Instruction Manual CI-ControlWave EPAC Part: D301384X012 March, 2011 ControlWave ExpressPAC ControlWave ExpressPAC (Process Automation Controller / 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) Chapter 1 – Introduction This manual focuses on the hardware aspects of the ControlWave ExpressPAC Process Automation Controller/Remote Terminal Unit (RTU). For information about the software used with the ControlWave ExpressPAC, refer to Getting Started with ControlWave Designer (D5085), the ControlWave Designer Programmer’s Handbook (D5125), and the online help in ControlWave Designer.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Wide operating temperature range: (–40 to +70C) (–40 to 158F) Battery backup for Static RAM (SRAM) and real-time clock. Nonincendive Class I, Division 2 (Groups C and D) Hazardous Location approvals - See Appendix A. Cost-effective for small RTU/process controller applications. 1.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 1-1.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Enclosure The ControlWave ExpressPAC enclosure is a standard NEMA 3R rated fiberglass enclosure. The enclosure consists of the body and the front cover. A continuous gasket seals the unit when you close the front cover. Two latches on the enclosure’s right side secure the cover. The enclosure includes a weatherproof connector (local port) mounted to the bottom of the cover and connected internally to RS-232 COM port 1.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 512KB boot/downloader FLASH, 8MB simultaneous read/write FLASH memory Board Variations The CPU/System Controller board has three basic variations: Table 1-1. CPU/System Controller board Variations CPU Nominal Input Power Ethernet Port? Solar Regulator ? Auxiliary Power Output? RTD Input? 14MHz ultra low power +6Vdc or +12Vdc No Yes Yes Yes. Connects to 100-ohm platinum bulb. Uses DIN 43760 curve.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) retention mode (powered by a backup 3.0V lithium battery). Critical system information that must be retained during power outages or when the system has been disabled for maintenance is stored here.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 1.6 Software Tools The ControlWave programming environment consists of a set of integrated software tools which allow you to create, test, implement, and download complex control strategies for use with the ControlWave ExpressPAC. Figure 1-2 graphically presents the programming environment. Figure 1-2.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) The ACCOL3 Firmware Library, available within ControlWave Designer, includes a series of ControlWave-specific function blocks. These pre-programmed function blocks let you accomplish various tasks common to most user applications including alarming, historical data storage, as well as process control algorithms such as PID control. For information on individual function blocks, see the online help within ControlWave Designer.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Chapter 2 – Installation This chapter discusses the physical configuration of the ControlWave ExpressPAC, considerations for installation, and instructions for setting switches and jumpers. In This Chapter 2.1 2.2 2.3 2.4 2.5 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations.............................2-3 Installation Overview...................
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 2-1.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Specifications for Temperature, Humidity and Vibration See document 420DS-7d available on our website for detailed technical specifications for temperature, humidity, and vibration for the ControlWave ExpressPAC. Ensure that the ambient temperature and humidity at the installation site remains within these specifications. Operation beyond the specified ranges could cause output errors and erratic performance.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) b) Enabling the backup battery by setting jumper W3 on the CPU/System Controller board to position 1 to 2. (See Section 2.3.2) b) Setting switches and jumpers on the CPU/System Controller board (see Section 2.3.1 and Section 2.3.2) and on the Process I/O board (see Section 3.2.1 and Section 3.2.2) and placing both boards (as a single assembly) into the chassis.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 2-2. ControlWave ExpressPAC NEMA 3R Enclosure Dimensions Revised Mar-2011 Mount the unit to a panel, a wall or to a vertical 2 inch pipe clamped at the rear of the unit using two clamps and four bolts. See Figure 24 and Figure 2-5. If you mount to a pipe, it must be anchored in cement deep enough to conform to local building codes associated with frost considerations.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) If your unit requires a solar panel, you can mount it to the same 2 inch pipe that holds the controller. Make sure there is adequate clearance for the solar panel. For more information on the solar panel, see Section 2.3.5. Only connect power wiring after the unit is mounted and properly grounded.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 2-4.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 2-5.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 2.2.2 Grounding the Housing The ControlWave ExpressPAC enclosure includes a ground lug that accommodates up to a #4 AWG wire size. Once you install the unit, run a ground wire between the enclosure’s ground lug and a known good Earth ground.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 2-6 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) SW2 Setting Function Mode ON (Disables core updump; factory default) OFF Core updump 5 SRAM Control Manages SRAM contents following a low power situation or a power outage. Values are: ON (Retain values in SRAM during restarts; factory default) OFF (Reinitialize SRAM) – Data in SRAM lost during power outage or re-start. 6 System Firmware Allows a remote download of system firmware (on units equipped with boot PROM version 4.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Switch Setting 7 Function Mode 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 solar power shunt regulation.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) If you connect solar panels to rechargeable battery systems to power the ControlWave ExpressPAC, there is a secondary power input you can use to provide power if there is no power from the solar panel/battery system. Caution At this time you can connect power wiring.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) BATTERY. Connections without the battery present can damage power supply components. Terminal Block Unplug removable connector TB1 from the CPU/System Controller Connector TB1 board. We recommend you do not plug the connector back into the CPU until the unit is already installed in the housing.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Nominal input source operating ranges for the DC power supply are: +6Vdc (+5.4Vdc to +16.0Vdc nominal operating range) +12Vdc (+11.4Vdc to +16.0Vdc nominal operating range) +24Vdc (+21.8Vdc to +28.0Vdc nominal operating range) Not all ControlWave ExpressPAC CPUs support all DC power supplies. Supported options are: 14MHz Ultra Low Power CPU: Supports +6Vdc or +12Vdc nominal power supply.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 2.3.5 Mounting the Solar Panel Depending upon the type of power system you choose, your ControlWave ExpressPAC may require a solar panel. The solar panel charges a rechargeable 6V 7AH lead acid battery. Solar panel wires enter the unit through a liquid tight conduit fitting on the bottom of the enclosure and connect to TB1 on the CPU/System Controller board.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 2-8.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 2-9.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 2.3.6 Connections to RS-232 Serial Port(s) on the CPU/System Controller Board An RS-232 port provides point-to-point, half-duplex and full-duplex communications (for a maximum of 20 feet using data quality cable). Your CPU includes two RS-232 ports and one port configurable for either RS-232 or RS-485 operation. RS-232 COM Port Names and Connectors RS-232 COM ports use different connector types. Table 2-6.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Note: A factory-installed wiring harness connects J4 (COM1) to the circular 5-pin Local Port connector at the bottom of the enclosure cover. Table 2-7.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) CW ExpressPAC 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 CW or 4 = DTR 5 = GND 7 = RTS 4 = DTR 8 = CTS 7 = RTS 3 = TXD 2 = RXD 1 = DCD
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) CW ExpressPAC 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 1 = DCD 2 = TXD To P2 Pin-2 7 = DCD 4 = RXD 9 = GND T
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) When interfacing to the COM3 port of a ControlWave, or the COM5 or COM6 port a ControlWaveEXP unit, use the cable presented in Figure 2-14 along with one of the cables shown in Figure 2-11 or Figure 2-12. RJ45 to DB9 Cable Ass’y.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Ensure that DCD is high to transmit (except when dialing a modem). Verify that each RS-232 transceiver has one active receiver while disabled (in power down mode); connect the DCD signal to the active receiver. Set CTS to high to transmit. If the port is set for full-duplex operation, RTS is always ON. Ensure that DTR is always high when port is active; DTR enables RS-232 transceivers.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) When serving as an RS-485 port, COM3 supports local network communications to multiple nodes up to 4000 feet away. Since the RS-485 port is intended for network communications, refer to Table 2-11 for the appropriate connections for wiring the master, first slave, and nth slave.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 2.3.8 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 ExpressPAC can support one Ethernet port.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 2-18). Figure 2-18.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Display only (no keypad) – (see Figure 2-20) Figure 2-19. Optional 2-Button and 25-Button Keypads Figure 2-20. 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.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Note: For further information on the installation and use of the optional keypads, refer to the ControlWave Display/Keypad Manual (D5135).
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ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC. 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 3.2 Process I/O Board ControlWave ExpressPAC may include an optional Process I/O board. The Process I/O board stands vertically on edge against the inner left side of the enclosure and 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.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) SW1 Function SW1-3 DI/HSC 2mA source current SW1-4 AO configuration Mode OFF = disabled ON = enabled OFF = current ON = voltage Figure 3-1.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Caution Power down the ControlWave ExpressPAC before you perform I/O wiring. Shut down any processes the ControlWave ExpressPAC 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 ExpressPAC is powered down.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 3-2.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 internally-sourced, 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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). The RTD connection enters the unit through the bottom of the enclosure. Wire the RTD according to Table 3-9 and Figure 3-4 and Figure 3-5.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 3.3.8 Connections to a Bristol Model 3808 Transmitter You can connect a Bristol 3808 transmitter (digital) to the ControlWave ExpressPAC 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 ExpressPAC (local communications).
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) CW ExpressPAC Figure 3-7. 3808 Transmitter to ControlWave ExpressPAC RS-485 Comm. Cable You can connect up to two 3808 transmitters to a ControlWave ExpressPAC 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) Chapter 4 – Operation This chapter provides general operational details for using the ControlWave ExpressPAC. In This Chapter 4.1 4.2 4.3 4.4 WARNING Powering Up/Powering Down the ControlWave ExpressPAC ........4-1 Communicating with the ControlWave ExpressPAC .......................4-2 4.2.1 Default Comm Port Settings .................................................4-2 4.2.2 Collecting Data from the ControlWave ExpressPAC ...........
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Power To remove power from the ControlWave ExpressPAC, unplug Down connectors TB1 and TB2 from the CPU/System Controller board. 4.2 Communicating with the ControlWave ExpressPAC You communicate to the ControlWave ExpressPAC by connecting a cable between a port on your PC workstation and one of the ControlWave ExpressPAC ports. The port at the PC workstation must match the configuration of the ControlWave ExpressPAC port. 4.2.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 4.3 Creating and Downloading an Application (ControlWave Project) Your ControlWave ExpressPAC 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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 ExpressPAC, then skip to step 4, otherwise, just proceed to step 3. 3.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave ExpressPAC, as well as some common maintenance procedures. In This Chapter 5.1 5.2 5.3 5.4 5.5 Equipment Upgrading Firmware ........................................................................5-2 Removing or Replacing Components ..............................................5-5 5.2.1 Accessing Modules for Testing ..
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) personnel. Any damage to the unit resulting from improper handling or incorrect service is not covered under the product warranty agreement. If qualified personnel are not available, the unit should be returned to the factory (with prior authorization) for evaluation and repairs. Harmful electrical potentials may still exist at the field wiring terminals even though the ControlWave ExpressPAC power source may be turned off or disconnected.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) The screens shown here may appear different depending upon the version of HyperTerminal you use. HyperTerminal requires *.BIN files; newer ControlWave firmware upgrade files use *.CAB files. In cases such as those, you should use the Remote System Firmware Downloader. 1. Connect a null modem cable between COM1 of the ControlWave ExpressPAC and any RS-232 port on the associated PC. 2.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 7. When the FLASH is ready for download, HyperTerminal repeatedly displays the letter C on the screen. In the HyperTerminal menu bar click Transfer > Send File (see Figure 5-2). 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.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) CWEXP01 E1S0410.bin Figure 5-4. HyperTerminal (Download in Progress) 5.2 Removing or Replacing Components This section provides information on accessing ControlWave ExpressPAC components for testing, as well as removal/replacement procedures. Caution Field repairs to the ControlWave ExpressPAC are strictly limited to the replacement of complete boards. Replacing board components constitutes tampering and violates the product warranty.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 2. Open the enclosure cover. 3. Shut down the ControlWave ExpressPAC by disconnecting the power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2). 4. Disconnect all removable card edge connectors from the CPU/System Controller board and the Process I/O board. Label or otherwise identify them so you can easily re-connect them later. 5.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Use this procedure to remove or replace the CPU/System Controller board and the Process I/O board. 1. If the ControlWave ExpressPAC is running, place any critical control processes under manual control. 2. Open the enclosure cover. 3. Shut down the ControlWave ExpressPAC by disconnecting the power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2). 4.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Note: If the real-time clock loses its battery backup, the ControlWave system variable _QUEST_DATE turns ON. You can monitor this to generate an alarm. See the System Variables section of the ControlWave Designer Programmer's Handbook (D5125) for more information. Caution You lose SRAM contents when you remove the backup battery. If you replace a backup battery, wait at least one minute before repowering the system.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 5.2.6 Removing/Replacing the Case-Mounted Radio or Modem Use this procedure to remove or replace the case-mounted radio or modem. 1. If the ControlWave ExpressPAC is running, place any critical control processes under manual control. 2. Open the enclosure cover. 3. Shut down the ControlWave ExpressPAC by disconnecting the power at the CPU/System Controller assembly terminal TB1 (and if applicable, TB2). 4.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) IDLE LED WD LED Figure 5-5. WD and IDLE LEDs The Ethernet port connector (J1) on the CPU/System Controller board contains two LEDs that indicate transmit (yellow) and receive (green) activity when lit. 5.3.2 Status Messages on LCD Display If your unit includes the optional LCD display, you may see the following status codes. Table 5-1.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 5.3.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 1. Start OpenBSI communications using NetView, TechView, or LocalView, and select the RTU you want to test. 2. Select Start >Programs > OpenBSI Tools >Common Tools > Diagnostics. The Main Diagnostics menu (Figure 5-6) opens. Figure 5-6. WINDIAG Main Diagnostics Menu 3. Select the component to be tested. See Section 5.3.4 for a description of the tests. Enter any prompted parameters (slot #, etc.).
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Port Loop-back Test Option Tests Pulse Counter inputs on the CPU/System Controller board. Prom/Ram Checks the SRAM and FLASH memory. Analog Input Checks AIs on the Process I/O board. Communications Checks serial communication ports COM1, 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.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Port 2 - RS-232 use loop-back wires (see Figure 5-7). Port 3 - RS-232 use loop-back wires (see Figure 5-8). Figure 5-8. COM3 RS-232 & RS-485 Loop-back Wires 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 5-8). These tests verify the correct operation of the communication ports.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Figure 5-9. Communications Diagnostic Menu 3. Enter 5 in the Number of Passes field. 4. Select a port to test (click to display all available ports). 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.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) A core updump may be required if the ControlWave ExpressPAC spontaneously enters a watchdog state that affects all system operation. This occurs when the system crashes as a result of a CPU timeout (resulting from improper software operation, a firmware glitch, and so on). In some cases, the watchdog state can recur but you cannot logically reproduce the conditions.
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 5.5 Calibration Checks The AO and AI on the Process I/O board are self-calibrating. To calibrate the RTD, use TechView software. See the TechView User’s Guide (D5131) for more information.
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Special Appendix for ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Appendix A – ControlWave ExpressPAC– Special Instructions for Class I, Division 2 Hazardous Locations 1. The ControlWave ExpressPAC RTU is listed by Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups C and D hazardous locations or non-hazardous locations only. Read this document carefully before installing a nonincendive ControlWave ExpressPAC RTU.
Special Appendix for ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) WARNING EXPLOSION HAZARD Do not disconnect solar power from the battery or any other power connections within the ControlWave ExpressPAC enclosure or any power connections to optional items such as radio/modem, or cabling to the display/keypad unless the area is known to be nonhazardous. WARNING EXPLOSION HAZARD Substitution of components may impair suitability for use in Class I, Division 2 environments.
Special Appendix for ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Module/Item Connector Wiring Notes document. CPU/System Controller board J2: 8-pin RJ-45 female connector – display or display/keypad interface Factory wired * CPU/System Controller board J4: COM1, 9-pin male Dsub RS-232 J11:COM1 3-pin RS-232 RS-232 Comm. Port connectors: For external network comm. Refer to model spec. and item 6 of this document.
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ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 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.com 3V lithium manganese dioxide battery Emerson Part Number 395620-01-5 P/N: DL 2450 TADIRAN http://www.tadiranbat.
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ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) Index A ACCOL3 Firmware Library ................................. 1-8 address default IP ........................................................ 4-2 Analog Inputs...................................................... 3-8 Analog Output..................................................... 3-9 E B Backup battery description ...................................................... 1-5 disconnecting.................................................
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) 3-4. 3-Wire RTD Temperature Input Wiring . 3-12 3-5. RTD Probe Installation/Removal diagram .313 3-6. 3808 Transmitter to ControlWave ExpressPAC RS-232 Comm. Cable Diagram.314 3-7. 3808 Transmitter to ControlWave ExpressPAC RS-485 Comm. Cable .......... 3-15 3-8. ControlWave ExpressPAC to 3808s - RS485 Network Diagram ................................ 3-15 4-1. Saving a Backup of Your Project ............ 4-4 5-1. HyperTerminal Mode Menu .......
ControlWave ExpressPAC Instruction Manual (CI-ControlWave EPAC) lock/unlock switch......................................... 2-11 use/ignore switch.......................................... 2-11 Software Tools.................................................... 1-7 Specifications for temperature, humidity, vibration................ 2-3 SRAM memory amount............................................................ 1-6 control switch................................................
Instruction Manual CI-ControlWave EPAC March, 2011 ControlWave ExpressPAC 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.
