ControlWave I/O Expansion Rack Quick Setup Guide Bristol Babcock D5122 – December, 2005
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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.
Before You Begin This guide is intended to help you get 'up-and-running' with a minimal amount of effort. It does NOT, however, tell you everything you need to know about setting up and configuring a ControlWave I/O Expansion Rack. We have included references throughout this book to other places in the documentation set, where you can get more details on a particular subject.
Table of Contents Introduction..................................................................................................................................... 6 Setting up the Hardware........................................................................................................... 7 Setting Configuration Parameters ............................................................................................ 7 Setting up the Host to Reference the I/O Expansion Rack .............................
Introduction Introduction The I/O capacity of the ControlWave Process Automation Controller can be increased by the addition of one or more ControlWave I/O Expansion Racks. The ControlWave Controller is referred to as the host of the I/O Expansion Racks. Communication between the I/O Expansion Rack and its host ControlWave is via Ethernet. The I/O Racks can be part of their own IP sub-net, or they can sit on the wider Ethernet network, depending upon the requirements of your particular application.
Introduction The configuration process for the I/O Expansion Rack is divided up into 3 parts. Setting up the Hardware This section gives you a quick overview of how to unpack the I/O Expansion Rack, install the modular components, set the switches, and connect the cable between the rack and the PC. References are included to the hardware manual for details of the individual steps.
Setting up the Hardware Bezel Port80 Display (Plastic bezel covers the power supply sequencer module in slot 1 and CPU module in slot 2.
Setting up the Hardware 3. Remove the CPU Module from its carton and install it into Chassis slot 2, i.e., the second slot from the left end of the installed unit. CPU Module DIP Switches may be configured before or after the module has been installed into the Chassis. (see Section 2.3.3. of CIControlWaveEXP). Reset Switch Port 80 Display SW1 Comm. Port 1 (J1) SW3 Lithium Battery 3.6V 950mA-hr ½ AA Cell Comm.
Setting up the Hardware • Switch bank SW1: all switches in the ON position, unless this I/O rack is part of a redundant pair. (A redundant pair would require two I/O Expansion Racks, hooked through a ControlWave Redundant I/O Switcher (CWREDIO) to the host ControlWave unit(s).) If this I/O rack is part of a redundant pair, set switch SW1-6 and SW1-7 as shown in the table, below: For these switches: SW1-6 SW1-7 If this I/O Expansion Rack is part of a redundant pair… This must be set OFF.
Setting up the Hardware 6. Install a ground wire between the Chassis Ground Lug and a known good Earth Ground (see Section 2.3.1.1 of CI-ControlWaveEXP). 7. Install Watchdog /MOSFET Redundancy Switch wiring (see Section 2.3.5.3 of CIControlWaveEXP). (OPTIONAL - perform this step only if you want to use this feature.) 8. Connect Bulk DC Power to the PSSM Module (see Section 2.3.5.1 and Section 2.3.5.2 of CIControlWaveEXP). Typical Configurations +12Vdc Bulk Supply #1 Pos. Term. +12Vdc Bulk Supply #1 Neg.
Setting Configuration Parameters Setting Configuration Parameters Establishing Communications Using LocalView Before you begin, you must plug a cable from a serial port on your PC running Open BSI, to serial port COM2 on the I/O Expansion Rack. 1. Click as follows: StartÆProgramsÆOpenBSI ToolsÆLocalView 2. Choose 'Local' for the mode, enter a name for the LocalView file, and click on [Create]. First, choose 'Local' as the mode. Next, enter a name for this LocalView file. Finally, click on [Create] 3.
Setting Configuration Parameters 4. First, turn off auto local address detection by answering "No" to the question. Then specify '1' as the local address, and 'CWave_RIO' as the RTU type. Finally, click on [Finish]. Turn off auto local address detection Choose 'CWave_RIO' Use "1" as the local address Finally, click on [Finish] 5. At this point, LocalView will create a temporary network with a single 'RTU'. Right-click on the icon, then choose RTUÆ RTU Configuration Parameters from the pop-up menus.
Setting Configuration Parameters Signing On in the Flash Configuration Utility Tabs for calling up other pages You must click here to sign-on with a username and password in order to access any flash parameters. For purposes of this configuration we are leaving the local address at a value of "1". If we were configuring I/O racks which communicated via MODBUS, the local address would be used as the MODBUS slave address. Enter the username and password and click on [OK].
Setting Configuration Parameters Defining an Ethernet Port When you have successfully signed on, click on the "Ports" tab. On the 'Ports' page, you must now define an Ethernet Port. Select the ENET1 port, then enter an IP address in "IP ADDR A" and an "IP MASK" to define the valid range of IP addresses to which this port can send data. Next, enter an IP address, then enter an IP mask to define the valid range of IP addresses to which this port can send data.
Setting Configuration Parameters Defining IP Parameters Click on the 'IP Parameters' tab, and specify the IP address of the host ControlWave controller in the "IP ADDR A" field; NOT the Network Host PC (NHP). If another ControlWave controller serves as a redundant standby unit for the host controller, enter the redundant unit's IP address in the "IP ADDR B" field.
Setting Configuration Parameters Setting Application Parameters Click on the 'Application Parameters' tab. This timeout determines what happens to output values when the I/O rack's power is restored following a power failure. This timeout determines what happens to output values when the I/O rack loses communications with its host controller.
Setting Configuration Parameters If the amount of time the power was off is greater than the specified Power Fail Timeout, DOs will be set to 0 (FALSE), and AOs will be set to the "User Configured Output" value. Power Fail Timeout is set to 65,535 seconds. AOs and DOs will be set to the last state they were in prior to the power failure.2 NOTE: In the event of a Watchdog failure (CPU failure, but power is not lost), AOs will be set to the "User Configured Output".
Setting Configuration Parameters Redundancy Transfer Unit A Addr This must be an IP address corresponding to an Ethernet port on the ‘A’ I/O Expansion Rack in a redundant pair. Unit B Addr This must be an IP address corresponding to an Ethernet port on the ‘B’ I/O Expansion Rack in a redundant pair.
Setting Configuration Parameters Saving Your Configuration Parameter Changes to the I/O Rack To save your configuration changes, click on the [Save to Rtu] button. This button saves ALL entries in the pages of the Flash Configuration Utility to the I/O Rack. NOTE: If you haven't signed on prior to clicking on this button, you will be prompted to do so. A prompt will now appear asking if you want to save the parameter changes to the NETDEF file.
Setting up the Host to Reference the I/O Rack Setting up the Host to Reference the I/O Rack Configuring the I/O Boards in ControlWave Designer Now that the I/O Expansion Rack is configured, you must make reference to its boards in the ControlWave project of the host ControlWave controller. NOTE This section assumes that the following has already been done: • • • The host controller must have been installed. The host controller must have a ControlWave project already defined.
Setting up the Host to Reference the I/O Rack Select List of Boards: NOTE: The I/O Configuration Wizard starts with page 2 by default; you do NOT need to use page 1 for this configuration. The I/O Configuration Wizard allows the user to identify which process I/O boards are actually installed in the I/O Expansion Rack. Boards should be selected from the “Available Boards List” list box in the ascending order of their slot number in the rack.
Setting up the Host to Reference the I/O Rack In the "Ext Rack Boards" section, is a list of boards which can reside in the I/O Expansion Rack.
Setting up the Host to Reference the I/O Rack The "Board Name" and "Map Type" may be left at their defaults. "Slot Number" should be set to the I/O slot number (1 through 8) in the I/O Expansion Rack which holds the corresponding board. NOTE: I/O slot 1 is equivalent to the 3rd slot in the chassis, I/O slot 2 is the 4th slot in the chassis, etc. Also, be aware that slot numbering between I/O rack(s) and local I/O in the host controller does not conflict, i.e.
Setting up the Host to Reference the I/O Rack Analog Boards (ER_AI16, ER_AO8) Some fields only appear in the Analog Output (AO) board and are not available for the Analog Input (AI); these will be noted, below: Analog Input (AI) Board Page Analog Output (AO) Board Page List of Available Pins Displays a list of the individual pins (I/O points) on this process I/O board. If the pin is displayed in RED, that pin is active. If the pin is left grayed out, that pin is considered unused.
Setting up the Host to Reference the I/O Rack Pin Name Defines a name identifying this pin. IMPORTANT: This name is used as a variable name in your POU to reference the I/O pin. Zero Defines the lowest value of the range for this I/O pin. Used to scale the input/output value. Span Span is added to the ZERO value to define the highest value of the range for this I/O pin. Used to scale the input/output value.
Setting up the Host to Reference the I/O Rack User Configured Output When checked, allows the user to enter a value for this pin which will be used as the hold value in the event there is a watchdog failure of the ControlWave. (AO ONLY) If the power fail timeout has been configured, please see the note on page 18 for more information. NOTE: "Hold Last Output" and "User Configured Output" are mutually exclusive. Either one may be configured for a particular pin, but NOT both.
Setting up the Host to Reference the I/O Rack Digital Output Board Page List of Available Pins Displays a list of the individual pins (I/O points) on this process I/O board. If the pin is displayed in RED, that pin is active. If the pin is left grayed out, that pin is considered unused. Pin Name Is a name identifying this pin. This name is used as a variable name in your POU to reference the I/O pin. Set Pin Status Sets the initial value for this digital output (DO). (DO ONLY).
Setting up the Host to Reference the I/O Rack List of Available Channels Displays a list of the individual channels (counter I/O points) on this process I/O board. If the channel is displayed in RED, that channel is active. If the channel is left grayed out, that channel is considered unused. Channel Name Is a name identifying this channel. This name is used as a variable name in your POU to reference the channel. Add Input Channel State When selected, displays the TRUE/FALSE value of the channel.
Setting up the Host to Reference the I/O Rack These variables are: Variable ERSTAT_x_BOARDSTATUS ERSTAT_x_BATSTAT ERSTAT_x_HOTCARDSTAT ERSTAT_x_HOTCARDCT ERSTAT_x_DOWNTIMEUSER ERSTAT_x_DOWNTIMEACT ERSTAT_x_WRITECT ERSTAT_x_READCT ERSTAT_x_CONNECTS ERSTAT_x_HEARTBEAT ERSTAT_x_MASTER_IS_B ERSTAT_x_STBYVALID ERSTAT_x_FAILOVERERR ERSTAT_x_REDUNSTAT ERSTAT_x_FAILOVER_O ERSTAT_x_BDSTR1 to ERSTAT_x_BDSTR8 Description Board status code. Always present. Battery status. Always present.
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