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Remote Automation Solution

Instruction Manual

Doc Number CI-ControlWave Micro

Part Number D301392X012

June 2013

ControlWave

Micro

Process Automation Controller

Summary of content (170 pages)

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Instruction Manual Doc Number CI-ControlWave Micro Part Number D301392X012 June 2013 ControlWave® Micro Process Automation Controller Remote Automation Solutions www.EmersonProcess.
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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.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Contents Chapter 1 – Introduction 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1-1 Scope of the Manual .................................................................................................................1-2 Physical Description ..................................................................................................................1-2 Housings ..............................................................................................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 Isolated Analog Output (AO) Module ...................................................................................... 3-29 Non-isolated Mixed I/O (MI/O) Module ................................................................................... 3-32 Isolated Vac Digital Input Module ...........................................................................................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Chapter 1 – Introduction This manual focuses on the hardware aspects of the ControlWave Micro hybrid controller (called the “ControlWave Micro” or “Micro” throughout the rest of this manual). For information about the software used with the Micro, refer to the ControlWave Micro Quick Setup Guide (D5124), the ControlWave Designer Programmer’s Handbook (D5125), and the online help in ControlWave Designer.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)       3-, 4- and 8-slot base housings with 2-, 4-, or 8-slot I/O expansion housings Wide operating temperature range: (–40 to +70C) (–40 to 158F) Variety of I/O modules (including mixed I/O) for cost-effective small RTU applications LED status indicators on the CPU, PSSM, and I/O modules Lithium coin cell battery (located on the CPU module) provides battery backup for the real-time clock and the system’s static RAM (SRAM) CE and Class I,
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)      Power Supply/Sequencer module (PSSM) (see Section 1.5 and Chapter 2) CPU module (see Section 1.4 and Chapter 2) One or more I/O modules (see Section 1.7 and Chapter 3) Optional Expansion Communication modules (ECOMs) (see Section 1.6 and Chapter 2) Peripheral components (such as keypad) (see Chapter 2) Figure 1-1 shows an 8-slot base housing with PSSM and CPU modules installed. Figure 1-1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 1.3 Housings ControlWave housings (whether base or expansion) are gold irriditeplated aluminum designed either for wall, DIN rail, or panel-mounting. They contain the printed circuit board (PCB) backplane that provides connections for the PSSM, the CPU module, any ECOMs, and any I/O modules. Base Three base housings are available:  3-slot base backplane supports one PSSM, one CPU, and one I/O module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) CPU Module The CPU module has several basic configurations, all of which Configurations have an on-board backup battery and different combinations of communications ports: Table 1-1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 1-3. CPU Module with Two Serial and Two Ethernet Ports CPU Backup Battery CPU modules have a coin cell socket that accepts a 3.0V, 220 mA-hr lithium battery. This battery provides backup power for the real-time clock and the system’s Static RAM (SRAM). CPU Memory There are several different types of memory used on the CPU module: Boot/Downloader FLASH Boot/download code is contained in a single 512 Kbyte FLASH chip.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) maintenance is stored here. This includes the last states of all I/O points, audit/archive historical data (if not stored in FLASH), the values of any variables marked RETAIN, the values of any variables assigned to the static memory area, and any pending alarm messages not yet reported. SDRAM The CPU module contains 64MB of synchronous dynamic random access memory (SDRAM).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 1-4. PSSM (with Run/Local/Remote Switch) Figure 1-5. PSSM (with Mode Switch) Board Fuse The PSSM is fused to protect the entire system using a 5x20mm slow blow fuse F1 rated at 3 Amps.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 1.6 Expansion Communications Modules An optional Expansion Communications module (see Figure 1-6) provides two additional serial communications ports and optionally a piggy-backed dial-up modem. Two basic versions of the module are available. Both serial communication ports support speeds of up to 115.2 KB. The top communication port (labeled C1) supports RS-232 operation while the second port (labeled C2) supports RS-485 operation.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) maximum wire size of #14 AWG. All I/O modules have surge protection that meets C37.90-1978 and IEC 801-5 specifications. Each I/O module connects to the backplane using a 36-pin male card-edge connector. All I/O modules are provided with two 10-point terminal block assemblies (for local termination) or two 14-pin mass Termination headers (for remote termination).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 1-8. ControlWave Programming Environment The tools which make up the programming environment include:   Revised Jun-2013 ControlWave Designer is your load-building package. It offers several different methods for you to create control strategy programs that run in your ControlWave Micro. You can use pre-made function blocks, ladder logic, or structured languages.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)  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.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Chapter 2 – Installation This chapter discusses the physical configuration of the ControlWave Micro, considerations for installation, and instructions for setting switches and jumpers on the CPU, PSSM, and ECOM modules. In This Chapter 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations .............................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Specifications for Temperature, Humidity and Vibration Caution  See document CWMICRO available on our website for detailed technical specifications for temperature, humidity, and vibration for the ControlWave Micro. This document is available on our website at: http://www.emersonprocess.com/remote/D301671X012.pdf.  Ensure that the ambient temperature and humidity at the installation site remains within these specifications.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2. Installing PC-based software (ControlWave Designer) 3. Establishing communications 4. Creating an application-specific control strategy (ControlWave project). 5. Creating application-specific web pages (optional) 6. Adding the ControlWave Micro to an OpenBSI network 7.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)  Housing One or more bezel assemblies; each bezel covers two I/O modules. The base housing (or chassis) for the ControlWave Micro is an openfaced aluminum assembly. In use, you install a blue plastic cover (“bezel”) over each pair of installed I/O modules, as shown in Figure 2-1.). Figure 2-1. 8-Slot Base Housing with Bezel Keyed cutouts in the housing’s rear wall (see Figure 2-2 through Figure 2-7) permit wall or panel mounting.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-2. 3-Slot Base Housing Figure 2-3.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-4. 8-Slot Base Housing Figure 2-5.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-6. 4-Slot Expansion Housing Figure 2-7.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.2.2 Mounting the Housing You can mount base or expansion housings to a panel or a wall. When mounting one of these units to a panel or wall, place it according to the following guidelines:  Ensure that the front of the ControlWave Micro is visible and accessible for service (for example, so you can easily install or remove modules).  Use the mounting holes provided in the base and expansion housings (see Figure 2-2 through Figure 2-7).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.2.3 Grounding the Housing Do not install any modules in the base or expansion housings until you have mounted and grounded those housings at the designated installation site. Caution Base housings have a ground lug (see Figure 2-2 through Figure 2-7) that accommodates up to a #4 AWG wire size.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.3 Power Supply/Sequencer Module (PSSM) Before we actually configure the PSSM and install it in the housing, we’re going to discuss some general information about how it works. 2.3.1 General Information about the PSSM The Power Supply/Sequencer module (PSSM) plugs into slot #1 (first slot from the left) on the ControlWave Micro’s backplane using connector P1, a 44-pin female non-keyed header (see Figure 2-2, Figure 2-3 and Figure 2-4).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-10. PSSM Module with Mode Switch, Display Interface, and without Watchdog Connector Two terminal blocks (see Figure 2-9) provide external input power and watchdog connector switch connections. Two red LEDs on the PSSM’s front panel enable you to monitor the status of the watchdog (WD) and Idle (IDLE) circuits. Note: The Idle LED is usually on, indicating when the CPU has free time at the end of its execution cycle.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Watchdog Switch PSSMs optionally include a watchdog metal oxide semiconductor fieldeffect transistor (MOSFET) switch connector. The purpose of the watchdog connector is to trigger an external alarm or annunciator if the ControlWave enters a “watchdog” condition in which the CPU cannot control your process.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)  JP5: Three-position Field Voltage Shutdown Trip Point Selection Jumper o 1-to-2 Installed = +12V Bulk Supply Field Voltage Shutdown Trip Point Selected o 2-to-3 Installed = +24V Bulk Supply Field Voltage Shutdown Trip Point Selected. (default) 2.3.4 Setting Mode Switch SW1 on the PSSM The version of the PSSM shown in Figure 2-10 has a DIP switch that controls whether the PSSM operates in Local Mode or Recovery Mode.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.3.6 Wiring a Bulk DC Power Supply to the PSSM At this time you can also connect power and watchdog wiring. However; for safety reasons and to prevent accidental damage to the your bulk DC power supply, do not connect the pluggable terminal block connectors TB1 and TB2 to the PSSM until after you install, wire, and configure the CPU module. Caution Follow the instructions in Section 2.3.5 General Wiring Guidelines when wiring connections.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Bulk 24 Vdc Power Supply Bulk 12 Vdc Power Supply HART/BTI module 250 mA 500 mA Isolated RTD module 13.5 mA 27 mA Isolated LLAI module 26.3 mA 52.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) trigger an external alarm or annunciator if the ControlWave Micro enters a “watchdog” condition in which the CPU cannot control your process. A watchdog condition occurs when:  A watchdog timer expires. This happens if the ControlWave project execution halts unexpectedly – “program crash.”  The controller powers up but is not yet running the ControlWave project.  The CPU module detects that the regulated 3.3 Vdc or 1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.4 CPU Module The CPU module, which controls the ControlWave Micro and handles memory and communication functions, can only be installed in Slot #2 of the ControlWave Micro backplane. Note: Do not confuse the CPU module (which has communication components) with the Expansion Communication module (ECOM), which does not have a CPU component or a battery backup but does have additional communication components.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-14.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-15. CPU Module with Two Serial and Two Ethernet Ports 2.4.1 Setting Jumpers on the CPU Module Each CPU module contains a number of jumpers (labeled with JPn) when n in the jumper number. See Figure 2-13, Figure 2-14, or Figure 2-15) to locate the jumpers. Note: When present, jumpers 1, 2, 3, 5, 6, and 9 (JP1, JP2, JP3, JP5, JP6, and JP9) are reserved for factory use only. Do not alter these jumpers from their factory settings.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) you leave these LEDs enabled during initial installation and setup. If power conservation is an issue, you can disable these LEDs by removing the jumper. Note: For maximum shelf life, the CPU module ships from the factory with the installed lithium backup battery disabled. You must enable it when you install the CPU module by placing JP8 on pins 1-2.    Jumper 8 (JP8) enables/disables the lithium backup battery on the CPU module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 2-4. CPU Module Switch SW2 SW2 Setting Function Mode 1 Watchdog Enable Controls whether the system enters a watchdog state when a crash or system hangup occurs and automatically restarts. Values are: ON (Enables watchdog circuit; factory default) OFF (Disables watchdog circuit and prevents automatic restart) 2 Lock/Unlock Soft Switches Controls the ability to modify soft switches, other configurations, and flash files.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) SW2 Setting Function Mode 8 Enable WINDIAG Suspends normal operation and allows diagnostic routines. Values are: ON (Permits normal system operation, including the boot project, and disables the WINDIAG diagnostics from running; factory default) OFF (Allow WINDIAG to run test; disable boot project and normal system operation.) Note: Setting both switch 8 and switch 3 to OFF (closed) sets all communication ports to 9600 bps operation.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.4.3 Connections to RS-232 Serial Port(s) on CPU or ECOM Modules 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 module includes either one or two RS-232 ports. If you require additional RS-232 ports, you can purchase an optional expansion communication module that can include either one (ECOM Type 1) or two (ECOM Type 2) RS-232 ports.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) RS-232 COM For the ControlWave Micro, half-duplex communications use Modbus Port Cables or BSAP protocol, while full-duplex communications use point-to-point protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 217) to connect with other devices (such as a PC, a printer, another ControlWave [except the CW_10/30/35]) when the ControlWave Micro uses the full-duplex PPP protocol.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-17. Full-duplex and Half-duplex Cable Use the half-duplex cable (shown in the bottom part of Figure 2-17) when connecting the ControlWave Micro to another ControlWave series unit (again, with the exception of the CW_10/30/35). When communicating with a Network 3000 series RTU 3305, RTU 3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of the cables shown in Figure 2-18.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) P1 CW (COM3) or CWEXP (COM5/6) 8-Pin P2 Pin 1 (Wht/Grn Stripe) to Pin 1 = Pin 2 (Wht/Blu Stripe) to Pin 6 = Pin 3 (Blu/Wht Stripe) to Pin 2 = Pin 4 (Grn/Wht Stripe) to Pin 7 = Pin 5 (Wht/Org Stripe) to Pin 3 = Pin 6 (Wht/Brn Stripe) to Pin 8 = Pin 7 (Orn/Wht Stripe) to Pin 4 = Pin 8 (Brn/Wht Stripe) to Pin 5 = DCD DSR/RX+ RXD/RXRTS TXD/TXCTS DTR/TX+ GND RJ45 Plug (Looking into Connector Intf.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)    The CPU module’s RS-485 port is COM3. If you have a Type 1 ECOM module in slot #3, its RS-485 port is COM5. If you have a Type 1 ECOM module in slot #4, its RS-485 port is COM9. If you have a Type 2 ECOM module in slot #3, its RS-485 ports are COM6 and COM7. If you have a Type 2 ECOM module in slot #4, its RS-485 ports are COM10 and COM11.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 2-12.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) enable receiver biasing and termination (as well as 2-wire or 4-wire selection) using an 8-position DIP switch located on the CPU and ECOM modules. See Table 2-5 in Section 2.4.2 Setting DIP Switches on the CPU Modules for information on RS-485 termination and loopback control switch settings. 2.4.5 Connections to Ethernet Port(s) on the CPU Module Caution The RJ45 Ethernet ports are located on the CPU module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 2-14. Ethernet 10/100Base-T CPU Module Pin Assignments Pin Description 1 Transmit Data+ (Output) 2 Transmit Data– (Output) 3 Receive Data+ (Input) 4 Not connected 5 Not connected 6 Receive Data– (Input) 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.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 2.5 Expanded Communications Module (ECOM) ControlWave Micros can support up to two optional expanded communications modules (ECOMs) which you can install only in slots #3 or #4 (in place of I/O modules). ECOMSs do not have a CPU component.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Transmit LEDs Receive LEDs Comm. Port 4/8 CR1 1-2 Installed = LEDs Enabled 2-3 installed = LEDs Disabled W1 1 W2 for Comm. Port 4/8 W1 Comm. Port 4/8 RS-232 J4 Comm. Port 5/9 2 1 W2 1-2 Installed = Loopback Disabled & 2-3 installed = RTS/CTS Loopback W3 CR2 W3 for Comm. Port 5/9 P1 1 J2 - for Factory Use ONLY Comm. Port 5/9 RS-232 J5 Comm. Port 6/10 CR3 T1 Comm. Port 6/10 RS-485 J6 O N 1 2 3 4 5 6 7 8 SW1 Comm.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) When connecting a ControlWave Micro to an external modem, use the cable configuration in Figure 2-25. Figure 2-25. Full-duplex and Half-duplex Cable Figure 2-26. ECOM Modem Installation 2.5.3 Modem Port (Type 1 ECOM only) You can mount an optional 56Kb PSTN Hayes-type modem on a Type 1 ECOM (see Figure 2-26). The ControlWave Micro then assigns the modem COM7 (if in slot #3) or COM11 (if in slot #4).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) also clock DTE/DCE serial data into (transmit) or out of (receive) the modem at rates up to 115.2 kHz. The factory supplies the modem pre-installed or in kit form with all required hardware. You install it on the ECOM1 module and then use the Ports page in the Flash Configuration utility (in NetView, LocalView, or TechView) to assign ports.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-27. PTSN Field Connections for ControlWave Micros Figure 2-28. Phone Cord Wiring The 56K PSTN modem is FCC-approved for use with public telephone lines. However, before you place a modem in operation, check the following items to make sure you meet all FCC requirements:    Revised Jun-2013 Connections to party line service are subject to state tariffs.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) o Contains device with FCC Registration Number: AU7-USA25814-M5-E o Ringer Equivalence Number (REN): 0.3B Note: The sum of all the RENs on your telephone lines should be less than five in order to assure proper service from the telephone company. In some cases, a sum of five may not be usable on a given line.  Make any direct connections to PSTN lines through standard plugs and jacks as specified in the FCC rules.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 2-29. Bezel Assembly 2.7 Optional Display/Keypads The ControlWave Micro supports two optional display/keypads:   A 2-button keypad (shown in the left of Figure 2-30) A 25-button keypad (shown in the right Figure 2-30) Figure 2-30.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Both keypads use the same 4-line by 20-character LCD displays. You connect the keypad to the ControlWave Micro using a cable, one end of which has an RJ-45 jack (connected into the RJ-45 equipped with two plugs. This cable connects between the RJ-45 display jack (J1) on the PSSM Board and RJ-45 jack (J1) on the remote Display/Keypad assembly. A potentiometer, provided on the keypad, allows you to set the contrast of the LCD display.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Chapter 3 – I/O Modules This chapter discusses the placement and wiring for I/O modules for the ControlWave Micro. The chapter begins with some general instructions on module installation that are common to most I/O modules. The balance of the chapter includes specific details for configuring and wiring each type of I/O module. In This Chapter 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 Module Placement ...........
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Note: This step is beyond the scope of this manual. Refer to the ControlWave Designer Programmer’s Handbook (D5125) for further instructions. Power down the ControlWave Micro before you install or remove any I/O module. Shut down any processes the ControlWave Micro may be managing (or switch them over manually or handle with another controller).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) ControlWave Micro I/O modules use compression-type terminals that accommodate up to #14 AWG wire. Insert the wire’s bared end (approx. ¼” max) into the clamp beneath the screw and secure the wire. To prevent shorts, ensure that no bare wire is exposed. If using standard wire, tin the bare end with solder to prevent flattening and improve conductivity. Allow some slack in the wires when making terminal connections.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Use AWG 14 or smaller wire (consult with the field device manufacturer for recommendations) for remote terminations. Leave some slack and plan for wire routing, identification, and maintenance. Route the cables running between the I/O module and the DIN-rail mounted terminal blocks out through the bottom of the I/O module assembly via the bezel assembly. Figure 3-2. Module Wiring: Remote Termination 3.2.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.3 Isolated Digital Input (DI) Module Isolated DI modules provide 16 isolated digital inputs. For 24V DI modules you can individually configure inputs for either externally sourced inputs or internally powered (dry contact) applications. Table 3-1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) source originating on the Power Supply/Sequencer module (PSSM). Setting Jumpers Set configuration jumpers W1 through W19 according to Table 3-3. Use jumper W19 (see Figure 3-3) to enable or disable the +21 Vdc field power supply. Note: Jumpers W1 through W12 and W15 through W19 only apply to 24V DI Modules. Table 3-3.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-3. Isolated DI Module (Local Termination) Figure 3-4 shows the wiring assignments associated with a DIN-rail mounted terminal block assembly for a DI module associated with either internally sourced or externally powered operation. Figure 3-5 shows the wiring assignments associated with a DIN-rail mounted terminal block assembly for a DI module associated with relay isolated 120 Vac operation.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-4. Isolated DI Module (Remote Termination, Internally Sourced or Externally Powered) Note: Fuses F0 to F7 are 1/8 A; F+ is a 2A fuse.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-5. Isolated DI Module (Remote Termination, Internally Sourced or Externally Powered with and without Fuses) Software Configuration To use data from an isolated DI module you must add a CWM_DI16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.4 Isolated Digital Output (DO) Module Isolated DO modules provide 16 DOs to control signaling functions. DO modules consist of a DO PCB with either two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination). DO modules also include two configuration jumpers, an LED board with 16 status LEDs (one for each point), and a cover assembly.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) function as follows: Table 3-6. Jumper Assignments: Isolated DO Module Jumper WI Purpose Description Configures DI1 Pins 1-2 installed = Manually enables status LEDs Pins 2-3 installed = Software enables status LEDs See Figure 3-6 for the location of this jumper.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-7 shows the terminal block assignments for a remotely terminated DIN-rail mounted open source isolated DO module. Figure 3-8 shows the terminal block assignments for a remotely terminated DIN-rail mounted relay isolated 24 Vdc DO module. Figure 3-7. Isolated DO Module (Remote Termination) Note: Fuses F0 to F7 are 1/8 A; F+ is a 2A fuse.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-8. Isolated DO Module (Remote Termination with Relay Isolated with 24 Vdc) Software Configuration To use data from an isolated DO module you must add a CWM_DO16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.5 Non-isolated Digital Input/Output (DI/O) Module Non-isolated DI/O modules consist of a digital input/output PCB with either two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination). The DI/O module also includes 14 configuration jumpers, an LED board with 16 status LEDs (one for each point), and a cover assembly.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Part Number 396567-04-5: Termination Connector Notes remote Includes LED daughterboard. Setting Jumpers DI/O modules provide 12 individually field configurable DIs and 4 non-configurable externally powered DOs. Using configuration jumpers W1 through W12, you can set each DI individually to provide either a 2 mA or 60 uA source current. Table 3-9 details jumper settings. Table 3-9.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-10. Non-isolated DI/O Module (Remote Termination) Software Configuration To use data from a non-isolated DI/O module you must add a CWM_MD board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.6 Non-isolated Analog Input/Output & Analog Input Module Non-isolated Analog Input/Output (AI/O) modules support six externally sourced 4–20mA or 1–5 Vdc single-ended analog inputs and optionally, two independently configurable 4–20 mA or 1–5 Vdc analog outputs. Non-isolated Analog Input (AI) modules are identical to AI/O modules but have a depopulated AO section.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 3-11. Non-Isolated AI/O Module Configurations Part Number Termination Connector 396568-01-7: local 396568-02-5: remote Notes Each non-isolated AI module (general part number 396569-XX-X) consists of a PCB with six AIs and comes with a module cover. There are two configurations: Table 3-12.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Wiring the Module Figure 3-11 shows field wiring assignments associated with the locally terminated AI/O and AI modules. Figure 3-12 shows field wiring assignments associated with remotely terminated AI/O and AI modules. Figure 3-11.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-12. Non-isolated AI/O and AI Modules (Remote Termination) Software Configuration To use data from a non-isolated AI/O module you must add a CWM_MA board in ControlWave Designer’s I/O Configurator, and then configure it. To use data from a non-isolated AI module you must add a CWM_AI6 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.7 Non-isolated High Speed Counter (HSC) Input Module Non-isolated High Speed Counter (HSC) Input modules provide up to four inputs.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Jumper Purpose Description W5 Programs Serial EEPROM Reserved for factory use only W6 Enables LEDs Pins 1-2 installed = Enables LEDs manually Pins 2-3 installed = Enables LEDs via software W7 & W8 Controls HSC1 Current Pins 1-2 installed = Enables additional 2 mA load Pins 2-3 installed = Enables 200 uA source; no 2 mA load W9 & W10 Controls HSC2 Current Pins 1-2 installed = Enables additional 2 mA load Pins 2-3 installed = Enables 20
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-13.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Note: Fuses F0, F2, F4, and F6 are 1/8 A. Figure 3-14. Non-isolated HSC Module (Remote Termination) Software Configuration To use data from a high speed counter module you must add a CWM_HSC4 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.8 Isolated Analog Input (AI) Module Isolated AI modules support eight 4–20 mA, 1–5 Vdc, or 0–10 Vdc differential analog inputs. AI modules consist of an AI PCB with two 10-point terminal block assemblies (for local termination) or two 14-pin mass termination headers (for remote termination), eight configuration jumpers, and a module cover assembly. The AI PCB connects with the backplane using a 36-pin gold-plated card-edge connector. Table 3-17.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 3-18. Isolated Analog Input Module Configurations Part Number Termination Connector 396604-03-0 local 396604-04-8 remote Notes Setting Jumpers AI modules have jumpers you can use to configure each of the eight AIs. You can individually configure AI for 4–20 mA, 1–5 Vdc, or 0– 10 Vdc isolated operation or internally sourced 4–20 mA non-isolated operation. See Table 3-19 for settings. Table 3-19.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 1 +AI 1 +AI Field TB FIELD CIRCUITRY Field TB2 -AI -AI Shield AI#1 (Example) Externally AI#1 (Example) Internally Sourced Chassis 4-20mA AI Ground Wiring Diagram TB1 P1 2 Shield 2 Chassis Powered Ground 0-10Vdc AI Wiring Diagram P3 } } P3 +AI1 -AI1 +AI2 -AI2 +AI3 -AI3 +AI4 -AI4 ISOGND ISOGND 1 2 3 4 5 6 7 8 9 10 TB1 P4 +AI5 -AI5 +AI6 -AI6 +AI7 -AI7 +AI8 -AI8 ISOGND ISOGND 1 2 3 4 5 6 7 8 9 10 TB2 P4 TB2 FIELD CIRCUITRY
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Note: Fuses F0, F2, F4, and F6 are 1/8 A. Figure 3-16. Isolated AI Module (Remote Termination) Software Configuration To use data from an isolated analog input module you must add a CWM_AI8 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.9 Isolated Analog Output (AO) Module AO modules support four independently configurable 4–20 mA or 1–5 Vdc isolated analog outputs. Analog output circuitry is electrically isolated from the CPU power system. AO modules consist of an AO PCB with two 10-point terminal block assemblies (TB1 and TB2 for local termination) or two 14-pin mass termination headers (P2 and P3 for remote termination), four configuration jumpers, and a module cover.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-17.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Note: Fuses F0, F2, F4, and F6 are 1/8 A. Figure 3-18. Isolated AO Module (Remotely Terminated) Software Configuration To use data from an isolated analog output module you must add a CWM_AO4 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.10 Non-isolated Mixed I/O (MI/O) Module Non-isolated Mixed I/O (MI/O) modules provide up to six individually field configurable DI/Os, four AIs, two HSC Inputs and, optionally, one AO. MI/O modules consist of an MI/O PCB with two 10-point terminal block assemblies (TB1 and TB2 for local termination) or two 14-pin mass termination headers (P2 and P3 for remote termination), 28 configuration jumpers, and a module cover.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 3-23.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-19. Non-isolated MI/O Module (Local Termination) Figure 3-20.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-21 shows terminal block assignments for remote termination. Figure 3-22 shows a wiring diagram for mixed I/O for local termination. Figure 3-23 shows a wiring diagram for mixed I/O for remote termination. Note: Fuses F1 to F6 are ¼ A; fused F7 to F15 are 1/8 A. Figure 3-21.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-22.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-23. MI/O Module Wiring (Remote Termination) Software Configuration To use data from a mixed I/O module you must add a CWM_MIX board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.11 Isolated Vac Digital Input Module Isolated Vac DI modules provide eight isolated DIs, which can interface to field-powered devices providing 110 Vac or 220 Vac. Table 3-24.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Wiring the Module Figure 3-24 shows field wiring assignments for a locally terminated Vac DI module. Figure 3-24. Isolated Vac DI Module Wiring (Local Termination) Software Configuration To use data from an Isolated Vac Digital Input module you must add a CWM_DI16 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.12 Relay Isolated Vac/Vdc Digital Output Module Caution You cannot install a relay isolated Vac/Vdc DO module in slot #1 of any expansion housing. Relay isolated Vac/Vdc DO modules provide a total of eight isolated DOs to control signaling functions. The DOs do not have surge protection (this is a customer-provided feature, if necessary). Table 3-26.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Table 3-27. Jumper Assignments: Isolated Vac DI Module Jumper W1 Purpose Description Enables DO status LED Pins 1-2 installed = Enables LEDs manually Pins 2-3 installed = Enables LEDs via software Wiring the Module Figure 3-25 shows field wiring assignments for a locally terminated relay isolated Vac/Vdc DO module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.13 Isolated Digital Input/Output (DI/O) Module Isolated Digital I/O modules provide four isolated DOs that are externally powered and twelve isolated DIs. Table 3-28. Isolated (DI/O) Module Characteristics Type Isolated Digital Outputs (DO) Number Supported 4 Characteristics Each isolated DO supports/includes:  Externally powered. Supports 500mA maximum load (nominally powered from a 10Vdc supply [30Vdc max]_  Surge protection.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Each of the four DO circuits contain an optically isolated open source MOSFET with surge suppressor and are capable of handling 500mA @ 30V. Use jumper W15 to enable power for DIs that are configured for internal power. The nominal input voltage is 24Vdc at 5mA. Setting Jumpers The isolated DI/O module has 15 jumpers you can use to configure inputs and outputs. See Table 3-29. Table 3-29.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-26. Isolated DI/O Module Wiring (Local Termination) Software Configuration To use data from an Isolated Digital Input/Output module you must add a CWM_MD board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.14 Isolated Resistance Temperature Device (RTD) Input Module RTD Input modules provide a total of four inputs. Firmware detects the RTD type (2-, 3- or 4 platinum wire) via the installation of jumper wires on the terminal block for 2-wire and 3-wire RTDs (see Figure 3-27). Table 3-30.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) similar to those assigned to the Remote DIN-Rail Mountable Terminal Blocks. Note: To maintain specified accuracy with a 3-wire RTD, you must match the two field wires that source and sink the RTD current within 0.01 ohms (matched in length and matched in wire type) and the ambient temperature on these wires must be the same. Figure 3-27.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-28. Isolated RTD Module Wiring (Remote Termination) Software Configuration To use data from an Isolated RTD Input module you must add a CWM_RTD4 board in ControlWave Designer’s I/O Configurator, and then configure it. See the ControlWave Designer Programmer's Handbook (D5125) for more information. That same manual includes an I/O Mapping section that describes, for advanced users, the I/O map for this module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.15 Isolated Low Level Analog Input (LLAI) Module Low Level Analog Input (LLAI) modules provide six individually isolated differential inputs for thermocouples or 10mV inputs plus one cold junction compensation (CJC) input for temperature compensation at the terminal block. Table 3-32.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) TB1 1 1 J2 P2 P1 J1 P2 W9 1 +AI1 -AI1 +AI2 -AI2 +AI3 -AI3 CJC+ CJC+ CJC+AI4 -AI4 +AI5 -AI5 +AI6 -AI6 P3 P3 1 2 3 4 5 6 7 8 9 10 TB1 1 2 3 4 5 6 7 8 9 10 TB2 TB2 TB1 + +AI1 -AI1 +AI2 -AI2 +AI3 -AI3 CJC+ CJC+ CJC- 1 2 3 4 5 6 7 8 = RTD EXC (Reference) 9 = RTD+ (Sense) 10 = RTD- (Return) Figure 3-29.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-30. Isolated LLAI Module Wiring (Remote Termination) Ranges & Table 3-34 provides the accuracy, resolution and temperature range for Errors the various thermocouples and 10mV LLAI inputs. Table 3-35 lists the RTD errors. Table 3-34. LLAI Module Input Accuracy and Resolution Input Type Accuracy/Range Resolution 25C –20C to +70C B – Thermocouple 100C to 200C 200C to 390C 390C to 840C 840C to 1820C 2.00C 1.00C 0.50C 0.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Input Type Accuracy/Range Resolution 25C –20C to +70C C – Thermocouple 0C to 2315C 0.16C  0.75C  1.5C N – Thermocouple – 270C to – 260C – 260C to – 250C – 250C to – 230C – 230C to – 150C – 150C to 1300C 1.50C 0.75C 0.50C 0.25C 0.09C  8C  4C  2C  1C  0.500C  16C  8C  4C  2C  1C J – Thermocouple – 210C to 191C 191C to 1200C 0.08C 0.11C  0.750C  0.500C  1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Thermocouple Type Process Temperature Range RTD Error with CJC @ 25C E – 270C to – 261C – 260C to – 245C – 244C to – 200C – 200C to – 87C – 86C to +25C +25C to 100C  10C  3C  1.50C  0.75C  0.39C  0.30C K – 270C to – 261C – 260C to – 247C – 246C to – 222C – 220C to – 160C – 159C to +25C +25C to 1372C  15.00C  4.50C  2.20C  1.10C  0.55C  0.30C  10.30C – 270C to – 261C  3.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.16 Non-isolated HART®/BTI Interface Module Non-isolated Highway Addressable Remote Transducer (HART)/Bristol Transmitters (BT) Interface modules provide eight channels individually configurable for HART, BTI, or 4–20 mA inputs. Additionally, you can configure two of the eight channels for 4–20 mA outputs.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) refreshes every second, unless a secondary master (such as a handheld device) is communicating on the loop.  Multi-drop HART communication with up to five HART Transmitters In this mode, you can communicate with up to five HART transmitters multi-dropped to the specified input channel.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Detailed Technical For detailed technical specifications, please see our website Specifications http://www.emersonprocess.com/remote. Configuration The non-isolated HART/BTI module (general part number 396983XX-X) has the following configurations: Table 3-36.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) TB1 Wiring Connections TB2 Wiring Connections 9 +24V 9 +24V 10 24VRET 10 24VRET If using remote terminations, see Figure 3-32. Figure 3-32. HART/BTI Terminal Blocks for Remote Termination (shown with and without fuses) Table 3-38. HART/BTI Connections for Remote Termination A = Top terminal block + = 24V A = Top terminal block + = 24V .0 = CHANNEL 1 0 = CHANNEL 5 .2 = CHANNEL 2 2 = CHANNEL 6 .4 = CHANNEL 3 4 = CHANNEL 7 .
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) .1 = ISOGND 1 = ISOGND .3 = ISOGND 3 = ISOGND .5 = ISOGND 5 = ISOGND .7 = ISOGND 7 = ISOGND - - = 24V RET = 24V RET Fuses: F0, F2, F4, F6: 1/8 A The transmitter (XMTR) may be a HART device, a Bristol 3508 transmitter, or a Bristol 3808 transmitter. HART devices may be multidropped, up to five devices on a channel, allowing up to 40 HART devices if all eight channels are used. The Bristol transmitters may not be multi-dropped.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Externally Sourced Transmitters An external 24V power source is required for applications with more than eight transmitters. Connect the positive terminal of each transmitter to the +24V external source (see Figure 3-34). Connect the negative terminal of each of up to five HART multidropped transmitters (or a single Bristol transmitter) to the appropriate channel terminal on the board’s terminal block.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-35. Switches and Jumpers on the HART/BTI Interface Module Caution Settings for SW3 and SW4 must be consistent with the I/O configuration of the corresponding channels in ControlWave Designer. To find the location of the switches on the board, see Figure 3-35. Table 3-39.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Set jumpers according to the Table 3-40, below: Note: Jumpers not mentioned here are for factory use only and should not be touched. Table 3-40. HART/BTI User-configurable Jumpers Jumper W5 Description RX, TX LED Enable Position 1 to 2: LEDs enabled Position 2 to 3: LEDs disabled Normally, you would enable the LEDs, unless power is a consideration, in which case you could disable them to save power.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3.17 IEC62591 Interface Module The IEC62591 interface module allows your ControlWave Micro to communicate to a network of IEC62591WirelessHART™ field devices such as transmitters. Once you install the module and configure the associated ControlWave project using ControlWave Designer (available in OpenEnterprise™ Field Tools), you connect it to a Smart Wireless Field Link so it can access the wireless network.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 3-36. IEC62591 Interface Module Connection You can install the IEC62591 interface module assembly in an open I/O slot in the ControlWave Micro except, due to a mechanical restriction, it cannot reside in the last slot of any housing. You must connect an RS-485 cable between the RS-485 port on the module, and the Smart Wireless Field Link. This requires a Belden 2twisted pair cable.Table 3-41 shows connections for the twisted pair cable.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) POWER B(-) + A B Twisted Pair 1 18 AWG 2-Twisted Shielded Pairs Cable Twisted Pair 2 Figure 3-37.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Termination Jumpers Figure 2-38. IEC62591 Module – Connecting Termination Jumpers Software Configuration After you configure a wireless network for your devices, you need to configure your ControlWave project to access the interface module, and through it, the wireless network.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Chapter 4 – Operation This chapter provides general operational details for using the ControlWave Micro. In This Chapter 4.1 4.2 4.3 4.4 4.5 WARNING Powering Up/Powering Down the ControlWave Micro ....................4-1 Setting Operating Mode (Run/Remote/Local or Mode Switch) .......4-2 Communicating with the ControlWave Micro ..................................4-3 4.3.1 Default Comm Port Settings ...............................................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 4.2 Setting the Operating Mode (Run/Remote/Local Switch or Mode Switch) The PSSM you receive has either a key-operated Run/Remote/Local switch (see Figure 2-9) or a Mode switch (see Figure 2-10). Run/Remote/ Local Switch You set the PSSM’s Run/Remote/Local switch using a removable key. You can remove this key when the switch is in any position to prevent an unauthorized person from changing the operating mode. Figure 4-2.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 4-3. Mode Switch 4.3 Communicating with the ControlWave Micro You communicate to the ControlWave Micro by connecting a cable between a port on your PC workstation and one of the ControlWave Micro ports. The port at the PC workstation must match the configuration of the ControlWave Micro port. 4.3.1 Default Comm Port Settings As delivered from the factory, ControlWave Micro communication ports have default settings.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Port COM11 PCB Default Configuration ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol ECOM Type 1 Modem port ECOM Type 2 RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol Notes:    Ethernet You can re-enable the factory default comm. settings at any time by setting switch SW2-3 on the CPU module to “OFF.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) a reset. For this reason, you should not change baud rate for the active port on which you are communicating, or communications will immediately stop due to the baud rate mismatch between the PC port and the controller port. If this happens accidentally, you can use CPU switch settings as discussed in the notes in Section 4.3.1 to restore defaults and re-establish communications. 4.3.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) o Set PSSM’s Mode Switch (SW1) for Local Mode. Note: COM1 has a factory default of 115.2 Kps (RS-232) using the Internet Point-to-Point Protocol (PPP). Do not connect COM1 to a PC unless you configure that PC’s RS-232 port for PPP. 2. Define the Micro project, setting communication and configuration parameters. 3. Download the project according to instructions in the Downloading section of the ControlWave Designer Programmer's Manual (D5125).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 4.5.1 Creating a Zipped Project File (*.ZWT) For Backup Note: The .zwt file is a complete backup of your entire project including code, comments and graphics. It may be stored on your PC or removable storage media. It may also be downloaded and archived to ControlWave Flash memory where it may be uploaded at a later time for editing. With your current ControlWave project open in ControlWave Designer, perform the following steps: 1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Zip Option Description Zip FW-Libraries This includes firmware libraries, such as ACCOL3.FWL in your zwt. Zip Pagelayouts This includes pagelayout information for printing your project, as well as graphical elements used in certain 1131 languages. 5. Click Zip and a progress bar displays the percent complete of the zipping process. 6. When the zip process completes, you’ll see a message box reporting successful completion. Click OK. 7.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 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, then skip to step 4, otherwise, just proceed to step 3. 3. Click and wait for the utility to retrieve all parameters from the ControlWave. 4. Click and specify a name for your FCP file, then click Save.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Chapter 5 – Service and Troubleshooting This chapter provides general diagnostic and test information for the ControlWave Micro. 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 ............................................5-5 5.2.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)  DC supply, variable to 30Vdc @ 2.5A (with vernier adjustment) Note: When you service a ControlWave Micro on site, we recommend that you close down (or place under manual control) any associated processes. This precaution prevents any processes from accidentally running out of control when you conduct tests.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)  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 Micro and any RS-232 port on the associated PC. 2. Click Start > Programs > Accessories > Communications > HyperTerminal 3.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) HyperTerminal menu bar click Transfer > Send File (see Figure 5-2). Figure 5-2. HyperTerminal (Ready to Download) 5-4 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 “CWMxxxxx.bin” (where xxxxx varies from release to release) and click Send to start the flash upgrade (see Figure 54).
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 5-3. Send File dialog box Figure 5-4. HyperTerminal (Download in Process) 5.2 Removing or Replacing Components This section provides information on accessing Micro modules for testing, as well as removal/replacement procedures. Caution Field repairs to ControlWave Micros are strictly limited to the replacement of complete modules. Replacing module components constitutes tampering and violates the product warranty.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) service procedures is not covered under the product warranty agreement. If you cannot properly perform these procedures, obtain authorization and then return the device to the factory for evaluation and repairs. 5.2.2 Removing/Replacing the Bezel 1. Grasp the sides of the bezel assembly and gently lift it up and then off its associated I/O module covers. 2.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3. Press down on the cover’s built-in top latch (with one hand) and up on the cover’s built-in bottom latch (with the other hand). 4. Carefully slide the PSSM module out of the front of the housing. If binding occurs, gently rock the module up and down to free it. 5. To replace a PSSM module, power must be off. Carefully align the PSSM module with the guides for slot 1 in the Micro and insert the module into the housing.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) need to replace a battery until the ControlWave Micro has been in service for an extended period (normally many years). The CPU module accommodates a 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 module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Removing / Replacing the Battery – Clip Type Holder Battery Part Numbers: BR2330, BR2335, BR2335-B 1. If the Micro is running, place any critical control processes under manual control. 2. Remove power from the ControlWave Micro. 3. Remove the CPU module from the housing. 4. To remove the lithium battery, gently pry up the tab holding the battery in the coin cell socket and remove the battery with a pair of tweezers or needle-nosed pliers.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Module LED Name LED Color Function PSSM 6 STATUS Red See Table 5-2 and Figure 5-5 CPU C1 RX (Comm 1) Red ON = RX activity (top left; see Figure 5-6) CPU C1 TX (Comm 1) Red ON = TX activity (top left; see Figure 5-6) CPU C2 RX (Comm 2) Red ON = RX activity (middle left; see Figure 5-6) CPU C2 TX (Comm 2) Red ON = TX activity (middle left; see Figure 5-6) CPU C3 RX (Comm 3) Red ON = RX activity (bottom left; see Figure 5-6)
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Module LED Name LED Color Function 9) MI/O DI INPUT (6 LEDs, 1 per point) Red LED ON = Input is present LED OFF = Input not present (see Figure 5-9) MI/O DI INPUT (6 LEDs, 1 per point) Red LED ON = Output is ON (see Figure 5-9) MI/O HSC INPUT (2 LEDs, 1 per point) Red LED ON = Input activity on input is present LED OFF = No activity on input (see Figure 59) IDI (Vac) INPUT (8 LEDs, 1 per point) Red LED ON = Input is present LED O
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 5-5. PSSM Status LED Hexadecimal Codes CPU Module The CPU module has four or six comm port activity LEDs on the CPU LEDs board. Units equipped with an Ethernet port have two additional LEDs located on each Ethernet RJ-45 connector. Table 5-3 details assignments for the LEDs on the CPU module. An ON LED indicates an associated transmit (TX) or receive (RX) activity. Table 5-3.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 5-6. CPU Module Comm Connectors and LEDs SLOT # 3 Receive LEDs SLOT # 4 Transmit LEDs Comm. Port 4 Status LEDs Comm. Port 8 Status LEDs Comm. Port 5 Status LEDs Comm. Port 9 Status LEDs Comm. Port 6 Status LEDs Comm. Port 10 Status LEDs Comm. Port 7 Status LEDs Comm. Port 11 Status LEDs Comm. Port 4 RS-232 Comm. Port 8 RS-232 Comm. Port 5 RS-485 Comm. Port 9 RS-485 Comm. Port 6 Radio Comm.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) SLOT# 3 SLOT# 4 Comm. Port 4 Receive LED Transmit LED Comm. Port 8 Receive LED Transmit LED Comm. Port 4 RS-232 Comm. Port 8 RS-232 Comm. Port 5 Receive LED Transmit LED Comm. Port 9 Receive LED Transmit LED Comm. Port 5 RS-232 Comm. Port 9 RS-232 Comm. Port 6 Receive LED Transmit LED Comm. Port 10 Receive LED Transmit LED Comm. Port 6 RS-485 Comm. Port 7 Receive LED Transmit LED Comm. Port 7 RS-485 Comm. Port 10 RS-485 Comm.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) I/O Module Cover P1 P1 LED PCB P2 P2 P3 TB1 I/O Module PCB P4 TB2 TB1 Local Termination I/O Module Diagram Remote Termination I/O Module Diagram TB2 DI1 DI2 DI3 DI4 Mixed I/O Module LED Assignments DI1 DI2 DI4 DI3 DI5 DI6 DI7 DI8 DI5 DI6 DI9 DI10 DI11 DI12 DO1 DO2 DO3 DI13 DI14 DI15 DI16 DO5 DO6 HSC1 HSC2 Isolated DI Module LED Assignments DI1 Note: 1st 8 DI LEDs are same as IDI (Vac) Module DO4 DO1 DO2 DO3
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 5-10. Status LEDs on HIB Note: To conserve power, you can disable the status LEDs by placing jumper W5 in position 2-3. 5.3.2 Checking Wiring/Signals Check I/O field wiring at the terminal blocks and at the field device. Inspect the wiring for continuity, shorts, and opens. Check I/O signals at their respective terminal blocks (see Table 5-4). Table 5-4.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 5.3.3 Common Communication Configuration Problems If serial communications do not function, it is often due to one of the following issues:  Baud rate mismatch – the baud rate at both ends of the communication line must match. If communications fail during a download of a new flash configuration profile (FCP) file, you may have changed the baud rate of the active communication line, since baud rate changes occur immediately on FCP download.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)      Turn CPU module switch SW2-8 OFF to run the WINDIAG program. Setting this switch off prevents the boot project from running and places the Micro in diagnostic mode. Use a null modem cable to connect RS-232 ports between the Micro and the PC; use an RS-485 cable (see Section 2.4.4) to connect the RS-485 ports of the Micro and the PC.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Port Module Default Configuation COM11 ECOM Type 1 Modem port ECOM Type 2 RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer protocol. You can connect an optional Ethernet port (situated on the CPU module) directly or via a network to a PC equipped with an Ethernet port (see Section 2.4.5). Before starting the WINDIAG program, place any critical processes the Micro is handling under manual control.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 5-12. WINDIAG Main Diagnostics Menu 3. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG performs the diagnostics and displays pass/fail results. 4. After performing all diagnostic testing, exit WINDIAG and then exit the NetView if you don’t have any other Micro units to test. When you close NetView, the system asks whether you want to close OpenBSI. Select Yes. 5.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Port Loop-back Test Option Tests Twisted Pair tests require the use of a loop-back plug. Low Level AI Checks Thermocouples and CJC on LLAI modules and check RTDs on RTD modules. WINDIAG allows you to select the communication port (1 through 4) to test.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Test Procedure Use this procedure to test the comm ports. Connect an external loop-back plug to the port on the CPU, ECOM1, or ECOM2 module to be tested. Valid ports are: 1.        J3 of CPU module for COM1 J4 of CPU module for COM2 J5 of CPU module for COM3 J1 of ECOM1 module for COM4 J2 of ECOM1 module for COM5 J1 of ECOM2 module for COM8 J2 of ECOM2 module for COM9 Select Communications on the WINDIAG Main Diagnostics Menu.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)  7. Ethernet Port Loop-back Test CTS RTS Failure Click Return to Menu to display the WINDIAG Main Menu. The Ethernet option on the WINDIAG Main Menu allows you to select the Ethernet communication port (1 through 3) to test. This test configures the Ethernet port’s ability to transmit and receive via the twisted pair. The text transmits frames and compares them against received frames.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure 5-17. Ethernet Diagnostic Menu 3. Enter 1 in the Number of Passes field. 4. Enter 1 in the Ethernet Port to Test field. 5. Click RUN next to the Loop-back out twisted pair field to start the test.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) watchdog state can recur but you cannot logically reproduce the conditions. The CPU module’s RAM contains “crash blocks,” a firmware function provided specifically for watchdog troubleshooting. You can view and save the crash blocks by viewing the Crash Block Statistic Web Page (see the Web_BSI Manual, D5087). On request, you can forward crash block files to our technical support personnel.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Once you complete the core updump, set the CPU module’s switch SW2-1 to ON (Watchdog Enabled) and SW2-4 to OFF (Core Updump Enabled). Additionally, if the PSSM has a mode switch, set switch SW1-1 to open (right) and SW1-2 to closed (left). If the PSSM has a Run/Remote/Local switch, set it to Local. With these switches set, power up the Micro and recommence standard operations.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Appendix A – ControlWave Micro Process Automation Controller – Special Instructions for Class I, Division 2 Hazardous Locations 1. The ControlWave Micro Process Automation Controller is listed by Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups A, B, C and D hazardous locations and non-hazardous locations only.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Appendix D – Modem Installation D2.1 Modem Installation & Configuration D2.1.1 Installing an Internal MultiTech Modem (MT9234SMI) To install a Model MT9234SMI Modem onto an ECOM Module, perform the following steps: Remove the ECOM Module from the controller (see Figure D1). Figure D1. Expansion Comm. Module Component Identification Diagram 1. Unplug the antenna cable from the RF Connector on any installed radio module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Figure D2. MultiTech Modem Installation Diagram Note: If necessary, you can use a small screwdriver to pry the cover panel from the PCB. 2. Install the nylon support post included in the kit onto the ECOM Module.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3. Mount the MultiTech Modem to the ECOM Module making sure that the interface connectors (J6, J7, J9 & J10 on the ECOM Module) align. 4. Plug the antenna cable(s) (if present - removed in Step 2) into the appropriate RF connector of an installed radio module(s). 5. Snap the cover panel onto the ECOM Module PCB and insert the ECOM Module into the appropriate backplane slot, i.e., Slot 3 or 4. 6. Apply power and test the unit. D2.1.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro)         5. D-4 Bits per second: 9600 Data bits: 8 Parity: None Stop bit: 1 Flow Control: None Send Factory Default AT&F0. Disable Flow Control AT&K0. Set baud rate using AT Command for example: AT$SB9600, (Modify for whatever baud rate you require.)  Write to memory AT&W. Set ECOM Module configuration jumper JP2 into a storage position.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 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 (DL 2032) http://www.duracell.
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Index A ACCOL3 Firmware Library ............................... 1-12 Analog Input (AI) Module Isolated ......................................................... 3-26 jumpers .................................................... 3-27 wiring ........................................................ 3-27 Non-isolated ................................................. 3-18 jumpers ....................................................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Expansion Communications (ECOM) modules .. 1-9 F Features .............................................................. 1-1 Field repair .......................................................... 5-5 Figures 1-1. 8 slot Base Housing ................................ 1-3 1-2. CPU Module with Three Serial Ports and optional Ethernet Port .................................. 1-5 1-3. CPU Module with Two Serial Ports and Two Ethernet Ports ..............
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3-29. Isolated LLAI Module Wiring (Local Termination) ............................................... 3-50 3-30. Isolated LLAI Module Wiring (Remote Termination) ............................................... 3-51 3-31. TB1 and TB2 Terminal Blocks ............ 3-56 3-32. HART/BTI Terminal Blocks for Remote Termination ................................................ 3-57 3-33. Example of Wiring Transmitters (1 per channel) – Internally Sourced ...
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) J Jumpers CPU .............................................................. 2-19 HART/BTI module ........................................ 3-61 Isolated AI .................................................... 3-27 Isolated AO ................................................... 3-30 Isolated DI ...................................................... 3-7 Isolated DI/O ................................................ 3-44 Isolated DO ..................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) Relay Isolated Vac/Vdc DO .............................. 3-41 Remote termination ............................................ 3-3 Repair in field ...................................................... 5-5 RS-232 Ports .................................................... 2-23 Cables .......................................................... 2-24 RS-485 Ports .................................................... 2-28 Cables ...........................
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ControlWave Micro Instruction Manual (CI-ControlWave Micro) 3-36. Non-isolated HART/BTI Interface Module356 3-37. HART/BTI TB1 and TB2 Wiring Connections – Local Termination .............. 3-56 3-38. HART/BTI Connections for Remote Termination ................................................ 3-57 3-39. HART/BTI Switch Settings for SW3 and SW4 (for Non multi-dropped HART devices only)............................................................ 3-60 3-40. HART/BTI User-configurable Jumpers 3-61 3-41.
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ControlWave Micro CI-ControlWave Micro Instruction Manual June 2013 Headquarters: Emerson Process Management Remote Automation Solutions 6005 Rogerdale Road Houston, TX 77072 U.S.A. T +1 281 879 2699 | F +1 281 988 4445 www.EmersonProcess.com/Remote Europe: Emerson Process Management Remote Automation Solutions Unit 8, Waterfront Business Park Dudley Road, Brierly Hill Dudley UK DY5 1LX T +44 1384 487200 | F +44 1384 487258 www.EmersonProcess.