Bristol CI-ControlWaveEXP ControlWave I/O Expansion Rack Instruction Manual

Instruction Manual
CI-ControlWaveEXP
Aug., 2006
ControlWave
(I/O Expansion Rack)
www.EmersonProcess.com/Bristol
ControlWave EXP
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 Bristol 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, failsafe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional
in-formation is required, the purchaser is advised to contact Bristol .
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol for repairs or evaluation, please note
the following: The party sending such materials is responsible to ensure that the
materials returned to Bristol 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 Bristol and save Bristol harmless from any liability or
damage which Bristol 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 at the back of this manual for
proper care and handling of ESD-sensitive components.
Bristol 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
WARRANTY
A.
Bristol warrants that goods described herein and manufactured by Bristol are free
from defects in material and workmanship for one year from the date of shipment
unless otherwise agreed to by Bristol in writing.
B.
Bristol warrants that goods repaired by it pursuant to the warranty are free from
defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.
C.
Warranties on goods sold by, but not manufactured by Bristol, are expressly limited
to the terms of the warranties given by the manufacturer of such goods.
D.
All warranties are terminated in the event that the goods or systems or any part
thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.
E.
THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
F.
No agent of Bristol is authorized to assume any liability for it or to make any written
or oral warranties beyond those set forth herein.
REMEDIES
A.
Buyer's sole remedy for breach of any warranty is limited exclusively to repair or
replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Watertown office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.
B.
Under no circumstances will Bristol be liable for incidental or consequential
damages resulting from breach of any agreement relating to items included in this
quotation, from use of the information herein or from the purchase or use by Buyer,
its em-ployees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify
proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very
important since the information permits the Bristol Repair Dept. to effectively and
efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com)
and sending it via E-Mail to [email protected]. A Bristol Repair Dept.
representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Inc.
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795
A Bristol Repair Dept. representative will return call (or other requested method)
with a RA number.
D. Phone
Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Department representative will record a RA number on the form and complete Part I, then
send the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and
return your product to you.
Bristol Inc. Repair Authorization Form
(off-line completion)
(Providing this information will permit Bristol Inc. to effectively and efficiently process your return. Completion is required
to receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________
RA #___________________SH_
Standard Repair Practice is as follows: Variations to this is
practice may be requested in the “Special Requests” section.
• Evaluate / Test / Verify Discrepancy
• Repair / Replace / etc. in accordance with this form
• Return to Customer
Part I
Line No.____________
Please be aware of the Non warranty standard charge:
• There is a $100 minimum evaluation charge, which is
applied to the repair if applicable (√ in “returned”
B,C, or D of part III below)
Please complete the following information for single unit or multiple unit returns
Address No.
(office use only) Address No.
(office use only)
Bill to :
Ship to:
Purchase Order:
Contact Name:____________________________________
Phone:
Fax:
Part II
E-Mail:
Please complete Parts II & III for each unit returned
Model No./Part No.
Description
Range/Calibration
S/N
Reason for return :
1.
Failure
Upgrade
Verify Operation
Other
Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2.
Comm. interface used:
3.
What is the Firmware revision? _____________________
Standalone
RS-485
Ethernet
Other:______________
Modem (PLM (2W or 4W) or SNW)
What is the Software &version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A. If product is within the warranty time period but is excluded due
to Bristol’s warranty clause, would you like the product:
repaired
returned
replaced
scrapped?
B. If product were found to exceed the warranty period,
would you like the product:
repaired
returned
replaced
scrapped?
C. If product is deemed not repairable would you like your product:
returned
replaced
scrapped?
D. If Bristol is unable to verify the discrepancy, would you like the product:
returned
replaced
*see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact
that has the most knowledge of the problem is:
______________________________ phone_____________________
If we are unable to contact this person the backup person is: _________________________ phone_____________________
Special Requests: ____________________________________________________________________________________
____________________________________________________________________________________________________
Ship prepaid to:
Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442
Fax: 860-945-3875
Form GBU 13.01 Rev. B 04/11/06
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
•
Avoid Delays and problems in getting your system on-line
•
Minimize installation, start-up and maintenance costs.
•
Make the most effective use of our hardware and software.
•
Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at three locations: Houston, Orlando and our Watertown, CT
headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol products and realize the full
potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 6856200.
A Few Words About Bristol Inc.
For over 100 years, Bristol® has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Inc. instruments, controllers, and systems running year-in and
year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Help Files / Release Notes
Many Bristol software products incorporate help screens. In addition, the software typically
includes a ‘read me’ release notes file detailing new features in the product, as well as other
information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone
support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about ControlWave call (860) 945-2394 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865
or e-mail: [email protected]
For technical questions regarding ACCOL products, OpenBSI Utilities, UOI and all other
software except for ControlWave and OpenEnterprise products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: [email protected]
The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/
For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-9464.
You can e-mail the Communication Technology Group at:
[email protected]
Telephone Support - Non-Technical Questions, Product Orders, etc.
Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed on the rear cover of
this manual) or to your Bristol-authorized sales representative.
Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office
covers your particular area.
Visit our Site on the World Wide Web
For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com
Training Courses
Bristol’s Training Department offers a wide variety of courses in Bristol hardware and
software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at (860) 945-2343 for course
information, enrollment, pricing, and scheduling.
CI-ControlWaveEXP
ControlWave
I/O Expansion Rack
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 1 - INTRODUCTION
1.1
1.2
1.2.1
1.2.1.1
1.2.1.2
1.2.1.3
1.2.1.4
1.2.1.5
1.2.2
1.2.2.1
1.2.2.2
1.2.2.3
1.2.2.4
1.2.3
1.2.3.1
1.2.4
1.2.5
1.2.5.1
1.2.5.2
1.2.5.3
1.2.5.4
1.2.5.5
GENERAL DESCRIPTION ........................................................................................... 1-1
PHYSICAL DESCRIPTION........................................................................................... 1-3
CPU Module ................................................................................................................... 1-3
CPU Module Connectors ............................................................................................... 1-5
CPU Module Switches .................................................................................................... 1-7
CPU Module System Battery......................................................................................... 1-8
CPU Module LEDs and LCDs ....................................................................................... 1-8
CPU Module Memory Summary.................................................................................... 1-8
Power Supply/Sequencer Module................................................................................... 1-9
PSSM Power Switch SW1 ............................................................................................ 1-12
PSSB Board Fuses ........................................................................................................ 1-12
PSSB Board Connectors ............................................................................................... 1-12
PSSM LEDs .................................................................................................................. 1-12
ControlWaveEXP Backplanes ................................................................................... 1-14
I/O Module Access......................................................................................................... 1-15
ControlWave I/O Expansion Rack Chassis................................................................ 1-16
ControlWaveEXP I/O Modules .................................................................................. 1-17
Analog Input Module .................................................................................................... 1-17
Analog Output Module ................................................................................................. 1-18
Digital Input Module .................................................................................................... 1-18
Digital Output Module ................................................................................................. 1-18
Universal Digital Input Module................................................................................... 1-18
Section 2 - INSTALLATION & OPERATION
2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.1.1
2.3.2
2.3.3
2.3.3.1
2.3.3.2
2.3.3.3
2.3.3.4
2.3.4
2.3.4.1
2.3.4.2
2.3.4.3
2.3.4.4
INSTALLATION IN HAZARDOUS AREAS................................................................. 2-1
INSTALLATION SITE CONSIDERATIONS ............................................................... 2-3
Temperature & Humidity Limits .................................................................................. 2-3
Vibration Limits ............................................................................................................. 2-3
INSTALLATION/CONFIGURATION........................................................................... 2-3
Mounting the ControlWave I/O Expansion Rack Chassis.......................................... 2-6
ControlWave I/O Expansion Rack Grounding............................................................. 2-6
Power Supply/Sequencer Module (PSSM) Installation ................................................ 2-6
CPU Module Installation ............................................................................................... 2-7
CPU Module Switch Configuration ............................................................................... 2-8
Communication Ports ................................................................................................... 2-10
RS-232 & RS-485 Interfaces ........................................................................................ 2-11
Ethernet Port ................................................................................................................ 2-15
I/O Module Installation & Wiring................................................................................ 2-16
Installation of I/O Modules .......................................................................................... 2-17
Wire Connections.......................................................................................................... 2-21
Shielding and Grounding ............................................................................................. 2-21
Digital Inputs................................................................................................................ 2-21
ControlWaveEXP
Contents / 0 - 1
CI-ControlWaveEXP
ControlWave
I/O Expansion Rack
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 2 - INSTALLATION (Continued)
2.3.4.4.1
2.3.4.5
2.3.4.5.1
2.3.4.6
2.3.4.6.1
2.3.4.7
2.3.4.7.1
2.3.4.8
2.3.4.8.1
2.3.5
2.3.5.1
2.3.5.2
2.3.5.3
2.3.6
2.3.7
2.4
2.4.1
2.4.2
2.4.2.1
2.4.2.2
2.4.2.3
2.4.3
2.4.4
2.4.4.1
2.4.4.2
2.4.5
Digital Input Configurations........................................................................................ 2-22
Digital Outputs ............................................................................................................. 2-25
Digital Output Configurations..................................................................................... 2-25
Analog Inputs................................................................................................................ 2-28
Analog Input Configurations ....................................................................................... 2-28
Analog Outputs ............................................................................................................. 2-32
Analog Output Configurations..................................................................................... 2-32
Universal Digital Input Modules ................................................................................. 2-35
Universal Digital Input Configurations ...................................................................... 2-35
Power Supply Wiring.................................................................................................... 2-38
Bulk Power Supply Current Requirements ................................................................ 2-38
Power Wiring ................................................................................................................ 2-40
Watchdog Switch & Redundant Unit Wiring.............................................................. 2-41
Installation of the Lithium Backup Battery ............................................................... 2-42
Installation of the Bezel Assembly .............................................................................. 2-43
OPERATIONAL DETAILS .......................................................................................... 2-44
Configuring & Downloading the Application Load..................................................... 2-44
Upgrading ControlWave I/O Expansion Rack Firmware ......................................... 2-44
Using LocalView to Upgrade ControlWaveEXP Firmware ..................................... 2-45
Using Hyperterminal to Upgrade ControlWaveEXP Firmware.............................. 2-49
Remote Upgrade of ControlWaveEXP Firmware ..................................................... 2-52
Operation of the Reset Switch (Button) ...................................................................... 2-53
Module Hot Swapping .................................................................................................. 2-53
I/O Module Hot Swap Removal.................................................................................... 2-53
I/O Module Hot Swap Installation............................................................................... 2-53
Soft Switch Configuration and Communication Ports ............................................... 2-53
Section 3 - SERVICE
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.5.1
3.2.5.2
3.3
3.3.1
3.3.2
3.3.3
3.4
3.4.1
0 - 2 / Contents
SERVICE INTRODUCTION ........................................................................................ 3-1
COMPONENT REMOVAL/REPLACEMENT PROCEDURES................................... 3-1
Accessing Modules For Testing...................................................................................... 3-1
Removal/Replacement of the Bezel Assembly............................................................... 3-2
Removal/Replacement of the CPU Module ................................................................... 3-2
Removal/Replacement of the Power Supply/Sequencer Module .................................. 3-2
Module Hot Swapping .................................................................................................... 3-3
I/O Module Hot Swap Removal...................................................................................... 3-3
I/O Module Hot Swap Installation................................................................................. 3-3
TROUBLESHOOTING TIPS......................................................................................... 3-3
Power Supply/Sequencer Module (PSSM) Voltage Checks .......................................... 3-3
LED Checks .................................................................................................................... 3-4
Wiring/Signal Checks ..................................................................................................... 3-9
GENERAL SERVICE NOTES ....................................................................................... 3-9
Extent of Field Repairs................................................................................................... 3-9
ControlWaveEXP
CI-ControlWaveEXP
ControlWave
I/O Expansion Rack
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 3 - SERVICE (Continued)
3.4.2
3.4.3
3.5
3.5.1
3.5.1.1
3.5.1.2
3.5.1.3
3.5.1.4
3.6
Disconnecting RAM Battery .......................................................................................... 3-9
Port 80 Display POST Checks ....................................................................................... 3-9
WINDIAG DIAGNOSTICS .......................................................................................... 3-12
Diagnostics Using WINDIAG ...................................................................................... 3-14
Communications Diagnostic Port Loop-back Test ...................................................... 3-16
Serial Communications Port External Loop-back Test Procedure ............................ 3-17
Ethernet Diagnostic Port Loop-back Test ................................................................... 3-17
Ethernet Port 1 External Loop-back Test Procedure ................................................. 3-19
CORE UPDUMP........................................................................................................... 3-19
Section 4 - SPECIFICATIONS
4.1
4.2
4.2.1
4.2.2
4.2.3
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.6
4.7
CPU, MEMORY & PROGRAM INTERFACE .............................................................. 4-1
POWER SUPPLY/SEQUENCER MODULE ............................................................... 4-4
Input Power Specs. ......................................................................................................... 4-4
Power Supply Sequencer Specs. .................................................................................... 4-5
Power Supply Connectors............................................................................................... 4-6
BACKPLANE PCB ......................................................................................................... 4-7
COMMUNICATION PORTS ......................................................................................... 4-8
INPUT/OUTPUT MODULE SPECIFICATIONS......................................................... 4-8
Analog Inputs.................................................................................................................. 4-8
Digital Inputs.................................................................................................................. 4-9
Analog Outputs ............................................................................................................... 4-9
Digital Outputs ............................................................................................................. 4-10
Universal Digital Inputs .............................................................................................. 4-11
ENVIRONMENTAL SPECIFICATIONS.................................................................... 4-12
DIMENSIONS .............................................................................................................. 4-12
APPENDICES/SUPPLEMENTAL INSTRUCTION
Special Instructions for Class I, Division 2 Hazardous Locations.................Appendix A
Open Modbus Interface Information ...............................................................Appendix B
MATERIAL SAFETY DATA SHEETS ........................................................... Appendix Z
Site Considerations for Equipment Installation, Grounding & Wiring ...........S1400CW
Care and Handling of PC Boards and ESD-Sensitive Components ..................... S14006
REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS
WINDIAG - Windows Diagnostics for Bristol Controllers ...................................D4041A
Open BSI Utilities Manual ...................................................................................... D5081
ControlWave I/O Expansion Rack Quick Setup Guide........................................... D5122
Getting Started with ControlWave Designer.......................................................... D5085
Open BSI Technician Toolkit Manual ..................................................................... D5087
ControlWave Designer Reference Manual .............................................................. D5088
ControlWave Designer Programmer’s Manual ....................................................... D5125
ControlWaveEXP
Contents / 0 - 3
BLANK PAGE
Section 1
INTRODUCTION
1.1 GENERAL DESCRIPTION
ControlWave™ I/O Expansion Racks employ a scalable, modular hardware architecture
with a modern and rugged industrial design that is both simple to install and configure.
ControlWave™ I/O Expansion Racks have been designed and integrated to provide high
performance with low power consumption. Units are available with Backplanes that
support up to 2, 4 or 8 I/O modules. Each ControlWave™ I/O Expansion Rack is comprised
of a Backplane Board (mounted in the Chassis), a CPU Module, a Power Supply Module
and from 1 to 8 I/O modules. The CPU Module utilizes an Intel’s 386EX microprocessor
running at 25 MHz. In addition to the microprocessor and control logic, the CPU Board
includes a Serial Real Time Clock, an RS-232 communication port (COM1), a
communications port that is factory configured with RS-232 or RS-485 hardware (COM2), 1
or 2MB of Static RAM (SRAM), 2 or 4MB of simultaneous Read/Write FLASH,
Boot/Downloader in a 512kB FLASH BIOS IC, an I/O Bus Connector, a 10/100baseT
Ethernet port, and a PC-104 Bus Expansion Connector.
All system modules plug into the Backplane Board (2, 4, or 8 I/O versions available). Each
I/O Module provides the circuitry and field interface hardware necessary to interconnect
the assigned field I/O circuits. Additionally the CPU Board implements a Port-80 Display
consisting of two TI TIL311 Displays that are visible from the front edge of the CPU
Module. The Port-80 Display assembly will display POST codes during system boot as well
as run time status information. Isolated power is generated and regulated by the Power
Supply/Sequencer Module that provides +3.3Vdc, +5Vdc, +12Vdc (optional) and -12Vdc
(optional) from a bulk 10.6 to 20 Vdc or 20.7 to 30 Vdc source.
ControlWave™ I/O Expansion Racks provide the following key features:
•
•
•
•
•
•
•
•
•
Low power consumption
Small size (supports panel-mount or 19-inch rack-mount installations)
One fixed RS-232 asynchronous serial port (COM1) (PC/AT 9-pin male D-sub
connector)
One factory configured communications port (COM2) (RS-232 or RS-485) (PC/AT 9pin male D-sub connector)
CPU Architecture compatible with IBM Personal Computers with a system BIOS.
Optional Hot-Swap I/O Modules for backplanes that support 2, 4 or 8 I/O Modules.
Discrete Input Modules - 16/32 (24V) DIs
Discrete Output Modules - 16/32 (Open Source) DOs
Analog Input Modules - 8/16 (4-20mA) Current Input AIs
Analog Input Modules - 8/16 (1-5V) Isolated Voltage Input AIs
Analog Output Modules - 4/8 (4-20mA) Current Output AOs
Analog Output Modules - 4/8 (1-5V) Voltage Output AOs
Universal Digital Input Modules - 6/12 (12V or 24V) Isolated UDIs (for High/Low
Speed Counting or Contact Closure operation)
FLASH Boot/Downloader - 512kbytes contained in a single IC
FLASH Memory - 2 or 4 Mbytes mounted in a 48-pin TSOP
Memory (SRAM) - 1MB of soldered-down static RAM (SRAM) is implemented with
two 256K x 16 asynchronous SRAMs mounted in two 44-pin TSOPs and configured
ControlWaveEXP
Introduction / 1-1
•
•
•
•
•
•
as a 1M x 32-bit array. The 44-pin TSOPs will accept the next density SRAMs, 512K
x 16 for a total of 2MB.
PC/104-Plus Bus (BBI Proprietary) for system expansion - A 33MHz, 32-bit
Peripheral Component Interconnect (PCI) 2.2 specification compliant bus interface
is provided on a 120-pin connector. The PC/104-Plus Bus supports an optional BBI
3.3V powered secondary communications board (SCB). SCBs contain two RS-485 and
two RS-232 serial ports.
Backplane I/O Bus with separate data, address and control buffers, supported by
four interrupt lines (IOBIRQ1-4) and a 6MHz I/O Bus Clock.
10/100BaseT Ethernet port implemented by a SMCS LAN91C111 MAC + PHY Chip.
The built-in transceiver provides a Full/Half-duplex auto negotiation
implementation with a RJ-45 10/100BaseT Connector (J4).
Port 80 Display - implemented by two TI TIL311 Displays on the CPU Board and
intended for POST codes during system boot as well as for run time status information.
Battery backup for the real-time clock and the system’s SRAM is provided by an
external 3.6V, 950mA-hr lithium ½ AA cell battery connected to the CPU via a 3-pin
connector.
Watchdog MOSFET Switch connections for alarm, annunciation and/or control. The
signal /WDOGB (that drives the Watchdog MOSFET Switch) is generated by the
CPU Module when improper software operation is detected. This function is
supported by the Idle LED and the Watchdog LED on the CPU Module.
Figure 1-1 - ControlWave™ I/O Expansion Rack with 8 I/O Modules
1-2 / Introduction
ControlWaveEXP
1.2 PHYSICAL DESCRIPTION
ControlWave™ I/O Expansion Racks are comprised of the following major components:
•
•
•
•
•
CPU Module (see Section 1.2.1) & System Battery (see Section 1.2.1.3)
Power Supply/Sequencer Module (see Section 1.2.2)
Backplane Assembly (supports 2, 4 or 8 I/O Modules (see Section 1.2.3)
Chassis Assembly (see Section 1.2.4)
One or more I/O Modules (2, 4 or 8 Max.) (see Section 1.2.5)
1.2.1 CPU Module
The CPU Module houses the CPU Board and if present the optional Secondary
Communications Board (SCB). The multilayer CPU Board provides ControlWaveEXP
CPU, I/O monitor/control, memory and communication functions and operates over an
extended temperature range with long-term product reliability.
ControlWaveEXP CPU Boards are based on Intel’s 386EX Integrated microprocessor. In
addition to the processor and control logic, the CPU board includes: one RS-232 COM port,
one RS-232 or RS-485 COM port, 1 or 2 MB SRAM, Boot/Downloader in Flash, 2 or 4 MB
Flash, an I/O bus connector, Serial Real Time Clock, and a 10/100BaseT Ethernet port.
• 386EX Processor featuring:
32-bit internal architecture
25-MHz processor core
Timer/Counter unit
Watchdog timer
Programmable chip selects with wait state generation
Programmable I/O pins
Interrupt control unit
Two UARTs
Power Management
DMA and bus arbiter unit
• 512kB Flash Boot/Downloader, 29LV040B, 90 ns, 8-bit access
• 1 or 2 MB SRAM, 3.3V, 256K x 16, 55 nsec, with battery back-up
• 2 or 4 MB simultaneous read/write Flash, 1M x 16, 90 nsec. or 2M x 16, 90 nsec.
• RS-232 serial COM port
• RS-232 or RS-485 serial COM port
• I/O Bus interface capable of driving up to 8 slots
• 10/100baseT Ethernet interface implemented by SMSC LAN91C111 MAC + PHY chip
• MAC address/ configuration in serial EEPROM
• Serial Real Time Clock with battery backup
• Diagnostic display
• 8-position general purpose DIP Switch (SW1)
• 8-position Configuration DIP Switch (SW2) for Comm. Port 2 (COM2)
• 4-position Recovery/Battery Enable DIP Switch (SW3)
• Reset Button (Momentary)
Figure 1-2 provides the CPU Module block diagram. The shaded components of Figure 1-2
are components that are only available on optional Secondary Comm. Boards.
ControlWaveEXP
Introduction / 1-3
Figure 1-2 - Block Diagram of ControlWave™ I/O Expansion Rack CPU Board
Two basic versions of the CPU Module are available:
CPU Bd. (CPU has 2 RS-232 & 1 Ethernet Ports) (without SCB)
CPU Bd. (CPU has 1 RS-232, 1 RS-485 & 1 Ethernet Ports) (without SCB)
Note:
CPU Modules with an RS-485 Port assigned to CPU Comm. Port 2, aren’t
available with a Secondary Communications Board (SCB).
The Boot/CPU Operating Firmware is contained in a single 512 Kbyte uniform sector
FLASH IC (referred to as the Boot/Downloader FLASH). This device resides on the Local
Bus, operates at 3.3V and is configured for 8-bit access.
The CPU Board contains a 48-pin TSOP site that accepts FLASH devices ranging in density
from 2 to 4 Mbytes. Units are factory configured for from 2 to 4 Mbytes of industrial
simultaneous read/write (SMR) FLASH memory. The FLASH memory provides 16-bit
read/write access and is connected to the Local Bus.
The base version of the CPU Module has 1Mbyte of soldered-down static RAM,
implemented with two 256K x 16 asynchronous 70ns SRAMs that are configured as a 1M x
32-bit array. SRAM operate at 3.3V and are packaged in 44-pin TSOPs. An additional
1Mbyte of SRAM may be factory added to raise the board total to 2Mbyte.
1-4 / Introduction
ControlWaveEXP
SRAM is placed into data retention mode (powered by a backup 3.6V lithium battery) when
power is lost. The SRAM supports 16-bit or 8-bit accesses and is connected to the Local Bus.
1.2.1.1 CPU Module Connectors
The CPU Modules contains nine (9) user accessible interface connectors. Their functionality is summarized in Table 1-1.
Table 1-1- User Accessible CPU Module Connector Summary
Ref.
J1
J2
J3
J4
J6
J1
J2
J3
J4
# Pins
9-pin
9-pin
8-pin
132-pin
3-pin
8-pin
9-pin
8-pin
8-pin
Function
COM1 male D-sub (RS-232)
COM2 male D-sub (RS-232 or RS-485)
Ethernet 10/100Base-T RJ-45
I/O Bus Connector
Battery Connector
COM3 RJ-45 (RS-485)
COM4 male D-sub (RS-485)
COM5 RJ-45 (RS-232)
COM6 RJ-45 (RS-232)
Notes
see Figure 4-2 & Table 4-2
see Figure 4-2 & Table 4-3
see Figure 4-4 & Table 4-5
see Figure 4-1
see Figure 4-5
SCB - see Figure 4-3 & Table 4-4
SCB - see Figure 4-2 & Table 4-3
SCB - see Figure 4-3 & Table 4-4
SCB - see Figure 4-3 & Table 4-4
Figure 1-3A - ControlWave I/O Expansion Rack CPU Module (without SCB)
CPU Board Comm. Port Connectors J1 and J2 and SCB Comm. Port Connector J2
The CPU Module supports up to three external 9-pin RS-232 serial ports (COM1, COM2 &
COM4. COM1 (J1), COM2 (J2) and COM4 (J2 - located on the Secondary Communications
Board (SCB) a PC/104 Plus expansion option) utilize standard 9-pin male D-sub connectors
and are PC/AT compatible ports. COM4 is factory configured for Isolated RS-485 operation.
COM2 can be factory configured for isolated RS-485 operation if the SCB option is not
present.
ControlWaveEXP
Introduction / 1-5
Figure 1-3B - ControlWave I/O Expansion Rack CPU Module (with SCB)
CPU Module Comm. Port Connectors J1, J3 and J4 (SCB)
Three 8-pin RJ-45 connectors (J1, J3 and J4) are provided on the Secondary Communications Board (SCB). COM5 (J3) and COM6 (J4) support RS-232 operation. COM3
(J1) is factory configured for isolated RS-485 operation.
Ethernet Port Connector J3
An Ethernet port is supported via an 8-pin RJ-45 connector. The 10/100BaseT Ethernet
interface is implemented using an SMSC LAN91C111 controller. This device logically
resides on the ISA bus and provides a full/half-duplex auto negotiation implementation.
CPU Board I/OB Connector J4
CPU Board I/O Bus connector J4 provides a 132-pin interface between slot #2 (P2) of the
Backplane PCB and the CPU Module. Separate data, address and control buffers provide
access to the I/O bus which in turn provides 2, 4 or 8 slots of memory mapped I/O Modules.
The CPU Board interface to the I/O Modules is level shifted to a 5V bus through a set of
buffers and transceivers that are capable of driving up to eight I/O Modules. The I/O Bus
Clock is a free running 6MHz clock.
A signal originating from the power supply sequencer (on the Power Supply Module)
disables the I/O bus buffers during insertion and removal of I/O Modules. Four interrupt
lines are provided for the I/O bus (IOBIRQ1, 2, 3 & 4). The interrupt request inputs are
pulled to ground to reduce power consumption due to the active driver setup used on the I/O
Modules. An IRQ signal is driven high when an interrupt is generated. The IRQ inputs will
be held high by the interrupting I/O Module until the CPUs interrupt service routine has
begun servicing it.
1-6 / Introduction
ControlWaveEXP
CPU Board Battery Connector J6
CPU Board connector J6 provides a 3-pin interface to an external 3.6V Lithium Battery
that is a component of the CPU Module. The 3.6V, 950mA-hr lithium ½ AA cell battery
provides backup power for the real-time clock, CMOS RAM and the system’s Static RAM
(SRAM). Battery backup is enabled when CPU Module switch SW3-4 is set to the ON
position.
1.2.1.2 CPU Module Switches
Cutouts are provided in the CPU Module to provide user access to the configuration
switches. Two user configurable DIP switches are provided on the CPU Board’s right side
(users left); eight-bit DIP switch SW1 is provided for user configuration settings while fourbit DIP switch SW3 provides battery back-up and forced recovery functions. The CPU
Board’s left side (users right) has one eight-bit DIP switch (SW2) that provides
configuration for Comm. Port 2 (COM2) with loopback control for RS-232 operation or
loopback, termination control, and receiver bias settings for isolated RS-485 operation.
The optional Secondary Communications Board (SCB) has two eight position DIP switches
(SW1 for COM3 & SW2 for COM4) that provide loopback, termination control, and receiver
bias settings for isolated RS-485 operation associated with these Comm. Ports.
For all DIP switches, an OFF switch is read as “one,” and an ON switch is read as “zero.”
Table 1-2 - CPU Bd. Switch SW1 - User Configurations
Switch
Function
SW1-1
Watchdog Enable
SW1-2
SW1-3
SW1-4
SW1-5
SW1-6
SW1-7
SW1-8
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Normal Run or
Core Updump
SRAM Control
Redundancy
Enable/Disable
Unit A/Unit B
Enable
WINDIAG
Setting
ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches or FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Normal Run Mode
OFF = Causes the system to start a Core Updump
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Redundancy Disable
OFF = Redundancy Enable
ON = CPU assigned as ‘A’ CPU – OFF = CPU assigned as ‘B’ CPU
ON = Don’t allow WINDIAG to run test
OFF = Disable boot project and allow WINDIAG to run test
Table 1-3 - CPU Bd. SW3 - Firmware Load Control/Recovery Mode/Battery Enable
Switch
SW3-1
Function
Not Used
System Firmware
Load Control *
Setting
ON = Disable remote download of System Firmware
OFF = Enable remote download of System Firmware
ON = Force recovery mode (via CW Console)
SW3-3 Force Recovery Mode
OFF = Recovery mode disabled
SRAM & RTC
ON = Battery back-up enabled
SW3-4
Battery Enable
OFF = Battery back-up disabled
* = Boot PROM version 06 or higher and System PROM version 4.7 or higher
SW3-2
ControlWaveEXP
Introduction / 1-7
Table 1-4
Assignments of CPU Bd. Switch SW2 and SCB Bd. Switches SW1 & SW2
Comm. Ports 2, 3, & 4 Loopback & Termination Control (Respectively)
Switch
1
2
3
4
5
RS-232 Function
(COM2) Switch ON
DTR to DSR Loopback
TXD to RXD Loopback
N/A
N/A
RTS to CTS Loopback
6
N/A
7
8
N/A
N/A
RS-485 Function
Switch ON
TX+ to RX+ Loopback
TX- to RX- Loopback
100 Ohm RX+ Termination
100 Ohm RX- Termination
N/A
Slow Slew Rate - Open =
Fast
Closed = Slow
RX+ Bias (End Node)
RX- Bias (End Node)
Setting
ON - Only for Diagnostics
ON - Only for Diagnostics
ON - End Nodes Only
ON - End Nodes Only
ON - Only for Diagnostics
ON/OFF - As required
Factory Default = ON
ON - End Nodes Only
ON - End Nodes Only
The Momentary Reset Button allows the user to reset (stop and restart) the ControlWaveEXP when the unit is being tested via WINDIAG.
1.2.1.3 CPU Module System Battery
The CPU Board connects to an external battery via a three-pin connector (J10). This 3.6V,
950mA-hr lithium ½ AA cell (battery) provides backup for the real-time clock and the
System SRAM.
The system SRAM is specified to have a standby current of 50:A maximum for each part.
For a system containing 1MB or 2MB of System SRAM, a worst-case current draw of 110:A
allows a battery life of approximately 8508 hours.
A supervisory circuit is used to switch to battery power when VCC falls below VCC-10%.
For maximum shelf life, the battery may be isolated from the circuit by setting switch SW34 (on the CPU Board) to the OFF position. If the Real-time clock looses its battery backup a
ControlWave Designer system variable bit (_QUEST_DATE) is set at the host. This bit can
be used to post a message or alarm to the PC (see the ‘Systems Variables’ section of the
ControlWave Designer Programmer’s Handbook D5125).
1.2.1.4 CPU Module LEDs and LCDs
All CPU Modules have eight (8) LEDs on the CPU Board. Units equipped with the optional
Secondary Communications Board (SCB) have eight (8) additional LEDs. Additionally, all
CPU Modules are provided with a Port 80 Display assembly consisting of two TI TIL311
Displays that are visible from the front of the CPU Module. The Port 80 LCD Display
assembly provides POST codes during system boot as well as run time status indication.
During normal system operation, the Port 80 Display is powered down.
1.2.1.5 CPU Module Memory Summary
A brief synopsis of CPU Module memory is provided herein.
Boot/Download FLASH
512 Kbytes contained in a single IC. Boot/Recovery Firmware that runs the CPU Board is
contained in this device. The Boot/Recovery Firmware is contained in a single 512 Kbyte
1-8 / Introduction
ControlWaveEXP
Uniform Sector FLASH (USF) IC. This device resides on the Local bus, operates at 3.3V
and is configured for 8-bit access.
Figure 1-4 - CPU Module LEDs
Switch SW3-3 provides for forced update/recovery of the CPU Operating System via a user
prompted menu (at a PC) or via a boot from the Boot Firmware. If SW3-3 has been set to
the OFF (open) position when a reset occurs, the boot-up code passes control to the built-in
Recovery Command Processor that sends a recovery menu out to the user via the recovery
serial connection (Comm. Port 1) and a terminal program running on an external host
computer.
FLASH Memory
2 Mbytes to 4 Mbytes simultaneous read/write (non-volatile) FLASH mounted in a 48-pin
TSOP. The System Firmware is stored here. The FLASH memory is configured for 16-bit
read/write access and is connected to the Local bus. No hardware write protection is
provided for the FLASH array.
Static RAM Memory (SRAM)
1 Mbyte of soldered-down static RAM (SRAM) is implemented with two 256K x 16
asynchronous 70ns SRAMs that are configured as a 256K x 32-bit array. Each SRAM device
operates at 3.3V and is packaged in a 44-pin TSOP. An additional 1Mbytes of SRAM may
be factory installed. SRAM is placed into data retention mode (powered by a backup 3.6V
lithium battery) when power is lost. The SRAM supports 16-bit or 8-bit accesses and is
connected to the Local bus. Critical system information that must be retained during power
outages or when the system has been disabled for maintenance is stored here. Data
includes: Last states of all I/O.
1.2.2 Power Supply/Sequencer Module
The Power Supply/Sequencer Module (PSSM) plugs into the system’s Backplane Board
(Connector P1) via Compact PCI (CPCI) type keyed 110-pin connector J1. The front of the
ControlWaveEXP
Introduction / 1-9
PSSM contains a system power switch, as well as two pluggable terminal blocks for
external input power, watchdog MOSFET switch and redundant unit selection connections.
Three LEDs, visible through the front panel, provide the following status conditions:
PWRGOOD (power good: green), MC (master clear active: red) and PWRFAIL (power fail:
red)
PSSMs contain a DC to DC Converter that generates isolated voltages (+5Vdc (VCC),
+12Vdc and -12Vdc) for the CPU and various I/O Modules that plug into the Backplane
Board. A piggy-back converter board provides the +3.3Vdc required for CPU logic, memory
and FLASH devices.
Figure 1-5 - Power Supply/Sequencer Module
Also contained on the PSSM is the sequencer circuit that monitors the incoming power as
well as the isolated output supplies and has a reset/early power fail warning controller that
interfaces with the system CPU Module. Master Clear and Power Fail signals are
generated by the sequencer circuit when incoming power or the isolated supply voltages fall
below specified limits. Additionally, the sequencer circuit controls an on-board watchdog
MOSFET switch that will open when Master Clear is active or the CPU Module asserts the
Watchdog Bad signal.
The power supply operates from +10.6 to +20V or +20.7 to +30V (dc) with the nominal input
supply configuration (12V or 24V) factory set by on-board jumpers. A supervisory circuit
1-10 / Introduction
ControlWaveEXP
monitors the incoming power and the isolated supply voltages. The isolated supplies are
shut down when the incoming voltage drops below +10.6V for a +12V system or +20.7V, for
a +24V system.
The circuit that drives the watchdog MOSFET switch is on the secondary side of the power
supply. A solid state relay (SSR) actuates the watchdog hardware and is factory enabled or
disabled via an on-board jumper. When either /MC or /WDOGB is active, the on-board
watchdog hardware will be OFF. /WDOGB is a signal generated by the CPU Module when
its hardware detects improper software operation.
Figure 1-6 - Power Supply/Sequencer Module Block Diagram
The watchdog MOSFET switch is powered via the VI input of the terminal block and its
switched output is connected to the VO/NO output of the terminal block. The external
power source connected to the COM terminal must be referenced to the return point of the
input source that powers the PSSM (-VIN (PSGND).
PSSMs provide hot swap capability to allow insertion or extraction of I/O modules into or
from the Backplane assembly while the unit is powered. Neither the CPU Module or PSSM
ControlWaveEXP
Introduction / 1-11
are hot swappable. PSSM circuitry monitors two signals from each I/O module to detect
board insertion or extraction events. The PSSM Hot Swap Monitor (HSM) will inform the
CPU of these events and instruct the CPU to tristate all I/O module bus interface signals
after an appropriate delay. Additionally, the PSSM HSM will generate a slot specific, I/O
module master clear signal, until the insertion or extraction has been completed.
In the event that the PSSM sequencer generates a master clear signal in response to power
supply input or output conditions, the hot swap monitor (HSM) will generate Master Clear
signals for all I/O module slots.
1.2.2.1 PSSM Power Switch SW1
Switch SW1 is used to connect input power to PSSM circuitry and shared or separate field
voltage sources to I/O Modules via Controlled Power MOSFETs when the I side of the
switch has been pressed to its actuated position. This will turn the unit ON.
1.2.2.2 PSSB Board Fuses
The PSSM contains two fuses that aren’t field replaceable. Slow Blow Fuse F1 is rated at
3A for a +12V/24V system - protects the entire system. Slow Blow Fuse F2 is rated at 10A protects I/O Module field supplies.
1.2.2.3 Board Connectors
Connectors TB1, TB2 and J1 function as described below.
PSSB Bd. Terminal Block Connector TB1
TB1 provides 2 watchdog MOSFET switch connections:
TB1-1 = VO - Watchdog MOSFET Switch Output
TB1-2 = VI - Watchdog MOSFET Switch Input
TB1-3 = VR - Redundant Unit Control Input
PSSB Bd. Terminal Block Connector TB2
TB2 provides 5 input connections for bulk power:
TB2-1 = (+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
TB2-2 = (+VINF) Connected to TB2-1 or +9Vdc to +30Vdc supply
TB2-3 = (-VIN) (1st Supply Ground)
TB2-4 = (-VINF) (2nd Supply Ground) Internally connected to TB2-3
TB2-5 = Chassis Ground - CHASSIS ( )
PSSB Bd. Connector J1
Connector J1 is a 110-pin keyed CPCI type connector that interfaces Power, Ground and
Master Clear(s), I/O Board resident status/control (/BDINSLTn, /SWSn, /HBIR_NMI &
/IOBTRI), power supply status (/PWR_FAIL) and watchdog status (/WDOGB) signals to
Connector P1 on the Backplane Board.
1.2.2.4 PSSM LEDs
Three LEDs, visible through the front panel, will provide status conditions PWRGOOD
(power good: green), MC (master clear active: red) and PWRDOWN (power down: red).
1-12 / Introduction
ControlWaveEXP
When power is first applied or when the unit is reset, the red MC LED will illuminate for a
short period of time. The green PWRGOOD LED should be ON whenever the unit is
running and no power problems have been detected. The red PWRDOWN LED should only
be ON when power has dropped below acceptable levels.
Figure 1-7 - ControlWaveEXP Backplane Assemblies
ControlWaveEXP
Introduction / 1-13
1.2.3 ControlWaveEXP Backplanes
ControlWaveEXP Backplanes provide for the interconnection of the Power Supply/Sequencer Module (PSSM), CPU Module and I/O Modules. Backplane Assembly versions
are available in three versions, i.e., for supporting 2, 4 or 8 I/O modules. All module slot
connections are implemented with Compact PCI (CPCI) type connectors.
The main complement of signals on the Backplane implement an I/O bus for data transfer
between the CPU and I/O Modules. The I/O bus signal definition consists of a subset of ISA
bus signals that support memory mapped I/O to the 2, 4 or 8 possible I/O Module slots.
Interrupt lines are available for the first four I/O slots (P3 through P6). Note: I/O slots P7 P10 are referred to as Non Interrupt Capable slots 5 - 8.
Isolated power (+5V, +12V, -12V and PCOM) from the PSSM is connected to the CPU
(which also receives +3.3V) and all I/O Module slot positions. Additionally, the PSSM
supplies switched field power (+VINSWS, -VIN (PSGND)) to all I/O Module slots. The
power supply monitor/sequencer circuit (within the PSSM) provides /MC and PWR_FAIL
signals to the CPU thus providing properly timed early warning of low input or supply
voltages followed by a CPU reset to support the WARM START CPU function. The
watchdog circuitry on the PSSM is controlled by CPU signal /WDOGB.
Figure 1-8 - Backplane Assembly with Connector Coding Devices Installed.
The hot swap monitor (HSM) circuitry within the PSSM provides for the safe insertion and
extraction of I/O modules under power by coordinating interface signal conditioning to the
involved I/O slot with the CPU and the involved I/O Module. During detected hot swap
events, the HSM receives hot swap status signals /BDINSLT1 - /BDINSLT8 and /SWS1 1-14 / Introduction
ControlWaveEXP
/SWS8 from their respective I/O slots, issues properly timed /HBIR_NMI and /IOBTRI
signals to the CPU Module and outputs /MCn to the associated I/O slot (where n is the
involved slot number).
1.2.3.1 I/O Module Access
I/O memory address space is a contiguous 64KB area addressed by IOBA0 - IOBA15. Each
I/O module has a 16-bit general purpose address decoder and can be plugged into any of the
eight available slots. 128 bytes of memory are assigned per I/O module for local address
space and block size. Each I/O slot connector has a uniquely hardwired 3-bit slot address
(SLOT0 - SLOT2) to provide for CPU differentiation of up to 8 I/O slot modules.
Interrupt access is available for I/O slots 1 through 4 (P3 - P6) only.
Table 1-5 - Backplane Connector Coding Key Assignment
Connector #
P1
P2
P3 - P10
Module Type
Power Supply
CPU
I/O
Coding Device Color
Yellow
Blue
Green
Connectors P1 through P10 are equipped with connector coding devices. These color-coded
devices are physically unique to ensure that only the correct module type can be installed.
Modules are equipped with mating connector coding devices (yellow, blue or green) that
provide the service technician with a quick visual indication of the backplane slot(s) where
the module in question can physically reside.
Figure 1-9 - Backplane PCB Block Diagram
ControlWaveEXP
Introduction / 1-15
1.2.4 ControlWave I/O Expansion Rack Chassis
The ControlWaveEXP Backplane PCB and the modules that comprise the system are
housed in a Stainless Steel Chassis designed to accommodate 2, 4 or 8 I/O Modules. Any
ControlWave I/O Expansion Rack Chassis can be panel/wall mounted. ControlWave I/O
Expansion Rack Chassis that support 8 I/O Modules can be mounted to a 19-inch
equipment rack in lieu of panel/wall mounting. ControlWave I/O Expansion Rack Chassis
are factory shipped without any modules installed. The Chassis assembly also contains a
Ground Lug that accommodates up to a #4 AWG Ground Wire. Grounding the unit is
accomplished by connecting a ground wire between the Ground Lug and a known good
Earth Ground.
Figure 1-10 - The Chassis Assembly (with & without Bezel)
1-16 / Introduction
ControlWaveEXP
1.2.5 ControlWaveEXP I/O Modules
Five I/O Modules are available factory configured for either local or remote field device
wiring termination. I/O Modules are factory configured, encased, and factory sealed. A brief
overview of each I/O Module type is provided below. I/O Module specifications are covered
in Section 4.5.
1.2.5.1 Analog Input Module
Two types of AI Modules are available, i.e., 4-20mA or 1-5 Vdc input versions. Each module
contains field interface circuitry for up to 16 or 8 analog inputs. Each AI Module consists of
a Terminal Board Assembly, an Analog Input PCB, an LED PCB, an LED Housing
Assembly, a Terminal Housing Assembly, as well as I/O assembly and mounting hardware.
AI PCBs are connected to their associated Terminal Board Assembly via a 44-pin header
and to the ControlWaveEXP Backplane via a 110-pin connector.
Figure 1-11 - ControlWave I/O Module
ControlWaveEXP
Introduction / 1-17
1.2.5.2 Analog Output Module
AO Modules are factory configured to support either 4-20mA or 1-5 Vdc analog outputs.
Each module contains field interface circuitry for up to 8 or 4 analog outputs. Each AO
Module consists of a Terminal Board Assembly, an Analog Output PCB (with a daughter
board when configured for 1-5V operation), an LED Housing Assembly, a Terminal Housing
Assembly, as well as I/O assembly and mounting hardware. Each AO PCB is connected to
its associated Terminal Board Assembly via a 44-pin header and to the unit’s Backplane via
a 110-pin connector.
1.2.5.3 Digital Input Module
ControlWave DI Modules are factory configured to support either externally powered
source or dry contact DI applications. Each module contains field interface circuitry for up
to 32 or 16 discrete inputs with an input range of 24Vdc, a nominal input current is 5mA
and 30 millisecond input filtering. Each DI Module consists of a Terminal Board Assembly,
a Discrete Input PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing
Assembly, as well as I/O assembly and mounting hardware. Each DI PCB is connected to
its associated Terminal Block Assembly via a 44-pin header and to the unit’s Backplane via
a 110-pin connector.
1.2.5.4 Digital Output Module
Digital Output (DO) Modules provide a total of 32 or 16 DOs for control of signaling
functions. Each output contains an optically isolated open source MOSFET and surge
suppressor that are capable of handling 500mA @ 31V. Each DO Module consists of a
Terminal Board Assembly, a Discrete Input PCB, an LED PCB, an LED Housing Assembly,
a Terminal Housing Assembly, as well as I/O assembly and mounting hardware. Each DO
PCB is connected to its associated Terminal Block Assembly via a 44-pin header and to the
unit’s Backplane via a 110-pin connector.
1.2.5.5 Universal Digital Input Module
Universal Digital Input (UDI) Modules provide a total of 12 or 6 inputs. Each input is
optically isolated from the field device. UDI Modules are factory configured with all inputs
set with debounce enabled or with all inputs set with debounce disabled. With debounce
enabled, spurious pulses caused by relay contact bounce are eliminated. Individual UDI
inputs can be customer configured for a polled input, interrupt on change of state (COS) or
totalizer operation. Field inputs can be driven signals, open collector outputs or relay
contacts. The maximum input frequency is 10 kHz. For any input used as a totalizer, the
maximum totalized count before rollover is 65535 and the totalizer is not resetable through
software. Each UDI Module consists of a Terminal Board Assembly, a Universal Digital
Input PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as
well as I/O assembly and mounting hardware. Each UDI PCB is connected to its associated
Terminal Block Assembly via a 44-pin header and to the unit’s Backplane via a 110-pin
connector.
1-18 / Introduction
ControlWaveEXP
Section 2
INSTALLATION & OPERATION
2.1 INSTALLATION IN HAZARDOUS AREAS
ControlWave I/O Expansion Racks are not furnished in a housing. The modules that comprise the system are housed in a Stainless Steel Chassis designed to accommodate 2, 4 or 8
I/O Modules. Any ControlWave I/O Expansion Rack Chassis can be panel/wall mounted.
ControlWave I/O Expansion Rack Chassis that support 8 I/O Modules can be mounted to a
19” equipment rack in lieu of wall/panel mounting. Use in Class I, Division 2, Groups A, B,
C and D hazardous areas will require the selection of an appropriate enclosure that meets
the NEMA Type 3X or 4X specification.
Figure 2-1 - 8-I/O Module ControlWave - Mounting Diagram
ControlWaveEXP
Installation & Operation / 2-1
Figure 2-2 - 4-I/O Module ControlWave - Mounting Dimensions
Figure 2-3 - 2-I/O Module ControlWave - Mounting Dimensions
2-2 / Installation & Operation
CI-ControlWaveEXP
2.2 INSTALLATION SITE CONSIDERATIONS
Check all clearances when choosing an installation site. Make sure that the ControlWave
I/O Expansion Rack will be accessible for wiring and service. To install the ControlWave
I/O Expansion Rack Chassis, see Section 2.3.1.
2.2.1 Temperature & Humidity Limits
ControlWave I/O Expansion Racks have been designed to operate over a -40°F to +158°F
(-40°C to +70°C) temperature range (with storage at up to +185°F (+85°C)) and a 0% to 95%
Relative Humidity range. Make sure that the ambient temperature and humidity at the
measuring site remains within these limits. Operation beyond these ranges could cause
output errors and erratic performance. Prolonged operation under extreme conditions could
also result in failure of the unit.
2.2.2 Vibration Limits
Check the mounted enclosure, panel or equipment rack for mechanical vibrations. Make
sure that the ControlWave I/O Expansion Rack is not exposed to a level of vibration that
exceeds those given in the specifications. The ControlWave’s vibration limits are 1g for 10 150 Hz & .5g for 150 - 2000 Hz.
2.3 INSTALLATION/CONFIGURATION
ControlWave I/O Expansion Racks are shipped from the factory in separately boxed
modules as follows:
Chassis Assembly
Power Supply/Sequencer Module
CPU Module & Bezel
AO - Analog Output Module
AI - Analog Input Module
DO - Digital Output Module
DI - Digital Input Module
UDI - Universal Digital Input Module
Overview of Configuration
An overview of the three (3) steps required to configure a ControlWave I/O Expansion
Rack are provided below. For additional details refer to the ControlWave I/O Expansion
Rack Quick Setup Guide - document # D5122.
Step 1. Hardware Configuration
This involves unpacking the ControlWave I/O Expansion Rack hardware, mounting the
chassis, installing I/O modules, wiring I/O terminations, making proper ground
connections, connecting a communication cable to the PC workstation and setting switches.
To install and configure the ControlWave I/O Expansion Rack follow steps 1 through 12
below:
1. Remove the Chassis from its carton and install it at its assigned work site (see Section
2.3.1).
ControlWaveEXP
Installation & Operation / 2-3
2. Remove the PSSM Module from its carton and install it into Chassis slot 1, i.e., the
first slot from the left end of the installed unit (see Section 2.3.2).
3. Remove the CPU Module from its carton and install it into Chassis slot 2, i.e., the
second slot from the left end of the installed unit. CPU Module DIP Switches may be
configured before or after the module has been installed into the Chassis. See Section
2.3.3.
4. Configure/Connect appropriate communication port(s) (see Section 2.3.3.2). Connect
COMM. Port 1 or 2 of the ControlWave (depending on CPU Switch SW1 settings –
see Section 2.3.3.1) to a COMM. Port of a PC (typically PC COMM. Port 1). Note:
ControlWave COMM. Port 1 can only be used if CPU Switch SW1-8 has been set ON.
5. Remove any I/O Modules from their cartons and install them into the ControlWave
Chassis. I/O Modules reside in slots 3 through 4, 3 through 6 or 3 through 10 for units
supporting 2, 4 or 8 I/O Modules respectively. Install I/O wiring to each I/O Module
(see Section 2.3.4).
6. Install a ground wire between the Chassis Ground Lug and a known good Earth
Ground (see Section 2.3.1.1).
7. Install Watchdog MOSFET Switch wiring and if required Redundancy Control wiring
(see Section 2.3.5.3).
8. Connect Bulk DC Power to the ControlWave’s PSSM Module (see Sections 2.3.5.1 &
2.3.5.2).
9. Install the Bezel so that it covers the PSSM and CPU Modules (see Section 2.3.7).
10. Plug an Ethernet cable from your network into the CPUs Ethernet Port (J1).
11. Open the Bezel door and apply power to the ControlWave I/O Expansion Rack by
setting the Power Switch on the PSSM Module to the ‘I’ position.
12. When the ControlWave I/O Expansion Rack completes its power-on sequence, the
Port 80 Display should be blank.
Step 2. Setting Configuration Parameters
This section describes how to establish communications with the rack using LocalView, and
how to use the Flash Configuration Utility to specify an Ethernet Port for the rack. This
section also discusses how to set up certain IP and application parameters.
1. Start LocalView and establish communications with the I/O rack (Local Mode).
2. When communications are established, call up the Flash Configuration utility from
within LocalView, by right-clicking on the RTU icon, and choosing "RTUÆRTU
Configuration Parameters".
3. Sign on with a username and password, then do the following:
• On the 'Ports' page of the Flash Configuration Utility, define an Ethernet Port for
the I/O rack. It must have a valid IP address.
2-4 / Installation & Operation
CI-ControlWaveEXP
•
•
On the 'IP Parameters' page, specify the IP address of the host ControlWave
controller in the "IP ADDR A" field.
On the 'Application Parameters' page, specify a "Power Fail Timeout" value,
which determines what happens to output values when the I/O rack's power is
restored following a power failure. Then specify a "Host Comm Loss Timeout"
value, which determines what happens to output values when the I/O rack loses
communications with its host ControlWave controller.
4. Click on the [Save to Rtu] button to save these changes to the I/O rack.
5. Power off the I/O rack, then turn it back on to activate the newly saved parameters.
Step 3. Setting up the Host to Reference the I/O Expansion Rack
This section shows how to use the I/O Configuration Wizard in ControlWave Designer to
modify the ControlWave Project in the host controller, so that it can make use of the
boards in the I/O Expansion Rack.
Now that the I/O Expansion Rack is configured, you must make reference to its boards in
the ControlWave project of the host ControlWave controller.
NOTE
This section assumes that the following has already been done:
• The host controller must have been installed.
• The host controller must have a ControlWave project already defined.
• ControlWave Designer software must have been installed on a PC to allow editing of
the ControlWave project.
1. Start ControlWave Designer software by clicking on StartÆProgramsÆOpenBSI
ToolsÆControlWave Designer
2. Open the ControlWave Project used in the Host Controller by clicking on File Æ
Open Project / Unzip Project.
3. Start the I/O Configuration Wizard by clicking as follows: ViewÆIO Configurator
4. Define I/O Boards in the I/O Configuration Wizard. This involves selecting the proper
board(s) from a list, specifying the IP addresses and slot numbers for the boards, and
defining variable names and other parameters for the individual I/O pins. (These
subjects are discussed in the ControlWave I/O Expansion Rack Quick Setup Guide
document# D5122) For more details on using the I/O Configuration Wizard, see the
Getting Started with ControlWave Designer Manual (document# D5085).
5. Once you have defined the I/O boards, and named the individual pins, you can
reference those pin names as I/O variables within your control strategy. For more
information on using variables see the Getting Started with ControlWave Designer
Manual (document# D5085) and the ControlWave Designer Reference Manual
(document# D5088).
6. Compile your revised project, and download it into the ControlWave host controller.
For details on compling and downloading, see the Getting Started with ControlWave
Designer Manual (document# D5085).
ControlWaveEXP
Installation & Operation / 2-5
2.3.1 Mounting the ControlWave I/O Expansion Rack Chassis
ControlWave I/O Expansion Racks equipped with an 8-I/O Module Chassis can be
mounted to a 19-inch equipment rack, a panel or a wall. These units are factory shipped
with the End Plates configured for 19-inch rack mounting. When mounting one of these
units to a panel or wall, it is to be positioned in accordance with the following restrictions:
-
-
The End Plates must be removed, rotated 180° and then reinstalled to accommodate
panel or wall mounting. Hole patterns and dimensions are provided in Figure 2-1.
The unit must be positioned so that the front of the assembly is visible and the unit is
accessible for service, i.e., installing an option or replacement of the Lithium Battery,
or installation/removal of any ControlWave Module.
ControlWave Modules should not be installed until the unit’s Chassis has been
mounted and grounded at a designated work site.
ControlWave I/O Expansion Racks that are equipped with a 2 or 4-I/O Module Chassis can
be wall or panel mounted. Mounting hole patterns are provided in Figures 2-2 and 2-3 for 2I/O and 4-I/O units respectively. When mounting one of these units to a panel or wall, it is
to be positioned in accordance with the following restrictions:
-
-
The unit must be positioned so that the front of the assembly is visible and the unit is
accessible for service, i.e., for replacement of the Lithium Battery, or for
installation/removal of any ControlWave Module.
ControlWave Modules should not be installed until the unit’s Chassis has been
mounted and grounded at a designated work site.
2.3.1.1 ControlWave I/O Expansion Rack Grounding
ControlWave I/O Expansion Rack Chassis are provided with a Ground Lug that
accommodates up to a #4 AWG wire size. A ground wire must be run between the Chassis
Ground Lug and a known good Earth Ground. The cases of the various ControlWave
Modules are connected to Chassis Ground when they have been installed and secured via
their two Captured Panel Fasteners. As an extra added precaution, it is recommended that
a #14 AWG wire be run from PSSM Power Connector TB2-5 (Chassis Ground) to the same
known good Earth Ground. The following considerations are provided for the installation of
ControlWave system grounds:
• Chassis Ground Lug to Earth Ground wire size should be #4 AWG. It is recommended
that stranded copper wire is used and that the length should be as short as possible.
• This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
• The wire ends should be tinned with solder prior to insertion into the Chassis Ground
Lug. Note: Use a high wattage Soldering Iron.
• The ground wire should be run such that any routing bend in the cable has a minimum
radius of 12-inches below ground and 8-inches above ground.
2.3.2 Power Supply/Sequencer Module (PSSM) Installation
The Power Supply/Sequencer Module (PSSM) must be installed prior to the installation of
the CPU Module. Power and Watchdog wiring can be performed at this time, however; for
safety reasons and to prevent accidental damage to the user’s bulk DC Power Supply, it is
recommended that pluggable Terminal Block connectors TB1 and TB2 are not connected to
the PSSM until the CPU Module has been installed, wired, and hardware configured.
2-6 / Installation & Operation
CI-ControlWaveEXP
Section 2.3.5.2 provides details on Watchdog Connector TB1 wiring and Section 2.3.5.1
provides details on DC Power Connector TB2 wiring. The PSSM resides in slot #1 (see
Figure 2-4).
2.3.3 CPU Module Installation
To configure the CPU Module, DIP Switches must be set (see Section 2.3.3.1) and Communication Ports must be wired (see Sections 2.3.3.2 through 2.3.3.4). The CPU Module
resides in slot # 2 (see Figure 2-5).
Figure 2-4 - PSSM Installed in ControlWaveEXP Slot #1
Figure 2-5 - PSSM & CPUM (with SCM) Installed in Slot #1 & #2 (Respectively)
ControlWaveEXP
Installation & Operation / 2-7
2.3.3.1 CPU Module Switch Configuration
ControlWave I/O Expansion Rack CPU Module DIP Switches must be set for the desired
performance options. Tables 2-1 and 2-2 provide an overview of switch settings. Note: CPU
Board Switch SW2 and Secondary Comm. Board Switches SW1 and SW2 are
covered in Section 2.3.3.3.
SW1-1 set OFF will disable the system from entering a watchdog state when a crash or
system hangup occurs. Setting SW1-1 OFF prevents the system from automatically
restarting.
SW1-2 set OFF prevents changing the Soft Switches, other configurations and FLASH files,
i.e., these items are locked. To change Soft Switch, configuration and FLASH files SW1-2
must be set to the ON position (see Section 2.4.6).
SW1-3 set OFF forces the use of Soft Switches as set per factory default (see Section 2.4.6).
For use of user defined Soft Switches, SW1-3 must be set to the ON position. Note: If both
SW1-3 and SW1-8 are set OFF (closed), communication ports COM1 and COM2 will be set
to 9600 bps operation.
SW1-4 set OFF will cause the ControlWave I/O Expansion Rack to perform a Core
Updump (see Section 3.6). Set SW1-4 to the ON position for normal operation.
SW1-5 set OFF forces the ControlWave I/O Expansion Rack to reinitialize SRAM when the
unit recovers from a low power or power outage condition. When set ON, the contents of
SRAMS will be retained and utilized when the system restarts.
SW1-6 set ON will disable redundancy operation and will allow the CPU to run as a stand
alone or forced application controller. Set SW1-6 to the OFF position for redundancy
operation, i.e., when operating as Unit A or Unit B in conjunction with a
ControlWaveRED or ControlWaveREDIO. When it is necessary to run a non-redundant
application place SW1-6 to the ON position.
SW1-7 set OFF will assign the CPU to System ‘B.’ Place SW1-7 to the ON position when it
is desired to utilize the CPU in System ‘A.’ SW1-7 is ignored when SW1-6 is ON.
SW1-8 set OFF places the unit into diagnostic mode. SW1-8 must be set OFF to run the
WINDIAG program resident on the local PC (see Section 3.5). When SW1-8 has been set
ON, diagnostics is disabled. SW1-8 must be set to the ON position for normal system
operation, i.e. for the Boot project to run. Note: If both SW1-3 and SW1-8 are set OFF
(closed), communication ports COM1 through COM6 will be set to 9600 bps operation.
Table 2-1 - CPU Bd. Switch SW1 - User Configurations (ON = Factory Default)
SW#
Function
SW1-1
Watchdog Enable
SW1-2
SW1-3
SW1-4
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Normal Run or
Core Updump
2-8 / Installation & Operation
Setting - (ON = Factory Default)
ON = Watchdog circuit is enabled
OFF = Watchdog circuit is disabled
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Normal Run Mode
OFF = Causes the system to start a Core Updump
CI-ControlWaveEXP
Table 2-1 - CPU Bd. Switch SW1 - User Configurations Continued
SW#
SW1-5
Function
SRAM Control
SW1-7
Redundancy
Enable/Disable
Unit A/Unit B
SW1-8
Enable WINDIAG
SW1-6
Setting - (ON = Factory Default)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Redundancy Disable
OFF = Redundancy Enable
ON = CPU assigned as ‘A’ CPU – OFF = CPU assigned as ‘B’ CPU
ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Allow WINDIAG to run test
Table 2-2 - CPU Bd. Switch SW3
Firmware Load Control/Recovery Mode/Battery Enable
Switch
SW3-1
Function
Not Used
System Firmware
Load Control *
Setting
ON = Disable remote download of System Firmware
OFF = Enable remote download of System Firmware
ON = Force recovery mode (via CW Console)
SW3-3 Force Recovery Mode
OFF = Recovery mode disabled
ON = Battery back-up enabled
SW3-4 SRAM & RTC Battery Enable
OFF = Battery back-up disabled
* = Boot PROM version 06 or higher and System PROM version 4.7 or higher
SW3-2
Figure 2-6 - CPU Board Switches SW1 & SW3
ControlWaveEXP
Installation & Operation / 2-9
2.3.3.2 Communication Ports
A ControlWave I/O Expansion Racks can be configured as a Slave to a host ControlWave,
Process Automation Controller, ControlWave Redundant Controller (ControlWaveRED)
or ControlWave Redundant I/O and Communications Switch Unit (ControlWave-REDIO)
on a Serial MODBUS or Open MODBUS network or connected to the host via IP. BSAP can
be used for WINDIAG diagnostics. Up to seven communication ports are contained on the
ControlWave I/O Expansion Rack’s CPU Module as follows:
COM1 - Port 1:
COM2 - Port 2:
COM3 - Port 3:
COM4 - Port 4:
COM5 - Port 5:
COM6 - Port 6:
Ethernet Port 1:
CPU Bd. J1, PC/AT 9-Pin Male D-Sub - RS-232
CPU Bd. J2, PC/AT 9-Pin Male D-Sub - RS-232 or RS-485
SCB Bd. J1, 8-Pin RJ-45 - RS-485
SCB Bd. J2, PC/AT 9-Pin Male D-Sub - RS-485
SCB Bd. J3, 8-Pin RJ-45 - RS-232
SCB Bd. J4, 8-Pin RJ-45 - RS-232
CPU Bd. J3, 8-Pin RJ-45 - Twisted Pair 10/100BaseT
Figure 2-7 - CPU Module Component Identification Diagram (Front View)
Communication Ports 1 through 6 support asynchronous operation. Communication Ports
COM1, COM5 & COM6 support RS-232 operation while COM3 and COM4 support RS-485
operation. COM2 is factory configured per order for RS-232 or RS-485 operation. RS-232
and RS-485 Ports are protected to ±8KV ESD (Contact). Ethernet and RS-485 Ports are
2-10 / Installation & Operation
CI-ControlWaveEXP
isolated to 500Vdc. Note: COM2 can only be configured for RS-485 operation if the
optional Secondary Comm. Board is not present.
Serial communications port COM1 is factory configured for serial IP point-to-point (PPP)
communications.
Serial communications port COM2 is typically used during initial configuration activities
for communications via LocalView. This allows the Flash Configuration Utility to be run to
set configuration parameters for the I/O Expansion Rack. Serial communication ports
COM3/4/5 or 6 may also be used for initial configuration activities.
2.3.3.3 RS-232 & RS-485 Interfaces
Communications ports COM1, COM5 and COM6 support RS-232 communications only
while ports COM3 and COM4 support RS-485 communications only. RS-232 or RS-485
communications can be provided on communications port COM2 (factory configured). These
connectors are summarized below.
CPU Bd. J1
CPU Bd. J2
SCB Bd. J1
SCB Bd. J2
SCB Bd. J3
SCB Bd. J4
-
PC/AT 9-Pin Male D-Sub - RS-232 - COM1 - Port 1 - (see Table 2-3/Figure 2-8)
PC/AT 9-Pin Male D-Sub - RS-232/RS-485 - COM2 - Port 2 - (see Table. 2-4/Fig. 2-8)
8-Pin RJ-45 - RS-485 - COM3 - Port 3 - (see Table 2-5/Figure 2-10)
PC/AT 9-Pin Male D-Sub - RS-485 - COM4 - Port 4 - (see Table. 2-4/Fig. 2-8)
8-Pin RJ-45 - RS-232 - COM5 - Port 5 - (see Table 2-5/Figure 2-10)
8-Pin RJ-45 - RS-232 - COM6 - Port 6 - (see Table 2-5/Figure 2-10)
RS-232 Ports
An RS-232 interface supports point to point half-duplex and full-duplex communications (20
feet maximum, using data quality cable). Half-duplex communications supported by the
ControlWave I/O Expansion Rack utilize MODBUS or BSAP protocol, while full-duplex is
supported by the Point to Point (PPP) protocol. ControlWave I/O Expansion Rack RS-232
ports utilize the “null modem” cable (Figure 2-9A) to interconnect with other devices such
as a PC, printer, or a ControlWave series unit (except CW_10/30/35) when the
ControlWave I/O Expansion Rack is communicating using the full-duplex PPP protocol.
The half-duplex cable shown in Figure 2-9A can be utilized when the ControlWave I/O
Expansion Rack is connected to any ControlWave series unit, except the CW_10, CW_30 or
CW_35. When interfacing from COM1 or COM2 to Port COM3 of either a ControlWave or
ControlWaveRED unit or to COM5 or COM6 of another ControlWaveEXP, the cable of
Figure 2-9B must be used along with along with one of Figure 2-9A.
An illustration of the CPU Module’s male 9-pin D-type connectors is provided in Figure 2-8.
Table 2-3 provides the connector pin assignments for Comm. Port 1. Table 2-4 provides the
connector pin assignments for Comm. Ports 2 and 4. Table 2-5 provides the connector pin
assignments for Comm. Ports 3, 5 & 6 (illustrated in Figure 2-10).
Note: The following facts regarding ControlWave I/O Expansion Rack RS-232 serial
Comm. ports should be observed when constructing communications cables:
• DCD must be high to transmit
• CTS must be high to transmit
• When port is set for full-duplex operation - RTS is always ON
• DTR is always high (when port is active)
• When port is set for half-duplex operation - CTS must go low after RTS goes low
ControlWaveEXP
Installation & Operation / 2-11
Figure 2-8 - Male DB9 9-Pin Connector Associated with COM1 & COM2
RS-485 Ports
ControlWave I/O Expansion Racks can use an RS-485 configured port for local network
communications to multiple nodes up to 4000 feet away. Since this interface is intended for
network communications, Table 2-6 provides the appropriate connections for wiring the
master, 1st 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 (daisy
chained) across the same lines. The master node should be wired to one end of the RS-485
cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used. Note:
Only half-duplex RS-485 networks are supported
Figure 2-9 - Communication Port RS-232 Cable Wiring Diagrams
2-12 / Installation & Operation
CI-ControlWaveEXP
Table 2-3 - CPU Board Connector J1 (COM1) Pin Assignment
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
RXD
TXD
DTR
GND
RTS
-
Description:
RS-232 Signals
N/A
Receive Data - Input
Transmit Data - Output
Data Terminal Ready - Output
Signal/Power Ground
N/A
Request To Send - Output
N/A
N/A
Table 2-4 - CPU Bd. Connector J2 (COM2) &
SCB Bd. Connector J2 (COM4) Pin Assignments
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
-
COM2 Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Signal/Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
Not Used
Signal
RS-485
RXDTXDTXD+
ISOGND
RXD+
COM2/4 Description:
RS-485 Signals
N/A
Receive Data - Input
Transmit Data - Output
Transmit Data +Output
Isolated Ground
Receive Data + Input
N/A
N/A
N/A
To ensure that the “Receive Data” lines are in a proper state during inactive transmission
periods, certain bias voltage levels must be maintained at the master and most distant
slave units (end nodes). These end nodes also require the insertion of 100-Ohm terminating
resistors to properly balance the network. CPU Bd. Switch SW2 (COM2), SCB Switch SW1
(COM3) and/or SCB Switch SW2 (COM4) must be configured at each node to establish
proper network performance. This is accomplished by configuring CPU Bd. SW2 (COM2),
SCB Switch SW1 (COM3) and/or SCB Switch SW2 (COM4) so that the 100-Ohm
termination resistors and biasing networks are installed at the end nodes and are removed
at all other nodes on the network (see Table 2-7 and Figures 2-8, 2-10 & 2-11).
Table 2-5 - SCB Bd. Connector J1 (COM3), J3 (COM5) & J4 (COM6)
Pin Assignments
Pin
#
1
2
3
4
5
6
7
8
Signal
RS-232
DCD
DSR
RXD
RTS
TXD
CTS
DTR
GND
ControlWaveEXP
COM4/5 Description:
RS-232 Signals
Data Carrier Detect Input
Data Set Ready Input
Receive Data Input
Request To Send Output
Transmit Data Output
Clear To Send Input
Data Terminal Ready Output
Signal/Power Ground
Signal
RS-485
RXD+
RXDTXDTXD+
ISOGND
COM3 Description:
RS-485 Signals
N/A
Receive Data + Input
Receive Data - Input
N/A
Transmit Data - Output
N/A
Transmit Data + Output
Isolated Ground
Installation & Operation / 2-13
Figure 2-10 - SCB RJ-45 Connectors J1 (COM3), J3 (COM5) & J4 (COM6)
Table 2-6 - RS-485 Network Connections
(see Tables 2-4 & 2-5 for ControlWave RS-485 Port Pin # Assignments)
From
Master
TXD+
TXDRXD+
RXDISOGND
To 1st
Slave
RXD+
RXDTXD+
TXDISOGND
To nth
Slave
RXD+
RXDTXD+
TXDISOGND
Figure 2-11 - CPU Module Comm. Port Switches
2-14 / Installation & Operation
CI-ControlWaveEXP
Table 2-7 - CPU Switch SW2 (COM2) & SCB Switches SW1 (COM3) & SW2 (COM4)
Loopback & Termination Control Settings
SWITCH
#
1
2
3
4
5
RS-232 Function
Switch ON
DTR to DSR Loopback
TXD to RXD Loopback
N/A
N/A
RTS to CTS Loopback
6
N/A
7
8
N/A
N/A
RS-485 Function
Switch ON
TX+ to RX+ Loopback
TX- to RX- Loopback
100 Ohm RX+ Termination
100 Ohm RX- Termination
N/A
Slow Slew Rate - ON = Fast
OFF = Slow
RX+ Bias (End Node)
RX- Bias (End Node)
Setting
ON - Only for Diagnostics
ON - Only for Diagnostics
ON - End Nodes Only
ON - End Nodes Only
ON - Only for Diagnostics
ON/OFF - As required
Factory Default = ON
ON - End Nodes Only
ON - End Nodes Only
Closed = Switch set OFF
2.3.3.4 Ethernet Port
ControlWave I/O Expansion Rack CPU Modules contain one Ethernet Port. This Port
utilizes a 100/10Base-T RJ-45 modular connector that typically provides a shielded twisted
pair interface to an Ethernet Hub. ControlWave I/O Expansion Rack Ethernet Port
assignment is provided below.
Ethernet Port 1: CPU Bd. J3, 8-Pin RJ-45 - Shielded Twisted Pair 10/100BaseT
A typical Ethernet Hub provides eight (8) 100/10Base-T RJ-45 Ports (with Port 8 having the
capability to link to another Hub or to an Ethernet communications port). Both ends of the
twisted pair Ethernet cable are equipped with modular RJ-45 connectors. These cables have
a one-to-one wiring configuration as shown in Figure 2-14. Table 2-8 provides the assignment and definitions of the 8-pin 10/100BaseT connector.
It is possible to connect two nodes in a point-to-point configuration without the use of a
Hub. However, the cable used must be configured such that the TX+/- Data pins are connected to the RX+/- Data pins (swapped) at the opposite ends of the cable (see Figure 2-13).
Figure 2-12 - RJ-45 Connector (Ethernet Port) J3 (CPU)
ControlWaveEXP
Installation & Operation / 2-15
Figure 2-13 - Point-to-Point 10BaseT 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.
Table 2-8 - Ethernet 10/100BaseT CPU Module Pin Assignments
Pin #
1
2
3
4
Description
Transmit Data+ (Output)
Transmit Data- (Output)
Receive Data+ (Input)
Not Connected
Pin #
5
6
7
8
Description
Not Connected
Receive Data- (Input)
Not Connected
Not Connected
Note: TX & RX are swapped at Hub’s.
Figure 2-14 - Standard 10BaseT Ethernet Cable (CPU Module to Hub)
2.3.4 I/O Module Installation & Wiring
ControlWave I/O Expansion Rack Chassis are available with Backplane Assemblies that
support 2, 4 or 8-I/O Modules. I/O Modules reside in slots 3 through 4, 3 through 6 or 3
through 10 for units supporting 2, 4 or 8-I/O Modules respectively. Figure 2-15 shows slot
assignments for an 8-I/O ControlWave I/O Expansion Racks. Units that support 2 or 4-I/O
Modules don’t have slots 5 through 10 or 7 through 10 respectively.
2-16 / Installation & Operation
CI-ControlWaveEXP
I/O Modules are configured per order and individually packaged. An I/O Module will reside
in one of up to 8-I/O slots subject to the following conditions: Backplane slots 3 through 6
support interrupt or non-interrupt driven I/O Modules, while slots 7 through 10 only
support non-interrupt driven I/O Modules.
2.3.4.1 Installation of I/O Modules
If installing one or more I/O Modules into an already operational unit, the procedure may
be performed while the unit is powered, however; the host ControlWave’s application load
(ControlWave Designer software) must be configured to accept the new I/O Module(s) (via
the ControlWave Designer I/O Configurator) and then the application load must be
downloaded into the host ControlWave before the new I/O Module(s) can become
operational. For new site installations, hardware configuration should take place with
power disconnected until the entire unit has been physically installed, configured and
wired.
Figure 2-15 - ControlWave Chassis Slot Assignments
(With & Without Bezel Installed)
ControlWaveEXP
Installation & Operation / 2-17
Perform steps 1 through 7 below for each I/O Module. I/O Modules are provided with a
removable Terminal Housing Assembly. This assembly has a door that swings downward to
provide access to the unit’s Terminal Handle which in turn is utilized to remove an
installed I/O Module once the module’s Captured Panel Fasteners have been loosened.
1. Remove the I/O Module from its shipping carton and remove the Terminal Housing
Assembly from the I/O Module (see Figure 2-16).
2. Turn the Terminal Block’s Quarter Turn Fasteners (counterclockwise) and remove the
Terminal Block Assembly from the I/O Module.
3. I/O Modules are available that support local terminations (field wiring connected
directly to the I/O Module’s Terminal Block PCB) or remote terminations (field wiring
connected to a remote DIN-rail mounted Terminal Block Assembly).
Figure 2-16 - Terminal Housing Assembly Removal
When installing wiring in conjunction with I/O Modules that are equipped with a Local
Terminal Block PCB, install the field wiring between the I/O Module’s Terminal Block
Assembly and field devices (see Figure 2-17). Use AWG 14 or smaller wire (consult with
the field device manufacturer for recommendations). Leave some slack and plan for wire
routing, identification, maintenance, etc. The bundled wires are to be routed out
2-18 / Installation & Operation
CI-ControlWaveEXP
through the bottom of the I/O Module Assembly between the Terminal Block Assembly
and the Terminal Housing Assembly.
Figure 2-17 - I/O Module (Local Termination) Wire Routing
For I/O Modules that are equipped with a Remote Terminal Block Assembly, install the
cables between the I/O Module’s Terminal Block Assembly and the DIN-rail mounted
Terminal Block Assembly. Install the field wiring between the DIN-rail mounted
Terminal Block Assembly and field devices (see Figures 2-18, 2-22, 2-23, 2-25, 2-26, 228, 2-29, 2-34 & 2-38). Use AWG 14 or smaller wire (consult with the field device
manufacturer for recommendations). Leave some slack and plan for wire routing,
identification, maintenance, etc. The cables that run between the I/O Module and the
DIN-Rail mountable Terminal Blocks are to be routed out through the bottom of the I/O
Module Assembly between the Header Block and the Terminal Housing Assembly. To
provide access to the Header Block’s lower ¼ Turn Fastener, cables associated with
connectors P3 and P4 should be secured via a Tie Wrap to the lower left side of the
Header Block Assembly, while cables associated with connectors P1 and P2 should be
secured to the lower right side of the Header Block Assembly via a second Tie Wrap (see
Figure 2-18).
ControlWaveEXP
Installation & Operation / 2-19
Figure 2-18 - I/O Module (Remote Termination) Wire Routing
Refer to the following sections for I/O Module wiring information:
2-20 / Installation & Operation
CI-ControlWaveEXP
Section 2.3.4.4 = DI Module
Section 2.3.4.5 = DO Module
Section 2.3.4.6 = AI Module
Section 2.3.4.7 = AO Module
Section 2.3.4.8 = UDI Module
4. Align the I/O Module with the assigned I/O Slot and install the unit into the Chassis.
When the assembly is fully seated, turn the I/O Module’s Captured Panel Fasteners
(clockwise) to secure the unit to the Chassis thus establishing a low resistance path
between the I/O Module and Chassis Ground.
5. Install the Local or Remote Terminal Block Assembly (with wiring harness) onto the I/O
Module (turning the Quarter Turn Fasteners (clockwise).
6. Replace the module’s Terminal Housing Assembly. Note: Door Labels are available as
MS Word files that can be typeset by the user to provide wiring identification for I/O
Modules. These labels are available on the Bristol Babcock Web site
www.controlwave.com and can be affixed to the inside of the Term. Housing’s Door.
7. Using a PC equipped with ‘ControlWave Designer’ and ‘OpenBSI’ software, con-figure
the host ControlWave’s application load. ControlWave Designer software must be
configured to accept the new I/O Module(s) (via the ControlWave Designer I/O
Configurator) and then the application load must be downloaded into the host
ControlWave Process Automation Controller CPU’s System FLASH and/or SDRAM
(see Section 2.4.1) to accept the new I/O Module (and any other modules that have been
added or removed) For new installations, this step can be skipped until the unit has
been wired and power applied.
2.3.4.2 Wire Connections
ControlWave I/O Expansion Rack I/O Modules utilize compression-type terminals that
accommodate up to #14 AWG wire. A connection is made by inserting the wire’s bared end
(1/4” max) into the clamp beneath the screw and securing the screw. The wire should be
inserted fully so that no bare wires are exposed to cause shorts. 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. The slack makes the
connections more manageable and minimizes mechanical strain on the terminal blocks.
2.3.4.3 Shielding and Grounding
The use of twisted-pair, shielded and insulated cable for I/O signal wiring will minimize
signal errors caused by electromagnetic interference (EMI), radio frequency interference
(RFI) and transients. When using shielded cable, all shields should only be grounded at one
point in the appropriate system. This is necessary to prevent circulating ground current
loops that can cause signal errors.
2.3.4.4 Digital Inputs (see Figures 2-19, 2-20, 2-21, 2-22 & 2-23)
ControlWave Digital Input (DI) Modules are factory-configured to support either
externally powered source or dry contact DI applications. Each module contains field
interface circuitry for up to 32 or 16 discrete inputs with an input range of 24Vdc, a
nominal input current is 5mA and 30 millisecond input filtering. DI Modules consists of a
Terminal Block Assembly (local) or a Header Block Assembly (remote), a Digital Input PCB,
ControlWaveEXP
Installation & Operation / 2-21
an LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O
assembly and mounting hardware.
DI field circuitry is electrically isolated from the module’s bus interface circuitry by surge
suppressors and optocouplers. Modules configured for use in dry contact applications
contain a 21Vdc power supply. The 21Vdc field supply is derived from a control circuit and
an isolated power supply that is powered by the output of the hot swap control circuit,
which in turn is powered by the +VIN/-VIN supply interfaced from the unit’s Backplane.
Each DI PCB is connected to its associated Terminal/Header Block Assembly via a 44-pin
header and to the unit’s Backplane via a 110-pin connector.
2.3.4.4.1 Digital Input Configurations
Digital Input Modules are factory configured to support either 32/16 externally sourced DIs
or 32/16 internally sourced DIs. Modules configured for use in dry contact applications
contain a 21Vdc power supply. The nominal input voltage is 24Vdc @ 5mA.
Figure 2-19 - Local Terminal Block Assembly Assignments
for Internally Sourced DI Operation or Externally Powered DI Operation
Figure 2-20 - Internally Sourced DI Module - Wiring Diagram
2-22 / Installation & Operation
CI-ControlWaveEXP
Figure 2-21 - Externally Powered DI Module - Wiring Diagram
Figure 2-22 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for Internally Sourced DI Operation or Externally Powered DI Operation
ControlWaveEXP
Installation & Operation / 2-23
Figure 2-23 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for Relay Isolated 120Vac DI Operation
Field wiring assignments associated with the locally terminated DI Modules and remotely
terminated DI Modules are provided in Figures 2-19 and 2-22 respectively. A special remote
termination module with built-in discrete relay module that supports input from 120Vac
2-24 / Installation & Operation
CI-ControlWaveEXP
DIs is also available (see Figure 2-23). The special remote termination module (with built-in
discrete relay module) is interfaced to an externally sourced DI Module.
2.3.4.5 Digital Outputs (see Figures 2-24, 2-25, 2-26 & 2-27)
Digital Output (DO) Modules provide a total of 32 or 16 DOs for control of signaling
functions. Each output contains an optically isolated open source MOSFET and surge
suppressor that are capable of handling 500mA @ 31V. DO Modules consist of a Terminal
Block Assembly (local) or a Header Block Assembly (remote), a Discrete Input PCB, an LED
PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O assembly
and mounting hardware.
DO field circuitry MOSFETs are electrically isolated from the module’s bus interface
circuitry by surge suppressors and optocouplers.
Output data is stored in an on board DO Load Register. Upon power up the DO Load
register is cleared and all outputs are set “off.”
Each DO PCB is connected to its associated Terminal/Header Block Assembly via a 44-pin
header and to the unit’s Backplane via a 110-pin connector.
2.3.4.5.1 Digital Output Configurations
Digital Output Modules provide a total of 32 or 16 DOs with surge protection. Each DO
utilizes an open source MOSFET that is capable of driving up to 31Vdc at up to 500mA. A
500Vdc MOV to Chassis and a 31Vdc Transorb (across output) are provided to protect each
DO. The maximum operating frequency is 20 Hz.
Figure 2-24 - Local Terminal Block Assembly Assignments
for Open Source Isolated DO Operation
ControlWaveEXP
Installation & Operation / 2-25
Field wiring assignments associated with the locally terminated DO Modules and remotely
terminated DO Modules are provided in Figures 2-24 and 2-25 respectively. A special
remote termination module with built-in discrete relay modules is also available (see Figure
2-26.
Figure 2-25 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for Open Source Isolated DO Operation
2-26 / Installation & Operation
CI-ControlWaveEXP
Figure 2-26 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for Relay Isolated 24Vdc DO Operation
ControlWaveEXP
Installation & Operation / 2-27
Figure 2-27 - Open Source Isolated DO Module - Wiring Diagram
2.3.4.6 Analog Inputs (see Figures 2-28 through 2-33)
Two types of AI Modules are available, i.e., 4-20mA or 1-5 Vdc input versions. Each module
contains field interface circuitry for up to 16 or 8 analog inputs. Each AI Module consists of
a Terminal Block Assembly (local) or a Header Block Assembly (remote), an Analog Input
PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as
I/O assembly and mounting hardware.
AI circuitry is electrically isolated from the module’s bus interface circuitry. On the isolated
side each AI signal is channeled through signal conditioning, surge suppression,
multiplexing and a 14-bit A to D converter. The bus interface circuitry consists of the
control logic to access A to D converters and multiplexers, static RAM (to store the latest
14-bit digitized data for each of the sixteen channels and the on board reference voltages)
and control logic to access the system bus.
The common mode range for 1-5V Analog Input Modules is 31Vdc. For 4-20 mA Analog
Input Modules, all inputs are referenced to the -VFXX of the module. Each AI PCB is
connected to its associated Terminal Block Assembly via a 44-pin header and to the unit’s
Backplane via a 110-pin connector.
2.3.4.6.1 Analog Input Configurations
AI Modules (with either 16 or 8 AI) are offered with 1-5V isolated inputs or with 4-20 mA
internally sourced inputs.
Field wiring assignments associated with the locally terminated AI Modules are provided in
Figure 2-30. Field wiring assignments associated with 4-20 mA remotely terminated AI
Modules and 1-5V remotely terminated AI Modules are provided in Figures 2-28 and 2-29
respectively.
Note:
Cable shields associated with AI wiring should be connected to the ControlWave Chassis
Ground. Multiple shield terminations will require a user supplied copper ground bus.
This ground bus must be connected to the ControlWave’s Chassis Ground Lug (using up
to a #4 AWG wire size) and must accommodate a connection to a known good Earth
2-28 / Installation & Operation
CI-ControlWaveEXP
Ground (in lieu of a direct connection from the Ground Lug) and to all AI cable shields.
Shield wires should use an appropriate Term. Lug and should be secured to the copper
bus via industry rugged hardware (screw/bolt, lockwasher and nuts).
Figure 2-28 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for 4-20 mA AI Operation
ControlWaveEXP
Installation & Operation / 2-29
Figure 2-29 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for 1-5V AI Operation
2-30 / Installation & Operation
CI-ControlWaveEXP
Figure 2-30 - Local AI Module Terminal Blocks Assembly Assignments
Figure 2-31 - Internally Sourced 4-20mA Current Loop AI - Wiring Diagram
Figure 2-32 - Internally Sourced (Externally Powered)
4-20mA Current Loop AI - Wiring Diagram
ControlWaveEXP
Installation & Operation / 2-31
Figure 2-33 - Externally Powered Isolated 1-5 Volt AI - Wiring Diagram
2.3.4.7 Analog Outputs (see Figures 2-34, 2-35, 2-36 & 2-37)
AO Modules are factory configured to support either 4-20mA or 1-5 Vdc analog outputs.
Each module contains field interface circuitry for up to 8 or 4 analog outputs. Each AO
Module consists of a Terminal Block Assembly (local) or a Header Block Assembly (remote),
an Analog Output PCB (with a daughter board when configured for 1-5V operation), an
LED PCB, an LED Housing Assembly, a Terminal Housing Assembly, as well as I/O
assembly and mounting hardware.
AO circuitry is electrically isolated from the module’s bus interface circuitry. On the
isolated side, each AO signal passes through one of two, 4-channel digital to analog converters (DAC) that drive voltage to current converters. The V to I circuits are powered by an
on board isolated 19V power supply and the DACs are powered by an isolated 5V sup-ply.
Outputs are protected from transients with surge suppressors. Each AO PCB is connected
to its associated Terminal Board Assembly via a 44-pin header and to the unit’s Backplane
via a 110-pin connector.
The maximum external load that can be connected to the 4-20mA output is 650 ohms. The
maximum external load current for the 1-5V output is 5mA. An additional error (associated
with the voltage output mode) is caused by the voltage drop across an inductor. This error is
not compensated and is equal to the output current times two inductor resistances, e.g., 2.5
ohms x 2 x .005A = 25mV (or 0.625% of span).
2.3.4.7.1 Analog Output Configurations
Analog Output Modules are factory configured to support either eight (8) 1-5V or 4-20mA
isolated outputs. Field wiring assignments associated with the remotely terminated AO
Modules and locally terminated AO Modules are provided in Figures 2-34 and 2-35
respectively.
2-32 / Installation & Operation
CI-ControlWaveEXP
Figure 2-34 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for AO 4-20mA and 1-5V Operation
ControlWaveEXP
Installation & Operation / 2-33
Figure 2-35 - Local AO Module Terminal Blocks Assembly Assignments
Figure 2-36 - 4-20mA Current Loop AO - Wiring Diagrams
Figure 2-37 - 1-5Vdc Voltage AO - Wiring Diagrams
2-34 / Installation & Operation
CI-ControlWaveEXP
2.3.4.8 Universal Digital Input Modules (see Figures 2-38 through 3-41)
Universal Digital Input (UDI) Modules provide a total of 12 or 6 inputs. Each input is
optically isolated from the field device. UDI Module inputs are factory configured with all
inputs set with debounce enabled or with all inputs set with debounce disabled. With
debounce enabled, spurious pulses caused by relay contact bounce are not counted. Individual UDI inputs can be customer configured for a polled input or totalizer operation.
Field inputs can be driven signals, open collector outputs or relay contacts. The maximum
input frequency is 10 kHz. For any input used as a totalizer, the maximum totalized count
before rollover is 65535 and the totalizer is not resetable through software. Each UDI
Module consists of a Terminal Board Assembly (local) or a Header Block Assembly (remote),
a Universal Input PCB, an LED PCB, an LED Housing Assembly, a Terminal Housing
Assembly, as well as I/O assembly and mounting hardware.
Universal Digital Input Module circuitry consists of signal conditioning circuitry, 4-bit
accumulators and a microcontroller. Signal conditioning circuitry includes optocouplers,
debounce circuitry and bandwidth limit circuitry. The microcontroller monitors and maintains delays for each input.
Each input of the UDI Module can be configured as a polled input with a 30 millisecond
filter or a 16-bit high speed counter with a 20 usec filter.
UDI circuits with debounce disabled have two field inputs, SET and COM. When the
debounce circuitry is enabled (factory), a change of state on both the SET and RESET field
inputs is required to accumulate counts. The maximum input frequency is 10 kHz with a
nominal input current of 5mA.
Delay registers for signal conditioning allow individual inputs to utilize one of three
software selectable delays. The 20 usec delay is used for the 10 kHz input range required
for high speed counting. The 1 millisecond delay is required for low speed counter
applications. 30 millisecond delays are required for general purpose inputs or contacts
where contact bounce may be an issue.
2.3.4.8.1 Universal Digital Input Configurations
UDI Modules provide a total of 12 or 6 UIs with surge protection. Each UDI Module is
capable of handling 24V inputs.
The field inputs are provided electrical isolation of 500Vdc to Chassis and 1500Vdc to
system logic. Each input is also protected with a 31dc Transorb (across input and to Field
Common) that meets the ANSI/IEEE standard C37.90-1978.
Field wiring assignments associated with the remotely terminated UDI Modules and locally
terminated UDI Modules are provided in Figures 2-38 and 2-39 respectively.
ControlWaveEXP
Installation & Operation / 2-35
Figure 2-38 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
for UDI Operation
2-36 / Installation & Operation
CI-ControlWaveEXP
Figure 2-39 - Local UDI Terminal Block/Configuration Diagram
Figure 2-40 - UDI (Debounce Enabled) Wiring Diagram
Figure 2-41 - UDI (Debounce Disabled) Wiring Diagram
ControlWaveEXP
Installation & Operation / 2-37
2.3.5 Power Supply Wiring
ControlWave PSSMs utilize compression-type terminals that accommodate up to #14 AWG
wire. A connection is made by inserting the wire’s bared end (1/4” max) into the clamp
adjacent to the screw and then securing the screw. The wire should be inserted fully so that
no bare wires are exposed to cause shorts. If using standard wire, tin the bare end with
solder to prevent flattening and improve conductivity.
Figure 2-42 - PSSM Wire Routing Diagram
Allow some slack in the wires when making terminal connections. The slack makes the
connections more manageable and helps to minimize mechanical strain on the terminal
blocks.
2.3.5.1 Bulk Power Supply Current Requirements
ControlWave I/O Expansion Racks are equipped with either a 12Vdc or 24Vdc Power
Supply Sequencer Module (PSSM). The maximum current required for the +12Vdc or
+24Vdc bulk power supply used with a particular ControlWave I/O Expansion Rack can be
estimated as follows:
2-38 / Installation & Operation
CI-ControlWaveEXP
Bulk +12/24Vdc Supply Current = CPU* + Sum of all I/O Modules
CPU, Chassis & PSSM 16 point AI Module 8 point AI Module 4 or 8 point AO Module 16 or 32 point DI Module 16 or 32 point DO Module 6 or 12 point UDI Module -
1A (with/without SCB)
2A per module
1A per module
1A per module
1A per module
(see Tables 2-9 & 2-10) (no surge current)
(see Tables 2-9 & 2-10) (no surge current)
This summation will accommodate steady state as well as power up in-rush current draw.
Note: When two bulk power supplies are required, the first supply (VIN) (see Fig. 2-43)
must be rated to handle 2 Amps.
Table 2-9 and 2-10 provide detailed steady state and loop power current requirements for
each ControlWave module.
Table 2-9 - Power Requirements for Bulk 12Vdc Power Supply
COMPONENTS
CPU, CHASSIS, PSSM
FPAI (4-20mA) - F. Populated
HPAI (4-20mA) - H. Populated
FPAI (1-5V) - F. Populated
HPAI (1-5V) - H. Populated
FPAO (4-20mA) - F. Populated
HPAO (4-20mA) - H. Populated
FPAO (1-5V) - F. Populated
HPAO (1-5V) - H. Populated
FPDI - F. Populated
HPDI - H. Populated
FPDO - F. Populated
HPDO - H. Populated
FPUDI - F. Populated
HPUDI - H. Populated
MAX
# of I/O
N/A
16
8
16
8
8
4
8
4
32
16
32
16
12
6
SYSTEM
A = 580mA
D = 81mA
D’ = 72.2mA
E = 76.2mA
E’ = 68.5mA
F = 39.9mA
F’ = 39.9mA
G = 39.9mA
G’ = 39.9mA
H = 58.3mA
H’ = 31.6mA
I = 85.1mA
I’ = 45.2mA
J = 54.2mA
J’ = 33.3mA
FIELD
12Vdc
N/A
K = 51.5mA
K’ = 27.1mA
0mA
0mA
L = 22.4mA
L’ = 22.4mA
M = 82.1mA
M’ = 53.3mA
N = 27.1mA
N’ = 27.1mA
0mA
0mA
0mA
0mA
NOTES
CPU with Ethernet
Add 50mA/Loop
Add 47.3mA/Loop
Add 52.2mA/Loop - Output @ 5mA
Add 9.47mA/Loop - Dry Contact
Table 2-10 - Power Requirements for Bulk 24Vdc Power Supply
COMPONENTS
CPU, CHASSIS, PSSM
CPU/SCB, CHASSIS, PSSM
CPU/SCB, CHASSIS, PSSM
FPAI (4-20mA) - F. Populated
HPAI (4-20mA) - H. Populated
FPAI (1-5V) - F. Populated
HPAI (1-5V) - H. Populated
FPAO (4-20mA) - F. Populated
HPAO (4-20mA) - H. Populated
FPAO (1-5V) - F. Populated
HPAO (1-5V) - H. Populated
FPDI - F. Populated
HPDI - H. Populated
FPDO - F. Populated
HPDO - H. Populated
FPUDI - F. Populated
HPUDI - H. Populated
ControlWaveEXP
MAX
# of I/O
N/A
N/A
N/A
16
8
16
8
8
4
8
4
32
16
32
16
12
6
SYSTEM
A = 290mA
B = 400mA
C = 310mA
D = 40.5mA
D’ = 36.1mA
E = 38.1mA
E’ = 34.3mA
F = 20.0mA
F’ = 20.0mA
G = 20.0mA
G’ = 20.0mA
H = 29.2mA
H’ = 15.8mA
I = 42.6mA
I’ = 22.6mA
J = 27.1mA
J’ = 16.7mA
FIELD
24Vdc
N/A
N/A
N/A
K = 52.2mA
K’ = 29.7mA
0mA
0mA
L = 26.9mA
L’ = 26.9mA
M = 56.8mA
M’ = 41.9mA
N = 29.7mA
N’ = 29.7mA
0mA
0mA
0mA
0mA
NOTES
CPU with Ethernet
CPU w/Ethernet SCB w/Ethernet
CPU w/Ethernet, SCB w/2-RS-232
Add 25mA/Loop
Add 23.6mA/Loop
Add 26.1mA/Loop - Output @ 5mA
Add 4.74mA/Loop - Dry Contact
Installation & Operation / 2-39
2.3.5.2 Power Wiring
DC Power is interconnected to the PSSM via Connector TB2. One or two Bulk DC supplies
can be connected to the ControlWave PSSM. The Bulk DC supply (nominally +12Vdc or
+24Vdc) connected to TB2-1 (+VIN) is converted, regulated and filtered by the PSSM to
produce +5Vdc, +3.3Vdc, +12Vdc (optional) and -12Vdc (optional). This PSSM circuit is
fused at 3A and is referred to as the LOGIC Supply since these voltages are used for CPU,
communications and I/O logic. The bulk DC (+9.0 to +30 Vdc) supply connected to TB2-2
(+VINF) is fused and switched by the PSSM before being supplied to all I/O. I/O Modules
use this supply to power field devices and I/O field interface circuitry. This PSSM circuit is
fused at 10A and is referred to as the FIELD Supply.
Figure 2-43 - PSSM TB2 Typical Wiring Schemes
The operating range of the LOGIC Supply is +10.6 to +20.0 Vdc (nominal +12Vdc input
source) or +20.7 to +30.0 Vdc (nominal +24Vdc input source). The operating range of the
FIELD Supply is +9.0 to +30.0 Vdc.
2-40 / Installation & Operation
CI-ControlWaveEXP
PSSM Connector TB2 provides 5 input connections for bulk power as follows:
TB2-1 =
TB2-2 =
TB2-3 =
TB2-4 =
TB2-5 =
(+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
(+VINF) Connected to TB2-1 or +9Vdc to +30Vdc supply
(-VIN) (1st Supply Ground)
(-VINF) (2nd Supply Ground) Internally connected to TB2-3
Chassis Ground - CHASSIS (;)
2.3.5.3 Watchdog Switch & Redundant Unit Wiring (see Figs. 2-42, 2-43, 2-44A & 2-44B)
The circuit that drives the Watchdog MOSFET switch is on the secondary side of the power
supply. A solid state relay (SSR) actuates the watchdog hardware and is factory enabled or
disabled via an on-board jumper. When either the Master Clear or Watchdog Bad signal are
active, the on-board watchdog hardware will be OFF. Watchdog Bad is a signal generated
by the CPU Module when its hardware detects improper software operation.
Figure 2-44A - Watchdog MOSFET Switch Field Wiring
Figure 2-44B - ControlWaveEXP to ControlWaveREDIO
Redundancy Field Wiring
ControlWaveEXP
Installation & Operation / 2-41
The watchdog MOSFET switch is powered via the VI input of the terminal block (TB1-2)
and its switched output is connected to the VO output of the terminal block (TB1-1). The
external power source connected to the VI terminal must be referenced to the return point
of the input source that powers the PSSM [-VIN or PSGND (TB2-3)].
PSSM Connector TB1 provides Watchdog MOSFET Switch and Redundancy Control connections as follows:
MOSFET Connections: (see Figures 2-42, 2-43 & 2-44)
TB1-1 = VO - Watchdog MOSFET Switch Output
TB1-2 = VI - Watchdog MOSFET Switch Input
TB1-3 = VR - Redundancy Unit Control Input (Used with ControlWaveREDIO)
2.3.6 Installation of the Lithium Backup Battery (see Figs. 2-5, 2-7 & 2-45)
The 3.6V Lithium backup battery located on the CPU Module connects to CPU Board
connector J6. This 950mA-hr lithium ½ AA cell battery is provided with a three-wire
connector (2-wires used). The battery provides backup for the real-time clock and the
system SRAM. A supervisory circuit is used to switch to battery power when VCC falls
below VCC - 10%. The Battery PCB provides a regulated +2.5Vdc to the CPU Module.
Figure 2-45 - Lithium Backup Battery Removal Diagram
2-42 / Installation & Operation
CI-ControlWaveEXP
The system SRAM has a standby current draw of 50uA maximum for each part. For a unit
containing 1MB of SRAM, a worst-case current draw of 110uA allows a battery life of
approximately 8508 hours, while for a unit containing 2MB of SRAM, a worst-case current
draw of 210uA results in a battery life of approximately 4254 hours.
CPU Board Switch SW3-4 must be set to the ON position to enable the battery. For
maximum shelf life, the battery may be isolated from the circuit by moving CPU Board
Switch SW3-4 to the OFF position.
The CPU Module is shipped with the Lithium backup battery installed. To remove the
Lithium backup battery, the Battery Retaining Clip must be removed from the Battery
Holder Assembly (see Figure 2-45). Once the replacement battery has been installed into
the Battery Holder Assembly on the Battery Backup PCB Assembly, the Battery Retaining
Clip can be easily snapped back into place.
2.3.7 Installation of the Bezel Assembly (see Figures 2-5 & 2-46)
The Bezel assembly covers the front of the PSSM and CPU Modules and acts like the I/O
Module’s Terminal Housing Assembly by providing the following functions:
It can be removed or its Terminal Door opened to access the PSSM and CPU
modules. Bundled wires and cables are routed downward between the modules and
the Bezel. The Bezel is functional and its appearance is contiguous with the I/O
Modules.
Figure 2-46 - Bezel Assembly (for CPU Module without SCB)
The appropriate Bezel assembly is shipped with the CPU Module and should be installed
whenever the unit is operational (except during service). The Bezel is secured to the
Chassis by two snaps. To remove the Bezel assembly, gently grasp its sides and pull out
and away from the Chassis.
ControlWaveEXP
Installation & Operation / 2-43
Installation of the Bezel assembly requires that its snaps be aligned with their mating
holders on the Chassis. Once the Bezel has been properly positioned on the Chassis, a slight
push should snap it into place.
2.4
OPERATIONAL DETAILS
ControlWave Process Automation Controllers are shipped from the factory with firmware
that allows the unit to be configured in conjunction with an IEC 61131 application program.
This section provides information as follows:
-
Steps required to configure and download the host ControlWave’s application load.
Steps required to download system firmware.
Operation of the CPU Module’s Reset Switch
Module Hot Swapping
Soft Switch Configurations and Communication Ports
Operational details on ControlWave LEDs, the PORT 80 Display and use of the BBI
WinDiag program for fault isolation are provided in Chapter 3.
2.4.1 Configuring & Downloading the Application Load
A host ControlWave Process Automation Controller must receive its configured application
load before it and the slave ControlWave I/O Expansion Rack can be placed into operation.
This will require connection of the ControlWave unit to a PC running Windows NT (4.0 or
higher), Windows 2000 or Windows XP Professional and equipped with ControlWave
Designer software & OpenBSI software. Configuration of the application load must be performed by an individual familiar with the various programming tools. The following software
user documentation is referenced:
Getting Started with ControlWave Designer Manual - D5085
ControlWave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Open BSI Technician’s Toolkit - D5087
An application load download can be initiated, i.e., from ControlWave Designer, or from the
OpenBSI 1131 Downloader for ControlWave Nodes. See Section 2.4.1 steps 1 through 3 of
instruction manual CI-ControlWave.
2.4.2 Upgrading ControlWave I/O Expansion Rack Firmware
ControlWave I/O Expansion Rack CPUs ship from the factory with system firmware
already installed. If an upgrade of the system firmware is required, use one of the
procedures below to download the new or replacement firmware from the PC.
Upgrade of system firmware via LocalView FLASH Mode requires OpenBSI 5.1 (or newer).
If you have an older version of OpenBSI, FLASH upgrades are to be performed via
Hyperterminal.
You will need a binary (*.BIN) system firmware file, and that file should be defined in the
Flash Master File (FLASH.MST). A sample Flash Master File is shown, below:
cwr0410.bin
Firmware - Release 04.1
2-44 / Installation & Operation
CI-ControlWaveEXP
Upgrade of an unattended ControlWaveEXP can be accomplished from a remote PC. This
capability is introduced in Section 2.3.2.3.
2.4.2.1 Using LocalView to Upgrade ControlWaveEXP Firmware
NOTE
Your ControlWaveEXP must be set to Recovery Mode ENABLE (ON) prior to performing
the FLASH upgrade, then set to Recovery Mode DISABLE (OFF) after the upgrade. On the
ControlWave this is accomplished via CPU Switch SW3-3. Also set CPU Switch SW1-3
(OFF) to ignore soft switch configuration and use factory defaults; set SW1-3 (ON) after
the upgrade.
A null modem cable (see Figure 2-9) must be connected to COM1 of the ControlWaveEXP
and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this purpose
must be set to run at 115.2 Kbaud. ControlWaveEXP CPU Switch SW3, position, 3 must
be set ON.
Start LocalView, Choose FLASH, Enter A Name, Click on [Create]
Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView. The
New View Mode dialog box will appear (see Figure 2-47).
"Mode"
Choose 'Flash' for the mode.
"Name"
Enter a name for the View Mode File in the "Name" field.
Figure 2-47 - Local View - New View Mode Menu
"Location"
If you want to store the View Mode File in a directory other than that shown in the
"Location" field, enter the new location there, or use the [Browse] push button to find
the directory.
When the "Mode", "Name", and "Location" have been specified, click on the [Create] push
button to activate the Communication Setup Wizard (see Figure 2-48).
Step 1 - Communication Setup
Complete the fields in the Communication Setup Wizard as described, below.
"What port would you like to use?"
Specify the PC port you would like to use; this would be the port on the PC which will be
connected to the serial cable, e.g. COM1:, COM2:, etc.
ControlWaveEXP
Installation & Operation / 2-45
"Would you like to use auto baud rate detection?" / "What baud rate would you like
to use?"
If you know which baud rate to use, answer no for auto baud detection, and specify the
baud rate. If you do not know which baud rate to use, choose auto baud detection.
Figure 2-48 - Communication Setup: Step 1 Menu
[Advanced Parameters]
See the ‘Advanced Communication Parameters Dialog Box’ section, later in this chapter
for details on this.
Click on the [Next] pushbutton to activate the next wizard (see Figure 2-49).
Step 2 - Flash RTU Setup
In the Flash RTU Setup Wizard (see Figure 2-49), complete the fields as described, below:
"What is the type of the RTU?"
Use the list box to select the type of controller you are connected to. In this case, you
should only choose from among the ControlWave-series options:
Select this option:
ControlWaveEXP
For this type of unit:
ControlWave I/O Expansion Rack
"
What is the local address of the RTU that you would like to connect to?"
Select the BSAP local address of the ControlWave unit (from 1 to 127) using the list
box provided.
2-46 / Installation & Operation
CI-ControlWaveEXP
Click on the [Next] push button to activate the Flash Data Setup Wizard.
Figure 2-49 - Flash RTU Setup Menu
Step 3 - Flash Data Setup
Complete the fields in the Flash Data Setup Wizard (see Figure 2-50), as described, below:
"Please enter the name of the binary file to Flash"
To upgrade system firmware, you must specify the path and name of a binary (*.BIN)
file on your hard disk containing the firmware. Normally, the contents of the various
available BIN files are described in a Flash Master File (see box at bottom of the dialog
box). If you have specified a Flash Master File, double-click on the description of the
binary file you want to download to the RTU. Its path and name will be copied into this
field. (If you do NOT have a Flash Master File, type the path and name of the binary file
directly into this field.)
"Location of Flash Master File"
Specifies the location of the Flash Master File (FLASH.MST). The contents of the
FLASH Master File will be displayed in the box at the bottom of the dialog box, and
may be used to select binary files for FLASH downloading. (See above). If necessary, you
can use the [Browse] push button to locate the FLASH Master File.
Click on [Finish] to install the specified BIN file in FLASH memory at the RTU.
Once the Flash download has begun, you will NOT be allowed to shut down LocalView,
unless you cancel the download, or it has been completed.
The progress of the Flash download will be displayed in the window. Any mismatch in file
versions, or if the type of .BIN file does not match the type of RTU, the download will be
aborted
ControlWaveEXP
Installation & Operation / 2-47
Figure 2-50 - Flash Data Setup Menu
Figure 2-51 - Local View Downloading System Firmware Menu
2-48 / Installation & Operation
CI-ControlWaveEXP
Advanced Communication Parameters Dialog Box
Figure 2-52 - Local View Advanced Communication Parameters Menu
“What is the Link Level Timeout Period”
This defines the maximum amount of time (in seconds) that Open BSI will wait to
receive a response to any one data link transaction. If 0 is entered as the link timeout
period, the system will use a default timeout calculated based on the baud rate of the
line.
"Would you like to use RTS/CTS signals?"
If your communication line uses Ready to Send (RTS) / Clear to Send (CTS) signals (not
to be confused with ControlWave variables used for this purpose), click on 'Yes'.
"Front Pad", "Back Pad"
These fields specify the number of null characters to insert at the beginning (front) or
ending (back) of a message. Null characters may be useful in situations where there
may be a momentary delay, which could cause the start of a message to be missed, for
example, while a radio link is being activated. To determine the delay caused by null
packing, perform the following calculation:
seconds of delay = (number of null characters x 10) / baud rate
2.4.2.2 Using Hyperterminal to Upgrade ControlWaveEXP Firmware
A null modem cable (see Figure 2-9) must be connected to COM1 of the ControlWaveEXP
and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this purpose
must be set to run at 115.2 Kbaud. ControlWaveEXP CPU Switch SW3, position, 3 must
be set ON.
1. If not already running, apply power to the associated PC.
2. Start the HyperTerminal program on the PC. Note: HyperTerminal is a Windows 95 (or
newer) application utility program. If using HyperTerminal for the first time, set the
communications properties (for the PC Port being utilized) 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.
ControlWaveEXP
Installation & Operation / 2-49
3. Set CPU Switch SW3 position 3 to ON (ON = Force Recovery).
4. Apply power by turning the PSSM’s ON/OFF Switch to the ON (‘I’) position. The
resident BIOS will initialize and test the hardware, this process is referred to as POST
(Power On Self Test).
A status of the POST progress is displayed on the Port 80 display. Unless there is a
problem these codes will scroll at a fast rate and won’t be discernable. Successful
completion is indicated with an 86 on the Port 80 display and with the cold start menu
being displayed on the PC’s screen. Detection of a fault will be indicated by a 2-digit code on
the Port 80 display. Refer to Section 3.4.3 for POST Status Code definition.
From the Hyperterminal Recovery Mode menu (Figure 2-53), press the ‘F’ key to enter
FLASH download. A message will be displayed warning that the FLASH is about to be
erased; press the ‘Y’ key at the prompt. The screen will display dots as the flash devices are
being erased; this could take a few minutes.
Figure 2-53 - HyperTerminal Recovery Mode Menu
5. When the FLASH is ready for download the letter C will be displayed on the screen. In
the HyperTerminal command bar click on Transfer and then Send File…(see Figure 254). In the Send File Dialog Box (see Figure 2-55), select “1KXmodem” for the protocol,
enter the filename of the appropriate .bin file in the format “CWPxxxxx.bin” (where
xxxxx varies from release to release). Click on the Send button to start the download
(see Figures 2-55 and 2-56). When the HyperTerminal Recovery Mode Menu of Figure 253 appears, the download has completed.
6. Close the HyperTerminal program. The null modem cable connected between the
ControlWaveEXP and the PC can be removed if desired.
2-50 / Installation & Operation
CI-ControlWaveEXP
Figure 2-54 - HyperTerminal FLASH Download Menu
(Ready to Download) - (Transfer/Send File Selected)
Figure 2-55 - HyperTermal Flash Download
(Send File Dialog Box - Enter Filename)
7. Set CPU Switch SW3 position 3 to OFF (OFF = Recovery Mode Disabled). Switch Power
OFF and then ON again via the PSSM’s ON/OFF Switch.
Once the ControlWave is running its application load, status codes posted to the Port 80
Display have a different meaning than the Port 80 POST Status Codes (see Section 3.4.3
for POST Status Codes). The PORT 80 Display is disabled during normal running
operation to save power. These Port 80 Running Status (Hex) Codes are listed in Table 211.
ControlWaveEXP
Installation & Operation / 2-51
Figure 2-56 - HyperTerminal FLASH Download (Download in Process)
Table 2-11 - PORT 80 - Running Status Codes
Hex Code
00
1D
51
86*
D0
D1
F0
FE
5E
BF
CA
CF
FA
Definition
No Application
Currently Loading the Boot Project
System Initialization in Progress
Recovery Mode
Diagnostic Mode
Running Diagnostic
NPX Error
FLASH Programming Error
System Start Error
Battery Fail
Hot Card Replacement in Progress
Invalid Checksum Detected
CPU Bd. Switch SW1-3 Set OFF
Ignore Soft Switch Configuration Use factory defaults
Notes
SW3-3 = ON
SW1-8 = OFF
Unit Stopped
Check SW3-4
Unit Stopped
Flashes for 1 second
At startup
Core Dump in process
or waiting to start
FF
Unit Crashed
Unit Stopped
FC
Waiting for Alt. Watchdog Timer
Unit Stopped
* Not an actual Running Status Code - SW3-3 should be OFF
FD
Waiting for Updump
2.4.2.3 Remote Upgrade of ControlWaveEXP Firmware
It is possible to download system firmware into an unattended remote ControlWaveEXP.
This function can only be accomplished if CPU Board Switch SW3-2 (associated with the
unit in question) is set in the OFF position (factory default). The procedure for performing a
remote download of system firmware is discussed in Appendix J of the Open BSI Utilities
Manual (document D5081). Note: Remote upgrade of ControlWaveEXP Firmware
requires Boot PROM version 4.7 or higher and System PROM version 4.7 or
higher.
2-52 / Installation & Operation
CI-ControlWaveEXP
2.4.3 Operation of The Reset Switch (Button)
The CPU Module’s Reset Switch is a momentary button that allows the operator to reset
(stop and restart) the ControlWaveEXP when the unit is being tested via WINDIAG.
Never use this switch during normal operation.
2.4.4 Module Hot Swapping
The CPU’s Hot Swap circuitry provides for installation and removal of any or all I/O
Modules while the unit is running its application load (RUN Mode). When an I/O Module is
initially removed or installed, the ControlWave I/O Expansion Rack halts operation for
300 milliseconds before resuming operation from where it halted. To replace an I/O Module,
follow the steps in sections 2.4.5.1 and 2.4.5.2 below.
2.4.4.1 I/O Module Hot Swap Removal
1. Shut down or place under manual control all processes associated with the I/O Module
being removed. Note: Although more than one I/O Module can be removed while
power is applied to the unit, the service technician must never remove or
insert more than one I/O Module at a time.
2. Remove the Terminal Housing Assembly (see Figure 2-16).
3. Turn the Terminal Board’s Quarter Turn Fasteners (counterclockwise), grasp the
Terminal Handle and remove the Terminal Board Assembly (with wiring harness) from
the I/O module.
4. Turn the I/O Module’s Captured Panel Fasteners (counterclockwise) until it can be
removed from the Chassis. Remove the I/O Module assembly in question from the
ControlWave I/O Expansion Rack’s Chassis.
5. If not already done, remove the Terminal Board Assembly from the replacement I/O
Module.
2.4.4.2 I/O Module Hot Swap Installation
1. Install the replacement I/O Module into the same I/O slot that the I/O Module assembly
in question was removed from. When the assembly is fully seated, turn the I/O Module’s
Panel Fasteners (clockwise) to secure the unit to the Chassis.
2. Install the original Terminal Board Assembly (with wiring harness) onto the
replacement I/O Module (turning the Quarter Turn Fasteners (clockwise).
3. Replace the Terminal Housing Assembly.
4. Remove from manual control any processes associated with the I/O Module.
2.4.5 Soft Switch Configuration and Communication Ports
Firmware defined soft switches that control many default settings for various system
operating parameters such as BSAP Local Address, EBSAP Group Number, communication port parameters, etc., can be viewed and, if desired, changed via ‘Configuration
Web Pages’ in Microsoft Internet Explorer via the Flash Configuration Utility. When
connecting the ControlWave I/O Expansion Rack to the PC (local or network) for the first
time you should be aware of the communication port default parameter settings provided
below (see Figures 2-6 through 2-10). Note: Communication port factory defaults can be
enabled anytime by setting CPU Board Switch SW1-3 to the OFF position.
COM1: From the factory, COM1 defaults to 9600 bps (RS-232) using the Internet Point to
Point Protocol (PPP). Note: ControlWave Port COM1 will be configured for RS-232
ControlWaveEXP
Installation & Operation / 2-53
operation (at 9600 baud) by setting CPU Switches SW1-3 and SW1-8 OFF. This
places the unit into diagnostic mode. To test COM1 using the WINDIAG program,
it must not otherwise be in use and CPU Switch SW1-8 must be set to the OFF
position. Connection to a PC requires the use of an RS-232 “Null Modem” cable
(see Figure 2-9).
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with an RJ-45 male plug and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 39284301-3 connected to a Bristol “RJ45 to DB9 Adapter” cable P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM1.
COM2: When factory set for RS-232 or RS-485 operation, COM2 defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM2 using the WINDIAG program, it must not otherwise be in use and CPU
Switch SW1-8 must be set to the OFF position. In lieu of the use of COM1, an RS232 “Null Modem” cable (see Figure 2-9A) can be connected between COM2 and
the PC (typically COM1) or an RS-485 cable (see Tables 2-4 & 2-6) can be
connected between COM2 and the PC’s RS-485 Port.
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with an RJ-45 male plug and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 39284301-3 connected to a Bristol “RJ45 to DB9 Adapter” cable P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM2.
If RS-485 communications is required an RS-485 cable can be assembled using the
connections provided in Tables 2-4 and 2-6.
COM3: Factory set for RS-485 operation, COM3 defaults to 9600 baud, 8-bits, no parity, 1
stop bit, BSAP/ControlWave Designer protocol operation. To test COM3 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW1-8 must
be set to the OFF position. In lieu of the use of COM1, an RS-485 cable (see Tables
2-5 & 2-6) can be connected between COM3 and the PC’s RS-485 Port. Use Adapter
cable P/N 392844-01-0 as required (see Figure 2-9B).
COM4: Factory set for RS-485 operation, COM4 defaults to 9600 baud, 8-bits, no parity, 1
stop bit, BSAP/ControlWave Designer protocol operation. To test COM4 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW1-8 must
be set to the OFF position. In lieu of the use of COM1, an RS-485 cable (see Tables
2-4 & 2-6) can be connected between COM4 and the PC’s RS-485 Port. Use Adapter
cable P/N 392844-01-0 as required (see Figure 2-9B).
COM5: RS-232 Port COM5 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test COM5 using the WINDIAG
program, it must not otherwise be in use and CPU Switch SW1-8 must be set to
the OFF position. In lieu of the use of COM1, an RS-232 “Null Modem” cable (see
Figure 2-9A) can be connected between COM5 and the PC (typically COM1).
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with RJ-45 male plugs and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 392843-
2-54 / Installation & Operation
CI-ControlWaveEXP
01-3 connected to two Bristol “RJ45 to DB9 Adapter” cables P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM5.
COM6: RS-232 Port COM6 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test COM6 using the WINDIAG
program, it must not otherwise be in use and CPU Switch SW1-8 must be set to
the OFF position. In lieu of the use of COM1, an RS-232 “Null Modem” cable (see
Figure 2-9) can be connected between COM6 and the PC (typically COM1).
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with RJ-45 male plugs and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 39284301-3 connected to two Bristol “RJ45 to DB9 Adapter” cables P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM6.
Others: The Ethernet Port can be connected directly or via a network to a PC equipped
with an Ethernet Port (see Figures 2-7 and 2-11 through 2-14). If not configured
with an address, the ControlWave I/O Expansion Rack uses DHCP (by default) to
obtain an IP address. Note: If you are going to use an Open Modbus device to communicate with the ControlWave I/O Expansion Rack, refer to Appendix B.
ControlWaveEXP
Installation & Operation / 2-55
BLANK PAGE
Section 3
SERVICE
3.1 SERVICE INTRODUCTION
This section provides general, diagnostic and test information for the ControlWave I/O
Expansion Rack.
The service procedures described herein will require the following equipment:
1.
2.
3.
4.
PC with null modem interface cable & Bristol’s WINDIAG Software
Loop-back plug, 9-pin female D-Sub & 8-pin male RJ-45 (for RS-232) (see Figure 3-11)
Loop-back plug, 9-pin female D-Sub & 8-pin male RJ-45 (for RS-485) (see Figure 3-12)
Loop-back plug, 8-pin male RJ-45 (for twisted pair Ethernet) (see Figure 3-13)
The following test equipment can be used to test the Power Supply/Sequencer Module:
1. DMM (Digital Multimeter): 5-1/2 digit resolution
2. Variable DC Supply: Variable to 30Vdc @ 2.5A (with vernier adjustment)
When ControlWave I/O Expansion Racks are serviced on site, it is recommended that any
associated processes be closed down or placed under manual control. This precaution will
prevent any processes from accidentally running out of control when tests are conducted.
Warning
Harmful electrical potentials may still be present at the field wiring terminals
even though the ControlWave I/O Expansion Rack’s power source may be
turned off or disconnected. Do not attempt to unplug termination connectors or
perform any wiring operations until all the associated supply sources are
turned off and/or disconnected.
Warning
Always turn off any external supply sources used for externally powered I/O
circuits, before changing any modules.
3.2 COMPONENT REMOVAL/REPLACEMENT PROCEDURES
This section provides information on accessing ControlWave I/O Expansion Rack modules
for testing, installation/removal procedures and I/O Module Hot Swapping.
3.2.1 Accessing Modules For Testing
Testing and replacement of ControlWave I/O Expansion Rack modules should only be
performed by technically qualified persons. Familiarity with the disassembly and test
procedures described in this manual are required before starting. Any damage to the
ControlWave I/O Expansion Rack resulting from improper handling or incorrect service
procedures will not be covered under the product warranty agreement. If these procedures
cannot be performed properly, the unit should be returned to Bristol (with prior
authorization from Bristol Inc.) for factory evaluation and repairs. All Modules (PSSM,
CI-ControlWaveEXP
Service / 3-1
CPU & I/O) are factory sealed to prevent tampering; if the seal is broken by other than
Bristol Inc. personnel, the warranty is void.
3.2.2 Removal/Replacement of the Bezel Assembly
Before the CPU Module can be removed, the Bezel Assembly (that covers the PSSM and the
CPUM) must be removed from the Chassis.
1. Remove any I/O Module from Chassis Slot 3. Grasp the sides of the Bezel Assembly
and gently pull it off the Chassis.
2. To replace the Bezel Assembly, align the Bezel’s two snaps (top and bottom) (one
near the top and one near the bottom) with their receptacles on the Chassis (centered between the PSSM’s and CPUM’s Captured Panel Fastener holes).
3.2.3 Removal/Replacement of the CPU Module
1. Remove the Bezel Assembly (see section 3.2.2).
2. If the ControlWave I/O Expansion Rack is running, place any critical control
processes under manual control and shut down the unit by setting the PSSM Power
Switch to the ‘O’ position.
3. Loosen the two Captured Panel Fasteners that secure the CPU Module to the
Chassis and then carefully slide the CPU Module out of the front of the Chassis.
4. To replace the CPU Module, the Power Supply/Sequencer Module must be installed
(see Section 3.2.4). Carefully align the CPU Module with Chassis Slot 2 and insert
the unit into the Chassis. When the assembly is fully seated (CPU Module
Connector J1 has mated with Backplane Connector P2), turn the module’s Captured
Panel Fasteners (clockwise) to secure CPU Module to the Chassis thus establishing
a low resistance path between the CPU Module and Chassis Ground. Make sure that
the module’s Captured Panel Fasteners are snug but don’t over-tighten them.
3.2.4 Removal/Replacement of the Power Supply/Sequencer Module
1. If the ControlWave I/O Rack is running, place any critical control processes under
manual control and shut down the unit by setting the PSSM Power Switch to the ‘O’
position.
2. Remove the Bezel Assembly (see Section 3.2.2).
3. Unplug the PSSM’s modular connectors TB1 (Power) and TB2 (Watchdog).
4. Remove the CPU Module (see Section 3.2.3). The CPU Module must be removed
prior to removal/replacement of the PSSM.
5. Loosen the two Captured Panel Fasteners that secure the PSSM to the Chassis and
then carefully slide the PPSM out of the front of the Chassis.
6. To replace the PSSM, the CPU Module must be removed. Carefully align the PSSM
with Chassis Slot 1 and insert the unit into the Chassis. When the assembly is fully
seated (PSSM Connector J1 has mated with Backplane Connector P1), turn the
module’s Captured Panel Fasteners (clockwise) to secure the Power
Supply/Sequencer Module to the Chassis thus establishing a low resistance path
between the PSSM and Chassis Ground. Make sure that the module’s Captured
Panel Fasteners are snug but don’t over-tighten them.
7. Replace the CPU Module (see Section 3.2.3) and apply power.
3-2 / Service
CI-ControlWaveEXP
3.2.5 Module Hot Swapping
The CPU’s Hot Swap circuitry provides for installation and removal of any or all I/O
Modules while the unit is running its application load (RUN Mode). When an I/O Module is
initially removed or installed, the ControlWave I/O Expansion Rack halts operation for
300 milliseconds before resuming operation from where it halted. To replace an I/O Module,
follow the steps in sections 3.2.5.1 and 3.2.5.2 below.
3.2.5.1 I/O Module Hot Swap Removal
1. Shut down or place under manual control all processes associated with the I/O Module
being removed. Note: Although more than one I/O Module can be removed while
power is applied to the unit, the service technician must never remove or
insert more than one I/O Module at a time.
2. Remove the Terminal Housing Assembly (see Figure 2-16).
3. Turn the Terminal Board’s Quarter Turn Fasteners (counterclockwise) and remove the
Terminal Board Assembly (with wiring harness) from the I/O module.
4. Turn the I/O Module’s Captured Panel Fasteners (counterclockwise) until it can be
removed from the Chassis. Remove the I/O Module assembly in question from the
Chassis. Note: To ease I/O Module removal, reinstall the Terminal Housing
Assembly and (with Terminal Door open) grasp the Terminal Handle and
remove the I/O Module.
5. If not already done, remove the Terminal Board Assembly from the replacement I/O
Module.
3.2.5.2 I/O Module Hot Swap Installation
1. Install the replacement I/O Module into the same I/O slot that the I/O Module assembly
in question was removed from. When the assembly is fully seated, turn the I/O Module’s
Panel Fasteners (clockwise) to secure the unit to the Chassis. Check the I/O Module’s
Green Status LED (see Figures 3-3 through 3-7).
2. Install the original Terminal Board Assembly (with wiring harness) onto the
replacement I/O Module (turning the Quarter Turn Fasteners (clockwise).
3. Replace the Terminal Housing Assembly.
4. Remove from manual control any processes associated with the I/O Module.
3.3 TROUBLESHOOTING TIPS
3.3.1 Power Supply/Sequencer Module (PSSM) Voltage Checks
One or two bulk power sources can be connected to the PSSM. PPSM connector TB2
provides 5 input terminal connections for bulk power (see Figure 3-1):
TB2-1 =
TB2-2 =
TB2-3 =
TB2-4 =
TB2-5 =
(+VIN) (+10.6V to +20V dc for +12V supply) (+20.7V to +30V dc for +24V supply)
(+VINF) Connected to TB2-1 or separate +9Vdc to +30Vdc supply
(-VIN) (1st Supply Ground)
(-VINF) (2nd Supply Ground) Internally connected to TB2-3
Chassis Ground - CHASSIS (;)
Bulk supply voltages can be checked at TB2 using a voltmeter or multimeter. PPSM’s are
factory configured for use with a nominal 12Vdc or 24Vdc bulk power supply. The
maximum and minimum input power switchpoints can be tested with the use of a Variable
dc Power Supply connected between TB2-1 (+) and TB2-3 (-). By increasing the input
CI-ControlWaveEXP
Service / 3-3
voltage (starting at +10.6Vdc or +20.7Vdc) for +12V or +24V units respectively, you can
determine the point at which the unit will turn on, i.e., the point at which the green
PWRGOOD LED on the PSSM comes ON (Vt+). By decreasing the input voltage (starting at
+20Vdc or +30Vdc) for +12V and +24V units respectively, you can determine the point at
which the unit turns off, i.e., the point at which the green PWRGOOD LED on the PSSM
goes OFF (Vt-). If the value of the bulk power supply’s +12Vdc or +24Vdc output approaches
the value of Vt+ or Vt- it should be replaced by one with the correct +12V or +24V output.
Figure 3-1 - Power Supply/Sequencer Module’s TB1, TB2 & LED Designations
3.3.2 LED Checks
All ControlWave Modules contain light emitting diodes (LEDs) that provide operational
and diagnostic functions. A brief synopsis of the individual module LEDs is provided as
follows:
PSSM:
CPUB:
1 MC LED, 1 PWRFAIL LED & 1 PWRGOOD LED
2 LEDs per Comm. Port = 4, 2 LEDs per Ethernet Port = 2
1 Idle LED, 1 Watchdog LED & the Port 80 Display Assembly
SCB:
2 LEDs per Comm. Port = 8
AIM:
1 Status LED plus 32 AI LEDs (i.e., 2 LEDs per AI @ 16 AI)
AOM:
1 FAIL LED & 1 GOOD LED
DIM:
1 Status LED plus 32 DI LEDs (i.e., 1 LED per DI @ 32 DI)
DOM: 1 Status LED plus 32 DO LEDs (i.e., 1 LED per DO @ 32 DO)
UDIM: 1 Status LED plus 12 UI LEDs (i.e., 1 LED per UDI @ 12 UDI)
ControlWave Module LED designations and functions are provided in Table 3-1.
3-4 / Service
CI-ControlWaveEXP
Table 3-1 - LED Assignment
PSSM
PSSM
PSSM
CPUB
CPUB
CPUB
CPUB
CPUB
CPUB
CPUB
CPUB
CPUB
SCB
SCB
SCB
SCB
SCB
SCB
SCB
SCB
MC
PWRFAIL
PWRGOOD
CR1 - WATCHDOG
CR2 - IDLE
CR1 - COMM 1 RX
CR1 - COMM 1 TX
CR1 - COMM 2 RX
CR1 - COMM 2 TX
CR2 - ENET Port 1
CR2 - ENET Port 1
PORT 80 DISPLAY
CR1 - COMM 3 RX
CR1 - COMM 3 TX
CR1 - COMM 4 RX
CR1 - COMM 4 TX
CR2 - COMM 5 RX
CR2 - COMM 5 TX
CR2 - COMM 6 RX
CR2 - COMM 6 TX
LED
Color
Red
Red
Green
Red
Red
Red
Red
Red
Red
Red/Green
Red/Green
Red LED
Red
Red
Red
Red
Red
Red
Red
Red
AIM
AI Bd. Status
Red/Green
Module
LED
Name
AOM
AOM
RANGE (16 LEDs)
(1 Per Point)
RANGE (16 LEDs)
(1 Per Point)
AO Bd. Status Fail
AO Bd. Status Pass
DIM
DI Bd. Status
Red/Green
DIM
INPUT (32 LEDs)
(1 Per Point)
Red
DOM
DO Bd. Status
Red/Green
DOM
OUTPUT (32 LEDs)
(1 Per Point)
Red
AIM
AIM
Red
Green
Red ***
Green ***
Function
ON 2msec after PWR_FAIL goes low *
ON = Bulk or Regulated Power out of Specs. *
ON = Normal operation - all supplies O.K. *
ON = Watchdog Condition - OFF = Normal
ON = Idle
ON = RX Activity (Top-Left - see Fig 3-2)
ON = TX Activity (Top-Right -see Fig 3-2)
ON = RX Activity (Bottom-Left - see Fig 3-2)
ON = TX Activity (Bottom-Right -see Fig 3-2)
ON Green = Receiving Data (Left -see Fig 3-2)
ON Red = Transmitting Data (Right - see Fig 3-2)
LED Matrix Status Codes (see Fig 3-2) **
ON = RX Activity (Top-Left - see Fig 3-2)
ON = TX Activity (Top-Right -see Fig 3-2)
ON = RX Activity (Bottom-Left - see Fig 3-2)
ON = TX Activity (Bottom-Right -see Fig 3-2)
ON = RX Activity (Top-Left - see Fig 3-2)
ON = TX Activity (Top-Right -see Fig 3-2)
ON = RX Activity (Bottom-Left - see Fig 3-2)
ON = TX Activity (Bottom-Right -see Fig 3-2)
ON Red = Fail State/Bd. not recognized
ON Green = Normal State (see Fig 3-3)
LED ON = Overrange or Underrange condition
(see Fig 3-3)
LED ON = In-range condition
(see Fig 3-3)
LED ON = AI Bd. Fail State/Bd. not recognized
LED ON = AI Bd. Normal or O.K. State
ON RED = DI Bd. Fail State/BD. not recognized
ON Green = DI Bd. Normal State (see Fig. 3-5)
LED ON = Input is present
LED OFF = Input is not present (see Fig 3-5)
ON RED = Fail State/Module not recognized
ON Green = Normal State (see Fig 3-6)
LED ON = Output is ON (see Fig 3-6)
ON RED = UI Bd. Fail State/Bd. not recognized
On Green = UI Bd. Normal or O.K. State
INPUT (12 LEDs)
LED ON = Input activity on input is present
UDIM
Red
(1 Per Point)
LED OFF = No activity on input (see Fig 3-7)
* = see Figure 3-1, ** = see Sections 2.4.2 & 3.4.4, *** = see Figure 3-4
UDIM
UDI Bd. Status Fail
CI-ControlWaveEXP
Red/Green
Service / 3-5
Figure 3-2 - CPU Module Port & LED Designations
Figure 3-3 - Analog Input (AI) Module LED Designations
3-6 / Service
CI-ControlWaveEXP
Figure 3-4 - Analog Output (AO) Module LED Designations
Figure 3-5 - Digital Input (DI) Module LED Designations
CI-ControlWaveEXP
Service / 3-7
Figure 3-6 - Digital Output (DO) Module LED Designations
Figure 3-7 - Universal Digital Input (UDI) Module LED Designations
3-8 / Service
CI-ControlWaveEXP
3.3.3 Wiring/Signal Checks
Check I/O Field Wires at the Card Edge Terminal Blocks and at the field device. Check
wiring for continuity, shorts & opens. Check I/O signals at their respective Terminal Blocks
(see Table 3-2).
Table 3-2 - I/O Field Wiring - Terminal Block Reference List
I/O Subsystem
Discrete Inputs
Discrete Outputs
Analog Inputs
Analog Output
Universal Inputs
Watchdog Ckt.
Figures
2-19 through 2-23
2-24 through 2-27
2-28 through 2-33
2-34 through 2-37
2-38 through 2-41
2-44A & 2-44B
Notes
See Section 2.3.4.4
See Section 2.3.4.5
See Section 2.3.4.6
See Section 2.3.4.7
See Section 2.3.4.8
See Section 2.3.5.3
3.4 GENERAL SERVICE NOTES
Certain questions or situations frequently arise when servicing the BBI Controllers. Some
items of interest are provided in Sections 3.4.1 through 3.4.4.
3.4.1 Extent of Field Repairs
Field repairs to ControlWave I/O Expansion Racks are strictly limited to the replacement
of complete modules. ControlWave Modules are sealed and employ a tamper indicator.
Disassembly of a ControlWave Module constitutes tampering and will violate the
warranty. Defective ControlWave Chassis or Modules must be returned to Bristol Babcock
for authorized service.
3.4.2 Disconnecting RAM Battery
The ControlWave I/O Expansion Rack’s Lithium RAM battery can be replaced while power
is on. Upon power-up, the unit will recover its last I/O states. The battery may be disabled
by setting CPU Switch SW3 position 4 to the OFF position.
3.4.3 Port 80 Display POST Checks
At start-up, by applying power or by depressing the momentary contact (RESET) switch,
the resident BIOS will initiate and test the hardware; this process is referred to as POST,
i.e., Power On Self Test.
The status of the POST progress (typically too fast to discern) is posted to the CPU
Module’s Port 80 Display. Successful POST completion is indicated with an 86 on the port
80 Display if the unit is in Recovery Mode. Detection of a fault will be indicated by a 2-digit
code on the Port 80 Display (see Table 3-3 and Table 2-11).
CI-ControlWaveEXP
Service / 3-9
Table 3-3 - Port 80 POST Status Codes
Hex Code
00
01
02
03
04
05
06
07
08
09
0A
0B
0C
0D
0E
0F
10
11
12
13
14
15
16
17
18
19
1A
1B
1C
20
21
22
23
24
25
26
27
28
29
2A
2B
2C
2D
2E
2F
30
31
32
33
34
35
36
3-10 / Service
Definition
POST beginning.
CPU register test about to start.
NMIs are disabled; delay starts.
power-on delay finished.
kbd BAT done; reading kbd SYS bit.
disabling shadowing & cache.
calcing ROM cksum, wait kbd ctrllr.
cksum okay, kbd ctrllr free.
verifying BAT cmd to kbd ctrllr.
N/A
N/A
issuing pin 23, 24 blocking & unblocking.
issuing kbd ctrllr NOP cmd next.
testing CMOS RAM shutdown register.
checking CMOS cksum, updating DIAG byte.
initializing CMOS (if req’d every boot).
init CMOS status reg for date/time.
disabling DMA, interrupt ctrllrs.
disabling Port B, disabling video display.
init board, start auto-mem detect.
starting timer tests.
testing 8254 T2, for spkr, part B.
testing 8254 T1, for refresh.
testing 8254 To, for 18.2 Hz.
starting memory refresh.
testing memory refresh.
testing 15usec refresh ON/OFF time.
testing base 64KB memory.
testing data lines.
testing address lines.
testing parity (toggling).
base 64KB mem read/write test.
system init before vector table init.
init vector table.
reading 8042 for turbo switch setting.
initiating turbo data.
any init after vector table init is next.
N/A
N/A
toggle parity before optional video ROM.
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
check ROM BIOS data area at seg 40h.
setting cursor for power-on msg.
CI-ControlWaveEXP
Table 3-3 - Port 80 POST Status Codes (Continued)
Hex Code
37
38
39
3A
40
41
42
43
44
45
46
47
48
49
4A
4B
4C
4D
4E
4F
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
80
81
82
83
84
85
86
87
88
89
8A
8B
8C
CI-ControlWaveEXP
Definition
displaying power-on message.
save cursor position.
display BIOS ident. String.
display “Hit <DEL> to …” msg.
preparing vm test. vrfy from display.
preparing descriptor tables.
enter virtual mode for memory test.
enable inits for diagnostics mode.
init data for checking wraparound at 0:0.
checking for wrap, find total memory size.
write extended memory test patterns.
write conventional memory test patterns.
finding low memory size from patterns.
finding high memory size from patterns.
check ROM BIOS data area again.
check for <DEL>, clear low mem for soft reset.
clearing ext mem for soft reset.
saving memory size.
on cold boot, display 1st 64KB memtest.
on cold boot, test all of low memory.
adjust memsize for 1K usage.
on cold boot, test high memory.
prepare for shutdown to real-mode.
saved regs & memsize, entering real-mode.
shutdown successful, restoring codepath.
disabling A20 line.
checking ROM BIOS data area again.
checking ROM BIOS data area some more.
clear the “Hit <DEL>” message.
test DMA page register.
verify from display memory (???).
test DMA0 base register.
test DMA1 base register.
checking ROM BIOS data area again.
checking ROM BIOS data area some more.
programming DMA ctrllrs 0 & 1
initializing INT ctrllrs 0 & 1.
N/A
N/A
N/A
N/A
N/A
check for memsize mismatch.
check for pswd or bypass setup.
pswd checked. Do pgming before setup.
call the setup module.
N/A
display power-on screen message.
display “Wait…” message.
N/A
N/A
Service / 3-11
Table 3-3 - Port 80 POST Status Codes (Continued)
Hex Code
8D
8E
8F
90
91
92
93
94
95
96
97
98
99
9A
9B
9C
9D
9E
9F
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
B0
B1
B2
B3
Definition
N/A
check floppy disks.
N/A
N/A
N/A
N/A
N/A
setting base & ext mem sizes.
N/A
N/A
N/A
processing after extension returns.
configuring timer data area, printer base addr.
configuring serial port base addrs.
initialization before coprocessor test.
initializing the coprocessor.
processing after coprocessor initialized.
N/A
N/A
kbd ID flag reset.
do cache memory test.
display any soft errors.
N/A
program memory wait states.
N/A
enable parity and NMIs.
N/A
N/A
N/A
N/A
test low memory exhaustively.
test extended memory exhaustively.
N/A
3.5 WINDIAG DIAGNOSTICS
Bristol’s WINDIAG Software is a diagnostic tool used for testing ControlWave I/O
Modules, CPU memory, communications ports, etc., for proper performance. The
ControlWave I/O Expansion Rack must be communicating with a PC equipped with
Bristol’s WINDIAG program. CPU Module configuration switch SW1-8 must be set to the
OFF (Closed) position to enable diagnostics. Communication between the ControlWave I/O
Expansion Rack (with/without application loaded) and the PC can be made via a Local or
Network Port with the following restrictions:
•
CPU Board Switch SW1-8 must be OFF (closed) to run the WINDIAG program. Setting
SW1-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into
diagnostic mode.
•
Any ControlWave I/O Equipment Rack serial communication port COM1 through
COM6 can be connected to the PC (PEI) provided their port speeds match. Most PCs
have a COM1 port (typically RS-232 and defaulted to 9600 bps operation).
3-12 / Service
CI-ControlWaveEXP
•
Communication port COM1 is only forced to 9600 bps operation when CPU Switches
SW1-3 and SW1-8 have both been set OFF (closed). COM1 can also be set to 9600 bps
operation via user defined Soft Switches.
•
Setting CPU Board Switches SW1-3 and SW1-8 OFF (closed) prevents the ‘Boot Project’
from running, places the unit into diagnostic mode and forces communication ports
COM1 through COM6 to operate at 9600 baud.
COM1: From the factory, COM1 defaults to 9600 bps (RS-232) using the Internet Point to
Point Protocol (PPP). Note: ControlWave Port COM1 will be configured for RS-232
operation (at 9600 baud) by setting CPU Switches SW1-3 and SW1-8 OFF. To test
COM1 using the WINDIAG program, it must not otherwise be in use and CPU
Switch SW1-8 must be set to the OFF position. Connection to a PC requires the
use of an RS-232 “Null Modem” cable (see Figure 2-9).
COM2: When factory set for RS-232 or RS-485 operation, COM2 defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test
COM2 using the WINDIAG program, it must not otherwise be in use and CPU
Switch SW1-8 must be set to the OFF position. In lieu of the use of COM1, an RS232 “Null Modem” cable (see Figure 2-9A) can be connected between COM2 and
the PC (typically COM1) or an RS-485 cable (see Tables 2-4 & 2-6) can be
connected between COM2 and the PC’s RS-485 Port.
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with an RJ-45 male plug and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 39284301-3 connected to a Bristol “RJ-45 to DB9 Adapter” cable P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM2.
If RS-485 communications is required an RS-485 cable can be assembled using the
connections provided in Tables 2-4 and 2-6.
COM3: Factory set for RS-485 operation, COM3 defaults to 9600 baud, 8-bits, no parity, 1
stop bit, BSAP/ControlWave Designer protocol operation. To test COM3 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW1-8 must
be set to the OFF position. In lieu of the use of COM1, an RS-485 cable (see Tables
2-5 & 2-6) can be connected between COM3 and the PC’s RS-485 Port.
COM4: Factory set for RS-485 operation, COM4 defaults to 9600 baud, 8-bits, no parity, 1
stop bit, BSAP/ControlWave Designer protocol operation. To test COM4 using the
WINDIAG program, it must not otherwise be in use and CPU Switch SW1-8 must
be set to the OFF position. In lieu of the use of COM1, an RS-485 cable (see Tables
2-4 & 2-6) can be connected between COM4 and the PC’s RS-485 Port.
COM5: RS-232 Port COM5 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test COM5 using the WINDIAG
program, it must not otherwise be in use and CPU Switch SW1-8 must be set to
the OFF position. In lieu of the use of COM1, an RS-232 “Null Modem” cable (see
Figure 2-9) can be connected between COM5 and the PC (typically COM1).
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with RJ-45 male plugs and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 392843CI-ControlWaveEXP
Service / 3-13
01-3 connected to two Bristol “RJ45 to DB9 Adapter” cables P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM5.
COM6: RS-232 Port COM6 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation. To test COM6 using the WINDIAG
program, it must not otherwise be in use and CPU Switch SW1-8 must be set to
the OFF position. In lieu of the use of COM1, an RS-232 “Null Modem” cable (see
Figure 2-9) can be connected between COM6 and the PC (typically COM1).
If the PC is equipped with an RS-232 Port that utilizes an RJ-45 jack, use either a
special “Null Modem” cable equipped with RJ-45 male plugs and wired like the
null modem cable of Figure 2-9A, or use Bristol “Null Modem” cable P/N 39284301-3 connected to two Bristol “RJ45 to DB9 Adapter” cables P/N 392844-01-0 (see
Figures 2-9A & 2-9B), to interconnect the PC to COM6.
Others: The Ethernet Port can be connected directly or via a network to a PC equipped
with an Ethernet Port (see Figures 2-7, and 2-11 through 2-14). If not configured
with an address, the ControlWave uses DHCP (by default) to obtain an IP
address.
To use the WINDIAG program place any critical process (associated with the ControlWave
I/O Expansion Rack in question) under manual control. WINDIAG cannot be run while the
ControlWave I/O Expansion Rack is running. Set the CPU Modules Switches SW1-3 and
SW1-8 to the OFF (closed) position. Perform steps 1 through 6 below.
1. Start the OpenBSI NetView Program. A menu similar to Figure 3-8 will appear.
2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI Tools,
then select Utilities Programs and then select Diagnostics.
3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 3-9 will
appear.
4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG
will perform the diagnostics and display pass/fail results.
5. After all diagnostic testing has been performed, exit the WINDIAG program and then
exit the Netview Program if there aren’t any other ControlWave I/O Expansion Racks
to be tested. When you close the Netview program you will be prompted as to whether or
not you want to close the OpenBSI program; select Yes.
6. Set CPU Switch SW1-8 to the ON (Open) position. The ControlWave I/O Equipment
Rack should resume normal operation.
3.5.1 Diagnostics Using WINDIAG
All Controllers Modules except the Power Supply/Sequencer Module can be tested using the
WINDIAG program. From WINDIAG’s Main Diagnostics Menu (see Figure 3-9) the
following diagnostic tests can be performed:
CPU & Peripherals Diagnostic:
PROM/RAM Diagnostic:
Communications Diagnostic:
Ethernet Diagnostic:
Analog Output Diagnostic:
Analog Input Diagnostic:
3-14 / Service
Checks the CPU Module (except for RAM & PROM).
Checks the CPU’s RAM and PROM hardware.
Checks Comm. Ports 1 through 6 - The External loopback tests require the use of a loop-back plug.
Checks Ethernet Port 1 - The Loop-back Out Twisted
Pair tests require the use of a loop-back plug.
Checks the Analog Output Module.
Checks the Analog Input Module.
CI-ControlWaveEXP
Discrete I/O Diagnostic:
High Speed Counter Diagnostic:
Checks the DI Module and/or the DO Module.
Checks the Universal Digital Input Module.
Figure 3-8 - Netview Startup Menu - Example with Multiple Networks
Figure 3-9 - WINDIAG Main Diagnostics Menu
CI-ControlWaveEXP
Service / 3-15
3.5.1.1 Communications Diagnostic Port Loop-back Test
WINDIAG’s Communications Diagnostic Menu (see Figure 3-11) provides for selection of
the communication port to be tested (1 or 2). Depending on the type of network (RS-232 or
RS-485) and the port in question, a special loop-back plug is required as follows:
Ports 1, 2 and 4 set-up for RS-232, use a 9-pin female D-type loop-back plug (see Fig. 3-10).
Ports 2 and 4 set-up for RS-485, use a 9-pin female D-type loop-back plug (see Fig. 3-12).
Port 3 set-up for RS-485, use an 8-pin male RJ-45 loop-back plug (see Fig. 3-12).
Ports 5 and 6 set-up for RS-232, use an 8-pin male JR-45 loop-back plug (see Fig. 3-10).
1
1 = DCD
4 = RTS
6 = CTS
7 = DTR
3 = RXD
5 = TXD
2
4 = DTR
5
7
3 = TXD
2 = RXD
8 = CTS
7 = RTS
1 = DCD
Figure 3-10 - RS-232 Loop-back Plugs
This group of tests verifies the correct operation of the Communication Interface. COM1
through COM6 can be tested with this diagnostic. The ControlWave I/O Expansion Rack
communication port that is connected to the PC (local or network and used for running
these tests) can’t be tested until diagnostics has been established via one of the other ports,
i.e., to test all ControlWave I/O Expansion Rack communication ports (via WINDIAG),
communications with the PC will have to be established twice (each time via a different
port). It should be noted that the ControlWave I/O Expansion Rack communication port
that is connected to the PC (RS-232, RS-485 or Ethernet) must be good for WINDIAG to run
the Communications Diagnostics.
Figure 3-11 - WINDIAG’s Communications Diagnostic Menu
3-16 / Service
CI-ControlWaveEXP
3.5.1.2 Serial Communications Port External Loop-back Test Procedure
1. Connect an external loop-back plug to the CPU Port to be tested, i.e., J1 of CPU for Port 1,
J2 of CPU for Port 2 or J1 through J4 of the SCB for Ports 3 through 6 respectively (see
Figures 3-10 through 3-12).
2. Type "1," "2," "3," "4," "5" or "6" for the port to test.
3. Set baud rate to test to 9600 baud or ALL ASYNC and the number of passes to 5.
4. Click on RUN button next to External loop-back.
Test responses:
a) Success - All sections of test passed
b) Failure - TXD RXD Failure
- CTS RTS Failure
Execution time < 5 sec.
Figure 3-12 - RS-485 Loop-back Plugs
3.5.1.3 Ethernet Diagnostic Port Loop-back Test
WINDIAG’s Ethernet Diagnostic Menu (see Figure 3-14) provides for selection of the
Ethernet communication port to be tested. A special loop-back plug is required to perform
the Ethernet loop-back test (see Figure 3-13).
Figure 3-13 - RJ-45 Ethernet Loop-back Plug
CI-ControlWaveEXP
Service / 3-17
Figure 3-14 - WINDIAG’s Ethernet Diagnostic Menu
If the ControlWave I/O Expansion Rack Ethernet port is connected to the PC (and used for
running these tests), it can’t be tested until diagnostics has been established via one of the
other ports, i.e., to test all ControlWave I/O Expansion Rack communication ports (via
WINDIAG), communications with the PC will have to be established at least twice (each
time via a different port. It should be noted that the ControlWave I/O Expansion Rack
communication port that is connected to the PC (RS-232, RS-485 or Ethernet) must be good
for WINDIAG to run the Communications Diagnostics.
This test configures the Ethernet to transmit and receive via the twisted pair port. Test
frames are transmitted and compared against received frames.
3-18 / Service
CI-ControlWaveEXP
3.5.1.4 Ethernet Port 1 External Loop-back Test Procedure
1. Connect an external RJ-45 Ethernet loop-back plug (see Figure 3-13) into the Ethernet
Port to be tested, i.e., J3 of CPU for Port 1.
2. Type "1" for the port to test.
3. Click on the "RUN" button next to the Loop-back out twisted pair test.
4. Click on RUN button next to External loop-back.
•
Test responses:
a) Success - All sections of test passed
b) Xmit Error
c) Rx Error
d) Buffer Compare Failure
3.6 CORE UPDUMP
In some cases a copy of the contents of SRAM can be uploaded to a PC for evaluation by
Bristol Inc. engineers. This upload is referred to as a ‘Core Updump.’ A Core Updump may
be required if the ControlWave I/O Equipment Rack repeatedly enters a ‘Watchdog State’
thus ill effecting system operation. A Watchdog State is entered when the system crashes,
i.e., a CPU timeout occurs due to improper software operation, a firmware glitch, etc. In
some cases the Watchdog State may reoccur but may not be logically reproduced.
‘Crash Blocks’ (a function of firmware provided for watchdog troubleshooting) are stored in
CPU RAM. The user can view and save the ‘Crash Blocks’ by viewing the Crash Block
Statistic Web Page (see Chapter 4 of the Open BSI Technician’s Toolkit - D5087). Crash
Block files should be forwarded to Bristol for evaluation. If additional information is
required to evaluate the condition, a Core Updump may be requested by Bristol. Once the
file generated by the Core Updump has been forwarded to Bristol, it will be evaluated and
the results will be provided to the user.
Follow the five steps below to perform a Core Updump.
1. Disable the Watchdog Timer by setting CPU Module Switch SW1-1 to the OFF position.
2. Wait for the error condition (typically FF on Port 80 Display).
3. Connect the ControlWave I/O Expansion Rack’s Comm. Port 1 to a PC using a Null
Modem Cable (see Figure 2-9).
4. Set CPU Module Switch SW1-4 to the OFF position to enable the Core Updump feature.
5. Start the PC’s HyperTerminal Program (at 115.2 kbaud) and generate a receive using
the 1KX-Modem protocol. Save the resulting Core Updump in a file to be forwarded to
Bristol for evaluation.
When the Core Updump has completed, set CPU Switch SW1-1 ON (Watchdog Circuit
Enabled), if required.
CI-ControlWaveEXP
Service / 3-19
BLANK PAGE
Section 4
SPECIFICATIONS
4.1 CPU, MEMORY & PROGRAM INTERFACE
Processor:
Intel 386EX microprocessor, 25MHz
Memory:
2/4Mbyte of system FLASH
1/2Mbtye of on-board static RAM
512Kbytes FLASH Boot/Downloader in a single IC
Real Time Clock:
Implemented via a Dallas DS1305 Serial Alarm Real
Time Clock. Features 96 bytes of nonvolatile RAM for
data storage.
Connectors:
(see Table 4-1 and referenced Tables)
Table 4-1 - CPU Module Connector Summary
Ref.
J1
J2
J3
J4
J5
J6
J1
J2
J3
J4
# Pins
9-pin
9-pin
8-pin
132-pin
24-pin
3-pin
8-pin
9-pin
8-pin
8-pin
Function
COM1 male D-sub (RS-232)
COM2 male D-sub (RS-232 or RS-485)
Ethernet 10/100BaseT RJ-45
I/O Bus Connector
Port 80 Diagnostics
Battery Connector
COM3 RJ-45 (RS-485)
COM4 male D-sub (RS-485)
COM5 RJ-45 (RS-232)
COM6 RJ-45 (RS-232)
Notes
see Figure 4-2 & Table 4-2
see Figure 4-2 & Table 4-3
see Figure 4-4 & Table 4-5
see Figure 4-1
Not use accessible
see Figure 4-5
SCB - see Figure 4-3 & Table 4-4
SCB - see Figure 4-2 & Table 4-3
SCB - see Figure 4-3 & Table 4-4
SCB - see Figure 4-3 & Table 4-4
Figure 4-1 - Power Supply Bd., CPU Bd. & I/O Bds. I/O Bus Connectors
Looking into Board Connectors
CI-ControlWaveEXP
Specifications / 4-1
Figure 4-2 - DB9 9-Pin Connector Associated with COM1, COM2 & COM4
Table 4-2 - CPU Board Connector J1 (COM1) Pin Assignment
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
RXD
TXD
DTR
GND
RTS
-
Description:
RS-232 Signals
N/A
Receive Data - Input
Transmit Data - Output
Data Terminal Ready
Output
Signal/Power Ground
N/A
Request To Send - Output
N/A
N/A
-
Table 4-3 - CPU Bd. Connector J2 (COM2)
& SCB Connector J2 (COM4) Pin Assignments
Pin
#
1
2
3
4
5
6
7
8
9
Signal
RS-232
DCD
RXD
TXD
DTR
GND
DSR
RTS
CTS
-
COM2 Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Transmit Data Output
Data Terminal Ready Output
Signal/Power Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
Not Used
Signal
RS-485
RXDTXDTXD+
ISOGND
RXD+
COM2/4 Description:
RS-485 Signals
N/A
Receive Data - Input
Transmit Data - Output
Transmit Data + Input
Isolated Ground
Receive Data + Output
N/A
N/A
N/A
Table 4-4 - SCB Bd. Connector J1 (COM3), J3 (COM5) & J4 (COM6)
Pin Assignments
Pin
#
1
2
3
4
5
6
7
8
Signal
RS-232
DCD
DSR
RXD
RTS
TXD
CTS
DTR
GND
4-2 / Specifications
COM4/5 Description:
RS-232 Signals
Data Carrier Detect Input
Data Set Ready Input
Receive Data Input
Request To Send Output
Transmit Data Output
Clear To Send Input
Data Terminal Ready Output
Signal/Power Ground
Signal
RS-485
RXD+
RXDTXDTXD+
ISOGND
COM3 Description:
RS-485 Signals
N/A
Receive Data + Input
Receive Data - Input
N/A
Transmit Data - Output
N/A
Transmit Data + Output
Isolated Ground
CI-ControlWaveEXP
1
8
Looking into
receptacle
Figure 4-3
RJ-45 Connector J1, J3 & J4 Associated with COM3, COM5 & COM6 on SCB
Table 4-5 - Ethernet 10/100BaseT RJ-45 Connector Pin Assignment
(CPU Connector J3)
Pin
#
1
2
3
6
4, 5, 7 & 8
Signal
Nmae
TXO+
TXORXI+
RXIN/C
Description:
Ethernet Signals
Transmit Data - Output
Transmit Data - Output
Receive Data - Input
Receive Data - Input
N/A
1
8
Looking into
receptacle
Figure 4-4 - RJ45 Ethernet Connector J3 = Ethernet 1
Figure 4-5 - Connector J6 - CPU Battery Header
CI-ControlWaveEXP
Specifications / 4-3
4.2 POWER SUPPLY/SEQUENCER MODULE
4.2.1 Input Power Specs.
Note: Voltages are dc unless otherwise specified.
Operating Range:
TB2-1 (+VIN) LOGIC (dc) Supply
+10.6V to +20.0V (+12V Input Supply) (Shutdown occurs
at +10.6V nominal)
+20.7V to +30.0V (+24V Input Supply) (Shutdown occurs
at +20.7V nominal)
TB2-2 (+VINF) FIELD (dc) Supply
+9.0V to +30.0V (Bulk Input Supply)
Output Voltages:
Isolated +3.3V, +5V, +12V (optional) & -12V (optional)
Output Current:
Typical (±12V Supplies Not Used)
1.5A (Max.) @ +5V
1A (Max.) @ +3.3V
0A @ ±12V
with 0A @ +3.3V
2A (Max.) @ +5V
200mA (Max.) @ +12V
200mA (Max.) @ -12V
Output Ripple:
With +5V @ 1A, +12V & -12V @ 200mA
+5V Output: 50mV, 110mVpp @ 30V input
+12V Output: 40mVpp @ 20V input
-12V Output: 50mVpp @ 24V input
With +5V @ 300mA, ±12V supplies OFF
+5V Output: 50mV, 280mVpp
Input Current:
With Supply Loading of 5V @ 1.25A, +3.3V @ 1.0A, +12V
& -12V @ 0mA
Vin @ +12V - Iin Max. 1.62A
Vin @ +24V - Iin Max. 0.80A
Fusing:
10A Slow Blow 5x20mm Fuse - FIELD Supply
3A Slow Blow 5x20mm Fuse - LOGIC Supply
Electrical Isolation:
500Vdc Primary to Secondary
Surge Suppression:
500Vdc MOV, (PSGND) to CHASSIS
32V Transient Suppressor from +VIN to -VIN (PSGND)
Meets ANSI/IEEE C37.90-1978
Terminations:
Pluggable, maximum wire size is 14 gauge
Shutdown:
+12V PSSM:
Max. ON Switchpoint = 11.11V
Min. OFF Switchpoint = 10.52V
4-4 / Specifications
CI-ControlWaveEXP
+24V System:
Max. ON Switchpoint = 22.05V
Min. OFF Switchpoint = 20.49V
Power Switch:
MOSFET Driven by Switch connected to Gate
4.2.2 Power Supply Sequencer Specs.
Signals Monitored:
Switched Input Supply Voltage (+VINSWS)
Isolated Output Voltages (+3.3V, +5V, +12V & -12V)
Sequencer Switchpoints
For Master Clear
& Power Fail
+12V Input Supply System
Input Power. Max. ON = +11.02V
Input Power Min. OFF = +10.78V
+24V Input Supply System
Input Power. Max. ON = +21.87V
Input Power Min. OFF = +21.09V
+5V Max. ON Switchpoint = +4.85V
+5V Min. OFF Switchpoint = +4.75V
±12V Max. ON Switchpoint = ±11.52V
±12V Min. OFF Switchpoint = ±11.38V
Sequencer Output Signals:
/MC, /PWR_FAIL - Timing on power down: /MC active
2msec after /PWR_FAIL asserted.
/MC, /PWR_FAIL - Timing on power up: /MC,
/PWR_FAIL active for 100msec after all monitored
voltage levels reach nominally good values.
Hot Swap Monitor:
Signals Monitored:
/BDINSLT1 - /BDINSLT8, /SWS1 - /SWS8, /MC
Output Signals:
/IOBTRI; timing on I/O Module insertion: Active 40µs
after /BDINSLTn asserted, and until 300ms after /SWSn
asserted
/IOBTRI; timing on I/O Module extraction: Active 40µs
after /SWSn negated, and until 20ms after /BDINSLTn
negated
/HBIR_NMI; timing on I/O Module insertion: Active when
/BDINSLTn asserted, and until 300ms after /SWSn
asserted
/HBIR_NMI; timing on I/O Module extraction: Active
when /SWSn negated, and until 20ms after /BDINSLTn
negated
CI-ControlWaveEXP
Specifications / 4-5
/MC1 - /MC8; timing on I/O Module insertion: Active
when /BDINSLTn asserted, and until 300ms after /SWSn
asserted
/MC1 - /MC8; timing on I/O Module extraction: Active
when /SWSn negated, and until 20ms after /BDINSLTn
negated
Watchdog Sequencer:
Input Signals: /MC & /WDOGB
Enable/ Disable: Via CPU Module Switch SW1-1
Watchdog MOSFET Switch populated: Voltage applied to
VI terminal TB1-2 (switched to VO terminal (TB1-1)
unless either /MC or /WDOGB is asserted; applied
voltage is referenced to -VIN (PSGND) at TB2-3
4.2.3 Power Supply Connectors (see Table 4-6 and referenced Tables)
Table 4-6 - Power Supply Board Connector Summary
Ref.
J1
TB1
TB2
# Pins
132-pin
3-pin
5-pin
Function
Backplane Connector
Watchdog Term. Block
Input Power Term. Block
Notes
see Figure 4-1
see Figure 4-6 & Table 4-7
see Figure 4-6 & Table 4-7
Figure 4-6 - Power Supply/Sequencer Module Connectors TB1 & TB2
Table 4-7 - Power Supply Terminal Blocks
TERM. #
TB1-1
TB1-2
TB1-3
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
NAME
VO
VI
VR
+VIN
+VINF
-VIN
-VINF
CHASSIS
4-6 / Specifications
FUNCTION
VO MOSFET Watchdog Switch Output
VI MOSFET Watchdog Switch Input
Redundancy Unit Control Input (Used with ControlWaveREDIO)
+10.6V to +30V (dc) Input
+9 to +30V (dc) Input (Field Device Power) or jumper to TB2-1
1st Supply Common
2nd Supply Common (Field Device Power) or jumper to TB2-3
Chassis Ground
CI-ControlWaveEXP
4.3 BACKPLANE PCB
Slots:
2, 4, or 8 I/O, 1 CPU & 1 Power Supply (Modules)
Data Bus:
Interrupts:
16-bit memory mapped access to I/O slave devices
1 each unique interrupts in I/O Slots 1 through 4
(IOBIRQn, where n = I/O Slot number 1, 2, 3 or 4)
Power:
+3.3V, +5V, +12V, -12V, PCOM
Connectors:
132-pin CPCI style connectors for CPU, PSSM and I/O
modules; three unique keying configurations prevent
module insertion into improper slot locations (see Figures
4-1 & 4-7 & Table 4-8)
Figure 4-7 - Backplane PCB Connector Assignment
Table 4-8 - Backplane PCB Connector Assignment
Number
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
CI-ControlWaveEXP
Function
Power Supply Module Intf.
CPU Module Interface
I/O Module #1 Interface
I/O Module #2 Interface
I/O Module #3 Interface
I/O Module #4 Interface
I/O Module #5 Interface
I/O Module #6 Interface
I/O Module #7 Interface
I/O Module #8 Interface
Reference
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
See Figures 4-1 & 4-7
Specifications / 4-7
4.4 COMMUNICATION PORTS
Connector/Port:
CPU Bd. J1 - 9-Pin D-Type - COM1 (RS-232)
CPU Bd. J2 - 9-Pin D-Type -COM2 (RS-232 or RS-485)
CPU Bd. J3 - 8-Pin RJ-45 - #1 -Ethernet 10/100BaseT
SCB Bd. J1 - 8-Pin RJ-45 - COM3 (RS-485)
SCB Bd. J2 - 9-Pin D-Type - COM4 (RS-485)
SCB Bd. J3 - 8-Pin RJ-45 -COM5 (RS-232)
SCB Bd. J4 - 8-Pin RJ-45 -COM6 (RS-232)
Baud Rate:
300 to 9600 (bps) for RS-232 or RS-485
10/100M (bps) for Ethernet
4.5 INPUT/OUTPUT MODULE SPECIFICATIONS
4.5.1 Analog Inputs
Number of Inputs:
16/8 Analog Inputs (Current Loop type input module)
16/8 Analog Inputs (Voltage type input module)
Input Type:
Isolated Voltage Input: 1-5 Vdc
Internally Sourced Current Loop: 4-20mA
Accuracy:
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -20ºC to +70ºC (-4ºF to +158ºF)
0.3% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
A/D Resolution:
14 Bits
Isolated Voltage/Current
Common Mode Range:
31Vdc referenced to Isolated Common (for 1-5 Vdc)
Powered Current Loop
Common Mode Range:
0V referenced to Isolated Common
Input Filtering:
300 msec to 99.9% of input value
Channel Settling Time:
680msec
Conversion Time:
25msec
On-board Reference:
1V, 5V
Surge Suppression:
31Vdc Transorb across input signals and (-) input to
CHASSIS. 500Vdc MOV isolated common to chassis.
Meets ANSI/IEEE C37.90-1978
Terminations:
Pluggable - Max. wire size is 14 gauge
Bus Access:
16 Bits Wide
Status Indication:
32/16 LEDs (two per point) plus 1 Status LED
4-8 / Specifications
CI-ControlWaveEXP
Power Consumption:
4-20 mA AI Module:
136 mA Max. @ 5Vdc (Full Population, 16 LEDs ON)
121.3 mA Max. @ 5Vdc (Half Population, 8 LEDs ON)
IIN (24V) = 52mA + 25mA/point (when point is @ 20mA)
IIN (12V) = 52mA + 50mA/point (when point is @ 20mA)
1-5 V AI Module: (@ 5Vdc)
128 mA Max. @ -5%/+105% (Full Pop., 16 LEDs ON)
115 mA Max. @ -5%/+105% (Half Pop., 8 LEDs ON)
4.5.2 Digital Inputs
Number of Inputs:
32/16
Input Voltage Range:
24V
Input Filtering:
30 milliseconds
Input Configuration:
Internally Sourced or Externally Sourced
(Factory Configured)
Input Current:
5mA nominal
‘0’ State Voltage:
‘1’ State Voltage:
below 10% of nominal input voltage
above 80% of nominal input voltage
Bus Access:
Sixteen Bits Wide (IOBD15 - IOBD0)
Electrical Isolation:
1500Vdc
Surge Suppression:
500Vdc MOV to CHASSIS
31Vdc Transorb across input and to FIELD COMMON
Meets ANSI/IEEE C37.90-1978
Terminations:
Pluggable, maximum wire size is 14 gauge
Status Indication:
32/16 LEDs (one per point) plus 1 Status LED
Power Consumption:
8 mA Max. @ 5Vdc (All Inputs OFF)
98 mA Max. @ 5Vdc (Full Pop., All DI ON, 32 LEDs ON)
43 mA Max. @ 5Vdc (Full Pop., All DI ON, 32 LEDs OFF)
53 mA Max. @ 5Vdc (Half Pop., All DI ON, 16 LEDs ON)
IIN (24V) = 30mA + 4.8mA/point (when point is configured
for Dry Contact - Internally Sourced operation)
IIN (12V) = 27mA + 9.5mA/point (when point is configured
for Dry Contact - Internally Sourced operation)
4.5.3 Analog Outputs
Number of Outputs:
8/4
Output Configurations:
Current Output - 4-20mA
Voltage Output - 1-5V (from daughter board)
CI-ControlWaveEXP
Specifications / 4-9
Resolution:
12 bits
Underrange/Overrange:
-5/+105 %
Accuracy:
Current Output:
0.1% of Span @ +25ºC (+77ºF)
0.2% of Span @ -20ºC to +70ºC (-4ºF to +158ºF)
0.3% of Span @ -40ºC to +70ºC (-40ºF to 158ºF)
Voltage Output Compliance (Iloadmax = 5mA):
(see Note1 & Note2)
0.1% of Span + X @ +25ºC (+77ºF)
0.2% of Span + X @ -20ºC to +70ºC (-4ºF to +158ºF)
0.3% of Span + X @ -40ºC to +70ºC (-40ºF to 158ºF)
where X = [(5 ohms x Iload)/4.4V x 100]
Note1:
Note2:
Does not include error due to inductors
5 ohm uncompensated series resistance with
Inductors
Surge Suppression:
500Vdc MOV to CHASSIS
31Vdc Transorb between signal and isolated ground
Meets ANSI/IEEE C37.90-1978
Settling time to .1%:
1 millisecond
Bus Access:
Sixteen Bits Wide
Terminations:
Pluggable, maximum wire size is 14 gauge
Status Indication:
2 LEDs (Fail & Good)
Power Consumption:
All AOs @ -5% = 60mA Max. @ 5Vdc (for Full & Half
Populated AO Module)
All AOs @ +105% = 67mA Max. @ 5Vdc (for Full & Half
Populated AO Module)
4-20 mA AO Module:
IIN (24V) = 27mA + 24mA/point (when point is @ 20mA)
IIN (12V) = 22.5mA + 47mA/point (when point is @ 20mA)
1-5V AO Module:
IIN (24V) = 27mA + 24mA/point + 6.19mA/point (when
point is @ 5mA)
IIN (12V) = 22.5mA + 47mA/point + 12.5mA/point (when
point is @ 5mA)
4.5.4 Digital Outputs
Number of Outputs:
32/16
Output Type:
Open Source (10- 31 Vdc - External Power)
4-10 / Specifications
CI-ControlWaveEXP
Surge Suppression:
500Vdc MOV to CHASSIS
31Vdc Transorb across output
Meets ANSI/IEEE C37.90-1978
Max. Operating Voltage:
31Vdc
Max. Operating Frequency:
20 Hz
Current Sink:
500mA Maximum
Electrical Isolation:
1500Vdc
Terminations:
Pluggable, maximum wire size is 14 gauge
Bus Access:
Sixteen Bits Wide
Status Indication:
32/16 LEDs (one per point) plus 1 Status LED
Power Consumption:
10 mA Max. @ 5Vdc (All DOs OFF)
90 mA Max. @ 5Vdc (Full Populated DO Module, All DOs
ON, 32 LEDs OFF)
143 mA Max. @ 5Vdc (Full Populated DO Module, All
DOs ON, 32 LEDs ON)
76 mA Max. @ 5Vdc (Half Populated DO Module, All DOs
ON, 16 LEDs ON)
4.5.5 Universal Digital Inputs
Number of Inputs:
12/6
Input Voltage Range:
24V
Input Frequency:
10KHz Max.
Input filtering:
Software Selectable:
1 msec (±0.5 msec) for Low Speed Counter
30 msec for Contact Closure
Hardware Set:
20 usec for High Speed Counter
Input configuration:
Hardware: Factory Configured
Set/Reset inputs, for debounce of contact closure
Software:
Interrupt on change of state (software configurable)
Monitor input status
Input current:
5mA +/- 10%
‘1’ State Voltage:
‘0’ State Voltage:
90% of input voltage range
10% of input voltage range
Bus Access:
Sixteen Bits Wide
CI-ControlWaveEXP
Specifications / 4-11
Max. Accumulator Value:
65536
Electrical isolation:
1500Vdc to system logic
500Vdc to CHASSIS
Surge Suppression:
31Vdc Transorb across input and to FIELD COMMOM
Meets ANSI/IEEE C37.90-1978
Terminations:
Pluggable, max wire size is 14 gauge
Status Indication:
12/6 LEDs (one per point) plus 1 Status LED
Power Consumption:
21 mA Max. @ 5Vdc (All Inputs OFF)
69 mA Max. @ 5Vdc (Full Populated UDI Module, All
UDIs ON, 12 LEDs OFF)
91 mA Max. @ 5Vdc (Full Populated UDI Module, All
UDIs ON, 12 LEDs ON)
56 mA Max. @ 5Vdc (Half Populated UDI Module, All
UDIs ON, 6 LEDs ON)
4.6 ENVIRONMENTAL SPECIFICATIONS
Temperature:
Operating:
Storage:
-40 to +158 °F (-40 to +70 °C)
-40 to +158 °F (-40 to +70 °C)
Relative Humidity:
0-95% Non-condensing
Vibration:
1g for 10 - 150 Hz
.5g for 150 - 2000 Hz
Shock:
30g (11 msec duration)
50g (11 msec duration)
RFI Susceptibility:
In conformity with the following standards:
ENV 50140 Radio-frequency electromagnetic field,
Amplitude modulated
ENV 50204 Radio-frequency electromagnetic field, Pulse
modulated
4.7 DIMENSIONS
2 I/O Chassis
4 I/O Chassis
8 I/O Chassis
ControlWaveEXP Installation
4-12 / Specifications
see Figure 4-8
see Figure 4-9
see Figure 4-10
see Figure 4-11
CI-ControlWaveEXP
Figure 4-8 - 2I/O ControlWave I/O Expansion Rack Chassis Assembly
CI-ControlWaveEXP
Specifications / 4-13
Figure 4-9 - 4I/O ControlWave I/O Expansion Rack Chassis Assembly
4-14 / Specifications
CI-ControlWaveEXP
Figure 4-10 - 8I/O ControlWave I/O Expansion Rack Chassis Assembly
CI-ControlWaveEXP
Specifications / 4-15
Figure 4-11 - ControlWave I/O Expansion Rack Installation Drawing
4-16 / Specifications
CI-ControlWaveEXP
ControlWave I/O Expansion Rack
Special Instructions for Class I, Division 2 Hazardous Locations
1. The Bristol, Inc. ControlWave I/O Expansion Rack is listed by Underwriters
Laboratories (UL) as nonincendive and is suitable for use in Class I, Division 2, Groups
A, B, C and D hazardous locations and non-hazardous locations only. Read this
document carefully before installing a nonincendive Bristol ControlWave I/O Expansion Rack. In the event of a conflict between the ControlWave Instruction Manual (CIControlWaveEXP) and this document, always follow the instructions in this document.
2. All 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.
3. WARNING: EXPLOSION HAZARD - Substitution of components may impair
suitability for use in Class I, Division 2 environments.
4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,
turn off power before servicing/replacing the unit and before installing or
removing I/O wiring.
5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the
power has been switched off or the area is known to be nonhazardous.
10/11/06
Appendix A, Document CI-ControlWaveEXP
Page 1 of 1
BLANK PAGE
ControlWave I/O Expansion Rack
Open Modbus Interface Information
Open Modbus Interface
The Open Modbus Interface allows access to areas of memory in the ControlWave I/O Expansion Rack serving as Modbus registers and coils.
In order to determine which coil / register numbers to reference in your Modbus commands,
please refer to the tables on the following pages.
IMPORTANT
By default, registers are transmitted upper byte or upper word (upper byte within a word) first.
If, because of the requirements of your protocol, or device, you need to change the order of
transmission, please follow the instructions at the end of this section.
System Data
Range: 1-100
Board Status
Hot Card Replacement
in progress
Battery Status
Board Type Register
(2 byte - transmitted
upper byte first)
Board 1
1
17
Board 2
2
17
Board 3
3
17
Board 4
4
17
Board 5
5
17
Board 6
6
17
Board 7
7
17
Board 8
8
17
18
1
18
2
18
3
18
4
18
5
18
6
18
7
18
8
Digital Data
Range: 101-420 (40 per board)
Example: To read DO output coil 5 on board 7, find DO output coils in the first column of the
table, below, then move along that row until you reach the board 7 column to determine the range
of DO output coil numbers for that board, in this case (341-372). The fifth coil in the range 341
to 372 would be 345, so your Modbus command should request coil 345.
06/07/02
Appendix B, Document CI-ControlWaveEXP
Page 1 of 6
ControlWave I/O Expansion Rack
Open Modbus Interface Information
Board Status
(all)
DO readback
status:
1-32
DI value
coils
1-32
DO output
coils
1-32
AI, AO outof-range
status
1-16 or
1-8
AI, AO
Convers-ion
Error
status
39
HSC Input
State
Status
1-12
AO Fail to
State
Status
9-32
Coils
9-32
(3 sets of 8)
Board 1
(101-140)
140
Board 2
(141-180)
180
Board 3
(181-220)
220
Board 4
(221-260)
260
Board 5
(261-300)
300
Board 6
(301-340)
340
Board 7
(341-380)
380
Board 8
(381-420)
420
101-132
141-172
181-212
221-252
261-292
301-332
341-372
381-412
101-132
141-172
181-212
221-252
261-292
301-332
341-372
381-412
101-132
141-172
181-212
221-252
261-292
301-332
341-372
381-412
101-116
or
101-108
141-156
or
141-148
181-196
or
181-188
221-236
or
221-228
261-276
or
261-268
301-316
or
301-308
341-356
or
341-348
381-396
or
381-388
139
179
219
259
299
339
379
419
101-112
141-152
181-192
221-232
261-272
301-312
341-352
381-392
109-132
149-172
189-212
229-252
269-292
309-332
349-372
389-412
101-112
141-152
181-192
221-232
261-272
301-312
341-352
381-392
113-136
153-174
193-214
233-254
273-294
313-334
353-374
393-414
*
See Note 1
HSC Reset
Coils 1-12
HSC Setup
Status
13-36
Coils
13-36
(2 sets of 12)
Input Registers (2 byte signed registers, transmitted upper byte first)
Range:101-260 (20 per board)
*
Note 1: First group must be set to 1 to have 2nd two groups written to board. Also, first group will always read as 0
- cleared as soon as written.
06/07/02
Appendix B, Document CI-ControlWaveEXP
Page 2 of 6
ControlWave I/O Expansion Rack
Open Modbus Interface Information
Example: To read AI register 8 on board 2, find AI value register in the first column of the
table, below, then move along that row until you reach the board 2 column to determine the
range of AI value register numbers, for that board, in this case (121-136). The eighth coil
in the range 121 to 136 would be 128, so your Modbus command should request register
128.
AI value
register 1-16
AO clamped
value register
1-8
HSC lower 16
bits
1-12
Board 1
(101-120)
101-116
Board 2
(121-140)
121-136
Board 3
(141-160)
141-156
Board 4
(161-180)
161-176
Board 5
(181-200)
181-196
Board 6
(201-220)
201-216
Board 7
(221-240)
221-236
Board 8
(241-260)
241-256
101-108
121-128
141-148
161-168
181-188
201-208
221-228
241-248
101-112
121-132
141-152
161-172
181-192
201-212
221-232
241-252
Output Registers (2 byte signed registers, transmitted upper byte first)
Range:501-660 (20 per board)
Example: To read AO register 7 on board 5, find AO value register in the first column of
the table, below, then move along that row until you reach the board 5 column to determine
the range of AO value register numbers, for that board, in this case (581-588). The seventh
coil in the range 581 to 588 would be 587, so your Modbus command should request
register 587.
AO value
register 1-8
Board 1
(501-520)
501-508
Board 2
(521-540)
521-528
Board 3
(541-560)
541-548
Board 4
(561-580)
561-568
Board 5
(581-600)
581-588
Board 6
(601-620)
601-608
Board 7
(621-640)
621-628
Board 8
(641-660)
641-648
Setup Registers (2 byte signed registers, transmitted upper byte first)
Range:1101-1420 (40 per board)
Example: To read the third AO last hold value register on board 4, find AO last hold value
registers in the first column of the table, below, then move along that row until you reach
the board 4 column to determine the range of AO last hold value register numbers, for that
board, in this case (1237-1244). The third register in the range 1237 to 1244 would be 1239,
so your Modbus command should request register 1239.
06/07/02
Appendix B, Document CI-ControlWaveEXP
Page 3 of 6
ControlWave I/O Expansion Rack
Open Modbus Interface Information
AI scales
register
1-32
AO scales
register
1-16
AO - Last
Hold Value
register
17-24
Board 1
(11011140)
11011132
Board 2
(11411180)
11411172
Board 3
(11811220)
11811212
Board 4
(12211260)
12211252
Board 5
(12611300)
12611292
Board 6
(13011340)
13011332
Board 7
(13411380)
13411372
Board 8
(13811420)
13811412
11011116
11411156
11811196
12211236
12611276
13011316
13411356
13811396
11171124
11571164
11971204
12371244
12771284
13171324
13571364
13971404
Long Input Registers (4 byte unsigned registers, transmitted upper word / upper
byte first)
Range:2101-2260 (20 per board)
Example: To read the third AO last hold value register on board 4, find AO last hold value
registers in the first column of the table, below, then move along that row until you reach
the board 4 column to determine the range of AO last hold value register numbers, for that
board, in this case (1237-1244). The third register in the range 1237 to 1244 would be 1239,
so your Modbus command should request register 1239.
HSC
Counts
Registers
1-12
HSC Timestamp
Register
13
Board 1
(21012120)
21012112
Board 2
(21212140)
21212132
Board 3
(21412160)
21412152
Board 4
(21612180)
21612172
Board 5
(21812200)
21812192
Board 6
(22012220)
22012212
Board 7
(22212240)
22212232
Board 8
(22412260)
22412252
2113
2133
2153
2173
2193
2213
2233
2253
Floating Point (FP) Inputs (4 byte FP, transmitted upper word / upper byte first)
Range:3101-3260 (20 per board)
Example: To read the eleventh FP input on board 7, go to the Board 7 column of the table,
below, to determine the range of FP inputs for that board, in this case 3221-3240. The
eleventh FP input in that range would be 3231, so your Modbus command should request
FP input 3231.
06/07/02
Appendix B, Document CI-ControlWaveEXP
Page 4 of 6
ControlWave I/O Expansion Rack
Open Modbus Interface Information
FP Inputs
Board 1
(31013120)
31013120
Board 2
(31213140)
31213140
Board 3
(31413160)
31413160
Board 4
(31613180)
31613180
Board 5
(31813200)
31813200
Board 6
(32013220)
32013220
Board 7
(32213240)
32213240
Board 8
(32413260)
32413260
Floating Point (FP) Outputs (4 byte FP, transmitted upper word / upper byte first)
Range:4101-4260 (20 per board)
Example: To read the first FP output on board 2, go to the Board 2 column of the table,
below, to determine the range of FP outputs for that board, in this case 4121-4140. The
first FP output in that range would be 4121, so your Modbus command should request FP
output 4121.
FP Outputs
Board 1
(41014120)
41014120
Board 2
(41214140)
41214140
Board 3
(41414160)
41414160
Board 4
(41614180)
41614180
Board 5
(41814200)
41814200
Board 6
(42014220)
42014220
Board 7
(42214240)
42214240
Board 8
(42414260)
42414260
Floating Point (FP) Setup (4 byte FP, transmitted upper word / upper byte first)
Range:5101-5420 (40 per board)
Example: To read the last FP setup register on board 3, go to the Board 3 column of the
table, below, to determine the range of FP setup registers for that board, in this case 41214140. The last FP setup register in that range would be 4121, so your Modbus command
should request FP setup register 4121.
FP Outputs
Board 1
(51015140)
51015140
Board 2
(51415180)
51415180
Board 3
(51815220)
51815220
Board 4
(52215260)
52215260
Board 5
(52615300)
52615300
Board 6
(53015340)
53015340
Board 7
(53415380)
53415380
Board 8
(53815420)
53815420
Reversing the Order of Byte Transmission of a Register
Swapping the order in which bytes are transmitted will cause 2 bytes to be transmitted
with the low order byte first, and 4 bytes to be transmitted upper word first, low order byte
first.
To perform this swap, choose the proper register, from the tables above, then add 10000 to
that register number when using it in a Modbus command.
06/07/02
Appendix B, Document CI-ControlWaveEXP
Page 5 of 6
ControlWave I/O Expansion Rack
Open Modbus Interface Information
Reversing the Order of Word Transmission of a Register
Swapping the order in which words are transmitted will cause 2 bytes to be transmitted as
in 0 series, and will cause 4 bytes to be transmitted lower word first, high order byte first.
To perform this swap, choose the proper register, from the tables above, then add 20000 to
that register number when using it in a Modbus command.
Reversing the Order of Byte / Word Transmission of a Register
Swapping the order in which bytes/words are transmitted will cause 2 bytes to be
transmitted with the low order byte first, and 4 bytes to be transmitted lower word first,
low byte first.
To perform this swap, choose the proper register, from the tables above, then add 30000 to
that register number when using it in a Modbus command.
06/07/02
Appendix B, Document CI-ControlWaveEXP
Page 6 of 6
ControlWave I/O Expansion Rack
Material Safety Data Sheets
Material Safety Data Sheets are provided herein to comply with OSHA’s Hazard
Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific
requirements.
Material Safety Data Sheets are provided in the order listed in Table Z-1 below.
TABLE Z-1 - MSDS for ControlWave Instruction Manual CI-ControlWaveEXP
Manufacturer
General Description
Eagle Pitcher
Lithium Thionyl Chloride Battery
(1/2 AA, 3.6V, 950 mAh - On-board)
SAFT America
Lithium Thionyl Chloride Battery
(1/2 AA, 3.6V, 950 mAh - On-board)
03/01/02
Bristol Babcock Part Number
or Media Notes
395600-01-4
Eagle Pitcher P/N LTC-9C
395600-01-4
SAFT P/N LS-14250
MSDS Not provided herein.
Appendix Z - CI-ControlWaveEXP
MSDS
BLANK PAGE
Supplement Guide - S1400CW
Issue: 04/05
TM
SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING
A Guide for the Protection of
Site Equipment & Personnel
In the Installation of
ControlWave
Process Automation Controllers
Bristol Babcock
NOTICE
Copyright Notice
The information in this document is subject to change without notice. Every effort has been
made to supply complete and accurate information. However, Bristol Babcock assumes no
responsibility for any errors that may appear in this document.
Request for Additional Instructions
Additional copies of instruction manuals may be ordered from the address below per
attention of the Sales Order Processing Department. List the instruction book numbers or
give complete model number, serial or software version number. Furnish a return address
that includes the name of the person who will receive the material. Billing for extra copies
will be according to current pricing schedules.
ControlWave® is a re registered trademark of Bristol Babcock. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their
respective companies, or trademark holders.
Copyright (c) 2005 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of
this manual may be reproduced in any form without the express written permission of
Bristol Babcock.
Supplement Guide S1400CW
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 1 - INTRODUCTION
1.1
1.2
GENERAL INTRODUCTION ....................................................................................... 1-1
MAJOR TOPICS ............................................................................................................. 1-1
Section 2 - PROTECTION
2.1
2.1.1
2.2
2.2.1
2.2.2
2.3
PROTECTING INSTRUMENT SYSTEMS................................................................... 2-1
Quality Is Conformance To Requirements.................................................................... 2-1
PROTECTING EQUIPMENT & PERSONNEL ........................................................... 2-1
Considerations For The Protection of Personnel .......................................................... 2-2
Considerations For The Protection of Equipment ........................................................ 2-2
OTHER SITE SAFETY CONSIDERATIONS............................................................... 2-3
Section 3 - GROUNDING & ISOLATION
3.1
3.2
3.3
3.3.1
3.3.1.1
3.3.1.2
3.3.1.3
3.3.2
3.3.3
3.4
3.4.1
3.4.2
POWER & GROUND SYSTEMS................................................................................... 3-1
IMPORTANCE OF GOOD GROUNDS......................................................................... 3-1
EARTH GROUND CONNECTIONS............................................................................. 3-1
Establishing a Good Earth Ground. .............................................................................. 3-1
Soil Conditions ................................................................................................................ 3-2
Soil Types ........................................................................................................................ 3-2
Dry, Sandy or Rocky Soil................................................................................................ 3-4
Ground Wire Considerations. ........................................................................................ 3-5
Other Grounding Considerations. ................................................................................. 3-6
ISOLATING EQUIPMENT FROM THE PIPELINE ................................................... 3-7
Meter Runs Without Cathodic Protection..................................................................... 3-7
Meter Runs With Cathodic Protection .......................................................................... 3-7
Section 4 - LIGHTNING ARRESTERS & SURGE PROTECTORS
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.2
STROKES & STRIKES .................................................................................................. 4-1
Chance of Being Struck by Lightning. .......................................................................... 4-1
Antenna Caution ............................................................................................................ 4-3
Ground Propagation ....................................................................................................... 4-5
Tying it all Together....................................................................................................... 4-5
Impulse Protection Summary ........................................................................................ 4-5
USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS................................ 4-6
Section 5 - WIRING TECHNIQUES
5.1
5.2
5.2.1
OVERVIEW ....................................................................................................................5-1
INSTRUMENT WIRING. .............................................................................................. 5-1
Common Returns ............................................................................................................5-1
Supplement S1400CW
Page 0-1
Table Of Contents
Supplement Guide S1400CW
SITE CONSIDERATIONS FOR EQUIPMENT
INSTALLATION, GROUNDING & WIRING
TABLE OF CONTENTS
SECTION
TITLE
PAGE #
Section 5 - WIRING TECHNIQUES (Continued)
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
Use of Twisted Shielded Pair Wiring (with Overall Insulation).................................. 5-2
Grounding of Cable Shields. .......................................................................................... 5-3
Use of Known Good Earth Grounds .............................................................................. 5-3
Earth Ground Wires ....................................................................................................... 5-3
Working Neatly & Professionally .................................................................................. 5-3
High Power Conductors and Signal Wiring .................................................................. 5-4
Use of Proper Wire Size ................................................................................................. 5-4
Lightning Arresters & Surge Protectors ....................................................................... 5-4
Secure Wiring Connections ............................................................................................ 5-5
REFERENCE DOCUMENTS
1.
2.
3.
4.
5.
6.
7.
IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std
142-1982
IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise inputs to Controllers
from External Sources - IEE Std 518-1982
Lightning Strike Protect; Roy B. Carpenter, Jr. & Mark N. Drabkin, Ph.D.; Lightning Eliminators &
Consultant, Inc., 6687 Arapahoe Road, Boulder Colorado
Lightning Protection Manual for Rural Electric Systems, NRECA Research Project 82-5, Washington DC,
1983
Grounding for the Control of EMI; Hugh W. Denny; Don White Consultants, Inc., 1983, 1st Edition
Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam
Street, Shreveport, Louisiana 71151
TeleFlow Modem Grounding Kit 621495-01-8 Installation Instructions - PIP-3530MGKI; Bristol Babcock,
Watertown, CT 06795
Supplement S1400CW
Page 0-2
Table Of Contents
Section 1 - Overview
1.1 INTRODUCTION
This document provides information pertaining to the installation of ControlWave
systems; more specifically, information covering reasons, theory and techniques for
protecting your personnel and equipment from electrical damage. Your instrument system
affects the quality of service provided by your company and many aspects of its operational
safety. Loss of instruments means lost production and profits as well as increased expenses.
Information contained in this document is for educational purposes. Bristol Babcock makes
no warranties or guarantees on the effectiveness or the safety of techniques described herein.
Where the safety of installations and personnel is concerned, refer to the National Electrical
Code Rules and rules of local regulatory agencies.
1.2 MAJOR TOPICS
Topics are covered in seven sections designed to pinpoint major areas of concern for the
protection of site equipment and personnel. The following overview is provided for each of
the major sections.
·
Section 2 - Protection
This section provides the reasons for protecting instrument systems. An overview of the
definition of quality and what we are trying to accomplish in the protection of site
installations and how to satisfy the defined requirements is presented. Additionally,
this section provides considerations for the protection of personnel and equipment.
·
Section 3 - Grounding & Isolation
Information pertaining to what constitutes a good earth ground, how to test and
establish such grounds, as well as when and how to connect equipment to earth grounds
is provided
·
Section 4 - Lightning Arresters & Surge Protectors
Some interesting information dealing with Lightning strikes and strokes is presented in
technical and statistical form along with a discussion of how to determine the likelihood
of a lightning strike. Protecting equipment and personnel during the installation of
radios and antenna is discussed in a review of the dangers to equipment and personnel
when working with antennas. Reasons for the use of lightning arresters and surge
protectors are presented along with overviews of how each device protects site
equipment.
·
Section 5 - Wiring Techniques
Installation of Power and “Measurement & Control” wiring is discussed. Information on
obscure problems, circulating ground and power loops, bad relays, etc. is presented.
Good wire preparation and connection techniques along with problems to avoid are
discussed. This sections list the ten rules of instrument wiring.
Section 1 - Overview
Page 1-1
S1400CW
Section 2 - Protection
2.1 PROTECTING INSTRUMENT SYSTEMS
Electrical instrumentation is susceptible to damage from a variety of natural and man
made phenomena. In addition to wind, rain and fire, the most common types of system and
equipment damaging phenomena are lightning, power faults, communication surges &
noise and other electrical interference’s caused by devices such as radios, welders,
switching gear, automobiles, etc. Additionally there are problems induced by geophysical
electrical potential & noise plus things that are often beyond our wildest imagination.
2.1.1 Quality Is Conformance To Requirements
A quality instrumentation system is one that works reliably, safely and as purported by the
equipment manufacturer (and in some cases by the system integrator) as a result of good
equipment design and well defined and followed installation practices. If we except the
general definition of quality to be, “quality is conformance to requirements,” we must also
except the premise that a condition of “quality” can’t exist where requirements for such an
end have not been evolved. In other words, you can’t have quality unless you have
requirements that have been followed. By understanding the requirements for a safe, sound
and reliable instrumentation system, and by following good installation practices (as
associated with the personnel and equipment in question), the operational integrity of the
equipment and system will be enhanced.
Understanding what is required to properly install BBI equipment in various environments, safely, and in accordance with good grounding, isolating and equipment
protection practices goes a long way toward maintaining a system which is healthy to the
owner and customer alike. Properly installed equipment is easier to maintain and operate,
and is more efficient and as such more profitable to our customers. Following good installation practices will minimize injury, equipment failure and the customer frustrations
that accompany failing and poorly operating equipment (of even the finest design). Additionally, personnel involved in the installation of a piece of equipment add to or subtract
from the reliability of a system by a degree which is commensurate with their technical
prowess, i.e., their understanding of the equipment, site conditions and the requirements
for a quality installation.
2.2 PROTECTING EQUIPMENT & PERSONNEL
ControlWave installations must be performed in accordance with National Electrical Code
Rules, electrical rules set by local regulatory agencies, and depending on the customer
environment (gas, water, etc), other national, state and local agencies such as the American
Water Works Association (AWWA). Additionally, installation at various customer sites may
be performed in conjunction with a “safety manager” or utility personnel with HAZMAT
(hazardous material) training on materials present (or potentially present) as required by
OSHA, the customer, etc.
Section 2 - Protection
Page 2-1
S1400CW
2.2.1 Considerations For The Protection of Personnel
Always evaluate the site environment as if your life depended on it. Make sure that you
understand the physical nature of the location where you will be working. Table 2-1
provides a general guideline for evaluating an installation site.
Table 2-1 - Installation Site Safety Evaluation Guide
#
1
2
3
4
5
6
7
8
9
Guide
Indoor or outdoor – Dress Appropriately
If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees,
spiders, snakes, etc.)
If indoor or outdoor – determine if there are any pieces of dangerous equipment or any
processes which might be a risk to your safety
If in a tunnel, bunker, etc. watch out for a build up of toxic or flammable gases. Make
sure the air is good. Watch out for local varmint (bees, spiders, snakes, etc.)
Hazardous or Non-Hazardous Environment – Wear appropriate safety equipment and
perform all necessary safety measures.
Before installing any equipment or power or ground wiring, make sure that there are no
lethal (life threatening) voltages between the site where the instrument will be installed
and other equipment, pipes, cabinets, etc. or to earth itself.
Never assume that adjacent or peripheral equipment has been properly installed and
grounded. Determine if this equipment and the ControlWave unit in question can be
touched simultaneously without hazard to personnel and/or equipment?
Before embarking to remote locations where there are few or no human inhabitants ask a
few simple questions like, should I bring water, food, hygienic materials, first aid kit, etc?
Be Prepared!
Observe the work habits of those around you – for your own safety!
Some of the items that a service person should consider before ever going on site can be
ascertained by simply asking questions of the appropriate individual. Obviously other
safety considerations can only be established at the installation site.
2.2.2 Considerations For The Protection of Equipment
Always evaluate the site installation/service environment and equipment. Understand the
various physical interfaces you will be dealing with such as equipment mounting and
supporting, ControlWave analog and digital circuits, power circuits, communication
circuits and various electrical grounds. Table 2-2 provides a general guideline for
evaluating the equipment protection requirements of an installation site.
Table 2-2 - Equipment Protection Site Safety Evaluation Guide
#
1
2
3
4
5
Guide
Environment - Class I, Division 2 - Nonincendive
Environment - Class I, Division 1 - Intrinsically Safe
Other - Safe or unrated area
Earth Ground - Established by mechanical/electrical or
(both) or not at all.
Is the area prone to lightning strikes?
Are there surge suppressors installed or to be installed?
Are there overhead or underground power or communication cables in the immediate area?
S1400CW
Page 2-2
Reference Section
See Appendix A of CI Manual
See Appendix B of CI Manual
See Section 3
See Section 4
See Section 4
See Section 2.3
Section 2 - Protection
Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued)
#
6
7
8
9
2.3
Guide
Is there an antenna in the immediate area?
How close is other equipment? Can someone safely touch this
equipment and a ControlWave simultaneously?
Determine equipment ground requirements. How will the
ControlWave and its related wiring be grounded? Consider Earth
Ground, Circuit Ground, Conduit Ground, Site Grounds!
Are there any obviously faulty or questionable power or ground
circuits?
Reference Section
See Section 4.1.2
See Section 2.3
See Section 3
See Section 2.3
OTHER SITE SAFETY CONSIDERATIONS
Overhead or underground power or communication cables must be identified prior to
installing a new unit. Accidentally cutting, shorting or simply just contacting power,
ground, communication or process control I/O wiring can have potentially devastating
effects on site equipment, the process system and or personnel.
Don’t assume that it is safe to touch adjacent equipment, machinery, pipes, cabinets or even
the earth itself. Adjacent equipment may not have been properly wired or grounded, may be
defective or may have one or more loose system grounds. Measure between the case of a
questionable piece of equipment and its earth ground for voltage. If a voltage is present,
something is wrong.
AC powered equipment with a conductive case should have the case grounded. If you don’t
see a chassis ground wire, don’t assume that it is safe to touch this equipment. If you notice
that equipment has been grounded to pipes, conduit, structural steel, etc., you should be
leery. Note: AWWA’s policy on grounding of electric circuits on water pipes states,
“The American Water Works Association (AWWA) opposes the grounding of
electrical systems to pipe systems conveying water to the customer’s premises….”
Be sure that the voltage between any two points in the instrument system is less than the
stand-off voltage. Exceeding the stand-off voltage will cause damage to the instrument and
will cause the instrument to fail.
Section 2 - Protection
Page 2-3
S1400CW
Section 3 - Grounding & Isolation
3.1 POWER & GROUND SYSTEMS
ControlWaves utilize DC power systems. AC power supplies are not provided with ControlWave units. ControlWave, ControlWave MICRO, ControlWave EFM/GFC/EFC,
ControlWaveRED, ControlWaveREDIO and ControlWave I/O Expansion Racks are
provided with a Ground Lug that accommodates up to a #4 AWG size wire for establishing
a connection to Earth Ground. In the case of the ControlWaveLP, a Chassis Ground
termination terminal (TB2, Pin-3), that accepts up to a #14 AWG size wire, is provided on
the unit’s Power Supply/Sequencer Board.
3.2 IMPORTANCE OF GOOD GROUNDS
ControlWave units (see above) are utilized in instrument and control systems that must
operate continually and within their stated accuracy over long periods of time with
minimum attention. Failures resulting from an improperly grounded system can become
costly in terms of lost time and disrupted processes. A properly grounded system will help
prevent electrical shock hazards resulting from contact with live metal surfaces, provide
additional protection of equipment from lightning strikes and power surges, minimize the
effects of electrical noise and power transients, and reduce signal errors caused by ground
wiring loops. Conversely, an improperly grounded system may exhibit a host of problems
that appear to have no relation-ship to grounding. It is essential that the reader (service
technician) have a good under-standing of this subject to prevent needless troubleshooting
procedures.
WARNING
This device must be installed in accordance with the National
Electrical Code (NEC) ANSI/NEPA-70. Installation in hazardous
locations must also comply with Article 500 of the code. For
information on the usage of ControlWave units in Class I, Division 2,
Groups C & D Hazardous and Nonhazardous locations, see appendix A
of the applicable Customer Instruction (CI) manual. For information
on the usage of ControlWave units in Class I, Division 1, Groups C &
D Hazardous locations, see appendix B of the applicable Customer
Instruction (CI) manual.
3.3 EARTH GROUND CONNECTIONS
To properly ground a ControlWave unit, the units Chassis Ground (post or terminal) must
ultimately be connected to a known good Earth Ground. Observe recommendations
provided in topics Establishing a Good Earth Ground and Ground Wire Considerations.
3.3.1 Establishing a Good Earth Ground
A common misconception of a ground is that it consists of nothing more than a metal pipe
driven into the soil. While such a ground may function for some applications, it will often
Section 3 - Grounding & Isolation
Page 3-1
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not be suitable for a complex system of sophisticated electronic equipment. Conditions such
as soil type, composition and moisture will all have a bearing on ground reliability.
A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into
conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG
solid copper wire should be used for the ground wire. The end of the wire should be clean,
free of any coating and fastened to the rod with a clamp. This ground connection should be
covered or coated to protect it from the weather and the environment.
Figure 3-1 - Basic Ground Rod Installation
3.3.1.1 Soil Conditions
Before installing a ground rod, the soil type and moisture content should be analyzed.
Ideally, the soil should be moist and moderately packed throughout to the depth of the
ground rod. However, some soils will exhibit less than ideal conditions and will require
extra attention.
Soil types can be placed into two general categories with respect to establishing and
maintaining a good earth ground, i.e., ‘Good Soil’ and ‘Poor Soil.’
To be a good conductor, soil must contain some moisture and free ions (from salts in the
soil). In very rainy areas, the salts may be washed out of the soil. In very sandy or arid area
the soil may be to dry and/or salt free to a good conductor. If salt is lacking add rock salt
(NaCl); if the soil is dry add calcium chloride (CaCl2).
3.3.1.2 Soil Types:
Good
Damp Loam
Salty Soil or Sand
Farm Land
Poor
Back Fill
Dry Soil
Sand Washed by a Lot of Rain
Dry Sand (Desert)
Rocky Soil
Ground Beds must always be tested for conductivity prior to being placed into service. A
brief description of ground bed testing in ‘Good Soil’ and ‘Poor Soil’ is provided herein.
Details on this test are described in the National Electrical Code Handbook. Once a reliable
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Section 3 - Grounding & Isolation
ground has been established, it should be tested on a regular basis to preserve system
integrity.
Figure 3-2 - Basic Ground Bed Soil Test Setup
Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods
Figure 3-2 shows the test setup for ‘Good Soil’ conditions. If the Megger* reads less than 5
ohms, the ground is good. The lower the resistance, the better the earth ground. If the
Section 3 - Grounding & Isolation
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Megger reads more than 10 ohms, the ground is considered ‘poor.’ If a poor ground is
indicated, one or more additional ground rods connected 10 feet from the main ground rod
should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1” x
¼-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the
Biddle Instrument Co. (now owned by AVO International). Other devices that
may be used to test ground resistance are “Viboground”; Associated Research,
Inc., “Groundmeter”; Industrial Instruments, Inc., and “Ground-ohmer”; Herman
H. Sticht Co., Inc.
If the Megger still reads more than 10 ohms, mix a generous amount of cooking salt, ice
cream salt or rock salt with water and then pour about 2.5 to 5 gallons of this solution
around each rod (including the test rods). Wait 15 minutes and re-test the soil. If the test
fails, the soil is poor and a ‘Poor Soil Ground Bed’ will have to be constructed.
Figure 3-4 shows a typical Poor Soil Ground Bed Electrode. A Poor Soil Ground Bed will
typically consists of four or more 10-foot long electrodes stacked vertically and separated by
earth. Figure 3-5 shows the construction of a Poor Soil Ground Bed. For some poor soil
sites, the ground bed will be constructed of many layers of ‘Capacitive Couplings’ as
illustrated. In extremely poor soil sites one or more 3’ by 3’ copper plates (12 gauge or 1/16”
thick) will have to be buried in place of the electrodes.
Figure 3-4 - Ground Electrode Construction for Poor Soil Conditions
3.3.1.3 Dry, Sandy or Rocky Soil
Very dry soil will not provide enough free ions for good conductance and a single ground rod
will not be effective. A buried counterpoise or copper screen is recommended for these
situations. It will be necessary to keep the soil moist through regular applications of water.
Sandy soil, either wet or dry, may have had its soluble salts leached out by rain water,
thereby reducing conductivity of the ground. High currents from lightning strikes could also
melt sand and cause glass to form around the ground rod, rendering it ineffective. A buried
counterpoise or copper screen is preferred for these installations along with regular
applications of salt water.
Rocky soil can pose many grounding problems. A counterpoise or copper plate will probably
be required. Constructing a trench at the grounding site and mixing the fill with a
hygroscopic salt such as calcium chloride may help for a time. Soaking the trench with
water on a regular basis will maintain conductivity.
Units with phone modems require the use of a lightning arrester. The lightning arrester
must be situated at the point where the communication line enters the building.
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Section 3 - Grounding & Isolation
Figure 3-5 - Poor Soil Ground Bed Construction Diagram
3.3.2 Ground Wire Considerations
ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveRED, ControlWave REDIO & ControlWave I/O Expansion Rack
ControlWave Chassis are provided with a Ground Lug that accommodates up to a #4 AWG
wire size. A ground wire must be run between the Chassis Ground Lug and a known good
Earth Ground. The cases of the various ControlWave Modules are connected to Chassis
Ground when they have been installed and secured via their two Captured Panel
Fasteners. As an extra added precaution, it is recommended that a #14 AWG wire be run
from PSSM Power Connector TB2-5 (Chassis Ground) (PSSM Connector TB1-3 for
ControlWave MICRO unit) (SCM Connector TB1-3 for ControlWave EFM) to the same
known good Earth Ground.
ControlWaveLP Process Automation Controller
A #14 AWG ground wire must be run from the ControlWaveLP’s PSSB Terminal TB2-3
(Chassis Ground) to a known good Earth Ground. In lieu of a direct connection to Earth
Section 3 - Grounding & Isolation
Page 3-5
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Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a
conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground
Bus. The panel, lug or bus in turn must be connected to a known good Earth Ground via a
#4 AWG wire.
General Considerations
The following considerations are provided for the installation of ControlWave system
grounds:
i Size of ground wire (running to Earth Ground should be #4 AWG. It is recommended
that stranded copper wire is used for this application and that the length should be as
short as possible.
i This ground wire should be clamped or brazed to the Ground Bed Conductor (that is
typically a stranded copper AWG 0000 cable installed vertically or horizontally).
i The wire ends should be tinned with solder prior to installation.
i The ground wire should be run such that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above ground.
The units Earth Ground Cable should be clamped to an exposed Ground Rod or to an AWG
0000 stranded copper Ground Cable that in turn should be connected to either an Earth
Ground Rod or Earth Ground Bed. Both ends of the units Earth Ground Cable must be free
of any coating such as paint or insulated covering as well as any oxidation. The connecting
point of the Ground Rod or AWG 0000 Ground Cable must also be free of any coating and
free of oxidation. Once the ground connection has been established (at either the Ground
Rod or Ground Cable) it should be covered or coated to protect it from the environment.
3.3.3 Other Grounding Considerations
Figure 3-6 - Grounding of Phone Line
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Section 3 - Grounding & Isolation
For applications employing equipment that communicates over telephone lines, a lightning
arrester Must Be provided. For indoor equipment the lightning arrester must be installed
at the point where the communication line enters the building as shown in Figure 3-6. The
ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.
Gas lines also require special grounding considerations. If a gas meter run includes a
thermocouple or RTD sensor installed in a thermowell, the well (not the sensor) must be
connected to a gas discharge-type lightning arrester as shown in Figure 3-7. A copper braid,
brazed to the thermal well, is dressed into a smooth curve and connected to the arrester as
shown. The curve is necessary to minimize arcing caused by lightning strikes or high static
surges. The path from the lightning arrester to the ground bed should also be smooth and
free from sharp bends for the same reason.
Figure 3-7 - Grounding of Thermometer Well in Gas Line
3.4 ISOLATING EQUIPMENT FROM THE PIPELINE
3.4.1 Meter Runs Without Cathodic Protection
ControlWave EFM/GFC/XFC’s may be mounted directly on the pipeline or remotely on a
vertical stand-alone two-inch pipe (see Figure 3-8). The Earth Ground Cable is to run
between the ControlWave EFM/GFC/XFC’s Ground Lug and Earth Ground (Rod or Bed)
even though the ControlWave EFM/GFC/XFC’s Multivariable Transducer may be
Section 3 - Grounding & Isolation
Page 3-7
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grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely
mounted, connect their chassis grounds to the pipeline or earth ground.
Figure 3-8 - ControlWave EFM (Installation is similar to GFC/XFC)
Remote Installation without Cathodic Protection
3.4.2 Meter Runs With Cathodic Protection
Dielectric isolators are available from Bristol Babcock and are always recommended as an
added measure in isolating the ControlWave EFM/GFC/XFC from the pipeline even
though the ControlWave EFM/GFC/XFC does provide 500V galvanic isolation from the
pipeline and should not be affected by cathodic protection or other EMF on the pipeline.
ControlWave EFM/GFC/XFC may be mounted directly on the pipeline (see Figure 3-9) or
remotely on a vertical stand-alone two-inch stand-pipe (see Figure 3-10). It is recommended
that isolation fitting always be used in remotely mounted meter systems. An isolation
fittings or gasket should be installed between the following connections:
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Section 3 - Grounding & Isolation
•
•
•
all conductive tubing that runs between the pipeline and mounting valve manifold
and/or the units multivariable pressure transducer
all conductive connections or tubing runs between the ControlWave EFM/GFC and
turbine meter, pulse transducer, or any input other device that is mounted on the
pipeline
any Temperature Transducer, Pressure Transmitter, etc. and their mount/interface to
the pipeline
Figure 3-9 - ControlWave EFM (Installation is similar to EFM/GFC/XFC)
Direct Mount Installation (with Cathodic Protection)
The ground conductor connects between the ControlWave EFM/GFC/XFC’s Ground Lug
and a known good earth ground. Connect the cases of Temperature Transducers, Pressure
Transmitters, etc., to the known good earth ground. If the mounting 2-inch pipe is in
continuity with the pipeline it will have to be electrically isolated from the ControlWave
EFM/GFC/XFC. Use a strong heat-shrink material such as RAYCHEM WCSM 68/22 EU
3140. This black tubing will easily slip over the 2-inch pipe and then after uniform heating
(e.g., with a rose-bud torch) it electrically insulates and increases the strength of the pipe
stand.
Section 3 - Grounding & Isolation
Page 3-9
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See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems
and Manifolds.
Figure 3-10 – ControlWave EFM (Installation is similar to GFC/XFC)
Remote Installation (with Cathodic Protection)
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Section 3 - Grounding & Isolation
Section 4 - Lightning Arresters & Surge Protectors
4.1 STROKES & STRIKES
Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay
to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak current will
average 18 KA for the first impulse and about half of that for the second and third
impulses. Three strokes (impulses) is the average per lightning strike. The number of
visible flashes that may be seen is not necessarily the number of electrical strokes.
A lightning strike acts like a constant current source. Once ionization occurs, the air
becomes a luminous conductive plasma reaching up to 60,000° F. The resistance of a struck
object is of little consequence except for the power dissipation on the object (I2 x R). Fifty
percent of all lightning strikes will have a first impulse of at least 18 KA, ten percent will
exceed the 60 KA level, and only about one percent will exceed 120 KA.
4.1.1 Chance of Being Struck by Lightning
The map of Figure 4-1 shows the average annual number of thunderstorm days
(Isokeraunic level) for the various regions within the continental U.S.A. This map is not
representative of the severity of the storm or the number of lightning strikes since it does
not take into account more than one lightning strike in a thunderstorm day. The
Isokeraunic or Isoceraunic number provides a meteorological indication of the frequency of
thunderstorm activity; the higher the Isokeraunic number the greater the lightning strike
activity for a given area. These levels vary across the world from a low of 1 to a high of 300.
Within the United States the Isokeraunic level varies from a low of 1 to a high of 100.
Figure 4-1 - Average Thunderstorm Days of the Year (for Continental USA)
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Page 4-1
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Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the
United States there is an average of 30 thunderstorm days per year. Any given storm may
produce from one to several strokes. Data on the subject indicates that for an average area
within the United States there can be eight to eleven strokes to each square mile per year.
The risk of stroke activity is increased for various areas such central Florida where up to 38
strokes to each square mile per year are likely to occur.
To determine the probability of a given structure (tower, building, etc.) (within your
location) being struck, perform the following computation:
1. Using the map of Figure 4-1 (or a comparable meteorological map for your local), find
the Isokeraunic level (I) for your area. Then using Chart 1, find “A” for your area.
2. Refer to Figure 4-1 to find the latitude. Then using Chart 2, find “B” for your latitude
(Lat.°).
3. Multiply “A” x “B” to get “C”.
4. To calculate the number of lightning strikes per year that are likely to strike a given
object (tower, mast, etc.), use the equation that follows (where “C” was calculated in
step 3 and “H” is equal to the height of the object.
Strikes Per Year = (“C” x H2) ÷ (.57 x 106 )
Chart 1
I
5
10
20
30
40
50
60
70
80
90
100
“A”
8
26
85
169
275
402
548
712
893
1069
1306
Chart 2
LAT.°
25
30
35
40
45
“B”
.170
.200
.236
.280
.325
Note for these charts:
I = Thunderstorm Days Per Year (Isokeraunic Number)
A = Stroke activity for associated Isokeraunic Area
B = Height/Stroke coefficient for associated latitude
For Example: On Long Island, New York (Isokeraunic number 20), Chart 1 gives “A” to
equal 85. The latitude is approximately 40°. Referring to Chart 2, “B” is found to be equal to
.28. “C” for this example is equal to 23.80. Using the equation for strikes per year, it is
determined that a 100-foot tower has .4 chances per year of being struck by lightning.
Assuming that no other structures are nearby, the tower will more than likely be struck by
lightning at least once in three years.
Note: The Isokeraunic activity numbers connoted as I, “A” and “B” in Charts 1 and 2 above
are provided for the continental United States. Isokeraunic data for various countries
is available from various federal or state Civil Engineering or Meterorelogical
organizations. This information is typically available from manufacturers of lightning
strike protection equipment (such as Lightning Arresters).
Since ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP and ControlWaveEXP units are dc operated systems that are isolated from AC
grids, they are typically immune to lightning strikes to power lines or power equipment
(except for inductive flashover due to close installation proximity). However, once a radio or
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Section 4 - Lightning & Surge
modem has been interfaced to a ControlWave, ControlWave MICRO, ControlWave
EFM/GFC/XFC, ControlWaveLP, or ControlWaveEXP the possibility of damage due to a
lightning strike on power or telephone lines or to a radio antenna or the antenna’s tower
must be considered. It is recommended that the additional lightning protection
considerations listed below be followed for units installed in areas with a high possibility or
history of stroke activity.
Units interfaced to a modem: In series with the phone line (as far away as possible
from the equipment) - for indoor installations the lightning arrester should typically be
located at the point where the line enters the structure.
Units interfaced to a radio: Mount antenna discharge unit (lightning arrester) as
close as possible to where the lead in wire enters the structure. See Antenna Caution
below.
4.1.2 Antenna Caution
Each year hundreds of people are killed, mutilated, or receive severe permanent injuries
when attempting to install or remove an antenna or antenna lead. In many cases, the
victim was aware of the danger of electrocution but failed to take adequate steps to avoid
the hazard. For your safety, and for proper installation maintenance, please read and
follow the safety precautions that follow - they may save your life.
i When installing or servicing an antenna:
DO NOT use a metal ladder. DO NOT step onto or touch an antenna mast while power
is applied to an associated radio unless the radio is a low power (low current) type.
DO NOT work on a wet or windy day, especially during a thunderstorm or when there is
lightning or thunder in your area. Dress properly; shoes with rubber soles and heels,
rubber gloves, long sleeve shirt or jacket.
i The safe distance from power lines should be at least twice the height of the antenna
and mast combination.
i Antenna Grounding per National Electrical Code Instructions:
A. Use AWG 10 or 8 aluminum or AWG 1 copper-clad steel or bronze wire, or larger as
ground wires for both the mast and lead-in. Securely clamp the wire to the bottom of
the mast.
B. Secure lead-in wire from antenna to antenna discharge (lightning arrester) unit and
the mast ground wire to the structure (building, shed, etc.) with stand-off insulators
spaced from 4 feet (1.22 meters) to 6 feet (1.83 meters) apart.
C. Mount antenna discharge unit as close as possible to where the lead-in wire enters
the structure.
D. The hole drilled through the wall for the lead-in wire should be just large enough to
accommodate the cable. Before drilling this hole, make sure there are no wires or
pipes, etc. in the wall.
E. Push the cable through the hole and form a rain drip loop close to where the wire
enters the exterior of the structure.
F. Caulk around the lead-in wire (where it enters the structure) to keep out drafts.
G. Install lightning arresters (antenna discharge units). The grounding conductor
should be run in as straight a line as practicable from the antenna mast and/or the
antenna discharge units to grounding electrode(s).
H. Only connect the antenna cable to the radio after the mast has been properly
grounded and the lead-in cable has been properly connected to lightning arresters
which in turn have each been properly connected to a known good earth ground.
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Page 4-3
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Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram
For all systems it is best to have all communication equipment input/output grounds tied
together. In the case of ControlWave units, this is accomplished via the unit’s Chassis
Ground (Typically at a ground lug, ground bus or ground plate). However additional
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Section 4 - Lightning & Surge
communication equipment lightning arresters and surge suppressors should be tied to the
same system ground. System ground consists of the tower leg grounds utility ground and
bulkhead-equipment ground-stakes that are tied together via bare copper wire.
4.1.3 Ground Propagation
As in any medium, a dynamic pulse, like R.F., will take time to propagate. This propagation
time will cause a differential step voltage to exist in time between any two ground rods that
are of different radial distances from the strike. With a ground rod tied to a struck tower,
the impulse will propagate its step voltage outwardly from this rod in ever-expanding
circles, like a pebble thrown into a pond. If the equipment house has a separate ground rod
and the power company and/or telephone company grounds are also separate, the dynamic
step voltage will cause currents to flow to equalize these separate ground voltages. Then if
the coax cable (associated with a radio) is the only path linking the equipment chassis with
the tower ground, the surge can destroy circuitry.
4.1.4 Tying it all Together
To prevent this disaster from occurring, a grounding system must be formed which
interconnects all grounds together. This will equalize and distribute the surge charge to all
grounds, and at the same time, it will make for a lower surge impedance ground system.
This interconnection can be done as a grid, where each ground has a separate line to each
other ground, or by using a “rat Race” ring which forms a closed loop (not necessarily a
perfect circle) which surrounds the equipment house completely.
By making this interconnection, it will be necessary to use proper I/O protectors for the
equipment. Of course, these should be a requirement regardless of whether this grounding
technique is used. I/O protectors are used for power lines (even those these don’t feed into a
ControlWave unit), telephone lines, and also to minimize EMI pick-up from a strike.
Ideally it is best to place all I/O protectors on a common panel that has a low inductance
path to the ground system. The ControlWave units would then have a single ground point
from its Chassis Ground Terminal/Ground Lug to this panel. In lieu of this, the
ControlWave unit in question should be tied to a ground rod that in turn is connected to
the Earth/System Ground created for the site.
Your protected equipment connected to a common single ground system, will now be just
like a bird sitting on a high tension wire. When lightning strikes, even with a 50 ohm surge
impedance ground system, the entire system consisting of equipment, ground system,
building, etc., will all rise together to the one million volt peak level (for example) and will
all decay back down together. So long as there is no voltage differential (taken care of by
protectors and ground interconnections, there will be no current flow through the
equipment and therefore no resulting equipment damage.
4.1.5 Impulse Protection Summary
i
i
i
i
Use more than one ground rod.
Place multi-ground stakes more than their length apart.
Tie Power, Telco, Tower, Bulkhead and equipment ground together.
Make all ground interconnect runs that are above ground with minimum radius
bends of eight inches and run them away from other conductors and use large solid
wire or a solid strap.
Section 4 - Lightning & Surge
Page 4-5
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i Watch out for dissimilar metals connections and coat accordingly.
i Use bare wire radials together where possible with ground stakes to reduce ground
system impedance.
i Use I/O protectors (Phone line, Radio) with a low inductance path to the ground
system.
i Ground the Coaxial Cable Shield (or use an impulse suppressor) at the bottom of the
tower just above the tower leg ground connection.
4.2 USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS
Units equipped with radios or modems use lightning arresters and surge protectors to
protect equipment from lightning strikes, power surges and from damaging currents that
have been induced onto communication lines.
The first line of defense is the Lightning Arrester. These devices typically use gas discharge
bulbs that can shunt high currents and voltages to earth ground when they fire. The high
current, high voltage gas discharge bulb has a relatively slow response time and only fire
when their gas has been ionized by high voltage.
The second line of defense is the Surge Protector, which is made of solid state devices, fires
very quickly and conducts low voltages and currents to ground. Surge protectors are built
into BBI 9600 bps modems.
Lightning Arresters are applied to circuits as follows:
i Equipment or circuits that can be exposed to lightning strikes, falling power lines,
high ground currents caused by power system faults, by operational problems on
electric railways, etc.
i Equipment installed in dry, windy areas, such as the Great Plains and the
Southwest Desert in the United States. Wind and wind blown dust can cause high
voltages (static) to appear on overhead wires, fences, and metal buildings.
Note: Lightning Arresters may explode if lightning strike is very close. Mount
lightning arresters where flying parts won't cause injury to equipment or
personnel.
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Section 4 - Lightning & Surge
Section 5 - Wiring Techniques
5.1 OVERVIEW
This section provides information pertaining to good wiring practices. Installation of Power
and “Measurement & Control” wiring is discussed. Information on obscure problems,
circulating ground and power loops, bad relays, etc. is presented. Good wire preparation
and connection techniques along with problems to avoid are discussed.
5.2 INSTRUMENT WIRING
Each of the rules listed below is briefly discussed; the emphasis herein is placed on the
avoidance of problems as well as equipment safety.
Rule 1 - Never utilize common returns.
Rule 2 - Use twisted shielded pairs (with overall insulation) on all Signal/Control circuits.
Rule 3 - Ground cable shields at one end only.
Rule 4 - Use known good earth grounds (Rod, Bed, System) and test them periodically,
Rule 5 - Earth connections must utilize smoothly dressed large wire.
Rule 6 - Perform all work neatly and professionally.
Rule 7 - Route high power conductors away from signal wiring according to NEC Rules.
Rule 8 - Use appropriately sized wires as required by the load.
Rule 9 - Use lightning arresters and surge protectors.
Rule 10 - Make sure all wiring connections are secure.
5.2.1 Common Returns
Use of common returns on I/O wiring is one of the most common causes of obscure and
difficult to troubleshoot control signal problems. Since all wires and connections have
distributed resistance, inductance and capacitance, the chances of a achieving a balanced
system when common returns are present is very remote. Balanced systems (or circuits) are
only achieved when all currents and voltages developed in association with each of the
common returns are equal. In a balanced system (or circuit) there are no noise or
measurment errors introduced due to by “sneak circuits.”
The illustration of Figure 5-1 shows the difference between testing an I/O circuit that is
discrete and has no sneak circuits and one that utilizes common returns. Common sense
tells us that it is tough to mix up connections to a twisted shielded pair (with overall vinyl
covering) to every end device. Do yourself a favor; to make start up easier, DON’T USE
COMMON RETURNS!
Section 5 - Wiring Techniques
Page 5-1
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Figure 5-1 - Field Wired Circuits With & Without A Common Return
5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation)
For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly
recommended. This type of cable provides discrete insulation for each of the wires and an
additional overall insulated covering that provides greater E.M.I. immunity and protection
to the shield as well.
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Section 5 - Wiring Techniques
5.2.3 Grounding of Cable Shields
DO NOT connect the cable shield to more than one ground point; it should only be grounded
at one end. Cable shields that are grounded at more than one point or at both ends may
have a tendency to induce circulating currents or sneak circuits that raise havoc with I/O
signals. This will occur when the ground systems associated with multipoint connections to
a cable shield have a high resistance or impedance between them and a ground induced
voltage is developed (for what ever reason, i.e., man made error or nature produced
phenomena).
5.2.4 Use of Known Good Earth Grounds
ControlWave units should only have one connection to earth ground. For ControlWave
and ControlWave MICRO Process Automation Controllers, ControlWave MICRO,
ControlWave EFM Electronic Flow Meters, ControlWave GFC/XFC Gas Flow Computers
and ControlWave I/O Expansion Racks, this connection is provided via the Ground Lug
that is situated on the bottom of the unit. ControlWaveLPs require the installation of a
ground lug, ground bus or ground plate/panel. Since ControlWave units are DC-based
systems, grounding does not take into account AC power grounding considerations. Earth
grounding the unit is absolutely necessary when the unit is equipped with a radio or
modem. Additionally these units should be connected to earth ground when they are
installed in areas that have frequent lightning strikes or are located near or used in
conjunction with equipment that is likely to be struck by lightning or if struck by lightning
may cause equipment or associated system failure. Earth Grounds must be tested and must
be known to be good before connecting the ControlWave. Earth grounds must be
periodically tested and maintained (see Section 4).
5.2.5 Earth Ground Wires
Earth connections must utilize smoothly dressed large wire. Use AWG 3 or 4 stranded
copper wire with as short a length as possible. Exercise care when trimming the insulation
from the wire ends. Twists the strands tightly, trim off any frizzes and tin the ends with
solder. The earth ground wire should be clamped or brazed to the Ground Bed Conductor
(that is typically a standard AWG 0000 copper cable. The earth ground wire should be run
such that any routing bend in the cable is a minimum 8-inch radius above ground or a
minimum 12-inch radius below ground.
5.2.6 Working Neatly & Professionally
Take pride in your work and observe all site and maintenance safety precautions. After
properly trimming the stranded pair wire ends, twist them in the same direction as their
manufacturer did and then tin them with solder. Install the tinned wire end into it’s
connector and then secure the associated connector’s clamping screw. Remember to check
these connections for tightness from time to time. If solid copper wire is used (in
conjunction with the DC Power System or for Earth Ground) make sure that the conductor
is not nicked when trimming off the insulation. Nicked conductors are potential disasters
waiting to happen. Neatly trim shields and whenever possible, coat them to protect them
and prevent shorts and water entry.
Section 5 - Wiring Techniques
Page 5-3
S1400CW
Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to
being costly.
5.2.7 High Power Conductors and Signal Wiring
When routing wires, keep high power conductors away from signal conductors. Space wires
appropriately to vent high voltage inductance. Refer to the National Electrical Code
Handbook for regulatory and technical requirements.
5.2.8 Use of Proper Wire Size
ControlWaves utilize compression-type terminals that accommodate up to #14 AWG gauge
wire. A connection is made by inserting the bared end (1/4 inch max.) into the clamp
beneath the screw and securing the screw.
Allow some slack in the wires when making terminal connections. Slack makes the
connections more manageable and minimizes mechanical strain on the PCB connectors.
Provide external strain relief (utilizing Tie Wrap, etc.) to prevent the loose of slack at the
ControlWave.
Be careful to use wire that is appropriately sized for the load. Refer to equipment
manufacturer’s Specs. and the National Electrical Code Handbook for information on wire
size and wire resistance. After installing the field wiring, test each load to determine if the
correct voltage or current is present at the load. If you know the resistance of the field wires
(Circular Mills x Length) you should be able to calculate the load voltage. Conversely, if you
know the minimum load voltage and current, you should be able to derive the maximum
voltage loss that is allowable due to line resistance and then the correct wire size.
Referring to Figure 5-2, a relay that is picked by 100 mA, with a loop supply voltage of 24V
and a total line resistance of 20 ohms, the load voltage (voltage across the relay) should be:
VL = VS - (VC + VC) where VC + VC = (RC + RC) I
22 = 24 - 2
where 2V
= (20 Ω) x 0.1 A
Figure 5-2 - Calculating Load Voltage due to Line Resistance
5.2.9 Lightning Arresters & Surge Protectors
Use lightning arresters in association with any radio or modem equipped unit. BBI 9600
bps modems are equipped with surge protection circuitry. Lightning arresters or Antenna
S1400CW
Page 5-4
Section 5 - Wiring Techniques
Discharge Units should be placed on the base of the antenna and at the point where the
antenna lead (typically coax) enters the site equipment building. When a modem is used, a
lightning arrester should be placed at the point where the phone line enters the site
equipment building. If you use a modem (manufactured by other than BBI) it is
recommended that you also install a surge suppressors or lightning arrester on the phone
line as close to the modem as possible. Any unit interfaced to a radio or modem must be
connected to a known good earth ground.
5.2.10 Secure Wiring Connections
Make sure that all wiring connections are secure. In time wires that were once round will
become flattened due to the pressure applied by screw compression type terminals and site
vibrations. After a while these compression screws have a tendency to become loose. Part of
a good maintenance routine should be to check and tighten all screws associated with
wiring terminal connections. Avoid nicking the wire(s) when stripping insulation.
Remember, nicked conductors will lead to future problems. Also remember to provide some
cabling slack and strain relief.
If installing stranded or braided wiring that has not been tinned, be sure to tightly twist
the end (in the same direction as manufactured) and then trim off any frizzed wires.
Section 5 - Wiring Techniques
Page 5-5
S1400CW
BLANK PAGE
READER RESPONSE FORM
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DOCUMENT NUMBER: S1400CW
TITLE: ControlWaveTM SITE CONSIDERATIONS For EQUIPMENT INSTALLATION,
GROUNDING & WIRING
ISSUE DATE: APR., 2005
COMMENT/COMPLAINT:
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Mail this page to:
Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Attn: Technical Publications Group, Dept. 315
Bristol Babcock
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2200
Fax: +1 (860) 945-2213
Website: www.bristolbabcock.com
U.S.A. Locations:
Northern Region
Bristol Babcock Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2381
Fax: +1 (860) 945-2525
[email protected]
Helicoid Instruments
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2218
Fax: +1 (860) 945-2213
[email protected]
Gulf Coast Region
Bristol Babcock Inc.
2000 Governor's Circle
Suite F
Houston, TX 77092-8731
Phone: +1 (713) 685-6200
Fax: +1 (713) 681-7331
Western Region
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1609 South Grove Avenue
Suites 106 & 107
Ontario, CA 91761
Phone: +1 (909) 923-8488
Fax: +1 (909) 923-8988
Southeast Region
Bristol Babcock Inc.
317 S. North Lake Blvd.
Suite 1016
Altamonte Springs, FL 32701
Phone: +1 (407) 740-7084
Fax: +1 (407) 629-2106
[email protected]
[email protected]
[email protected]
Central Region
Bristol Babcock Inc.
300 North Coit Road
Suite 1300
Richardson, TX 75080
Phone: +1 (972) 238-8935
Fax: +1 (972) 238-8198
[email protected]
Rocky Mountain Region
Bristol Babcock Inc.
906 San Juan Blvd., Suite A
Farmington, NM 87401
Phone: +1 (505) 320-5046
Fax: +1 (505) 327-3273
Communications
Technology Group
Bristol Babcock Inc.
317 S. North Lake Blvd.
Suite 1016
Altamonte Springs, FL 32701
Phone: +1 (407) 629-9464
Fax: +1 (407) 629-2106
[email protected]
[email protected]
International Affiliates:
Canada
Bristol Babcock, Canada
234 Attwell Drive
Toronto, Ont. M9W 5B3
Canada
PH: 416-675-3820
FAX: 416-674-5129
[email protected]
Mexico
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
PH: (52-55)-52-81-81-12
FAX: (52-55)-52-81-81-09
[email protected]
United Kingdom
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
[email protected]
Asia Pacific
Bristol Babcock, Inc.
PO Box 1987
Bunbury, Western Australia
6231
PH: +61 (0) 8 9791 3654
FAX: +61 (0) 8 9791 3173
[email protected]
Victoria, Australia
PH: +61 (0) 3 9384 2171
FAX: +61 (0) 3 8660 2501
Calgary Office
Bristol Babcock, Canada
3812 Edmonton Trail N.E.
Calgary, Alberta T2E 5T6
Canada
PH: 403-265-4808
FAX: 403-233-2914
[email protected]
RC Rev: 05-Feb-04
Villahermosa Office
BBI, S.A. de C.V.
Av. Plomo No.2
Bodega No. 1 - Ciudad
Industrial
Villahermosa, Tabasco 86010
Mexico
PH: 52-993-353-3142
FAX: 52-993-353-3145
[email protected]
Middle East
Bristol Babcock Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
PH: +44 (0) 1905 856950
FAX: +44 (0) 1905 856969
[email protected]
ESDS Manual
S14006
4/15/92
CARE AND HANDLING
OF
PC BOARDS
AND
ESD-SENSITIVE
COMPONENTS
BRISTOL BABCOCK
BLANK PAGE
ESDS Manual
S14006
4/15/92
TABLE OF CONTENTS
PAGE
TOOLS AND MATERIALS REQUIRED
1
ESD-SENSITIVE COMPONENT HANDLING PROCEDURE
2
1.
Introduction
2
2.
General Rules
3
3.
Protecting ESD-Sensitive Components
5
4.
Static-Safe Field Procedure
6
5.
Cleaning and Lubricating
8
6.
Completion
10
TOOLS AND MATERIALS REQUIRED
1.
Tools
Anti-Static Field kit. It is recommended that an anti-static field kit be kept on any
site where solid-state printed circuit boards and other ESD-sensitive components are handled. These kits are designed to remove any existing static charge
and to prevent the build-up of a static charge that could damage a PC board or
ESD-sensitive components. The typical anti-static field kit consists of the
following components:
1.
A work surface (10mm conductive plastic sheet with a female snap
fastener in one corner for ground cord attachment).
2.
A 15-foot long ground cord for grounding the work surface.
3.
Wrist strap (available in two sizes, large and small, for proper fit and
comfort) with a female snap fastener for ground cord attachment.
4.
A coiled ground cord with a practical extension length of 10 feet for
attachment to the wrist strap.
Toothbrush (any standard one will do)
1
ESDS Manual
#S14006
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2.
Materials
●
Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent)
●
Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent)
●
Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent)
ESD-SENSITIVE COMPONENT HANDLING PROCEDURE
1.
Introduction
Microelectronic devices such as PC boards, chips and other components are electrostatic-sensitive. Electrostatic discharge (ESD) of as few as 110 volts can damage or
disrupt the functioning of such devices. Imagine the damage possible from the 35,000
volts (or more) that you can generate on a dry winter day by simply walking across a
carpet. In fact, you can generate as much as 6,000 volts just working at a bench.
There are two kinds of damage that can be caused by the static charge. The more
severe kind results in complete failure of the PC board or component. This kind of
damage is relatively simple, although often expensive, to remedy by replacing the
affected item(s). The second kind of damage results in a degradation or weakening
which does not result in an outright failure of the component. This kind of damage is
difficult to detect and often results in faulty performance, intermittent failures, and
service calls.
Minimize the risk of ESD-sensitive component damage by preventing static build-up and
by promptly removing any existing charge. Grounding is effective, if the carrier of the
static charge is conductive such as a human body. To protect components from
nonconductive carriers of static charges such as plastic boxes, place the component
in static-shielding bags.
This manual contains general rules to be followed while handling ESD-sensitive
components. Use of the anti-static field kit to properly ground the human body as well
as the work surface is also discussed.
2
ESDS Manual
S14006
4/15/92
Table 1
Typical Electrostatic Voltages
Electrostatic Voltages
Means of Static
Generation
Walking across carpet
Walking over vinyl floor
Worker at bench
Vinyl envelopes for work instructions
Poly bag picked up from bench
Work chair padded with poly foam
2.
10-20 Percent
Relative Humidity
35,000
12,000
6,000
7,000
20,000
18,000
65-90 Percent
Relative Humidity
1,500
250
100
600
1,200
1,500
General Rules
(1)
ESD-sensitive components shall only be removed from their static-shielding
bags by a person who is properly grounded.
(2)
When taken out of their static-shielding bags, ESD-sensitive components shall
never be placed over, or on, a surface which has not been properly grounded.
(3)
ESD-sensitive components shall be handled in such a way that the body does
not come in contact with the conductor paths and board components. Handle
ESD-sensitive components in such a way that they will not suffer damage from
physical abuse or from electric shock.
(4)
EPROMS/PROMS shall be kept in anti-static tubes until they are ready to use
and shall be removed only by a person who is properly grounded.
(5)
When inserting and removing EPROMS/PROMS from PC boards, use a chip
removal tool similar to the one shown in the figure following. Remember, all work
should be performed on a properly grounded surface by a properly-grounded
person.
3
ESDS Manual
#S14006
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Typical Chip Removal Tool
4
(6)
It is important to note when inserting EPROMS/PROMS, that the index notch on
the PROM must be matched with the index notch on the socket. Before pushing
the chip into the socket, make sure all the pins are aligned with the respective
socket-holes. Take special care not to crush any of the pins as this could destroy
the chip.
(7)
Power the system down before removing or inserting comb connectors/plugs or
removing and reinstalling PC boards or ESD-sensitive components from card
files or mounting hardware. Follow the power-down procedure applicable to the
system being serviced.
(8)
Handle all defective boards or components with the same care as new components. This helps eliminate damage caused by mishandling. Do not strip used PC
boards for parts. Ship defective boards promptly to Bristol Babcock in a staticshielding bag placed inside static-shielding foam and a box to avoid damage
during shipment.
ESDS Manual
S14006
4/15/92
CAUTION
Don't place ESD-sensitive components and paperwork in the same bag.
The static caused by sliding the paper into the bag could develop a charge and
damage the component(s).
(9)
3.
Include a note, which describes the malfunction, in a separate bag along with each
component being shipped. The repair facility will service the component and
promptly return it to the field.
Protecting ESD-Sensitive Components
(1)
As stated previously, it is recommended that an electrically-conductive anti-static
field kit be kept on any site where ESD-sensitive components are handled. A
recommended ESD-protective workplace arrangement is shown on page 7. The
anti-static safety kit serves to protect the equipment as well as the worker. As a safety
feature, a resistor (usually of the one-megohm, 1/2-watt, current-limiting type) has
been installed in the molded caps of the wrist strap cord and the ground cord. This
resistor limits current should a worker accidently come in contact with a power
source. Do not remove the molded caps from grounded cords. If a cord is damaged,
replace it immediately.
(2)
Be sure to position the work surface so that it does not touch grounded conductive
objects. The protective resistor is there to limit the current which can flow through
the strap. When the work surface touches a grounded conductive object, a short is
created which draws the current flow and defeats the purpose of the current-limiting
resistor.
(3)
Check resistivity of wrist strap periodically using a commercially-available system
tester similar to the one shown in the figure below:
5
ESDS Manual
#S14006
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Note: If a system checker is not available, use an ohmmeter connected to the cable
ends to measure its resistance. The ohmmeter reading should be 1 megohm +/15%. Be sure that the calibration date of the ohmmeter has not expired. If the
ohmmeter reading exceeds 1 megohm by +/- 15%, replace the ground cord with a
new one.
4.
Static-safe Field Procedure
6
(1)
On reaching the work location, unfold and lay out the work surface on a convenient
surface (table or floor). Omit this step if the table or floor has a built-in ESD-safe work
surface.
(2)
Attach the ground cord to the work surface via the snap fasteners and attach the
other end of the ground cord to a reliable ground using an alligator clip.
(3)
Note which boards or components are to be inserted or replaced.
(4)
Power-down the system following the recommended power-down procedure.
(5)
Slip on a known-good wristband, which should fit snugly; an extremely loose fit is not
desirable.
(6)
Snap the ground cord to the wristband. Attach the other end of the ground cord to
a reliable ground using the alligator clip.
ESDS Manual
S14006
4/15/92
(7)
The components can now be handled following the general rules as described
in the instruction manual for the component.
(8)
Place the component in a static-shielding bag before the ground cord is
disconnected. This assures protection from electrostatic charge in case the work
surface is located beyond the reach of the extended ground cord.
C
D
✰R
E
A
F
R
G
B
R
R
EARTH GROUND
FLOOR
OF
BUILDING
LEGEND
A
- Chair with ground (optional)
B
- ESD protective floor mat (optional)
C
- Wrist strap
D
- ESD protective trays, etc.
E
- Ionizer
F
- Other electrical equipment
G
- Workbench with ESD protective table top
✰ NOTE: ALL RESISTORS 1M Ω +/-10% 1/2W
7
ESDS Manual
#S14006
4/15/92
5.
(9)
If a component is to undergo on-site testing, it may be safely placed on the
grounded work surface for that purpose.
(10)
After all component work is accomplished, remove the wrist straps and ground
wire and place in the pouch of the work surface for future use.
Cleaning And Lubricating
The following procedure should be performed periodically for all PC boards and
when a PC board is being replaced.
CAUTION
Many PC board connectors are covered with a very fine gold-plate.
Do not use any abrasive cleaning substance or object such as a pencil eraser to
clean connectors.
Use only the approved cleaner/lubricants specified in the procedure following.
WARNING
Aerosol cans and products are extremely combustible.
Contact with a live circuit, or extreme heat can cause an
explosion.
Turn OFF all power and find an isolated, and ventilated
area to use any aerosol products specified in this procedure.
(1)
8
Turn the main line power OFF. Blow or vacuum out the component. This should
remove potential sources of dust or dirt contamination during the remainder of
this procedure.
ESDS Manual
S14006
4/15/92
(2)
Clean PC board connectors as follows:
a.
Review the static-safe field procedure detailed earlier.
b.
Following the ESD-sensitive component handling procedures, remove
the connectors from the boards and remove the PC boards from their
holders.
c.
Use cleaner to remove excessive dust build-up from comb connectors
and other connectors. This cleaner is especially useful for removing dust.
d.
Liberally spray all PC board contacts with Inhibitor. The inhibitor:
●
Provides a long lasting lubricant and leaves a protective film to
guard against corrosion
●
Improves performance and reliability
●
Extends the life of the contacts
●
Is nonconductive, and is safe for use on most plastics
e.
Clean the comb contacts using a lint-free wiping cloth.
f.
Lightly mist all comb contacts again with Inhibitor.
NOTE: Do not use so much Inhibitor that it drips.
g.
(3)
Repeat the above procedure for the other PC boards from the device.
Cleaning PC edge connectors
a.
Use cleaner to remove excessive dust build-up from connectors. This
cleaner is especially useful for removing dust.
b.
Liberally spray the outboard connector with Inhibitor.
c.
Lightly brush the outboard connector with a soft, non-metallic, bristle
brush such as a toothbrush.
9
ESDS Manual
#S14006
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6.
10
d.
Spray the connector liberally to flush out any contaminants.
e.
Remove any excess spray by shaking the connector or wiping with either
a toothbrush, or a lint-free wiping cloth.
Completion
(1)
Replace any parts that were removed.
(2)
Make sure that the component cover is secure.
(3)
Return the system to normal operation.
(4)
Check that the component operates normally.
BLANK PAGE
ControlWave I/O Expansion Rack
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525
www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882
www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09
www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969
www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955
www.EmersonProcess.com/Bristol
Customer Instruction Manual
CI-ControlWaveEXP
Oct., 2006
The information in this document is subject to change without notice. Every effort has
been made to supply complete and accurate information. However, Bristol, Inc.
assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your
local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software
delivered herewith. The Customer shall inspect and test such software and other
materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and
fitness for a particular purpose, concerning the software and other materials delivered
herewith.
TeleFlow™ is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service
mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in
this document are for information only, and belong to their respective companies, or
trademark holders.
Copyright (c) 2006, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part
of this manual may be reproduced in any form without the express written permission of
Bristol Inc.
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