(ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read supplemental document S14006 for proper care and handling of ESD-sensitive components. A Division of Emerson Process Management 1100 Buckingham Street, Watertown, CT 06795 Remote Automation Solutions...
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Chapter 1 – Introduction This manual focuses on the hardware aspects of the ControlWave Express Remote Terminal Unit (RTU). For information about the software used with the ControlWave Express, refer to Getting Started with ControlWave Designer (D5085), the ControlWave Designer Programmer’s Handbook (D5125), and the online help in ControlWave Designer.
ControlWave Express Instruction Manual (CI-ControlWave Express) Nonincendive Class I, Division 2 (Groups A, B, C and D) Cost-effective for small RTU/process controller applications. 1.1 Scope of the Manual This manual contains the following chapters: 1.2 Physical Description The ControlWave Express consists of a CPU/System Controller Board (SCB) with a piggy-back mounted LED board, an optional process I/O board, and a two-piece enclosure.
Figure 1-1. ControlWave Express Component Identification 1.3 CPU/System Controller Board The CPU (central processing unit) and System Controller Board (SCB) contains the ControlWave Express CPU, I/O monitor/control, memory, and communication functions. The CPU/System Controller board includes: Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit ...
ControlWave Express Instruction Manual (CI-ControlWave Express) transmit (TX) and receive (RX) LEDs for each communication port 2 MB of battery backed Static RAM (SRAM), 512KB boot/downloader FLASH, 8MB simultaneous read/write FLASH memory Board Variations The CPU/System Controller board has three basic variations: Table 1-1.
FLASH Memory The ControlWave Express includes 8 MB of FLASH memory. The FLASH memory holds the system firmware and the boot project. Optionally FLASH memory also stores the zipped ControlWave project (*.zwt), user files, and historical data (audit/archive files).The FLASH does not support hardware write protection.
ControlWave Express Instruction Manual (CI-ControlWave Express) Type Discrete Input / Output (DI/DO) 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 Express.
The I/O Configurator, accessible via a menu item in ControlWave The ACCOL3 Firmware Library, available within ControlWave OpenBSI Utilities provides a set of programs that allow you to OpenBSI Harvester is a special add-on package that allows ...
ControlWave Express Instruction Manual (CI-ControlWave Express) Communication Protocols In addition to the Bristol Synchronous/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.
Chapter 2 – Installation This chapter discusses the physical configuration of the ControlWave Express, considerations for installation, and instructions for setting switches and jumpers. In This Chapter 2.1 Site Considerations When choosing an installation site, check all clearances. Ensure that the ControlWave Express is accessible for wiring and service.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 2-1. ControlWave Express Component Identification See document Specifications for Temperature, Humidity and Vibration Ensure that the ambient temperature and humidity at the installation Check the mounted enclosure, panel, or equipment rack for 420DS-6c available on our website for detailed technical specifications for temperature, humidity, and vibration for...
Caution 2.1.1 Class I, Div 2 Installation Considerations Underwriters Laboratories (UL) lists the ControlWave Express as non- incendive and suitable only for use in Class I, Division 2, Group A, B, C, and D hazardous locations and non-hazardous locations. Read this chapter and Appendix A carefully before you install a ControlWave Express in a hazardous location.
ControlWave Express Instruction Manual (CI-ControlWave Express) Note 2.2.1 Unpacking Components Depending upon how you order it, the ControlWave Express may Packaging arrive pre-assembled, or in a number of separate boxes. If you did not order it pre-assembled, you must identify, unpack, and assemble the components.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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 Revised Mar-2011 Installation...
ControlWave Express Instruction Manual (CI-ControlWave Express) 2.2.3 Grounding the Housing The ControlWave Express enclosure does not include a ground lug. Instead, you must use one or more of the mounting screws to secure a ground cable to the unit. Once you have installed the unit, run a ground wire (#4 AWG max wire size) between one of the mounting screws for the enclosure to a known good earth ground.
2.3 Configuring the CPU/System Controller Board To configure the CPU/System Controller board, you need to set some switches and jumpers. Solar Pwr. In + Power In + Aux. Power Out + Sec. Battery Input Input Input Output Output Input Output Input Input Input...
ControlWave Express Instruction Manual (CI-ControlWave Express) 2.3.1 Setting DIP Switches on the CPU/System Controller Board Before you install the CPU/System Controller board, you must determine the settings for three banks of DIP switches. Refer to Figure 2-3 for the location of the DIP switch banks. Refer to Tables 2-1, 2-2, and 2-3 for an explanation of the DIP switch positions.
SW2 Setting Note: Table 2-3. RS-485 Configuration Switch SW3 Switch Setting Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Function Mode Core Updump Causes the ControlWave Express to perform a core updump, provided you have set the SW1 switches to allow recovery mode.
W14: COM3 configuration selection: W15: COM3 configuration selection: W16: COM3 configuration selection: W17: Input power selection (controls solar power shunt regulation. W18: COM1 connector selection: 2.3.3 General Wiring Guidelines Allow some slack in the wire while making terminal connections. 2.3.4 Wiring Power to the CPU/System Controller Board Caution Revised Mar-2011...
ControlWave Express Instruction Manual (CI-ControlWave Express) Depending upon the CPU type, the ControlWave Express accepts either Power Supply a 6Vdc, 12Vdc or 24Vdc bulk power input. You can estimate the Current maximum current required for your ControlWave Express using the Requirements following equation: Bulk +6/12/24 Vdc Supply Current = CPU/System Controller Board (with...
Alternatively, you can power low powered versions of the ControlWave Express using a solar panel connected to a user-supplied rechargeable 7AH (6V/12V) lead acid battery at connections TB1-1 and TB1-2. TB1 connections are: ...
ControlWave Express Instruction Manual (CI-ControlWave Express) The ControlWave Express includes an alternative power connecter, Terminal Block TB2, to provide power if none is available at TB1. For example, you Connector TB2 can connect a bulk DC power supply to TB2 to handle situations where the solar panel/battery does not have sufficient power.
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.) Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 2-5. Male DB9 9-Pin Connector Table 2-6. RS-232 COM1 and COM2 Port Connector Pin Assignment RS-232 Signal Table 2-7.
ControlWave Express Instruction Manual (CI-ControlWave Express) CW or P 9-Pin Female J4 (COM1) “D” Connector 5 = GND To P2 Pin-5 4 = DTR To P2 Pin-6 8 = CTS 3 = TXD To P2 Pin-2 7 = RTS To P2 Pin-1 2 = RXD To P2 Pin-3 6 = DSR...
3305/3310/3330/3335/CW_10/30/35 9-Pin Male “D” Connector 1 = DTR To P2 Pin-1 6 = CTS 2 = TXD To P2 Pin-2 7 = DCD To P2 Pin-4 4 = RXD To P2 Pin-3 9= GND To P2 Pin-5 5 = RTS 3305/3310/3330/3335/CW_10/30/35 9-Pin Male “D”...
ControlWave Express Instruction Manual (CI-ControlWave Express) When interfacing to the COM3 port of a ControlWave, or the COM5 or COM6 port a ControlWaveEXP unit, use the cable presented in Figure 2-9 along with one of the cables shown in Figure 2-6 or Figure 2-7. RJ45 to DB9 Cable Ass’y.
2.3.6 Connections to the COM3 (RS-485/RS-232) Serial Port on the CPU/System Controller Board You use jumpers W12 through W16 to configure COM3 of the ControlWave Express for either RS-232 or RS-485 operation. See Section 2.3.2 for information on these jumpers. Table 2-8.
ControlWave Express Instruction Manual (CI-ControlWave Express) To ensure that the “Receive Data” lines are in a proper state during inactive transmission periods, you must maintain certain bias voltage levels at the master and most distant slave units (end nodes). These end nodes also require the insertion of 100Ω...
2.3.7 Connections to the Ethernet Port on the CPU/System Controller Board Caution The 33MHz ControlWave Express can support one Ethernet port. This port uses a 10/100Base-T RJ-45 modular connector (J1) that provides a shielded twisted pair interface 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).
ControlWave Express Instruction Manual (CI-ControlWave Express) Note You can connect two nodes in a point-to-point configuration without using a hub. However, you must configure the cable so that the TX+/- Data pins connect to the RX+/- Data pins (swapped) at the opposite ends of the cable (see Figure 2-12).
Both keypads use the same 4-line by 20-character LCD displays. The Display without a keypad has a 2-line display with 10 characters on the first line, and 6 characters on the second line. This display shows variable values on line 1, and variable 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.
Chapter 3 – I/O Configuration and Wiring This chapter discusses setting I/O configuration switches and jumpers and wiring I/O connections to the ControlWave Express. In This Chapter 3.1 I/O Options ControlWave Express comes with the following standard I/O: In addition, three different versions of the optional process I/O board are available: Type...
3.2 Process I/O Board ControlWave Express may include an optional Process I/O board. The Process I/O board mounts to the CPU/System Controller board using six nylon mounting posts. To configure the Process I/O board, you need to set some switches and jumpers.
Caution 3.3 I/O Wiring The ControlWave Express 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. ¼”...
3.3.1 Non-Isolated Discrete Inputs (DI) on TB2 and TB3 of Process I/O Board Process I/O Board terminal block connector TB2 provides interface to four dedicated non-isolated Discrete Inputs DIs – DI1 through DI4. In addition, terminal block connector TB3 provides two additional points that can serve as either discrete inputs or discrete outputs (DI5 and DI6 when wired as inputs).
3.3.2 Non-Isolated Discrete Outputs (DO) on TB3 of Process I/O Board Process I/O Board terminal block connector TB3 provides interface to two dedicated non-isolated discrete outputs DOs – DO1 and DO2. In addition, terminal block connector TB3 provides two additional points that can serve as either discrete inputs or discrete outputs (DO3 and DO4 when wired as outputs).
3.3.3 Non-Isolated Analog Inputs (AI) on TB6 of Process I/O Board Process I/O Board terminal block connector TB6 provides interface to three single-ended analog inputs (AIs). Table 3-5. Non-Isolated AI General Characteristics Setting Jumpers See Section 3.2.1 for details on setting jumpers. Wiring Each AI includes three terminals (field power, AI# and DGND).
3.3.4 Non-Isolated Analog Output (AO) on TB7 of Process I/O Board Process I/O Board terminal block connector TB7 provides interface to a single analog output (AO). Table 3-6. Non-Isolated AO General Characteristics Setting Jumpers See Section 3.2.1 for details on setting jumpers. Wiring See Figure 3-2 for wiring diagrams.
3.3.5 Non-Isolated Pulse Counter/Discrete Inputs on TB5 of CPU/System Controller Board CPU/System Controller Board connector TB5 provides interface to two internally sourced open collector pulse counter/discrete inputs (Pulse1 and Pulse2) with a 1 second scan rate. Pulse counters act like high speed counters but cannot function with contact relays because they lack contact debounce circuitry.
3.3.6 Non-Isolated High Speed Counter (HSC) / Discrete Inputs (DI) on TB4 of Process I/O Board Process I/O Board connector TB4 provides interface to two internally sourced single-ended high speed counter/discrete inputs (HSC1 and HSC2). Table 3-8. Non-Isolated High Speed Counter/Discrete Inputs General Characteristics Wiring See Figure 3-2 for wiring diagrams.
3.3.7 Resistance Temperature Device (RTD) Inputs on CPU/System Controller Board CPU/System Controller Board connector TB6 provides connection to a 3-wire 100 ohm platinum bulb RTD (using the DIN 43760 curve). Wire the RTD according to Table 3-9 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.
ControlWave Express Instruction Manual (CI-ControlWave Express) To install the RTD probe, screw the fitting body into the thermowell Installing the RTD with a 7/8” open-end wrench. While you apply pressure against the Probe 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”...
3.3.8 Connections to a Bristol Model 3808 Transmitter You can connect a Bristol 3808 transmitter (digital) to the ControlWave Express through either an RS-232 or RS-485 port. Communication schemes and cable lengths determine the type of communication port you need to use. In general RS-232 communications require that you place the 3808 transmitter within 25 feet of the ControlWave Express (local communications).
ControlWave Express Instruction Manual (CI-ControlWave Express) 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.
Chapter 4 – Operation This chapter provides general operational details for using the ControlWave Express. In This Chapter WARNING 4.1 Powering Up/Powering Down 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.
ControlWave Express Instruction Manual (CI-ControlWave Express) Power Down 4.2 Communicating with the ControlWave Express You communicate to the ControlWave Express by connecting a cable between a port on your PC workstation and one of the ControlWave Express ports. The port at the PC workstation must match the configuration of the ControlWave Express port.
4.3 Creating and Downloading an Application (ControlWave Project) Your ControlWave Express executes an application called a ControlWave project. You create the project using PC-based ControlWave Designer software. Instructions for creating a ControlWave project are beyond the scope of this manual. Please refer to the following sources for information: ...
ControlWave Express Instruction Manual (CI-ControlWave Express) Notes: You may find it useful to maintain more than one backup copy in If you don’t keep more than one backup copy, it’s a good idea to 4.4.1 Creating a Zipped Project File (*.ZWT) For Backup Note: With your current ControlWave project open in ControlWave Designer, perform the following steps:...
4.4.2 Saving Flash Configuration Parameters (*.FCP) You must establish communications with the ControlWave Express using NetView, LocalView, or TechView before you can run the Flash Configuration utility. Note: Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Zip Option Description Zip User-Libraries If you created your own user-defined functions or function blocks, you must select this to preserve them.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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 represent tuning parameters ...
Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave Express, as well as some common maintenance procedures. In This Chapter You need the following equipment to perform the procedures described Equipment in this chapter: To run diagnostics software: ...
ControlWave Express Instruction Manual (CI-ControlWave Express) Caution Upgrading Firmware The ControlWave Express ships from the factory with system firmware already installed. If you need to upgrade the system firmware (stored in Flash memory) to acquire new functionality or restore firmware, you can use one of several methods.
Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Connect a null modem cable between COM1 of the ControlWave Express and any RS-232 port on the associated Click Start > Programs > Accessories > Communications > HyperTerminal If using HyperTerminal for the first time, set the communication properties (for the PC port) via the Properties Menu as follows: Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop bits: = 1, and Flow control: = None and then click OK.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-2. HyperTerminal In the Send File dialog box (see Figure 5-3), select 1KXmodem for the protocol, enter the filename of the appropriate .bin file in the format “E1Sxxxxx.bin” or “E3Sxxxxxx.bin” (where E1S refers to 14 MHz CPUs, and E3S refers to 33 MHz CPUs and xxxxx varies from release to release) and click Send to start the flash upgrade (see Figure 5-4).
5.2 Removing or Replacing Components This section provides information on accessing ControlWave Express components for testing, as well as removal/replacement procedures. Caution 5.2.1 Accessing Modules for Testing Only technically qualified personnel should test and/or replace ControlWave Express components. Read completely the disassembly and test procedures described in this manual before starting.
ControlWave Express Instruction Manual (CI-ControlWave Express) 5.2.3 Removing/Replacing the Backup Battery Note Shut down the ControlWave Express by disconnecting the power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2). Loosen the two thumb screws and remove the removable card edge cover.
The CPU/System Controller board accommodates a 3 V, 300 mA lithium coin cell backup battery housed in a coin-cell socket (S1). A supervisory circuit on the CPU switches to battery power when the regulated 3.3 Vdc falls out of specification. The battery then provides backup power for the real-time clock (RTC) and the system SRAM on the CPU/System Controller board.
ControlWave Express Instruction Manual (CI-ControlWave Express) For maximum shelf life, you can isolate the battery from the circuit by Disabling placing jumper W3 on pins 2-3. 5.3 General Troubleshooting 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.
Table 5-1. LEDs on Piggy-back LED board Color IDLE STAn Receive GREEN Transmit YELLOW Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-6. CPU/System Controller LEDs Description ON = Power good ON = Watchdog condition – program crash; OFF = Normal operation ON = CPU has free time at end of execution cycle.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-7 shows the possible LED patterns for the STAn codes and Table 5-1includes descriptions for the various LED patterns and LCD status codes (if you have an attached Display/Keypad). Figure 5-7. CPU/System Controller Board LED Patterns - LED Hexadecimal Codes Table 5-2.
LED6 LED5 LED4 LED3 STA6 STA5 STA4 STA3 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 idle LED (IDLE – CR1 left) that have identical functions to WD and IDLE described in Table 5-1.
ControlWave Express Instruction Manual (CI-ControlWave Express) 5.4 WINDIAG Diagnostic Utility Caution WINDIAG is a software-based diagnostic tool you use to test the performance of I/O, CPU memory, communication ports, and other system components. . WINDIAG is a PC-based program, so the ControlWave Express must be attached to and communicating with a PC running WINDIAG.
5.4.1 Available Diagnostics WINDIAG’s Main Diagnostics Menu (see Figure 5-9) provides the following diagnostic selections: Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-9. WINDIAG Main Diagnostics Menu Select the component to be tested. See Section 5.4.1 for a description of the tests.
ControlWave Express Instruction Manual (CI-ControlWave Express) WINDIAG allows you to select the communication port to test. Port Loop-back Depending on the type of network (RS-232 or RS-485) and the port in Test 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.
Note: Port 3 - RS-485 use loop-back wires or CPU Switch SW3 (see These tests verify the correct operation of the communication ports. Note Use this procedure to test the communication ports. Test Procedure Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) You can configure RS-485 loopback by setting CPU/System Controller board switches SW3-1 &...
ControlWave Express Instruction Manual (CI-ControlWave Express) 5.5 Core Updump In some cases—such as when a ControlWave Express fails for no apparent reason—you can upload a copy of the contents of SRAM and SDRAM to a PC for support personnel and service engineers to evaluate.
By setting the CPU/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).
152 of the Canadian Electrical Code for installation in Canada. The 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.
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. Revised Mar-2011 ControlWave Express Instruction Manual (CI-ControlWave Express) Manufacturer...
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