Emerson ControlWave EFM 3808 Instruction manual

Instruction Manual
Doc Number CI-ControlWave EFM
Part Number D301383X012
December 2013
ControlWave® EFM
(Electronic Flow Meter)
Remote Automation Solutions
www.EmersonProcess.com/Remote
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. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may
leave an operating process without protection. Depending upon the application, this could result in
possible damage to property or injury to persons. It is suggested that the purchaser review the
need for additional backup equipment or provide alternate means of protection such as alarm
devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches,
etc. If additional information is required, the purchaser is advised to contact Remote Automation
Solutions.
RETURNED EQUIPMENT WARNING
When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions are clean to safe levels, as such levels are
defined and/or determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions may incur or suffer due
to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in
accordance with OSHA rules and regulations pertaining to "Design Safety Standards for Electrical
Systems," 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are in agreement
with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that
include electrically operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an
electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this
can result in erratic operation or complete failure of the equipment. Read supplemental document
S14006 for proper care and handling of ESD-sensitive components.
ControlWave EFM Instruction Manual
Contents
Chapter 1 – Introduction
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1-1 Scope of the Manual ...............................................................................................................1-2 Physical Description ...............................................................................................................1-3 Housings and Enclosure .......................................................................................................1-3 CPU Module .............................................................................................................................1-4 System Controller Module (SCM) ..........................................................................................1-6 Expansion Communications Modules ..................................................................................1-7 I/O Modules ..............................................................................................................................1-8 Software Tools.........................................................................................................................1-8 Overview of the Gas Flow Measurement Application .......................................................1-10 Chapter 2 – Installation
2-1 2.1 Site Considerations ................................................................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations.................................................................2-2 2.2 Installation Overview ..............................................................................................................2-5 2.3 Unpacking Components .........................................................................................................2-6 2.4 Mounting the EFM Housing....................................................................................................2-7 2.4.1 Grounding the Housing ............................................................................................2-13 2.4.2 Connecting to the Multi-Variable Transducer (MVT) .............................................2-13 2.4.3 Process Pipeline Connection (Meter Runs without Cathodic Protection) ..........2-15 2.4.4 Process Pipeline Connection (Meter Runs with Cathodic Protection) ................2-15 2.5 System Controller Module (SCM) ........................................................................................2-17 2.5.1 General Information about the SCM ........................................................................2-17 2.5.2 SCM Installation Overview .......................................................................................2-19 2.5.3 Setting Jumpers on the SCM ...................................................................................2-19 2.5.4 Setting Mode Switch SW1 on the SCM ...................................................................2-19 2.5.5 General Wiring Guidelines .......................................................................................2-20 2.5.6 Wiring a Bulk DC Power Supply to the SCM ..........................................................2-21 2.6 Using a Solar Panel and Lead Acid Battery to Power the EFM ........................................2-22 2.6.1 Mounting the Solar Panel .........................................................................................2-22 2.6.2 Installing the Lead Acid Battery and Solar Panel Harness ...................................2-24 2.7 Power Distribution Board (Optional) ...................................................................................2-26 2.8 21V Power Supply (Optional) ...............................................................................................2-28 2.9 CPU Module ...........................................................................................................................2-29 2.9.1 Setting Jumpers on the CPU Module ......................................................................2-30 2.9.2 Setting DIP Switches on the CPU Module ..............................................................2-31 2.9.3 Connections to RS-232 Serial Port(s) on CPU or ECOM Modules .......................2-34 2.9.4 Connections to RS-485 Serial Port(s) on CPU or ECOM Modules .......................2-39 2.9.5 Connections to Ethernet Port on the CPU Module ................................................2-42 2.10 Expanded Communications Module (ECOM) .....................................................................2-44 2.10.1 RS-232 Ports ..............................................................................................................2-45 2.10.2 RS-485 Ports ..............................................................................................................2-45 2.10.3 Modem Port (Type 1 ECOM only) ............................................................................2-46 2.11 Bezels .....................................................................................................................................2-49 2.12 Case Mounted Radio/Modem ...............................................................................................2-50 2.13 Optional Display/Keypads ....................................................................................................2-50 Chapter 3 – I/O Modules
3-1 3.1 Module Placement ...................................................................................................................3-2 3.2 Wiring .......................................................................................................................................3-3 Revised Dec-2013
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ControlWave EFM Instruction Manual
3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.2.1 Local Termination ....................................................................................................... 3-3 3.2.2 Shielding and Grounding ........................................................................................... 3-4 Non-isolated Digital Input/Output (DI/O) Module ................................................................. 3-5 Non-isolated Analog Input/Output & Analog Input Module ................................................ 3-7 Non-isolated High Speed Counter (HSC) Input Module .................................................... 3-10 Non-isolated Mixed I/O (MI/O) Module ................................................................................3-12 Resistance Temperature Device (RTD) Inputs on SCM .................................................... 3-16 Digital to Relay I/O Board Option ........................................................................................ 3-18 Connections to a Bristol Model 3808 Transmitter ............................................................. 3-20 Chapter 4 – Operation
4-1 4.1 Powering Up/Powering Down the ControlWave EFM.......................................................... 4-1 4.2 Communicating with the ControlWave EFM ........................................................................ 4-2 4.2.1 Default Comm Port...................................................................................................... 4-2 4.2.2 Changing Port Settings .............................................................................................. 4-3 4.2.3 Collecting Data from the ControlWave EFM ............................................................ 4-4 4.3 Creating and Downloading an Application (ControlWave Project) ................................... 4-4 4.4 Creating and Maintaining Backups ....................................................................................... 4-5 4.4.1 Creating a Zipped Project File (*.ZWT) For Backup................................................. 4-5 4.4.2 Saving Flash Configuration Parameters (*.FCP) ..................................................... 4-7 4.4.3 Backing up Data .......................................................................................................... 4-8 Chapter 5 – Service and Troubleshooting
5-1 5.1 Upgrading Firmware ............................................................................................................... 5-2 5.2 Removing or Replacing Components ................................................................................... 5-5 5.2.1 Accessing Modules for Testing ................................................................................. 5-6 5.2.2 Removing/Replacing the Bezel.................................................................................. 5-6 5.2.3 Removing/Replacing the CPU Module ...................................................................... 5-6 5.2.4 Removing/Replacing the SCM ................................................................................... 5-7 5.2.5 Removing/Replacing an I/O Module .......................................................................... 5-7 5.2.6 Removal/Replacement of an Expansion Communication Module ......................... 5-8 5.2.7 Removal/Replacement of the Rechargeable Lead-acid Battery............................. 5-8 5.2.8 Removal/Replacement of a Power Distribution Board............................................ 5-9 5.2.9 Removal/Replacement of a 21V Power Supply Board ............................................ 5-9 5.2.10 Removal/Replacement of a Digital to Relay I/O Board .......................................... 5-10 5.2.11 Removal/Replacement of a Case-Mounted Radio/Modem.................................... 5-10 5.2.12 Removing/Replacing the Backup Battery .............................................................. 5-10 5.2.13 Enabling / Disabling the Backup Battery ................................................................ 5-12 5.3 General Troubleshooting Procedures ................................................................................ 5-12 5.3.1 Checking LEDs .......................................................................................................... 5-12 5.3.2 Checking Wiring/Signals .......................................................................................... 5-18 5.3.3 Calibration Checks.................................................................................................... 5-18 5.3.4 Common Communication Configuration Problems .............................................. 5-18 5.4 WINDIAG Diagnostic Utility .................................................................................................. 5-19 5.4.1 Available Diagnostics ............................................................................................... 5-22 5.5 Core Updump ........................................................................................................................ 5-26 Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations
A-1
Appendix D – Modem Installation
D-1
Appendix Z – Sources for Obtaining Material Safety Data Sheets
Z-1
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ControlWave EFM Instruction Manual
Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Electronic Flow Meter (EFM) (called the “ControlWave EFM” or
“EFM” throughout the rest of this manual). For information about the
software used with the EFM, refer to Getting Started with ControlWave
Designer (D5085), the ControlWave Designer Programmer’s Handbook
(D5125), and the online help in ControlWave Designer. For information
on the flow measurement application used in the ControlWave EFM,
see the ControlWave Flow Measurement Applications Guide (D5137).
This chapter details the structure of this manual and provides an
overview of the ControlWave EFM and its components.
In This Chapter
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Scope of the Manual ........................................................................1-2 Physical Description ........................................................................1-3 Housings and Enclosure .................................................................1-3 CPU Module ....................................................................................1-4 System Controller Module (SCM) ....................................................1-6 Expansion Communications Modules .............................................1-7 I/O Modules......................................................................................1-8 Software Tools .................................................................................1-8 Overview of the Gas Flow Measurement Application....................1-10 The ControlWave EFM measures differential pressure, static pressure,
and temperature and computes flow for both volume and energy for up
to four meter runs in accordance with API (American Petroleum
Institute) and AGA (American Gas Association) standards.
Features ControlWave EFMs have the following key features:
 Exceptional performance and low power consumption through use
of the ARM microprocessor


Two CPU options (33 MHz or 150 MHz)
Two RS-232 and one RS-485 asynchronous serial communication
ports


Optional Ethernet port (150 MHz CPU only)
Optional Expansion Communication modules (ECOMs) with
optional built-in modem and/or radio
Wide operating temperature range: (–40 to +70C) (–40 to 158F)
Variety of I/O modules (including mixed I/O)


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

RTD input
Lithium coin cell battery (located on the CPU module) provides
battery backup for the real-time clock and the system’s static RAM
(SRAM)

Keypad /. Display for operator interaction.
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ControlWave EFM Instruction Manual

Nonincendive Class I, Division 2 (Groups C and D) Hazardous
Location approvals
Figure 1-1. ControlWave EFM Enclosure (shown with 25-Button Display/Keypad Assembly and local
circular port)
1.1 Scope of the Manual
This manual contains the following chapters:
1-2
Chapter 1
Introduction
Provides an overview of the hardware and
general specifications for the ControlWave EFM.
Chapter 2
Installation
Provides information on mounting the housing,
wiring power, configuring the CPU module and
optional Expanded Communications module
(ECOM), and related peripherals such as the
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ControlWave EFM Instruction Manual
optional keypad.
Chapter 3
I/O Modules
Provides general information and wiring
diagrams for the I/O modules.
Chapter 4
Operation
Provides information on day-to-day operation of
the ControlWave EFM.
Chapter 5 Service and
Troubleshooting
Provides information on service and
troubleshooting procedures.
1.2 Physical Description
ControlWave EFMs are furnished in a NEMA 3X rated Hoffman®
enclosure. The flow computer hardware comprises a backplane board
(mounted in a housing), a system controller module (SCM) and a CPU
module. Optional expansion communication module(s) may reside in
slots 3 and 4 of the housing in lieu of I/O modules. The CPU module
includes the communication ports and the system memory.
All system modules plug into the backplane (either 4-slot or 8-slot).
Each I/O module provides the circuitry and field interface hardware
necessary to interconnect the assigned field I/O circuits. Non-isolated
power is generated and regulated by the system controller module
(SCM) that provides +3.3Vdc for all logic and bulk power for I/O field
circuits from either a bulk 6Vdc or bulk 12Vdc source.
1.3 Housings and Enclosure
The ControlWave EFM housings are open-faced gold-irridite aluminum
which (whether base or expansion) are gold irridite-plated aluminum.
They house the printed circuit board (PCB) backplane and all
ControlWave EFM modules. The housing mounts to a fabrication panel
on the inner rear wall of the enclosure.
Two housings are available:



4-slot backplane supports one system controller module (SCM), one
CPU, and two I/O modules.
8-slot base housing supports one SCM, one CPU, and up to six I/O
modules. The 8-slot housing does not allow use of the internal
battery/solar panel option.
You can substitute one or two expansion communication modules
(ECOMs) for I/O modules in slots 3 and 4.
The ControlWave EFM sits in a standard NEMA 3X Hoffman®
enclosure, which also houses the multivariable transducer, battery, and
communication equipment such as a radio or modem. The enclosure
consists of two pieces, the body and the front cover. A continuous
gasket seals the unit when you close the cover. A hinge on the left side
(facing the front of the unit) if formed by molded channels on the front
cover and the body that capture a stainless steel pin. Two latches on
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ControlWave EFM Instruction Manual
the enclosure’s right side secure the cover when you close it.
A weatherproof communication connector, either a 9-pin male D-type
connector or a circular 3-pin connector (the local port) mounts to the
bottom of the enclosure and connects internally to RS-232
communication port 1 for local communications.
The front cover includes a liquid crystal display (LCD) and keypad for
local operator access.
1.4 CPU Module
The CPU (central processing unit) module houses the multi-layer PCB,
which contains the CPU, I/O monitor/control, memory, and
communication functions.
The CPU module includes:










Sharp LH7A400 System-on-Chip ARM microprocessor with 32-bit
ARM9TDMI Reduced Instruction Set Computer (RISC) core,
operating at 1.8V with a system clock speed of 33 MHz or 150
MHz.
two RS-232 communication ports,
one RS-485 communication port
one 10/100baseT Ethernet ports (150 MHz units only)
2 MB of battery backed Static RAM (SRAM),
64MB of Synchronous Dynamic RAM (SDRAM),
512KB boot/downloader Flash,
16MB simultaneous read/write Flash memory
transmit (TX) and receive (RX) LEDs for each communication port
configuration DIP switches (described in Chapter 2.)
CPU Module The CPU module has two basic configurations, both of which have
Configurations an on-board backup battery and different combinations of
communications ports:
Table 1-1. CPU Module Configurations
Number of
RS-232
Ports
Number of
RS-485
Ports
Number of
Ethernet Ports
2
1
0
left side of Figure 1-2
2
1
1
right side of Figure 1-2
See Figure
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 EFM Instruction Manual
Figure 1-2. 33MHz CPU Module with Three Serial Ports (left), 150 MHz CPU Module with Three
Serial Ports and One Ethernet Port (right)
CPU Backup Battery CPU modules have a coin cell socket that accepts a 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.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.
FLASH Memory
The CPU module contains 16 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.
System Memory (SRAM)
The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by a lithium backup battery). Critical system information that must be
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ControlWave EFM Instruction Manual
retained during power outages or when the system has been disabled for
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). SDRAM holds the running application
(ControlWave project) as well as a copy of system firmware and the
current values of any variables not marked RETAIN or stored in the
static memory area. This allows the system to run faster than it will
from the SRAM memory. SDRAM is not battery-backed.
1.5 System Controller Module (SCM)
The System Controller Module (SCM) takes power from an external
bulk DC power supply (or an optional solar panel and lead acid battery
combination) and then provides +3.3Vdc power and GND through the
ControlWave EFM housing/backplane to all installed modules. The
SCM also supplies switched field power to I/O module slots.
Power Options The SCM operates with a nominal input of either 6V or 12V received
from a bulk supply connected to a pluggable terminal block, or from a
30 or 40 watt solar panel connected to a rechargeable lead acid battery.
If your EFM includes options such as the 21V power supply for external
transmitters, a case-mounted radio/modem, or a digital to relay I/O
board, you need a power distribution board as well.
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ControlWave EFM Instruction Manual
1.6 Expansion Communications Modules
Expansion Comm. Modules provide two additional serial
communications ports and optionally the choice of a piggy-backed dialline modem or piggy-backed 900 MHz Spread Spectrum radio (or both).
The top port (labeled C1) supports RS-232 operation while the second
one (labeled C2) supports RS-485 operation. You can optionally order
the RS-485 port with isolation to 500Vdc. You can install up to two
expansion communication modules in backplane slots 3 and 4.
Figure 1-3. Expansion Communications (ECOM) Module
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ControlWave EFM Instruction Manual
1.7 I/O Modules
The ControlWave EFM supports factory-configured I/O modules
including analog I/O, analog input, digital I/O, high speed counter and
mixed I/O.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-4
shows a typical I/O module housing.
Configuration jumpers on I/O modules accommodate individual field
I/O user configuration. Terminations are pluggable and accept a
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. With the exception of the mixed I/O module, 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). Mixed I/O modules have two 10-point terminal blocks for
local termination only.
Figure 1-4. Two ControlWave EFM I/O Modules (with Bezel)
1.8
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.
Figure 1-5 graphically presents the programming environment.
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ControlWave EFM Instruction Manual
Figure 1-5. ControlWave Programming Environment
The tools which make up the programming environment include:



ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), and the ControlWave Designer
Programmer’s Handbook (document D5125).
The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O modules in the
ControlWave and configure the individual mapping of I/O points for
digital and analog inputs and outputs. For information on the I/O
Configurator see the ControlWave Designer Programmer’s
Handbook (document D5125).
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 EFM Instruction Manual

OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).

OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).

A series of web page controls are available for retrieval of real-time
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. Alternatively,
developers can place the controls in third-party ActiveX compatible
containers such as Visual BASIC or Microsoft® Excel. For
information on the ActiveX controls, see the Web_BSI Manual
(document D5087).
User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).


Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).
Communication In addition to the Bristol Synchronous/Asynchronous Protocol
Protocols (BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port using serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.
1.9 Overview of the Gas Flow Measurement Application
Note: For detailed information on the gas flow measurement
application and web pages refer to the ControlWave Flow
Measurement Applications Guide (D5137).
You can purchase the ControlWave EFM with a pre-programmed flow
measurement application already loaded.
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The ControlWave standard gas flow measurement application collects
static pressure, differential pressure and temperature data and computes
flow, energy, and volume for a station.
A station typically refers to a single flow computer and all its
associated meter runs. Each meter run refers to measurement of natural
gas through a single pipeline. The ControlWave EFM supports up to
four meter runs. Meter runs can use orifice, turbine, or ultrasonic
meters.
The application includes an auto-selector, PID/flow pressure control
algorithm per run or per station.
If you have the optional expansion communication module, you can
interface to a chromatograph to provide energy throughput as well as
composition information.
The application also supports a nomination function.
1.9.1 Data Acquisition – Static Pressure, Differential Pressure,
Temperature Variables
The application requires these process inputs for orifice measurement:
 static pressure (SP) collected once per second
 differential pressure (DP) collected once per second
 flowing temperature (T) collected once per second
The application requires these process inputs for measurement using a
positive displacement (PD), turbine, or ultrasonic meter:
 static pressure (SP) collected once per second
 frequency input collected once per second
 flowing temperature (T) collected once per second
The application also collects self-test and compensation variables at
intervals of four seconds or less.
Pressure data can come from any of the following sources:



Analog pressure transmitters connected to analog input points on a
process I/O module in the ControlWave flow computer.
Built-in multivariable transducer.
External multivariable transmitters (Bristol or Rosemount) using
BSAP or Modbus communications through an RS-485
communication port.
1.9.2 Flow and Volume Calculations
Flow and volume calculations conform to American Petroleum Institute
(API) and American Gas Association (AGA) standards.
Supported flow calculations include:
 AGA3-1985/NX-19
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ControlWave EFM Instruction Manual
 AGA3-1992 with selectable AGA8 Gross or AGA8 Detail
 AGA7/NX-19
 AGA7 with selectable AGA8 Gross or AGA8 Detail
 Auto-adjust AGA7/NX-19
 Auto-adjust AGA7 with selectable AGA8 Gross or AGA8 Detail
The application performs a complete flow calculation using the process
variables every second. Each calculation includes instantaneous rate
according to API 14.3, compressibility according to AGA 8 Detail or
Gross method, and updates of all volumes, totals, and archive averages.
1.9.3 Flow Rate and Flow Time Calculations (AGA3)
For orifice flow measurement, the application compares the differential
pressure value to a low flow cutoff value every second. If the
differential pressure falls below the low flow cutoff value, flow is
considered to be zero for that second. Hourly and daily flow time is
defined to be the number of seconds for which the differential pressure
exceeded the cutoff value for the period.
The values for static and differential pressure and temperature are used
as inputs to the flow equations. You can select API 14.3 (AGA3, 1992)
and AGA8 calculations, with compressibility calculations according to
AGA Report No. 8, 1992 (with 1993 errata). The application supports
both the detail method and the two gross methods of characterization
described in AGA 8. Users may also select the AGA3, 1995 and NX-19
flow equations to calculate the rate of flow.
1.9.4 Flow Rate and Flow Time Calculations (AGA7)
When using PD meters, turbine meters or ultrasonic meters, the
application calculates flow rate by applying the correction factor
computed by the AGA7 calculations to the frequency of the input
pulses. When the frequency drops below 1 Hz, the application sets the
flow rate estimate to zero; however, volume calculations still
accumulate. The flow time recorded is the time for which the flow rate
is non-zero.
1.9.5 Extension Calculation and Analog Averaging
For orifice meters, the application calculates the flow extension every
second. The extension is the square root of the product of the absolute
upstream static pressure times the differential pressure. This extension is
used in the flow rate calculation. When there is no flow, the application
reports the arithmetic averages of static pressure and temperature. This
allows you to monitor static pressure and temperature during shut-in
periods.
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1.9.6 Energy Calculation
The application offers the option of using a fixed volumetric heating
value or calculating the energy content of the gas according to AGA
Report No. 5.
1.9.7 Volume and Energy Integration
The application integrates and accumulates volume and energy at the
end of every calculation cycle. The application calculates the volume
for a cycle by multiplying the calculated rate by the flow time for that
cycle. The application calculates the energy for a cycle by multiplying
the volume at base conditions by the heating value.
1.9.8 Downstream Pressure Tap
The multivariable transducer typically measures static pressure from an
integral tap on the upstream, high-pressure leg of the differential
pressure connection. The transducer can also measure static pressure at
the downstream pressure tap, with the measurement taken from the lowpressure side to the high-pressure side. In this installation, the
differential signal from the transducer is negative. If, while using the
integral smart multivariable transmitter (MVT) or an external MVT, you
select the downstream tap location during MVT configuration, the MVT
firmware changes the sign of the differential pressure to provide a
positive DP value.
1.9.9 Historical Data Storage (Audit Records/ Archive Files)
The ControlWave supports two distinct types of historical data storage –
audit records and archive files.
Where feasible, both forms of archive data conform to the requirements
of the API Chapter 21. Specifically, the averages of the process
variables stored in the data archive are for flowing periods, appropriate
to their usage in the equations, and any gas-related parameter designated
an event that is changed by an operator either remotely or locally causes
an entry in the audit log.
Audit Records
(Alarms and
Events)
The audit system maintains a history of alarms and certain events that
have an impact on the calculated and reported gas flow rates and
volumes.
The application stores the most recent 500 alarms and the most recent
500 events. As new alarms/events arrive, they overwrite the oldest
entries. Internally, the ControlWave stores alarms and events separately
to prevent recurring alarms from overwriting configuration audit data
events. The application reports alarms and events in the same log.
The following circumstances generate an audit record:
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Introduction
1-13
ControlWave EFM Instruction Manual
 Any operator change to a configuration variable
 Any change in the state of an alarm variable
 A system restart
 Certain other system events
You can view audit records on-screen in the audit log.
See Appendix K of the OpenBSI Utilities Manual (D5081) for help on
interpreting audit records.
Archive files store the value of process variables and other calculated
Archive Files
variables at specified intervals along with the date and time of each
(Averages,
totals, and other entry. This includes flow rates, volumes and other calculated values.
When archive files fill up, new values overwrite the oldest entries in the
values)
files.
The application displays archive file data in hourly, data, and periodic
logs you can view on screen.
Log Breaks
You can configure the application to support the "breaking" of a log
period when an operator-changes a parameter. When this occurs, the log
period in process closes out to make a log, and a new log begins.
Note: To prevent the system from creating several very short logs due
to a series of successive configuration changes, log breaks don’t
occur if a log contains less than 60 seconds (flowing or
otherwise) of data. This means that is a user enters 15
configuration changes over a two minute period, the log breaks
only twice. By default the log break feature is disabled.
Hourly Historical Data Log
Each meter run maintains an hourly data log that holds one record for
every contract hour. Hourly logs hold 840 entries or 35 days; this
ensures that the previous period of hourly data is always resident in
flash memory.
The hourly data log stores the following items:









1-14
corrected volume
uncorrected volume
accumulated energy
average static pressure
average temperature
average differential pressure
average specific gravity
average heating value
flow time
Introduction
Revised Dec-2013
ControlWave EFM Instruction Manual
 uncorrected count
ControlWave EFM maintains an hourly historical log for each of up to
four runs.
Daily Historical Data Log
Each meter run maintains a daily data log that holds one record for
every contract gas day. You can change the contract hour so the contract
gas day starts at some time other than midnight. The daily log holds 62
entries; this ensures that the previous calendar month of daily data is
always resident in flash memory.
The daily data log stores the following items:
 corrected volume
 uncorrected volume
 accumulated energy
 average static pressure
 average temperature
 average differential pressure
 average specific gravity
 average heating value
 flow time
 uncorrected count
ControlWave EFM maintains a daily historical log for each of up to four
runs.
Periodic Historical Data Log
Each meter run maintains a periodic data log that holds one record for
every log interval. Each log interval is 15 minutes. The periodic
historical data log holds 1440 records, or four days of 15 minute data.
The periodic historical data log stores the following items:
 flowing differential pressure
 flowing static pressure
 flowing temperature
 frequency
ControlWave EFM maintains a daily historical log for each of up to four
runs.
1.9.10 Run Switching
If you use multiple meter runs in the application, you can configure run
switching. Run switching (also known as meter run staging or tube
switching) allows changes to the number of meter runs currently active
to meet the gas flow demand for the station.
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Introduction
1-15
ControlWave EFM Instruction Manual
1.9.11 Sampler and Odorizer
Samplers are external devices which measure the quality of the gas
stream. Because natural gas is odorless and colorless, devices called
odorizers inject an additive to the gas stream that allows people to
detect the presence of natural gas in the event of a gas leak.
1.9.12 Flow Rate Control – DCC (Jog Control) Using PID
To configure the EFM to perform flow rate control you wire the two
discrete outputs to the open and close inputs of a controller. The EFM
uses a proportional/integral/derivative (PID) algorithm to cause the
measured rate of flow to match a user-entered setpoint. When the flow
rate falls below the setpoint, the open output is pulsed. When the flow
rate rises above the setpoint, the close output is pulsed. The PID
equation calculates the duration of the open or close pulse; the
minimum pulse duration is 1.0 seconds. The user changeable parameters
are:
 Flow setpoint in MSCFH
 Deadband in % of setpoint
 Proportion gain
 Integral time in repeats/minute
 Derivative time in seconds
 Valve travel time (full close to full open)
 Process control limiting
 Pressure override limits
The flow control algorithm runs once per second.
1.9.13 Pulse Output for External Totalizer or Sampler
When you configure the EFM to provide a pulse output based on
volume, the operator provides a control volume and pulse duration.
After each calculation cycle, the application compares an internal
volume accumulator to the control volume. If the accumulator exceeds
the control volume then a pulse is output and the accumulator is reduced
by the volume represented by the pulse. You can use the pulse output to
drive an external totalizer, odorizer, gas sampler, or similar device.
1.9.14 Nominations
Nominations allow you to configure the EFM to allocate precise
amounts of gas flow (called nomination values) during specific time
periods, called nomination periods. When the nomination value is
reached, the system performs an action (such as opening or closing a
valve). Prior to reaching the nomination value, the application compares
the volume/energy to a configured alarm level and generates an alarm
when the volume/energy meets or exceeds that alarm level.
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ControlWave EFM Instruction Manual
Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave
EFM, considerations for installation, and instructions for setting
switches and jumpers on the CPU, SCM, and ECOM modules.
In This Chapter
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 Site Considerations..........................................................................2-1 2.1.1 Class I, Div 2 Installation Considerations .............................2-2 Installation Overview........................................................................2-5 Unpacking Components ..................................................................2-6 Mounting the EFM Housing .............................................................2-7 2.4.1 Grounding the Housing ......................................................2-13 2.4.2 Connecting to the Multi-Variable Transducer (MVT)..........2-13 2.4.3 Process Pipeline Connection (Meter Runs without Cathodic
Protection) ........................................................................2-15 2.4.4 Process Pipeline Connection (Meter Runs with Cathodic
Protection) ........................................................................2-15 System Controller Module (SCM) ..................................................2-17 2.5.1 General Information about the SCM ..................................2-17 2.5.2 SCM Installation Overview .................................................2-19 2.5.3 Setting Jumpers on the SCM .............................................2-19 2.5.4 Setting Mode Switch SW1 on the SCM..............................2-19 2.5.5 General Wiring Guidelines .................................................2-20 2.5.6 Wiring a Bulk DC Power Supply to the SCM .....................2-21 Using a Solar Panel and Lead Acid Battery to Power the EFM ....2-22 2.6.1 Mounting the Solar Panel ...................................................2-22 2.6.2 Installing the Lead Acid Battery and Solar Panel Harness 2-24 Power Distribution Board (Optional) ..............................................2-26 21V Power Supply (Optional) ........................................................2-28 CPU Module ..................................................................................2-29 2.9.1 Setting Jumpers on the CPU Module .................................2-30 2.9.2 Setting DIP Switches on the CPU Module .........................2-31 2.9.3 Connections to RS-232 Port(s) on CPU or ECOM ............2-34 2.9.4 Connections to RS-485 Port(s) on CPU or ECOM ............2-39 2.9.5 Connections to Ethernet Port on the CPU Module ............2-42 Expanded Communications Module (ECOM) ...............................2-44 2.10.1 RS-232 Ports ......................................................................2-45 2.10.2 RS-485 Ports ......................................................................2-45 2.10.3 Modem Port (Type 1 ECOM only) ......................................2-46 Bezels ............................................................................................2-49 Case Mounted Radio/Modem ........................................................2-50 Optional Display/Keypads..............................................................2-50 2.1 Site Considerations
When choosing an installation site, check all clearances. Ensure that the
ControlWave EFM front cover (hinged on the left side) can be opened
for wiring and service and that the LCD/keypad is visible and accessible
to the on-site operator.
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ControlWave EFM Instruction Manual
Caution
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:


Specifications
for Temperature,
Humidity and
Vibration
Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
See document 1660DS-5i available on our website for detailed
technical specifications for temperature, humidity, and vibration for
the ControlWave EFM. This document is available on our website at
www.emersonprocess.com/remote.
 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.
Prolonged operation under extreme conditions could also result in
failure of the unit.
 Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave EFM is not
exposed to a level of vibration that exceeds that provided in the
technical specifications.
2.1.1 Class I, Div 2 Installation Considerations
Underwriters Laboratories (UL) lists the ControlWave EFM as nonincendive and suitable only for use in Class I, Division 2, Group C, and
D hazardous locations and non-hazardous locations. Read this chapter
and Appendix A carefully before you install a ControlWave EFM in a
hazardous location.
Perform all power and I/O wiring for unrated circuits in accordance
with Class I, Division 2 wiring methods as defined in Article 501-4 (b)
of the National Electrical Code, NFPA 70 (for installations within the
United States) or as specified in Section 18-152 of the Canadian
Electrical Code (for installation in Canada).
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave EFM is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not connect or disconnect equipment unless the power is switched
off and the area is known to be non-hazardous.
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ControlWave EFM Instruction Manual
Figure 2-1. 4-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with
D-Type Local Port)
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Installation
2-3
ControlWave EFM Instruction Manual
Figure 2-2. 8-Slot ControlWave EFM (Internal View) Component Identification Diagram (Shown with
Circular Local Port)
2-4
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ControlWave EFM Instruction Manual
2.2 Installation Overview
Installing a ControlWave EFM involves several general steps:
1.
Unpack, mount and ground the unit. (See Section 2.3 and Section
2.4.)
2.
Remove the System Controller Module (SCM) and configure
jumpers and mode switch as needed, then re-install it in chassis slot
1. (See Section 2.5.)
3.
Remove the CPU, enable the backup battery jumper and set
switches as needed then re-install it in chassis slot 2. (See Section
2.9.)
4.
Configure/connect the communication port to a PC or other
devices. (See Section 2.9.3 to Section 2.10.3.
5.
Install I/O wiring to each I/O module, connect a cable to a Bristol
3808 transmitter (if required). (See Chapter 3).
6.
Install the bezels to protect the I/O modules (see Section 2.11.)
7.
If required, install the RTD probe (see Section 3.7.)
8.
Install the rechargeable lead acid battery and solar panel (if
provided). (See Section 2.6.)
9.
Connect DC power wiring and apply power. (See Section 2.5.6.)
10. Install PC-based software (ControlWave Designer and/or
OpenBSI/TechView)
11. Establish communications
12. Create an application-specific control strategy (ControlWave
project).
13. Create application-specific web pages (optional)
14. Add the ControlWave EFM to an OpenBSI network
15. Download the application-specific ControlWave project into the
ControlWave EFM.
Notes:


Revised Dec-2013
If you purchased the ControlWave EFM with the standard
application already loaded, you do not need to create an application,
or web pages, and the application is already downloaded for you.
ControlWave Designer would only be necessary if you also
purchased application source code and wanted to edit it.
Steps 10 through 15 require that you install and use ControlWave
Designer software on your PC. This manual focuses on hardware
installation and preparation. Software installation and configuration
is beyond the scope of this manual.
Installation
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ControlWave EFM Instruction Manual
2.3 Unpacking Components
Packaging
The ControlWave EFM ships from the factory fully assembled with all
components installed except for the unit’s solar panel and battery (if
provided); these items ship separately.
If you ever need to re-install modules into the housing, follow these
guidelines:
Notes:




Do not install modules in the housing until you mount and ground
the housing at the designated installation site.
The SCM module must reside in slot #1 of the housing.
The CPU module must reside in slot #2 of the housing.
The first ECOM module (if you have one) must reside in slot #3 of
the housing (the first I/O slot); a second ECOM module (if you have
one) must reside in slot #4 of the housing (the second I/O slot).
Housing The housing (or chassis) for the ControlWave EFM is an open-faced
gold irridite coated aluminum assembly. The eight slot housing has six
I/O slots; the four slot housing has two I/O slots. You can substitute one
or two expansion communication modules for I/O modules in the first
two I/O slots.
Keyed cutouts in the housing’s rear wall permit wall or panel mounting.
The housing is mounted to the fabricated panel on the inner rear wall of
the enclosure and has the following components:




2-6
Built-in guides on the top and bottom of the housing permit easy
installation and removal of modules
Built-in ground lug (on bottom of unit)
Backplane provides seating and electrical interface to all modules.
Internal mounting brackets support the various system components
in the enclosure such as the battery and ControlWave EFM base
assembly. The battery and EFM base assembly mount to the
fabrication panel which secures to the inner rear wall of the
enclosure. If you have a radio/modem it mounts using the
radio/modem mounting bracket beneath the battery mounting
bracket on units with a 4-slot chassis.
Installation
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ControlWave EFM Instruction Manual
Figure 2-3. 8/4-Slot ControlWave EFM Housing - The 4-Slot Chassis is shown with ECOMs in Slots 3
& 4)
2.4 Mounting the EFM Housing

Revised Dec-2013
You must position the ControlWave EFM vertically with the
transducer (MVT) at its base. Make sure clearances are adequate so
that you can open the door, and ensure the front of the assembly is
visible and accessible for service, installation, and for operator
access to the LCD display/keypad.
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ControlWave EFM Instruction Manual





You can mount the unit to a wall, or to a vertical 2 inch pipe
clamped at the rear of the unit with two clamps and four bolts. You
must anchor the pipe in cement deep enough to conform to local
building codes associated with frost considerations.
If your unit requires a solar panel, make sure there is sufficient
clearance. You can mount the solar panel to the same 2” pipe that
secures the unit.
You mount the MVT to a process manifold which then mounts to
the main (meter run) directly or via two pipes. (See Figure 2-9,
Figure 2-10, and Figure 2-11).
Only connect power wiring after the unit is mounted and properly
grounded.
I/O, power, RTD, antenna and communication port cabling enters
the bottom of the unit through conduit or special function fittings.
(1)
1” NPT Conduit Hub
(3)
(5)
(7)
RTD Cable Assembly or Sealing Plug
5” Liquid Tight Conduit Fitting or Plug
Solderless Ground Lug
(2) Local Port D-Type Jack Male D-Type Jack or
Circular Female Jack
(4) Battery Ventilation Assembly
(6) Ant. Cable Fitting, Polyphaser,
(8) Multivariable Transducer
Figure 2-4. ControlWave EFM Bottom View
2-8
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ControlWave EFM Instruction Manual
Figure 2-5. Side View of ControlWave EFM Mounted to a 2” Pipe
Revised Dec-2013
Installation
2-9
ControlWave EFM Instruction Manual
Figure 2-6. 4-Slot ControlWave EFM
2-10
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ControlWave EFM Instruction Manual
Figure 2-7. 8-Slot ControlWave EFM - Base Chassis Assembly Dimensions
Revised Dec-2013
Installation
2-11
ControlWave EFM Instruction Manual
Figure 2-8. ControlWave EFM NEMA 3X Enclosure Dimensions
2-12
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ControlWave EFM Instruction Manual
2.4.1 Grounding the Housing
The ControlWave EFM enclosure includes a ground lug. Once you have
installed the unit, run a ground wire (#4 AWG max wire size) between
the ground lug (see Figure 2-4) and a known good earth ground. As an
added precaution, run a #14 AWG wire from SCM power connector
TB1-3 (chassis ground) to the same known good earth ground. For more
information on grounding see the ControlWave Grounding Supplement
(S1400CW):
Additional grounding guidelines include:




Use stranded copper wire (#4 AWG) to earth ground, and keep the
length as short as possible.
Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
Using a high-wattage soldering iron, tin the wire ends with solder
before you insert them into the chassis ground lug.
Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.
2.4.2 Connecting to the Multi-Variable Transducer (MVT)
The ControlWave EFM’s multivariable transducer (MVT) secures to the
bottom of the enclosure. The MVT pressure assembly connects to the
process manifold either directly or by tubing. Within the body of the
transducer, metal diaphragms are exposed to the gas. Solid-state strain
gauge sensors in the neck of the transducer measure the pressure applied
to the diaphragms and produce proportional electrical signals.
The neck of the transducer extends into the bottom of the enclosure,
with the body of the transducer outside the enclosure. The MVT cable
connector is factory mated with System Controller module connector
P2.
The MVT provides connection ports on the process flange as the
standard arrangement. Optional manifold blocks may also be specified.
Figure 2-9 details MVT process flange and optional manifold block
connector mounting dimensions.
Standard Process Flange for MVT – Two process flanges containing
the connection ports are assembled to the transmitter. Port designations
(L and H) are stamped on the body of the flanges. Ports accept ¼-18
NPT pipe connections to 2-1/8 in. centers for connection to orifice taps
or a standard three-valve manifold. These process flange connections
are illustrated at the top of Figure 2-9.
Revised Dec-2013
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ControlWave EFM Instruction Manual
Four bolts and nuts hold the two process flange assemblies in place.
When you remove the bolts, you can reposition the flanges so that the
connections can emanate from the front, rear or bottom of the
transducer. Take care not to damage the sensor module assembly during
this procedure. Once you position the flange, tighten the bolts in an
alternating sequence to about 20-30 foot-pounds of torque.
Optional Process Manifold Blocks – Process manifold blocks may be
installed on the transducers to permit the use of connector assemblies
having different connection centers. The manifold blocks, which are
oval in appearance, mate with the transmitter’s process flange. The
blocks may be installed in several positions to achieve different
connection centers as shown in Figure 2-9.
Figure 2-9. Process Flange and Optional Manifold Block Connectors
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ControlWave EFM Instruction Manual
2.4.3 Process Pipeline Connection (Meter Runs without Cathodic
Protection)
You can mount the ControlWave EFM directly on the pipeline or
remotely on a vertical stand-alone two-inch pipe or on a wall. The Earth
ground cable must run between the EFM’s ground lug and Earth ground
(rod or bed) even though the ControlWave EFM’s multivariable
transducer (MVT) may be grounded to the pipeline. If any pressure
transmitters or pulse transducers are remotely mounted, connect their
chassis grounds to the pipeline or Earth ground.
Note: For installation of the unit without cathodic protection, a direct
mount installation is similar to Figure 2-10 and a remote
installation is similar to Figure 2-11. The main difference is that
without cathodic protection, whether you’re mounting directly
or remotely, you do not use the transducer to manifold dielectric
isolation kit.
2.4.4 Process Pipeline Connection (Meter Runs with Cathodic
Protection)
You can mount the ControlWave EFM directly on the pipeline (using a
manifold block) or remotely on a vertical stand-alone two-inch pipe or
on a wall.
2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.
Transducer to Manifold
Dielectric Isolation Kit
Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Bottom Washers (4)
Mounting Bolts (4)
AWG 4 Ground Wire
Ground Rod or System
Figure 2-10. ControlWave EFM Direct Mount Installation with Cathodic Protection
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ControlWave EFM Instruction Manual
Transducer to Manifold
Dielectric Isolation Kit
Multivariable
Transducer
(MVT)
Dielectric Gasket
& Flange Seals (2)
AWG 4 Ground Wire
Valve Block
Manifold
Top Washers (4)
Dielectric Bolt Sleeves (4)
Isolating
Fittings
Bottom Washers (4)
Mounting Bolts (4)
2” Pipe-mounting Package
Note: Mounting Pipe does not
contact the Main Pipeline.
Ground Rod or System
Clamp(s)
Figure 2-11. ControlWave EFM Remote Installation with Cathodic Protection
Dielectric isolators are available and are always recommended as an
added measure in isolating the ControlWave EFM from the pipeline
even though the enclosure does provide some galvanic isolation from
the pipeline and should not be affected by the cathodic protection or
other EMF on the pipeline.
It is recommended that isolation fitting always be used in remotely
mounted meter systems.
Install isolation fittings or gaskets between the following connections:

All conductive tubing that runs between the pipeline and mounting
valve manifold and/or the unit’s multivariable transducer (MVT).
 All conductive connections or tubing runs between the ControlWave
EFM and a turbine meter, pulse transducer, or any other I/O device
that is mounted on the pipeline.
 Any temperature transducer, pressure transmitter, etc. and their
mount/interface to the pipeline.
In remote installations, the ground conductor connects between the
ControlWave EFM’s chassis ground lug and a known earth ground.
Connect the cases of temperature transducers, pressure transmitters, etc.
to the known good earth ground. If the mounting 2-inch pipe (when
used) is in continuity with the pipeline you must electrically isolate it
2-16
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ControlWave EFM Instruction Manual
from the EFM. Use a strong heat-shrink material such as RAYCHEM
WCSM 68/22 EU 3140. This black tubing easily slips over the 2-inch
pipe and then after uniform heating (with a rosebud torch) it electrically
insulates and increases the strength of the pipe stand. See F1670SS-0a
for information on PGI direct mount systems and manifolds.
2.5 System Controller Module (SCM)
Before we actually configure the SCM and install it in the housing,
we’re going to discuss some general information about how it works.
2.5.1 General Information about the SCM
DC power from a bulk DC supply (nominally +6 Vdc or +12 Vdc)
connects to the System Controller Module (SCM) on connector TB1.
The SCM converts, regulates, and filters the power to provide +3.3 Vdc
to modules in the backplane.
The SCM plugs into slot #1 (first slot from the left) on the ControlWave
EFM’s backplane using connector P1, a 44-pin female non-keyed
header (see Figure 2-12).
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ControlWave EFM Instruction Manual
WATCHDOG LED
JP5, JP6, JP7, JP8 & JP9
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System
(Red)
CR27
IDLE LED
(Red)
CR26
CR25
CR24
Staus LEDs
(Red)
1
JP6
JP7
1
1
JP5
JP8
1
JP9
1
SW1 = Mode Switch
J2
Display Intf.
Connector
2
J2
RJ-45
TB1
Input Power
Connector
1A
P1
TB2
RTD Interface
Connector
P2
MVT Interface
Connector
(+4.5/4.9Vdc to +16.0Vdc for +6V supply)
TB1-1 +VIN (+9.6/10.3Vdc to +16.0Vdc for +12V supply)
TB1-2 -VIN (Supply Ground)
TB1-3 Chassis Ground (CHASSIS)
JP1 - Factory Configured
(Not Shown)
JP7 - 1.2V Reference Source Current Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System
JP5 - Power Fail Trip Point Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System
JP8 - Supply Shutdown Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System
JP6 - Supply Shutdown Trip Point Selection
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System
JP9- Power Fail Trip Point Hysterisis
1-to-2 Installed = 12V Bulk System
2-to-3 Installed = 6V Bulk System
Figure 2-12. System Controller Module Component Identification Diagram
Another connector (TB2-future) provides an RTD connection, and an
RJ-45 connector provides the interface to the display/keypad.
Two red LEDs on the SCM’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. If the LED is off, it
indicates the CPU has no free time and may be overloading.
Six additional LEDs provide system status codes (see Chapter 5).
Board Fuse
2-18
The SCM is fused to protect the entire system using a 5x20mm slow
blow fuse F1 rated at 1 Amp.
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ControlWave EFM Instruction Manual
2.5.2 SCM Installation Overview
There are several steps you need to follow when you install the SCM.
1. Identify the carton holding the SCM and remove it from that carton.
See Section 2.3.
2. Set jumpers on the SCM based on whether your external DC bulk
power supply provides +12V or +6V. See Section 2.5.3.
3. If your SCM includes a mode switch (SW1) set it according to
Section 2.5.4.
4. Slide the SCM into slot #1 of the housing.
5. Unplug terminal block connector TB1 from the SCM and wire it to
an external bulk DC power supply. See Section 2.5.6.
6. If you want to use the RTD connector TB2, unplug it from the SCM
and wire it to an RTD according to instructions in Section 3.7.
7. After you configure and install the CPU module in slot #2 re-connect
terminal blocks to their connectors to apply power to the unit.
2.5.3 Setting Jumpers on the SCM
The SCM has five jumpers (JP5, JP6, JP7, JP8, JP9) which you set
based on whether your bulk DC power supply will provide +12V or
+6V. See Figure 2-12 to locate the jumpers on your version of the
SCM.
 JP5, JP6, JP7, JP8 and JP9: Three-position bulk power system
selection Jumper:
o 1-to-2 Installed = Choose this to select +12V Bulk System
o 2-to-3 Installed = Choose this to select +6V Bulk System
2.5.4 Setting Mode Switch SW1 on the SCM
The SCM has a DIP switch that controls whether the SCM operates in
Local Mode or Recovery Mode.
Local Mode is the normal operating mode for the ControlWave EFM,
and is the factory default. We recommend you use the factory default
unless you have a reason to use Recovery Mode.
Only use Recovery Mode during system firmware upgrades or core
updumps. See Chapter 5 for more information on these subjects.
Table 2-1 lists the SW1 settings:
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ControlWave EFM Instruction Manual
Table 2-1. SCM Switch SW1
Switch position
Mode
Both switches set to right (Open) or
both switches set to left (Closed)
Activates Recovery mode, used for
firmware upgrades or core updumps.
Upper switch (SW-1) set to right
Activates Local mode, used for
(Open) and lower switch (SW-2) set to normal operation. (This is the factory
left (Closed)
default)
Note: Only the SCM SW1 switch settings listed in the table have been
tested.
2.5.5 General Wiring Guidelines




2-20
ControlWave EFMs use compression-type terminals that
accommodate up to #14 AWG wire.
When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to 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 wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.
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ControlWave EFM Instruction Manual
2.5.6 Wiring a Bulk DC Power Supply to the SCM
At this time you can also connect power 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 to
the SCM until after you install, wire, and configure the CPU module.
Caution
Follow the instructions in Section 2.5.5 General Wiring Guidelines when
wiring connections.
You can connect one bulk DC power supply (nominally either +12 Vdc
or +6 Vdc) to the SCM using connector TB1.
Use the following formula to determine the maximum current required:
Bulk + 6/12 Vdc Supply Current = CPU + Sum of all ECOM modules and I/O modules, optional boards
and optional case-mounted modem/radio
Notes:




This summation accommodates steady state current draw.
Table 2-2 provides detailed steady state power current requirements
for each ControlWave EFM base assembly module. Current
consumption in this table is based on the standard EFM application
(ControlWave project).
In the case of a case-mounted modem or radio, the unit’s
manufacturer
Power requirements for the optional digital to relay I/O board, 21V
power supply board, and the battery charger power manager board
are provided in the ControlWave EFM product data sheet.
Refer to Table 2-2 for ControlWave EFM bulk power requirements.
Table 2-2. Bulk Power Requirements
Bulk 12 Vdc
Power Supply
Bulk 6 Vdc
Power Supply
CPU + SCM and backplane
8.6 mA
14 mA
Non-isolated AI/AO Module
2.8 mA + (47.2 mA – VEXT)
5.6 mA + (47.2 mA – VEXT)
Non-isolated DI/O Module
12 mA
24 mA
Non-isolated HSC Module
5 mA
10 mA
16.67 mA + (24.3 mA – VEXT)
34 mA + (24.3 mA – VEXT)
ECOM without modem/radio
22 mA
45 mA
ECOM with MultiTech modem
56 mA
112 mA
ECOM with MDS radio
277 mA
555 mA
ECOM with modem & MDS radio
311 mA
622 mA
ECOM with FreeWave radio
272 mA
545 mA
ECOM with modem and FreeWave
radio
306 mA
612 mA
Component
Non-isolated Mixed I/O module
(with optional AO board)
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ControlWave EFM Instruction Manual
Terminal Block Unplug removable connector TB1 from the SCM and wire DC power to
Connector TB1 the connector. We recommend you do not plug the connector back into
the SCM until the CPU module is already installed in the housing.
TB1 provides three input connections for bulk DC power:



TB1-1: (+VIN) (+4.5V/4.9V to +16V dc for +6V supply)
(+9.6/10.3V to +16V dc for +12V supply)
TB1-2 = (-VIN) (Supply Ground)
TB1-3 = Chassis Ground - CHASSIS ( )
Figure 2-13 shows the typical wiring at the SCM’s TB1 block.
Figure 2-13. SCM TB1 Wiring
Note: As an added precaution, we recommend that you run a #14
AWG wire from the TB1-3 power connection (Ground) to the
same known good earth ground used for the base housing.
2.6 Using a Solar Panel and Lead Acid Battery to Power the EFM
Instead of an external bulk DC power supply, you can use a solar panel
and rechargeable lead acid battery combination to power the EFM.
You can order this option with a 30W/40W solar panel with a built-in
regulator and a 12V, 33AH lead acid battery.
2.6.1 Mounting the Solar Panel
You can mount the solar panel to a 2” to 2-3/8” pipe using muffler
(pipe) clamps. You secure the pipe clamps using four ¼-20 nuts and
washers. See Figure 2-14.
Allow sufficient clearance so that you can swivel the solar panel for
optimum alignment with the sun, and so you can adjust the tilt angle for
maximum performance to accommodate the latitude of the installation
site. Solar panel wires enter the unit through a liquid tight conduit fitting
on the bottom of the enclosure.
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ControlWave EFM Instruction Manual
A
A
B
B
D
C
E
Note 2: Item D slots
accommodate Tilt
Angle Adjustment.
A
A
NOTE 1: To Attach item C to item D:
Slide two bolts (A) through the top and bottom
Solar Panel (Centered) Channel Holes. Affix item
C to item D via 2 sets of item A hardware as
follows: Flat Washer, Lock Washer & Hex Nut
(Max. Torque = 120 Inch-Pounds).
A
B
A
E
C
B
D
Adjustable
Tilt Angle
A
E
Vertical
Pole
A - 6 places consists of
the following hardware:
A
A
D
A
B
5/16-18 x .75 Hex Hd. Bolt
5/16 Flat Washer
5/16 Spring Lock Washer
5/16-18 Hex Nut
B - 2 places:
A
C
2-3/8 U-Clamp Assembly
C - Adjustable Angle Bracket
(Attaches to Solar Panel)
D - Pole Mounting Bracket
E - 30 or 40 Watt Solar Panel
Figure 2-14. 30/40 Watt Solar Panel Mounting Diagram
Swivel and Tilt You must swivel the solar panel for optimum alignment with the sun. In
Angle the northern hemisphere, face the panel due south (not magnetic south).
In the southern hemisphere, face the panel due north (not magnetic
north).
30/40 watt solar panel systems have adjustable tilt angles. Adjust the tilt
angle for maximum performance to accommodate the latitude of your
installation site. Table 2-3 shows the angle (from horizontal) at which
you should install the solar panel to maximize annual energy output. At
most latitudes, performance can be improved by less of an angle during
the summer and more of an angle during winter.
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ControlWave EFM Instruction Manual
Table 2-3. Solar Panel Tilt Angle
Latitude
0-4°
Tilt Angle
10° from Horizontal
5-20°
Add 5° to the Local Latitude
21-45°
Add 10° to the Local Latitude
46-65°
Add 15° to the Local Latitude
66-75°
80° from Horizontal
Connecting the Internally, you connect the solar panel wires directly to the rechargeable
Solar Panel to lead acid battery:
the Lead Acid
PWR (red wire) terminal
Battery
GND (black wire) terminal
See Section 2.6.2 for more information on these connections.
2.6.2 Installing the Lead Acid Battery and Solar Panel Harness
Remove the rechargeable sealed lead-acid battery from its shipping
carton and install it on its mounting bracket within the enclosure as
illustrated in Figure 2-15.
1. Remove connector TB1 from the system controller module (SCM)
and remove the battery/power harness from the battery
charger/power manager board.
2. Remove the lead-acid battery from its shipping carton.
3. Install the lead-acid battery (on end) as illustrated in Figure 2-15.
Note: Before you install it, make sure the lead-acid battery is fully
charged.
4. Route the solar panel power wiring harness into the enclosure
through the solar power conduit fitting (see Item 5 of Figure 2-4).
5. Connect the solar panel harness to the internal battery (red =
positive & black = negative).
6. Secure the battery using the battery clamp.
7. When you are ready to apply power, connect the battery power
harness to either the power distribution board (if present) or to TB1
on the SCM.
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ControlWave EFM Instruction Manual
Figure 2-15. Enclosure with Sealed Lead-acid Battery Installed
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ControlWave EFM Instruction Manual
2.7 Power Distribution Board (Optional)
If your ControlWave EFM includes any of the following optional
components, it also requires the power distribution board.
 21V Power Supply Board for external transmitters
 Digital to Relay I/O Board
 Case-mounted radio or modem
The power distribution board, as well as the 21V power supply board
and the digital to relay I/O board mount inside the enclosure using a
Snap Track and dual PCB mounting bracket.
Figure 2-16. Power Distribution Board
Power distribution boards include six terminal block connectors:
TB1
Primary Power Input: (three-conductor) (from user supplied bulk
power source)
 TB1-1 = Power+ (Pos. input)
 TB1-2 = Power– (Neg. input)
 TB1-3 = Chassis (GND)
TB2 - Main Power Output 1: (two-conductor) (to SCM Power
Connector TB1)
 TB2-1 = PWR1+ to TB1-1 on SCM (+VIN)
 TB2-2 = PWR1– to TB1-2 on SCM (–VIN)
TB3 - Main Power Output 2: (two-conductor) (to 21V PS Board
Connector TB1)
 TB3-1 = PWR2+ to TB1-1 on 21VPS (+VIN)
 TB3-2 = PWR2– to TB1-2 on 21VPS (GND)
TB4 - Fused Power Output 1: (two-conductor) (to Digital to Relay I/O
Board Connector J1)

2-26
TB4-1 = FPWR1+ to J1-10 on D-to-R I/O Bd. (PWR+)
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ControlWave EFM Instruction Manual
 TB4-2 = FPWR1– to J1-9 on D-to-R I/O Bd. (PWR GND)
TB5 - Fused Power Output 2: (two-conductor) (to External
Modem/Radio Pwr. Connector)
 TB5-1 = FPWR2+ to Radio/Modem Power+
 TB5-2 = FPWR2– to Radio/Modem Power– (PWR GND)
TB6 - Fused Power Output 3: (two-conductor) (optional use - similar
to TB5)


TB6-1 = FPWR3+ to Radio/Modem Power+
TB6-2 = FPWR3– to Radio/Modem Power– (PWR GND)
Note: Fuse F1 is rated at 1.5A and protects the solar panel regulator
circuitry. Fuse F3 is rated at .5A and protects fused power output
1. F1 and F3 are provided for Class I, Div. 1 hazardous location
use only, which does not apply to the ControlWave EFM.
Figure 2-17. Power Distribution Board and Other Options - Snap Track Mounting
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ControlWave EFM Instruction Manual
2.8 21V Power Supply (Optional)
The 21V power supply is typically used to provide power to
temperature and pressure transmitters (such as the Bristol 3508) that
require higher than +12V but lower than +21.4V (± .8V) to operate.
The 21V power supply has two terminal blocks that accommodate
power connections between the EFM and the remote transmitters. TB1
is a three-position terminal block that provides input power from the
power distribution board (see Section 2.7). Four-position terminal block
(TB2) provides +21V power and ground to the remote transmitters. See
Table 2-4 and Figure 2-18 for details on these connections.
Figure 2-18. 21V Power Supply Board
Table 2-4 - 21V Power Supply Board Terminal Designations
2-28
21VPS
TB#
21VPS TB
Name
Connection to
Power Dist. Bd.
Connection to
XMTR
TB1-1
+12VIN
TB3-1
N/A
TB1-2
12VGND
TB3-2
N/A
TB1-3
CHASSISGND
N/A
N/A
TB2-1
+21V
N/A
XMTR1+
TB2-2
21VGND
N/A
XMTR1-
TB2-3
+21V
N/A
XMTR2+
TB2-4
21VGND
N/A
XMTR2-
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ControlWave EFM Instruction Manual
2.9 CPU Module
The CPU module, which controls the ControlWave EFM and handles
memory and communication functions, can only be installed in Slot #2
of the 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.
Identify the carton holding the CPU module and remove it from that
carton. The CPU module has two basic configurations, each of which
have on-board communications components:


CPU with two RS-232 serial ports, and one RS-485 serial port (see
Figure 2-19)
CPU with two RS-232 serial ports, one RS-485 serial port, and one
Ethernet port (see Figure 2-20). The Ethernet option is only
available for 150 MHz CPU.
Figure 2-19. CPU Module with Three Serial Ports
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ControlWave EFM Instruction Manual
Figure 2-20. CPU Module with Three Serial Ports and One Ethernet Port
2.9.1 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 2-19 or Figure 2-20 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.


2-30
Jumper 4 (JP4) enables the Idle and Status LEDs on the SCM. It
comes enabled from the factory. (We recommend 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.)
Jumper 7 (JP7) enables the Communication Port Status LEDs on the
CPU module. It comes enabled from the factory. We recommend
you leave these LEDs enabled during initial installation and setup. If
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ControlWave EFM Instruction Manual
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.
Pins 1-2: Enables the CPU module’s backup battery.
Pins 2-3: Disables the CPU module’s backup battery (Factory
default)
Jumper 10 (JP10) specifies how COM1 is enabled.
Pins 1-2: Enables COM1 whenever DCD is active. (Factory
default)
Pins 2-3: Enables COM1 whenever you connect a cable to the
port.
Jumper 11 (JP11) when present, specifies how COM2 is enabled.
Pins 1-2: Enables COM2 whenever DTR is ON. (Factory
default)
Pins 2-3: Port is always enabled. This setting can be used to
control external radios that feature DTR sleep modes.
2.9.2 Setting DIP Switches on the CPU Module
Before you install the CPU module, you must determine the settings for
three banks of DIP switches. Refer to Figure 2-19 or Figure 2-20 for
the location of the DIP switch banks on each CPU module. Refer to
Tables 2-5 through 2-7 for DIP switch setting values.
Note: Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF.
Table 2-5. CPU Module Switch SW1
SW1 Setting
Revised Dec-2013
Function
Mode
1
N/A
Not currently used.
2
N/A
Not currently used.
3
Force
Recovery
Mode
Enables recovery mode. Values are:
ON (enables recovery mode)
OFF (disables recovery mode). – This is the factory
default.
4
N/A
Not currently used.
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ControlWave EFM Instruction Manual
Table 2-6. 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. Values are:
ON (Unlocks soft switches and flash files; factory
default).
OFF (Locks soft switches, configurations, and flash files)
3
Use/Ignore
Soft Switches
Controls the use of soft switches. Values are:
ON (Enable user-defined soft switches configured in flash
memory; factory default)
OFF (Disable soft switch configuration and use factory
defaults)
Note: Setting both switch 3 and switch 8 to OFF (closed)
sets all serial communication ports to 9600 bps
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.
4
Core Updump
Causes the ControlWave EFM to perform a core updump,
provided you have set the SCM mode switch to Recovery
mode. Values are:
ON (Disables core updump; factory default)
OFF (Core updump via SCM mode switch SW1)
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 4.7 or higher and
system PROM version 4.7 and higher). Values are:
ON (Enable remote download of system firmware; factory
default)
OFF (Disable remote download of system firmware)
7
N/A
Not currently used.
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.
All serial communication ports must be set at 9600
bps before WINDIAG can perform communication
tests.
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ControlWave EFM Instruction Manual
Notes:


Table 2-7 describes switch settings for the RS-485 port. You may
want to review Section 2.9.4 Connections to RS-485 Serial Port(s)
before you set these switches.
Table 2-7 applies to the following switches:
o SW3 on CPU Module – controls COM3
o SW1 on Type 1 ECOM Module – controls COM5/COM9
o
SW1 on Type 2 ECOM Module – controls COM6/COM10
o
SW2 on Type 2 ECOM Module – controls COM7/COM11
Table 2-7. RS-485 Configuration Switch
SW3 Setting
Function
Mode
1
TX+ to RX+ Loopback
ON (only for diagnostics or 2-wire)
2
TX- to RX- Loopback
ON (only for diagnostics or 2-wire)
3
100 Ohm RX+ Termination
ON (End nodes only)
4
100 Ohm RX- Termination
ON (End nodes only)
5
N/A
Not currently used
6
Slew Rate (ISO485 Only)
ON (Slow rate enabled)
OFF (Fast rate enabled)
Note: On CPU module, not currently used.
7
RX+ Bias (End Node)
ON (End nodes only)
8
RX- Bias (End Node)
ON (End nodes only)
After you configure the jumpers and DIP switches, slide the CPU
module into slot #2 (the second slot from the left) of the housing (see
Figure 2-6 or Figure 2-7).
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ControlWave EFM Instruction Manual
2.9.3 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 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. The ControlWave EFM
can support up to two expansion communication modules, for a total of
up to four additional RS-232 ports beyond those on the CPU module.
Expansion communication modules reside in slot #3 and slot #4.
RS-232 COM
Port Names and
Connectors
RS-232 COM ports are assigned names based on their location in the
ControlWave EFM.

The CPU module RS-232 ports are COM1 and COM2.
Table 2-8. RS-232 Connectors on CPU
Connector
Name
# Pins
Function
Notes
J3
COM1
9-pin
9-pin male D-sub (RS-232).
Also supports circular 3-pin
female connector (local port)
at the bottom of the enclosure.
Figure 2-21 & Table 2-8
J4
COM2
9-pin


9-pin male D-sub (RS-232)
See Figure 2-19, Figure 2-20,
See Figure 2-19, Figure 2-20
Figure 2-21 & Table 2-8
If you have an ECOM module with one RS-232 port, this is COM4
if the module is in slot #3 or COM8 if the module is in slot #4.
If you have an ECOM module with two RS-232 ports, those ports
are COM4 and COM5, respectively, if the ECOM module is in slot
#3, or COM8 and COM9, respectively, if the ECOM module is in
slot #4.
Table 2-9. RS-232 Connectors on Expansion Communications Modules
Connector
J4
Name
#
Pins
Function
Notes
COM4 (when in slot 3)
9-pin
9-pin male D-sub (RS232)
See Figure 2-21, Figure 2-31,
Figure 2-32 & Table 2-10
9-pin
9-pin male D-sub (RS232)
See Figure 2-21, Figure 2-32 &
Table 2-10
COM8 (when in slot 4)
J5
COM5 (when in slot 3)
COM9 (when in slot 4)
Only available on ECOM Type
2 models.
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ControlWave EFM Instruction Manual
RS-232 COM For the ControlWave EFM, half-duplex communications use Modbus or
Port Cables BSAP protocol, while full-duplex communications use point-to-point
protocol (PPP). RS-232 ports use a “null modem” cable (see Figure 222) to connect with other devices (such as a PC, a printer, another
ControlWave [except the CW_10/30/35]) when the ControlWave EFM
uses the full-duplex PPP protocol.
Note: You can configure the ControlWave EFM as either a master or
slave node on a Modbus or BSAP network.
Figure 2-21 illustrates the CPU module’s male 9-pin D-type connector.
Use the content provided in Table 2-8 to determine pin assignments for
the COM1 and COM2 ports and the expansion communication ports
COM4/5 and COM8/9.
Figure 2-21. Male DB9 9-Pin Connector
Table 2-10. RS-232 Port Connector Pin Assignment
Pin
RS-232
Signal
1
DCD
Data Carrier Detect Input
2
RXD
Receive Data Input
3
TXD
Transmit Data Output
4
DTR
Data Terminal Ready Output
5
GND
Signal/Power Ground
6
DSR
Data Set Ready Input
7
RTS
Request to Send Output
8
CTS
Clear to Send Input
9
RS-232 Description
N/A
Use the “null modem” cable for full-duplex (PPP protocol)
communications when connecting a ControlWave EFM to a PC. (See
top part of Figure 2-22.)
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ControlWave EFM Instruction Manual
Figure 2-22. Full-duplex and Half-duplex Cable
Use the half-duplex cable (shown in the bottom part of Figure 2-22)
when connecting the ControlWave EFM 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 2-23.
Figure 2-23. Full-duplex and Half-duplex Cable
When connecting the ControlWave EFM to an external (case-mounted)
modem or radio, use the cable shown in
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ControlWave EFM Instruction Manual
Figure 2-24. Communication Interface Cable for Connection to Case-Mounted (External) Radio or
Modem
When interfacing to the COM3 port of a ControlWave, or the COM5 or
COM6 port a ControlWaveEXP unit, use the cable presented in Figure
2-25 along with the cable shown in Figure 2-22 or Figure 2-23.
Figure 2-25. Full-duplex and Half-duplex Cable
If you use the local port circular connector see Figure 2-26, Figure 2-27
and Table 2-11.
Figure 2-26. PC Connected to ControlWave EFM via D-Type Local Port (use Null Modem Cable P/N
392843-01-3)
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ControlWave EFM Instruction Manual
Figure 2-27. PC Connected to ControlWave EFM via Circular Local Port (use Cable P/N 395402-018 [10 foot cable] or P/N 395402-02-6 [25 foot cable])
Table 2-11. RS-232 Port (COM1) Connector Pin Assignment (COM1 Connectors – Circular Local
Port & D-Type “C1” Connector on CPU)
COM1 Pin
RS-232
Signal
1
DCD
Data Carrier Detect
Input
Green
1
2
RXD
Receive Data Input
White
7
3
TXD
Transmit Data Output
Red
2
4
DTR
Data Terminal Ready
Output
Brown
4
5
GND
Signal/Power Ground
Black
6
6
DSR
Data Set Ready Input
7*
RTS
Request to Send
Output
8*
CTS
* RTS connected to CTS
RS-232 Cable
Guidelines
Wire
Color
Local Port
RS-232
Pin
Clear to Send Input
Observe the following guidelines when constructing RS-232
communication cables:

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RS-232 Description
Ensure that DCD is high to transmit (except when dialing a modem)
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ControlWave EFM Instruction Manual




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.
Note: Control DTR using the PORTCONTROL function block and
the _Pn_AUTO_DTR system variable in your ControlWave
project. If you turn DTR off through these mechanisms, the
port remains off, even though hardware is fully configured.



When port is set for half-duplex operation, CTS must go low after
RTS goes low.
All RS-232 comm ports support RTS, DTR, CTS, DCD, and DSR
control signals.
All RS-232 comm port I/O signals are protected by surge protectors.
2.9.4 Connections to RS-485 Serial Port(s) on CPU or ECOM
Modules
The RS-485 port supports local network communications to multiple
nodes up to 4000 feet away.
Your CPU module includes one RS-485 port.
If you require additional RS-485 ports, you can purchase an optional
expansion communication module that includes one or two RS-485
ports. The ControlWave EFM can support up to two expansion
communication modules, for a total of up to four additional RS-485
ports beyond the one on the CPU module. Expansion communication
modules reside in slot #3 and slot #4.
RS-485 COM
Port Names and
Connectors
RS-485 COM ports are assigned names based on their location in the
ControlWave EFM.


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.
Table 2-12 provides the connector assignments for CPU port COM3;
Table 2-13 shows the assignments for ECOM1 port COM5/9; and Table
2-14 shows assignments for ECOM2 ports COM6/10 and 7/11.
Revised Dec-2013
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ControlWave EFM Instruction Manual
Table 2-12. RS-485 Connectors on CPU
Connector
Name
# Pins
Function
Notes
J5
COM3
9-pin
9-pin male D-sub (RS-485)
See Figure 2-19 and Figure 2-
20.
Table 2-13. RS-485 Connectors on Type 1 Expansion Communications Modules
Connector
Name
# Pins
Function
Notes
J5
COM5 (when in slot 3)
9-pin
9-pin male D-sub
(RS-485)
See Figure 2-31 & Table 2-14
COM9 (when in slot 4)
Only available on ECOM Type
2 models.
Table 2-14. RS-485 Connectors on Type 2 Expansion Communications Modules
Connector
J6
Name
# Pins
Function
Notes
COM6 (when in slot 3)
9-pin
9-pin male D-sub
(RS-485)
See Figure 2-32 & Table 2-14
9-pin
9-pin male D-sub
(RS-485)
See Figure 2-32 & Table 2-14
COM10 (when in slot
4)
J7
COM7 (when in slot 3)
COM11 (when in slot
4)
RS-485 COM Figure 2-21 illustrates the CPU module’s male 9-pin D-type connector.
Port Cables Use the content provided in Table 2-15 to determine pin assignments for
the COM3 port on the CPU (CPU switch SW3), and COM5/9,
COM6/10, and COM7/11 expansion communication ports (ECOM
switches SW1 and SW2).
Table 2-15. RS-485 Port Connector Pin Assignment
Pin
RS-485 Signal
1
2-40
RS-485 Description
N/A
2
RXD–
Receive Data – Input
3
TXD–
Transmit Data – Output
4
TXD+
Transmit Data + Output
5
GND/
ISOGND
Ground/Isolated Ground
6
RXD+
Receive Data + Input
7
N/A
8
N/A
9
N/A
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ControlWave EFM Instruction Manual
Since the RS-485 port is intended for network communications, refer to
Table 2-16 for the appropriate connections for wiring the master, first
slave, and nth slave.
Essentially, the master and the first slave transmit and receive data on
opposite lines; all slaves (from the first to the nth) are paralleled (daisychained) across the same lines. Wire the master node to one end of the
RS-485 cable run using a 24-gauge paired conductor cable (such as a
Belden 9843).
Note: ControlWave EFMs support only half-duplex RS-485 networks.
Table 2-16. RS-485 Network Connections
From Master
To First Slave
To nth Slave
TXD+
RXD+
RXD+
TXD–
RXD–
RXD–
RXD+
TXD+
TXD+
RXD–
TXD–
TXD–
GND/ISOGND
GND/ISOGND
GND/ISOGND
ISOGND with isolated RS-485 ports only.
To ensure that the “Receive Data” lines are in a proper state during
inactive transmission periods, you must maintain certain bias voltage
levels at the master and most distant slave units (end nodes). These end
nodes also require the insertion of 100Ω terminating resistors to
properly balance the network.
You must also configure switches at each node to establish proper
network performance. Accomplish this by configuring switches listed so
that the 100Ω termination resistors and biasing networks are installed at
the end nodes and are removed at all other nodes on the network. You
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 2.9.2 Setting DIP Switches on
the CPU Modules for information on RS-485 termination and loopback
control switch settings.
Revised Dec-2013
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ControlWave EFM Instruction Manual
2.9.5 Connections to Ethernet Port on the CPU Module
Caution
The RJ45 Ethernet port is located on the CPU module (150 MHz version
only). The SCM also has one RJ45 port for the optional Display/Keypad.
Never connect Ethernet to the Display/Keypad port or damage to the SCM
will result.
ControlWave EFMs can support up to two Ethernet ports. These use a
10/100Base-T RJ-45 modular connector that provides a shielded
twisted pair interface to an Ethernet hub. Two LEDs per port provide
transmit and receive status indications:
Port assignments are:

Ethernet Port 1: CPU Bd. J6, 8-Pin RJ-45 - Shielded Twisted Pair
10/100Base-T
 Ethernet Port 2: CPU Bd. J5, 8-Pin RJ-45 - Shielded Twisted Pair
10/100Base-T
A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with
port 8 having the capability to link either to another hub or to an
Ethernet communications port). Both ends of the Ethernet twisted pair
cable are equipped with modular RJ-45 connectors.
1
8
Looking into
receptacle
Figure 2-28. RJ-45 Ethernet Connector
These cables have a one-to-one wiring configuration as shown in Figure
2-29. Table 2-17 provides the assignment and definitions of the 8-pin
10/100Base-T connectors.
Figure 2-29. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)
2-42
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ControlWave EFM Instruction Manual
Table 2-17. 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. 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 2-30).
Figure 2-30. Point-to-Point 10/100Base T Ethernet Cable
The maximum length of one segment (CPU to hub) is 100 meters (328
feet). The use of Category 5 shielded cable is recommended.
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ControlWave EFM Instruction Manual
2.10 Expanded Communications Module (ECOM)
ControlWave EFM 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.
Two Types of
ECOM Modules
There are two types of ECOM module:

Type 1 Expansion Communications Module (ECOM1) with one RS232 port, one RS-485 serial port, and an optional modem port (see
Figure 2-31)
 Type 2 Expansion Communications Module (ECOM2) with two
RS-232 serial ports and two RS-485 serial ports (see Figure 2-32)
Identify the carton holding the ECOM module(s) and remove the
module from that carton.
Figure 2-31. Type 1 ECOM with Two Serial Ports and a Modem
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ControlWave EFM Instruction Manual
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. Port 6/10
RS-485 Network
Configuration
Comm. Port 7/11
Isolation
Transformers
for
Isolated RS-485
CR4
T2
Comm. Port 7/11
RS-485
J7
O N
1 2 3 4 5 6 7 8
SW2
Comm. Port 7/11
RS-485 Network
Configuration
If In Slot #3 - Comm. Port Assignments = 4, 5, 6 & 7
If in Slot #4 - Comm. Port Assignments = 8, 9, 10 & 11
Figure 2-32. Type 2 ECOM with Two RS-232 and Two RS-485 Ports
Detailed Technical For detailed technical specifications, please see document
Specifications CWMICRO:COM available on our website
http://www.emersonprocess.com/remote/D301673X012.pdf.
2.10.1 RS-232 Ports
Type 1 ECOMs include one RS-232 port. Type 2 ECOMs include two
RS-232 ports. For information on connecting to these ports, including
cabling information, see Section 2.9.3.
2.10.2 RS-485 Ports
Type 1 ECOMs include one RS-485 port. Type 2 ECOMs include two
RS-485 ports. For information on connecting to these ports, including
cabling information, see Section 2.9.4.
Revised Dec-2013
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ControlWave EFM Instruction Manual
When connecting a ControlWave EFM to an external (case-mounted)
modem, use the cable configuration in Figure 2-33.
Figure 2-33. Full-duplex and Half-duplex Cable
Figure 2-34. ECOM Modem Installation
2.10.3 Modem Port (Type 1 ECOM only)
You can mount an optional 56Kb PSTN Hayes-type modem on a Type
1 ECOM (see Figure 2-34).
The ControlWave EFM then assigns the modem COM7 (if in slot #3) or
COM11 (if in slot #4).
You can configure the MultiTech model MT9234SMI modem module
for publicly switched telephone network (PSTN) operation. You can
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ControlWave EFM Instruction Manual
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. Configure a profile for the
modem using AT commands submitted using a terminal emulation
program (such as HyperTerminal). Users typically use AT commands
only when checking the modem’s active or stored profile or when
reconfiguring a modem (to turn auto answer on or off, etc.).
Prior to shipment from the factory, the MultiTech modems are preconfigured using the following steps:
1.
Connect pin Enable modem setup by setting jumper JP2 on the
ECOM to 2-3.
2.
Connect via HyperTerminal (Parameters = 9600, 8, N, 1, None)
to ECOM port C1 using the null modem cable (see Figure 2-22).
3.
Send Factory Default = AT&F0
4.
Disable Flow Control = AT&K0
5.
Set baud rate using AT Command: AT$SB9600, or whatever
baud rate you require.
6.
Write to Memory. = AT&W
7.
Disable setup mode. Park JP2 (no connection)
Note: You can reconfigure the modem using AT commands and a
terminal program (like HyperTerminal). Connect pins 2 and 3 of
JP2 with a suitcase jumper, and use a null modem cable (see
Figure 2-22) to connect the PC to the modem (COM4 or
COM8).
PSTN
Connections
Figure 2-35 shows a publicly switched telephone network (PSTN)
using a single master and three remote ControlWave EFMs (equivalent
to EFMs for this application) each equipped with a PSTN modem.
This application requires only one remote connection.
Use a cable with standard telephone connectors (RJ11s) on each end.
Plug one end of the cable into the RJ11 connector jack on the ECOM
and the end into a RJ11 wall jack. The telephone company provides the
necessary subscriber loops at its central system along with the phone
numbers for each destination.
Caution
Revised Dec-2013
Connect only one modem on each drop. If you attempt to parallel two or
more modems across a single drop, an impedance mismatch occurs,
adversely affecting the signal. Modems cannot provide reliable
communications under these conditions.
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ControlWave EFM Instruction Manual
Figure 2-35. PTSN Field Connections for ControlWave Micros (and EFMs)
Figure 2-36. 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:



2-48
Connections to party line service are subject to state tariffs.
Connections to telephone company-provided coin service (central
office implemented systems) are prohibited.
The equipment compliance information is summarized as follows:
o Complies with Part 68 FCC Rules.
o Contains device with FCC Registration Number: AU7-USA25814-M5-E
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ControlWave EFM Instruction Manual
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. The PSTN line connector
plugs into J1 on the modem. Notify your telephone company that the
jack (connector) required for your device is one of the following:
o USOC: RJ11C or
o USOC: RJ11W
Note: The jack provided on the Modem (J1) is a 6-pin TELCO RJ-
11. The connections to the modem are pin 3 PSTN-Tip, and
pin 4 PSTN-Ring.

After the telephone company has installed the above jack, connect
the modem to your equipment by inserting the appropriate
equipment interface RJ11 plug into the modem and wall connector.
2.11 Bezels
Bezels are blue plastic covers (see Figure 2-37) that protect an adjacent
pair of I/O modules and provide an easy way for you to route wiring.
The factory provides bezels with each order. Install bezels over I/O
modules whenever the ControlWave EFM is operational; remove the
bezels for maintenance procedures.
Bezels attach to the module covers of two adjacent I/O modules. Hooks
on the bezels (see Figure 2-37) attach to notches in the upper and lower
portions of the module covers. Align the hooks on the bezel with the
notches on the I/O module covers and slide the bezel down. To remove
the bezel, grasp its sides and gently squeeze them, and pull up and then
away from the I/O modules.
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ControlWave EFM Instruction Manual
Figure 2-37. Bezel Assembly
2.12 Case Mounted Radio/Modem
An alternative to using a Type 1 ECOM module with an integrated
modem/radio is to order a case-mounted modem/radio. In this
configuration, the ControlWave EFM ships from the factory with a user
selected radio or modem installed within the enclosure (beneath the
battery mounting bracket) or as a radio-ready unit, in other words, ready
for field installation of a factory-supplied radio. The installer must
ensure that the remote antenna (associated with a case mounted radio) is
properly installed and connected.


See the ControlWave Radio-Ready Installation Guide (D5138) for
information on installing factory-supplied radios in the field.
See the ControlWave PSTN Modem Installation Guide
(D301734X012) for information on installing the 9600 bps PSTN
modem.
2.13 Optional Display/Keypads
The ControlWave EFM supports two optional display/keypads:


2-50
A 2-button keypad (shown in the left of Figure 2-38)
A 25-button keypad (shown in the right Figure 2-38)
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ControlWave EFM Instruction Manual
Figure 2-38. Optional 2-Button and 25-Button Keypads
Both keypads use the same 4-line by 20-character LCD displays. You
connect the keypad to the ControlWave EFM 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 (J2) on the
SCM module 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.
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 EFM Instruction Manual
Chapter 3 – I/O Modules
This chapter discusses the placement and wiring for I/O modules for the
ControlWave EFM. 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 Module Placement ...........................................................................3-2 Wiring ...............................................................................................3-3 3.2.1 Local Termination .................................................................3-3 3.2.2 Shielding and Grounding ......................................................3-4 Non-isolated Digital Input/Output (DI/O) Module .............................3-5 Non-isolated Analog Input/Output & Analog Input Module ..............3-7 Non-isolated High Speed Counter (HSC) Input Module ................3-10 Non-isolated Mixed I/O (MI/O) Module ..........................................3-12 Resistance Temperature Device (RTD) Inputs on SCM ...............3-16 Digital to Relay I/O Board Option ..................................................3-18 Connections to a Bristol Model 3808 Transmitter .........................3-20 Installation Installing any I/O module in the ControlWave EFM involves the same
basic steps:
1. Remove the I/O module and associated I/O module cover from the
shipping carton. The cover snaps on or off to provide access to the
unit’s I/O connectors.
Notes:



I/O modules for the ControlWave EFM use local termination where
field wiring connects directly to the I/O module’s removable
terminal blocks.
You can use the ControlWave Loop Power Supply to provide
regulated and isolated 24Vdc field power for externally powered
non-isolated I/O. See PIP-ControlWaveLS.
Modules normally ship from the factory completely assembled.
2. When installing wiring in conjunction with the I/O modules, install
the field wiring between the I/O module’s removable terminal
blocks and field devices. (See Section 3.2 Wiring.)
3. Align the I/O module with its intended slot on the base housing and
slide the module into the housing. Make sure the module I/O module
cover snaps into the appropriate securing notches on the housing.
4. Plug the local cable assemblies into the appropriate I/O module
connectors
Revised Dec-2013
I/O Modules
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ControlWave EFM Instruction Manual
5. After installing and wiring two I/O modules into adjacent slots in
the housing, cover the modules with a protective bezel. The bezels
snap on and off for maintenance.
6. Using a PC running the ControlWave Designer and OpenBSI
software, configure the ControlWave EFM to accept the new I/O
modules and download the revised ControlWave project.
Note: This step is beyond the scope of this manual and is only
required if you are not using the base flow measurement
application which has I/O already defined. Refer to the
ControlWave Designer Programmer’s Handbook (D5125)
for further instructions.
Power down the ControlWave EFM before you install or remove any I/O
module. Shut down any processes the ControlWave EFM 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 EFM is
powered down.
Caution
Before any I/O modules can become operational, you must use
ControlWave Designer to configure and then download the application
(project). The exception to this is if the application is already configured
for you.
Do not install any modules in the housing until you have mounted and
grounded the housing at its designated installation site.
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:


Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)
3.1 Module Placement
You can place I/O modules in the housing:



4-slot housing: supports up to two I/O modules in slots 3 and 4.
8-slot housing: supports up to six I/O modules in slots 3 through 8.
Optionally you can install an expansion communication module in
slot 3, slot 4, or both, instead of an I/O module.
Note: Some modules have placement restrictions. Note these in the
individual descriptions.
3-2
I/O Modules
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ControlWave EFM Instruction Manual
Figure 3-1. ControlWave EFM Slot Assignments
3.2 Wiring
I/O modules support local termination where field wiring connects
directly to the module’s removable terminal blocks.
ControlWave EFM I/O modules use compression-type terminals that
accommodate up to #14 AWG wire. Consult with the field device
manufacturer for recommendations if using smaller wire sizes. 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. Slack makes the wires more
manageable and helps minimize mechanical strain on the terminal
blocks.
3.2.1 Local Termination
For I/O modules equipped with local terminal blocks, install the field
wiring between the I/O module’s removable terminal block connectors
and field devices (see Figure 3-1). Use AWG 14 or smaller wire
(consult with the field device manufacturer for recommendations).
Leave some slack and plan for wire routing, identification, and
maintenance. Route the bundled wires out through the bottom of the I/O
Revised Dec-2013
I/O Modules
3-3
ControlWave EFM Instruction Manual
module assembly between the terminal block and the terminal housing.
All I/O wiring should be routed in/out of the enclosure through the 1”
NPT conduit hub.
Figure 3-2. Module Wiring: Local Termination
3.2.2 Shielding and Grounding
Use twisted-pair, shielded and insulated cable for I/O signal wiring to
minimize signal errors caused by electromagnetic interference (EMI),
radio frequency interference (RFI), and transients. When using shielded
cable, ground all shields at only one point in the appropriate system.
This prevents circulating ground current loops that can cause signal
errors.
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I/O Modules
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ControlWave EFM Instruction Manual
3.3 Non-isolated Digital Input/Output (DI/O) Module
Non-isolated DI/O modules consist of a digital input/output PCB with
two 10-point terminal block assemblies for local 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. The DI/O
module connects with the backplane using a 36-pin gold-plated cardedge connector.
Non-isolated DI/O modules contain field interface circuitry for up to 12
digital inputs and four digital outputs.
Table 3-1. Non-Isolated DI/DO Module General Characteristics
Type
Digital
Inputs (DI)
Number
Supported
12
Characteristics
Each DI supports/ includes:
 Internally sourced DI operation for dry
contacts pulled internally to 3.3Vdc when
field input is open.
 Surge suppressor
 Signal conditioning
 Filter time of 15 ms
 Jumper to configure source current for either
2 mA or 60 uA
Digital
Outputs
(DO)
4
 Dedicated LED on module turns ON when
DI is ON.
Each DO supports/ includes:
 Open drain MOSFET provides 100mA at
30Vdc to an externally powered device.
 Surge suppressor
 Current sink to ground of DI/DO module
 Dedicated LED on module turns ON when
DO is ON.
Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.
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 3-2
details jumper settings.
Table 3-2. Jumper Assignments: Non-isolated DI/O Module
Jumper
Purpose
Description
W1-W12
Configures DI1 through DI12
(respectively)
Pins 1-2 installed = 2mA Source Current
Pins 2-3 installed = 60uA Source Current
Enables LEDs
Pins 1-2 installed = allows manual enabling of LEDs
W13
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I/O Modules
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ControlWave EFM Instruction Manual
Jumper
W14
Purpose
Description
Pins 2-3 installed = allows software enabling of LEDs
Programs Serial EEPROM
Reserved for factory use only
Wiring the Module Figure 3-3 shows the terminal block assignments for the locally
terminated DI/O module.
Figure 3-3. Non-isolated DI/O Module (Local 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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3.4 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.
AI/O modules consist of an AI/O PCB with two 10-point terminal block
assemblies for local termination, 12 configuration jumpers, and a cover
assembly. The AI/O module connects with the backplane using a 36-pin
gold-plated card-edge connector.
Table 3-3. Non-Isolated AI/O and AI Module General Characteristics
Type
Analog Inputs
(AI)
Number
Supported
6 on AI/O
Module
6 on AI
Module
Characteristics
Each AI supports/includes:
 Jumper to configure input for either 4–
20mA or 1–5 Vdc
 Signal conditioning that provides 2 Hz
low pass filter
 Transorb for surge suppression
Analog Outputs
(AO)
2 on AI/O
Module
None on AI
Module
 Analog to Digital converter
Each AO supports/includes:
 Jumper to configure output for either 4–
20mA or 1–5 Vdc
 maximum external load to the 4–20mA
output of either 250 ohms with an
external 11V power source or 650
ohms with an external 24V power
source.
 maximum external load current to the
1–5 Vdc output is 5 mA with an
external 11-30 V power source.
 AO operation requires an 11–30Vdc
power source connected to the VEXT
terminal of the AI/O module.
Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.
Configurations Each non-isolated AI/O module (general part number 396568-01-7)
consists of a PCB with six AIs, 2 AOs, and comes with a module
cover.
Each non-isolated AI module (general part number 396569-01-3)
consists of a PCB with six AIs and comes with a module cover.
Cable Shields Connect cable shields associated with AI wiring to the ControlWave
EFM’s housing ground. Multiple shield terminations require that you
supply a copper ground bus (up to a #4 AWG wire size) and connect it
Revised Dec-2013
I/O Modules
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ControlWave EFM Instruction Manual
to the housing’s ground lug.
This ground bus must accommodate a connection to a known good earth
ground (in lieu of a direct connection from the ground lug) and to all AI
cable shields. Shield wires should use an appropriate terminal lug.
Secure them to the copper bus using industry rugged hardware
(screw/bolt, lock washer, and nuts).
Setting Jumpers AI/O and AI modules have jumpers you can use to configure each of
the six AIs. You can individually configure AIs for 1–5 Vdc or 4–20
mA operation. See Table 3-4.
Table 3-4. Jumper Assignments: Non-isolated AI/O and AI Module
Jumper
Purpose
Description
JP1-JP6
Configures AI1 through AI6
(respectively)
Pins 1-2 installed = 4-20 mA AI
Pins 2-3 installed = 1-5 V AI
JP71
AO1 Field Output
Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5 V AO
JP81
AO2 Field Output
Pins 1-2 installed = 4-20 mA AO
Pins 2-3 installed = 1-5 V AO
JP91
AO1 Output Type
Pins 1-2 installed = 1-5 V AO
Pins 2-3 installed = 4-20 mA AO
JP101
AO2 Output Type
Pins 1-2 installed = 1-5 V AO
Pins 2-3 installed = 4-20 mA AO
Configures ISP Connector
Reserved for factory use only
JP1
W1
Programs Serial EEPROM
Reserved for factory use only
1 Configuration for JP7 and JP9 must match (that is, both 1-5 V or 4-20mA)
Configuration for JP8 and JP10 must match (that is, both 1-5 V or 4-20mA)
Wiring the Module Figure 3-4 shows field wiring assignments associated with the locally
terminated AI/O and AI modules.
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ControlWave EFM Instruction Manual
Figure 3-4. Non-isolated AI/O and AI Module Configuration (Local 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. 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 these modules.
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ControlWave EFM Instruction Manual
3.5 Non-isolated High Speed Counter (HSC) Input Module
Non-isolated High Speed Counter (HSC) Input modules provide up to
four inputs. You can individually configure HSC module inputs for
either a 10 KHz (high speed) or 300 Hz (low speed) input, and as a 16bit high speed counter
HSC modules consist of a HSC PCB with two 10-point terminal block
assemblies for local termination, 14 configuration jumpers, an LED
daughter board with four status LEDs (one for each point), and a cover
assembly. The HSC PCM connects with the backplane using a 36-pin
gold-plated card-edge connector.
Table 3-5. High Speed Counter Module General Characteristics
Type
High Speed
Counter Inputs
(HSC)
Number
Supported
4
Characteristics
Each HSC supports/includes:
 Jumper to configure point as either a
low speed input (300 Hz) or a high
speed input (10 KHz).
 Jumper to configure HSC current.
 Bandwidth limiting
 Surge suppression
 Field inputs can be driven by signals or
relay contacts.
 LED status indicator
Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.
Setting Jumpers HSC modules support up to four HSC inputs. Configure the HSC
jumpers (W1 through W14) according to Table 3-6.
Table 3-6. Jumper Assignments: Non-isolated HSC Module
Jumper
Purpose
Description
W1 – W4
Configures HSC1 through
HSC4 (respectively)
Pins 1-2 installed = Enables 300 Hz (low speed input)
Pins 2-3 installed = Enables 10 KHz (high speed input)
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 200 uA source; no 2 mA load
W11 & W12
Control HSC3 Current
Pins 1-2 installed = Enables additional 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
W13 & W14
Controls HSC4 Current
Pins 1-2 installed = Enables additional 2 mA load
Pins 2-3 installed = Enables 200 uA source; no 2 mA load
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ControlWave EFM Instruction Manual
Wiring the Module Figure 3-5 shows field wiring assignments for the locally terminated
HSC module.
Figure 3-5. Non-isolated HSC Module (Local 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. 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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I/O Modules
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ControlWave EFM Instruction Manual
3.6 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, 28 configuration
jumpers, and a module cover. The MI/O PCB connects to the backplane
using a 36-pin gold-plated card-edge connector.
Note: Unless otherwise noted, I/O circuitry is identical to circuitry
used on corresponding I/O modules in earlier sections of this
chapter.
The high speed counters support surge suppression, bandwidth limiting,
and 20 µs (50 kHz) filtering. You can individually field configure the
HSC inputs to enable/disable contact debounce circuitry and for 2 mA
or 200µA (low power) operation. The maximum frequency of an HSC
input signal is 15 kHz.
Detailed Technical For detailed technical specifications, please see our website
Specifications http://www.emersonprocess.com/remote.
Optional AO Optionally, certain configurations of MI/O modules can also support
one externally powered (VEXT = 11–30 Vdc) analog output.
AO circuitry consists of a 12-bit resolution Digital-to-Analog Converter
(DAC).
Configurations The non-isolated Mixed I/O (MI/O) module (general part number
396630-XX-X) has the following configurations:
Table 3-7. Mixed I/O Module Configurations
Part Number
I/O Included
Termination
Connector
Notes
396897-01-0
4AI, 2HSC, 6DI/DO
local
includes LED daughterboard
396897-02-9
4AI, 2HSC, 6DI/DO
local
includes LED daughterboard
& 1AO (on daughterboard)
Setting Jumpers MI/O modules have 28 jumpers you can use to configure each input or
output. See Table 3-8. See Figure 3-7 for jumper locations.
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ControlWave EFM Instruction Manual
Table 3-8. Jumper Assignments: Non-isolated MI/O Module
Jumper
Purpose
Description
1
Configures optional AO for
voltage or current output
Pins 1-2 installed = Sets AO for current output
Pins 2-3 installed = Sets AO for voltage output
W2
Configures optional AO for
voltage or current output
Pins 1-2 installed = Sets AO for voltage output
Pins 2-3 installed = Sets AO for current output
W3
Enables DI/DO status LEDs
Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
W4
Enables HSC status LEDs
Pins 1-2 installed = Enables LEDs manually
Pins 2-3 installed = Enables LEDs via software
W5 & W6
Controls HSC1 Current
Pins 1-2 installed = Permits additional 2 mA load
Pins 2-3 installed = Permits 200 uA source; no 2 ma load
W7 & W8
Controls HSC2 Current
Pins 1-2 installed = Permits additional 2 mA load
Pins 2-3 installed = Permits 200 uA source; no 2 ma load
W9 & W10
Configures HSC1 and HSC2
debounce (respectively)
Pins 1-2 installed = Enables HSC debounce
Pins 2-3 installed = Disabled HSC debounce
W11-W16
Configures DI1 through DI6
current (respectively)
Pins 1-2 installed = Sets 2 mA source current
Pins 2-3 installed = Sets 60 uA source current
W17-W22
Select DI/O1 through DI/O6
points (respectively)
Pins 1-2 installed = Sets digital input operation
Pins 2-3 installed = Sets digital output operation
W23-W26
Configures AI1 through AI4
(respectively)
Pins 1-2 installed = 4–20 mA AI (250Ω resistor in)
Pins 2-3 installed = 1–5 Vdc AI
W272
Selects AO Voltage
Pins 1-2 installed = N/A
Pins 2-3 installed = External Field Voltage (TB2-9)
W28
Enables HSC Circuitry
W1
Pins 1-2 installed = Enable (power) HSC circuit
Pins 2-3 installed = Disable HSC circuit
1 W1 jumper located on optional AO daughterboard.
2 Set W27 always to pins 2-3.
Wiring the Module Figure 3-6 shows field wiring assignments for a locally terminated
MI/O module. See Figure 3-7 for jumper locations and terminal
blocks.
Revised Dec-2013
I/O Modules
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ControlWave EFM Instruction Manual
Figure 3-6. Mixed I/O Module Wiring Diagram
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ControlWave EFM Instruction Manual
Figure 3-7. Non Isolated Mixed I/O Module Configuration Diagram
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.
Revised Dec-2013
I/O Modules
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ControlWave EFM Instruction Manual
3.7 Resistance Temperature Device (RTD) Inputs on SCM
System controller module connector TB2 provides connection to a 3wire 100 ohm platinum bulb RTD (using the DIN 43760 curve).
Wire the RTD according to Table 3-9, Figure 3-8 and Figure 3-9. In
this configuration, the return lead connects to the RTD- terminal and the
two junction leads (Sense and Excitation) connect to the RTD+ and
RTD EXC terminals.
Caution
Never ground the RTD cable shield at both ends or allow it to come in
contact with metallic/conductive conduit because multiple ground paths
can cause RTD input errors.
Table 3-9. RTD Connections to System Controller Module Connector
TB2
TB2 Pin
Signal
Function
1
RTD EXC
Excitation
2
RTD+
Sense
3
RTD-
Return
Figure 3-8. 3-Wire RTD Temperature Input Wiring
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ControlWave EFM Instruction Manual
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 3-9. RTD Probe Installation/Removal Diagram
Software Configuration To use data from the RTD your ControlWave project must include a
CWM_ECPU which you set up using ControlWave Designer’s I/O
Configurator. 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.
Revised Dec-2013
I/O Modules
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ControlWave EFM Instruction Manual
3.8 Digital to Relay I/O Board Option
Digital to relay I/O boards accept up to two discrete input signals from
an open drain MOSFET device and convert them to Form C relay
output signals using solid state relay (SSR) logic. The minimum current
load will be 100mA. Figure 3-10 provides a component view of the
Digital to Relay I/O Board.
Each ControlWave EFM discrete output is converted to a Form C relay
output signal which can be configured for opposite or identical state
conditions, i.e., both Normally Open (NO) or Normally Closed (NC) or
one Normally open with the other Normally Closed.
Figure 3-10. Digital to Relay I/O Board
The Digital to Relay I/O Board contains ten (10) Jumpers which allow
Digital to Relay I/O
Board Jumper Settings you to configure contacts for Normally Open/Normally Closed states.
You can configure contacts associated with each of the Form C Relays
for identical or opposite states.
Note: Jumper Pairs W3/W5, W4/W6, W7/W9 and W8/W10 must be set
in opposite states.
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ControlWave EFM Instruction Manual
You can optionally tie the commons associated with each form C relay
(R0COM and R1COM) to the ControlWave EFM power ground or to a
floating ground. Jumper W1 is associated with Outputs R0A and R0B
and W2 is associated with outputs R1A and R1B. When you install
jumper W1, it ties the common (C) associated with outputs R0A and
R0B to ControlWave EFM power ground; when jumper W1 is not
installed, the common is floating. When you install jumper W2 it ties
the common (C) associated with outputs R1A and R1B to ControlWave
EFM power ground; when jumper W2 is not installed, the common will
be floating.
Table 3-10 provides the relationship between Jumper settings and Form
C Relay Outputs.
Table 3-10 Jumper Settings versus Form C Relay Output States
Jumpers
W3/W5
R0A
State
Jumpers
W4/W6
R0B
State
Jumpers
W7/W9
R1A
State
Jumpers
W7/W9
R1B
State
IN/OUT
NO
IN/OUT
NO
IN/OUT
NO
IN/OUT
NO
OUT/IN
NC
OUT/IN
NC
OUT/IN
NC
OUT/IN
NC
NO = Normally Open; NC = Normally Closed
Table 3-11 - Digital to Relay I/O Board Connections to J1/P1
J1 Pin Signal
Function
Wiring Connections
1
R1B
Relay 1 Output B
To field
2
R1A
Relay 1 Output A
To field
3
R1COM
Relay 1 Common
To field (see W2)
4
Chassis GND
Chassis Ground
Chassis ground lug
5
R0COM
Relay 0 Common
To field (jumper W1)
6
R0B
Relay 0 Output B
To field
7
R0A
Relay 0 Output A
To field
9
Power GND
Power ground
Power distribution board TB4 pin 2 (black
wire)
10
Power – DC
Power – 6/12 V dc
Power distribution board TB4 pin 1 (red
wire)
11
DOut0
Discrete Output 0
DI/O module TB 2-5 through TB 2-8 or
mixed I/O module TB1-1 through TB1-6
(yellow wire)
12
DOut1
Discrete Output 1
DI/O module TB 2-6 through TB 2-8 or
mixed I/O module TB1-2 through TB1-6
(orange wire)
8
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I/O Modules
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ControlWave EFM Instruction Manual
The DI/DO module (Section 3.3) and the mixed I/O module (Section
3.6) provide independent firmware controlled open drain outputs, which
can be used for control or signaling functions (DI/DO Modules provide
up to four DO while the mixed I/O module provides up to 6 DO). Each
output is wired to the source terminal of an N Channel MOSFET
capable of switching up to 16 Volts at up to 100mA. When closed, the
FET shorts the output to ground with resistance of .5 Ohms or less.
These outputs are protected by 16V Transorbs.
Caution
Since these outputs are not isolated, exercise care to ensure that the
load current does not affect operation of the ControlWave EFM or related
devices
You can wire two of these outputs to field circuitry via the Digital to
Relay I/O Board option (see Figure 3-11). Table 3-11 provides the
wiring connections for the DI/O module or the mixed I/O module and
the Digital to Relay I/O Board.
Figure 3-11. Digital to Relay I/O Board Wiring Diagram
3.9 Connections to a Bristol Model 3808 Transmitter
You can connect a Bristol 3808 transmitter (digital) to the ControlWave
EFM 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 EFM
(local communications). You can use RS-485 communications to reach
transmitters up to 4000 feet away (remote communications).
Figure 3-12 details RS-232 wiring connections required between the
ControlWave EFM and the 3808 transmitter.
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ControlWave EFM Instruction Manual
Figure 3-12. 3808 Transmitter to ControlWave EFM RS-232 Comm. Cable Diagram
Figure 3-13 details RS-485 wiring connections required between the
ControlWave EFM and the 3808 transmitter.
Note: For loopback and termination control use switch SW3 on the
CPU module to configure COM3. Use switch SW1 on the
ECOM module to configure COM5 or COM9.
Figure 3-13. 3808 Transmitter to ControlWave EFM RS-485 Comm. Cable
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I/O Modules
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ControlWave EFM Instruction Manual
You can connect up to eight (8) Bristol 3808 transmitters to a
ControlWave EFM using a half-duplex RS-485 network. See Figure 314 for an illustration of this type of network.
Figure 3-14. ControlWave EFM to 3808s - RS-485 Network Diagram
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ControlWave EFM Instruction Manual
Chapter 4 – Operation
This chapter provides general operational details for using the
ControlWave EFM.
In This Chapter
4.1 4.2 4.3 4.4 Powering Up/Powering Down the ControlWave EFM .....................4-1 Communicating with the ControlWave EFM ....................................4-2 4.2.1 Default Comm Port ...............................................................4-2 4.2.2 Changing Port Settings ........................................................4-3 4.2.3 Collecting Data from the ControlWave EFM ........................4-4 Creating and Downloading an Application (ControlWave Project) ..4-4 Creating and Maintaining Backups ..................................................4-5 4.4.1 Creating a Zipped Project File (*.ZWT) For Backup ............4-5 4.4.2 Saving Flash Configuration Parameters (*.FCP) .................4-7 4.4.3 Backing up Data ...................................................................4-8 EXPLOSION HAZARD
WARNING
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave EFM is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
4.1 Powering Up/Powering Down the ControlWave EFM
The ControlWave EFM receives power from either an external bulk
power or a rechargeable lead acid battery and solar panel combination.
Power connects to connector TB1 on the SCM. Chapter 2 includes
instructions for wiring power supply to the ControlWave EFM.
To apply power to the ControlWave EFM, plug the power supply into
connector TB1 on the SCM.
To remove power from the ControlWave EFM, unplug the power
supply from connector TB1 on the SCM.
Mode Switch
The mode switch (SW1) is a two-position piano type DIP switch that
allows you to configure the mode for firmware upgrades, core
updumps, or normal running operations (see Figure 4-1).

Revised Dec-2013
Set both DIP switches to either the Open position (to the right) or
the Closed position (to the left) to place the ControlWave EFM in
Operation
4-1
ControlWave EFM Instruction Manual
Recovery mode. Use Recovery mode for a firmware upgrade or a
core updump (see Chapter 5).

Set SW1-1 (the upper DIP switch) to the Open (right) position and
SW1-2 (the lower DIP switch) to the Closed (left) position to place
the ControlWave EFM in Local mode, which is used for normal
running operations.
Figure 4-1. Mode Switch
4.2 Communicating with the ControlWave EFM
You communicate to the ControlWave EFM by connecting a cable
between a port on your PC workstation and one of the ControlWave
EFM ports.
The port at the PC workstation must match the configuration of the
ControlWave EFM port.
4.2.1 Default Comm Port As delivered from the factory, ControlWave EFM
communication ports have default settings. Table 4-1 details these
defaults.
Table 4-1. Default Comm Port Settings (by PCB)
Port
PCB
Default Configuration
COM1
CPU
Ships from factory at RS-232; 115.2 Kbps using BSAP. Once
the default switch is OFF, a factory default of IP Point-to-Point
protocol (PPP) at 115,200 applies.
COM2
CPU
RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM3
CPU
RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM4
ECOM Type 1 or Type
2
RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM5
ECOM Type 1
RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 2
RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 1
Not applicable
ECOM Type 2
RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 1
Not applicable
ECOM Type 2
RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM6
COM7
4-2
Operation
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ControlWave EFM Instruction Manual
Port
PCB
Default Configuration
COM8
ECOM Type 1 or Type
2
RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM9
ECOM Type 1
RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 2
RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
ECOM Type 1
Radio port
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
COM10
COM11
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.”
If you set both SW2-3 and SW2-8 to “OFF” all serial ports
(including COM1) become 9600 baud/BSAP. This is used for
diagnostics mode.
For information on communication cables see Chapter2.
Using an optional Ethernet port (located on the CPU module), you can
connect either directly or through a network to a PC equipped with an
Ethernet port.
The Ethernet port is only available for the 150 MHz CPU. If the
Ethernet port is present, the factory pre-configures its initial IP address
and mask, as follows:
ETH1 IP Address: 10.0.1.1 IP Mask: 255.255.255.0
Because each unit that ships from the factory has this address initially
pre-programmed, you should only use this address for “bench” testing
and configuration. You must change this address before putting the
ControlWave unit on an actual network, since an address conflict
would exist as soon as you place the second ControlWave unit online.
4.2.2 Changing Port Settings
You change port settings (baud rate, port type, IP address, and so on)
using the Flash Configuration utility.
You must establish communications with the ControlWave EFM using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.
Revised Dec-2013
Operation
4-3
ControlWave EFM Instruction Manual
Note: For detailed information on using the Flash Configuration utility,
see Chapter 5 of the OpenBSI Utilities Manual (D5081).
Caution
When you change the baud rate for a port, the baud rate changes as
soon as you write the flash file changes to the RTU, and do not require
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 4.2.1 to restore
defaults and re-establish communications.
4.2.3 Collecting Data from the ControlWave EFM
OpenBSI utilities such as DataView, Data Array Save/Restore and
Harvester allow you to collect real time data (values of variables, array
values, alarm messages) and historical data (audit records, archive files)
from the ControlWave. See the OpenBSI Utilities Manual (D5081) for
details. SCADA software such as OpenEnterprise can then present this
data to an operator in the form of graphical displays and reports.
4.3 Creating and Downloading an Application (ControlWave Project)
Your ControlWave executes an application called a ControlWave
project. Certain standard projects are available for purchase, or you can
purchase PC-based ControlWave Designer software and create your
own project. Instructions for creating a ControlWave project are beyond
the scope of this manual. Please refer to the following sources for
information:
 Getting Started with ControlWave Designer (D5085)
 ControlWave Designer Programmer’s Handbook (D5125)
 ControlWave Designer online help
You must connect the EFM to a PC running ControlWave Designer
software and OpenBSI software.
Note: You can download an application either from ControlWave
Designer or from the OpenBSI 1131 Downloader.
o Set the SCM’s Mode switch to local mode (that is, SW1-1 to
Open [right] and SW1-2 to Closed [left]).
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.
1.
4-4
Define the EFM project, setting communication and
configuration parameters.
Operation
Revised Dec-2013
ControlWave EFM Instruction Manual
2.
Download the project according to instructions in the
Downloading section of the ControlWave Designer
Programmer's Manual (D5125).
3.
After the download completes successfully, leave Mode switch
(SW1) in local mode.
4.4 Creating and Maintaining Backups
You should always maintain a current backup of each ControlWave
project and keep it in a safe place, preferably in a location physically
separate from the controller.
The reason we recommend you keep a backup files is that if a disaster
occurs that damages or destroys your ControlWave hardware (flood,
lightning strike, etc.) you don’t want to also lose its control strategy
software programs. Otherwise, when the unit is repaired or replaced,
you’d have to create a new ControlWave project from scratch, which
might take a lot longer than replacing a few damaged modules.
Always maintain a backup copy of your ControlWave project in a safe
place.
Caution
Anytime you modify your ControlWave project, be sure to create a new
backup of the new project.
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 (*.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. Click File > Save Project As / Zip Project As.
Revised Dec-2013
Operation
4-5
ControlWave EFM Instruction Manual
Figure 4-2. Saving a Backup of Your Project
2. In the “Save/Zip project as” dialog box, specify a project name in
the File name field. In Figure 4-2 we chose the name mynewproj.
3. In the Save as type field, choose Zipped Project Files (*.zwt).
4. In the Zip Options area, select which additional files you want to
include in the zwt file. Other than increasing the file size of the zwt,
it doesn’t hurt to check any or all of these options.
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.
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.
4-6
Operation
Revised Dec-2013
ControlWave EFM Instruction Manual
7. Copy the resulting zwt file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the project, just open the zwt
file in ControlWave Designer, load libraries as needed, then compile
the project and download it into the ControlWave.
4.4.2 Saving Flash Configuration Parameters (*.FCP)
You must establish communications with the ControlWave using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.
Note: For detailed information on using the Flash Configuration utility,
see Chapter 5 of the OpenBSI Utilities Manual (D5081).
1.
Start the Flash Configuration utility. To do this in NetView or
LocalView, right-click on the icon for this ControlWave and
choose RTU > RTU Configuration Parameters.
To do this in TechView, click Operations > Access Flash
Parameters or click the Access Flash icon
Revised Dec-2013
.
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. When the status line indicates successful
completion, your FCP file in done.
Operation
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ControlWave EFM Instruction Manual
5.
Copy the resulting FCP file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the FCP parameters to the
controller, establish communications with the unit, start the
Flash Configuration utility, and load the FCP file using the Read
from FCP button, then choose the Write to RTU button.
4.4.3 Backing up Data
You can back up certain types of data and restore it if needed. There are
other types of data that you can only collect, but you cannot restore.



4-8
If you have certain variables that represent tuning parameters
(setpoints, for example) you can use tools such as the OpenBSI
DataView recipe feature to save those values to a recipe file on the
PC, and then restore them at a later time. See Chapter 8 of the
OpenBSI Utilities Manual (D5081).
You can store the contents of read/write data arrays using the
OpenBSI Data Array Save/Restore utility. See Chapter 13 of the
OpenBSI Utilities Manual (D5081).
You can collect alarms, and historical data (audit records, archive
files) but you cannot restore alarms or historical data.
Operation
Revised Dec-2013
ControlWave EFM Instruction Manual
Chapter 5 – Service and Troubleshooting
This chapter provides general diagnostic and test information for the
ControlWave EFM.
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 ............................................5-6 5.2.2 Removing/Replacing the Bezel ............................................5-6 5.2.3 Removing/Replacing the CPU Module.................................5-6 5.2.4 Removing/Replacing the SCM .............................................5-7 5.2.5 Removing/Replacing an I/O Module ....................................5-7 5.2.6 Removal/Replacement of an ECOM Module .......................5-8 5.2.7 Removal/Replacement of the Lead-acid Battery .................5-8 5.2.8 Removal/Replacement of a Power Distribution Board .........5-9 5.2.9 Removal/Replacement of a 21V Power Supply Board ........5-9 5.2.10 Removal/Replacement of a Digital to Relay I/O Board ......5-10 5.2.11 Removal/Replacement of Case-Mounted Radio/Modem ..5-10 5.2.12 Removing/Replacing the Backup Battery ..........................5-10 5.2.13 Enabling / Disabling the Backup Battery ............................5-12 General Troubleshooting Procedures ...........................................5-12 5.3.1 Checking LEDs...................................................................5-12 5.3.2 Checking Wiring/Signals ....................................................5-18 5.3.3 Calibration Checks .............................................................5-18 5.3.4 Common Communication Configuration Problems ............5-18 WINDIAG Diagnostic Utility ...........................................................5-19 5.4.1 Available Diagnostics .........................................................5-22
Core Updump ................................................................................5-26 You need the following equipment to perform the procedures described
in this chapter:
To run diagnostics software:
 PC with WINDIAG software, and either OpenBSI LocalView,
NetView, or TechView for communications.
 Null modem interface cable
 Loop-back plug, 9-pin female D-Sub (for RS-232) (see Figure 5-12)
 Loop-back plug, 9-pin female D-Sub (for RS-485) (see Figure 5-13)
 Loop-back plug, 8-pin RJ-45 male (for twisted pair Ethernet) (see
Figure 5-15)
To perform firmware upgrades:
 Null modem interface cable
 PC with the following software:
o OpenBSI LocalView
o OpenBSI System Firmware Downloader and either NetView,
LocalView, or TechView for communications.
o HyperTerminal (included in Windows®)
To replace the SRAM backup battery:
Revised Dec-2013
Service & Troubleshooting
5-1
ControlWave EFM Instruction Manual

Depending on the type of battery holder, either a small flat head
screwdriver, or tweezers/needle nose pliers.
Note: When you service a ControlWave EFM 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.
Caution
Harmful electrical potentials may still exist at the field wiring terminals
even though the ControlWave EFM’s power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or
perform any wiring operations until you verify that all associated power
supply sources are turned off and/or disconnected.
Always turn off any external supply sources for externally powered I.O
circuits before you change any modules.
WARNING
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave EFM is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not disconnect equipment unless the power is switched off or the
area is known to be non-hazardous.
See Appendix A for details on Class I Division 2 usage of this device.
5.1
Upgrading Firmware
The ControlWave EFM CPU ships from the factory with system
firmware already installed. If you need to upgrade the system firmware
(stored in Flash memory) to acquire new functionality or restore
firmware, you can use one of several methods.
System
Firmware
Downloader
Use this tool to download system firmware to an unattended remote
ControlWave EFM. To use this utility, you must set CPU module
switch SW2-6 ON (the factory default position).
Note: For further information and detailed use instructions, refer to
Appendix J of the OpenBSI Utilities Manual (D5081).
LocalView
5-2
One of the standard OpenBSI utilities, LocalView requires OpenBSI
version 5.1 (or newer). If you have an older version of OpenBSI, use
HyperTerminal.
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
Note: For further information and detailed use instructions, refer to the
Flash Mode section of Chapter 5 of the OpenBSI Utilities
Manual (D5081).
HyperTerminal
HyperTerminal is a communications utility program included with
Microsoft® Windows® XP.
Notes:

If you are using a version of OpenBSI older than 5.1, or do not have
OpenBSI software, you can only perform a firmware upgrade using
HyperTerminal.
 While HyperTerminal is included in Microsoft® Window® XP,
some newer versions of Windows® do not include it.
 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 EFM and any RS-232 port on the associated PC.
Revised Dec-2013
2.
Click Start > Programs > Accessories > Communications >
HyperTerminal
3.
If using HyperTerminal for the first time, set the communication
properties (for the PC port) via the Properties Menu as follows:
Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop
bits: = 1, and Flow control: = None and then click OK.
4.
Either set the SCM’s mode switch (SW1) for Recovery Mode,
that is, set both switches in the OPEN or CLOSED position or
set CPU Switch SW1-3 ON (ON = Force Recovery).
5.
Apply power; to the ControlWave EFM. The resident BIOS
initializes and tests the hardware, this process is referred to as
POST (Power On Self Test). Unless there is a problem, SCM
status LEDS show status code 10 (LED #5 ON). If you see a
different status code, see Section 5.3.1
6.
From the HyperTerminal Mode menu (Figure 5-1), press the F
key to enter FLASH download. A message warns that the
FLASH is about to be erased; press the Y key at the prompt. The
screen displays dots as the system erases the flash memory; this
could take a few minutes.
Service & Troubleshooting
5-3
ControlWave EFM Instruction Manual
Figure 5-1. HyperTerminal Mode Menu
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.
5-4
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 “CWExxxxx.bin” (where xxxxx varies from release to
release) and click Send to start the flash upgrade (see Figure 54). When you see the HyperTerminal Mode Menu again, it
means the download has completed.
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
Figure 5-3. Send File dialog box
9.
Exit HyperTerminal and power down the ControlWave EFM. If
desired, you can disconnect the null modem cable between the
ControlWave EFM and the PC.
10.
Set the SCM’s mode switch (SW1) for Local Mode, i.e., SW1-1 in
the OPEN (Right) position and SW1-2 in the CLOSED (Left)
position or if CPU Module Switch SW1-3 was set for Recovery
Mode, set it to the OFF position (OFF = Recovery Mode
Disabled).
11.
Restore power to the ControlWave EFM.
Figure 5-4. HyperTerminal (Download in Process)
5.2 Removing or Replacing Components
This section provides information on accessing EFM modules for
testing, as well as removal/replacement procedures.
Revised Dec-2013
Service & Troubleshooting
5-5
ControlWave EFM Instruction Manual
Caution
Field repairs to ControlWave EFMs are strictly limited to the
replacement of complete modules. Replacing module components
constitutes tampering and violates the product warranty. Return
defective modules or housings to the factory for authorized service.
5.2.1 Accessing Modules for Testing
Only technically qualified personnel should test and/or replace EFM
modules. Read completely the disassembly and test procedures
described in this manual before starting. Any damage to the
ControlWave EFM resulting from improper handling or incorrect
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. To replace the bezel, align the latches (left and right, top and
bottom) with the associated notches in the I/O module cover. Press
the bezel in so that the notches capture its latches and slide it
downward until it securely seats.
5.2.3 Removing/Replacing the CPU Module
Use this procedure to remove or replace the CPU module.
5-6
1.
If the EFM is running, place any critical control processes under
manual control.
2.
Shut down the EFM by disconnecting power from the system
controller module (SCM).
3.
Disconnect any CPU module communication cables. Label or
otherwise identify them so you can easily return them to their
assigned communication ports. .
4.
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).
5.
Carefully slide the CPU module out of the front of the housing.
If any binding occurs, gently rock the module up and down to
free it.
6.
To replace a CPU module, power must be off. Carefully align
the CPU module with the guides for slot 2 in the EFM and insert
the module into the housing. When the module correctly seats,
its cover should latch to the housing.
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
7.
Replace any communication cables, apply power, and test the
module.
5.2.4 Removing/Replacing the SCM
Use this procedure to remove or replace the System Controller Module
(SCM).
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Unplug the SCM’s modular connectors.
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 SCM out of the front of the housing. If binding
occurs, gently rock the module up and down to free it.
5.
To replace an SCM, power must be off. Carefully align the SCM
with the guides for slot 1 in the EFM and insert the module into
the housing. When the module correctly seats, its cover should
latch to the housing.
6.
Replace power and watchdog cables and then apply power and test
the unit.
5.2.5 Removing/Replacing an I/O Module
Use this procedure to remove or replace an I/O module.
Revised Dec-2013
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Remove the applicable bezel (see Section 5.2.2).
3.
Unplug local termination cable headers from I/O module
connectors TB1 and TB2 and set the cables aside. Label or
otherwise identify these cables so you can easily return them to
their assigned connectors.
4.
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).
5.
Carefully slide the I/O module out of the front of the housing. If
binding occurs, gently rock the I/O module up and down to free
it.
6.
To replace an I/O module, power must be off. Carefully align the
I/O module with the applicable I/O slot and insert the unit into
the housing. When the module correctly seats, its cover should
latch to the housing.
7.
Connect local termination cables to I/O module connectors.
Service & Troubleshooting
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ControlWave EFM Instruction Manual
8.
5.2.6
Apply power and test the unit.
Removal/Replacement of an Expansion Communication Module
Use this procedure to remove or replace an expansion communication
(ECOM) module.
5.2.7
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Disconnect any ECOM module communication cables. Label or
otherwise identify them so you can easily return them to their
assigned communication ports. .
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 ECOM module out of the front of the
housing. If binding occurs, gently rock the ECOM module up
and down to free it.
5.
To replace an ECOM module, power must be off. Carefully
align the ECOM module with the appropriate slot (3 or 4) and
insert the unit into the housing. When the module correctly seats,
its cover should latch to the housing.
6.
Connect communication cables to ECOM module connectors.
7.
Apply power and test the unit.
Removal/Replacement of the Rechargeable Lead-acid Battery
Use this procedure to remove or replace the rechargeable lead acid
battery.
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Disconnect the power cables from the battery terminals (remove
screw and nut on each terminal).
3.
Loosen the two 11/32” nuts on the ends of the battery clamp.
Lift the battery clamp and rotate it rearward.
4.
Carefully lift up and remove the rechargeable lead-acid battery.
Note: Make sure your replacement lead acid battery is fully charged
before you install it.
5-8
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
5.2.8
5.
To replace the battery, align the unit so that the negative battery
terminal is oriented to the top and right as illustrated in Figure 215 and place the battery into the battery mounting bracket
(battery clamp must be in the released position.
6.
Raise the battery clamp and rotate it forward until you can lower
it to secure the rechargeable lead-acid battery. Tighten the two
11/32” nuts on the ends of the battery clamp.
7.
Replace the power cables to the battery terminals (black/NEG,
Red/POS).
8.
Apply power and test the unit.
Removal/Replacement of a Power Distribution Board
Use this procedure to remove or replace the optional power distribution
board.
5.2.9
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Unplug wiring harnesses from power distribution board
connectors TB1 through TB6. Label or otherwise identify them
so you can easily re-connect them later.
3.
Slide the power distribution board toward the front of the unit
and remove it from its snap track holder.
4.
To replace the power distribution board, slide it into its snap
track holder. Replace wiring harness connectors TB1 through
TB6.
5.
Apply power and test the unit.
Removal/Replacement of a 21V Power Supply Board
Use this procedure to remove or replace the optional 21V power supply
board.
Revised Dec-2013
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Unplug wiring harnesses from 21V power supply board
connectors TB1 and TB2.
3.
Slide the 21V power supply board toward the front of the unit and
remove it from its snap track holder.
4.
To replace the 21V power supply board, slide it into its snap track
holder. Replace wiring harness connectors TB1 and TB2.
5.
Apply power and test the unit.
Service & Troubleshooting
5-9
ControlWave EFM Instruction Manual
5.2.10 Removal/Replacement of a Digital to Relay I/O Board
Use this procedure to remove or replace the optional digital to relay I/O
board.
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Unplug wiring harnesses from digital to relay I/O board
connector J1.
3.
Slide the digital to relay I/O board toward the front of the unit
and remove it from its snap track holder.
4.
To replace the digital to relay I/O board, slide it into its snap
track holder. Replace wiring harness connector J1/P1.
5.
Apply power and test the unit.
5.2.11 Removal/Replacement of a Case-Mounted Radio/Modem
Use this procedure to remove or replace a case-mounted radio or
modem.
1.
If the EFM is running, place any critical control processes under
manual control and shut down the unit by disconnecting power
from the SCM.
2.
Remove the removable lead-acid battery (if present) (see Section
5.2.7).
3.
Disconnect (unplug) all connectors (power and interface) from
the radio/modem.
4.
Remove the mounting screws from the bottom (inside) of the
battery mounting bracket and remove the radio/modem (with
mounting plate if present).
5.
Replace the radio/modem in the reverse order from which it was
removed.
6.
Apply power and test the unit.
5.2.12 Removing/Replacing the Backup Battery
Note: The CPU module draws power from the battery only if the
module loses power. For a ControlWave EFM containing 2MB
of SRAM, a worst-case current draw of 42 uA allows a battery
life of approximately 5238 hours. This means you should not
need to replace a battery until the ControlWave EFM has been in
service for an extended period (normally many years).
5-10
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
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.
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. This enables the SRAM to completely discharge.
After you install the new battery, ensure that you have placed jumper
JP8 on pins 1-2 (to enable the battery).
The procedure for replacing the battery varies slightly depending upon
the type of battery holder – snap type or clip type.
Removing /
Replacing the
Battery – Snap
Type Holder
Battery Part
Numbers:
CR2032
DL2032
Inner clip
1. If the EFM is running, place any critical control processes under
manual control.
2. Remove power from the ControlWave EFM.
3. Remove the CPU module from the housing.
4. To remove the lithium battery, insert the tip of a small flat head
screw driver into the gap between the battery and the holder. (The
gap is on the side of the holder that doesn’t have the inner clip
against the battery.) Gently push the screwdriver at an angle
underneath the battery and it will pop out of the holder.
5. To install the replacement battery, press one side of the battery
against the inner clip of the holder then press the battery down into
the slot so it snaps in.
6. Replace the CPU module in slot 2 of the housing.
7. Re-connect power to the ControlWave EFM.
Gap between
battery and holder
Revised Dec-2013
8. Once the battery has been replaced, the unit executes its Flash-
based application (“boot project”) at power-up, but all of the
current process data is lost. At power-up, the EFM acts as though it
had just been booted and reverts back to the initial values specified
in its application.
Service & Troubleshooting
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ControlWave EFM Instruction Manual
Removing /
Replacing the
Battery – Clip
Type Holder
Battery Part
Numbers:
BR2330,
BR2335,
BR2335-B
1. If the EFM is running, place any critical control processes under
manual control.
2. Remove power from the ControlWave EFM.
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. Install the replacement battery.
5. Replace the CPU module in slot 2 of the housing.
6. Re-connect power to the ControlWave EFM.
7. Once the battery has been replaced, the unit executes its Flash-
based application (“boot project”) at power-up, but all of the
current process data is lost. At power-up, the EFM acts as though it
had just been booted and reverts back to the initial values specified
in its application.
5.2.13 Enabling / Disabling the Backup Battery
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.
Enabling
To enable the battery, install jumper JP8 on pins 1-2.
Disabling
For maximum shelf life, you can isolate the battery from the circuit by
placing jumper JP8 on pins 2-3.
5.3 General Troubleshooting Procedures
This section presents some procedures to troubleshoot problems with
the EFM.
5.3.1 Checking LEDs
Most EFM modules contain light emitting diodes (LEDs) that provide
operational and diagnostic functions.
Table 5-1 shows LED assignments on EFM modules.
Table 5-1. LED Assignments on Modules
Module
LED Name
LED Color
Function
SCM
IDLE
Red
ON = Idle
SCM
WD
Red
ON = Watchdog condition
OFF = Normal
5-12
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
Module
LED Name
LED Color
Function
SCM
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 right; 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 right; see Figure 5-6)
CPU
C3 RX (Comm 3)
Red
ON = RX activity (bottom left; see Figure 5-6)
CPU
C3 TX (Comm 3)
Red
ON = TX activity (bottom right; see Figure 5-6)
CPU
ENET Port 1
Green
ON = RX activity (top; see Figure 5-6)
CPU
ENET Port 1
Yellow
ON = TX activity (bottom; see Figure 5-6)
ECOM1
EC 4/8 RX (Comm 4)
Red
ON = RX activity (top left; see Figure 5-7)
ECOM1
EC 4/8 TX (Comm 4)
Red
ON = TX activity (top right; see Figure 5-7)
ECOM1
EC 5/9 RX (Comm 5)
Red
ON = RX activity (2nd from top left; see Figure
5-7)
ECOM1
EC 5/9 TX (Comm 5)
Red
ON = RX activity (2nd from top right; see Figure
5-7
ECOM1
Radio RX (Comm6)1
Red
ON = RX activity (3rd from top left; see Figure
5-7) (Note: Radio no longer offered- ignore always ON)
ECOM1
Radio TX (Comm6)1
Red
ON = TX activity (3rd from top right; see Figure
5-7) Note: Radio no longer offered (always
OFF)
ECOM1
Modem RX (Comm7)1
Red
ON = RX activity (bottom left;; see Figure 5-7)
ECOM1
1
Red
ON = TX activity (bottom right; see Figure 5-7)
EC4/8 RX (Comm 4/8)
1
Red
ON = RX activity (top left; see Figure 5-8)
EC4/8 TX (Comm 4/8)
1
Red
ON = TX activity (top right; see Figure 5-8)
ECOM2
EC5/9 RX (Comm 5/9)
1
Red
ON = RX activity (2nd from top left; see Figure
5-8)
ECOM2
EC5/9 TX (Comm 5/9) 1
Red
ON = TX activity (2nd from top right; see Figure
5-8
ECOM2
EC6/10 RX (Comm 6/10) 1
Red
ON = RX activity (3rd from top left; see Figure
5-8)
ECOM2
EC6/10 TX (Comm 6/10) 1
Red
ON = TX activity (3rd from top right; see Figure
5-8)
ECOM2
EC7/11 RX (Comm 7/11) 1
Red
ON = RX activity (bottom left;; see Figure 5-8)
ECOM2
EC7/11 TX (Comm 7/11)
1
Red
ON = TX activity (bottom right; see Figure 5-8)
DI/OM
INPUT (12 LEDs,1 per point)
Red
LED ON = Input is present
LED OFF = Input not present (see Figure 5-9)
DI/OM
OUTPUT (4 LEDs,1 per point)
Red
LED ON = Output is ON (see Figure 5-9)
HSCM
INPUT (4 LEDs, 1 per point)
Red
LED ON = Input activity on input is present
LED OFF = No activity on input (see Figure 59)
ECOM2
ECOM2
Modem TX (Comm7)
1
Radio or modem with Type 1 comm board only
Revised Dec-2013
Service & Troubleshooting
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ControlWave EFM Instruction Manual
SCM System As the EFM runs its application, status codes post to the six LEDs on
Status LED the SCM. Table 5-2 provides activity descriptions of the LEDs; Figure
Codes 5-5 shows what the LEDs look like for each hex code.
Table 5-2. System Status LED Codes on SCM
Status in
Hex
LED 6
ED 5
LED 4
LED 3
LED 2
LED 1
Activity Indicator
00
0
0
0
0
0
0
Application Running
01
0
0
0
0
0
1
Unit in Diagnostic Mode
03
0
0
0
0
1
1
Unit Running Diagnostics
04
0
0
0
1
0
0
Flash XSUM Error
05
0
0
0
1
0
1
Error Initializing Application Device
07
0
0
0
1
1
1
Flash Programming Error
08
0
0
1
0
0
0
Using Factory Defaults (flashed at start)
09
0
0
1
0
0
1
Battery Failure Detected (flashed at
startup)
0A
0
0
1
0
1
0
Currently Loading the Boot Project
0B
0
0
1
0
1
1
System Initialization in Progress
10
0
1
0
0
0
0
Waiting in Recovery Mode
11
0
1
0
0
0
1
Error Testing SDRAM
12
0
1
0
0
1
0
Error Testing SRAM
20
1
0
0
0
0
0
Application Loaded
28
1
0
1
0
0
0
Stopped at Break Point
30
1
1
0
0
0
0
No Application Loaded
38
1
1
1
0
0
0
Running with Break Points
3B
1
1
1
0
1
1
Waiting for a Power-down (after NMI)
3E
1
1
1
1
1
0
Waiting for Updump to be Performed
3F
1
1
1
1
1
1
Unit Crashed (Watchdog Disabled)
5-14
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ControlWave EFM Instruction Manual
Figure 5-5. SCM Status LED Hexadecimal Codes
CPU Module The CPU module has six comm port activity LEDs on the CPU board.
LEDs Units equipped with an Ethernet port have two additional LEDs
located on the 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. CPU Module LEDs
Revised Dec-2013
LED Ref
LED Function
C1
Transmit (TX) COM1
C1
Receive (RX) COM2
C2
Transmit (TX) COM2
C2
Receive (RX) COM2
C3
Transmit (TX) COM3
C3
Receive (RX) COM3
E1 – Bottom
Ethernet Link Transmit (TX)
E1 – Top
Ethernet Link Receive (RX)
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ControlWave EFM Instruction Manual
Figure 5-6. CPU Module Comm Connectors and LEDs
5-16
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ControlWave EFM Instruction Manual
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. Port 10
Radio
(Radio no longer offered)
(Radio no longer offered)
Comm. Port 7
Modem
Comm. Port 11
Modem
Figure 5-7. Type 1 Expansion Comm Module Comm Connectors and LEDs
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. Port 11
Receive LED
Transmit LED
Comm. Port 11
RS-485
Figure 5-8. Type 2 Expansion Comm Module Comm Connectors and LEDs
Revised Dec-2013
Service & Troubleshooting
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ControlWave EFM Instruction Manual
Figure 5-9. I/O Module LEDs
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 Figure 3-2 for wiring diagrams).
5.3.3 Calibration Checks
To calibrate the MVT and the RTD, use TechView software. See the
TechView User’s Guide (D5131) for more information.
5.3.4 Common Communication Configuration Problems
If serial communications do not function, it is often due to one of the
following issues:


5-18
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. You can
always re-establish factory default baud rates for communication
ports by powering down the unit, and then setting CPU switch SW23 to OFF and restoring power.
Incorrect BSAP local address – this address must be an integer from
1 to 127 and must be unique on this particular BSAP communication
line. You set the BSAP local address using the flash configuration
utility. If this ControlWave EFM is a BSAP slave node, and the
range of addresses defined for the BSAP master port end of the
communication line does not encompass the local BSAP address
defined for this ControlWave EFM, BSAP communications will not
function.
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Revised Dec-2013
ControlWave EFM Instruction Manual

Incorrect EBSAP Group number – if you use expanded BSAP the
EBSAP group number must be correct; if you are not using EBSAP,
the group number must be 0.
If IP communications do not function, it is often due to incorrect IP
addresses or masks. Check to see that the IP address you defined for the
ControlWave EFM is compatible with the range of IP addresses defined
for the communication line on which the unit resides. Also check that
the IP address of the default gateway is correct.
5.4 WINDIAG Diagnostic Utility
WINDIAG is a software-based diagnostic tool you use to test the
performance of I/O modules, CPU memory, communication ports, and
other system components. .
WINDIAG is a PC-based program, so the EFM must be attached to and
communicating with a PC running WINDIAG. Set configuration switch
SW2-8 OFF (closed) on the CPU module to enable the diagnostic
routines.
Establish communication between the EFM (with/without an
application loaded) and the PC with a local or network port under the
following conditions:





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 EFM in diagnostic mode.
Use a null modem cable to connect RS-232 ports between the EFM
and the PC; use an RS-485 cable (see Section 2.4.4) to connect the
RS-485 ports of the EFM and the PC.
Reserve the port running a diagnostic test for exclusive use; you
cannot use that port for any other purpose during testing.
Connect any EFM communication port to the PC provided their port
speeds match. Most PCs have a COM1 port (typically RS-232 and
defaulted to 9600 bps operation).
Configure the EFM communication port to be tested using
WINDIAG for 9600 baud, 8-bits, no parity, 1 stop bit, and
BSAP/ControlWave Designer protocol operation. Communication
port COM1 is only forced to 9600 bps operation when you have set
switch SW2-3 on the CPU module to OFF.
Table 5-4. COM Port Defaults for Diagnostics
Port
Module
Default Configuation
COM1
CPU
RS-232: 115.2 kbd using IP PPP protocol
To run diagnostics, set RS-232 to 9600 baud by setting CPU
switches SW2-3 and SW2-8 OFF.
COM2
CPU
RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
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ControlWave EFM Instruction Manual
Port
Module
Default Configuation
COM3
CPU
RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM4
ECOM Types 1 or
2
RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM5
ECOM Type 1
RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 2
RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 1
Not applicable
ECOM Type 2
RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 1
Not applicable
ECOM Type 2
RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM8
ECOM Types 1 or
2
RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
COM9
ECOM Type 1
RS-485: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 2
RS-232: 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol.
ECOM Type 1
Radio port
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.
COM6
COM7
COM10
COM11
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 2.9.5).
Before starting the WINDIAG program, place any critical processes the
EFM is handling under manual control. You cannot run WINDIAG
while the EFM is running applications. Set the CPU modules switches
SW2-3 and SW2-8 to OFF, and perform the following steps:
1.
5-20
Start the NetView program in OpenBSI with your current
network NETDEF file. A menu displays (similar to the one in
Figure 5-10):
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
Figure 5-10. NetView
2.
Select Start >Programs > OpenBSI Tools >Common Tools >
Diagnostics. The Main Diagnostics menu (Figure 5-11)
displays.
Figure 5-11. 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 EFM units to test.
When you close NetView, the system asks whether you want to
close OpenBSI. Select Yes.
Revised Dec-2013
Service & Troubleshooting
5-21
ControlWave EFM Instruction Manual
5.
Set switch SW2-8 on the CPU module to ON (open). The EFM
should resume normal operation.
5.4.1 Available Diagnostics
Using WINDIAG, you can test all EFM modules with the exception of
the SCM. WINDIAG’s Main Diagnostics Menu (see Figure 5-11)
provides the following diagnostic selections:
Port Loop-back
Test
Option
Tests
CPU & Peripherals
Checks the CPU module (except for RAM &
PROM).
Analog Output
Checks AOs on AI/O, AO, or Mixed I/O modules.
High Speed Counter
Checks HSCs on HSC or Mixed I/O modules.
Prom/Ram
Checks the CPU’s RAM and PROM hardware.
Analog Input
Checks AIs on AI/O, AI, or Mixed I/O modules.
Communications
Checks Communication ports 1 through 9 (but
not COM6 or COM7). The External loop-back
tests require the use of a loop-back plug.
Discrete I/O
Checks DIs on DI, DI/O, or Mixed I/O modules
and/or checks DOs on DO, DI/O, or Mixed I/O
modules.
Ethernet
Checks Ethernet Port 1. The Loop-back Out
Twisted Pair tests require the use of a loop-back
plug.
WINDIAG allows you to select the communication port (1 through 4)
to test. Depending on the type of network (RS-232 or RS-485) and the
port in question, a special loop-back plug is required:

RS-232 ports use a 9-pin female D-type loop-back plug (shown in
Figure 5-12).
Figure 5-12. RS-232 Loop-back Plug

5-22
RS-485 ports use a 9-pin female D-type loop-back plug (shown in
Figure 5-13).
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
Figure 5-13. RS-485 Loop-back Plug
These tests verify the correct operation of the serial ports.
Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
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.









2.
Revised Dec-2013
J3 of CPU module for COM1
J4 of CPU module for COM2
J5 of CPU module for COM3
J4 of ECOM1 module for COM4/8
J5 of ECOM1 module for COM5/9
J4 of ECOM2 module for COM4/8
J5 of ECOM2 module for COM5/9
J6 of ECOM2 module for COM6/10
J7 of ECOM2 module for COM7/11
Select Communications on the WINDIAG Main Diagnostics
Menu. The Communications Diagnostic screen opens:
Service & Troubleshooting
5-23
ControlWave EFM Instruction Manual
Figure 5-14. 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. At the completion of the test (which
generally takes about 5 seconds), any failed results appear in the
Status field to the right of the RUN button:


7.
Ethernet Port
Loop-back Test
TXD RXD Failure
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) 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. You need a special loop-back plug (shown in
Figure 5-15) to perform the Ethernet loop-back test:
5-24
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
Figure 5-15. RJ-45 Ethernet Loop-back Plug
Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
Test Procedure
Use this procedure to test the Ethernet port.
1.
Connect an external Ethernet loop-back plug (see Figure 5-15)
to the Ethernet port on the CPU module to be tested.
2.
Select Ethernet on the WINDIAG Main Diagnostics Menu.
The Ethernet Diagnostic screen opens:
Figure 5-16. Ethernet Diagnostic Menu
3.
Revised Dec-2013
Enter 1 in the Number of Passes field.
Service & Troubleshooting
5-25
ControlWave EFM Instruction Manual
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. At the completion of the test, any failed results appear in
the Status field next to the Loop-back out twisted pair label:





No Hardware Present
Loop-back Send Failed
Loop-back Receive Failed
Loop-back Compare Failed
Error Information Returned
6.
Disconnect the loop-back plug and reconnect the Ethernet cable
to the EFM and the Ethernet hub.
7.
Click Return to Menu to display the WINDIAG Main Menu.
5.5 Core Updump
In some cases—such as when a EFM fails for no apparent reason—you
can upload a copy of the contents of SRAM and SDRAM to a PC for
support personnel and service engineers to evaluate. This upload is
called a “core updump.”
A core updump may be required if the EFM 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.
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. If they need additional
information to evaluate the condition, the technical support group may
request a core updump. Once the core updump process generates a file,
you can forward that file to the support personnel for evaluation and
resolution.
Use the following steps to preserve the “failed state” condition at a
system crash and perform a core updump:
1.
Set switch SW2-1 on the CPU module to OFF (Disable
Watchdog Timer). If switch SW2-4 is ON, set it to OFF (Enable
Core Updump).
Note: The factory default setting for switch SW2-4 is OFF.
2.
5-26
Wait for the error condition (typically 3F on the SCM’s status
LEDs).
Service & Troubleshooting
Revised Dec-2013
ControlWave EFM Instruction Manual
3.
Connect the ControlWave EFM’s Comm Port 1 to a PC using a
null modem cable.
4.
If the SCM’s mode switch has a Run/Remote/Local switch, set it
as follows. Set both SW1-1 and SW1-2 to the right (open)
operation or both to the left (closed).
Start the PC’s HyperTerminal program (at 115.2 kbaud) and
generate a receive using the 1KX-Modem protocol. Save the
resulting core updump in a file so you can forward it later to the
technical support group.
5.
By setting the CPU module switches SW2-1 and SW2-4 both off before
the EFM fails, you prevent the EFM from automatically recovering
from the failure and enable it to wait for you to take a core updump.
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
Disabled).
Additionally, for the SCM mode switch, set switch SW1-1 to open
(right) and SW1-2 to closed (left).
With these switches set, power up the EFM and recommence standard
operations.
Revised Dec-2013
Service & Troubleshooting
5-27
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ControlWave EFM Instruction Manual
Appendix A – ControlWave EFM Electronic Flow Meter –
Special Instructions for Class I, Division 2
Hazardous Locations
1. The ControlWave Electronic Flow Meter (EFM) 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 appendix carefully before
installing a nonincendive ControlWave Electronic Flow Meter
(EFM). In the event of a conflict between the ControlWave EFM
Instruction Manual (CI-ControlWave EFM) and this appendix,
always follow the instructions in this appendix
2. The ControlWave Electronic Flow Meter (EFM) includes both
nonincendive and unrated field circuits. Unless a circuit is
specifically identified in this appendix as nonincendive, the circuit is
unrated. Unrated circuits must be wired using Div. 2 wiring methods
as specified in article 501-4(b) of the National Electrical Code
(NEC), NFPA 70 for installations in the United States, or as
specified in Section 18-152 of the Canadian Electrical Code for
installation in Canada.
3. The local communications port terminates in a D-Type connector on
the bottom of the ControlWave Electronic Flow Meter (EFM)
enclosure. The wiring on this connector is unrated. No connections
may be made to this port unless the user ensures that the area is
known to be nonhazardous. Connections to this port are temporary,
and must be short in duration to ensure that flammable
concentrations do not accumulate while it is in use.
4. The optional power system (solar panel and battery) approved for
use with the nonincendive ControlWave Electronic Flow Meter
(EFM) are described in the model specification. The connection to
the solar panel is approved as a nonincendive circuit so that Division
2 wiring methods are not required. The nominal panel voltage must
match the nominal battery voltage (12V).
5. An RTD is normally supplied with the ControlWave EFM.
Connection to the RTD is approved as a nonincendive circuit, so
that Division 2 wiring methods are not required.
6. Signal connectors available for customer wiring are listed in Table
A1. I/O connections are unrated and must be wired using Div. 2
wiring methods.
Revised Dec-2013
Appendix A
A-1
ControlWave EFM Instruction Manual
7. The UL listed nonincendive ControlWave EFM may include
radio/modem communications (listed on the model spec.) that is
used in conjunction with a 30W Solar Panel and 12V, 33AH Lead
Acid Battery System. Connection to the radio or modem is approved
as a nonincendive circuit, so that Division 2 wiring methods are not
required.
8. The UL listed nonincendive ControlWave EFM may include a
Digital to Relay I/O Board (option). No field wiring
connections/removals should be made at the Digital to Relay I/O
Board unless the area is known to be nonhazardous. Digital to Relay
I/O Board I/O circuitry is unrated an must be wired using Div. 2
wiring methods.
9. The UL listed nonincendive ControlWave EFM may include a 21V
Power Supply Board (option). No field wiring connections/removals
should be made at the 21V Power Supply Board unless the area is
known to be nonhazardous. 21V Power Supply Board Transmitter
Interface circuitry is unrated and must be wired using Div. 2 wiring
methods.
WARNING #1
EXPLOSION HAZARD
Do NOT disconnect Solar Power from the Battery or any other power
connections within the ControlWave EFM enclosure (including
connectors TB1 through TB6 on the Power Distribution Board,
connector TB1 on the System Controller Module, any power
connections to optional items such as radio, modem, Digital to Relay
I/O Board, 21V Power Supply Board, or cabling to the Display/Keypad)
unless the area is known to be nonhazardous.
WARNING #2
EXPLOSION HAZARD
Substitution of components may impair suitability for use in Class I,
Division 2 environments.
WARNING #3
EXPLOSION HAZARD
The area must be known to be nonhazardous before
servicing/replacing the unit and before installing or removing I/O
wiring.
WARNING #4
EXPLOSION HAZARD
Do NOT disconnect equipment unless power has been disconnected
and the area is known to be non-hazardous.
A-2
Appendix A
Revised Dec-2013
ControlWave EFM Instruction Manual
Table A-1. Module/Board Customer Wiring Connectors
Module/Item
CPU Module
CPU Module
Connector
J3 – COM1, 9-pin Male Dsub
J4 – COM2, 9-pin Male Dsub RS-232
J5 – COM3, 9-pin Male Dsub RS-485
Wiring Notes
Factory connected to local comm. port.
Refer to item 3 of this appendix.
Remote comm. port: For radio or external
network comm. Refer to model spec. and
item 6 of this appendix. When used for
network comm., use Div 2 wiring
methods. If COM2 is used in conjunction
with a radio/modem refer to item 7 of this
appendix.
SCM Module
J2 – Display interface RJ45 female
Factory Wired.*
SCM Module
P2 – MVT interface
Factory Wired.*
SCM Module
TB1 – Input power
Typically factory wired *
SCM Module
TB2 – RTD Interface
Field wired – refer to Item 5 of this
appendix.
Exp. Comm. Module 1
J4 – COM4, 9-pin Male Dsub RS-232
Remote Comm. Port: For radio or
external Network Comm. Refer to model
spec. and item 6 of this appendix. When
used for Network Comm., use Div. 2
wiring methods. If COM4 is used in
conjunction with a radio/modem refer to
item 7 of this appendix.
J5 – COM5, 9-pin Male Dsub RS-485
Exp. Comm. Module 1
J8 – COM7, RJ11 female
Modular connection to phone company
equipment.
Exp. Comm. Module 2
J4 – COM8, 9-pin Male Dsub RS-232
Remote Comm. Port: For radio or
external Network Comm. Refer to model
spec. and item 6 of this appendix. When
used for Network Comm., use Div. 2
wiring methods. If COM8 is used in
conjunction with a radio/modem refer to
item 7 of this appendix.
J5 – COM9, 9-pin Male Dsub RS-485
Exp. Comm. Module 2
J8 – COM11, RJ11 female
Modular connection to phone company
equipment. Refer to the warning #2, #3,
#4, and item 7 of this appendix.
Analog I/O Module
TB1/TB2 – 10-pin terminal
blocks
Field I/O wiring connectors are unrated;
use Div. 2 wiring methods.*
Digital I/O Module
TB1/TB2 – 10-pin terminal
blocks
Field I/O wiring connectors are unrated;
use Div. 2 wiring methods.*
HSC Input Module
TB1/TB2 – 10-pin terminal
blocks
Field I/O wiring connectors are unrated;
use Div. 2 wiring methods.*
Mixed I/O Module
TB1/TB2 – 10-pin terminal
blocks
Field I/O wiring connectors are unrated;
use Div. 2 wiring methods.*
Digital to Relay I/O Board
J1 10-pin in-line connector
Field I/O wiring connector is unrated; use
Div. 2 wiring methods. Refer to item 8 of
this appendix.*
Power Distribution Board (See
warning #1 of this appendix)
TB1 – 3-pin terminal block
TB2 – 2-pin terminal block
TB3 – 2-pin terminal block
TB4 – 2-pin terminal block
Primary Power Input – User wired *
Main Power Out 1 – Factory wired *
Main Power Out 2 – Factory wired *
Fused Power Out 1 – Factory wired *
Revised Dec-2013
Appendix A
A-3
ControlWave EFM Instruction Manual
Module/Item
Connector
TB5 – 2-pin terminal block
TB6 – 2pin terminal block
Wiring Notes
Fused Power Out 2 – Factory wired *
Fused Power Out 3 – Factory wired *
21V Power Supply Board (See
warning #1 and item 9 of this
appendix)
TB1 – 3-pin terminal block
TB2 – 4-pin terminal block
12V power input – Factory wired *
21V Transmitter Power – Field wired
TB2 is unrated, use Div. 2 wiring
methods.
Enclosure bottom
Local Port circular
connector
Local comm. port – Factory wired. Refer
to item 3 of this appendix. *
Note: * These wires should only be installed/removed when the item
(PCB) in question is installed / removed or when checking
wiring continuity. The area must be known to be nonhazardous
before servicing / replacing the unit and before installing or
removing PCBs, connectors, or individual I/O or power wires.
Refer to warnings #2, #3, #4 of this appendix. All input power
and I/O wiring must be performed in accordance with Class I,
Division 2 wiring methods as defined in Article 501-4(b) of the
National Electrical Code, NFPA 70, for installations within the
United States, or as specified in Section 18-152 of the Canadian
Electrical Code for installation in Canada.
A-4
Appendix A
Revised Dec-2013
ControlWave EFM Instruction Manual
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. Grasp the ECOM Module with one hand. Squeeze
both sides of the cover panel (just below the unit’s top) and pull up
and away to release the cover panel and EMI Gasket from the PCB
(see Figure D2).
Revised Dec-2013
Modem Installation
D-1
ControlWave EFM Instruction Manual
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.
D-2
Modem Installation
Revised Dec-2013
ControlWave EFM Instruction Manual
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.
D2.1.2 Configuring the MultiTech Modem (MT9234SMI)
To configure a model MT9234SMI Modem (installed on an ECOM
Module), perform the following steps:
1.
If required, remove the ECOM Module from the controller (see
Figure D1).
2.
Place the modem into configuration mode by setting ECOM
Module jumper JP2 onto pins 2 and 3. This enables
configuration of the modem through Comm. Port 4 for modem
on ECOM1 or through COMM. Port 8 for modem on ECOM2.
3.
Connect a full duplex ControlWave null modem cable (see
Figure D3) between a PC and Comm. Port 4 (ECOM1) to
configure modem on ECOM1 or Comm. Port 8 (ECOM2) to
configure modem on ECOM2.
PC
9-Pin Female
“D” Connector
CW u/CW EFM
9-Pin Female
“D” Connector
P1
P2
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
(Looking into
Wire Terminal Side
of
Cable Connectors)
or
vice
versa
1 = DCD
6 = DSR
2 = RXD
7 = RTS
3 = TXD
8 = CTS
4 = DTR
5 = GND
Figure D2. Internal Modem Configuration P/N 392843-01-3 Full-duplex Null Modem
Cable Diagram
4.
Revised Dec-2013
Open HyperTerminal on the PC and set the PC communication
port settings as follows:
Modem Installation
D-3
ControlWave EFM Instruction Manual








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.
Modem Installation
Revised Dec-2013
ControlWave EFM Instruction Manual
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.com
PANASONIC (CR 2032)
LITHIUM
MANGANESE
DIOXIDE COIN
CELL BATTERY
Emerson Part
Number & Media
Notes
W15020X0012
http://www.panasonic.com
ENERGIZER (CR 2032)
http://www.energizer.com
SANYO (CR 2032)
VARTA (CR 2032)
http://www.vartamicrobattery.com
B.B. Battery Co., Ltd.
(BP33-12)
12V – 33AH/20 HR
SEALED LEAD
ACID BATTERY
395407-03-6
http://www.bb-battery.com/
Revised Dec-2013
Appendix Z
Z-1
This page is intentionally left blank
ControlWave EFM Instruction Manual
Index
A
D
ACCOL3 Firmware Library ................................. 1-9
Analog averaging .............................................. 1-12
Defaults
Comm Ports .................................................... 4-2
Diagnostic software........................................... 5-19
Digital to relay I/O board
removing and replacing ................................ 5-10
Disconnecting RAM Battery ..................... 5-11, 5-12
Display/Keypad ................................................. 2-50
Downloading
the ControlWave project ................................. 4-4
B
Backplanes ......................................................... 1-3
Backups .............................................................. 4-5
Battery
Disconnecting ...................................... 5-11, 5-12
Lithium backup ............................................. 5-10
removing and replacing the lead-acid battery 5-8
replacing ....................................................... 5-10
Bezel
Removing ....................................................... 5-6
Replacing........................................................ 5-6
Boot FLASH memory
amount............................................................ 1-5
C
Cables
RS-232 ......................................................... 2-35
RS-485 ......................................................... 2-40
Chassis ............................................................... 2-6
Checking
LEDs ............................................................. 5-12
Wiring ........................................................... 5-18
Class I, Division 2 ........................................ 2-2, A-1
Communication problems
common reasons for ..................................... 5-18
Communication Ports
defaults ........................................................... 4-2
Ethernet ........................................................ 2-42
Modem.......................................................... 2-46
RS-232 ......................................................... 2-34
RS-485 ......................................................... 2-41
Communications
Ethernet Loop-back Test ..................... 5-24, 5-25
Loop-back Test .................................... 5-22, 5-23
protocols supported ...................................... 1-10
ControlWave project
downloading ................................................... 4-4
Core Updump ................................................... 5-26
CPU Module
description ...................................................... 1-4
Installation .................................................... 2-29
jumpers ......................................................... 2-30
Lithium battery backup ................................. 5-10
removing ......................................................... 5-6
replacing ......................................................... 5-6
switches ........................................................ 2-31
Revised Dec-2013
Index
E
ECOM
Installation .................................................... 2-44
ECOM Modules
removing ......................................................... 5-8
replacing ......................................................... 5-8
Energy calculation............................................. 1-13
Energy integration ............................................. 1-13
Environmental specifications .............................. 2-2
Ethernet Loop-back Test ......................... 5-24, 5-25
Ethernet Ports ................................................... 2-42
Extension calculation ........................................ 1-12
F
Features .............................................................. 1-1
Field repair .......................................................... 5-6
Figures
1-1. ControlWave EFM Enclosure .................. 1-2
1-2. CPU Module ............................................ 1-5
1-3. Expansion Communications (ECOM)
Module .......................................................... 1-7
1-4. Two ControlWave EFM I/O Modules with
bezel ............................................................. 1-8
1-5. ControlWave Programming Environment 1-9
2-1. 4 Slot ControlWave EFM Component ID
Diagram ........................................................ 2-3
2-2. 8 Slot ControlWave EFM Component ID
Diagram ........................................................ 2-4
2-3. 8 or 4 Slot ControlWave EFM Housing ... 2-7
2-4. ControlWave EFM Bottom View.............. 2-8
2-5. Side View of ControlWave EFM ............. 2-9
2-6. 4-Slot ControlWave EFM ...................... 2-10
2-7. 8-Slot ControlWave EFM – Base Chassis
Assembly Dimensions ................................ 2-11
2-8. ControlWave EFM NEMA 3X Enclosure
Dimensions ................................................. 2-12
2-9. Process Flange and Optional Manifold
Block Connectors ....................................... 2-14
2-10. ControlWave EFM Direct Mount
Installation with Cathodic Protection .......... 2-15
IND-1
ControlWave EFM Instruction Manual
2-11. ControlWave EFM Remote Installation with
Cathodic Protection .................................... 2-16
2-12. System Controller Module Component ID
Diagram ...................................................... 2-18
2-13. SCM TB1 Wiring ................................. 2-22
2-14. 30 or 40 Watt Solar Panel Mounting
Diagram ...................................................... 2-23
2-15. Enclosure with Sealed Lead-acid Battery
Installed ...................................................... 2-25
2-16. Power Distribution Board .................... 2-26
2-17. Power Distribution Board and Other
Options – Snap Track Mounting ................ 2-27
2-18. 21V Power Supply Board .................... 2-28
2-19. CPU Module with Three Serial Ports .. 2-29
2-20. CPU Module with Three Serial Ports and
One Ethernet Port ...................................... 2-30
2-21. Male DB9 9-Pin Connector ................. 2-35
2-22. Full-duplex and Half-duplex Cable ...... 2-36
2-23. Full-duplex and Half-duplex Cable ...... 2-36
2-24. Communication Interface Cable for
Connection to Case-Mounted (External) Radio
or Modem ................................................... 2-37
2-25. Full-duplex and Half-duplex Cable ...... 2-37
2-26. PC Connected to ControlWave EFM via DType Local Port .......................................... 2-37
2-27. PC Connected to ControlWave EFM via
Circular Local Port...................................... 2-38
2-28. RJ-45 Ethernet Connector .................. 2-42
2-29. Standard 10/100Base-T Ethernet Cable
(CPU Module to Hub) ................................. 2-42
2-30. Point-to-Point 10/100Base T Ethernet
Cable .......................................................... 2-43
2-31. ECOM1 with Two Serial Ports, and a
Modem ....................................................... 2-44
2-32. ECOM2 with Two RS-232 and Two RS485 Ports .................................................... 2-45
2-33. Full-duplex and Half-duplex Cable ...... 2-46
2-34. ECOM Modem Installation .................. 2-46
2-35. PTSN Field Connections for ControlWave
Micros (and EFMs) ..................................... 2-48
2-36. Phone Cord Wiring .............................. 2-48
2-37 Bezel Assembly.................................... 2-50
2-38. Optional 2-Button & 25-Button Keypads ..251
4-1. Mode Switch............................................ 4-2
4-2. Saving a Backup of Your Project ............ 4-6
5-1. HyperTerminal Mode Menu .................... 5-4
5-2. HyperTerminal (Ready to Download)...... 5-4
5-3. Send File dialog box................................ 5-5
5-4. HyperTerminal (Download in progress) .. 5-5
5-5. SCM Status LED Hexadecimal Codes.. 5-15
5-6. CPU Module Comm Connectors & LEDs ..516
5-7. Type 1 ECOM Comm Connectors and LEDs5-17
5-8. Type 2 ECOM Comm Connectors and LEDs5-17
5-9. I/O Module LEDs ................................... 5-18
5-10 NetView ................................................ 5-21
5-11. WINDIAG Main Diagnostics Menu ...... 5-21
5-12. RS-232 Loop-back Plug ...................... 5-22
IND-2
Index
5-13. RS-485 Loop-back Plug ...................... 5-23
5-14 Communications Diagnostic menu....... 5-24
5-15 RJ-45 Ethernet Loop-back Plug ........... 5-25
5-16. Ethernet Diagnostic Menu ................... 5-25
Firmware upgrade ............................................... 5-2
HyperTerminal ................................................ 5-3
LocalView ....................................................... 5-3
System Firmware Downloader ....................... 5-2
FLASH memory
amount............................................................ 1-5
Flow calculations
supported...................................................... 1-11
Flow rate calculations
AGA3 ............................................................ 1-12
AGA7 ............................................................ 1-12
Flow time calculations
AGA3 ............................................................ 1-12
AGA7 ............................................................ 1-12
Fuse
SCM .............................................................. 2-18
G
Grounding ......................................................... 2-13
H
Hazardous locations
special instructions for .................................... A-1
Historical data storage ...................................... 1-13
Housings ...................................................... 1-3, 2-6
Humidity
specifications .................................................. 2-2
HyperTerminal .................................................... 5-3
I
I/O Configurator .................................................. 1-9
I/O Modules
general............................................................ 1-8
removing ......................................................... 5-7
replacing ......................................................... 5-7
Installation
Class 1, Div 2 ................................................. 2-2
CPU .............................................................. 2-29
ECOM ........................................................... 2-44
Overview......................................................... 2-5
SCM .............................................................. 2-19
J
Jumpers
CPU .............................................................. 2-30
SCM .............................................................. 2-19
K
Keypad/Display ................................................. 2-50
Revised Dec-2013
ControlWave EFM Instruction Manual
L
Lead acid battery
removing and replacing .................................. 5-8
LEDs
Checking....................................................... 5-12
CPU module ................................................. 5-15
LocalView............................................................ 5-3
Loop-back Test ........................................ 5-22, 5-23
S
M
Material Safety Data Sheets (MSDS)
how to obtain .................................................. Z-1
Memory
Boot FLASH.................................................... 1-5
FLASH amount ............................................... 1-5
SDRAM amount.............................................. 1-6
SRAM amount ................................................ 1-6
Mode switch ........................................................ 4-1
Modem ................................................................ D-1
Communication Ports ................................... 2-46
Modem (case mounted)
removing and replacing ................................ 5-10
Modules
CPU ....................................................... 1-4, 2-29
I/O ................................................................... 1-8
SCM ....................................................... 1-6, 2-17
Mounting the housing ......................................... 2-7
N
Nominations ...................................................... 1-16
O
Odorizer ............................................................ 1-16
Operator’s keypad/display ................................ 2-50
P
Packaging
modules .......................................................... 2-6
Power
connecting or disconnecting ........................... 4-1
Power distribution board
removing and replacing .................................. 5-9
Power supply board (21V)
removing and replacing .................................. 5-9
Pressure tap ..................................................... 1-13
Protocols
supported in ControlWave ............................ 1-10
PSTN ................................................................ 2-47
PSTN Modem ................................................... 2-46
R
Radio (case mounted)
removing and replacing ................................ 5-10
RAM Battery
Disconnecting ...................................... 5-11, 5-12
Revised Dec-2013
Repair in field ...................................................... 5-6
RS-232 Ports .................................................... 2-34
Cables........................................................... 2-35
RS-485 Ports .................................................... 2-41
Cables........................................................... 2-40
configuration switch ...................................... 2-33
Run switching.................................................... 1-15
Running diagnostic software ............................. 5-19
Index
Sampler ............................................................. 1-16
SCM ............. See System Controller Module (SCM)
SDRAM memory
amount ............................................................ 1-6
Service Tools ...................................................... 5-1
Site Considerations ............................................. 2-1
Soft Switches
lock/unlock switch ......................................... 2-32
use/ignore switch .......................................... 2-32
Software Tools .................................................... 1-8
Specifications
for temperature, humidity, vibration ................ 2-2
SRAM memory
amount ............................................................ 1-6
control switch ................................................ 2-32
Switches
CPU .............................................................. 2-31
Mode ............................................................... 4-1
System Controller Module (SCM) ..................... 2-17
Installation .................................................... 2-19
Jumpers ........................................................ 2-19
LEDs ............................................................. 5-14
Mode Switch ................................................... 4-1
removing ......................................................... 5-7
replacing ......................................................... 5-7
TB1 Connectors............................................ 2-22
System Firmware Downloader ............................ 5-2
T
Tables
1-1. CPU Module Configurations
1-4
2-1. SCM Switch SW1 .................................. 2-20
2-2. Bulk Power Requirements ..................... 2-21
2-3. Solar Panel Tilt Angle ............................ 2-24
2-4. 21V Power Supply Board Terminal
Designations ............................................... 2-28
2-5. CPU Module Switch SW1 ..................... 2-31
2-6. CPU Module Switch SW2 ..................... 2-32
2-7. RS-485 Configuration Switch ................ 2-33
2-8. RS-232 Connectors on CPU ................. 2-34
2-9. RS-232 Connectors on ECOM .............. 2-34
2-10. RS-232 Port Connector Pin Assignment . 235
2-11. RS-232 Port Connector Pin Assignment . 238
2-12. RS-485 Connectors on CPU ............... 2-40
2-13. RS-485 Connectors on Type 1 ECOM 2-40
IND-3
ControlWave EFM Instruction Manual
2-14. RS-485 Connectors on Type 2 ECOM 2-40
2-15. RS-485 Port Connector Pin Assignment .240
2-16. RS-485 Network Connections............. 2-41
2-17. Ethernet 10/100Base-T CPU Module Pin
Assignments ............................................... 2-43
4-1. Default Comm Port Settings (by PCB) .... 4-2
5-1. LED Assignments on Modules .............. 5-12
5-2. System Status LED Codes on SCM ..... 5-14
5-3. CPU Module LEDs ................................ 5-15
5-4. COM Port Defaults for Diagnostics ....... 5-19
A-1. Module/Board Customer Wiring Connectors
......................................................................... 3
TB1 Connector
SCM.............................................................. 2-22
Temperature
specifications .................................................. 2-2
Troubleshooting .................................................. 5-1
common communication configuration problems
................................................................... 5-18
general.......................................................... 5-12
IND-4
Index
U
Unpacking components ...................................... 2-6
Updump ............................................................ 5-26
switch ............................................................ 2-32
Upgrading firmware ............................................ 5-2
V
Vibration
specifications .................................................. 2-2
Volume calculations
supported...................................................... 1-11
Volume integration ............................................ 1-13
W
Watchdog
enable switch ................................................ 2-32
WINDIAG .......................................................... 5-19
Wiring
Checking....................................................... 5-18
Revised Dec-2013
This page is intentionally left blank
ControlWave EFM
CI-ControlWave EFM
Instruction Manual
December 2013
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Remote Automation Solutions
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Emerson Process Management
Remote Automation Solutions
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Remote Automation Solutions
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Remote Automation Solutions
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