shields. Shield wires should use an appropriate terminal lug.
  • Page 81 ControlWave EFM Instruction Manual Figure 3-4. Non-isolated AI/O and AI Module Configuration (Local Termination) Software Configuration To use data from a non-isolated AI/O module you must add a CWM_MA board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.

  • Page 82: Non-Isolated High Speed Counter (Hsc) Input Module

    ControlWave EFM Instruction Manual 3.5 Non-isolated High Speed Counter (HSC) Input Module Non-isolated High Speed Counter (HSC) Input modules provide up to four inputs. You can individually configure HSC module inputs for either a 10 KHz (high speed) or 300 Hz (low speed) input, and as a 16-...
  • Page 83 ControlWave EFM Instruction Manual Wiring the Module Figure 3-5 shows field wiring assignments for the locally terminated HSC module. Figure 3-5. Non-isolated HSC Module (Local Termination) Software Configuration To use data from a high speed counter module you must add a CWM_HSC4 board in ControlWave Designer’s I/O Configurator, and...

  • Page 84: Non-Isolated Mixed I/O (Mi/O) Module

    ControlWave EFM Instruction Manual 3.6 Non-isolated Mixed I/O (MI/O) Module Non-isolated Mixed I/O (MI/O) modules provide up to six individually field configurable DI/Os, four AIs, two HSC Inputs and, optionally, one MI/O modules consist of an MI/O PCB with two 10-point terminal block assemblies (TB1 and TB2) for local termination, 28 configuration jumpers, and a module cover.
  • Page 85 ControlWave EFM Instruction Manual Table 3-8. Jumper Assignments: Non-isolated MI/O Module Jumper Purpose Description Configures optional AO for Pins 1-2 installed = Sets AO for current output voltage or current output Pins 2-3 installed = Sets AO for voltage output...
  • Page 86 ControlWave EFM Instruction Manual Figure 3-6. Mixed I/O Module Wiring Diagram 3-14 I/O Modules Revised Dec-2013...
  • Page 87 ControlWave EFM Instruction Manual Figure 3-7. Non Isolated Mixed I/O Module Configuration Diagram Software Configuration To use data from a mixed I/O module you must add a CWM_MIX board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.

  • Page 88: Resistance Temperature Device (Rtd) Inputs On Scm

    ControlWave EFM Instruction Manual 3.7 Resistance Temperature Device (RTD) Inputs on SCM System controller module connector TB2 provides connection to a 3- wire 100 ohm platinum bulb RTD (using the DIN 43760 curve). Wire the RTD according to Table 3-9, Figure 3-8 and Figure 3-9. In...
  • Page 89 ControlWave EFM Instruction Manual Installing the RTD To install the RTD probe, screw the fitting body into the thermowell Probe with a 7/8” open-end wrench. While you apply pressure against the sheath to force the tip of the RTD probe into the bottom of the thermowell (so that the probe tip is in contact with the bottom of the thermowell), tighten the 9/16”...

  • Page 90: Digital To Relay I/O Board Option

    100mA. Figure 3-10 provides a component view of the Digital to Relay I/O Board. Each ControlWave EFM discrete output is converted to a Form C relay output signal which can be configured for opposite or identical state conditions, i.e., both Normally Open (NO) or Normally Closed (NC) or...
  • Page 91 ControlWave EFM Instruction Manual You can optionally tie the commons associated with each form C relay (R0COM and R1COM) to the ControlWave EFM power ground or to a floating ground. Jumper W1 is associated with Outputs R0A and R0B and W2 is associated with outputs R1A and R1B. When you install jumper W1, it ties the common (C) associated with outputs R0A and R0B to ControlWave EFM power ground;...

  • Page 92: Connections To A Bristol Model 3808 Transmitter

    Since these outputs are not isolated, exercise care to ensure that the Caution load current does not affect operation of the ControlWave EFM or related devices You can wire two of these outputs to field circuitry via the Digital to Relay I/O Board option (see Figure 3-11).
  • Page 93 ControlWave EFM Instruction Manual Figure 3-12. 3808 Transmitter to ControlWave EFM RS-232 Comm. Cable Diagram Figure 3-13 details RS-485 wiring connections required between the ControlWave EFM and the 3808 transmitter. For loopback and termination control use switch SW3 on the Note: CPU module to configure COM3.
  • Page 94 ControlWave EFM Instruction Manual You can connect up to eight (8) Bristol 3808 transmitters to a ControlWave EFM using a half-duplex RS-485 network. See Figure 3- 14 for an illustration of this type of network. Figure 3-14. ControlWave EFM to 3808s - RS-485 Network Diagram...

  • Page 95: Chapter 4 - Operation

    Substitution of components may impair suitability for use in Class I, Division 2 environments. When the ControlWave EFM is situated in a hazardous location, turn off power before servicing or replacing the unit and before installing or removing I/O wiring.

  • Page 96: Communicating With The Controlwave Efm

     Set SW1-1 (the upper DIP switch) to the Open (right) position and SW1-2 (the lower DIP switch) to the Closed (left) position to place the ControlWave EFM in Local mode, which is used for normal running operations. Figure 4-1. Mode Switch 4.2 Communicating with the ControlWave EFM...

  • Page 97: Changing Port Settings

    4.2.2 Changing Port Settings You change port settings (baud rate, port type, IP address, and so on) using the Flash Configuration utility. You must establish communications with the ControlWave EFM using NetView, LocalView, or TechView before you can run the Flash Configuration utility.

  • Page 98: Collecting Data From The Controlwave Efm

    Section 4.2.1 to restore defaults and re-establish communications. 4.2.3 Collecting Data from the ControlWave EFM OpenBSI utilities such as DataView, Data Array Save/Restore and Harvester allow you to collect real time data (values of variables, array values, alarm messages) and historical data (audit records, archive files) from the ControlWave.

  • Page 99: Creating And Maintaining Backups

    ControlWave EFM Instruction Manual Download the project according to instructions in the Downloading section of the ControlWave Designer Programmer's Manual (D5125). After the download completes successfully, leave Mode switch (SW1) in local mode. 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 separate from the controller.
  • Page 100 ControlWave EFM Instruction Manual Figure 4-2. Saving a Backup of Your Project In the “Save/Zip project as” dialog box, specify a project name in the File name field. In Figure 4-2 we chose the name mynewproj. In the Save as type field, choose Zipped Project Files (*.zwt).

  • Page 101: Saving Flash Configuration Parameters (*.Fcp)

    ControlWave EFM Instruction Manual 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 into the ControlWave.

  • Page 102: Backing Up Data

    ControlWave EFM Instruction Manual Copy the resulting FCP file to backup media (CD-ROM, thumb drive, etc.) If you ever need to restore the FCP 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.

  • Page 103: Chapter 5 - Service And Troubleshooting

    ControlWave EFM Instruction Manual Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave EFM. In This Chapter     Upgrading Firmware ................ 5-2     Removing or Replacing Components ..........5-5  ...

  • Page 104: Upgrading Firmware

    Harmful electrical potentials may still exist at the field wiring terminals Caution even though the ControlWave EFM’s power source may be turned off or disconnected. Do not attempt to unplug termination connectors or perform any wiring operations until you verify that all associated power supply sources are turned off and/or disconnected.
  • Page 105 *.CAB files. In cases such as those, you should use the Remote System Firmware Downloader. Connect a null modem cable between COM1 of the ControlWave EFM and any RS-232 port on the associated PC. Click Start > Programs > Accessories > Communications > HyperTerminal...
  • Page 106 ControlWave EFM Instruction Manual Figure 5-1. HyperTerminal Mode Menu When the FLASH is ready for download, HyperTerminal repeatedly displays the letter C on the screen. In the HyperTerminal menu bar click Transfer > Send File (see Figure 5-2). (Ready to Download) Figure 5-2.

  • Page 107: Removing Or Replacing Components

    ControlWave EFM Instruction Manual Figure 5-3. Send File dialog box Exit HyperTerminal and power down the ControlWave EFM. If desired, you can disconnect the null modem cable between the ControlWave EFM and the PC. Set the SCM’s mode switch (SW1) for Local Mode, i.e., SW1-1 in...

  • Page 108: Accessing Modules For Testing

    Read completely the disassembly and test procedures described in this manual before starting. Any damage to the ControlWave EFM resulting from improper handling or incorrect service procedures is not covered under the product warranty agreement. If you cannot properly perform these procedures, obtain authorization and then return the device to the factory for evaluation and repairs.

  • Page 109: Removing/Replacing The Scm

    ControlWave EFM Instruction Manual Replace any communication cables, apply power, and test the module. 5.2.4 Removing/Replacing the SCM Use this procedure to remove or replace the System Controller Module (SCM). If the EFM is running, place any critical control processes under manual control and shut down the unit by disconnecting power from the SCM.

  • Page 110: Removal/Replacement Of An Expansion Communication Module

    ControlWave EFM Instruction Manual Apply power and test the unit. 5.2.6 Removal/Replacement of an Expansion Communication Module Use this procedure to remove or replace an expansion communication (ECOM) module. If the EFM is running, place any critical control processes under manual control and shut down the unit by disconnecting power from the SCM.

  • Page 111: Removal/Replacement Of A Power Distribution Board

    ControlWave EFM Instruction Manual To replace the battery, align the unit so that the negative battery terminal is oriented to the top and right as illustrated in Figure 2- 15 and place the battery into the battery mounting bracket (battery clamp must be in the released position.

  • Page 112: Removal/Replacement Of A Digital To Relay I/O Board

    SRAM, a worst-case current draw of 42 uA allows a battery life of approximately 5238 hours. This means you should not need to replace a battery until the ControlWave EFM has been in service for an extended period (normally many years).
  • Page 113 If the EFM is running, place any critical control processes under Replacing the manual control. Battery – Snap Remove power from the ControlWave EFM. Type Holder Remove the CPU module from the housing. Battery Part To remove the lithium battery, insert the tip of a small flat head Numbers: screw driver into the gap between the battery and the holder.

  • Page 114: Enabling / Disabling The Backup Battery

    If the EFM is running, place any critical control processes under Replacing the manual control. Battery – Clip Remove power from the ControlWave EFM. Type Holder Remove the CPU module from the housing. Battery Part To remove the lithium battery, gently pry up the tab holding the...
  • Page 115 ControlWave EFM Instruction Manual Module LED Name LED Color Function 6 STATUS See Table 5-2 and Figure 5-5 C1 RX (Comm 1) ON = RX activity (top left; see Figure 5-6) C1 TX (Comm 1) ON = TX activity (top right; see Figure 5-6) C2 RX (Comm 2) ON = RX activity (middle left;...
  • Page 116 ControlWave EFM Instruction Manual SCM System As the EFM runs its application, status codes post to the six LEDs on Status LED the SCM. Table 5-2 provides activity descriptions of the LEDs; Figure Codes 5-5 shows what the LEDs look like for each hex code.
  • Page 117 ControlWave EFM Instruction Manual Figure 5-5. SCM Status LED Hexadecimal Codes CPU Module The CPU module has six comm port activity LEDs on the CPU board. Units equipped with an Ethernet port have two additional LEDs LEDs located on the Ethernet RJ-45 connector. Table 5-3 details assignments for the LEDs on the CPU module.
  • Page 118 ControlWave EFM Instruction Manual Figure 5-6. CPU Module Comm Connectors and LEDs 5-16 Service & Troubleshooting Revised Dec-2013...
  • Page 119 ControlWave EFM Instruction Manual S LOT # 3 S LOT # 4 R eceive LE Ds T ransmit LE Ds Comm. P ort 4 S tatus LEDs Comm. P ort 8 S tatus LE Ds Comm. P ort 5 S tatus LE Ds Comm.

  • Page 120: Checking Wiring/Signals

    1 to 127 and must be unique on this particular BSAP communication line. You set the BSAP local address using the flash configuration utility. If this ControlWave EFM is a BSAP slave node, and the range of addresses defined for the BSAP master port end of the...

  • Page 121: Windiag Diagnostic Utility

    If IP communications do not function, it is often due to incorrect IP addresses or masks. Check to see that the IP address you defined for the ControlWave EFM is compatible with the range of IP addresses defined for the communication line on which the unit resides. Also check that the IP address of the default gateway is correct.
  • Page 122 ControlWave EFM Instruction Manual Port Module Default Configuation COM3 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol. COM4 ECOM Types 1 or RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol.
  • Page 123 ControlWave EFM Instruction Manual Figure 5-10. NetView Select Start >Programs > OpenBSI Tools >Common Tools > Diagnostics. The Main Diagnostics menu (Figure 5-11) displays. Figure 5-11. WINDIAG Main Diagnostics Menu Select the module to be tested. Enter any prompted parameters (slot #, etc.).

  • Page 124: Available Diagnostics

    ControlWave EFM Instruction Manual Set switch SW2-8 on the CPU module to ON (open). The EFM should resume normal operation. 5.4.1 Available Diagnostics Using WINDIAG, you can test all EFM modules with the exception of the SCM. WINDIAG’s Main Diagnostics Menu (see Figure 5-11)
  • Page 125 ControlWave EFM Instruction Manual Figure 5-13. RS-485 Loop-back Plug These tests verify the correct operation of the serial ports. : You cannot test a communications port while you are using it. Note You can only test currently unused ports. After you complete...
  • Page 126 ControlWave EFM Instruction Manual Figure 5-14. Communications Diagnostic Menu Enter 5 in the Number of Passes field. Select a port to test (click  to display all available ports). : The port you select must correlate to the port on which you Note placed the loop-back plug in step 1.
  • Page 127 ControlWave EFM Instruction Manual Figure 5-15. RJ-45 Ethernet Loop-back Plug : You cannot test a communications port while you are using it. Note You can only test currently unused ports. After you complete 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.

  • Page 128: Core Updump

    ControlWave EFM Instruction Manual Enter 1 in the Ethernet Port to Test field. Click RUN next to the Loop-back out twisted pair field to start the test. At the completion of the test, any failed results appear in the Status field next to the Loop-back out twisted pair label: ...
  • Page 129 ControlWave EFM Instruction Manual Connect the ControlWave EFM’s Comm Port 1 to a PC using a null modem cable. If the SCM’s mode switch has a Run/Remote/Local switch, set it as follows. Set both SW1-1 and SW1-2 to the right (open) operation or both to the left (closed).
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  • Page 131 Read this appendix carefully before installing a nonincendive ControlWave Electronic Flow Meter (EFM). In the event of a conflict between the ControlWave EFM Instruction Manual (CI-ControlWave EFM) and this appendix, always follow the instructions in this appendix The ControlWave Electronic Flow Meter (EFM) includes both nonincendive and unrated field circuits.
  • Page 132 I/O Board I/O circuitry is unrated an must be wired using Div. 2 wiring methods. The UL listed nonincendive ControlWave EFM may include a 21V Power Supply Board (option). No field wiring connections/removals should be made at the 21V Power Supply Board unless the area is known to be nonhazardous.
  • Page 133 ControlWave EFM Instruction Manual Table A-1. Module/Board Customer Wiring Connectors Module/Item Connector Wiring Notes CPU Module J3 – COM1, 9-pin Male D- Factory connected to local comm. port. Refer to item 3 of this appendix. CPU Module J4 – COM2, 9-pin Male D- Remote comm.
  • Page 134 ControlWave EFM Instruction Manual Module/Item Connector Wiring Notes TB5 – 2-pin terminal block Fused Power Out 2 – Factory wired * TB6 – 2pin terminal block Fused Power Out 3 – Factory wired * 21V Power Supply Board (See TB1 – 3-pin terminal block 12V power input –...
  • Page 135 ControlWave EFM Instruction Manual Appendix D – Modem Installation D2.1 Modem Installation & Configuration D2.1.1 Installing an Internal MultiTech Modem (MT9234SMI) To install a Model MT9234SMI Modem onto an ECOM Module, perform the following steps: Remove the ECOM Module from the controller (see Figure D1).
  • Page 136 ControlWave EFM Instruction Manual Figure D2. MultiTech Modem Installation Diagram Note: If necessary, you can use a small screwdriver to pry the cover panel from the PCB. Install the nylon support post included in the kit onto the ECOM Module.
  • Page 137 ControlWave EFM Instruction Manual Mount the MultiTech Modem to the ECOM Module making sure that the interface connectors (J6, J7, J9 & J10 on the ECOM Module) align. Plug the antenna cable(s) (if present - removed in Step 2) into the appropriate RF connector of an installed radio module(s).
  • Page 138 ControlWave EFM Instruction Manual  Bits per second: 9600  Data bits:  Parity: None  Stop bit:  Flow Control: None  Send Factory Default AT&F0.  Disable Flow Control AT&K0.  Set baud rate using AT Command for example: AT$SB9600, (Modify for whatever baud rate you require.)
  • Page 139 ControlWave EFM Instruction Manual Appendix Z – Sources for Obtaining Material Safety Data 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.
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  • Page 141 2-2. 8 Slot ControlWave EFM Component ID protocols supported ........1-10 Diagram ............2-4 ControlWave project 2-3. 8 or 4 Slot ControlWave EFM Housing ... 2-7 downloading ........... 4-4 2-4. ControlWave EFM Bottom View ....2-8 Core Updump ........... 5-26 2-5.
  • Page 142 Connection to Case-Mounted (External) Radio or Modem ........... 2-37 2-25. Full-duplex and Half-duplex Cable ..2-37 Grounding ............2-13 2-26. PC Connected to ControlWave EFM via D- Type Local Port .......... 2-37 2-27. PC Connected to ControlWave EFM via Circular Local Port ........2-38 Hazardous locations 2-28.
  • Page 143 ControlWave EFM Instruction Manual Repair in field ............5-6 RS-232 Ports ............ 2-34 Lead acid battery Cables ............2-35 removing and replacing ........5-8 RS-485 Ports ............ 2-41 LEDs Cables ............2-40 Checking ............5-12 configuration switch ........2-33 CPU module ..........5-15 Run switching ............
  • Page 144 ControlWave EFM Instruction Manual 2-14. RS-485 Connectors on Type 2 ECOM 2-40 2-15. RS-485 Port Connector Pin Assignment .2- Unpacking components ........2-6 Updump ............5-26 2-16. RS-485 Network Connections ..... 2-41 switch ............2-32 2-17. Ethernet 10/100Base-T CPU Module Pin Upgrading firmware ..........
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  • Page 146 OpenEnterprise are trademarks of Remote Automation Solutions. AMS, PlantWeb and the Jebel Ali Free Zone — South 2 PlantWeb logo are marks of Emerson Electric Co. The Emerson logo is a trademark and service Dubai U.A.E. mark of the Emerson Electric Co. All other marks are property of their respective owners.

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