Instruction Manual CI-ControlWave Express Feb., 2009 Bristol ControlWave Express Bristol ControlWave Express (Remote Terminal Unit) Remote Automation Solutions www.EmersonProcess.
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING! Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference. 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.
WARRANTY A. Remote Automation Solutions (RAS) warrants that goods described herein and manufactured by RAS are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by RAS in writing. B. RAS warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer. C.
How to return material for Repair or Exchange Before a product can be returned to Remote Automation Solutions (RAS) for repair, upgrade, exchange, or to verify proper operation, Form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the RAS Watertown Repair Dept. to effectively and efficiently process the repair order. You can easily obtain a RA number by: A.
Remote Automation Solutions (RAS) Repair Authorization Form (on-line completion) (Providing this information will permit Bristol, also doing business as Remote Automation Solutions (RAS) to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.) Date RA # SH Line No. Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
Emerson Process Management Training GET THE MOST FROM YOUR EMERSON INSTRUMENT OR SYSTEM • Avoid Delays and problems in getting your system on-line • Minimize installation, start-up and maintenance costs. • Make the most effective use of our hardware and software. • Know your system. As you know, a well-trained staff is essential to your operation. Emerson offers a full schedule of classes conducted by full-time, professional instructors.
CI-ControlWave Express ControlWave Express Remote Terminal Unit INSTALLATION FORWARD NOTE for all ControlWave Express Installers: READ THIS SECTION FIRST! This manual has been designed for the following audience: • Customer Site Engineers, who must plan for the installation and implementation of the ControlWave Express. • Instructors who must become familiar with and teach Field Engineers/Technicians on the installation, operation and repair of ControlWave Express.
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CI-ControlWave Express ControlWave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - ControlWave Express INTRODUCTION 1.1 1.2 1.3 1.3.1 1.3.2 1.3.2.1 1.3.2.2 1.3.2.3 1.3.2.4 1.3.2.5 1.3.3 1.3.3.1 1.3.3.2 1.3.3.3 1.3.3.3.1 1.3.3.3.2 1.3.3.3.3 1.3.3.3.4 1.3.3.3.5 1.3.3.3.6 1.4 1.5 1.5.1 1.5.2 1.5.3 GENERAL DESCRIPTION ........................................................................................... 1-1 ControlWave PROGRAMMING ENVIRONMENT ..........................
CI-ControlWave Express ControlWave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 2 - ControlWave Express INSTALLATION & OPERATION (Continued) 2.3.3.2 2.3.3.3 2.3.3.3.1 2.3.3.3.2 2.3.3.4 2.3.4 2.3.4.1 2.3.4.2 2.3.4.3 2.3.4.3.1 2.3.4.4 2.3.4.4.1 2.3.4.5 2.3.4.5.1 2.3.4.6 2.3.4.6.1 2.3.4.7 2.3.4.7.1 2.3.4.8 2.3.4.8.1 2.3.4.9 2.3.5 2.3.6 2.3.7 2.3.7.1 2.3.7.2 2.3.7.3 2.3.8 2.4 2.4.1 2.4.2 2.4.2.1 2.4.2.2 2.4.2.3 2.4.3 2.4.4 2.4.5 2.4.5.1 2.4.5.
CI-ControlWave Express ControlWave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 3 - ControlWave Express SERVICE 3.1 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.5.1.1 3.5.1.2 3.6 3.7 SERVICE INTRODUCTION ........................................................................................ 3-1 COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1 Accessing Components For Testing .......................................
CI-ControlWave Express ControlWave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # APPENDICES/SUPPLEMENTAL INSTRUCTION (Continued) Sources for Obtaining Material Safety Data Sheets ..................................... Appendix Z Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW Care and Handling of PC Boards and ESD-Sensitive Components .....................
Section 1 ControlWave Express INTRODUCTION 1.1 GENERAL DESCRIPTION ControlWave Express remote terminal units (RTU) have been designed to perform as the ideal platform for remote site automation, measurement and data management in process control and manufacturing. ControlWave Express RTUs measure temperature and monitor a variety of analog and digital inputs.
microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC) is the core of the CPU/System Controller Board.
1.2 ControlWave PROGRAMMING ENVIRONMENT The ControlWave programming environment uses industry-standard tools and protocols to provide a flexible, adaptable approach for various process control applications in the water treatment, wastewater treatment, and industrial automation business. Figure 1-2 - ControlWave - Control Strategy Software Diagram ControlWave Express RTUs provide an ideal platform for remote site automation, measurement, and data management in the oil and gas industry.
• ControlWave Designer programming package offers several different methods for generating and debugging control strategy programs including function blocks, ladder logic, structured languages, etc. The resulting programs are fully compatible with IEC 61131-3 standards. Various communication methods as offered, including TCP/IP, serial links, as well as communication to Bristol Open BSI software and networks.
will remain on. When interfaced to a keypad, the operator may activate the display at any time by pressing the appropriate front panel button. 1.3.2 CPU/System Controller Board The multilayer CPU/System Controller Board provides ControlWave Express CPU, I/O monitor/control, memory and communication functions. ControlWave Express CPU/System Controller Boards operate over an extended temperature range with long-term product reliability.
1 NOTE: Ultra Low Power & Low Power CPU/System Controller Bds. Don’t have an Ethernet Port. Solar Pwr. In and Aux. Power Out are not available on units equipped F3 with an Ethernet Port. Do Not Connect a 24V Solar Panel to Connector TB1-1 & TB1-2! 3 4 Power 5 6 1 Power 2 1 2 3 4 1 6 5 6 9 5 COM1 RS-232 7 8 W1 W18 3 2 1 1 NOTE: J11 normally used 3 COM2 RS-232 4 5 COM1 for CW GFC and CW RS-232 Express PAC only.
A supervisory circuit is used to switch to battery power when VCC falls out of specification. For maximum shelf life, the battery may be isolated from the circuit by removing the Backup Battery Jumper W3 from position 1 to 2 and then storing it in position 2 to 3. If the real-time clock looses its battery backup a ControlWave Designer system variable bit (_QUEST_DATE) is set.
Table 1-1 - CPU/System Controller Board Connector Summary (Continued) Ref. TB1 # Pins 6-pin TB2 TB3 TB4 TB5 TB6 2-pin 8-pin 5-pin 4-pin 3-pin Function Solar Panel, Battery/Power Supply & Aux Out, Secondary battery input Term. Block (COM2 - RS-232) Term. Block (COM3 – RS-232/RS-485) Pulse Input Connector RTD Input Notes Main Power Connector See Section 2.3.9 See Table 2-3A or 4-2 See Table 2-3C or 4-3 See Section 2.3.
• • • • • TB1-4 TB1-5 TB1-6 TB2-1 TB2-2 - Ground (GND) Auxiliary Power Out+: for an external radio/modem * Ground (GND) Secondary battery input Ground (GND) Note: * = Not available on units equipped with an Ethernet Port. Power may be provided by a user supplied rechargeable 6/12V Lead Acid Battery (used in conjunction with a Solar Panel), or a range of other user-supplied battery systems or bulk (nominal +6Vdc, +12Vdc or +24Vdc) power supply.
1.3.2.
• W17 - Input Power Selection (Controls Solar Power Shunt Reg.) N/A for +24Vdc CPUs 1 to 2 = 6V Power 2 to 3 = 12V Power • W18 - COM1 Connector Selection 1 to 2 = Connector J4 (D connector) is active 2 to 3 = Alternate connector J11 is active 1.3.2.4 CPU/System Controller Board Configuration Switches Three user-configurable DIP-Switches are provided on the CPU/System Controller Board. These switches provide the following functionality: • Four-bit DIP-Switch SW1 provides forced recovery functions.
Table 1-4 - CPU/System Controller Bd.
• • • Two Non-Isolated Internally-Sourced High Speed Counter Inputs (or DI operation supported) Three Non-Isolated Single-Ended 1-5V or 4 to 20mA Analog Inputs (Optional) One Non-Isolated Externally-Powered 1-5V or 4 to 20mA Analog Output (Optional) 1.3.3.
Figure 1-4 - ControlWave Express Process I/O Board 1-14 / Introduction CI-ControlWave Express Click here to return to Table of Contents
1.3.3.2 Process I/O Board Connectors Process I/O Boards are equipped with up to six (6) I/O interface connectors that function as follows (see Table 1-5): Table 1-5 - Process I/O Board Connector Summary Ref. P1 TB2 TB3 # Pins 20-Pin 6-Pin 8-pin TB4 TB6 TB7 8-pin 9-pin 4-pin Function Bd. Power and I/O Bus Digital Input (DI1 – DI4) Interface Digital Output (DO1 & DO2) & DI/O (DI5/DO3 & DI6/DO4) Interface High Speed Counter Input Interface Analog Input Interface Analog Output Interface Notes Intf.
power is applied to the field device (controlled via jumper JP4) and can be supplied by the system battery or an external power source. Each AI channel can be individually configured for 4 to 20mA or 1-5V operation (via JP5 for AI1, JP6 for AI2 and JP7 for AI3). AIs are supplied with a two hertz low pass filter and surge suppression (via 30Vdc Transorbs). 1.3.3.3.5 Non-isolated Analog Output (also see Section 2.3.4.7) Terminal Block TB7 provides interface to 1 Analog Output.
• Uses pre-configured web pages for user readings, configuration and maintenance. Web pages can be modified and new pages configured to work with a modified application load • Resides on a BSAP SCADA network • Provides audit trail and archives • Allows the user to select engineering units, including English and metric The primary function of the ControlWave Express is to provide data acquisition, a local display, communications, output control, input status and self test and diagnostics.
RS-232 or RS-485 operation. Any serial communication port can be configured for local communications, i.e., connected to a PC loaded with ControlWave Designer and OpenBSI software. RS-232 Ports An RS-232 interface supports Point-to-Point, half-duplex and full-duplex communications (20 feet maximum, using data quality cable). Half-duplex communications supported by the ControlWave Express utilize MODBUS or BSAP protocol, while full-duplex is supported by the Point-to-Point (PPP) protocol.
Section 2 ControlWave Express INSTALLATION & OPERATION 2.1 INSTALLATION IN HAZARDOUS AREAS Each ControlWave Express RTU is furnished in an enclosure/chassis that accommodates mounting to a Panel or a DIN-Rail and have been designed to operate in a protected Class I, Division 2, Groups C & D environment with a nonincendive rating (see Appendix A). Figure 2-1 - ControlWave Express Component Identification A Dimensional drawing of the NEMA Enclosure is provided in Figure 2-2. 2.
Chassis. Two Thumb Screws can be loosened to facilitate removal of the Card Edge Cover, and thus accommodating all instrument field wiring. Information on mounting the ControlWave Express assembly is provided in Section 2.3.1 Mounting the ControlWave Express. 2.2.1 Temperature & Humidity Limits ControlWave Express RTUs have been designed to operate over a -40°F to +158°F (-40°C to +70°C) temperature range (with storage at up to +185°F (+85°C)) and a 0% to 95% relative humidity range.
5. Install I/O wiring to the Process I/O Board and to the CPU/System Controller Board if Pulse Inputs are present (see Section 2.3.4). Install a communications cable to a Model 3808 Transmitter if required (see Section 2.3.6). 6. Install a ground wire between the Enclosure and a known good Earth Ground (see Section 2.3.7.3). 7. If required, install the RTD Probe (see Section 2.3.5) 8. Connect DC Power wiring to the ControlWave Express CPU/System Controller Board (see Sections 2.3.7.1 & 2.3.7.2). 9.
Detailed information on the Flash Configuration Utility, and LocalView is included in Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in Chapter 6 of that same manual. TechView is described in the TechView User’s Guide (document# D5131). Step 4. Create an Application-Specific Control Strategy in ControlWave Designer At this point, you can create your application-specific control strategy using ControlWave Designer.
You can use whichever HTML creation package you want to create the pages, however, all ControlWave Express related web pages (whether standard or user-created) must be viewed within Microsoft® Internet Explorer. The web pages may reside either on a PC workstation, or they can be downloaded into FLASH memory at the ControlWave Express. If stored at the ControlWave Express, you must use the ControlView utility to retrieve the pages (using FTP) for viewing in Internet Explorer. Step 6.
Figure 2-2 - ControlWave Express Dimensions - Power wiring should not be installed until the unit has been mounted and grounded at a designated work site. I/O wiring, external power wiring, local comm. port, and network (RS-232 and RS-485) comm. port cabling enter the unit though a slot on the left side of the Removable Card Edge Cover.
2.3.2 Process I/O Board Configuration I/O Board jumpers and Switch SW1 must be set to configure field I/O (see Figure 2-3).
2.3.3 CPU/System Controller Board Configuration To configure the CPU/System Controller Board, Jumpers must be set (see Figure 2-4), DIPSwitches must be set (see Section 2.3.3.1) and Communication Ports must be wired (see Sections 2.3.3.2 through 2.3.3.3).
1 NOTE: Ultra Low Power & Low Power CPU/System Controller Bds. Don’t have an Ethernet Port. Solar Pwr. In and Aux. Power Out are not available on units equipped F3 with an Ethernet Port. Do Not Connect a 24V Solar Panel to Connector TB1-1 & TB1-2! 3 4 Power 5 6 1 Power 2 1 2 3 4 1 6 5 6 9 5 COM1 RS-232 7 8 W1 W18 3 2 1 1 NOTE: J11 normally used 3 COM2 RS-232 4 5 COM1 for CW GFC and CW RS-232 Express PAC only.
SW2-5 set OFF forces the ControlWave Express to reinitialize SRAM when the unit recovers from a low power or power outage condition. When set ON, the contents of SRAM will be retained and utilized when the system restarts. Note: If the Battery is removed from the CPU Module (CPU removed), the CPU should not be installed (and power applied) before one minute has passed unless SW2-5 on the CPU has been set OFF.
Figure 2-5 - Communication Ports – CPU Board RS-232 Cable Wiring Diagram CI-ControlWave Express Installation & Operation / 2-11 Click here to return to Table of Contents
Diagrams of RS-232/485 interfaces and connectors are shown in Figures 2-4 and 2-5 Hardware connector pin wiring assignments are provided in Tables 2-3A through 2-3C. 2.3.3.3 RS-232 & RS-485 Interfaces ControlWave Express RS-232 & RS-485 communication schemes are discussed herein. 2.2.3.3.1 RS-232 Ports An RS-232 interface supports Point-to-Point, half-duplex and full-duplex communications (20 feet maximum, using data quality cable).
Table 2-3B - RS-232 Port (COM1) Alternate Connector (COM1 Connector J11) Pin # 1 2 3 Signal RS-232 GND RXD TXD Description: RS-232 Signals Power Ground Receive Data Input Transmit Data Output NOTE: Choice of COM1 connectors (J4 or J11) determined by jumper W18. 2.2.3.3.2 RS-485 Ports ControlWave Express RTUs can use an RS-485 communication port for network communications to multiple nodes up to 4000 feet away.
Table 2-4 - RS-485 Network Connections (see Table 2-3C ControlWave Express RS-485 Port Pin # Assignments) From Master TXD+ TXD− RXD+ RXD− GND/ISOGND* To 1st Slave RXD+ RXD− TXD+ TXD− GND/ISOGND* To nth Slave RXD+ RXD− TXD+ TXD− GND/ISOGND* * ISOGND with Isolated RS-485 Ports Only! Note: Pins 1, 2, 3, 4 & 9 of BBI Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485 Comm. Ports are assigned as follows: 1 = TXD+, 2 = TXD-, 3 = RXD+, 4 = RXD- & 9 = ISOGND. Table 2-5 - CPU/System Controller Bd.
1 8 Looking into receptacle Figure 2-6 - RJ-45 Connector (Ethernet Port) J1 on CPU/System Controller Board Figure 2-7 - Point-to-Point 10/100Base-T Ethernet Cable Figure 2-8 - Standard 10/100Base-T Ethernet Cable (CPU/System Controller Board to Hub) Table 2-6 - Ethernet 10/100Base-T Pin Assignments Pin # 1 2 3 4 Description Transmit Data+ (Output) Transmit Data- (Output) Receive Data+ (Input) Not Connected Pin # 5 6 7 8 Description Not Connected Receive Data- (Input) Not Connected Not Connected Note
2.3.4 I/O Wiring ControlWave Express RTUs are provided with card edge terminal blocks that accommodate field wiring. Wiring is routed into the enclosure/chassis through a slot in the removable card edge cover. 2.3.4.1 I/O Wire Connections ControlWave Express RTUs utilize terminal blocks equipped with compression-type terminals that accommodate up to #16 AWG wire. A connection is made by inserting the wire’s bared end (1/4” max) into the clamp beneath the screw and securing the screw.
Figure 2-9 – Process I/O Board Field I/O Wiring Diagrams CI-ControlWave Express Installation & Operation / 2-17 Click here to return to Table of Contents
2.3.4.4 Dedicated Non-isolated Digital Outputs Process I/O Board Terminal Block connector TB3 provides interface to 2 dedicated nonisolated Digital Outputs (DOs) and two selectable DI/Os. Digital Outputs have a 30V operating range and are driven by Open Drain MOSFETs that provide 400 mA (Max.) at 30Vdc. The maximum output frequency is 20 Hz. Transorbs (30Vdc) provide surge suppression between each signal and ground. 2.3.4.4.
Note: Cable shields associated with AI wiring should be connected to the ControlWave Express Chassis Ground. Multiple shield terminations will require a user supplied copper ground bus. This ground bus must be connected to the ControlWave Express Chassis Ground (using up to a #4 AWG wire size) and must accommodate a connection to a known good Earth Ground (in lieu of a direct connection from the ControlWave Express Chassis Ground) and to all AI cable shields.
2.3.4.8 Non-isolated High Speed Counter/Digital Inputs Process I/O Board Terminal Block connector TB4 provides the interface to two internallysourced single-ended High Speed Counter/Digital Inputs (HSC/DIs). All Input circuits have surge suppression and signal conditioning. HSC inputs are switch-selectable (SW1-1 for HSC1 & SW1-2 for HSC2) for high frequency (10 kHz) or low frequency (300 Hz). High Speed Counter/Digital inputs are sourced from 3.
2.3.5 RTD Wiring A 3-wire RTD may be provided with the ControlWave Express (equipped with a 14MHz CPU/System Controller Board). Connector TB6 on the CPU/System Controller Board accommodates a removable three-wire Terminal Block (TB6). This connector accommodates a 100-ohm platinum bulb using the DIN 43760 curve. ControlWave Express RTUs use the common three-wire configuration.
2.3.6 Connection to a Model 3808 Transmitter A Model 3808 Transmitter (Digital) can be interfaced to a ControlWave Express via an RS232 or an RS-485 communication scheme. Communication schemes and cable lengths determine the type of communication port utilized. In general RS-232 communications are utilized when the Model 3808 Transmitter is situated within 25 feet of the ControlWave Express, i.e., for local communications.
Figure 2-15 - ControlWave Express to 3808s - RS-485 Network Diagram Figures 2-13 and 2-14 detail the RS-232 and RS-485 wiring connections required between the ControlWave Express and the Model 3808 Transmitter. Up to two Model 3808 Transmitters can be connected to a ControlWave Express via a halfduplex RS-485 Network. An illustration of this network is provided in Figure 2-15. 2.3.
• • TB1-1 - Solar Power In + (TB1-2 = GND ) (GND = −) TB1-5 - Auxiliary Power Out + - for External Radio/Modem (TB1-6 = GND) (GND = −) A secondary power input is available at connector TB2: • • TB2-1 – Input TB2-2 – Ground ControlWave Express Terminal Blocks utilize compression-type terminals that accommodate up to #16 AWG wire. A connection is made by inserting the wire’s bared end (1/4” max) into the clamp adjacent to the screw and then securing the screw.
2.3.7.2 Power Wiring One Bulk DC supply can be connected to the ControlWave Express CPU/System Controller Board. The Bulk DC supply (nominally +6Vdc, +12Vdc or +24Vdc) connected to TB1-3 (Power In +) and TB1-4 (GND -) is converted, regulated and filtered by the CPU/System Controller Board to produce +3.3Vdc. This CPU/System Controller Bd. circuit is fused at 3.5A (F3).
2.3.8 Operation of the Lithium Backup Coin-cell Battery CPU/System Controller Boards are equipped with a Coin-cell Socket (S1) that accommodates a 3.0V, 300 mA-hr lithium coin cell. A supervisory circuit on the CPU/System Controller Board is used to switch to battery power when the regulated 3.3Vdc VCC falls out of specification. The CPU/System Controller Board switches the battery voltage to the VBAT3.
familiar with the various programming tools. The following software user documentation is referenced: Getting Started with ControlWave Designer Manual - D5085 ControlWave Designer Reference Manual - D5088 Open BSI Utilities Manual - D5081 Web_BSI Manual - D5087 ControlWave Designer Programmer’s Handbook – D5125 An application download can be initiated from ControlWave Designer, or from the OpenBSI 1131 Downloader. 1.
purpose must be set to run at 115.2 Kbaud. ControlWave Express CPU Switch SW1, position, 3 must be set ON. Start LocalView, Choose FLASH, Enter A Name, Click on [Create] Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView. The New View Mode dialog box will appear (see Figure 2-17). Figure 2-17 - Local View - New View Mode Menu "Mode" Choose 'Flash' for the mode. "Name" Enter a name for the View Mode File in the "Name" field.
Step 3 - Flash Data Setup Complete the following fields in the Flash Data Setup Wizard: "Please enter the name of the binary file to Flash" To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file on your hard disk containing the firmware. Click on [Finish] to install the specified BIN file in FLASH memory at the RTU. Once the Flash download has begun, you will NOT be allowed to shut down LocalView, unless you cancel the download, or it has been completed.
Figure 2-19 - Flash RTU Setup Menu 2-30 / Installation & Operation CI-ControlWave Express Click here to return to Table of Contents
Figure 2-20 - Flash Data Setup Menu (Note: Substitute \e1sxxxxbin or \e3sxxxx for cwe04...
2.4.2.2 Using HyperTerminal to Upgrade ControlWave Express Firmware A half-duplex null modem cable (see Figure 2-5) must be connected to COM1 of the ControlWave Express and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this purpose must be set to run at 115.2 Kbaud. ControlWave Express CPU/System Controller Board Switch SW1, position, 3 must be set to the ON position. 1. If not already running, apply power to the associated PC. 2. Start the HyperTerminal program on the PC.
5. When the FLASH is ready for download the letter C will be displayed on the screen. In the HyperTerminal command bar click on Transfer and then Send File (see Figure 223). In the Send File Dialog Box (see Figure 2-24), select “1KXmodem” for the protocol, enter the filename of the appropriate .bin file in the format “e1sxxxxx.bin” or “e3sxxxxx.bin” (where xxxxx varies from release to release). Click on the Send button to start the download (see Figure 2-24).
Figure 2-25 - HyperTerminal FLASH Download (Download in Process) (Note: Substitute \e1sxxxxbin or \e3sxxxx.bin for cwe04...
Figure 2-27 - CPU/System Controller LED Board - LED Hexadecimal Codes (See Table 2-12 for Definitions) Table 2-12 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Display Board. LED LED LED LED LED 6 5 4 3 2 LED STA6 STA5 STA4 STA3 STA2 STA1 1 Status In Hex LCD Disp.
2.4.2.3 Remote Upgrade of ControlWave Express Firmware It is possible to download system firmware into an unattended remote ControlWave Express. This function can only be accomplished if CPU Board Switch SW2-6 (associated with the unit in question) is set in the ON position (factory default). The procedure for performing a remote download of system firmware is discussed in Appendix J of the Open BSI Utilities Manual (document D5081).
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program. COM3: RS-232/RS-485 Communications Port COM3 on the CPU/System Controller Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
Figure 2-28 - LCD Display (Only) Assembly Installation Drawing 2.4.5.2 Operation of the Dual-button Display/Keypad Assembly The Display will have a timeout of 20 minutes. If there has been no keypad activity for this time the display will “logout,” i.e., the display will be turned off and scrolling stopped until a key press occurs. When a key press occurs after a timeout the display will return to the opening screen.
Figure 2-29 - Dual-button Display/Keypad Assembly Installation Drawing Displays are organized into screens as follows: Opening Screen: User defined strings List Selection Screen: List Name List Number The List Selection screen is entered from the main opening screen by pressing the right arrow. Once here the operator can select which list is to be viewed. The operator can traverse though different list numbers by pressing the down arrow key.
Figure 2-30 - 25-Button Display/Keypad Assembly Installation Drawing Display Element Screen: Variable Name Variable Name The Display Element screen is entered from the list selection screen by pressing the right arrow. Once here the operator can view the variables in the list. Once entered the first element of the list is displayed and then next element will be displayed after the scroll timeout occurs.
Automatic Mode In Automatic mode a set of screens (based on the application) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for displaying the screens and responding to key presses. Screens are fixed and start off with an opening screen, which displays user information passed into the function block. Users can view a list to select which list is to be scrolled.
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Section 3 ControlWave Express SERVICE 3.1 SERVICE INTRODUCTION This section provides general, diagnostic and test information for the ControlWave Express. The service procedures described herein will require the following equipment: 1. PC with null modem interface cable & Bristol WINDIAG Software 2. Loop-back plugs/wires (for RS-232 and RS-485) (see Figures 3-9 & 3-10) The following test equipment can be used to test the Power Supply/Sequencer Module: 1. DMM (Digital Multimeter): 5-1/2 digit resolution 2.
3.2.2 Removal/Replacement of the CPU/System Controller Board & the Process I/O Board 1. Loosen the two Thumb Screws and remove the Removable Card Edge Cover. 2. If the ControlWave Express is running, place any critical control processes under manual control and shut down the unit by disconnecting power to the CPU/System Controller Board Assembly at TB1 and, if applicable, TB2. 3.
Bulk supply voltages can be checked at TB1 using a voltmeter or multimeter. CPU/System Controller Board Assemblies are factory configured for use with a nominal 6Vdc or 12Vdc bulk power supply. The maximum and minimum input power switch-points can be tested with the use of a Variable dc Power Supply connected between TB1-3 (+) and TB1-4 (-). By increasing the input voltage (starting at less than +4.3Vdc, 9.5Vdc or 19.
Figure 3-1 - CPU/System Controller LED Board – Status LED Hexadecimal Codes (See Table 3-1 for Definitions) Table 3-1 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Display Board. LED LED LED LED LED LED 6 5 4 3 2 1 Status In Hex LCD Disp.
1 1 1 1 1 1 1 1 0 1 1 1 0 0 0 1 0 0 1 1 0 0 1 0 30 38 3B 3E NO APP BREAKP POWERD UPDUMP 1 1 1 1 * = Flashed at startup 1 1 3F NOTRUN No Application Loaded Running with Break Points Waiting for Power-down (after NMI) Waiting for Updump to be Performed Unit Crashed (Watchdog Disabled) 3.3.3 Wiring/Signal Checks Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check wiring for continuity, shorts & opens.
1 NOTE: Ultra Low Power & Low Power CPU/System Controller Bds. Don’t have an Ethernet Port. Solar Pwr. In and Aux. Power Out are not available on units equipped F3 with an Ethernet Port. Do Not Connect a 24V Solar Panel to Connector TB1-1 & TB1-2! 3 4 Power 5 6 1 Power 2 1 2 3 4 1 6 5 6 9 5 COM1 RS-232 7 8 W1 W18 3 2 1 1 NOTE: J11 normally used 3 COM2 RS-232 4 5 COM1 for CW GFC and CW RS-232 Express PAC only.
Figure 3-3 - Process I/O Board Component Identification Diagram CI-ControlWave Express Service / 3-7 Click here to return to Table of Contents
Figure 3-4 - Process I/O Board Field I/O Wiring Diagram 3-8 / Service CI-ControlWave Express Click here to return to Table of Contents
Figure 3-5 - CPU/System Controller Board Field I/O Wiring Diagram 3.4.2 Disconnecting RAM Battery The ControlWave Express RTU Lithium RAM battery cannot be replaced while power is on. Once the RAM battery has been replaced, the unit will still execute its FLASH-based application (Boot Project) upon power-up, but all of the current process data will have been lost. Upon power-up, the unit will act as though it had just been booted and it will revert back to the initial values specified in its application.
• CPU/System Controller Board Switch SW2-8 must be OFF to run the WINDIAG program. Setting SW2-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode. • Any ControlWave Express communication port can be connected to the PC provided their port speeds and configuration match, e.g., baud rate, parity, stop bits, protocol, etc. This can be accomplished via user-defined Soft Switches.
Figure 3-6 – NetView - Example with Multiple Networks Figure 3-7 - WINDIAG Main Diagnostics Screen CI-ControlWave Express Service / 3-11 Click here to return to Table of Contents
4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG will perform the diagnostics and display pass/fail results. 5. After all diagnostic testing has been performed, exit WINDIAG program and then exit the NetView. When you close Netview, you will be prompted as to whether or not you want to close OpenBSI; select Yes. 6. Set ControlWave Express CPU/System Controller Board Switch SW2-8 to the ON (Open) position. The ControlWave Express should resume normal operation. 3.5.
Figure 3-8 - COM1 & COM2 RS-232 Loop-back Plug/Wires Figure 3-9 - COM3 RS-232 & RS-485 Loop-back Wires Note: RS-485 Loopback can be achieved via CPU Switches SW3-1 & SW3-2 set ON 3.5.1.2 Serial Comm. Port External Loop-back Test Procedure Connect an external loop-back plug or loop-back wires to the Communication Port to be tested (see Figures 3-8 and 3-9). 1. Type "1," "2," "3," or "4" for the port to test. 2. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5. 3.
Figure 3-10 - WINDIAG’s Communications Diagnostic Menu 3.6 CORE UPDUMP In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for evaluation by Emerson Remote Automation Solutions division engineers. This upload is referred to as a ‘Core Updump.’ A Core Updump may be required if the ControlWave Express repeatedly enters a ‘Watchdog State’ thus ill-effecting system operation. A Watchdog State is entered when the system crashes, i.e.
1. Set CPU/System Controller Board Switch SW2-1 OFF (Disable Watchdog Timer). If Switch SW2-4 is ON, set it to OFF (Enable Core Updump). Note: The factory default setting for SW2-4 is OFF. 2. Wait for the error condition (typically 3F on CPU/System Controller Board Status LEDs or NOTRUN on optional LCD Display). 3. Connect ControlWave Express Comm. Port 1 to a PC using a half-duplex Null Modem Cable (see Figures 2-5A). 4.
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Section 4 ControlWave Express SPECIFICATIONS 4.1 CPU, MEMORY & PROGRAM INTERFACE Processor: Sharp’s LH7A400 32-bit ARM9TDMI RISC Core System-on-Chip with 32-bit Memory: 8 Mbytes of simultaneous read/write FLASH 2 Mbyte of on-board SRAM 512 Kbytes FLASH Boot/Downloader Real Time Clock: A Semtech SH3000 support IC provides a full BCD clock calendar with programmable periodic/wakeup interrupt and a programmable clock generator with adjustable spectrum spreading.
4.2.2 Power Supply Sequencer Specs. Signals Monitored: Input Power Sequencer Switchpoints: +3.3V Max. ON Switchpoint = +3.15V +3.3V Min. OFF Switchpoint = +3.00V +1.8V Max. ON Switchpoint = +1.72V +1.8V Min. OFF Switchpoint = +1.64V Sequencer Output Signals: PFDLYCLK Timing on power down 2msec after POWERFAIL VIN100M timing on power up 1.8 second delay for Good Power POWERGOOD incoming power, 3.3V & 1.8V in Spec. 4.2.
Table 4-2 - RS-232 Ports (COM1 & 2) Connector Pin Assignments (J4 - COM1 & TB3 COM2) Located on CPU/System Controller Bd. Pin # 1 2 3 4 5 6 7 8 9 Signal RS-232 DCD RXD TXD DTR GND DSR RTS CTS Description: RS-232 Signals Data Carrier Detect Input Receive Data Input Transmit Data Output Data Terminal Ready Output Signal/Power Ground Data Set Ready Input Request To Send Output Clear To Send Input N/A Figure 4-1 - DB9 9-Pin Connectors J4 (COM1) on CPU/System Controller Bd. Figure 4-2 - 8-Position Term.
Table 4-3 - RS-232/485 Port (COM3) Connector TB4 Pin Assignments Pin # 1 2 3 4 5 Signal RS-232 RXD TXD GND Description: RS-232 Signals Receive Data InputTransmit Data Output Signal/Power Ground Signal RS-485 RXD+ RXD− TXD− TXD+ GND Description: RS-485 Signals Receive Data + Input Receive Data − Input Transmit Data − Output Transmit Data + Output Ground Figure 4-3 - 5-Position Term. Block (COM3) TB4 on CPU/System Controller Board 4.2.3.
Max. Input Frequency: 10 kHz Signal conditioning: 20 microsecond Filtering. Figure 4-5 - 4-Position Pulse Input Interface Terminal Block TB5 RTD Input Note: Only Available on 14MHz CPUs RTD Type: 100-ohm platinum bulb (using the DIN 43760 curve). Configuration: The common three-wire configuration is accommodated. In this configuration, the return lead connects to the RTDterminal while the two junction leads (Sense and Excitation) connect to the RTD+ terminals.
Figure 4-7 - Process I/O Board Edge View (Connector Identification) 4-6 / Specifications CI-ControlWave Express Click here to return to Table of Contents
4.3.2 Non-isolated Digital Input/Output Circuitry Specs. Non-isolated Digital Inputs Number of Inputs: 4 Fixed, 2 Selectable DI - Internally Sourced (Dry Contact) operation Input Filtering: 15 milliseconds Input Current: Switch Selectable (SW1-3) DI1 through DI4 (SW1-3: ON = 2mA, OFF = 60uA) DI5 & DI6 (SW1-3: ON = 2.2mA, OFF = 200uA) Bus Access: SPI ON State Voltage: below 1.3V OFF State Voltage: above 1.
Input Impedance: 1 Meg ohm for 1-5V inputs 250 ohm for 4-20mA inputs Settling Time: 600 msec to within 0.1% of input signal Conversion Time: 20 usec Non-isolated Analog Outputs Number of Outputs: 4-20mA Output Compliance: 1-5V Output: 1 AO (1-5V or 4-20mA) individually jumper configurable 250 ohm load with 11V External Power Source 650 ohm load with 24V External Power Source 5mA maximum output current into external load with external voltage range of 11 to 30 Vdc General AI/AO Circuitry Specs.
Input Frequency: Individually switch-selectable high (10kHz Max), or low (300 Hz). SW1-1 (HSC1), SW1-2 (HSC2). Input filtering: 20 microseconds on high speed (HS) and 1 millisecond on low speed (LS). Signal Conditioning: Bandwidth limiting ON State Voltage: below 1.46V OFF State Voltage: above 1.90V Bus Access: SPI Electrical isolation: None Surge Suppression: 30V Transorb between signal and ground Meets ANSI/IEEE C37.
Figure 4-8 - ControlWave Express Dimensions 4-10 / Specifications CI-ControlWave Express Click here to return to Table of Contents
ControlWave Express Special Instructions for Class I, Division 2 Hazardous Locations 1. 2. 3. 4. 5. 6. 7. 8. Bristol’s ControlWave Express RTU is listed by Underwriters Laboratories (UL) as nonincendive and (when installed in a NEMA 1 or better enclosure) is suitable for use in Class I, Division 2, Group C and D hazardous locations or nonhazardous locations only. Read this document carefully before installing a nonincendive ControlWave Express RTU.
ControlWave Express Special Instructions for Class I, Division 2 Hazardous Locations Table A1 -Module/Board Connector Customer Wiring Connectors (Continued) Module/Item Connector Process I/O Board TB2: 6-pin Term. Block DI Interface Process I/O Board TB3: 8-pin Term. Block DO/DI Interface Process I/O Board TB4: 8-pin Term. Block HSC Interface Process I/O Board TB6: 9-pin Term. Block AI Interface Process I/O Board TB7: 4-pin Term.
Appendix C HARDWARE INSTALLATION GUIDE Hardware Configuration There are seven (7) main steps required to configure a ControlWave Express. This appendix provides an overview of these steps with an emphasis on the installation and configuration of the hardware. This appendix is intended for users who have already installed at least one ControlWave Express. Figure C-1 - ControlWave Express - Component Identification Diagram Step 1.
1 NOTE: Ultra Low Power & Low Power CPU/System Controller Bds. Don’t have an Ethernet Port. Solar Pwr. In and Aux. Power Out are not available on units equipped F3 with an Ethernet Port. Do Not Connect a 24V Solar Panel to Connector TB1-1 & TB1-2! 3 4 Power 5 6 1 Power 2 1 2 3 4 1 6 5 6 9 5 COM1 RS-232 7 8 W1 W18 3 2 1 1 NOTE: J11 normally used 3 COM2 RS-232 4 5 COM1 for CW GFC and CW RS-232 Express PAC only.
Figure C-3 – Process I/O Board Component Identification Diagram CI-ControlWave Express Appendix C - Hardware Installation Guide / C-3 Click here to return to Table of Contents
Step 1. Hardware Configuration (Continued) 2. Remove the Process I/O Board and the CPU/System Controller Board (as one assembly). Table C-1 - CPU/System Controller Bd.
Step 1. Hardware Configuration (Continued) 3. Make sure that the Lithium Backup Battery has been enabled, i.e., Backup Battery Jumper W3 on the CPU/System Controller Assembly should be installed on jumper posts 1-2). Configure the CPU/System Controller Board DIP-Switches and Jumpers. Tables C-1 through C-3 provides overviews of the switch settings (see Figure C-2). Configure the Process I/O Board’s DIP-Switches and Jumpers (see Figure C-3).
COM6 of a ControlWaveEXP, the cable of Figure C-4D must be used along with the one of Figure C-4A or C-4B.
Step 1. Hardware Configuration (Continued) Tables C-4A through C-4C provide the connector pin assignments for the Comm. Ports. Note: The following facts regarding ControlWave Express RS-232 serial communication ports should be observed when constructing communications cables: • • • • • • • • DCD must be high to transmit (except when dialing a modem) Each RS-232 transceiver has one active receiver while in powerdown mode (disabled); the DCD signal is connected to the active receiver.
Step 1. Hardware Configuration (Continued) RS-485 Ports ControlWave Express RTUs can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for network communications, Table C-5 provides the appropriate connections for wiring the master, 1st slave, and nth slave.
a one-to-one wiring configuration as shown in Figure C-7. Table C-6 provides the assignments and definitions of the 8-pin 10/100Base-T connector. It is possible to connect two nodes in a point-to-point configuration without the use of a Hub. However, the cable used must be configured such that the TX+/- Data pins are connected to the RX+/- Data pins (swapped) at the opposite ends of the cable (see Figure C7).
Step 1. Hardware Configuration (Continued) 5. Install I/O wiring to the Process I/O Board and CPU/System Controller Board (see Figures C-11 and C-12 and Section 2.3.4 if required). Install a communications cable between the ControlWave Express and a Model 3808 Transmitter (Network of Transmitters) if required (see Figures C-8 through C-10). Figures C-8 and C-9 detail the RS-232 and RS-485 wiring connections required between the ControlWave Express and the Model 3808 Transmitter.
Step 1. Hardware Configuration (Continued) Up to two (2) Model 3808 Transmitters can be connected to a ControlWave Express via a half duplex RS-485 Network. An illustration of this network is provided in Figure C10.
Figure C-12 – Process I/O Board Field I/O Wiring Diagrams C-12 / Appendix C - Hardware Installation Guide CI-ControlWave Express Click here to return to Table of Contents
Step 1. Hardware Configuration (Continued) 6. Install a ground wire between the Enclosure/Chassis and a known good Earth Ground. ControlWave Express Enclosures are not provided with a Ground Lug. A ground wire (#4 AWG Max. wire size) must be run between the Enclosure/Chassis via one or more mounting screws (see Figure C-1) and a known good Earth Ground.
subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will limit the available system resources. IMPORTANT: When you start ControlWave Designer, you will be reminded to register the software. Unregistered software can only be used for a maximum of 30 days. For more information on the registration process, see Chapter 2 of the Open BSI Utilities Manual (document# D5081). Step 3.
On the variables declaration page(s) in ControlWave Designer, you will need to mark any variable you want to make accessible to external programs, such as Open BSI’s DataView utility, as “PDD”. Similarly, any variables which should be collected into a database, or exported using the OLE for Process Control (OPC) Server must be marked as “OPC.” Variables marked as OPC can be built into a text file by the OpenBSI Signal Extractor.
the ControlWave Express is reset, or if there has been a failure of the backup battery, the control strategy can be restarted from the beginning, i.e. from the BOOT project in FLASH memory. Downloading the Application Any ControlWave Express must have a configured ControlWave project (application) before it can be placed into operation. This will require connection of the ControlWave Express to a PC running ControlWave Designer and OpenBSI software.
IDLE (Red) - the CPU has free time at the end of its execution cycle and may be overloaded TX1, TX2, TX3 (Red) - transmit activity on COM1, COM2 & COM3 (respectively) RX1, RX2, RX3 (Red) - receive activity on COM1, COM2 & COM3 (respectively) Six Status LEDs (Red) - provide run time status codes (see Table C-7 and Figure C-13) Normally, the Idle LED should be ON most of the time (unless disabled). When the Idle LED is OFF, it indicates that the CPU has no free time, and may be overloaded.
(See Table C-7 for Definitions) Table C-7 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Board. LED LED LED LED LED LED 6 5 4 3 2 STA2 1 STA1 Status In Hex LCD Disp.
Instruction Manual CI-ControlWave Express Oct., 2006 ControlWave Express ControlWave Express DISPLAY/KEYPAD ASSEMBLY - GUIDE Appendix E www.EmersonProcess.
APPENDIX E ControlWave Express Display/Keypad Assembly Guide TABLE OF CONTENTS SECTION TITLE PAGE # E1.1 E2.1 E2.1.1 E3.1 E4.1 E4.1.1 E4.1.2 E4.1.3 E4.1.3.1 E4.1.3.2 E4.1.4 E4.1.5 E4.1.6 E4.1.7 E5.1 OVERVIEW ................................................................................................................... E-1 DISPLAY FUNCTION BLOCK DESCRIPTION......................................................... E-2 DISPLAY Function Block Parameters .................................................
Appendix E DISPLAY/KEYPAD ASSEMBLY GUIDE E1.1 OVERVIEW Bristol Display/Keypad assemblies provide a built-in, local, user interface for the ControlWave Express These assemblies allow an operator or engineer to view and modify variable values and associated status information, via an ACCOL3 Function Block. Variables can include inputs, process variables, calculated variables, constants, setpoints, tuning parameters and outputs used in a measurement or control application.
Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode. Automatic Mode In Automatic Mode a set of screens (based on the application load) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for displaying the screens and responding to key presses. Screens are fixed and start off with an opening screen, which displays user information passed into the function block.
Figure 2 - ACCOL3 DISPLAY Function Block Parameters E3.1 PREPARING THE ControlWave PROJECT In order for the keypad and display to operate, the ControlWave Designer project must include a properly configured Display Function Block. Once the Keypad is operating, a user who has signed on with a password can scroll through the names of variable lists and choose a list to read or change. Use Up Arrow and Down Arrow keys to select the Username and use the numeric keys to enter your password.
Figure 3 - Creating the Identifier Message Step 2: Defining a Scroll List Once the Keypad is operating properly, you can automatically scroll through a list of variables created via DISPLAY Function Block Parameters iiList2Scroll and iiListMode. Scrolling can be done without entering a password. The variables in the list are displayed one at a time and in the same order in which they were entered in the variable list. Later, we'll discuss other variable lists that can be accessed with the keypad.
Note 1 : If your display shows something else, press the [F4] key until you see the words Login and Scroll on the bottom line. If your screen is blank, turn the brightness screw clockwise. This screw is located to the left of the Keypad (looking at the rear of the 25-Button Display/Keypad Assembly (see Figure 17). If no letters appear, the controller has not been programmed properly to operate the keypad. The words Login and Scroll at the bottom of the screen are on the legend line.
formation will appear on the screen and remain there for 1 to 30 seconds (default = 2). The variable name appears on the first line. The variable value appears on the second line and status information appears on the third line. An example is shown in Figure 6. When all variables in the list have been displayed, they will be shown again in the same order. This is called Single Variable Mode. Pressing Mlti [F2] activates Multiple Variable Mode.
If your password is not recognized, the asterisks will be erased after you press [ENTER]. Check your password and try again. Figure 7 - Logging On Once the correct password has been entered, the display will look like Figure 7C. When the second line shows READ/WRITE, you can read and write variable parameters. When it shows READ ONLY you cannot change variable parameters. You are only permitted to read variable information.
The current time is shown in the form of hours:minutes:seconds. Figure 8 - Clock Display E4.1.3.1 Changing the Time From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third line. Enter the new time there and press [ENTER]. Valid times range from 00:00:00 to 23:59:59. Invalid entries will be ignored. The display will be updated to show the new time.
E4.1.4 Choosing a Variable List from the List Menu The List Menu is another area where variable information can be seen. As explained earlier in this section, your first opportunity to read variable information is by choosing the SCROLL function from the Initial Display. The variable name and value are presented from the Scroll List. This function is available to all users even without signing-on. The List Menu will show other groups of variable which you can choose to read.
time, you must first log-off and then log-on using the correct password. See your Systems Engineer for the correct password. Before making any changes, first check the signal inhibit status field (See Figure 12). When the display shows ME (manual enable) you can change variable parameters. When it shows MI (manual inhibit), you cannot alter the parameters of this variable. If the field indicates MI, press the OPER I/E key to change it to ME.
Notes for Figure 12 1. Variable Name (Example 1: @GV.FLOW_RATE) (Example 2: @GV.TOTAL_FLOW_RATE) 2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be shown as asterisks. Analog values are displayed in floating point format, for example, 0.0125, 99.627, and 1287.66. When the value cannot be shown in floating point format, scientific format is used (1.287668E+10 or 1.25E-02 for example). 3.
1) String SITE_NAME WEST SUNBURY PUMP STATION CE ME 2) Analog TOTAL_FLOW_RATE 1260.578 CE MI 3) Logical FLOW_ALARM OFF CE MI AE NA E4.1.7 Signing-Off Once you have logged-on, use the [INIT] key at any time to log-off. When this key has been pressed, the screen will look like Figure 13. Press Yes (F1) to sign-off. You are signed-off when the Identifier Display (Figure 3C) appears. If you do not want to log-off, press Exit (F4) to leave the Log-Off Display.
E5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO.
Figure 15 - 25 Button Keypad Table 1 - 25 Button Keypad Keys KEY F1, F2, F3, F4 INIT 0 to 9, -, . Δ ∇ ALM I/E ALM ACK A/M OPER I/E DEL ENTER FUNCTION Function keys will take on a variety of different functions depending on the situation. The function of these keys is listed on the legend line (bottom line) of the display. The INIT key is used to terminate the keyboard session and sign-off. These keys are used to change the value of analog variables in the CONFIGURATION mode.
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. Manufacturer DURACELL General Description 3V Lithium Manganese Dioxide Battery Part Number DL 2450 http://www.duracell.
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Supplement Guide - S1400CW Issue: 04/05 TM SITE CONSIDERATIONS For EQUIPMENT INSTALLATION, GROUNDING & WIRING A Guide for the Protection of Site Equipment & Personnel In the Installation of ControlWave Process Automation Controllers Bristol Babcock Click here to return to Table of Contents
NOTICE Copyright Notice The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol Babcock assumes no responsibility for any errors that may appear in this document. Request for Additional Instructions Additional copies of instruction manuals may be ordered from the address below per attention of the Sales Order Processing Department.
Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - INTRODUCTION 1.1 1.2 GENERAL INTRODUCTION ....................................................................................... 1-1 MAJOR TOPICS ............................................................................................................. 1-1 Section 2 - PROTECTION 2.1 2.1.1 2.2 2.2.1 2.2.2 2.3 PROTECTING INSTRUMENT SYSTEMS....................
Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # Section 5 - WIRING TECHNIQUES (Continued) 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10 Use of Twisted Shielded Pair Wiring (with Overall Insulation).................................. 5-2 Grounding of Cable Shields. .......................................................................................... 5-3 Use of Known Good Earth Grounds .........................
Section 1 - Overview 1.1 INTRODUCTION This document provides information pertaining to the installation of ControlWave systems; more specifically, information covering reasons, theory and techniques for protecting your personnel and equipment from electrical damage. Your instrument system affects the quality of service provided by your company and many aspects of its operational safety. Loss of instruments means lost production and profits as well as increased expenses.
Section 2 - Protection 2.1 PROTECTING INSTRUMENT SYSTEMS Electrical instrumentation is susceptible to damage from a variety of natural and man made phenomena. In addition to wind, rain and fire, the most common types of system and equipment damaging phenomena are lightning, power faults, communication surges & noise and other electrical interference’s caused by devices such as radios, welders, switching gear, automobiles, etc.
2.2.1 Considerations For The Protection of Personnel Always evaluate the site environment as if your life depended on it. Make sure that you understand the physical nature of the location where you will be working. Table 2-1 provides a general guideline for evaluating an installation site. Table 2-1 - Installation Site Safety Evaluation Guide # 1 2 3 4 5 6 7 8 9 Guide Indoor or outdoor – Dress Appropriately If outdoor, what kind of environment, terrain, etc.
Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued) # 6 7 8 9 2.3 Guide Is there an antenna in the immediate area? How close is other equipment? Can someone safely touch this equipment and a ControlWave simultaneously? Determine equipment ground requirements.
Section 3 - Grounding & Isolation 3.1 POWER & GROUND SYSTEMS ControlWaves utilize DC power systems. AC power supplies are not provided with ControlWave units. ControlWave, ControlWave MICRO, ControlWave EFM/GFC/EFC, ControlWaveRED, ControlWaveREDIO and ControlWave I/O Expansion Racks are provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing a connection to Earth Ground.
not be suitable for a complex system of sophisticated electronic equipment. Conditions such as soil type, composition and moisture will all have a bearing on ground reliability. A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG solid copper wire should be used for the ground wire. The end of the wire should be clean, free of any coating and fastened to the rod with a clamp.
ground has been established, it should be tested on a regular basis to preserve system integrity. Figure 3-2 - Basic Ground Bed Soil Test Setup Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5 ohms, the ground is good. The lower the resistance, the better the earth ground.
Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is indicated, one or more additional ground rods connected 10 feet from the main ground rod should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x ¼-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the Biddle Instrument Co. (now owned by AVO International). Other devices that may be used to test ground resistance are “Viboground”; Associated Research, Inc.
Figure 3-5 - Poor Soil Ground Bed Construction Diagram 3.3.2 Ground Wire Considerations ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveRED, ControlWave REDIO & ControlWave I/O Expansion Rack ControlWave Chassis are provided with a Ground Lug that accommodates up to a #4 AWG wire size. A ground wire must be run between the Chassis Ground Lug and a known good Earth Ground.
Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground Bus. The panel, lug or bus in turn must be connected to a known good Earth Ground via a #4 AWG wire. General Considerations The following considerations are provided for the installation of ControlWave system grounds: i Size of ground wire (running to Earth Ground should be #4 AWG.
For applications employing equipment that communicates over telephone lines, a lightning arrester Must Be provided. For indoor equipment the lightning arrester must be installed at the point where the communication line enters the building as shown in Figure 3-6. The ground terminal of this arrester must connect to a ground rod and/or a buried ground bed. Gas lines also require special grounding considerations.
grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely mounted, connect their chassis grounds to the pipeline or earth ground. Figure 3-8 - ControlWave EFM (Installation is similar to GFC/XFC) Remote Installation without Cathodic Protection 3.4.
• • • all conductive tubing that runs between the pipeline and mounting valve manifold and/or the units multivariable pressure transducer all conductive connections or tubing runs between the ControlWave EFM/GFC and turbine meter, pulse transducer, or any input other device that is mounted on the pipeline any Temperature Transducer, Pressure Transmitter, etc.
See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds.
Section 4 - Lightning Arresters & Surge Protectors 4.1 STROKES & STRIKES Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will average 18 KA for the first impulse and about half of that for the second and third impulses. Three strokes (impulses) is the average per lightning strike. The number of visible flashes that may be seen is not necessarily the number of electrical strokes.
Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the United States there is an average of 30 thunderstorm days per year. Any given storm may produce from one to several strokes. Data on the subject indicates that for an average area within the United States there can be eight to eleven strokes to each square mile per year.
modem has been interfaced to a ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP, or ControlWaveEXP the possibility of damage due to a lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower must be considered. It is recommended that the additional lightning protection considerations listed below be followed for units installed in areas with a high possibility or history of stroke activity.
Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram For all systems it is best to have all communication equipment input/output grounds tied together. In the case of ControlWave units, this is accomplished via the unit’s Chassis Ground (Typically at a ground lug, ground bus or ground plate).
communication equipment lightning arresters and surge suppressors should be tied to the same system ground. System ground consists of the tower leg grounds utility ground and bulkhead-equipment ground-stakes that are tied together via bare copper wire. 4.1.3 Ground Propagation As in any medium, a dynamic pulse, like R.F., will take time to propagate.
i Watch out for dissimilar metals connections and coat accordingly. i Use bare wire radials together where possible with ground stakes to reduce ground system impedance. i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground system. i Ground the Coaxial Cable Shield (or use an impulse suppressor) at the bottom of the tower just above the tower leg ground connection. 4.
Section 5 - Wiring Techniques 5.1 OVERVIEW This section provides information pertaining to good wiring practices. Installation of Power and “Measurement & Control” wiring is discussed. Information on obscure problems, circulating ground and power loops, bad relays, etc. is presented. Good wire preparation and connection techniques along with problems to avoid are discussed. 5.
Figure 5-1 - Field Wired Circuits With & Without A Common Return 5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation) For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly recommended. This type of cable provides discrete insulation for each of the wires and an additional overall insulated covering that provides greater E.M.I. immunity and protection to the shield as well.
5.2.3 Grounding of Cable Shields DO NOT connect the cable shield to more than one ground point; it should only be grounded at one end. Cable shields that are grounded at more than one point or at both ends may have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O signals.
Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to being costly. 5.2.7 High Power Conductors and Signal Wiring When routing wires, keep high power conductors away from signal conductors. Space wires appropriately to vent high voltage inductance. Refer to the National Electrical Code Handbook for regulatory and technical requirements. 5.2.
Discharge Units should be placed on the base of the antenna and at the point where the antenna lead (typically coax) enters the site equipment building. When a modem is used, a lightning arrester should be placed at the point where the phone line enters the site equipment building. If you use a modem (manufactured by other than BBI) it is recommended that you also install a surge suppressors or lightning arrester on the phone line as close to the modem as possible.
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ESDS Manual S14006 4/15/92 CARE AND HANDLING OF PC BOARDS AND ESD-SENSITIVE COMPONENTS BRISTOL BABCOCK Click here to return to Table of Contents
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ESDS Manual S14006 4/15/92 TABLE OF CONTENTS PAGE TOOLS AND MATERIALS REQUIRED 1 ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 2 1. Introduction 2 2. General Rules 3 3. Protecting ESD-Sensitive Components 5 4. Static-Safe Field Procedure 6 5. Cleaning and Lubricating 8 6. Completion 10 TOOLS AND MATERIALS REQUIRED 1. Tools Anti-Static Field kit.
ESDS Manual #S14006 4/15/92 2. Materials ● Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent) ● Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent) ● Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent) ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 1. Introduction Microelectronic devices such as PC boards, chips and other components are electrostatic-sensitive. Electrostatic discharge (ESD) of as few as 110 volts can damage or disrupt the functioning of such devices.
ESDS Manual S14006 4/15/92 Table 1 Typical Electrostatic Voltages Electrostatic Voltages Means of Static Generation 10-20 Percent Relative Humidity Walking across carpet Walking over vinyl floor Worker at bench Vinyl envelopes for work instructions Poly bag picked up from bench Work chair padded with poly foam 2.
ESDS Manual #S14006 4/15/92 Typical Chip Removal Tool (6) It is important to note when inserting EPROMS/PROMS, that the index notch on the PROM must be matched with the index notch on the socket. Before pushing the chip into the socket, make sure all the pins are aligned with the respective socket-holes. Take special care not to crush any of the pins as this could destroy the chip.
ESDS Manual S14006 4/15/92 CAUTION Don't place ESD-sensitive components and paperwork in the same bag. The static caused by sliding the paper into the bag could develop a charge and damage the component(s). (9) 3. Include a note, which describes the malfunction, in a separate bag along with each component being shipped. The repair facility will service the component and promptly return it to the field.
ESDS Manual #S14006 4/15/92 Note: If a system checker is not available, use an ohmmeter connected to the cable ends to measure its resistance. The ohmmeter reading should be 1 megohm +/15%. Be sure that the calibration date of the ohmmeter has not expired. If the ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a new one. 4. Static-safe Field Procedure (1) On reaching the work location, unfold and lay out the work surface on a convenient surface (table or floor).
ESDS Manual S14006 4/15/92 (7) The components can now be handled following the general rules as described in the instruction manual for the component. (8) Place the component in a static-shielding bag before the ground cord is disconnected. This assures protection from electrostatic charge in case the work surface is located beyond the reach of the extended ground cord.
ESDS Manual #S14006 4/15/92 5. (9) If a component is to undergo on-site testing, it may be safely placed on the grounded work surface for that purpose. (10) After all component work is accomplished, remove the wrist straps and ground wire and place in the pouch of the work surface for future use. Cleaning And Lubricating The following procedure should be performed periodically for all PC boards and when a PC board is being replaced.
ESDS Manual S14006 4/15/92 (2) Clean PC board connectors as follows: a. Review the static-safe field procedure detailed earlier. b. Following the ESD-sensitive component handling procedures, remove the connectors from the boards and remove the PC boards from their holders. c. Use cleaner to remove excessive dust build-up from comb connectors and other connectors. This cleaner is especially useful for removing dust. d. Liberally spray all PC board contacts with Inhibitor.
ESDS Manual #S14006 4/15/92 6. d. Spray the connector liberally to flush out any contaminants. e. Remove any excess spray by shaking the connector or wiping with either a toothbrush, or a lint-free wiping cloth. Completion (1) Replace any parts that were removed. (2) Make sure that the component cover is secure. (3) Return the system to normal operation. (4) Check that the component operates normally.
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Bristol ControlWave Express (Remote Terminal Customer Instruction Manual CI-ControlWave Express Unit) February, 2009 NOTICE “Remote Automation Solutions (“RAS”), division of Emerson Process Management shall not be liable for technical or editorial errors in this manual or omissions from this manual.
