Instruction Manual CI-ControlWave Express Part: D301386X012 March, 2011 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.
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.
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ControlWave Express Instruction Manual (CI-ControlWave Express) Contents Chapter 1 – Introduction 1.1 1.2 1.3 1.4 1.5 1.6 1-1 Scope of the Manual .................................................................................................................1-2 Physical Description..................................................................................................................1-2 CPU/System Controller Board ................................................................................
ControlWave Express Instruction Manual (CI-ControlWave Express) 4.4 Creating and Maintaining Backups ...........................................................................................4-3 4.4.1 Creating a Zipped Project File (*.ZWT) For Backup .....................................................4-4 4.4.2 Saving Flash Configuration Parameters (*.FCP) ..........................................................4-5 4.4.3 Backing up Data...................................................................
ControlWave Express Instruction Manual (CI-ControlWave Express) 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) Hazardous Location approvals when installed in a suitable enclosure - see Appendix A. Cost-effective for small RTU/process controller applications. 1.1 Scope of the Manual This manual contains the following chapters: Chapter 1 Introduction Provides an overview of the hardware and general specifications for the ControlWave Express.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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.
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.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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. System Memory (SRAM) The ControlWave Express has 2 MB of static random access memory (SRAM).
ControlWave Express Instruction Manual (CI-ControlWave Express) Table 1-2. Process I/O Configurations 1.
ControlWave Express Instruction Manual (CI-ControlWave Express) OpenBSI Utilities provides a set of programs that allow you to configure a communication network of ControlWave controllers, download files to the controllers, and collect data from the network. OpenBSI also exports data from the network to a SCADA/host package, such as OpenEnterprise. For information on configuring OpenBSI communications, see the OpenBSI Utilities Manual (document D5081).
ControlWave Express Instruction Manual (CI-ControlWave Express) Communication In addition to the Bristol Synchronous/Asynchronous Protocol Protocols (BSAP), ControlWave supports communications using: Internet Protocol (IP) - You can use an Ethernet port or use a serial port with serial IP using Point-to-Point Protocol (PPP). Other supported protocols include: Modbus, Allen-Bradley DF1, CIP, DNP3, and Hex Repeater. See the ControlWave Designer online help for details and restrictions.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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 2.2 2.3 2.4 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations .............................2-3 Installation Overview.........................
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 2-1. ControlWave Express Component Identification Specifications for Temperature, Humidity and Vibration 2-2 See document 420DS-6c available on our website for detailed technical specifications for temperature, humidity, and vibration for the ControlWave Express. Ensure that the ambient temperature and humidity at the installation site remains within these specifications.
ControlWave Express Instruction Manual (CI-ControlWave Express) Caution Placement of the ControlWave Express in Class 1, Division 2 (Group A, B, C, and D) hazardous locations requires that you install it in a NEMA 1 or better enclosure. 2.1.1 Class I, Div 2 Installation Considerations Underwriters Laboratories (UL) lists the ControlWave Express as nonincendive and suitable only for use in Class I, Division 2, Group A, B, C, and D hazardous locations and non-hazardous locations.
ControlWave Express Instruction Manual (CI-ControlWave Express) f) Installing a ground wire between the enclosure and a known good Earth ground. (See Section 2.2.3) g) Connecting the RTD probe (if required). (See Section 3.3.7) h) Wiring power to the unit. (See Section 2.3.4) i) Turning on power. (See Section 4.1) 2. Installing PC-based software (ControlWave Designer). 3. Establishing communications. 4. Creating an application-specific control strategy (ControlWave project). 5.
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 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.
ControlWave Express Instruction Manual (CI-ControlWave Express) 2.3 Configuring the CPU/System Controller Board To configure the CPU/System Controller board, you need to set some switches and jumpers. 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.
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. Note: Examine each bank of DIP switches carefully to note the switch direction for ON or OFF. Table 2-1.
ControlWave Express Instruction Manual (CI-ControlWave Express) SW2 Setting Function Mode 4 Core Updump Causes the ControlWave Express to perform a core updump, provided you have set the SW1 switches to allow recovery mode. Values are: ON (Disables core updump; factory default) OFF Core updump 5 SRAM Control Manages SRAM contents following a low power situation or a power outage.
ControlWave Express Instruction Manual (CI-ControlWave Express) Switch Setting Function Mode 5 N/A Not currently used 6 N/A Not currently used 7 RX+ Bias (End Node) ON (4-wire = Both End nodes only; 2-wire= One end node only) OFF = No bias RX- Bias (End Node) 8 ON (4-wire = Both End nodes only; 2-wire= One end node only) OFF = No bias 2.3.2 Setting Jumpers on the CPU/System Controller Board The CPU has several jumpers. W1: COM1 CTS usage: o 1-to-2 Installed = COM1 CTS source is from device.
ControlWave Express Instruction Manual (CI-ControlWave Express) o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W14: COM3 configuration selection: o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W15: COM3 configuration selection: o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W16: COM3 configuration selection: o 1-to-2 Installed = COM3 is RS-232 o 2-to-3 Installed = COM3 is RS-485 W17: Input power selection (controls so
ControlWave Express Instruction Manual (CI-ControlWave Express) Power Supply Depending upon the CPU type, the ControlWave Express accepts either Current a 6Vdc, 12Vdc or 24Vdc bulk power input.
ControlWave Express Instruction Manual (CI-ControlWave Express) 14MHz Ultra Low Power CPU: Supports +6Vdc or +12Vdc nominal power supply. 33MHz Low Power CPU: Supports +12Vdc nominal or +24Vdc nominal power supply. 33MHz CPU with Ethernet: Supports +12Vdc nominal or +24Vdc nominal power supply. 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.
ControlWave Express Instruction Manual (CI-ControlWave Express) Terminal Block The ControlWave Express includes an alternative power connecter, Connector TB2 TB2, to provide power if none is available at TB1. For example, you can connect a bulk DC power supply to TB2 to handle situations where the solar panel/battery does not have sufficient power. TB2 connections are: TB2-1 = Power Input TB2-2 = Ground (GND) 2.3.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 2-5. Male DB9 9-Pin Connector Table 2-6.
ControlWave Express Instruction Manual (CI-ControlWave Express) CW Express CW or PC 9-Pin Female “D” Connector P1 J4 (COM1) 9-Pin Female { “D” Connector P2 TB3 (COM2) P2 1 = DCD 5 = GND 4 = DTR 8 = CTS 3 = TXD 7 = RTS 2 = RXD 6 = DSR 1 = DCD To P2 Pin-5 To P2 Pin-6 To P2 Pin-2 To P2 Pin-1 To P2 Pin-3 To P2 Pin-4 To P2 Pin-7 or vice versa 1 = DCD 6 = DSR 2 = RXD 7 = RTS 3 = TXD 8 = CTS 4 = DTR 2 = RXD 3 = TXD or 4 = DTR 5 = GND 6 = DSR 7 = RTS 5 = GND 8 = CTS CW 9-Pin Female “D” Connector P1
ControlWave Express Instruction Manual (CI-ControlWave Express) CW Express 3305/3310/3330/3335/CW_10/30/35 9-Pin Male “D” Connector P1 J4 (COM1) 9-Pin Female { “D” Connector P2 TB3 (COM2) P2 1 = DCD 1 = DTR 6 = CTS 2 = TXD 7 = DCD 4 = RXD 9= GND 1 = DCD To P2 Pin-1 2 = RXD or 2 = RXD 7 = RTS 3 = TXD 8 = CTS 4 = DTR To P2 Pin-2 To P2 Pin-4 To P2 Pin-3 To P2 Pin-5 5 = GND 8 = CTS J4 (COM1) 9-Pin Female { “D” Connector P2 2 = TXD 4 = RXD 9 = GND 2 = RXD 3 = TXD 2 = RXD 7 = RTS 3 = TXD 8 =
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.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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) Table 2-10. RS-485 Network Connections From Master To First Slave To nth Slave TXD+ RXD+ RXD+ TXD– RXD– RXD– RXD+ TXD+ TXD+ RXD– TXD– TXD– GND GND GND 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).
ControlWave Express Instruction Manual (CI-ControlWave Express) 2.3.7 Connections to the Ethernet Port on the CPU/System Controller Board Caution The RJ45 Ethernet port is connector (J1) located on the CPU/System Controller board. The board also has one RJ45 port (J2) for the optional Display/Keypad. Never connect Ethernet to J2 (the Display/Keypad port) or damage will result. The 33MHz ControlWave Express can support one Ethernet port.
ControlWave Express Instruction Manual (CI-ControlWave Express) Pin Description 7 Not connected 8 Not connected Note: You can swap TX and RX at the hub. 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). Figure 2-12.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 2-14. Display with No Keypad 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.
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ControlWave Express Instruction Manual (CI-ControlWave Express) 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 3.2 3.3 I/O Options .......................................................................................3-1 Process I/O Board ...........................................................................3-2 3.2.1 Setting Jumpers on the Process I/O Board .....
ControlWave Express Instruction Manual (CI-ControlWave Express) 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. See Figure 3-1 for the location of the switches and jumpers. 3.2.1 Setting Jumpers on the Process I/O Board The Process I/O board has several jumpers.
ControlWave Express Instruction Manual (CI-ControlWave Express) SW1 SW1-4 Function Mode OFF = current ON = voltage AO configuration Figure 3-1.
ControlWave Express Instruction Manual (CI-ControlWave Express) Caution Power down the ControlWave Express before you perform I/O wiring. Shut down any processes the ControlWave Express may be managing (or switch them over manually or handle with another controller). Perform any hardware configuration (wiring, jumper configuration, and installation) only when the ControlWave Express is powered down.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 3-2.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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). Table 3-3.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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). Table 3-4.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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 Type Number Supported Analog Inputs (AI) 3 (on TB6) Characteristics Jumper-selectable using JP5, JP6, and JP7 for either 4-20mA or 1-5V operation.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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 Type Analog Output (AO) Number Supported Characteristics 1 (on TB7) Supports either 4-20mA or 1-5V operation. Selection using jumper JP1 and switch SW1-4.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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. Table 3-7.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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) 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” nut using an open-end wrench against the 7/8” fitting body. Figure 3-5.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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.
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ControlWave Express Instruction Manual (CI-ControlWave Express) Chapter 4 – Operation This chapter provides general operational details for using the ControlWave Express. In This Chapter 4.1 4.2 4.3 4.4 WARNING Powering Up/Powering Down the ControlWave Express ................4-1 Communicating with the ControlWave Express ..............................4-2 4.2.1 Default Comm Port Settings .................................................4-2 4.2.2 Collecting Data from the ControlWave Express .............
ControlWave Express Instruction Manual (CI-ControlWave Express) Power To remove power from the ControlWave Express, unplug connectors Down TB1 and TB2 from the CPU/System Controller board. 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. 4.2.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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.
ControlWave Express Instruction Manual (CI-ControlWave Express) Notes: You may find it useful to maintain more than one backup copy in case the backup media itself fails, for example, a CD-ROM becomes unreadable because it melted in the sun or a thumb drive fails because someone spilled coffee on it. If you don’t keep more than one backup copy, it’s a good idea to periodically test your backup copy to verify that the media has not failed. 4.4.1 Creating a Zipped Project File (*.
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. Zip Frontend-Code If you selected Zip User-Libraries you should also select this option to include compiled code for libraries in your zip file. Otherwise, you need to re-compile your user libraries with the project when you unzip the zwt.
ControlWave Express Instruction Manual (CI-ControlWave Express) To do this in TechView, click Operations > Access Flash Parameters or click the Access Flash icon . 2. Depending upon how your system is configured, the Flash Configuration – Loading Options dialog box may open. If it does, choose Load from device and wait for the utility to retrieve all parameters from the ControlWave Express, then skip to step 4, otherwise, just proceed to step 3. 3.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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 5.1 5.2 5.3 5.4 5.5 5.6 Equipment Upgrading Firmware ........................................................................5-2 Removing or Replacing Components ..............................................5-5 5.2.1 Accessing Modules for Testing ..
ControlWave Express Instruction Manual (CI-ControlWave Express) Harmful electrical potentials may still exist at the field wiring terminals even though the ControlWave Express 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. Caution Always turn off any external supply sources for externally powered I.
ControlWave Express Instruction Manual (CI-ControlWave Express) 1. Connect a null modem cable between COM1 of the ControlWave Express and any RS-232 port on the associated PC. 2. Click Start > Programs > Accessories > Communications > HyperTerminal 3. 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. 4.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-2. HyperTerminal (Ready to Download) 8. 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).
ControlWave Express Instruction Manual (CI-ControlWave Express) CWEXP01 E1S0410.bin Figure 5-4. HyperTerminal (Download in Progress) 5.2 Removing or Replacing Components This section provides information on accessing ControlWave Express components for testing, as well as removal/replacement procedures. Caution Field repairs to the ControlWave Express are strictly limited to the replacement of complete boards. Replacing board components constitutes tampering and violates the product warranty.
ControlWave Express Instruction Manual (CI-ControlWave Express) 2. Shut down the ControlWave Express by disconnecting the power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2). 3. Loosen the two thumb screws and remove the removable card edge cover. Also loosen the captive fastener that secures the CPU/System Controller and Process I/O board assembly in the housing. See Figure 2-1 to locate these components. 4.
ControlWave Express Instruction Manual (CI-ControlWave Express) 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) Disabling For maximum shelf life, you can isolate the battery from the circuit by 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. These LEDs are visible through the chassis cover window.
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-6. CPU/System Controller LEDs Table 5-1. LEDs on Piggy-back LED board LED Color Description PG RED ON = Power good WD RED ON = Watchdog condition – program crash; OFF = Normal operation IDLE RED ON = CPU has free time at end of execution cycle. Should be on frequently.
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).
ControlWave Express Instruction Manual (CI-ControlWave Express) LED6 STA6 0 0 0 1 1 1 1 1 LED5 STA5 0 1 1 0 0 1 1 1 LED4 STA4 1 0 0 0 1 0 1 1 LED3 STA3 0 0 0 0 0 0 0 0 LED2 STA2 1 0 1 0 0 0 0 1 LED1 STA1 1 0 0 0 0 0 0 1 Status In Hex 0B 10 12 20 28 30 38 3B LCD Display INIT RECOV RAMERR STOP HALT NO APP BREAKP POWERD 1 1 1 1 1 0 3E UPDUMP 1 1 1 1 1 1 3F NOTRUN Indication Definition System Initialization in Progress Waiting in Recovery Mode Error Testing SRAM Application Loaded Stoppe
ControlWave Express Instruction Manual (CI-ControlWave Express) 5.4 WINDIAG Diagnostic Utility The ControlWave Express cannot execute your control strategy while it runs diagnostic routines; place any critical processes controlled by the ControlWave Express under manual control before starting this procedure. 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. .
ControlWave Express Instruction Manual (CI-ControlWave Express) Figure 5-9. WINDIAG Main Diagnostics Menu 3. Select the component to be tested. See Section 5.4.1 for a description of the tests. Enter any prompted parameters (slot #, etc.). WINDIAG performs the diagnostics and displays pass/fail results. After performing all diagnostic testing, exit WINDIAG. 4. Set switches SW2-3 and SW2-8 on the CPU module to ON. The ControlWave Express should resume normal operation. 5.4.
ControlWave Express Instruction Manual (CI-ControlWave Express) Port Loop-back Test Option Tests COM2, and COM3. The External loop-back tests require the use of a loop-back plug. Discrete I/O Checks DIs and DOs on the Process I/O board. Ethernet Checks the Ethernet port. Keypad & Display Checks the optional display/keypad hardware. WINDIAG allows you to select the communication port to test.
ControlWave Express Instruction Manual (CI-ControlWave Express) Note: You can configure RS-485 loopback by setting CPU/System Controller board switches SW3-1 & SW3-2 ON. Port 3 - RS-485 use loop-back wires or CPU Switch SW3 (see Figure 5-11). These tests verify the correct operation of the communication ports. Note: You cannot test a communications port while you are using it. You can only test currently unused ports.
ControlWave Express Instruction Manual (CI-ControlWave Express) Note: The port you select must correlate to the port on which you placed the loop-back plug in step 1. 5. Select 115200 or ALL ASYNC as the baud rate (click to display all available rates). 6. Click RUN to start the test. At the completion of the test (which generally takes about 5 seconds), any failed results appear in the Status field to the right of the RUN button: 7.
ControlWave Express Instruction Manual (CI-ControlWave Express) 4. Set the ControlWave Express for Recovery Mode by setting both SW1-1 and SW1-2 to the right for open operation or both to the left for closed operation. 5. Start the PC’s HyperTerminal program (at 115.2 kbaud) and generate a receive using the 1KX-Modem protocol. Save the resulting core updump in a file so you can forward it later to the technical support group.
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Special Appendix for ControlWave Express Instruction Manual (CI-ControlWave Express) Appendix A – ControlWave Express– Special Instructions for Class I, Division 2 Hazardous Locations 1. The ControlWave Express RTU is listed by Underwriters Laboratories (UL) as nonincendive (when installed in a NEMA 1 or better enclosure) and is suitable for use in Class I, Division 2, Groups A, B, C and D hazardous locations or non-hazardous locations only.
Special Appendix for ControlWave Express Instruction Manual (CI-ControlWave Express) WARNING EXPLOSION HAZARD Substitution of components may impair suitability for use in Class I, Division 2 environments. WARNING EXPLOSION HAZARD The area must be known to be nonhazardous before servicing/replacing the unit and before installing or removing I/O wiring. WARNING EXPLOSION HAZARD Do NOT disconnect equipment unless power has been disconnected and the area is known to be non-hazardous. Table A-1.
Special Appendix for ControlWave Express Instruction Manual (CI-ControlWave Express) Module/Item Connector Wiring Notes Process I/O board TB3: 8-pin terminal block DO/DI interface Discrete output/input field wiring: Field I/O wiring connector is unrated, use Div. 2 wiring methods. * Process I/O board TB4: 8-pin terminal block HSC interface High speed counter field wiring: Field input wiring connector is unrated, use Div. 2 wiring methods.
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ControlWave Express Instruction Manual (CI-ControlWave Express) 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. Manufacturer General Description DURACELL http://www.duracell.
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ControlWave Express Instruction Manual (CI-ControlWave Express) Index A ACCOL3 Firmware Library ................................. 1-7 address default IP ........................................................ 4-2 Analog Inputs...................................................... 3-8 Analog Output..................................................... 3-9 Discrete Outputs ................................................. 3-7 Display/Keypad .................................................
ControlWave Express Instruction Manual (CI-ControlWave Express) 5-3. Send File dialog box................................ 5-4 5-4. HyperTerminal (Download in progress) .. 5-5 5-5. ControlWave Express LED ..................... 5-8 5-6. CPU/System Controller LED................... 5-9 5-7. CPU/System Controller Board LED Patterns ................................................................... 5-10 5-8. WD and IDLE LEDs .............................. 5-11 5-9. WINDIAG Main Diagnostics Menu........
ControlWave Express Instruction Manual (CI-ControlWave Express) Switches CPU ................................................................ 2-8 Process I/O board .......................................... 3-2 System Firmware Downloader............................ 5-2 T Tables 1-1. CPU/System Controller board Configurations .............................................. 1-4 1-2.Process I/O Configurations ...................... 1-6 2-1. CPU/System Controller Board Switch SW1 ................................
Instruction Manual CI-ControlWave Express March, 2011 ControlWave Express NOTICE Emerson Process Management Remote Automation Solutions 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2262 Fax: +1 (860) 945-2525 www.EmersonProcess.com/Remote Emerson Process Management Remote Automation Solutions 6338 Viscount Rd. Mississauga, Ont. L4V 1H3 Canada Phone: 905-362-0880 Fax: 905-362-0882 www.EmersonProcess.com/Remote Emerson Process Management SA de CV Calle 10 #145 Col.
