Remote Automation Solutions Diagnostics For Bristol Controllers Guide
Below you will find brief information for D4041A Controller Diagnostic, ControlWaveLP Process Automation Controller, ControlWave Process Automation Controller, ControlWaveMICRO/EFM Electronic Flow Meter, ControlWaveRED Redundant Controller, ControlWave Express/ExpressPAC. This manual provides instructions for using the WINDIAG software to diagnose issues with Bristol controllers, covering tests for CPU & Peripherals, PROM/RAM, Serial & Ethernet Communications, Analog and Discrete I/O, and other modules.
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Instruction Manual
D4041A
Mar., 2007
Windows Diagnostics
(for Bristol Controllers)
WINDIAG www.EmersonProcess.com/Bristol
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) 685-
6200.
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 Control Wave 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 Control Wave 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.
WINDIAG
WINDOWS DIAGNOSTICS for Bristol CONTROLLERS
TABLE OF CONTENTS
SECTION TITLE PAGE #
1.1
1.2 DIAGNOSTIC
1.3
1.4 REQUIRED
1.5 CONNECTING THE PC TO THE CONTROLLER...................................................... 1-5
INSTALLING
1.7 COMMUNICATIONS WITH THE RTU ........................................ 1-6
1.7.1 Establishing Communications Using LocalView:......................................................... 1-6
1.7.2 Establishing Communications Using NetView:.......................................................... 1-10
1.8 DOWNLOADING THE DIAGNOSTIC LOAD FILE TO THE CONTROLLER
3000
1.8.1 Downloading ................................................................................................................. 1-13
1.8.2 Communications
1.9 EXECUTING
1.9.1 Selecting Categories ............................................................................................. 1-15
1.9.2 Entering Number of Passes ......................................................................................... 1-17
Messages ........................................................................................................... 1-18
1.10 TRAVELING THROUGH THE DIAGNOSTIC SYSTEM.......................................... 1-18
1.11 CONCLUDING
Chapter 2 - 33XX, CW_10, CW_30, CW_35 & 3305 CPU & Peripherals
2.1 33XX CPU & PERIPHERALS INTRODUCTION ........................................................ 2-1
INTERNAL
2.2.1 Programmable Interrupt Controller (PIC).................................................................... 2-2
2.2.2 Direct Memory Access (DMA) ........................................................................................ 2-3
2.2.3 Internal
2.3
Timers............................................................................................................... 2-3
EXTERNAL PERIPHERALS......................................................................................... 2-3
2.3.1 LEDs................................................................................................................................ 2-3
2.3.2 Real Time Clock (RTC)................................................................................................... 2-4
Battery.............................................................................................................. 2-6
2.3.4 Floating
Chapter 3 - 33XX, CW_10, CW_30, CW_35 & 3305 Memory
3.1 33XX & CW_XX MEMORY INTRODUCTION............................................................. 3-1
PROM
3.3 DIAGNOSTIC
3.3.1 RAM Testing of 33XX Units........................................................................................... 3-3
3.3.2 RAM testing of CW_10, CW-30 and CW_35 Units ....................................................... 3-7
Chapter 4 - 33XX & 3305 Communications
4.1
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WINDOWS DIAGNOSTICS for Bristol CONTROLLERS
TABLE OF CONTENTS
SECTION TITLE
Chapter 4 - 33XX & 3305 Communications (Continued)
PAGE #
4.2 COMMUNICATION PORT DIAGNOSTICS ................................................. 4-1
4.2.1 Hardware Setup For Serial Comm. Ports 4-1
4.2.1.1 Serial Comm. Port External Loop-back Plug................................................................ 4-3
4.2.2 Serial Communication Port Selection ........................................................................... 4-3
4.2.3 Serial Communication Port Baud Rate Selection......................................................... 4-4
4.2.4 Serial
4.3
Communication
DIAGNOSTICS ............................................................................. 4-5
4.3.1 Ethernet Port Hardware Setup ..................................................................................... 4-5
4.3.1.1 Attachment Unit Interface (AUI) Port Hardware Setup ............................................. 4-5
4.3.1.2 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup............................................... 4-6
Port
4.3.2.1 Chip Internal Loop-back Test RUN Button .................................................................. 4-7
4.3.2.2 Loop-back Out AUI Port & Loop-back Out Twisted Pair Test RUN Button .............. 4-7
4.3.2.3 Return Hardware Address Test RUN Button............................................................... 4-7
4.3.3 Ethernet Port Diagnostic Error/Failure Messages....................................................... 4-8
4.4 COMM. PORT IDENTIFICATION & SETUP.............................................................. 4-8
Chapter 4A – CW_10, CW_30 & CW_35 Communications
4A.1 CW_10/30/35
4A.2 SERIAL
4A.2.1
INTRODUCTION ........................................... 4A-1
COMMUNICATION PORT DIAGNOSTICS .............................................. 4A-1
Hardware
4A.3 ETHERNET DIAGNOSTICS .......................................................................... 4A-5
4A.3.1 Ethernet Port Hardware Setup .................................................................................. 4A-6
4A.3.1.1 10/100Base-T (RJ-45 - Twisted Pair) Port Hardware Setup..................................... 4A-6
4A.3.2 Port
4A.3.2.1 Loop-back Out Twisted Pair Test RUN Button ......................................................... 4A-6
4A.3.2.2 Return Hardware Address Test RUN Button............................................................ 4A-7
4A.3.3 Ethernet Port Diagnostic Error/Failure Messages.................................................... 4A-7
4A.4 COMM.
Chapter 5 - RTU 3305 I/O Tests
5.1
5.1.2 Menu
I/O
5.1.1 Hardware
Access.................................................................................................................... 5-1
5.1.3 Entry/Display
5.2 OUTPUT
5.2.1 Analog Output Circuitry Calibration ............................................................................ 5-2
5.3
Verification.................................................................................................. 5-6
5.2.3 Interference
(AI)
5.3.1 Analog Input Circuitry Offset Calibration .................................................................... 5-8
5.3.2 Analog Input Termination Test ..................................................................................... 5-9
5.4
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WINDOWS DIAGNOSTICS for Bristol CONTROLLERS
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SECTION TITLE PAGE #
Chapter 5 - RTU 3305 I/O Tests (Continued)
5.5 OUTPUT
5.5.1 Automatic Discrete Output Test.................................................................................. 5-12
5.5.2 Manual Discrete Output Test ...................................................................................... 5-13
5.6
5.6.1 DI
5.7
Circuitry
5.6.2 DI Tests ...................................................................................................5-15
COMPLETEING
Chapter 6 - Control Wave LP Process Automation Controller Diagnostics
6.1 Control WaveLP DIAGNOSTICS INTRODUCTION .................................................. 6-1
6.1.1 Overview of WINDIAG Testing ..................................................................................... 6-4
Using
6.1.3 Diagnostics
6.2
6.2.1 RUN
6.2.2 RUN
&
LEDs ...................................................................................................................... 6-7
Lithium .................................................................................................................. 6-8
6.2.3 RUN Supply......................................................................................................... 6-8
6.2.4 Real Time Clock (RTC)................................................................................................... 6-8
PROM
6.3.1 PROM
6.3.2 RAM
6.4
Diagnostic
COMMUNICATION PORT DIAGNOSTICS ............................................... 6-12
6.4.1 Hardware Setup and Testing of Serial Comm. Ports ................................................. 6-12
ANALOG
6.5.1 Analog Output Circuitry Calibration Verification...................................................... 6-15
6.5.1.1 4-20 mA Analog Output Calibration Verification....................................................... 6-15
6.5.1.2 1-5V Analog Output Calibration Verification ............................................................. 6-17
ANALOG
6.6.1 1-5V AI Calibration (Without Internal References) ................................................... 6-18
6.6.2 Isolated 4-20 mA Analog Input Channel Test ............................................................ 6-19
6.6.3 Internally Sourced 4-20 mA Analog Input Channel Test........................................... 6-20
6.6.4 1-5V Analog Input Channel Test ................................................................................. 6-21
6.7 OUTPUT
6.7.1 Discrete Output Sequence Test ................................................................................... 6-22
6.7.2 Discrete Output Display Test ...................................................................................... 6-23
6.8 INPUT
6.8.1 Discrete Input Circuitry Test....................................................................................... 6-27
6.8.2 Discrete Input Display Test ......................................................................................... 6-27
6.9 HIGH SPEED COUNTER INPUT (HSC) TESTS ...................................................... 6-30
6.9.1 High Speed Counter Circuit in Non-debounce Mode Test ......................................... 6-31
6.9.2 High Speed Counter Circuit in Debounce Mode Test................................................. 6-32
6.9.3 HSC Circuit Internally Sourced Mode Verification Test ........................................... 6-35
6.10 Control WaveLP Power Supply Test .......................................................................... 6-35
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SECTION TITLE
Chapter 7 - Control Wave Process Automation Controller
& Control Wave I/O Expansion Rack Diagnostics
PAGE #
7.1 Control Wave DIAGNOSTICS INTRODUCTION ....................................................... 7-1
7.1.1 Overview of WINDIAG Testing ..................................................................................... 7-5
Using
7.1.3 Diagnostics
7.2
Test
TESTING
7.2.1 RUN
7.2.2 RUN
&
LEDs ...................................................................................................................... 7-9
Lithium ................................................................................................................ 7-10
7.2.3 Real Time Clock (RTC)................................................................................................. 7-10
PROM
7.3.1 PROM Diagnostic
7.3.2 RAM
7.4 COMMUNICATION PORT DIAGNOSTICS ............................................... 7-13
7.4.1 Hardware Setup and Testing of Serial Comm. Ports ................................................. 7-13
ETHERNET
7.5.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup............................................. 7-16
Port
7.5.2.1 Loop-back Out Twisted Pair Test RUN Button .......................................................... 7-18
7.5.2.2 Return Hardware Address Test RUN Button............................................................. 7-18
7.5.3 Ethernet Port Diagnostic Error/Failure Messages..................................................... 7-18
ANALOG
7.6.1 Analog Output Circuitry Calibration Verification...................................................... 7-20
7.6.1.1 4-20 mA Analog Output Calibration Verification....................................................... 7-22
7.6.1.2 1-5V Analog Output Calibration Verification ............................................................. 7-22
ANALOG
7.7.1 4-20 mA Analog Input Channel Test........................................................................... 7-24
7.7.2 1-5V Analog Input Channel Test ................................................................................. 7-28
7.8 OUTPUT
7.8.1 Automatic Discrete Output Test.................................................................................. 7-30
7.8.2 Discrete Output Display Test ...................................................................................... 7-31
7.8.3 Manual Discrete Output Load Test............................................................................. 7-34
DISCRETE
7.9.1 Automatic Discrete Input Test .................................................................................... 7-36
7.9.2 Discrete Input Display Test ......................................................................................... 7-37
7.10 UNIVERSAL DIGITAL INPUT (UDI) TESTS ........................................................... 7-41
7.10.1 High Speed Counter Display Test ............................................................................... 7-42
7.11 LOW LEVEL ANALOG INPUT SETUP..................................................................... 7-47
Hardware
7.11.2 Access.................................................................................................................. 7-47
7.11.3 Low Level Analog Input & RTD Tests ........................................................................ 7-51
7.11.4 Low Level Analog Input Display ................................................................................. 7-51
7.12 Control Wave I/O MODULE EEPROM TEST ........................................................... 7-54
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WINDOWS DIAGNOSTICS for Bristol CONTROLLERS
TABLE OF CONTENTS
SECTION TITLE PAGE #
Chapter 7 - Control Wave Process Automation Controller
& Control Wave I/O Expansion Rack Diagnostics (Continued)
7.13 TESTING CWs & CWEXPs VIA A CWREDIO .......................................................... 7-55
Considerations WINDIAG
Chapter 7A Control Wave RED Redundant Controller Diagnostics
7A.1 Control Wave RED DIAGNOSTIC INTRODUCTION.............................................. 7A-1
7A.1.1 Overview of WINDIAG Testing .................................................................................. 7A-5
7A.1.2
7A.1.3 Test
7A.2 TESTING CPU & PERIPHERALS ............................................................................ 7A-6
RUN
7A.2.2 Lithium ............................................................................................................... 7A-8
7A.2.3 Real Time Clock (RTC)................................................................................................ 7A-8
7A.3 PROM/RAM
7A.3.1 PROM
7A.3.2 Diagnostic
7A.4 SERIAL
7A.4.1 Hardware Setup and Testing of Serial Comm. Ports .............................................. 7A-11
PORT
7A.5.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup.......................................... 7A-14 port
7A.5.2.1 Loop-back Out Twisted Pair Test RUN Button ....................................................... 7A-16
7A.5.2.2 Return Hardware Address Test RUN Button.......................................................... 7A-16
7A.5.3 Ethernet Port Diagnostic Error/Failure Messages.................................................. 7A-17
Chapter 7B - Control Wave MICRO/EFM Process Automation Controller&
Electronic Flow Meter Diagnostics
7B.1 Control Wave MICRO/EFM DIAG. INTRODUCTION ............................................ 7B-1
7B.1.1 Overview of WINDIAG Testing .................................................................................. 7B-8
7B.1.2
7B.1.3 Test
7B.2 TESTING CPU & PERIPHERALS .......................................................................... 7B-12
RUN
7B.2.2
7B.2.3 Power
7B.2.4 Real Time Clock (RTC).............................................................................................. 7B-13
7B.3 PROM / RAM DIAGNOSTIC TESTING .................................................................. 7B-15
7B.3.1 PROM
7B.3.2 Diagnostic
7B.4 SERIAL
7B.4.1 Hardware Setup and Testing of Serial Comm. Ports .............................................. 7B-17
PORT
7B.5.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup.......................................... 7B-20
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SECTION TITLE
Chapter 7B - Control Wave MICRO/EFM Process Automation Controller&
Electronic Flow Meter Diagnostics (Continued)
PAGE #
7B.5.2 Port
7B.5.2.1 Loop-back Out Twisted Pair Test RUN Button ....................................................... 7B-21
7B.5.2.2 Return Hardware Address Test RUN Button.......................................................... 7B-21
7B.5.3 Ethernet Port Diagnostic Error/Failure Messages.................................................. 7B-22
7B.6 ANALOG OUTPUT (AO) TESTS ............................................................................. 7B-22
7B.6.1 Output
7B.6.1.1 4-20 mA Analog Output Calibration Verification.................................................... 7B-22
7B.6.1.2 1-5V Analog Output Calibration Verification .......................................................... 7B-26
7B.7 ANALOG INPUT (AI) TESTS................................................................................... 7B-27
7B.7.1 4-20 mA Analog Input Channel Test........................................................................ 7B-27
7B.7.2 1-5V Analog Input Channel Test .............................................................................. 7B-31
7B.7.3 Analog Input Calibration Routine ............................................................................ 7B-33
7B.8 DISCRETE OUTPUT (DO) TESTS .......................................................................... 7B-35
7B.8.1 Automatic Discrete Output Test............................................................................... 7B-35
7B.8.2 Discrete Output Display Test ................................................................................... 7B-35
7B.8.3 Manual Discrete Output Load Test.......................................................................... 7B-37
7B.9 DISCRETE INPUT (DI) TESTS ............................................................................... 7B-44
7B.9.1 Automatic Discrete Input Test ................................................................................. 7B-45
7B.9.2 Discrete Input Display Test ...................................................................................... 7B-45
7B.10 HIGH SPEED COUNTER TESTS ........................................................................... 7B-52
7B.10.1 High Speed Counter Display Test ............................................................................ 7B-52
7B.11 LOW LEVEL ANALOG INPUT SETUP.................................................................. 7B-56
Hardware
7B.11.2 Access............................................................................................................... 7B-57
7B.11.3 Low Level Analog Input Tests .................................................................................. 7B-61
7B.11.4 Low Level Analog Input Display .............................................................................. 7B-62
7B.12 Control Wave MICRO/EFM I/O MODULE EEPROM TEST ................................ 7B-65
7C.1 Control Wave GFC/GFC-CL/XFC/Express/ExpressPAC and Corrector
INTRODUCTION............................................................................... 7C-1
7C.1.1 Overview of WINDIAG Testing .................................................................................. 7C-8
Diagnostics
7C.1.3 Test
7C.2 TESTING CPU & PERIPHERALS .......................................................................... 7C-10
LEDs Wave GFC-CL only) .............................................................. 7C-10
RUN
7C.2.3 Power
7C.2.4 Real Time Clock (RTC).............................................................................................. 7C-12
7C.3 PROM / RAM DIAGNOSTIC TESTING .................................................................. 7C-13
PROM
7C.3.2
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WINDOWS DIAGNOSTICS for Bristol CONTROLLERS
TABLE OF CONTENTS
SECTION TITLE PAGE #
Chapter 7C - ControlWave GFC/GFC-CL/XFC and ControlWave Express/ExpressPAC
7C.4 SERIAL COMMUNICATION PORT DIAGNOSTICS ............................................ 7C-15
7C.4.1 Hardware Setup and Testing of Serial Comm. Ports .............................................. 7C-15
7C.5 ANALOG OUTPUT (AO) TESTS ............................................................................. 7C-18
7C.5.1 Output
7C.5.1.1 4-20 mA Analog Output Calibration Verification.................................................... 7C-19
7C.5.1.2 1-5V Analog Output Calibration Verification
( Control Wave GFC-CL/EXPRESS only)............................................................... 7C-23
7C.6 ANALOG INPUT (AI) TESTS................................................................................... 7C-24
7C.6.1 4-20 mA Analog Input Channel Test ( Control Wave GFC-CL/EXPRESS only) . 7C-25
7C.6.2 1-5V Analog Input Channel Test .............................................................................. 7C-27
7C.6.3 Analog Input Calibration Routine ............................................................................ 7C-28
7C.7 DISCRETE OUTPUT (DO) TESTS .......................................................................... 7C-29
7C.7.1 Automatic Discrete Output Test............................................................................... 7C-30
7C.7.2 Discrete Output Display Test ................................................................................... 7C-31
7C.7.3 Manual Discrete Output Load Test.......................................................................... 7C-32
INPUT (DI) TESTS ............................................................................... 7C-34
7C.8.1 Automatic Discrete Input Test ................................................................................. 7C-34
7C.8.2 Discrete Input Display Test ...................................................................................... 7C-34
7C.9 HIGH SPEED COUNTER TESTS ........................................................................... 7C-36
7C.9.1 High Speed Counter Display Test ............................................................................ 7C-36
7C.10 Control Wave GFC-CL/XFC/EXPRESS I/O EEPROM TEST.............................. 7C-39
Chapter 8 - 33XX Low level Analog Input Modules
8.1 LOW LEVEL ANALOG INPUT SETUP....................................................................... 8-1
8.1.1 Hardware
8.1.2 Menu
8.1.3 Entry/Display
LOW
Fields....................................................................................................... 8-1
LEVEL ANALOG INPUT TESTS........................................................................ 8-4
8.2.1 0 Percent of AI ................................................................................................................ 8-4
8.2.2 Self Test (DPC 3330) ...................................................................................................... 8-4
8.2.3 Ambient Temperature, Zero and Gain Reference (DPC 3330/3335 and RTU 3310) .. 8-4
8.3 LOW LEVEL ANALOG INPUT DISPLAY - DPC 3330/3335 and RTU 3310............. 8-4
8.4
Chapter 9 - 33XX Analog Output & Analog Input Modules
9.1
9.1.1 Hardware
9.1.2 Menu
9.1.3 Entry/Display
ANALOG
Fields....................................................................................................... 9-3
TESTS .................................................................................. 9-4
9.2.1 Calibration ...................................................................................................................... 9-5
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SECTION TITLE
Chapter 9 - 33XX Analog Output & Analog Input Modules (Continued)
9.2.3 Interference
PAGE #
9.3
Test........................................................................................................... 9-12
INPUT
9.3.1 Reference Calibration ..................................................................................... 9-13
9.3.2 Instrumentation Calibration....................................................................... 9-20
Verification................................................................................................ 9-21 9.3.3 Calibration
9.3.4 Analog Input Termination Test ................................................................................... 9-21
TESTING............................................................................................ 9-24
Chapter 10 - 33XX Discrete Output/Discrete Input Modules
10.1 DISCRETE
10.1.1
I/O
Hardware
Menu
Configuration .............................................................................................. 10-1
Access.................................................................................................................. 10-2
Entry/Display
10.2 DISCRETE OUTPUT (DO) TESTS ............................................................................. 10-4
10.2.1 Automatic Discrete Output Test.................................................................................. 10-4
10.2.2 Manual Discrete Output Test ...................................................................................... 10-4
10.3 DISCRETE INPUT (DI) TESTS .................................................................................. 10-6
DI
10.3.2 Termination
TESTING.......................................................................................... 10-15
Chapter 11 - 33XX High Speed Counter Module
11.1 HIGH SPEED COUNTER (HSC) SETUP .................................................................. 11-1
Hardware
11.1.2
11.1.3 Fields..................................................................................................... 11-4
11.2 HIGH SPEED COUNTER (HSC) TESTS ................................................................... 11-4
Counter
Input
11.2.3 Circuitry
TESTING....................................................................................... 11-11
Chapter 12 - 33XX High Speed Analog Input Modules
12.1 HIGH SPEED ANALOG INPUT SETUP ................................................................... 12-1
Hardware
12.1.2
Entry/Display
12.2 HIGH SPEED ANALOG INPUT (HSAI) TESTS ....................................................... 12-2
Reference
12.2.2
12.2.3
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SECTION TITLE
Chapter 12 - 33XX High Speed Analog Input Modules (Continued)
PAGE #
12.2.4 Test......................................................................................................................... 12-5
12.2.5 Analog Channel Offset Adjustment............................................................................. 12-5
12.2.6 Analog Input Termination Test ................................................................................... 12-7
12.2.7 Engine Speed Input test...............................................................................................12-8
TESTING ........................................................................................ 12-8
Chapter 13 - 3330 Redundant System
13.1 3330 REDUNDANT SYSTEM INTERCONNECTION .............................................. 13-1
13.2 REDUNDANT
13.2.1 Configuration .............................................................................................. 13-1
13.2.2 Downloading and Preliminary Testing ....................................................................... 13-2
13.3 REDUNDANCY
13.3.1 Redundancy
13.3.2
13.3.3
13.3.4
TESTING............................................................................................ 13-9
Communications
13.4 COMPLETING
Chapter 14 - LCDs & LCDs with 4 X 20 Display and 25-Button Keyboard
14.1 MENU ACCESS ........................................................................................................... 14-1
14.2 LCD TEST ........................................................................................................ 14-2
14.3 LCD MOVING PIXEL TEST ....................................................................................... 14-3
14.4 LCD CHARACTER ROM TEST .................................................................................. 14-3
14.5 KEYBOARD
Chapter 15 - Check Before Operate System
15.1 GENERAL..................................................................................................................... 15-1
SETUP ................................................................................................................ 15-1
15.3 FUNCTIONS OF DIAGNOSTIC MENU .................................................................... 15-1
15.4 INITIATING
Chapter 16 - Honeywell Smartline Transmitter Interface Module
16.1 GENERAL..................................................................................................................... 16-1
TEST
16.3 FUNCTIONS OF HONEYWELL DIAGNOSTIC MENU .......................................... 16-1
Screen
16.3.2 Screen 2 - RUN Loopback Tests................................................................................... 16-5
16.4 INITIATING
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SECTION TITLE PAGE #
Chapter 17 - Bristol Teletrans Interface (BTI) Board
17.1 GENERAL..................................................................................................................... 17-1
17.2 PRELIMINARY
ACCESS ........................................................................................................... 17-2
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Chapter 1
Preparation
1.1 INTRODUCTION
Certain components of a Network 3000-series or Control Wave-series process controller can be tested for hardware faults, using the Open BSI Diagnostics utility program. The Diagnostics utility program is included on the Open BSI Software CD-ROM, and is installed, and executed, from the PC workstation. The PC workstation must be connected to the controller for which diagnostic testing is to be performed.
Within the Diagnostics utility program, controllers are referred to by the term 'RTU'.
1.2 DIAGNOSTIC TEST CONFIGURATIONS
A Network 3000-series controller may be tested as a stand-alone unit or as part of a redundant pair. Control Waves, Control Wave MICRO s, Control Wave EFM s, Control -
Wave GFC-CL s, Control Wave GFC s, Control Wave Express , Control Wave
ExpressPAC s Control Wave XFC s, Control Wave Corrector s, Control Wave LP s,
Control Wave I/O Expansion Racks, Control -Wave_ 10 s, Control Wave_ 30 s and
Control Wave_ 35 s are tested as stand-alone units while Control Wave RED s are tested as part of a redundant pair. This chapter describes general requirements for all configurations. Subsequent chapters describe the various categories of testing available, for a stand-alone unit. Chapter 13 is devoted to the special requirements of the 3330 redundancy diagnostics.
The following controllers are supported by the Diagnostics utility program: RTU 3305, RTU
3310, DPC 3330, RIO 3331 RED 3332, DPC 3335, RTU CW_10 , DPC CW_30 , DPC CW_35 ,
Control Wave, Control Wave MICRO , Control Wave EFM , Control Wave GFC-CL ,
Control Wave GFC , Control Wave Express , Control Wave ExpressPAC , Control Wave
XFC s, Control Wave Corrector , Control Wave LP , Control Wave RED and Control -
Wave I/O Expansion Rack s. Tables 1-1 through 1-4, detail chapter assignments for the various controllers.
Table 1-1 - 33XX, CW_10, CW_30 & CW_35 Chapter Assignments
Chapters #
2
Description
CPU & Peripherals
D4041A
4
4A
33XX Communication Ports
CW_10 , CW_30
8, 9, 10, 11, 12,13 & 15 I/O Modules
& CW_35 Comm. Ports
14
16
17
4 x 20 Display/Keyboard
Honeywell Smartline Transmitter Intf.
Bristol Teletrans Intf. (BTI)
Preparation / 1-1
Table 1-2 - 3305 Chapter Assignments
Chapters #
2
Description
CPU & Peripherals
5 I/O
14 2 X 16 LCD & 4 x 20 Display/Keyboard
Table 1-3 – RED 3332 Chapter Assignments
Chapters #
2
Description
CPU & Peripherals
13 3330 System
Table 1-4 - Control Wave (Except CW_10/30/35) Chapter Assignments
Chapters #
6
7
7A
Description
Control Wave LP Diagnostics
Control Wave & Control Wave I/O
Expansion Rack Diagnostics
Control Wave RED Redundant
Controller Diagnostics
7B
7C
Control Wave MICRO Diagnostics
Control Wave EFM Diagnostics
Control Wave GFC-CL/GFC ,
Control Wave Express ,
Control Wave ExpressPAC ,
Control Wave XFC and
Control Wave Corrector Diagnostics
1.3 SOFTWARE REQUIRED
The Diagnostics utility is included as part of any of the following software kits included on the Open BSI Software CD-ROM:
• Open BSI Essentials • ACCOL
• ControlWave Designer • Technician
Table 1-5 - Diagnostic Load Files for Network 3000 Series Controllers
If you have THIS type of controller…
Use this diagnostic load file for testing
(NOTE: these files are located in the default \OPENBSI installation directory on your PC workstation)
Stand-alone DPC 3330 with 186-based CPU
Redundant pair of DPC 3330s with 186-CPU
(connected through an RED 3332)
DIAG530.ACL
DIAG530R.ACL
Stand-alone DPC 3330 with 386EX Real Mode CPU DIAGXRM.ACL
Redundant pair of DPC 3330s with 386-Real Mode based CPU (connected through an RED 3332)
DIAGXRMR.ACL
D4041A Preparation / 1-2
Table 1-5 - Diagnostic Load Files for Network 3000 Series Controllers (Continued)
If you have THIS type of controller…
Use this diagnostic load file for testing
(NOTE: these files are located in the default \OPENBSI installation directory on your PC workstation)
Stand-alone DPC 3330 with 386EX Protected Mode
CPU
Redundant pair of DPC 3330s with 386-Protected
Mode based CPU (connected through an RED 3332)
DIAGXPM.ACL
DIAGXPMR.ACL
Stand-alone DPC 3335 with 186-based CPU DIAG530.ACL
Stand-alone DPC 3335 with 386EX-Real Mode CPU DIAGXRM.ACL
Stand-alone DPC 3335 with 386EX-Protected Mode
CPU
DIAGXPM.ACL
Stand-alone RTU 3305
Stand-alone RTU 3310 with 186-based CPU
DIAG05.ACL
DIAG530.ACL
Stand-alone RTU 3310 with 386EX Real Mode CPU DIAGXRM.ACL
Stand-alone RTU 3310 with 386EX Protected Mode
CPU
DIAGXPM.ACL
In addition to the Diagnostics utility, a set of ACCOL diagnostic load files for various
Network 3000-series controllers is provided. These load files are described in the Table 1-5.
Note 1: There is NO specialized Diagnostic project for Control Wave, Control Wave MICRO,
Control-
WaveEFM, ControlWaveGFC-CL, ControlWaveGFC, ControlWaveExpress, ControlWaveExpressPAC,
ControlWaveCorrector, ControlWaveXFC,
Control Wave LP , Control Wave EXP , Control Wave
RED , Control Wave_ 10 , Control Wave_ 30 Controllers and Control Wave_ 350 Controllers.
1.4 HARDWARE REQUIRED
In order to run the Diagnostics utility, you must install it (via the appropriate kit on the
Open BSI CD-ROM) onto your PC workstation.
Warning
PC workstations are NOT certified for operation in hazardous areas. Make sure that these devices are only used in a safe environment. Failure to do so may result in property damage, injury and/or loss of life.
In addition to the PC workstation, you will need the external test equipment listed in Table
1-6 for checking and calibrating internal circuitry. Test equipment requirements are reiterated in the various chapters.
Table 1-6 - External Test Equipment
Qty. Item
1 Digital Multimeter (DMM), (45 PPM or better accuracy)
1 dc Voltage Source, Variable to 31 Vdc ± 0.001 Vdc (10 μ V resolution for ControlWave)
1 Precision dc Current Source, 1 mA to 20 mA ± 1 microamp
1 Power Supply, Variable to 120 Vdc ± 0.200 mVdc, 100 mA
1
1
Dual Channel Oscilloscope, at least 20 MHz, 10 mV to 10 V/division,
1 μ sec to 1 sec/division time base
Pulse Generator or Square Wave Generator, adjustable offset, adjustable amplitude to 24 V, and adjustable frequency to 10 kHz
1 Frequency Counter, 1 MHz ± 0.1 Hz
D4041A
Chapters
5, 6, 7, 7B/C, 9, 10, 12
5, 6, 7, 7B/C, 9, 10, 12
5, 6, 7, 7B/C, 9, 12
10
6, 7, 11
6, 7, 7B/C, 11, 12
11
Preparation / 1-3
Table 1-6 - External Test Equipment (Continued)
Qty.
1
Item
Pulse Totalizer/Accumulator (or Frequency Counter with Totalizer function) (must be able to accumulate at least 70,000 pulses)
2 250-ohm ± 0.01% resistors (2 for chapter 5)
2 2.2 k-ohm, ½ watt, ± 1% resistors ( 1 for chapters 5, 10)
1 1 k-ohm, ½ watt, ± 1% resistor (see Figures 6-27, 6-28, 7-36, 7-37, 7B-
35 & 7B-36)
1 250-ohm, 30-watt, ± 5% resistor (see Figures 7B-24 & 7C-19A) (for
100 mA GFC DO load)
1 75-ohm, 30-watt, ± 5% resistor (see Figure 7C-19B) (for 400 mA XFC
DO load)
1 50-ohm, 50-watt, ± 5% resistor (see Figures 7-26 & 7B-25) (for 500 mA DO load)
1 1 k-ohm, 30watt, ± 5% resistor (for 12V DO) (GFCs & XFCs)
1 510-ohm, 30watt, ± 5% resistor (for 6V DO) (GFCs only)
1 NPN Transistor - 2N2222 (see Figures 6-27, 6-28, 7-36, 7-37, 7B-35,
7B-36, 7C-24A, 7C-24B & 7C-25)
1 Form C Relay - for Debounce Enabled HSC (12/24V) (see Figures 6-
28, 7-37 & 7B-36)
1 Loop-back test cable - Honeywell Smartline Transmitter (see Figure
16-3)
1
External Loop-back Plug for 33XX testing of RS-232/485 COM Ports
(9-pin, Male, D-Type) (see Figure 4-2)
1
External Loop-back Plug for 33XX testing of RS-232/485 COM Ports
(15-pin, Male, D-Type) (see Figure 4-2)
1
1
1
1
1
Network Interface Box for Loop-back testing of RS-485 COM Ports
BIP1 and BIP2 on CPU Boards and RS-485 Ports on Expansion
Comm. Bds.
External Loop-back Plug for 3305 testing of RS-232 COM Ports (9pin, Male, D-Type) (see Figure 4-2)
External Loop-back Plug for 3305 testing of RS-485 COM Ports (9pin, Male, D-Type) (see Figure 4-2)
External Loop-back Plug for CW_10 , CW_30 & CW_35 testing of RS-
232 COM Ports (9-pin, Male, D-Type) (see Figure 4A-2)
External Loop-back Plug for CW_10 , CW_30 & CW_35 testing of RS-
485 COM Ports (9-pin, Male, D-Type) (see Figure 4A-3)
5
5, 10, 11
6, 7, 7B/C
7C
7C
6, 7, 7B/C
16
4, 13
4
4
4
4
4A
4A
Chapters
6, 7, 7B/C
7, 7B/C
7C
7, 7B
6, 7, 7B, 11
2 50 ohm BNC Terminators (for Ethernet testing)
1 BNC Tee Connector (for Ethernet testing)
1
1
1
Ethernet 10Base-T RJ-45, Twisted Pair, 8-pin Male, Loop-back Plug
(see Figures 7-13 & 7B-13)
External Loop-back Plug for ControlWave testing of RS-232 COM
Ports (9-pin, Female, D-Type) (see Figures 6-9, 7-10, 7B-10 & 7C-
9A/B)
External Loop-back Plug for ControlWave testing of RS-232 COM
Ports (8-pin, Male, RJ-45) (see Figure 7-10)
4
4
4, 7, 7A, 7B
6, 7, 7A, 7B/C
7, 7A
1
1
External Loop-back Plug for ControlWave testing of RS-485 COM
Ports (9-pin, Female, D-Type) (see Figures 6-10, 7-11 & 7B-11)
External Loop-back Plug for ControlWave testing of RS-485 COM
Ports (8-pin, Male, RJ-45) (see Figure 7-11)
6, 7, 7A, 7B
7, 7A
1 267 ohm, 5 watt, ± 5% resistor (see Figure 6-19) (for 100 mA DO load) 6
1 2280 ohm, .5 watt, ± 5% resistor (see Figure 6-19) 6
1 LED (rated for 10mA) (see Figure 6-19) 6 & 7C
D4041A Preparation / 1-4
1.5 CONNECTING THE PC TO THE CONTROLLER
Connect a cable between an RS-232 serial port (e.g. COM1, COM2) on the PC Workstation, and one of the serial ports on the controller (RTU). The controller port must have been configured for either RS-232 or RS-423 operation. The choice of serial ports on the controller depends on the type of controller, and the diagnostic loads being used:
•
•
For 186-based controllers, connect to Port A
For 386EX-Real Mode controllers, connect to Port BIP 1
•
•
•
•
•
•
•
•
For 386EX Protected Mode controllers, connect to Port BIP 1
For CW_10 RTUs or CW_30/35 DPCs, connect to any RS-232 Port except the Utility
Port
For Control Wave controllers, connect to COM1, COM2 or COM4
For Control Wave MICRO & Control Wave EFM controllers, connect to COM1, COM2,
COM4 or COM8
For Control Wave GFC-CL / GFC/Express / ExpressPAC / XFC/Corrector controllers, connect to COM1 or COM2
For Control Wave I/O Expansion Racks connect to COM1, 2, 3, 4, 5 or 6. Note: COM5
& COM6 require Open BSI version 5.0 or higher to operate
For Control Wave LP controllers, connect to COM1, 2, 3, 4, or 5
For Control Wave RED controllers, connect to COM1, COM2 or COM4 of either CPUA or CPUB or to COM1, COM2, COM3 or COM4 of the CCRS Module
Figure 1-1 - PC Connection to Controller for Diagnostics
Refer to the appropriate controller hardware manual for details on port hardware configuration (refer to manual CI-3305, CI-3310*, CI-3330*, CI-3335*, CIControl Wave,
CIControl Wave MICRO , CIControl Wave EFM , CIControl Wave GFC-CL , CICon trol Wave GFC , CIControl Wave Express , CIControl Wave EPAC , CIControl Wave
XFC , CIControl Wave Corrector , CIControl Wave LP , CIControl Wave EXP or CI-
Control Wave RED as required for your model). For details on port hardware configuration of a CW_10 RTU, CW_30 DPC or CW_35 DPC refer to PIP-CW_10 Upgrade Kit, PIP-
CW_30 Upgrade Kit or PIP-CW_35 Upgrade Kit.
* For the 386EX Real Mode based models, see Section 3BA of the appropriate manual. For
386EX Protected Mode based models, see Section 3BB of the appropriate manual. For
386EX Protected Mode based models (with Ethernet), see Section 3BC of the appropriate manual.
D4041A Preparation / 1-5
1.6 INSTALLING THE DIAGNOSTICS SOFTWARE ON THE PC
The Diagnostics Utility software is installed on the PC by loading any of the following kits from the Open BSI CD-ROM:
• OpenBSI Essentials
• ACCOL Workbench
• ControlWave Designer
• Technician Toolkit
See Chapter 2 of the Open BSI Utilities Manual (document # D5081) for information on each kit.
1.7 ESTABLISHING COMMUNICATIONS WITH THE RTU
Communications between the RTU (controller), and the PC workstation, are controlled by
Open BSI software. Open BSI provides two different utilities for performing communication; LocalView and NetView.
NetView is available only if you have loaded the OpenBSI Essentials kit.
LocalView is available in the OpenBSI Essentials, ControlWave Designer, Technician
Toolkit, and ACCOL Workbench kits.
The choice of whether to use LocalView or NetView is up to the user, however, if you choose
NetView, you must have already included the controller as part of your Bristol Babcock network configuration files.
1.7.1 Establishing Communications Using LocalView:
Prerequisites:
Before establishing communications with a locally attached controller (RTU), you need to:
• Connect the PC communication cable to one of the available serial ports on the controller (either BIP 1, BIP2, Port A through D, or Port G through J) for a Network
3000-series controller, for a CW_10 ports 1 through 6, for a CW_30 ports 1 through 6 or
1 through 10, for a CW_35 ports 3 through 6, 9 and 10, for a Control Wave ports COM1,
COM2 or COM4, for Control Wave MICRO s and Control Wave EFM s ports COM1,
COM2, COM4 or COM8, for a Control Wave GFC-CL / GFC / Express/ExpressPAC /-
XFC or a Control Wave Corrector ports COM1 or COM2, for a Control Wave I/O
Expansion Rack ports COM1 or COM2, for a Control Wave LP ports COM1 through
COM5 or for a Control Wave RED ports COM1, COM2 or COM4 of either CPUA or
CPUB or to COM1, COM2, COM3 or COM4 of the CCRS Module.
For Network 3000 users, if an ACCOL load is already running in the unit, you must choose a port already configured as a Slave, Pseudo Slave, or Pseudo Slave with Alarms
Port. If the unit is empty (no ACCOL load running) the first thing you need to do is to download an ACCOL load.
For Network 3000 users, you must know the baud rate of the port you are connecting to, as configured in the running ACCOL load. If there is no running ACCOL load (unit is
D4041A Preparation / 1-6
empty) you should use one of the default ports (as determined by switch settings, or if this is an IP controller, by soft switches) at 9600 baud.
For Control Wave, Control Wave MICRO , Control Wave RED , Control Wave EFM /-
GFC-CL / GFC / Express / ExpressPAC / XFC/Corrector , or Control Wave_ 10 / 30/35 users, the baud rate is determined based on soft-switch settings. If the applicable CPU’s default switch SW1-3 (SW2-3 for Control Wave MICRO s, Control Wave EFM / GFC/-
GFC-CL/Express / ExpressPAC/Corrector s & CW_10/30/35 s) is in the OFF position, soft-switches are ignored, and the baud rate for all serial Comm. Ports (except COM1) will default to 9600 baud (BSAP); COM1 in this case will default to serial IP (PPP).
Note: CPU switch SW1-8 (SW2-8 for Control Wave MICRO/EFM / GFC/GFC-CL/-
Express / ExpressPAC/Corrector s & CW_10/30/35 s) must be set OFF to run the
DIAG program. COM1 is set to 9600 baud (BSAP) when SW1-3 and SW1-8 (or SW2-3 and SW2-8) are both set to the OFF position.
• For Wave EXP (I/O Expansion Rack) users, the baud rate is determined based on soft-switch settings. If the default switch SW3-3 is in the OFF position, soft-switches are ignored, and the baud rate for COM1 and COM2 defaults to 9600 baud. Note: CPU switch SW3-8 must be set OFF to run the DIAG program.
For Wave LP users, the baud rate is determined based on soft-switch settings.
If the default switch SW4-3 is in the OFF position, soft-switches are ignored, and the baud rate for COM2 through COM5 defaults to 9600 baud; you should not use COM1 in this case since it will default to serial IP (PPP). Note: CPU switch SW4-8 must be set
OFF to run the DIAG program.
You should be in the same physical location as the controller, so that you can view failure LEDs, etc. when performing the various diagnostic tests. For this reason, we will
NOT discuss use of LocalView's dial-up options.
The following steps assume you do NOT have a view mode file already configured, and so you will be creating a new one:
Start LocalView, Enter A Name For The View Mode File, Click on [Create]
Start LocalView by clicking on Start Æ Programs Æ OpenBSI Tools Æ LocalView . The
New View Mode dialog box (Figure 1-2) will appear:
"Mode"
'Local' should already be selected for the mode.
"Name"
In order to use LocalView, you need to define a View Mode File (*.LVG). Enter the basename of the View Mode File in the "Name" field.
"Location"
If you want to save your View Mode File in a directory other than that shown in the
"Location" field, type in the directory name, or choose an alternate location using the
[Browse] push button.
D4041A Preparation / 1-7
Figure 1-2 - New View Mode Dialog Box
When the name and location have been chosen, click on the [Create] push button.
This will activate the Communication Setup Wizard.
Step 1 - Communication Setup Wizard
Complete the fields in the Communication Setup Wizard, as described, below:
D4041A
Figure 1-3 - Communications Setup Wizard
Preparation / 1-8
"What port would you like to use?"
This refers to the port on the PC (such as COM1, COM2, etc.)
"What baud rate would you like to use?"
This is the baud rate for the PC port, however, it must match the baud rate used at the controller's port.
"Would you like to use RTS/CTS signals?"
Leave this setting alone.
"Front Pad", "Back Pad"
Leave this setting alone.
If you want to accept the defaults you can click on the [Finish] push button, at this point.
If you want to use setup parameters other than the defaults, click on the [Next >] push button.
Step 2 - RTU Setup Wizard
If you choose ‘No’ for auto address detection, enter the local address here.
Figure 1-4 - RTU Setup Wizard
Complete the fields in the RTU Setup Wizard, as described, below
"Would you like auto local address detection?"
Choosing 'Yes' which is the default, will allow you to set up a local connection without knowing the local address of the RTU, because LocalView will sequentially poll each address, until it finds an address which answers. Choosing 'No' will require you to specify the local address in the field below. (NOTE: If the RTU is empty, waiting for a download, or is in a watchdog failure condition, you must NOT use auto local address detection, because the RTU will be unable to answer a poll.
"What is the local address of the RTU that you would like to connect to?"
Type the local address of the RTU (from 1 to 127) or select the address using the list box
D4041A Preparation / 1-9
provided. This field need only be used if you answer 'No' for the auto address detection question, above.
"What is the type of the RTU?"
Use the list box to select the type of controller (RTU) you are connected to. Choices include: 3305, 3310, 3330, 3335, ControlWave, CWave_Micro, CWave_GFC,
CWave_XFC, CWave_Express, CWave_LP and CWave_30. Note: For a Control Wave
I/O Expansion Rack select Control Wave; for a Control Wave EFM select CW_Micro; for a Control Wave GFC-CL , select CWave_GFC; for a Control Wave GFC , Control Wave
Express , Control Wave ExpressPAC or Control Wave Corrector select CW_Express.
"Control Strategy file name:"
In this field enter the path and file name of the Diagnostic load file, appropriate to your unit (see Table 1-1 for a list). You can use the [Browse] button to locate the directory path and control strategy file name, or you can type this information in directly.
Click on the [Finish] push button to exit the RTU Setup wizard.
After You Have Finished With the Setup Wizards…
When you exit the wizards, your View Mode File is now complete, and LocalView will attempt to use it. LocalView will create a small BSAP network, and will attempt to poll the attached controller.
If the Open BSI system starts successfully, LocalView will add an icon for a single controller (RTU) to the small BSAP network, and you will be free to activate various Open
BSI utilities to communicate with this RTU. If this is a direct connection and the RTU has no control strategy file running in it, turn OFF auto address detection, to prevent polling, and then you can use the Downloader, at this point, to download a diagnostic load file.
NOTE: ControlWave series units don’t use a diagnostic load file.
If auto local address detection is on, and polling is NOT successful, the message 'No RTU
Found' will appear in red in the status bar. This indicates there is a problem establishing the connection. You can re-activate the wizards to view/modify the parameters you entered and try again.
1.7.2 Establishing Communications Using NetView:
Prerequisites:
Before you can establish communications with a controller (RTU) through NetView you must have done the following:
• Configured a Network Host PC (NHP).
• Configured a controller network.
• Configured a communication line.
• Included the RTU as part of the controller network.
For information on performing these configuration activities, see Chapter 6 of the Open BSI
Utilities Manual (document # D5081).
D4041A Preparation / 1-10
Start NetView
Start NetView by clicking on Start Æ Programs Æ OpenBSI Tools Æ NetView .
Figure 1-5 - NetView Startup Menu
Open the Network Definition File containing this controller
If you have a Network Definition
File named CURRENT.NDF, Net-
View should open it automatically on start-up, and communications should begin. Otherwise, open whichever Network Definition File contains the controller on which you want to perform diagnostic tests.
To do this, click on File Æ Open and choose the Network Definition File you want to open, then click on [Open] .
Communications with the controller should start.
Specifying the Diagnostic Load File (Network 3000 users ONLY)
If this is a Network 3000-series controller, you should specify the diagnostic load file you want to download for this controller.
To do this, click on the key icon, and the Sign On dialog box will appear.
D4041A Preparation / 1-11
Now, enter the system password, (if none =
666666) and click on [OK] .
Next, right-click on the icon for the controller you want to test, and choose "Properties" from the pop-up menu.
In the Rtu Properties dialog box, enter the path and base name of the diagnostic load file or use the [Browse] key to locate it. Click on the [OK] button when finished.
NOTE: If you need help choosing the diagnostic load file, see Table 1-5.
1.8 DOWNLOADING THE DIAGNOSTIC LOAD FILE TO THE
CONTROLLER (Network 3000 Users ONLY)
Note 2: The procedures outlined in this section do not pertain to RIO-3331 systems.
RIO-3331s do not require a diagnostic ACCOL load to be downloaded.
D4041A Preparation / 1-12
Before executing off-line diagnostics on any controller you should be sure that all process control systems associated with the controller are either disconnected or properly protected.
WARNING
If a controller is on line, there will be a total loss of its normal functions when it is reset and loaded with the off-line diagnostic load. If Process I/O
Board diagnostic tests are performed, it will additionally affect anything connected to the associated PI/O points. Make sure in advance that all critical processes are turned off, or placed under manual control. A process running out of control can result in property damage, injury and even loss of life.
The reset button on the processor board of the controller should be pressed to clear the unit and to execute the Self-Test diagnostic sequence. The Failure LEDs should be observed for proper completion of the diagnostic sequence and verification of any PI/O boards. For the controllers, the communications ports are also checked as part of preparation for download and any failures are indicated via the Failure LEDS. See the hardware manual associated with your controller for details of the Self-Test Diagnostic sequence.
If the presence of all installed process I/O (PI/O) boards is not indicated at the end of the diagnostic sequence, the off-line diagnostic tests for the appropriate board type(s) should be run to further identify any failure conditions and to aid in calibration if necessary. For the controller, if the Failure LEDS indicate a problem with any of the communications ports, the off-line communications diagnostic should be run on those ports.
When Self-Test is completed, the diagnostic ACCOL load can be downloaded.
1.8.1 Downloading
Before you attempt a download, be sure you:
• Follow the warnings described above concerning isolating the controller from any connections to a real process.
• Start communications using either NetView or
LocalView. Communications must be active in order to perform the download.
• Identify in NetView or LocalView the diagnostic load file you want to download (discussed in previous sections).
In LocalView (or NetView), rightclick on the RTU icon associated with the controller, and choose RTU Æ Download from the pop-up menu.
The Downloader utility will be started. Enter the password for accessing the controller in the "Password" field, and click on the [Begin] button (for DIAG loads this is 666666). The diagnostic load file (specified earlier) will be downloaded into the controller.
D4041A Preparation / 1-13
Figure 1-6 - Download Utility Menu
1.8.2 Communications Problems Checklist
A timeout or other error while attempting to download the diagnostic load file into the controller can be the result of improper connections or incorrect assignments. The following checklist should help you to identify any setup errors:
1. Make sure you have the proper cable between the PC and the controller and that it is connected to the appropriate port at each unit. The PC must be connected to Port A of the 186-based controllers or BIP1 if the controller is a 386EX-based Controller.
(If you are doing other diagnostic testing described in Chapters 2 through 12, or if you are doing 3330 redundancy diagnostics described in Chapter 13, you will be using Port
A/BIP1.)
2.
Depending on the controller in question, Port A/BIP1 must be configured for RS232 or
RS423 communications. See the hardware manual for your unit to verify that the jumper and switch settings are correct or see the Quick Reference Guides contained within Chapter 4.
3. Make sure you have entered the correct hardware local address of the node you want to test in LocalView or NetView. This address is a number between 1 and 127 assigned at the time of installation and set using jumpers or switches on the processor board. See the appropriate hardware manual for details. Getting this information in advance will avoid unnecessary delays in completing diagnostic testing.
4.
Make sure you have set the baud rate for communications in NetView or LocalView at
9600.
D4041A Preparation / 1-14
5. Check the status of the controller. Following a reset the Halt LED and Failure LEDs should be off and the Watchdog LED should be on. If any of the Failure LEDs are on try resetting the unit again. Consult the hardware manual for the proper interpretation of the Failure LED pattern if the unit fails to reset properly.
6. Make sure you are selecting the proper diagnostic load file for your controller. See Table
1-5 for details.
1.9 EXECUTING OFF-LINE DIAGNOSTIC PROCEDURES
Now that the diagnostic load has been downloaded into the controller, you can perform the diagnostic procedures described in detail in the subsequent chapters of this manual. Before you begin diagnostics always follow the steps below:
• Start LocalView (see Section 1.7.1) or NetView (see Section 1.7.2).
• To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
• Once WINDIAG has been entered (and the unit to be tested has been selected on the initial WINDIAG entry menu), the Diagnostic Test Category Menu (Figure 1-7) will appear.
1.9.1 Selecting Test Categories
The Diagnostic Test Category Menu (Figure 1-7) offers a selection of test categories. Select the category you want by highlighting the applicable test and then clicking on the "Run" button at the bottom of the screen. The screen will change and the menu associated with your selection will appear. An example of a Diagnostic Test Menu is shown in Figure 1-8.
Most tests or procedures involve user entry of a cycle count and possibly a hardware device selection such as a PIO board number (see note 5) or communications port designation. A limited number of procedures or displays default to a continuous mode and will be so noted.
Specific test procedures are then initiated using "Run" buttons.
In addition to the above entry points, a typical test menu contains three columns: TEST,
PASS and STATUS. The TEST column provides a list of specific tests; the PASS column contains the current cycle count; and the STATUS column denotes the test results. In addition, a "Number of Failures" field near the top of the menu displays the count of test cycles that failed.
Note 3: If a PIO Board Number (Slot Number) is entered and the slot is empty, a "Board Requested
Not In Target" message will appear at the bottom left corner of the selected menu screen.
D4041A Preparation / 1-15
D4041A
Figure 1-7 - Diagnostic Test Category Menus
Preparation / 1-16
1.9.2 Entering Number of Passes
Diagnostic tests are run on a cyclic basis. At the conclusion of each cycle or pass, the test repeats until the total number of cycles have been executed or some other termination condition occurs. The "Number of Passes" field, shown in Figure 1-8, shows the default of 1 pass. Valid entries for this field include numbers from 1 through 256 as well as "Continuous/Repeat after Error," or "Continuous/Stop after Error" (set via one of the three
"Radio" buttons located near the top of the menu).
Figure 1-8 - Sample Diagnostic Menu
As a test is being executed, a running count of the number of passes will be displayed under the PASS column while the number of failures, if any, will appear to the right of "Number of Failures." If you have entered a specific cycle count, the test will conclude when the number in the PASS column coincides with your entry in the "Number of Passes" field. If you select CR Mode the test will execute continuously until you terminate it by pressing the applicable "ABORT" button, or by exiting the screen by pressing the "Return to Menu" button at the bottom of the screen. If you select CS Mode the test will terminate if it encounters a failure, otherwise it will execute continuously until you terminate it as described above.
There are no specific recommendations for the number of passes that should be performed.
However, the more passes you implement, the longer your testing will take. In general,
D4041A Preparation / 1-17
keep the number of passes confined to a low number unless you are tracking down longterm errors or intermittent problems.
A test that is in progress can be stopped by pressing the applicable "ABORT" button, by selecting another test on the same menu, or by exiting from the menu using the "Return to
Menu" button at the bottom of the screen.
1.9.3 Status Messages
The status of the test in progress is updated in the RTU at the end of each pass or cycle.
This status is collected periodically by the PC and displayed in the STATUS column. If no errors have been detected, "Success" will appear under the STATUS column and the
"Number of Failures" will be 0. However, if an error is encountered, "Fail" will be displayed in the STATUS column and the number of failed passes will be displayed in the "Number of
Failures" field. In many instances, additional text will be displayed with the "Fail" message to identify the type of failure. These messages are defined, where appropriate, in the chapters that follow. Note that if a failure is occurring intermittently, the STATUS column may alternate between "Success" and "Fail", however the "Number of Failures" field will accurately reflect the number of failed cycles while the PASS column will reflect the total number of cycles. If "Number of Passes" is set to CS, test execution will stop when the first error is encountered. This may be useful in order to capture a failure message to the printer for an intermittent failure case.
If the screen indicates "No Return Status" under the STATUS column, this means that no test results are displayed at the PC for this particular procedure. The test may use the
Failure LEDS at the RTU (controller), or may require external test equipment connected to the controller. These details are covered in the description of the individual procedures.
1.10 TRAVELING THROUGH THE DIAGNOSTIC SYSTEM
After entering your test selection at the Diagnostic Test Category Menu (Figure 1-7), a typical check-out sequence of a stand-alone RTU (controller) might be:
1. Select CPU and Peripherals Diagnostic.
2. Set number of passes.
3. Select each applicable test on this menu in order, letting it execute to completion. If a test is not applicable to all units, the unit(s) to which it applies will be noted (for example, DPC 3330). If you select a test that does not apply to your unit, the error message "Invalid diagnostic for selected remote" will appear on the PC status line at the bottom of the screen.
4. Press the appropriate "RUN" button to proceed to the next test category or press
"Return to Menu" to return to the Diagnostic Test Category Menu.
Note that with the exception of a ControlWave series unit, after executing the
RAM Diagnostics on the PROM/RAM Diagnostic Menu (see Figures 3-1, 6-7, 7-8,
7A-8, 7B-8 or 7C-7), you must reload the DPC/RTU in order to continue with other diagnostic tests; therefore, you may want to save this test for last.
D4041A Preparation / 1-18
1.11 CONCLUDING DIAGNOSTIC TESTING
When any or all testing is complete, you may exit the Diagnostic Control Program by clicking on the X in the upper right hand corner of the open menu and then closing the diagnostic utility.
Power at the DPC/RTU (controller) should be turned off. When other than a Control Wave family unit is returned to its normal process control or network function it must be reset and downloaded with its normal ACCOL load file. Control Wave_ 10 , Control Wave_ 30 ,
Control Wave_ 35 , Control Wave, Control Wave MICRO , Control Wave EFM , Control-
Wave GFC , Control Wave GFC-CL , Control Wave Express , Control Wave ExpressPAC ,
Control Wave XFC , Control Wave Corrector , Control Wave RED and Control Wave I/O
Expansion Rack units must be taken out of diagnostics mode by powering down, setting the appropriate CPU switch to the ON position and then reapplying power.
Control Wave Switch: SW1-8
Control Wave RED
Control
Control
Wave
Wave EFM
Switch:
MICRO
SW2-8
Control Wave GFC-CL Switch: SW2-8
Control Wave GFC Switch:
Control Wave Express
SW2-8
SW2-8
Control Wave ExpressPAC Switch: SW2-8
Control Wave Corrector Switch: SW2-8
Control Wave XFC SW1-8
Control Wave EXP Switch: SW3-8
Control Wave_ 10 Switch: SW2-8
Control Wave_ 30 Switch: SW2-8
Control Wave_ 35 Switch: SW2-8
D4041A Preparation / 1-19
BLANK PAGE
Chapter 2
33XX, CW_10, CW_30, CW_35 & 3305
CPU and Peripherals
2.1 CPU & PERIPHERALS INTRODUCTION
This chapter describes the diagnostic testing for the CPU and its associated peripheral devices. All of the elements to be tested are on the processor board of the controller (CPU
Board for CW_10 s, CW_30 s and CW_35/31 s) (CPU Engine Board for the 3310/30/31/35)
(PMPP Board for the RTU 3305) with the following exceptions:
C Some older versions of 186 based DPC3330s may have the 256K RAM Expansion Board with its own battery (called External Battery).
Before the tests described in this chapter can be performed, the following steps must be performed:
1. Establish communication between the PC and the RTU (see Sections 1.7).
Communication between a Control Wave_ 10 , Control Wave_ 30 or Control Wave_ 35/31 and the PC (equipped with Bristol’s WINDIAG program can be made via a Local or
Network Port with the following restrictions:
• CPU Board Switch SW2-8 must be OFF to run the WINDIAG program. Setting it OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode.
• Any ControlWave communication port (except the Utility Port) can be connected to the
PC provided their port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to 9600 bps operation).
• For a CW_10 or CW_30 unit, communication port 1 is only forced to 9600 bps operation when CPU Switches SW2-3 and SW2-8 have both been set OFF. Communication port 1 can also be set to 9600 bps operation via user defined Soft Switches. From the factory communication port 1 is set for to 115.2 kbd (RS-232), BSAP operation. From the factory all other serial communication ports default to 9600 baud, 8-bits, no parity, 1 stop bit,
(RS-232) BSAP/ControlWave Designer protocol operation when set for factory defaults.
• Setting CPU Board Switches SW2-3 and SW2-8 OFF prevents the ‘Boot Project’ from running, places the unit into diagnostic mode and forces all CW_10 , CW_30 or
CW_35/31 serial communication ports to operate at 9600 baud.
• Either of the optional Ethernet Ports can be connected directly or via a network to a PC equipped with an Ethernet Port. If not configured with an address, the CW_10 , CW_30 or CW_35/31 uses DHCP (by default) to obtain an IP address.
• To use the WINDIAG program, place any critical process (associated with the unit in question) under manual control. WINDIAG cannot be run while a CW_10 , CW_30 or
CW_35/31 application is running. Set CPU Switch SW2-8 to the OFF position.
• Before you start WINDIAG, either Local View (see Section 1.7.1) or NetView (see Section
1.7.2) must be running. To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
2. Download the Diagnostic Load File (Network 3000 Users ONLY) (see Section 1.8).
3. Start WINDIAG (see Section 1.9).
D4041A 33XX, CW_XX & 3305 CPU and Peripherals / 2-1
4. At the Diagnostic Test Category Menu select the ‘CPU and Peripherals’ Diagnostic (see
Section 1.10).
These tests do not require removal of any board or any special external equipment.
In this chapter, you will be using the PC display shown in Figure 2-1. To get to this display, start at the Diagnostic Test Category Menu (Figure 1-7). Highlight the "CPU &
Peripherals" selection and then click the
"
Run
"
button at the bottom of the screen.
Figure 2-1 - CPU And PERIPHERALS Diagnostic Menu
Note 1’: The following tests aren’t applicable to Control Wave_ 10 , Control Wave_ 30 and
Control Wave_ 35/31 units: RUN Pic, RUN Dma, RUN Timers & RUN Floating Point CoProcessor.
2.2 INTERNAL PERIPHERALS
These tests exercise the microprocessor CPU and its integrated peripherals (see note 1).
Note 1: Failure messages may be different depending on the type of CPU.
2.2.1 Programmable Interrupt Controller (PIC)
(see note 1’)
Click on the "RUN Pic" button. This will test the integrated programmable interrupt controller. The STATUS column will show Success or Fail. For the 386EX Real Mode based
33XX Controller, the Failure Message will appear as follows:
Fail - PIC Diag Fail.
D4041A 33XX, CW_XX & 3305 CPU and Peripherals / 2-2
2.2.2 Direct Memory Access (DMA)
(see note 1’)
Click on the "RUN Dma" button. This test exercises each of the two integrated DMA channels in the nonsynchronized and/or synchronized mode. The STATUS column will show the test results. Sample messages are shown below. If a failure occurs, the failing channel and mode will be shown.
Success
Fail - Channel 0 Nonsynchronized
Fail - Channel 1 Nonsynchronized
Fail - Channel 0 Synchronized
Fail - Channel 1 Synchronized
2.2.3 Internal Timers
(see note 1’)
Click on the "RUN Timers" button. The timers are tested using a software timing loop. For the 186 based CPU the internal timer count registers are tested on a bit-by-bit basis. Test results will be displayed in the STATUS column (sample messages are shown below).
Success
Fail - CPU Timer 1 Failure
Fail - CPU Timer 2 Failure
Fail - Count Register Failure
2.3 EXTERNAL PERIPHERALS
These tests exercise the various peripheral devices external to the microprocessor chip.
2.3.1 LEDs
Click on the "RUN LEDs" button. Look at the Failure LEDs at the controller. For RTU
3305, RTU 3310, DPC 3330 and DPC 3335, they should turn on and off in the sequence shown in Figure 2-2. For this test, no messages are reported at the PC.
D4041A
Figure 2-2 - LED Test
33XX, CW_XX & 3305 CPU and Peripherals / 2-3
The number and position of the Failure LEDs is a function of the controller type. Table 2-1 describes where the Failure LEDs are located for each controller type.
Controller
RTU 3305
No. of LEDs
6
Location of LEDs
Edge of PMPP Board
DPC 3330/3335
RTU 3310
DPC CW_35/31
DPC CW_30
RTU CW_10
6
6
Edge of CPU Engine Board
Edge of CPU Board
Table 2-1 - LED Test
Status LEDs associated with the CW_10 RTU, CW_30 DPC, CW_35 DPC and CW_31 RIO are situated on the CPU Board. These LEDs will initially all go off then will individually come on and off in the following sequence (ending with Status LED1 ON):
STATUS1 (CR7 for CW_10/30) or (CR1 for CW_35/31)
STATUS2 (CR8 for CW_10/30) or (CR2 for CW_35/31)
STATUS3 (CR9 for CW_10/30) or (CR3 for CW_35/31)
STATUS4 (CR10 for CW_10/30) or (CR4 for CW_35/31)
STATUS5 (CR11 for CW_10/30) or (CR5 for CW_35/31)
STATUS6 (CR12 for CW_10/30) or (CR6 for CW_35/31)
STATUS5 (CR11 for CW_10/30) or (CR5 for CW_35/31)
STATUS4 (CR10 for CW_10/30) or (CR4 for CW_35/31)
STATUS3 (CR9 for CW_10/30) or (CR3 for CW_35/31)
STATUS2 (CR8 for CW_10/30) or (CR2 for CW_35/31)
STATUS1 (CR7 for CW_10/30) or (CR1 for CW_35/31)
The RUN LEDs test will provide pass/fail status indications for the CW_10 , CW_30 and
CW_35/31 as follows: RUN LEDs – Pass = X (--- No Return Status ---) where x = the number of the pass. For this test, no messages are reported at the PC.
2.3.2 Real Time Clock (RTC)
(see notes 2 & 3)
Click on the "RTC Diagnostic" button. The PC will proceed to the RTC Diagnostic Menu shown in Figure 2-3.
Note 2: This test applies to RTU 3310, DPC 3330/3335, RTU CW_10 & DPC CW_30 units only.
This set of tests will determine if the RTC chip is fully functional. This menu has its own
Number of Passes field that is independent of what is set at the CPU and Peripherals
Diagnostic Menu (Figure 2-1). Individual tests are initiated by clicking the appropriate
"RUN" button.
Note 3: If your unit has the Dallas Semiconductor DS1287 RTC chip, the status of its internal battery can be tested using the Lithium Battery test (see Section 2.3.3).
Time Registers Test
This test checks the RTC registers and will display either "SUCCESS" or "FAILURE - RTC" under the STATUS column.
D4041A 33XX, CW_XX & 3305 CPU and Peripherals / 2-4
Alarm Registers Test ( Not applicable to CW_10, CW_30 and CW_35 units )
This test checks the RTC Alarm Registers and will display either "SUCCESS" or
"FAILURE - RTC Alarm" under the STATUS column.
Set Time: 01-JAN-87 00:00:00
For this function, the Number of Passes should be set to 1. This function sets the RTC to the date and the time shown and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Set Time from PEI (see note 4)
For this function the Number of Passes should be set to 1. This function sets the RTC using the date and time from the PC clock and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Note 4: Only the date and time (down to minutes) will be used from the PC. The seconds at the RTC will ALWAYS be initialized at 30.
D4041A
Figure 2-3 - Real Time Clock Diagnostic Menu
33XX, CW_XX & 3305 CPU and Peripherals / 2-5
Read Time
This function reads the date and time from the RTC and displays it in the STATUS column at the PC. To set the RTC to a known starting point, use one of the SET TIME functions.
Then set the Number of Passes to continuous (CR or CS) and activate the READ TIME function to visually monitor the accuracy of the RTC.
When finished, return to the CPU and Peripherals Diagnostic Menu (Figure 2-1) by clicking on the "Return To Menu" button at the bottom of the screen.
2.3.3 Lithium Battery
(see notes 5 through 7)
This test checks the status of the on-board battery that maintains the data in the system
RAM if power is lost. When the battery(s) are functioning properly, the controller can lose power but still retain its ACCOL load and continue running from the point of power loss when power is restored.
For 186 based and 386EX Real Mode based 33XX Controllers using the Dallas Semiconductor DS1287 Real Time Clock chip (RTC), this test also checks the RTC internal battery status (186 Controllers require firmware level AG.00 or later for 3310/30/35 and B.04 or later for RIO 3331). If this battery fails, the controller can still recover from the loss of power; however, for the 3310/30/35 Controllers the date and time (#TIME.nnn Signals) will be questionable until corrected from an external source and for RIO 3331 outputs will not be automatically restored.
Click on the "RUN Lithium" button of the CPU And Peripheral Diagnostic Menu (Figure 2-
1). The STATUS column will show either "SUCCESS" or one of the following messages:
Lithium Battery Failure
Internal Battery Failure (Not applicable to CW_10 , CW_30 or CW_35/31 )
External Battery Failure (Not applicable to CW_10 , CW_30 or CW_35/31 )
RTC Battery Failure (Not applicable to CW_10 , CW_30 or CW_35/31 )
The first two messages relate to the main system battery (the message varies with the
ACCOL software version and/or unit type). The third message relates to the original 186based DPC 3330 Memory Expansion Board battery. If any failure message is reported, the indicated battery should be replaced as soon as possible.
The last message relates to the Dallas Semiconductor DS1287 Real Time Clock chip (RTC) which has its own internal battery. If this failure is reported, there is no user replacement.
The board must be returned for repair.
Note 5: This test applies to CW_10/30/35/31s, RTU 3310 and DPC 3330/3335 units only.
Note 6: For 186-based units only . If you are using an ACCOL software version earlier than 5.6 with
AG.00 or later PROMs, a DS1287 RTC battery failure will be reported as "External Battery
Failure." Since the DPC 3330 with the Memory Expansion Board does not use the DS1287
RTC, the interpretation of the message is not ambiguous.
Note 7: For 186-based original DPC 3330s (with optional Memory Expansion Board), this test also checks the status of the battery that maintains the data in the 256K of RAM on this board.
D4041A 33XX, CW_XX & 3305 CPU and Peripherals / 2-6
2.3.4 Floating Point Coprocessor
(see note 1’) (see note 8)
These tests exercise the basic functions of the Intel 80C387 (386EX Real Mode based units) and Intel 80C187 (186-based units) numeric coprocessor. Click on the "RUN Floating Point
CoProcessor" button of the CPU And Peripheral Diagnostic Menu (Figure 2-1). Once this selection item has been made, the following tests will be performed internally.
1. The first diagnostic test checks for the presence of the Numeric Processor Extension
(NPX). If it is not found or if it does not initialize properly, the following error message is displayed: NPX Not Present. If no errors are found, the next test is performed.
2. The NPX Control Operations Test verifies that the NPX can be set-up with proper options and the loading and unloading of the NPX registers (stacks) are working properly. If the test is successful, the next test is performed; otherwise the following error message is displayed: NPX Cntrl/Status Failure.
3. The NPX Arithmetic Operations Test verifies that the NPX performs basic arithmetic functions correctly. If the test is successful, the next test is performed, otherwise the following error message is displayed: NPX Arith. Oper. Fail.
4. The fourth test verifies that the NPX performs the transcendental operations properly.
If the test is successful the next test is performed, otherwise the following error message is displayed: NPX Transc. Oper. Fail.
5.
The next test to execute is the NPX Exception Generation Test. It verifies that the NPX handles the exceptions when they are masked. If the test is successful, the next test is performed, otherwise the following error message is displayed: NPX Except. Gener. Fail.
6. The final test verifies that the NPX generates the correct interruptions as the result of unmasked exceptions, and that the interrupt handling is correct. If the NPX Exception
Interrupt Generation test is successful, a success message is displayed at the PC indicating that all Floating Point Coprocessor tests have been completed successfully.
Otherwise, the following error message is displayed: NPX Except. Inter. Fail.
Note 8: This test applies to controllers running ACCOL 5.0 or later versions. This test does not apply to RIO 3331.
D4041A 33XX, CW_XX & 3305 CPU and Peripherals / 2-7
BLANK PAGE
Chapter 3
33XX, CW_10, CW_30 CW_35 & 3305 Memory
3.1 33XX & CW_XX MEMORY INTRODUCTION
Each 33XX or CW_XX controller has a mixture of PROM and RAM memory to support both the firmware and the ACCOL software. The PROM/RAM Diagnostic Menu shown in Figure
3-1 is accessed from the Diagnostic Test Category Menu described in Chapter 1 (Figure 1-
7).
Figure 3-1 - PROM/RAM Diagnostic Menu (see note 1)
Note 1: Note: The RAM test is a destructive test…doesn’t apply to CW_10,CW_30 or CW_35 units.
The RDC must be reset and downloaded upon completion of the test.
D4041A 33XX, CW_XX & 3305 Memory /3-1
3.2 PROM DIAGNOSTIC TEST
PROM diagnostic testing is done by calculating a checksum on the PROM contents and comparing it against a checksum stored in the PROMs when they were programmed. The
PROM diagnostic is designed to test both the firmware EPROMs and, if present, the
ACCOL EPROMs or CUSTOM EPROM on a single execution of the test. Any failure will identify the failing hardware.
After setting the Number of Passes, click on the "RUN PROM Diagnostic" button to begin the test. After the test is completed, one of the following responses will be displayed under the STATUS column.
Success
Fail - System PROM Failure
- Custom PROM Failure (doesn’t apply to CW_XX units)
- ACCOL PROM Failure (see note 2) (doesn’t apply to CW_XX units)
Note 2: Requires RMS02 or later for ACCOL FLASH diagnostic in 386EX Real/Protected Mode.
For 386EX Real/Protected Mode based 3310/30/35 units and 186-based 3310/30/35, any system firmware failures will be reported as System PROM Failure.
A Custom EPROM Failure applies to 386EX Real/Protected Mode based units and the latest 186-based units in which the Custom EPROM data is included in the same EPROM device with the system firmware. This failure also applies to older 186-based units with system firmware revision AC.10 or later, which have a custom application EPROM installed in socket U3B for DPC 3330 CPU Engines. In all cases, this EPROM is tested separately from the system firmware.
An ACCOL PROM Failure message indicates a problem with the ACCOL load in FLASH or, for 186-based units, a problem with the optional EPROMs that incorporate the ACCOL load. In the original DPC 3330 the ACCOL EPROMs reside on a piggy-back memory board which connects to the CPU Engine Board. For the latest DPC 3330/35/10 units, ACCOL
PROMs replace RAM chips. In all cases, jumper and/or switch settings must be set to indicate the presence of ACCOL EPROMs. Check the hardware manual for your controller for details and to verify that your 33XX unit is correctly configured.
Normally a system PROM or ACCOL PROM failure would be detected during the Self-test diagnostics executed when a 33XX Controller is reset and the unit would not accept a download or execute an EPROM resident ACCOL load. For 386EX Real/protected Mode, if the unit reports an ACCOL PROM self test failure, resetting the unit again will bypass the error and the unit will wait for download to reprogram the ACCOL FLASH. The PROM
Failure would be indicated via a special pattern in the Failure LEDs. A Custom PROM Selftest Failure indicates a warning pattern in the LEDs, but does not prevent the unit from running. (For more details on self-test LED patterns, see the hardware manual for your
33XX Controller). If a unit passes the self-test diagnostics, but shows a PROM failure in the
Off-Line PROM diagnostics, it indicates an intermittent hardware problem that is affecting the EPROMs. ( Note: A unit configured with an EPROM resident ACCOL load cannot accept the standard diagnostic load file; therefore, off-line diagnostics may not be executed consistently. All ACCOL tasks should be stopped by setting their Rate Signal to 0.0 before attempting to execute the off-line diagnostics ).
D4041A 33XX, CW_XX & 3305 Memory /3-2
3.3 RAM DIAGNOSTIC TEST
This test verifies that each bit of read/write memory can be written and read correctly and that each memory location can be addressed without adversely affecting another memory location. For 33XX units, this test checks all installed RAM memory including the RAM on the processor board, as well as RAM located on a RAM Expansion board. For CW_10 ,
CW_30 and CW_35 units, this test checks all RAM installed on the unit’s CPU Board. Any failures are reported by giving the full address of the failing location which enables isolating the failure to the board and chip level.
NOTE
Executing the RAM test destroys the contents of the 33XX memory. For 186-based 33XX units using firmware AF.01 or earlier, in order to conduct any further diagnostic testing, the unit must be reset and redownloaded. For 186-based 33XX units having firmware AG.00 or later and 386EX Real/Protected Mode based units, the unit will be automatically reset and will require a redownload for any further diagnostic testing.
3.3.1 RAM Testing of 33XX Units
For 33XX units using firmware AF.01 or earlier (applicable to 186-based units only):
The "Number of Passes" field does not apply. Once installed, this test will run continuously until it is stopped by resetting the 33XX.
To start the test, click on the "RUN RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
Success
Fail - XXXX:YYYY where XXXX is the segment of the failed location and YYYY is the offset.
Because the RAM test overwrites the ACCOL diagnostic load, normal communications with the PEI are disrupted and it is normal to see "Timeout This Transmission" and "Still
Waiting For RAM Diagnostic Return Message" on the status line of the PC. As long as these messages continue to be generated, no fault is indicated. At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
The time to complete a cycle is dependent on the total RAM installed and the clock speed of the processor. Each 64K of RAM requires approximately 90 seconds in a 6 MHz unit, approximately 45 seconds in a 12 MHz unit, and approximately 23 seconds in a 20 MHz unit. A unit having 128K of RAM would thus require 3 minutes in a 6 MHz unit, 1.5 minutes in a 12 MHz unit and 45 seconds in a 20 MHz unit before it would respond to the
PC with status. For a unit with additional RAM, adjust the figures accordingly.
If a failure is reported, the address indicates the board where the failing RAM resides as shown in table 3-1. Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, push the red reset button on the
33XX unit or click on the "ABORT RAM Diagnostic" button. Return to the PROM/RAM
Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first select "Return to Menu"
D4041A 33XX, CW_XX & 3305 Memory /3-3
before it will exit from the PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the 33XX.
If you want to execute further diagnostic testing, you must download the 33XX with the appropriate ACCOL diagnostic load file as described in chapter 1.
Table 3-1 - RAM Diagnostic Failure Identification (see note 4)
Segment Offset DPC 3330
3000
3000
4000 - 7000
8000 - B000
0000 - 0FFF CPU Engine
1000 - FFFF CPU Engine any any
Memory Board
N/A
Note 4: The RAM Expansion Board for the DPC 3330 requires AC.10 Release firmware or later.
See Table 3-3 or 3-4 for location of RAM on a 3305, 3310 or 3335, or the latest 3330.
For 386EX Real/Protected Mode and 186-based 33XX units using firmware AG.00 or later:
To start the test, enter the desired "Number of Passes" then click on the "RUN RAM
Diagnostic" button. The number of passes options are:
• A numerical count
• CR (Continuous/Repeat on Error)
• CS (Continuous/Stop on Error)
VISUAL INDICATION (For 386EX Real Mode or 186-based 33XX Units
LEDs 1-6 on the 33XX CPU board provide information on the RAM test as it is being executed. LEDs 5 and 6 flash in an alternating pattern while testing is in progress and
LEDs 1 through 4 indicate the segment address (in Hex) which is being tested (see
Table 3-3). LEDs 5 and 6 flash at a faster rate when testing segments 2000 and 3000.
When a full test pass is completed (all segments tested), or if an error is detected, LEDs
5 and 6 will stop flashing and LEDs 1 through 4 will indicate the segment address where testing stopped (either the last segment or the segment failed).
VISUAL INDICATION (For 386EX Protected Mode 33XX Units
LEDs 1-6 on the 33XX CPU board provide information on the RAM test as it is being executed. LEDs 5 and 6 flash in an alternating pattern while testing is in progress and
LEDs 1 through 4 indicate the address range which is being tested (see Table 3-4).
When a full test pass is completed (all segments tested), or if an error is detected, LEDs
5 and 6 will stop flashing and LEDs 1 through 4 will indicate the segment address where testing stopped (either the last segment or the segment failed).
When LEDs 5 and 6 stop flashing, status is also sent to the PC and one of the following responses should appear under the STATUS column:
Success 0XXXK RAM Fail YYYY:ZZZZ where,
XXX is the size of the RAM that was tested successfully (see note 5) or
YYYY is the segment address of the failed location and
ZZZZ is the offset address of the failed location.
D4041A 33XX, CW_XX & 3305 Memory /3-4
Note 5: For 186-based units, verify that the size of the RAM that was tested successfully matches the size of the RAM installed in your unit. For 386EX Real Mode controllers, the RAM size is always 508K.
NUMBER OF PASSES AND RESET ACTION - Termination of the RAM diagnostic varies depending on what is entered in the "Number of Passes" field. In all cases, testing can be stopped by clicking on the "ABORT RAM Diagnostic" or "Return To Menu" buttons at the PC, or the Reset button on the 33XX.
CR (Continuous/Repeat after Error) - the RAM test will run continuously, reporting status as described above at the completion of each full pass or when an error is detected. The display will indicate the Pass Count, Number of Failures, and the status last reported at the PC.
Numerical Count - the 33XX will perform the specified number of test passes, reporting status as described above at the end of each full pass or whenever an error is detected.
When the pass count expires, the unit will automatically reset itself. The display will indicate the Pass Count, Number of Failures, and the status last reported to the PC. The message "RAM test completed, RTU has reset and ready for download" will appear at the bottom of the PC screen.
NOTE
For both CR and Numerical Count, the Number of Failures field will indicate if any failures occurred; however, the failure location information may be overwritten if a subsequent pass is successful. If intermittent failures occur, set the Number of Passes to
CS to retain the failure information.
CS (Continuous/Stop after Error) - the 33XX will run continuously, reporting status as described above at the completion of each full pass or when an error is detected. After reporting a failure it will automatically reset itself and the display will indicate the Pass
Count and the address of the location where the failure was detected. In this case the
Number of Failures will be 1.
NOTE
In certain situations the unit may not automatically reset even though testing has stopped. If this occurs, use the [Abort RAM Diagnostic] or [Return to Menu] buttons, or press the Reset button at the 33XX. Remember to first save or record any needed information that is on the display.
TIMING - Because the RAM test overwrites the ACCOL load, communications with the
PEI are disrupted and it is normal to see "Timeout this Transmission" or "Still Waiting for
RAM Diag Return Message" on the status line of the PC. As long as these messages continue to be generated, no fault is indicated. Status should be returned from the 33XX to the PC at the end of each pass of the RAM diagnostic or when an error is detected, as described earlier.
The time to complete a cycle is dependant on the total RAM installed and the clock speed of the processor. Table 3-2 shows timing to test RAM in different types of 33XX controllers.
Table 3-3 shows the LED pattern displayed (for 186-based and 386EX Real Mode-based
33XX units) when the RAM diagnostic is active, indicating the segment being tested. It also shows on which board the segment is located. The segment: Offset of a failed memory location is displayed at the PC.
D4041A 33XX, CW_XX & 3305 Memory /3-5
Table 3-2 - RAM Test Timing
Time to Test Each
RAM Segment
Segment
Size
Total Time - (Test Start
to Response to PEI)
186-based
12MHz w/128K of RAM
186-based
12MHz w/504K of RAM
186-based
20MHz w/128K of RAM
386EX Real Mode based
24MHz w/508K of RAM
45 Seconds
45 Seconds
23 Seconds
14 Seconds
64K-byte
64K-byte
64K-byte
64K-byte
1.5 Minutes
6 Minutes
45 Seconds
1.83 Minutes
386EX Protected Mode
24MHz
1.5 Minutes .5M-byte See Note below:
Note: For a unit with additional RAM, adjust Table 3-2 figures accordingly.
Table 3-3 - RAM Diagnostic Failure ID (For 186 & 386EX Real Mode-based Units)
Segment Offset
LED
Pattern
4-3-2-1
Location Of Memory
Original Current
DPC 3330 3305/10/30 3335
2000
3000
4000
5000
6000 any any any any any
0 0 1 0
0 0 1 1
0 1 0 0
0 1 0 1
0 1 1 0
CPU Engine CPU Engine CPU Module
CPU Engine CPU Engine CPU Module
Exp.Mem.Bd CPU Engine CPU Module
Exp.Mem.Bd CPU Engine CPU Module
Exp.Mem.Bd CPU Engine *
7000 any 0 1 1 1 Exp.Mem.Bd CPU Engine *
8000**
9000** any any
1 0 0 0
1 0 0 1
N/A
N/A
CPU Engine CPU Module
CPU Engine CPU Module
Note: * = Only present in 386EX Real Mode 3335 units and RTU 3305s.
Note: ** = Segments 8000 & 9000 apply only to 386EX Real Mode units and RTU 3305s.
Note: The RIO 3331 unit has 64K of RAM (Segment 2000). The RAM test defaults to continuous operation with no LED display or return of size information on test com-pletion. The unit must be manually reset on test completion. After reset, the Watchdog LED will remain active until the RIO 3331 receives configuration information from a host unit.
Table 3-4 shows the LED pattern displayed (for 386EX protected Mode-based 33XX units) when the RAM diagnostic is active, indicating the address range being tested. It also shows on which board the RAM is located. The RAM address range of a failed memory location is displayed at the PC.
Table 3-4 - RAM Diagnostic Failure ID (For 386EX Protected Mode-based Units)
Address
Range
LED
Pattern
4-3-2-1
.5 to 1M 0 0 0 1
1M to 2M 0 0 1 0
2M to 3M 0 1 0 0
3M to 4M 0 1 1 0
4M to 5M 1 0 0 0
Location Of Memory
3310/30 3335
CPU Engine CPU Module
Exp. Mem. Bd Exp. Mem. Bd
Exp. Mem. Bd Exp. Mem. Bd
Exp. Mem. Bd Exp. Mem. Bd
Exp. Mem. Bd Exp. Mem. Bd
D4041A 33XX, CW_XX & 3305 Memory /3-6
3.3.2 RAM Testing of CW_10 and CW_30 and CW_35 Units
Set the "Number of Passes" field to a number from 1 to 256 or to either "Continuous/Repeat
After Error" or "Continuous/Stop After Error." If a "Continuous" selection is made, the test will run continuously until it is stopped by selecting "ABORT Diagnostic Test."
To start the test, click on the "RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
Pass is indicated by: Size X.XMB
Current where X.X is the size of RAM given in MB.
Failure is indicated by: Fail - YYYYYYYY where YYYYYYYY is the address that failed.
At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, click on the "ABORT RAM
Diagnostic" button. Return to the PROM/RAM Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first click on the "Return to Menu" button before it will exit from the
PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the
CW_10, CW_30 or CW_35 .
D4041A 33XX, CW_XX & 3305 Memory /3-7
BLANK PAGE
Chapter 4
33XX & 3305 Communications
4.1 33XX COMMUNICATIONS INTRODUCTION
This chapter provides communications diagnostic tests associated with standard BBI serial communication ports (A, B, C, D, G, H, I, J, BIP1 & BIP2) and the Ethernet port. Section
4.2 details test associated with RS-232/485 and EIA-562 serial communication ports, while
Section 4.3 provides information on tests associated with the Ethernet CPU Board's Ethernet circuitry.
33XX Quick Reference Guides and Communication Port Identification Diagrams are provided at the end of this chapter to facilitate switch and jumper settings required for communication port testing (see Section 4.4).
4.2 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 4-3), verify the operation of the Serial Communications Controller (SCC) and associated interfaces for the
33XX serial communications ports. Testing is done in both a polled environment where the
SCC chip is interrogated for event status, and in an interrupt-driven environment where the SCC chip presents an interruption to the firmware to report events. Each SCC can control two ports. The ports are paired as follows:
BIP1/BIP2 - 32 Bit CPU Board (386EX Real/Protected Mode only)
A/B
C/D
A/B
C/D
A/B/G/H
- 3330/35 Comm. Engine Board or 3310 MFIB
- 3330/35 Comm. Engine Board or 3310 MFIB
C/D/I/J
A
B/C/D -
-
-
-
-
-
3330/35 2 Port Enhanced Comm Board (Socket #1)
3330/35 2 Port Enhanced Comm Board (Socket #2)
3330 4 Port Enhanced Comm. Board (Socket #1)
3330/35 4 Port Enhanced Comm. Board (Socket #2)
3305 Power Supply/CPU Board
3305 Multifunction I/O Board
4.2.1 Hardware Setup For Serial Comm. Ports
These tests use a loop-back technique to verify correct operation of the port being tested.
For most units, loop-back mode is set with switches on the board where the port is located.
For the 3310, there are no switches and an external loop-back plug is required as detailed in section 4.2.1.1.
Tables 4-1 & 4-2 provide the applicable switch settings and port locations for units supporting loop-back mode.
RS-485 Comm. Ports BIP1, BIP2 (3310, 3330 and 3335), A/C, B/D, G/I and H/J (3330), A/C,
B/D, I and J (3335) requires the use of a Network Interface Box with loop-back testing (see
Figure 4-1).
D4041A 33XX & 3305 Communications 41
(for BIP1/BIP2 and Enhanced Comm. Bd. RS-485 Ports)
(Loop-Back via DIP-Switch Not Employed - Disregard settings in Table 4-1)
Note: If NIB is not used and Loop-back is performed via DIP-Switch, failure may occur at
38.4 Kbaud.
Figure 4-1 - 3310/30/35 RS-485 Port Loop-back Test Diagram
Table 4-1 - Loop-back Mode Switch Settings (see Note 1)
Ports
BIP1
BIP2
Controller
386EX*
386EX*
Switch
SW3
SW4
Location
CPU Board
CPU Board
Setting (ON)
Bold = RS-485
(OFF)
2 , 3, 4, 7 & 8
2 , 3, 4, 7 & 8
A/C
A/C
A/B/C
D
B/D
B/D
G/I
H/J
186/386EX*
186/386EX*
186 (3305)
186 (3305)
186/386EX*
386EX*
386EX Protected Mode
386EX Protected Mode
SW1
SW1
SW1
SW1
SW2
SW3
SW2
SW4
Comm Engines
392094-01-0, 392031-01-9,
392002-XX-X, 392043-01-7
& 392058-01-4
Enhanced Comm Bd.
PMPP Bd.
Multifunction I/O Bd.
Comm Engines
392094-01-0, 392031-01-9,
392002-XX-X, 392043-01-7
& 392058-01-4
Enhanced Comm Bd.
Enhanced Comm Bd.
Enhanced Comm Bd.
2 - 6 = RS-232
7 - 12
1, 2 , 3, 4, 7 & 8
(see Table 4-2)
6, 7 & 8
1 - 6 = RS-232
7 - 12
1, 2 , 3, 4, 7 & 8
1, 2 , 3, 4, 7 & 8
1, 2 , 3, 4, 7 & 8
* = Real or Protected Mode
** = Settings in Bold = OFF for RS-485, otherwise for RS-232 & RS-485 settings are ON
Note 1: Record the switch settings (normal operation) before changing them to facilitate restoration of normal operation when testing is completed.
Table 4-2 - 3305 RTU PMPP Board Switch SW1 Loop-back Assignments
Port ID
Port C
Port C
Port C
Switch #
1
2
3
On Definition
TXD to RXD Loop-back
RTS to CTS Loop-back
DTR to DCD Loop-back
D4041A 33XX & 3305 Communications 42
Table 4-2 - 3305 PMPP Board Switch SW1 Loop-back Assignments (Continued)
Port ID
Port B
Port B
Port B
Port A
Port A
Switch #
4
5
6
7
8
On Definition
TXD to RXD Loop-back
RTS to CTS Loop-back
DTR to DCD Loop-back
TXD to RXD Loop-back
RTS to CTS Loop-back
4.2.1.1 Serial Comm. Port External Loop-back Plug
If you have a 3310 (either 386EX Real/Protected Mode based or 186-based) you must use an external loop-back plug instead of setting switches. This applies to any unit that does not have switches for loop-back. If you are testing communications on a 3330 Redundant
System (the full procedure is described in Chapter 13 3330 Redundant System), you must use a 9-pin external loop-back plug at the Redundancy Switch Panel (RSP).
This plug will work for 3330 Redundancy Switch Panel diagnostic testing of asynchronous communications on ports configured for RS-423. When testing a port configured for RS-485
(a requirement for synchronous communications) the appropriate configuration switches on the CPU or Comm. Engine Boards must be set for RS-485 loop-back (see Table 4-1).
Figure 4-2 - 33XX Loop-back Plugs
4.2.2 Serial Communication Port Selection
Operation of BIP1 (386EX Real/Protected Mode) or Port A (all other units) is automatically verified since it is already connected to the PC during diagnostic testing. The PC port should NOT, therefore, be selected as the "Port to Test." If you start the Communications
Diagnostic on the PC port you will lose communications with the PC and will have to reset and download the 33XX again. The port to be tested is selected by entering a letter (A, B, C,
D, G, H, I or J) or a number (1 for BIP1 & 2 for BIP2) at the "Port to Test" field. Note:
Ports G, H, I and J are only available with Protected Mode CPUs.
D4041A 33XX & 3305 Communications 43
4.2.3 Serial Communication Port Baud Rate Selection
Position the cursor at the jog point immediately to the right of the words "Baud Rate to
Test." Click on this jog point to display the available baud rate selections. You can choose one specific baud rate for testing, or you can test all asynchronous baud rates in every test cycle by positioning the selection to "ALL ASYNC." The SYNC option (see note 2) is a separate test and may not apply to all ports depending on your hardware and firmware levels.
Figure 4-3 - Communications Diagnostic Menu
Note 2: For 186-based 33XX Controllers, Synchronous mode is available in ACCOL 5.0 and later versions in units running at 12 MHz or higher. A port must be configured for RS-485 communications to run the synchronous mode test. For 386EX Real/Protected Mode based
33XX Controllers, Synchronous mode is not available for Ports BIP1, BIP2, H and J.
4.2.4 Serial Communication Port Diagnostic Test Execution
Set the Number of Passes, Port designation, and baud rate. Make sure that the proper switches are set (or, if applicable, that the loop-back plug is installed at the port.) Click on
D4041A 33XX & 3305 Communications 44
the "RUN External loop-back" button. The test will proceed and return one of the following responses under the STATUS column (see note 3):
Success
Fail Polling Asynch Failure
Interrupt Asynch Failure
Sync Failure
RTS/CTS Failure
Comm Engine 2 not detected
Configuration Error
If you select Port C or Port D on the DPC 3330/35 Controller, but do not have a second
Communications Engine Board installed, the "Comm Engine 2 not Detected" message will be displayed (see note 3).
If the "RTS/CTS Failure" message is displayed, ensure that the loop-back switches or plug are configured correctly.
When you have finished with communications port testing, be sure to return the switch settings on the board to their original positions (or remove the loop-back plug).
Note 3: For 186-based 33XX Controllers messages may vary slightly for software versions earlier than
5.0 or different firmware versions. All messages are not applicable to all units.
4.3 ETHERNET PORT DIAGNOSTICS
The Ethernet Diagnostic menu of Figure 4-4 can be entered from either the Communication
Diagnostic Menu (Figure 4-3) or the Diagnostic Test Category Menu (Figure 1-7). This menu provides four poke points; three associated with Ethernet circuitry test and one that provides the Return Hardware Address (which resides in EEPROM). These tests verify the operation and integrity of the PCNET (Ethernet) Controller and the Ethernet port hardware on the Ethernet CPU Board.
4.3.1 Ethernet Port Hardware Setup
To perform either the AUI Port (Attachment Unit Interface, 15-conductor D-Type Port) or
Twisted Pair (10Base-T, RJ45 Port) loop-back test, hardware associated with the port in question must be properly configured.
4.3.1.1 Attachment Unit Interface (AUI) Port Hardware Setup
The AUI Port must be connected to an Ethernet Media Attachment Unit (MAU) that draws less than 120mA at 12Vdc. The MAU provides a BNC coaxial (10BASE2) interface to the
Ethernet. To configure the MAU for loop-back testing, the coaxial connections to the associated BNC T-connector must be disconnected and two (2) 50 Ohm BNC terminators must be installed on the BNC T-connector. Once the MAU has been configured, the "Loopback out AUI port" test can be activated. If the “ RUN Loop-back out AUI port ” test is initiated while the MAU is attached to the Ethernet backbone, a Failures Status will be posted.
D4041A 33XX & 3305 Communications 45
Figure 4-4 - Ethernet Diagnostic Menu
4.3.1.2 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup
The 10Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub. To configure the system for the "Loop-back out twisted pair" test, either remove the standard
RJ-45 cable from the CPU Board's RJ-45 connector and replace it with a loop-back plug, or remove the RJ-45 cable associated with the port in question from the hub and install the unterminated end into an RJ-45 Jack configured for loop-back. Table 4-3 provides the pin identification and description for the RJ-45 port. Pin-1 (TX+) must be connected to Pin-3
(RX+) and Pin-2 (TX-) must be connected to Pin-6 (RX-) for proper loop-back test configuration.
If the "RUN Loop-back out twisted pair " test is initiated while the port is attached to an
Ethernet Hub, a Failures Status will be posted.
D4041A 33XX & 3305 Communications 46
Table 4-3 - Ethernet 10Base-T (RJ-45) Connector Pin Assignments
Pin # Pneumonic
1
2
TX+
TX-
5
6
3
4
7 & 8 -
-
RX+
-
RX-
Description
Transmit Data+
Transmit Data-
Receive Data+
Not Connected
Not Connected
Receive Data-
Not Connected
4.3.2 Ethernet Port Diagnostic Test Execution
There are four unique test selections (Test Buttons) provided on the Ethernet Diagnostic
Menu. These buttons are discussed below.
4.3.2.1 Chip Internal Loop-back Test RUN Button
Set the Number of Passes. Click on the "RUN Chip internal loop-back " button. The test will proceed and will return one of the following responses under the STATUS column:
Success
Fail No Hardware Present
Error Information Returned
4.3.2.2 Loop-back Out AUI Port & Loop-back Out Twisted Pair Test RUN Button
Set the Number of Passes. In the case of the AUI Port test, make sure that BBI MAU
Jumper Plug (JP1) is set in position 2-3 (its normal operating position) and that the MAU has been properly configured (see Section 4.3.1.1). In the case of the Twisted Pair Port test make sure that the port is properly configured with a cable or jack for loop-back testing (see
Section 4.3.1.2). Click on the appropriate test button. The test will proceed and return either 'Success' or one of the following responses under the STATUS column:
Fail No Hardware Present
Loop-back Send Failed
Loop-back Receive Failed
Loop-back Compare Failed
Error Information Returned
When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., in the case of the Twisted Pair port
(RJ45) disconnect the loop-back cable or jack-plug and reconnect the Ethernet cable to both the Ethernet CPU Board and the Ethernet Hub, and in the case of the AUI Port remove the
50 Ohm terminators and the BNC Tee Connector and re-install the Ethernet coaxial cable to the MAU .
4.3.2.3 Return Hardware Address Test RUN Button
Set the Number of Passes. Click on the "RUN Return hardware address" button. The test will proceed and if successful the hardware address will be displayed. The hardware
D4041A 33XX & 3305 Communications 47
address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all Ethernet
CPU Boards. The remainder of the hardware address is unique for each board manufactured and is stored in EEPROM. If the error message "Error Information
Returned" is displayed instead of the hardware address, and the unit has been programmed with a proper hardware address, the Ethernet CPU Board should be replaced.
4.3.3 Ethernet Port Diagnostic Error/Failure Messages
If either a "No Hardware Present" or "Error Information Returned" message is displayed, ensure that the loop-back test requirements have been properly established (see Section
4.3.1.1 for AUI port or Section 4.3.1.2 for Twisted Pair port). If test requirements have been met and the cable associated with the port test in question is known to be good (and in the case of the AUI port, the MAU unit is known to be good), the Ethernet CPU Board should be replaced with a good unit.
In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare
Failed" message, check the cable in question (and in the case of the AUI port, check the
MAU unit). If the cable associated with the port test in question is known to be good (and in the case of the AUI port, the MAU unit is known to be good), the Ethernet CPU Board should be replaced with a good unit.
4.4 COMM. PORT IDENTIFCATION & SETUP
Quick Reference Guides and Communication Port Identification Diagrams are provided herein to facilitate setup and testing of the various communication ports. Table 4-4 provides a listing of Quick Reference Guides while Table 4-5 provides a listing of Comm. Port
Identification Diagrams.
Table 4-4 - Listing of Quick Reference Guides & Comm. Port I.D. Diagrams
Quick Reference Guides
RTU 3305 Quick Reference Guide
DPC-3335 & RIO-3331 Obsolete Comm. Board
Quick Reference Guide
DPC-3335 & RIO-3331 Enhanced Comm. Board
Quick Reference Guide
DPC-3335 CPU Engine (Intel 80186)
Quick Reference Guide
DPC-3335 CPU Engine (Intel 80386)
Quick Reference Guide
DPC-3335 Comm. Port Quick Reference Guide
DPC-3330 & RED-3332 Obsolete Comm. Board
Quick Reference Guide
DPC-3330 & RED-3332 Enhanced Comm. Board
Quick Reference Guide
DPC-3330/RTU-3310 CPU Engine (Intel 80186)
Quick Reference Guide
DPC-3330/RTU-3310 CPU Engine (Intel 80386)
Quick Reference Guide
RTU-3310 Multi-Function Interface Board
Quick Reference Guide
Figure #
4-6
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-19
D4041A 33XX & 3305 Communications 48
Table 4-5 - Listing of Comm. Port Identification Diagrams
Comm. Port I.D. Diagrams
RTU-3310 Comm. Ports E & F Identification Diagram
RTU 3305
DPC-3330 Comm. Port I.D. Diagram
(CPU with On-board BIP1/BIP2)
DPC-3330 Comm. Port I.D. Diagram
(Ethernet CPU with Off-board BIP1/BIP2)
RTU-3310 Comm. Ports A, B, C & D I.D. Diagram
(RTU 3310 with Through-hole MFIB Board)
RTU-3310 Comm. Ports A, B, C & D I.D. Diagram
(RTU 3310 with Surface Mount MFIB Board)
Figure #
4-5
4-6
4-17
4-18
4-20
4-21
D4041A
Figure 4-5 - RTU-3310 Comm. Ports E & F Identification Diagram
33XX & 3305 Communications 49
D4041A
Figure - 4-6 - RTU 3305 Quick Reference Guide
33XX & 3305 Communications 410
D4041A
Figure 4-7 - RTU 3305 Comm. Port Identification Diagram
33XX & 3305 Communications 411
Figure 4-8 - DPC-3335 & RIO-3331 Obsolete Comm. Board Quick Reference Guide
D4041A 33XX & 3305 Communications 412
Figure 4-9 - DPC-3335 & RIO-3331 Enhanced Comm. Board Quick Reference Guide
D4041A 33XX & 3305 Communications 413
Figure 4-10 - DPC-3335 CPU Engine (Intel 80186) Quick Reference Guide
D4041A 33XX & 3305 Communications 414
Figure 4-11 - DPC-3335 CPU Engine (Intel 80386) Quick Reference Guide
D4041A 33XX & 3305 Communications 415
D4041A
Figure 4-12 - DPC-3335 Comm. Port Quick Reference Guide
33XX & 3305 Communications 416
D4041A
Figure 4-13 - DPC-3330 Obsolete Comm. Board Quick Reference Guide
33XX & 3305 Communications 417
Figure 4-14 - DPC-3330 Enhanced Comm. Board Quick Reference Guide
D4041A 33XX & 3305 Communications 418
D4041A
Figure 4-15 - DPC-3330/RTU-3310 CPU Engine (Intel 80186)
Quick Reference Guide
33XX & 3305 Communications 419
D4041A
Figure 4-16 - DPC-3330/RTU-3310 CPU Engine (Intel 80386)
Quick Reference Guide
33XX & 3305 Communications 420
D4041A
Figure 4-17 - DPC-3330 Comm. Port I.D. Diagram
(CPU with On-board BIP1/BIP2)
33XX & 3305 Communications 421
D4041A
Figure 4-18 - DPC-3330 Comm. Port I.D. Diagram
(Ethernet CPU with Off-board BIP1/BIP2)
33XX & 3305 Communications 422
Figure 4-19 - RTU-3310 Multi-Function Interface Board Quick Reference Guide
D4041A 33XX & 3305 Communications 423
Figure 4-20 - RTU-3310 Comm. Ports A, B, C & D Identification Diagram
(RTU 3310 with Through-hole MFIB Board)
D4041A 33XX & 3305 Communications 424
Figure 4-21 - RTU-3310 Comm. Ports A, B, C & D Identification Diagram
(RTU 3310 with Surface Mount MFIB Board)
D4041A 33XX & 3305 Communications 425
BLANK PAGE
Chapter 4A
CW_10, CW_30 & CW_35 Communications
4A.1 CW_10/30/35 COMMUNICATIONS INTRODUCTION
This chapter provides communications diagnostic tests associated with standard Bristol serial communication ports [A (1), B (2), C (3), D (4), G (7), H (8), I (9), J (10), BIP1 (5) &
BIP2 (6)] and the Ethernet ports. Section 4A.2 details test associated with RS-232/485 serial communication ports, while Section 4A.3 provides information on tests associated with the Ethernet CPU Board's Ethernet circuitry.
CW_10 , CW_30 & CW_35 Communication Port Identification Diagrams are provided at the end of this chapter to facilitate switch and jumper settings required for communication port testing (see Section 4A.4).
4A.2 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 4A-1) verify the operation of the Universal Asynchronous Receiver Transmitters (UARTs) and associated interfaces for the Control Wave_ 10 , Control Wave_ 30 or Control Wave_ 35/31 serial communications ports. Testing is done in both a polled environment (where the UART is interrogated for event status), and in an interrupt-driven environment (where the UART presents an interruption to the firmware to report events).
COM5/6 - CW_XX CPU Board
COM1/2 - CW_30 2-Port CB #1 or CW_10 MFIB
COM3/4 - CW_30 2-Port CB #2, CW_10 MFIB or CW_35 2-Port CB
COM1/2/7/8 - CW_30 4-Port CB #1
COM3/4/9/10 - CW_30 4-Port CB #2 or CW_35 4-Port CB
4A.2.1 CW_XX Hardware Setup and Testing of Serial Comm. Ports
These tests use a loop-back technique to verify correct operation of the port being tested.
For loop-back mode an external loop-back plug is required as detailed. Testing of a
Control Wave_ 10 , Control Wave_ 30 or Control Wave_ 35 serial communications port can be made with the following restrictions:
• The Wave_ XX communication port connected to the PC (running the DIAG program) must be configured for 8-bits, no parity, 1 stop bit, BSAP/ Control Wave
Designer protocol operation. This can be accomplished via user defined Soft Switches or by setting CPU Board Switch SW2-3 OFF.
• Communication port COM1 is only forced to 9600 bps operation when CPU Switches
SW2-3 and SW2-8 have both been set OFF. If required, COM1 can also be set to 9600 bps operation via user defined Soft Switches.
1.
Connect the appropriate loop-back plug (see Figure 4A-2 for RS-232 or Figure 4A-3 for
RS-485) to the port to be tested. Remember that the port connected to the PC cannot be tested. When performing an RS-485 loop-back test, the following CW_XX switches can be utilized in lieu of a Loopback Plug:
CPU Bd. – SW3 for Port 5 – CW_10, CW_30 or CW_35/31 (see Table 4A-1)
CPU Bd. – SW4 for Port 6 – CW_10, CW_30 or CW_35/31 (see Table 4A-1)
CB1
CB1
CB1
CB1
CB2
CB2
CB2
CB2
CB
CB
CB
CB
MFIB
MFIB
MFIB
– SW1 for Port 1 – CW_30 (see Table 4A-2)
– SW2 for Port 7 – CW_30 (see Table 4A-2)
– SW3 for Port 2 – CW_30 (see Table 4A-2)
– SW4 for Port 8 – CW_30 (see Table 4A-2)
– SW1 for Port 3 – CW_30 (see Table 4A-2)
– SW2 for Port 9 – CW_30 (see Table 4A-2)
– SW3 for Port 4 – CW_30 (see Table 4A-2)
– SW4 for Port 10 – CW_30 (see Table 4A-2)
– SW1 for Port 3 – CW_35 (see Table 4A-2)
– SW2 for Port 4 – CW_35 (see Table 4A-2)
– SW3 for Port 9 – CW_35 (see Table 4A-2)
– SW4 for Port 10 – CW_35 (see Table 4A-2)
– SW2 for Port 2 – CW_10 (see Table 4A-3)
– SW3 for Port 3 – CW_10 (see Table 4A-3)
– SW4 for Port 4 – CW_10 (see Table 4A-3)
Figure 4A-1 – CW_XX Communications Diagnostic Menu
Table 4A-1 – CW_10/30/31/35 CPU Board Switch SW3/SW4 Assignments
RS-485
Loopback & Termination Control (COM5 = SW3 & COM6 = SW4)
SWITCH
#
RS-485 Function
Switch ON
Setting
SW3/4-1 TX+ to RX+ Loopback/2-Wire ON - Only for Diagnostics
SW3/4-2 TX − to RX − Loopback/2-Wire ON - Only for Diagnostics
SW3/4-3 100 Ohm RX+ Termination
SW3/4-4 100 Ohm RX − Termination
ON - End Nodes Only
ON - End Nodes Only
SW3/4-7
SW3/4-8
RX+ Bias (End Nodes/Node)
RX − Bias (End Nodes/Node)
ON - 4-Wire = Both End Nodes
ON - 2-Wire = One End Node Only
ON - 4-Wire = Both End Nodes
ON - 2-Wire = One End Node Only
Table 4A-2 – CB Board Switches SW1 - SW4 - RS-485 Configuration Selections
SW1- SW4
1
2
Function
TX+ to RX+ Loopback
TX − to RX − Loopback
Setting
ON = Loopback Enabled, 2-Wire
OFF = Loopback Disabled, 4-Wire
ON = Loopback Enabled, 2-Wire
OFF = Loopback Disabled, 4-Wire
ON = Termination Installed
OFF = No Termination
ON = Termination Installed
OFF = No Termination
5 OFF
6 OFF
Termination ON = Bias Enabled
OFF = No Bias
Termination ON = Bias Enabled
OFF = No Bias
Table 4A-3 – MFIB Board Switches SW2 - SW4 - RS-485 Configuration Selections
SW1- SW4
1
2
Function
TX+ to RX+ Loopback
TX − to RX − Loopback
Setting
ON = Loopback Enabled, 2-Wire
OFF = Loopback Disabled, 4-Wire
ON = Loopback Enabled, 2-Wire
OFF = Loopback Disabled, 4-Wire
5 OFF
6 OFF
Termination
OFF = No Bias
Termination
OFF = No Bias
2.
Access the Communications Diagnostic Menu. The Communications Diagnostic Menu
(see Figure 4A-1) is accessed from the Diagnostic Test Category Menu (Figure 1-7) by highlighting the "Communications" selection and then clicking on the "Run" button at the bottom of the screen.
9-Pin Male
“D” Connector
Loop-back Plug
(Looking from rear/wire side of Plug)
5 = RTS
4 = RXD
7 = DCD
2 = TXD
6 = CTS
1 = DTR
Figure 4A-2 - RS-232 Loop-back Plug/Wires
9-Pin Male
“D” Connector
Loop-back Plug
(Looking from rear/wire side of Plug)
4 = RXD
_
3 = RXD+
2 = TXD
_
1 = TXD+
Figure 4A-3 - RS-485 Loop-back Wires
3.
Select the port to be tested, i.e., COM1, COM2, COM3, etc. at the "Port to Test" field of the Communications Diagnostic Menu (Figure 4A-1).
4.
Set the "Baud Rate to Test" field to 115200 baud or ALL ASYNC.
5.
Set the "Number of Passes" to any number from 1 to 256, or select "Continuous/Repeat after Error," or "Continuous/Stop after Error" via one of the three "Radio" buttons located near the top of the menu.
6.
Click on the "RUN External Loop-back" Test button. The Status: indication will switch from "IDLE" to "Working." If an incorrect baud rate has been set, or a port without a loopback plug has been selected, the test will fail and the message "Time Out Waiting
For Response" will be posted next to "Error Status:".
The test will proceed and return one of the following responses under the STATUS column:
Success
Fail - Polling Asynch Failure
- Interrupt Asynch Failure
- Sync
- RTS/CTS
-
Configuration Error
If the "RTS/CTS Failure" message is displayed, ensure that the loop-back plug is correctly configured and installed.
When you have finished with communications port testing, be sure to remove the loop-back plug or in the case of RS-485 ports, set the applicable switches to the normal run operation positions.
4A.3 ETHERNET PORT DIAGNOSTICS
The Ethernet Diagnostic menu of Figure 4A-4 is entered from the Diagnostic Test Category
Menu (Figure 1-7). This menu provides four poke points; three associated with Ethernet circuitry test and one that provides the Return Hardware Address (which resides in
EEPROM). These tests verify the operation and integrity of the PCNET (Ethernet)
Controller and the Ethernet port hardware on the CPU Board (for CW_30/31/35 units)
Figure 4A-4 - Ethernet Diagnostic Menu
4A.3.1 Ethernet Port Hardware Setup
To perform the Twisted Pair (10Base-T, RJ45 Port) loop-back test, hardware associated with the port in question must be properly configured.
4A.3.1.1 10/100Base-T (RJ-45 - Twisted Pair) Port Hardware Setup
The 10/100Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub.
To configure the system for the "Loop-back out twisted pair" test, either remove the standard RJ-45 cable from the CW_30/31/35 CPU Board's RJ-45 connector and replace it with a loop-back plug, or remove the RJ-45 cable associated with the port in question from the hub and install the unterminated end into an RJ-45 Jack configured for loop-back.
Table 4A-4 provides the pin identification and description for the RJ-45 port. Pin-1 (TX+) must be connected to Pin-3 (RX+) and Pin-2 (TX-) must be connected to Pin-6 (RX-) for proper loop-back test configuration (see Figure 4A-5).
If the "RUN Loop-back out twisted pair " test is initiated while the port is attached to an
Ethernet Hub, a Failure Status will be posted.
Figure 4A-5 - RJ-45 Ethernet Loop-back Plug
Table 4A-4 - Ethernet 10/100Base-T (RJ-45) Connector Pin Assignments
Pin # Pneumonic Description
1 TX+
2 TX-
3 RX+
6 RX-
Note: Pins 4, 5, 7 & 8 aren’t connected
4A.3.2 Ethernet Port Diagnostic Test Execution
There are four unique test selections (Test Buttons) provided on the Ethernet Diagnostic
Menu. The “RUN Chip internal loop-back” and the “Run Loop-back out AUI port” tests aren’t applicable to CW_30/31/35 units. The applicable buttons are discussed below.
4A.3.2.1 Loop-back Out Twisted Pair Test RUN Button
Set the Number of Passes. Make sure that the port is properly configured with a cable or jack for loop-back testing (see Section 4A.3.1.2). Click on the appropriate test button. The
test will proceed and return either 'Success' or one of the following responses under the
STATUS column:
Fail - No Hardware Present
- Loop-back
- Loop-back Receive
- Loop-back Failed
- Error Information Returned
When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jackplug and reconnect the Ethernet cable to both the CPU Board and the Ethernet Hub.
4A.3.2.2 Return Hardware Address Test RUN Button
Set the Number of Passes. Click on the "RUN Return hardware address" button. The test will proceed and if successful the hardware address will be displayed. The hardware address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all CCPU
Boards. The remainder of the hardware address is unique for each board manufactured and is stored in EEPROM. If the error message "Error Information Returned" is displayed instead of the hardware address, and the unit has been programmed with a proper hardware address, the CW_30/31/35 CPU Board should be replaced.
4A.3.3 Ethernet Port Diagnostic Error/Failure Messages
If either a "No Hardware Present" or "Error Information Returned" message is displayed, ensure that the loop-back test requirements have been properly established (see Section
4A.3.1.1 for Twisted Pair port). If test requirements have been met and the cable associated with the port test in question is known to be good, the CW_30/31/35 CPU Board should be replaced with a good unit.
In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare
Failed" message, check the cable in question. If the cable associated with the port test in question is known to be good, the CW_30/31/35 CPU Board should be replaced with a good unit.
4A.4 COMM. PORT IDENTIFCATION & SETUP
Communication Port Identification Diagrams are provided herein to facilitate setup and testing of the various communication ports. Table 4A-5 provides a listing of Comm. Port
Identification Diagrams.
Table 4A-5 - Listing of Comm. Port Identification Diagrams
Comm. Port I.D. Diagrams
CW_10 CPU Board Component I.D. Diagram
CW_10 MFIB Board Component I.D. Diagram
CW_30 CPU Board Component I.D. Diagram
CW_30 2-Port CB Board Component I.D. Diagram
CW_30 4-Port CB Board Component I.D. Diagram
CW_31/35 CPU Board Component I.D. Diagram
CW_35 2-Port CB Board Component I.D. Diagram
CW_35 4-Port CB Board Component I.D. Diagram
Figure #
4A-6
4A-7A & B
4A-8
4A-9
4A-10
4A-11
4A-12
4A-13
BIP1 = Comm. Port 5
&
BIP2 = Comm. Port 6
21
BIP1
RS-485
CONFIG.
W15 - BIP1
W22 - BIP2
W14 - BIP1
W21 - BIP2
1
{
BIP1
RTS TO CTS
BIP2
RTS TO CTS
{ 1 TO 2 = CTS Source is Port
2 To 3 = RTS to CTS Loopback
1 TO 2 = DSR on Pin-8 of D-Conn.
2 TO 3 = DTR on Pin-8 of D-Conn.
1 TO 2 = Enable Com. Status LEDs
2 To 3 = Disable Com. Status LEDs
BIP2
RS-485
CONFIG.
W9 - W13 BIP1
W16-W20 BIP2
1 TO 2 = RS-232
2 TO 3 = RS-485
SW#
SW2-1
Function
Watchdog Enable
Setting
ON = Watchdog circuit is Enabled
SW2-2
SW2-3
SW2-4
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
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 Switches Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Mode Switch (SW1)
SW2-5 SRAM Control
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
SW2-6
SW2-7
N/A
N/A
SW2-8 Enable WINDIAG
ON = Normal Operation (don’t allow WINDIAG to run test)
OFF = Disable boot project (allow WINDIAG to run test)
NOTE: Except for SW2-4, ON = Factory Default)
S1
1 TO 2 = Enable Battery Back-up
2 To 3 = Disable Battery Back-up
ON
1 2 3 4
ON
1 2 3 4 5 6 7 8
1 TO 2 = Enable Power Good Status LED
2 To 3 = Disable Power Good Status LED
PLD
JTAG
SW# Function
SW3/4-1 TX+ to RX+ Loopback
SW3/4-2 TX- to RX- Loopback
SW3/4-3 100 Ohm RX+ Termination
SW3/4-4 100 Ohm RX- Termination
SW3/4-7 RX+ Bias (End Nodes/Node)
Setting
ON - Loopback for Diagnostics (2-Wire)
OFF - Loopback Disabled (4-Wire)
ON - Loopback for Diagnostics (2-Wire)
OFF - Loopback Disabled (4-Wire)
ON - End Nodes Only
ON - End Nodes Only
SW3/4-8 RX- Bias (End Nodes/Node)
OFF - 2-Wire = One End Node Only
-
OFF - 2-Wire = One End Node Only
SW# Function
Recovery/Local
SW1-1/2
SW1-3
Mode
Force Recovery
Mode
SW1-4 Not Used
Setting
Both ON or OFF = Recovery Mode
SW1-1 OFF & SW1-2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
OFF = Recovery Mode Disabled
N/A
1 TO 2 = Enable Status LEDs
2 To 3 = Disable Status LEDs
I/O
BUS
BIP1 BIP2
Maintenance
5V IN
WATCH
DOG
CR3 CR2
UPORT
J8 = Utility Port
1
2
3
4
J8
TX
LEDs J5
RX
LEDs
Figure 4A-6 - CW_10 CPU Board Component Identification Diagram
Figure 4A-7A - CW_10 MFIB (Original Board) Component Identification Diagram
Figure 4A-7B - CW_10 MFIB (Present Board) Component Identification Diagram
Figure 4A-8 - CW_30 CPU Board Component Identification Diagram
Figure 4A-9 - CW_30 - 2-Port CB Board Component Identification Diagram
RX TX
PORT H(J) or 8(10)
PORT B(D) or 2(4)
PORT B(D) or 2(4) RS/Modem
1-2 = RS, 2-3 = Modem
STATUS LEDs
1-2 = ENABLED, 2-3 = DISABLED
PORT A(C) or 1(3)
W2, W3, W4, W5 & W8 - 1-2 = RS-232, 2-3 = RS-485
W6 - 2-3 = RTS to CTS, W7 - 1-2 = DSR, 2-3 = DTR
PORT B(D) or 2(4)
W9, W10, W11, W14 & W15 - 1-2 = RS-232, 2-3 = RS-485
W12 - 2-3 = RTS to CTS, W13 - 1-2 = DSR, 2-3 = DTR
PORT G(I) or 7(9)
W17, W18, W19, W20 & W23 - 1-2 = RS-232, 2-3 = RS-485
W21 - 2-3 = RTS to CTS, W22 - 1-2 = DSR, 2-3 = DTR
PORT H(J) or 8(10)
W24, W25, W26, W27 & W30 - 1-2 = RS-232, 2-3 = RS-485
W28 - 2-3 = RTS to CTS, W29 - 1-2 = DSR, 2-3 = DTR
RX TX
PORT G(I) or 7(9)
PORT A(C) or 1(3)
ON
1 2 3 4 5 6 7 8
PORT A(C) or
PORT 1(3)
ON
SW1 - SW4
1,2 ON = TX RX Loopback
3,4 ON = Term. Enabled
7,8 ON = Bias Enabled
ON
1 2 3 4 5 6 7 8
PORT G(I) or
PORT 7(9)
1 2 3 4 5 6 7 8
PORT B(D) or
PORT 2(4)
ON
1 2 3 4 5 6 7 8
PORT H(J) or
PORT 8(10)
TX
RX
Figure 4A-10 - CW_30 4-Port CB Board Component Identification Diagram
Figure 4A-11 – CW_35/31 CPU Module Component Identification Diagram
Figure 4A-12 - CW_35 2-Port CB Board Component Identification Diagram
Figure 4A-13 - CW_35 4 -Port CB Board Component Identification Diagram
Chapter 5
RTU 3305 I/O Tests
5.1 ANALOG I/O SETUP
RTU 3305s contain the following I/Os:
Eight Discrete Inputs (DIs) with interrupt capability
Two Discrete Outputs (DOs)
Six selectable bi-directional DI/DO points
Four Analog Inputs (AIs) - Optional
Two Analog Outputs (AOs) - Optional
One High-speed Counter Input (HSC) - ( No Test Herein )
5.1.1 Hardware Configuration
For the tests in this chapter, you will need the Digital Multimeter (DMM), the DC Voltage
Source, the Precision Current Source, two 250 Ohm ± .01% resistors and one 2.2 k Ohm ½ watt resistor described in Chapter 1. Set up for testing as follows:
1. Disconnect power from the RTU 3305.
2. Make sure that all signal wiring is disconnected from the field wiring terminals.
Information is provided within this chapter for configuring jumper settings for various tests. If necessary, refer to the appropriate section of the controller hardware manual CI-
3305 for more specific information.
3. Reapply power. If the 3305 unit was executing the DIAG load when you powered down, there is no need to reset and reload it; simply continue with proper menu selection at the PC. If you have not previously downloaded the DIAG file, refer to
Chapter 1 for the recommended procedures.
4.
You are now ready to begin testing. I/O testing is covered in the following sections:
Section 5.2 - Analog Output Testing Section 5.5 - Discrete Output Testing
Section 5.3 - Analog Input Testing Section 5.6 - Discrete Input Testing
Section 5.4 - Completing AI/AO Testing Section 5.7 - Completing DI/DO Testing
5.1.2 Menu Access
The test procedures in this chapter begin with the Diagnostic Test Category Menu (Figure
1-7). From that display, you will be asked to select from one of the following test categories:
Analog Output
Analog Input
Discrete I/O
(If you need help with this menu, see Sections 1.7.4 through 1.8.)
D4041A RTU 3305 I/O Tests / 5-1
5.1.3 Entry/Display Fields
Analog Output Diagnostic, Analog Input Diagnostic, Discrete Input/Output Diagnostic, and the High-speed Counter Diagnostic menus discussed in this chapter contain the following entry and display fields:
Number of Passes
Enter the number of test cycles you want to execute, or enter one of the Continuous Modes
(see Section 1.9.2 of Chapter 1 for details).
Board Number to Test
Enter a 1 if you are testing DIs or a 2 if testing DOs. If testing AIs or AOs the board number to test will be automatically posted as a 3 or 4 respectively. If testing the HSC a 5 will be automatically posted as the board number to test.
Board Type Returned
This field’s display will be blank or will show ??? except when testing AO logic. When testing AO logic, AO will be posted after any AO test has been initialized.
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays
‘
Working
’
or
‘
Idle
’
to indicate if a test is in process or not.
5.2 ANALOG OUTPUT (AO) TESTS
The AO tests are used to calibrate the analog outputs on the MI/OB Board, check for linearity in the Analog-to-Digital conversion, and check for AO channel interference.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Output" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu of Figure 5-1. Set the Number of Passes to 1 or Continuous (CR or CS).
5.2.1 Analog Output Circuitry Calibration
For this procedure the following items are required:
One or two 250 Ohm ± 0.01% resistor(s).
A Digital Multimeter (DMM) (see Chapter 1).
Adjustments are identified in Figure 5-2. Wiring terminals are identified in Figure 5-3.
D4041A RTU 3305 I/O Tests / 5-2
Figure 5-1 - Analog Output Diagnostic Menu
In this procedure you will be calibrating the base voltages for the 4-20 mA Analog Outputs
AO1 and AO2. Access to adjustable resistors on the MI/OB Board is provided by access holes on the PMPP Board (see Figure 5-2). The Analog Output Circuitry is calibrated as follows:
1.
For AO1, connect a 250 Ohm 0.01% resistor across terminals TB2-10 (AO1+) and
TB2-9 (AO1-). For AO2, connect a 250 Ohm 0.01% resistor across terminals TB2-12
(AO2+) and TB2-11 (AO2-) (see Figure 5-3).
2. On the Analog Output Diagnostic Menu (Figure 5-1), click on the "RUN Signal Cond.
Zero" button.
D4041A RTU 3305 I/O Tests / 5-3
Figure 5-2 - RTU 3305 Adjustable Resistors & DC Measurement Points
D4041A RTU 3305 I/O Tests / 5-4
Figure 5-3
RTU 3305 MI/OB Field Wiring Edge Connector Assignments
3. Use the DMM to measure across the field terminals associated with AO1 or AO2
(depending on which AO is being calibrated), or use it as an Ammeter in series with the 250 Ohm resistor and AO1+ and AO1- or AO2+ and AO2- and adjust the respective potentiometer (R95 for AO1 & R101 for AO2) for either +1.000V dc
" 0.001V or 4mA " 0.004mA (see Figures 5-2 & 5-3).
D4041A RTU 3305 I/O Tests / 5-5
DMM Connection
Analog TB1
Output (+) (-) Adjustment
AO1 10 = AO1-A 9 = AO1-B R95
AO2 12 = AO2-A 11 = AO2-B R101
4.
Click on the "RUN Signal Cond. Span" selection.
5. Use the DMM to measure across the field terminals associated with AO1 or AO2
(depending on which AO is being calibrated), or use it as an Ammeter in series with the 250 Ohm resistor and AO1+ and AO1- or AO2+ and AO2- and adjust the respective potentiometer (R93 for AO1 & R98 for AO2) for either +5.000V dc
" 0.001V or 20mA " 0.004mA (see Figures 5-2 & 5-3).
DMM Connection
Analog TB2
Output (+) (-) Adjustment
AO1 10 = AO1-A 9 = AO1-B R93
AO2 12 = AO2-A 11 = AO2-B R98
6.
Repeat steps 2 through 5 until both outputs are within specification.
7. Leave the 250 Ohm test resistor installed and proceed to Section 5.2.2 for calibration verification.
5.2.2 Calibration Verification
Once the base voltage calibration has been done, the following procedure determines if the
DAC is working linearly throughout the specification range.
At the PC, the "RUN Calibration" test allows you to select one of seven points to test relative to the voltage range of the analog outputs. Position the cursor at the jog point just to the right of "RUN Calibration." As you press ( ↑ or ↓ ), the seven options are displayed in turn. The option on the screen will become active when you click on the "RUN Calibration" selection.
1. With the "UNDERRANGE" option on the screen click on the "RUN Calibration" button.
2.
The DMM connection points for the calibration procedures are the same as described in Step 3 of Section 5.2.1. Verify that the DMM reads +0.800Vdc " 0.004V.
3.
At the PC, bring up the next option, and click on the "RUN Calibration" button.
Verify that the DMM reads the appropriate voltage level. The following list shows the expected voltage readings for each of the seven test settings.
UNDERRANGE - +0.800V " 4mV
0% - +1V " 4mV
25% - +2V " 4mV
50% - +3V " 4mV
75% - +4V " 4mV
100% - +5V " 4mV
OVERRANGE - +5.2V " 4mV
D4041A RTU 3305 I/O Tests / 5-6
4. Repeat Step 3 for each of the test settings.
5.
If ANY of the voltages are not within tolerance the board is in need of repair or recalibration.
6. If all measurements are within tolerance, proceed to Section 5.2.3 for interference testing.
5.2.3 Interference Test
This test helps to determine if there is interference between adjacent output channels.
1. On the Analog Output Diagnostic Menu (Figure 5-1), click on the "RUN Interference
Test" button.
2. The status of the test will be displayed as follows: for AO2/4 board: Channel 1/3 - 0% Channel 2/4 - 100%
This indicates that AO1 has been set for a 0% output and AO2 ahas been set for a
100% output. Note: For RTU 3305s, /3 and /4 have no meaning.
3. Using the DMM as a Voltmeter across the terminal points or as an Ammeter in series with the test resistor (see Figure 5-3) (as described in 5.2.1), verify that the
0% channel(s) and the 100% channel(s) read as indicated below.
0% - +1V " 4mV or 4mA " 0.004mA
100% - +5V " 4mV or 20mA " 0.004mA
4. At the PC, click on the "RUN Interference Test" button. The loading of the two AO channels will be interchanged and the display will indicate:
Channel 1/3 - 100% Channel 2/4 - 0%
This indicates that Channels 1 and 2 are applicable. Note: For RTU 3305s, /3 and
/4 have no meaning.
5.
Repeat Step 3. Any variance from the specified readings indicates interference between the adjacent outputs. The board should be repaired or replaced.
5.3 ANALOG INPUT (AI) TESTS
The AI tests are used to calibrate reference voltages, to calibrate and verify the instrumentation amplifier and to verify correct operation of the analog inputs.
For these tests, you will need the Digital Multimeter (DMM), DC Voltage Source and the
Precision Current Source described in Chapter 1.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Input" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu of Figure 5-4. Set the Number of Passes to 1 or Continuous (CR or CS).
D4041A RTU 3305 I/O Tests / 5-7
Figure 5-4 - 3305 Analog Input Diagnostic Menu
Note: Since the RTU 3305 does not have an Analog Input Instrument Amplifier calibration procedure, the RUN 0 Percent Of AI, RUN 100 Percent Of AI and the
RUN Verify Amplifier Calibration tests selections are not applicable. If any of these tests are selected, the following message will be posted under the status column: Unit Not In Diag Mode.
5.3.1 Analog Input Circuitry Offset Calibration
For this procedure you will need the Variable dc Power Supply and the Digital Multimeter
(DMM) described in Chapter 1.
Adjustments are identified in Figures 5-2. Wiring terminals are identified in Figure 5-3.
D4041A RTU 3305 I/O Tests / 5-8
In this procedure you will be calibrating the base voltages for the Analog Inputs Circuits.
Access to adjustable resistors on the MI/OB Board is provided by access holes on the PMPP
Board (see Figure 5-2). The Analog Input Offset is calibrated as follows:
1. Set MI/OB Board Jumpers W8A/B through W11A/B for 1-5V operation (see Fig. 5-2).
2. Apply 1.000 Vdc (0% Span) between TB2-2 (AI+) and TB2-1 (AI-) and adjust potentiometer R143 on the MI/OB Board (see Figures 5-2 & 5-3). From the Analog Input
Diagnostic Menu (Figure 5-4), click on the "Analog Input Display" button. The
Analog Input Display Menu will appear (see Figure 5-6). With 1.000 Vdc applied to
TB2-2 (AI+) and TB2-1 (AI-) and R143 properly adjusted, the Diagnostics program will display the correct value for AI1 as 0BA hexadecimal.
3. Apply 5.000 Vdc (100% Span) between TB2-2 (AI+) and TB2-1 (AI-) and adjust potentiometer R144 on the MI/OB Board (see Figures 5-2 & 5-3). With 5.000 Vdc applied to TB2-2 (AI+) and TB2-1 (AI-) and R144 properly adjusted, the Diagnostics program will display the correct value for AI1 as F46 hexadecimal.
4. Repeat steps 2 and 3 until the Analog Input Circuitry Offset calibration is within specification.
5. Set MI/OB Board Jumpers W8A/B through W11A/B for the desired input configuration.
5.3.2 Analog Input Termination Test
These procedures check the analog input values at the Analog Input terminal block (TB2).
These procedures include all four AIs in each test, however you may select only those tests for specific input types based on your actual configuration.
For this procedure you will need the Variable dc Power Supply, Digital Multimeter (DMM) and the Precision Current Source described in Chapter 1.
1-5V Isolated Analog Inputs
1.
Verify that jumpers W8A/B through W11A/B on the MI/OB Board are correctly configured (see Figure 5-5).
D4041A
Figure 5-5 - AI Input Range Jumper Assignments
RTU 3305 I/O Tests / 5-9
Figure 5-6 - 33XX Analog Input Display Menu
2.
From the Analog Input Diagnostic Menu (Figure 5-4), click on the "Analog Input
Display" button. The Analog Input Display Menu will appear (see Figure 5-6).
3. Connect the Voltage Source (+) to AI1-A and the Voltage Source (-) to AI1-B at TB2.
(see Figure 5-3).
4. For the input voltages shown below, the associated hex value should appear under the AI-01 heading on the display.
INPUT VOLTAGE HEX READING
+0.8V " 0.001V 000 4 = (000 - 004)
+1.0V " 0.001V
+3.0V " 0.001V
+5.0V " 0.001V
+5.2V " 0.001V
800
F46
4 = (7FB - 804)
4 = (F42 - F4A)
After each input voltage value (.8V, 1V, etc.) click on the "End Test" button at the bottom of the screen. Adjust the voltage source to the next value and then click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (see Figure
5-4).
D4041A RTU 3305 I/O Tests / 5-10
5. Move the Voltage Source to the next AI on TB2 and repeat Step 4 for each of the four/eight analog inputs, checking the hex reading under the appropriate heading.
4-20mA Isolated Analog Inputs
1. Verify that jumpers W8A/B through W11A/B on the MI/OB Board are correctly configured (see Figure 5-5).
2. Click on the "Analog Input Display" button. The Analog Input Display Menu will appear (see Figure 5-6).
3. Connect the Precision Current Source output to AI1-A and the return to AI1-B at
TB2 (see Figure 5-3).
4. For the input currents shown below, the associated hex value should appear under the AI-01 heading on the display.
CURRENT
4mA 0.004mA " 4 = (0B6 - 0BE)
20mA " 0.004mA " 4 = (F42 - F4A)
5. Set the Precision Current Source output to zero and remove it from TB2. Reconnect it to the next AI on TB2 and repeat Step 4 for each of the four/eight analog inputs, checking the hex reading under the appropriate heading.
WARNING
Be sure to set the current source to zero before removing it after each input is tested.
4-20mA Internally Sourced Analog Inputs
1.
Verify that jumpers W8A/B through W11A/B are correctly configured (see Fig. 5-5).
2. Using the DMM, measure between AI1-A and the ground (PCOM) connection at
TB3-1. The DMM should read +21V to +28V for a 12V system or +24V for a 24V system.
3.
Move the DMM to the next AI on TB2 and repeat Step 2 for each of the four analog inputs.
5.4 COMPLETING AI/AO TESTING
At the conclusion of the AO and/or AI tests, disconnect power from the RTU 3305. Any test equipment must be turned off and removed from the MI/OB Board terminals. Return all jumper settings to their original positions. Reconnect field wiring and restore operation as required.
5.5 DISCRETE OUTPUT (DO) TESTS
These tests check the discrete output circuitry of the RTU 3305’s MI/OB Board, including the output registers and the output paths to the terminal block.
D4041A RTU 3305 I/O Tests / 5-11
For the tests in this chapter, you will need the Digital Multimeter (DMM), Variable Power
Supply, and the 2.2 k Ohm resistor described in Chapter 1.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu of Figure 5-7. Set the Number of Passes field to "CR" for continuous mode.
5.5.1 Automatic Discrete Output Test
All of the DOs will be automatically sequenced for this test. Each DO will be enabled in turn for approximately 0.2 seconds. Be sure to set the Number of Passes to "CR" to provide a continuous test cycle.
1. On the MI/OB Board, verify that jumper W7 is installed in position 1-2. This enables the LEDs.
2.
On the Discrete Input/Output Diagnostic Menu (see Figure 5-7), set the Board
Number to Test to 2 and then click on the "RUN Discrete Output Sequence" button.
NOTE: No test information will be displayed on the menu.
3.
The DI/O status LEDs should sequence in a rotating pattern (see Figure 5-8). Each
DO should turn on for approximately 200 msec. Proceed to Section 5.5.2 for the
Manual Discrete Output Test.
D4041A
Figure 5-7 - Discrete Input/Output Diagnostic Menu
RTU 3305 I/O Tests / 5-12
Figure 5-8 - MI/OB Board DI/O LED Identification Diagram
5.5.2 Manual Discrete Output Test
Be sure to install MI/OB Board jumper W7 in position 1-2 to enable the LEDs and set DI/O jumpers W1 through W6 for DO operation. Construct the test setup shown in Figure 5-10.
This provides a supply source and load for the DOs.
Figure 5-9 - 3305 MI/OB Board Discrete Input/Output Jumpers
D4041A
Figure 5-10 - 3305 DO Test – Test Setup
RTU 3305 I/O Tests / 5-13
From the Discrete Input/Output Diagnostic Menu (Figure 5-7), set the Board Number to
Test to 2 and click on the "Discrete Output Display" button. The Discrete Output Display
Menu (Figure 5-11) will appear.
This screen shows the number of DO being tested (8). For each DO position a status indication of IDLE or WORKING is provided. IDLE means that WINDIAG is not testing the selected DO and WORKING indicates a WINDIAG test is in process.
Note:
No information will be displayed until a DO number is entered in the "Drive DO:" field and you press [Start Test].
Figure 5-11 - 3305 Discrete Output Display Menu
1.
On the Discrete Output Display (Figure 5-11), set the cursor at the "Drive DO:" input field, type the number "1" (for DO1), and then click on "Start Test."
2. With the test setup connected to DO1 (see Figure 5-10), verify that the DMM reads
+24 V (nominal), that the status LED (DS1) is ON and that the DO display 1 is highlighted in red.
3.
At the PC, change the "Drive DO:" input field to the next DO and then click on
"Start Test."
4. Verify that the DMM reads 0.0 V, that the status LED is OFF and that the DO1 display is a "0".
D4041A RTU 3305 I/O Tests / 5-14
5. Connect the test setup to each DO in turn, and repeat Steps 1-4 (changing the Drive
DO # from 1 to 2 etc). Note that as each DO is turned on, all other DOs will be off.
The previously tested DO # that was highlighted in red will cease to be highlighted and its associated LED will go off.
6.
At the PC, click on "End Test" to return to the Discrete Input/Output Diagnostic
Menu (Figure 5-7).
7.
Turn off and remove all test equipment. If the status LEDs aren’t normally enabled, move MI/OB Board jumper W7 to position 2-3.
5.6 DISCRETE INPUT (DI) TESTS
These tests check the DIs including the interrupt circuitry and the input paths from the
MI/OB Board’s termination block.
At the PC, highlight the "Discrete I/O" selection and click on the
“
Run
”
button at the bottom of the Diagnostic Test Category Menu (Figure 1-7). The PC will proceed to the menu shown in Figure 5-7. Set the Board Number to Test to 1.
5.6.1 DI Circuitry Test
This test verifies that all discrete inputs can be turned on and that all can be turned off. An internal DI Pattern Register (DIPR) is connected to the DIs using special hardware test circuitry. A sequence of test values is written to the DIPR and the values read from the DIs are compared with the known values written. A polling failure is reported when the values do not match.
If the above test is successful, the diagnostic program then verifies that all of the DI
Interrupt Mask Register bits can be turned on and off and that each DI generates an interrupt when it changes state if the corresponding mask register bit is on. An interrupt failure is reported when an expected interrupt does not occur or when an unexpected interrupt does occur.
At the Discrete Input/Output Diagnostic Menu (Figure 5-7), set the desired Number of
Passes and then click on the "RUN Discrete Input Circuitry" button. The test will automatically progress through all the DI circuitry and display one of the following messages:
Success
Failure
Fail - Interrupt
Interrupt
5.6.2 DI Termination Tests
A total of 14 Discrete Inputs are available. DI7-14 are dry contact inputs with 1msec filtering and DI/O1-6 (when configured for DI operation) are dry contact inputs with 30msec filtering. Inputs are internally sourced from the system power (12 or 24 V). DIs feature surge suppression. Their input range is dependent on the RTU 3305 system input power, i.e., 0-24 or 0-12 Vdc ± 10%. In addition to Dry Contact inputs from relays, switches etc., DI7 through DI14 can accept inputs from Low Speed Turbine Meters.
D4041A RTU 3305 I/O Tests / 5-15
Field connections for DI1 through DI14 are located at TB1. A Discrete Input is activated by closing the connection between the +DI and -DI terminal in question with a dry contact (see
Figure 5-3).
To configure DI/O1 through DI/O6 for DI operation the MI/OB Board Jumper associated with the DI/O in question must be set in the
“
A
”
position (see Figure 5-9).
1. On the MI/OB Board, install jumper W7 in position 1-2 to enable the LEDs.
2. On the Diagnostic Input/Output Diagnostic Display (Figure 5-7), click on the "Discrete Input Display" button. The Discrete Input Display Menu (Figure 5-12) will appear.
14
???
Figure 5-12 – 3305 Discrete Input Display Menu
3. Connect a jumper wire across the DI1 terminals at TB1 (DI1-A and DI1-B).
4. Check that the STATUS value of DI1 on the Discrete Input Display Menu changes from "IDLE" to "WORKING" and that the associated status LED (DS1) turns ON.
5. Move the jumper wire to the (+) and (-) terminals of each successive DI and verify that the STATUS of each selected DI changes from "IDLE" to "WORKING" and that its status LED turns ON. Verify that each DI status returns to "IDLE" and the status LED turns OFF following removal of the jumper.
6. Drive multiple DIs using test patterns with alternate DIs in the ON and OFF state, e.g. DI1,3,5,7 etc. ON and DI2,4,6, etc. OFF. Verify that the correct status of each is displayed in the status LEDs and on the Discrete Input Display. This verifies that individual DIs are not affected by the state of other positions.
7. At the completion of the test remove all input jumper wires from the DI Board.
D4041A RTU 3305 I/O Tests / 5-16
8. At the PC, click on "End Test" to return to the Discrete Input/Output Diagnostic
Menu (Figure 5-7).
5.7 COMPLETING DI/DO TESTING
At the conclusion of the DO and/or DI tests, disconnect power from the RTU 3305. Any test equipment must be turned off and removed from the MI/OB Board terminals. Return all jumper settings to their original positions. Reconnect field wiring and restore operation as required.
D4041A RTU 3305 I/O Tests / 5-17
BLANK PAGE
Chapter 6
ControlWaveLP
Process Automation Controller Diagnostics
6.1 Control
Wave
LP DIAGNOSTICS INTRODUCTION
This chapter describes the diagnostic testing for the Control Wave LP Process Automation
Controller. The various elements to be tested (CPU memory, communication ports, I/O circuits, etc.) are individually accessed from the Diagnostic Test Category Menu described in chapter 1 (see Figure 1-7). Control Wave diagnostic tests provide pass/fail indications to assist the service technician in determining if a module requires further service.
Communications between the Control Wave LP and the PC (equipped with BBI’s DIAG program) can be made via a Local or Network Port with the following restrictions:
• CPU Board Switch SW4-8 must be OFF to run the DIAG program. Setting SW4-8 OFF will prevent the
‘
Boot Project
’
from running and will place the unit into diagnostic mode.
• Any Wave communication port can be connected to the PC provided their port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to 9600 bps operation).
• Communication port COM1 is only forced to 9600 bps operation when CPU Switches
SW4-3 and SW4-8 have both been set OFF. COM1 can also be set to 9600 bps operation via user defined Soft Switches.
• Setting CPU Board Switches SW4-3 and SW4-8 OFF prevents the
‘
Boot Project
’
from running, places the unit into diagnostic mode and forces communication ports COM1 through COM5 to operate at 9600 baud.
• CPU Board DIP Switch SW1 must be configured for RS-232 or RS-485 operation as required. When communication with a PC in RS-485 mode, switches SW1-7 and SW1-8 must be set ON; switches SW1-3 and SW1-4 must be set OFF.
COM1: From the factory, COM1 defaults to 115.2 kbd (RS-232) using the Internet Point to
Point Protocol (PPP). Note: Control Wave LP Port COM1 will be configured for RS-
232 operation (at 9600 bps) by setting CPU switches SW4-3 and SW4-8 OFF. This will prevent the boot project from running and places the unit into diagnostic mode .
CPU Switch SW4-8 must be set OFF to run the WINDIAG program.
To test COM1 using the DIAG program, it must not be in use. Connection to a PC requires the use of an RS-232 "Null Modem" cable (see Figure 6-1).
COM2: From the factory, COM2 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. To test COM2 using the DIAG program, it must not be in use. Note: CPU Switch SW4-8 must be set OFF to run the WINDIAG program.
It is recommended that an RS-232 "Null Modem" cable be connected between COM2 and the PC (typically COM1) (see Figure 6-1).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-1
Figure 6-1 - Comm. Port RS-232 Cable Wiring Diagram for Connection to a PC
COM3: When factory set for RS-232 or RS-485 operation, COM3 defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To test
COM3 using the DIAG program, it must not be in use. Note: CPU Switch SW4-8 must be set OFF to run the WINDIAG program.
In lieu of COM2, either an RS-232
"Null Modem" cable (see Figure 6-1) can be connected between COM3 and the PC
(typically COM1) or an RS-485 cable can be connected between COM3 and the
PC’s RS-485 Port.
If RS-485 communications is required an RS-485 cable can be assembled using the connections provided in Tables 6-1 and 6-2.
COM4: From the factory, COM4 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. To test COM4 using the DIAG program, it must not be in use. Note: CPU Switch SW4-8 must be set OFF to run the WINDIAG program.
In lieu of COM2 or COM3, it is recommended that an RS-
232 "Null Modem" cable be connected between COM4 and the PC (typically COM1)
(see Figure 6-1).
Figure 6-2 - Male DB9 9-Pin Connector Associated with COM1 through COM5
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-2
Figure 6-3 - CPU Board Switches SW1, SW2 & SW4
COM5: From the factory, COM5 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. To test COM5 using the DIAG
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-3
program, it must not be in use. Note: CPU Switch SW4-8 must be set OFF to run the WINDIAG program.
In lieu of COM2, COM3 or COM4, it is recommended that an RS-232 "Null Modem" cable be connected between COM5 and the PC (typically
COM1) (see Figure 6-1).
Table 6-1 - COM1 through COM5 (CPU) Connector Pin Assignment
Pin
#
Signal
RS-232
1 DCD
2 RXD
3 TXD
4 DTR
5 GND
Description:
RS-232 Signals
Data Carrier Detect (Input)
Receive Data (Input)
Signal
RS-485
CTS+
RXD-
Transmit Data (Output) TXD-
Data Terminal Ready (Output) TXD+
Signal/Power Ground GND
Description:
RS-485 Signals - COM3
Clear to Send + Input
Receive Data - Input
Transmit Data - Output
Transmit Data + Output
Signal/Power Ground
6 DSR
7 RTS
8 CTS
9 RI
Data Set Ready (Input)
Request To Send (Output)
Clear To Send (Input)
Ring Indicator (Input)
RXD+
RTS-
CTS-
RTS+
Receive Data + Input
Request to Send - Output
Clear to Send - Input
Request to Send + Output
Note: RS-485 Signals in Table 6-1 are only available on COM3 .
Table 6-2 - RS-485 Network Connections
(see Tables 6-1 for Control Wave LP RS-485 Port Pin # Assignments)
From
Master
To 1st
Slave
To nth
Slave
TXD+ RXD+ RXD+
TXD- RXD- RXD-
RXD+ TXD+ TXD+
RXD- TXD- TXD-
ISOGND ISOGND ISOGND
6.1.1 Overview of WINDIAG Testing
To use the WINDIAG program place any critical process (associated with the Control -
Wave LP unit in question) under manual control. WINDIAG cannot be run while the
Control Wave LP application is running. Set the CPU Modules Switch SW4-8 to the OFF
(closed) position (see Figure 6-3). Perform steps 1 through 6 below.
2.
Before you begin, either LocalView (see Section 1.7.1) or NetView (see Section 1.7.2) must be running.
3.
To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
4.
Once WINDIAG has been entered (and the unit to be tested has been selected on the initial WINDIAG entry menu, the Diagnostic Test Category Menu (Figure 1-7) will appear.
5.
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.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-4
0.
Set the Control Wave CPU Switch SW4-8 to the ON position (set SW4-3 to the ON position if it is desired to use the soft switches rather than the factory defaults) and then restart the unit via the Power Switch. The Control Wave should resume normal operation.
Figure 6-4 - ControlWaveLP Diagnostic Component Identification Diagram
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-5
6.1.2 Diagnostics Using WINDIAG
All Controllers Modules except the Power Supply/Sequencer Module can be tested using the
WINDIAG program. From the Diagnostic Test Category Menu (see Figure 1-7) the following diagnostic tests can be performed:
CPU & Peripherals Diagnostic: See Section 6.2
Checks the CPU Module (except for RAM & PROM).
PROM/RAM Diagnostic:
Communications Diagnostic:
See Section 6.3
Checks the CPU’s RAM and PROM hardware.
See Section 6.4
Checks Comm. Ports 1 through 5 - The External loopback tests require the use of a loop-back plug.
Analog Output Diagnostic:
Analog Input Diagnostic:
Discrete I/O Diagnostic:
See Section 6.5
Checks the Analog Output circuitry.
See Section 6.6
Checks the Analog Input circuitry.
See Section 6.7 for DO & Section 6.8 for DI
Checks the DI circuitry and/or the DO circuitry.
High Speed Counter Diagnostic: See Section 6.9
Checks the High Speed Counter circuitry.
Analog Output Diagnostic, Analog Input Diagnostic, Discrete Input/Output Diagnostic, and the High-speed Counter Diagnostic menus discussed in this chapter contain the following entry and display fields:
Number of Passes
Enter the number of test cycles you want to execute (1 to 256), or enter one of the Continuous Modes (see Section 1.9.2 of Chapter 1).
Board Number to Test
The Board Number to Test will be "1" for all I/O types except Analog Outputs. For AOs use numbers "8" through "11" depending on the position of switch S1 on the AO Module (where
S1 Pos. 8 = Board # 8, S1 Pos. 9 = Board # 9, S1 Pos. A = Board # 10 and S1 Pos. B = Board
# 11) (see Sections 6.5.1.1 and 6.5.1.2). Note: Except for AO Tests, the Board Number to
Test field numbers (other than 1) apply only to Control Wave Process Automation
Controllers. Note: On secondary or "Display" menus, the "Board Number Returned" should match the "Board Number to Test," i.e., "1."
Board Type Returned
This field displays the type of I/O circuitry being tested. It provides you with a verification of the I/O circuitry type being tested by posting one of the following board types: AI8, DO8,
DI16 or HSC4. "AO Point to Test" is posted on the Analog Output Linearity Calibration
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-6
Menu instead of "Board Number Returned." The "AO Point to Test" adjustment point represents the AO circuit number to be tested (1 to 4).
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays
‘
Working
’
or
‘
Idle
’
to indicate if a test is in process or not.
6.1.3 Diagnostics Test Equipment
The test detailed in this chapter require the use of the following external test equipment:
C Digital Multimeter (DMM), 1 ohm to 10 M ohm (45 PPM or better accuracy)
C DC Voltage Source, Variable to 35 V dc ( ± 10 microvolt resolution)
C Precision Current Source, 1 mA to 20 mA ( ± 1 microamp resolution)
C One 267-ohm, (5-watt) ± 5% resistor (used as the 100mA load for DO testing), one
2280-ohm (.5-watt) ± 5% and one LED - see Figure 6-19.
C One NPN Transistor (2N2222) (used in HSC Test Circuit - see Figures 6-27 & 6-28)
C One 1 k-ohm ± 5% resistor (used in UDI HSC Test Circuit - see Figures 6-27 & 6-28)
C One 12/24V Form C Relay (used in UDI HSC Test Circuit - see Figure 6-28)
C Pulse Generator, adjustable offset, adjustable amplitude to 24 V, and adjustable frequency to 10 kHz (with totalizer/accumulator function) - see Figures 6-27 & 6-28)
C Accumulator (Totalizer) - Required if Pulse Gen. doesn’t have totalizer function.
C RS-232 Loop-back Plugs (see Figure 6-9)
C RS-485 Loop-back Plugs (see Figure 6-10)
6.2 TESTING CPU & PERIPHERALS
These tests do not require removal of any board or any special external equipment. At the
Diagnostic Test Category Menu (see Figure 1-7), highlight the "CPU And Peripherals" selection and then click on the "Run" button at the bottom of the screen. Figure 6-5 will be invoked (without the Bulk 24Vdc Supply Voltage posted).
The following tests aren’t applicable to Control Wave LP units: RUN Pic, RUN Dma, RUN
Timers & RUN Floating Point Coprocessor.
6.2.1 RUN LEDs
Click on the "RUN LEDs" button. The RUN LEDs test provide pass/fail status indications as follows: RUN LEDs - Pass = X (--- No Return Status---) where x = the number of the pass. For this test, no messages are reported at the PC.
While the test is running observe the Status LEDs on the FMI/OB Board. The Status LEDs will individually turn ON and then OFF in the following sequence: STAT1, STAT2, STAT3,
STAT4, STAT5, STAT6, STAT5, STAT4, STAT3, STAT2, STAT1.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-7
Figure 6-5 - CPU and PERIPHERALS Diagnostic Menu
(with Bulk 24Vdc Supply Voltage Posted)
6.2.2 RUN Lithium
This test checks the status of the on-board battery that maintains the data in the system
RAM if power is lost. When the battery(s) are functioning properly, the controller can lose power but still retain its application load and continue running from the point of power loss when power is restored.
Click on "RUN Lithium" button. The STATUS column will show either "SUCCESS" or
"Lithium Battery Fail."
6.2.3 RUN Power Supply
Click on the "RUN Power Supply" button. The Control Wave LP ’s bulk power level will be posted to the CPU and Peripherals Diagnostic Menu shown in Figure 6-5.
6.2.4 Real Time Clock (RTC)
Click on the "RTC Diagnostic" button. The PC will proceed to the RTC Diagnostic Menu shown in Figure 6-6.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-8
This set of tests will determine if the RTC chip is fully functional. This menu has its own
Number of Passes field that is independent of what is set at the CPU and Peripherals
Diagnostic Menu (Figure 6-5). Individual selections are made by positioning the cursor at the appropriate selection point and clicking the left mouse button.
Time Registers Test
Figure 6-6 - Real Time Clock Diagnostic Menu
This test checks the RTC registers and will display either "SUCCESS" or "FAILURE - RTC" under the STATUS column.
Alarm Registers Test
This test checks the RTC Alarm Registers and will display either "SUCCESS" or
"FAILURE - RTC Alarm" under the STATUS column.
Set Time: 01-JAN-87 00:00:00
For this function, the Number of Passes should be set to 1. This function sets the RTC to the date and the time shown and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Set Time from PEI (see note 1)
For this function the Number of Passes should be set to 1. This function sets the RTC using the date and time from the PC clock and displays "SUCCESS" under the STATUS column.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-9
The user should verify that the function worked by using the Read Time selection.
Note 1: Only the date and time (down to minutes) will be used from the PC. The seconds at the RTC will ALWAYS be initialized at 30.
Read Time
This function reads the date and time from the RTC and displays it in the STATUS column at the PC. To set the RTC to a known starting point, use one of the SET TIME functions.
Then set the Number of Passes to continuous (CR or CS) and activate the READ TIME function to visually monitor the accuracy of the RTC.
When finished, return to the CPU and Peripherals Diagnostic Menu by clicking on the
"Return To Menu" button.
6.3 PROM / RAM DIAGNOSTIC TESTING
Each Control Wave LP Process Automation Controller has a mixture of PROM and RAM memory to support both the firmware and the software load. The PROM/RAM Diagnostic
Menu shown in Figure 6-7 is accessed from the Diagnostic Test Category Menu described in
Chapter 1 (Figure 1-7).
D4041A
Figure 6-7 - PROM/RAM Diagnostic Menu (see notes 2 & 3)
ControlWaveLP Process Automation Controller Diagnostics / 6-10
Note 2: The Note: The RAM test is a destructive test…doesn’t apply to Control Wave units.
Note 3: The Error Status: If rtu was not reset automatically,…doesn’t apply to Control Wave units.
6.3.1 PROM Diagnostic Test
PROM diagnostic testing is done by calculating a checksum on the FLASH memory contents and comparing it against a checksum stored in FLASH memory when they were programmed. The PROM diagnostic is designed to test both the firmware FLASH memory and the load FLASH memory in a single execution of the test.
After setting the Number of Passes, click on the "RUN PROM Diagnostic" button to begin the test. After the test is completed, one of the following responses will be displayed under the STATUS column.
Success
PROM
6.3.2 RAM Diagnostic Test
This test verifies that each bit of read/write memory can be written and read correctly and that each memory location can be addressed without adversely affecting another memory location. This test checks all RAM memory installed in the Control Wave Process
Automation Controller. Any failures are reported by giving the full address of the failing location which enables isolating the failure to the board and chip level.
Set the "Number of Passes" field to a number from 1 to 256 or to either "Continuous/Repeat
After Error" or "Continuous/Stop After Error." If a "Continuous" selection is made, the test will run continuously until it is stopped by selecting "ABORT Diagnostic Test."
To start the test, click on the "RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
Pass is indicated by: Size X.XMB
Current where X.X is the size of RAM given in MB.
Failure is indicated by: Fail - YYYYYYYY where YYYYYYYY is the address that failed.
At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, click on the "ABORT RAM
Diagnostic" button. Return to the PROM/RAM Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first click on the "Return to Menu" button before it will exit from the
PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the
Control Wave LP Process Automation Controller.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-11
6.4 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 6-8) verify the operation of the Universal Asynchronous Receiver Transmitter (UART) and associated interfaces for the Control Wave LP serial communications ports. Testing is done in both a polled environment (where the UART is interrogated for event status), and in an interruptdriven environment (where the UART presents an interruption to the firmware to report events). Each UART can control two ports. The ports are paired as follows:
A/B/C/D/E CPU Peripheral UARTs on CPU Board (A = COM1, B = COM2, etc.)
Figure 6-8 - Communications Diagnostic Menu
6.4.1 Hardware Setup and Testing of Serial Comm. Ports
These tests use a loop-back technique to verify correct operation of the port being tested.
For loop-back mode an external loop-back plug is required as detailed. The Control Wave communication port to be tested can’t be the one connected to the PC.
1.
Connect the appropriate loop-back plug (see Figure 6-9 for RS-232 or Figure 6-10 for
RS-485) to the port to be tested. Remember that the port connected to the PC cannot
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-12
be tested. Note: When testing COM3, set CPU Switch SW1 for RS-232 or RS-485 opertation (see Figure 6-3). If set for RS-485 operation TXD to RXD and RTS to CTS
Loop-back settings must be enabled.
2.
Access the Communications Diagnostic Menu. The Communications Diagnostic Menu
(see Figure 6-8) is accessed from the Diagnostic Test Category Menu (Figure 1-7) by highlighting the "Communications" selection and then clicking on the "Run" button at the bottom of the screen.
Figure 6-9 - RS-232 Loop-back Plug
Figure 6-10 - RS-485 Loop-back Plug
3.
The port to be tested is selected by entering the port designation, i.e., COM1, COM2,
COM3, COM4 or COM5.
4.
Set the "Baud Rate to Test" field to the desired speed (max value = 115.2K) or choose
"ALLASYNC."
5.
Set the "Number of Passes" to any number from 1 to 256, or select "Continuous/Repeat after Error," or "Continuous/Stop after Error" via one of the three "Radio" buttons located near the top of the menu.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-13
6.
Click on the "RUN External Loop-back" Test button. The Status: indication will switch from "IDLE" to "Working." If an incorrect baud rate has been set, or a port without a loopback plug has been selected, the test will fail and the message "Time Out Waiting
For Response" will be posted next to "Error Status:" The test will proceed and return one of the following responses under the STATUS column:
Success
Fail - Polling Asynch Failure
- Interrupt Asynch Failure
Failure
- RTS/CTS
Error
If the "RTS/CTS Failure" message is displayed, ensure that the loop-back plug is correctly configured and installed (for RS-485 also make sure that CPU Switch SW1 has been properly configured).
When you have finished with communications port testing, be sure to remove the loop-back plug (and configure CPU Switch SW1 for appropriate operation).
6.5 ANALOG OUTPUT (AO) TESTS
The AO tests are used to check Analog Output Modules to ensure they are fully operational.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Output" selection and then click on the
“
Run
”
button at the bottom of the screen.
The PC will proceed to the Analog Output Linearity Calibration Menu (see Figure 6-11).
D4041A
Figure 6-11 - Analog Output Linearity Calibration Menu
ControlWaveLP Process Automation Controller Diagnostics / 6-14
6.5.1 Analog Output Circuitry Calibration Verification
For this procedure the following items are required:
A Digital Multimeter (DMM) (see Chapter 1).
Wiring terminals for AO Terminal Blocks (TB5 through TB8) are identified in Figure 6-12.
WARNING
Only the "RUN Set 0% (after Cal)", "RUN Set 100% (after Cal)", "RUN Set Output to
UnderRange" and the "RUN Set Output to OverRange" Tests buttons are to be utilized by other than factory personnel. DO NOT initiate any other tests. The tests discussed herein provide for testing Analog Output Modules; calibration is not covered. DO NOT attempt to calibrate an Analog Output Module.
6.5.1.1 4-20 mA Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 6-11) provides for test setup configuration of the Analog Output Module to be tested.
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until stopped by clicking on the appropriate “ ABORT ” button.
2.
Set the "Board Number to Test" to "8," "9," "10" or "11" based upon the position of S1 on the AO Module (where S1 Pos. 8 = Board # 8, S1 Pos. 9 = Board # 9, S1 Pos. A =
Board # 10 and S1 Pos. B = Board # 11). Note: If a board number that does not match the S1 setting is entered the message " Invalid Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the menu.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1 to 4). Set the value accordingly.
4.
Connect the Digital Multimeter (in current Mode) (+) lead to the +AO# terminal and the (-) lead to the -AO# terminal of the appropriate AO Module Terminal Block
Assembly (see Figures 6-4 & 6-12).
5.
Click on "RUN Set 0% (after Cal)" Test button. Verify that the DMM displays 4.000 mA
( ± .0172 mA).
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the DMM displays 20.000
mA ( ± .0172 mA).
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 3.200 mA ( ± .129 mA).
8.
Click on "RUN Set Output to OverRange" Test button. Verify that the DMM displays
20.800 mA ( ± .129 mA).
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-15
Figure 6-12 - ControlWaveLP- AO Terminal Block Assembly Assignments
10.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by selecting the Return to Menu button at the bottom of the Analog Output
Linearity Calibration Menu (Figure 6-11).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-16
6.5.1.2 1-5V Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 6-11) provides for test setup configuration of the Analog Output Module to be tested.
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until it is stopped by clicking on the appropriate “ ABORT ” button.
2.
Set the "Board Number to Test" to "8," "9," "10" or "11" based upon the position of S1 on the AO Module (where S1 Pos. 8 = Board # 8, S1 Pos. 9 = Board # 9, S1 Pos. A =
Board # 10 and S1 Pos. B = Board # 11). Note: If a board number that does not match the S1 setting is entered the message " Invalid Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the menu.
3. The "AO Point to Test" adjustment point represents the AO circuit number being tested (1 to 4 or 8). Set the value accordingly.
4. Connect the Digital Multimeter (in voltage Mode) (+) lead to the +AO#V terminal and the (-) lead to the -AO# terminal of the local or remote AO Module Terminal Block
Assembly (see Figures 6-4 & 6-12).
5.
Click on the "RUN Set 0% (after Cal)" Test button. Verify that the meter displays 1.000
Vdc ( ± .004 V).
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the meter displays 5.000
Vdc ( ± .004 V).
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 0.800 Vdc ( ± .030 V).
8.
Click on the "RUN Set Output to OverRange" Test button. Verify that the DMM displays 5.200 Vdc ( ± .030 V).
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
10.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by clicking on the "Return to Menu" button at the bottom of the Analog
Output Linearity Calibration Menu (Figure 6-11).
6.6 ANALOG INPUT (AI) TESTS
The AI tests are used to check Analog Input circuits to ensure they are fully operational. A
Precision Current Source is required for 4-20mA AI testing and a Variable dc Voltage
Source is required for 1-5V AI testing.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Input" selection and then click on the “ Run ” button at the bottom of the screen. The PC will proceed to the Analog Input Diagnostic Menu (see Figure 6-13).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-17
The Analog Input Diagnostic Menu (Figure 6-13) provides for test setup configuration of the
Analog Input circuit to be tested. Only the "Analog Input Display" button is utilized.
Figure 6-13 - Analog Input Diagnostic Menu
6.6.1 1-5V AI Calibration (Without Internal References)
The gain and offset adjustment values (in hexadecimal format) will be displayed under the
“ 1V-REF ” and “ 5V-REF ” columns on the Analog Input Display Menu (see Figure 6-14).
AIs Without Internal Reference
1.
Configure Jumper W20A/B for Isolated Voltage Input operation (see Figure 6-15).
2.
Connect a voltage standard (+) lead to AI1 at TB3-2 and (-) lead to AI1 at TB3-1 (see
Figure 6-15 and Table 6-4).
3.
On the Analog Input Diagnostic Menu (Figure 6-13) click on the Analog Input Display
Button. The Analog Input Display Menu (Figure 6-14) will appear.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-18
4.
Set the voltage standard to 1.000V (±.001V).
5.
Adjust R111 until 0333 ±6 hex counts (032D to 0339) is displayed under the “AI-01” column.
6.
Set the voltage standard to 5.000V (±.001V).
7.
Adjust R112 until 3CCC ±6 hex counts (3CC6 to 3CD2) is displayed under the “AI-01” column.
8.
Repeat steps 4 and 7 until further adjustments are not required.
6.6.2 Isolated 4-20 mA Analog Input Channel Test
A Precision Current Source capable of providing 20 mA with 1 : A resolution will be required to perform AI testing of a 4-20mA AI Module.
1. Configure the Jumpers (W20A/B through W27A/B) associated with the analog input circuit to be tested for isolated current input operation (see Figure 6-15).
2.
Connect the positive output of the Precision Current Source to the (-) input AI channel
# (e.g., for AI1 = Pin AI-B1 of Term. Block TB3). Connect the negative output of the
Precision Current Source to the (+) input AI channel associated with the AI channel # in question (e.g., for AI1 = Pin AI-A1 of Term. Block TB3) (See Figure 6-15 and Table 6-
3).
Table 6-3 - Analog Input Terminal Block TB3 Pin Assignments
Block
Label
AI-B
AI-A
AI-B
AI-A
AI-B
AI-A
AI-B
AI-A
Pin #
(Label)
1 (1)
2 (1)
3 (S)
4 (S)
5 (2)
6 (2)
7 (3)
8 (3)
Name
AI1-
AI1+
Pin #
(Label)
9 (S)
10 (S)
Shield 11 (4)
Shield 12 (4)
AI2-
AI2+
13 (5)
14 (5)
AI3-
AI3+
15 (S)
16 (S)
Name
Pin #
(Label)
Shield 17 (6)
Shield 18 (6)
AI4-
AI4+
AI5-
AI5+
19 (7)
20 (7)
21 (S)
22 (S)
Shield 23 (8)
Shield 24 (8)
Name
AII6-
AI6+
AI7-
AI7+
Shield
Shield
AI8-
AI8+
3 On the Analog Input Diagnostic Menu (Figure 6-13) click on the "Analog Input
Display" button. The Analog Input Display menu (Figure 6-14) will appear.
The test will proceed until it is stopped by clicking on the “ End Test ” button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI
Values should be 8. The Board Type Returned should be AI8.
For input currents of 4mA ±0.001mA and 20mA ±0.001mA the following hex values should be displayed under the associated AI column, i.e., AI-01 through AO-08:
4mA ±0.001mA Hex Reading = 0333 ± 0015 counts (0324 to 0342)
20mA ±0.001mA Hex Reading = 3CCC ± 0015 counts (3CBD to 3CDB)
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-19
4. Set the Precision Current Source output to zero and remove it from the AI Module’s
Term. Block. Reconnect it to the next AI on TB3 and repeat Steps 1 through 3 for each of the eight analog inputs, checking the hex reading under the appropriate AI channel.
When testing has been completed, click on the "End Test" button and return to the
Analog Input Diagnostic menu (Figure 6-13).
Figure 6-14 - Analog Input Display Menu (with 5V or 20 mA on AI-01)
6.6.3 Internally Sourced 4-20 mA Analog Input Channel Test
1.
Configure the Jumpers (W20A/B through W27A/B) associated with the analog input circuit to be tested for internally sourced current input operation (see XMTR Current
Loop, Figure 6-15).
2. Install Jumper W29.
3. Measure the voltage between TB3-2(A) and TB3-1(B) for AI channel 1 (see Table 6-3 and Figure 6-15). The value should be +24Vdc ±1.2Vdc.
4. Repeat step 3 for channels 2 through 8.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-20
Figure 6-15 - Analog Input Module - Local Terminal Blocks
WARNING
Be sure to set the current source to zero before removing it after each input is tested.
6.6.4 1-5V Analog Input Channel Test
A Variable dc Voltage Source capable of outputting 5.000V with 10uV resolution will be required to perform AI testing of a 1-5V AI circuit.
1. Configure the Jumpers (W20A/B through W27A/B) associated with the analog input circuit to be tested for isolated voltage input operation (see Figure 6-15). Install
Jumper W29.
2.
Connect the positive output of the Variable dc Voltage Source to the (+) input AI channel # (e.g., for AI1 = Pin AI-A1 of Term. Block TB3). Connect the negative output of the Variable dc Voltage Source to the (-) input AI channel # in question (e.g., for AI1
= Pin AI-B1 of Term. Block TB3) (See Figure 6-15).
3.
Apply 0.8 Vdc (±0.001V) to the Analog Input being tested. Click on the "Analog Input
Display" button on the Analog Input Diagnostic Menu (Figure 6-13). Vary the input voltage from 0.8 Vdc to 6.0 Vdc and verify that the hex values provided in Table 6-4 below are displayed accordingly for the AI channel being tested.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-21
Table 6-4 - 1-5Vdc Analog Input Circuits - Voltage versus AI Hex Values
Input
Voltage
HEX
Reading
0.8 ±0.001 Vdc 0050 ± 15 (0041 to 005F)
1.0 ±0.001 Vdc 0333 ± 15 (0324 to 0342)
3.0 ±0.001 Vdc 2000 ± 15 (1FF1 to 200F)
5.0 ±0.001 Vdc 3CBD ± 15 (3CBD to 3CDB)
5.2 ±0.001 Vdc 3FB0 ± 15 (3FA1 to 3FBF)
6.0 ±0.001 Vdc 3FFF
4. Set the Variable dc Voltage Source to zero and remove it from the AO Module’s Term.
Block. Reconnect it to the next AI on the appropriate Term. Block and repeat Steps 1 and 3 for each of the eight analog inputs, checking the hex reading under the appropriate AI channel. When testing has been completed, click on the “ End Test ” button to return to the Analog Input Diagnostic menu.
WARNING
Be sure to set the voltage source to zero before removing it after each input is tested.
6.7 DISCRETE OUTPUT (DO) TESTS
These tests check the discrete output circuitry of a Control Wave DO Module, including the output registers and the output paths to the terminal block.
For the tests in this chapter, you will need the DMM and Variable dc Voltage Source described in Chapter 1. You will also need a 267-ohm, 5-watt resistor (required to provide a
100mA DO load from a 24 Vdc source), a 2280-ohm, .5-watt resistor and an LED.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the “ Run ” button at the bottom of the screen. The PC will proceed to the menu shown in Figure 6-16.
6.7.1 Discrete Output Sequence Test
All of the DOs will be automatically sequenced for this test. Each DO will be enabled in turn for approximately 0.2 seconds. Be sure to set the Number of Passes to "Continuous/Stop after Error" to provide a continuous test cycle.
1.
Install Jumper W18. Construct the test circuit of Figure 6-19 and connect it to terminals associated with TB2 DO1 (see Table 6-5 and Figure 6-19).
2. On the Discrete Input/Output Diagnostic Menu (see Figure 6-16), set the "Board
Number to Test" to "1." Set the Number of Passes to "Continuous/Stop after Error" and then click on the "RUN Discrete Output Sequence" Test button. NOTE: No test information will be displayed on the menu.
3. The DO LEDs should sequence in a rotating pattern (see Figure 6-18). Each DO should turn on for approximately 200 msec (each DO LED will turn ON and then OFF accordingly). Additionally, the Board Type Returned should be DO8. Proceed to Section
6.7.2 for the Discrete Output Display Test.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-22
Figure 6-16 - Discrete Input/Output Diagnostic Menu - DO Sequence (has run)
6.7.2 Discrete Output Display Test
This test checks each DOs output circuitry. You will need the Digital Multimeter (DMM), the Variable dc Voltage Source, 267-ohm, 5-watt resistor (required to provide a 100mA DO load from the 24Vdc source), a 2280-ohm, .5-watt resistor and an LED.
1.
Shut off the Control Wave LP Process Automation Controller.
2.
Construct the test circuit of Figure 6-19 (DO1 example). The test circuit of Figure 6-19 provides a 100mA load with the power supply providing 24Vdc. Turn on Control-
Wave LP power. Field connections for DO1 through DO8 are located at TB2 (see Table
6-5).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-23
3. On the Discrete Input/Output Diagnostic Menu (see Figure 6-16), set the "Number of
Passes" to 1 and then click on the "Discrete Output Display" button. The Discrete
Output Display Menu (Figure 6-17) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
Block
Label
DO-B
DO-A
DO-B
DO-A
Figure 6-17 - Discrete Output Display - Initial Entry
Table 6-5 - Discrete Output Terminal Block TB2 Pin Assignments
Pin #
(Label)
1 (1)
2 (1)
3 (2)
4 (2)
Name
DO1-
DO1+
DO2-
DO2+
Pin #
(Label)
5 (3)
6 (3)
7 (4)
8 (4)
Name
DO3-
DO3+
DO4-
DO4+
Pin #
(Label)
9 (5)
10 (5)
11 (6)
12 (6)
Name
DO5-
DO5+
DO6-
DO6+
Pin #
(Label)
13 (7)
14 (7)
15 (8)
16 (8)
Name
DO7-
DO7+
DO8-
DO8+
4. On the Discrete Output Display Menu (see Figure 6-17), the Status: indication will change from IDLE to WORKING once "Start Test" has been selected. When the Status: indication changes back to IDLE, it will appear similar to the Discrete Output Display
Menu of Figure 6-18.
The Discrete Output Display menu will display DOs numbers (8) and will post the
Number of Valid DO Values (8), the Board Number Returned (1), the Board Type
Returned (DO8). Observe the FMI/OB’s DO LEDs. DO LED 1 should be ON and all other DO LEDs should be OFF.
5. On the Discrete Output Display Menu (see Figure 6-16), set the Drive DO: for the desired DO channel number (1 to 8). Measure the voltage drop between the DO#terminal and the DO#+ output terminal (with the output in question turned ON) (DO1-
= Pin B1 and +DO1 = Pin A1 - see Figure 6-19 and Table 6-5). The output will be turned ON once the “ Start Test ” button has been selected. The DO voltage drop should
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-24
not exceed 0.25V. Shut off the Control Wave LP Process Automation Controller and the test circuit’s power source.
Figure 5-10 - 3305 DO Test – Test Setup
Figure 6-18 - Discrete Output Display - Tests in Progress
D4041A
Figure 6-19 - Discrete Output Terminal Block TB2, DO LEDs &
DO Term. Block & 100mA Load Test Circuit
ControlWaveLP Process Automation Controller Diagnostics / 6-25
6.
Move the test circuit to the next DO to be tested. Reapply power to the Control -
Wave LP and the test circuit. Repeat step 5 for each channel to be tested.
6.8 DISCRETE INPUT (DI) TESTS
These tests check the Control Wave LP discrete input circuitry to ensure each DI is fully operational.
For the Digital Input Display Test (see Section 6.8.2), you will need the Variable dc Voltage
Source described in Chapter 1 and a short jumper wire (3” long).
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the
Discrete Input/Output Diagnostic Menu (see Figure 6-20).
D4041A
Figure 6-20 - Discrete Input/Output Diagnostic Menu - DI Circuitry
ControlWaveLP Process Automation Controller Diagnostics / 6-26
6.8.1 Discrete Input Circuitry Test
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 6-20), set the "Board
Number to Test" to 1. Set the "Number of Passes" field to "Continuous/Stop after Error" and then click on the "RUN Discrete Input Circuitry" Test button.
2.
The Status field of Figure 6-20 will display the result of the test with on e of the following messages:
Success
Polling
Interrupt
Unexplained
= Passed Test
= Failed in DI Polling Test
= Failed in DI Interrupt Test
= Unexpected Interrupt from DI Interrupt Circuitry
When the test has completed (via “ ABORT ” ), the Board Type Returned should be DI16.
Proceed to Section 6.8.2 for the Discrete Input Display Test.
6.8.2 Discrete Input Display Test
These tests check the DI circuits inputs and LEDs.
Externally Powered (Isolated) DI Test
1.
Install Jumper W17. Configure DI Jumpers for externally powered operation and then turn all odd DIs ON by applying 24V between their associated TB pairs (see Table 6-6 and Figure 6-21).
2.
On the Discrete Input/Output Diagnostic Menu (see Figure 6-20), set the "Number of
Passes" to "Continuous/Repeat after Error" and then click on the "Discrete Input
Display" Test button. The Discrete Input Display Menu (see Figure 6-22) will appear.
The odd DI numbers (1, 3, 5, 7, 9, 11, 13 & 15) should be highlighted (in RED) (see
Figure 6-23) and the FMI/OB’s odd DI LEDs (labeled CR33, CR35, CR37, CR39, CR42,
CR44, CR46 & CR48) should be ON.
3.
Turn all odd DIs OFF. Verify that the associated FMI/OB LEDs turn OFF and that the odd DI numbers of Figure 6-23 are not displayed in RED.
4.
Repeat steps 1 and 2 for all even DIs (2, 4, 6, 8, 10, 12, 14 & 16). The even DI numbers should be highlighted in RED (see Figure 6-23) and the FMI/OB’s even DI LEDs
(labeled CR34, CR36, CR38, CR40, CR43, CR45, CR47 & CR41) should be ON.
5.
Turn all even DIs OFF. Verify that the associated FMI/OB LEDs turn OFF and that the evend DI numbers of Figure 6-23 are not displayed in RED.
6.
Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Display Menu.
Internally Powered (Dry Contact) DI Test
1.
Configure DI Jumpers for internally sourced operation and then turn all odd DIs ON by placing a short between their associated TB pairs (see Table 6-6 and Figure 6-21).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-27
Figure 6-21 - Local Terminal Block Assembly Assignments and Test Examples for Internally Sourced DI Operation or Externally Powered DI Operation
2.
On the Discrete Input/Output Diagnostic Menu (see Figure 6-20), set the "Number of
Passes" to "Continuous/Repeat after Error" and then click on the "Discrete Input
Display" Test button. The Discrete Input Display Menu (see Figure 6-22) will appear.
The odd DI numbers (1, 3, 5, 7, 9, 11, 13 & 15) should be highlighted (in RED) (see
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-28
Figure 6-23) and the FMI/OB’s odd DI LEDs (labeled CR33, CR35, CR37, CR39, CR42,
CR44, CR46 & CR48) should be ON.
3.
Turn all odd DIs OFF. Verify that the associated FMI/OB LEDs turn OFF and that the odd DI numbers of Figure 6-23 are not displayed in RED.
4.
Repeat steps 1 and 2 for all even DIs (2, 4, 6, 8, 10, 12, 14 & 16). The even DI numbers should be highlighted in RED (see Figure 6-23) and the FMI/OB’s even DI LEDs
(labeled CR34, CR36, CR38, CR40, CR43, CR45, CR47 & CR41) should be ON.
5. Turn all even DIs OFF. Verify that the associated FMI/OB LEDs turn OFF and that the even DI numbers of Figure 6-23 are not displayed in RED.
6. Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Display Menu.
Block
Label
DI-B
DI-A
DI-B
DI-A
DI-B
DI-A
DI-B
DI-A
Figure 6-22 - Discrete Input Display Menu - No Inputs
Table 6-6 - Discrete Input Terminal Block TB1 Pin Assignments
Pin #
(Label)
1 (1)
2 (1)
3 (2)
4 (2)
5 (3)
6 (3)
7 (4)
8 (4)
Name Pin #
(Label)
DI1-
DI1+
DI2-
DI2+
DI3-
DI3+
DI4-
DI4+
9 (5)
10 (5)
11 (6)
12 (6)
13 (7)
14 (7)
15 (8)
16 (8)
Nam e
Pin #
(Label)
DI517 (9)
DI5+ 18 (9)
DI619 (10)
DI6+ 20 (10)
DI721 (11)
DI7+ 22 (11)
DI823 (12)
DI8+ 24 (12)
Nam e
Pin #
(Label)
DI925 (13)
DI9+ 26 (13)
DI1027 (14)
DI10+ 28 (14)
DI1129 (15)
DI11+ 30 (15)
DI1231 (16)
DI12+ 32 (16)
Name
DI13-
DI13+
DI14-
DI14+
DI15-
DI15+
DI16-
DI16+
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-29
Figure 6-23 - Discrete Input Display Menu - DIs 1, 3, 5 & 7 ON
6.9 HIGH SPEED COUNTER INPUT (HSC) TESTS
These tests check the high speed counter input circuitry of a Control Wave LP to ensure each HSC circuit is complete and fully operational. Each of the HSC inputs may be individually configured with debounce circuitry either enabled or disabled. Individual debounce are enabled when their associated debounce jumper is installed. The debounce jumper must be installed when wiring field devices to the HSCSET or HSCRESET input terminals. Each counter is assigned three field inputs; SET, RESET and COMMON. When the associated debounce circuit is enabled, a change of state on both the SET and RESET inputs is required to accumulate counts. The maximum input frequency is 10 kHz.
Note: The RUN Counter Test is not applicable to the Control Wave LP .
To perform the High Speed Counters Display Tests (see Section 6.9.2), the test setup of
Figure 6-27 is required for circuits with Debounce Disabled and the test setup of Figure 6-
28 is required for circuits with Debounce Enabled.
In addition to the equipment shown in Figures 6-27 and 6-28 you will need a dual trace oscilloscope to calibrate the square wave produced by the Pulse Generator. Note: If the
Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the "High Speed Counter" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the High Speed Counters Diagnostic Menu (see Figure 6-24).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-30
Figure 6-24 - High Speed Counters Diagnostic Menu - Counters Test Running
6.9.1 High Speed Counter Circuit in Non-debounce Mode Test
1.
Configure Jumpers W33, W35, W37 and W39 in position 2 to 3.
2.
Construct a test circuit for debounce disabled (see Fig. 6-27). Set the Pulse Generator for a 5V output at 10kHz with a 0V offset and a 50% duty cycle (see Figure 6-25).
Connect the test circuit to the #SET and #COM terminals of TB4 associated with HSC1
(see Figure 6-29 and Table 6-8).
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-31
3.
From the Diagnostic Test Category Menu (see Figure 1-7) highlight the "High Speed
Counter" selection and then click on the "Run" button at the bottom of the screen. The
PC will proceed to the High Speed Counters Diagnostic Menu (see Figure 6-24).
Figure 6-25 - Square Wave (50% Duty Cycle)
4.
Set the "Number of Passes" to "Continuous/Stop after Error" and then click on the
"RUN" button adjacent to the "High Speed Counters Display" selection. Run this test for a minimum of 100,000 pulses. The High Speed Counters Diagnostic Menu will post
Board Number Returned (1), the Board Type Returned (HSC4) and the Number of
Failures. The Status: should change from IDLE to WORKING while the test is running. Verify that the count is displayed both at the totalizer and on the High Speed
Counters Diagnostics Menu (see Figure 6-24).
5.
Repeat steps 2 through 4 for each of the remaining High Speed Counter circuits.
6.
To End the HSC Counters Test, click on the "ABORT Counter Test" button.
6.9.2 High Speed Counter Circuit in Debounce Mode Test
1.
Configure Jumpers W33, W35, W37 and W39 in position 2 to 3. Install Jumpers W32,
W34, W36 and W38 (to set all four HSC circuits so that debounce is enabled).
2.
Construct a test circuit for debounce enabled (see Figure 6-28). Set the Pulse Generator for a 5V output at the maximum acceptable frequency of the relay with a 0V offset and a 50% duty cycle (see Figure 6-25). Connect the test circuit to the #SET, #RESET and
#COM terminals of TB4 associated with HSC1 (see Figure 6-29 and Table 6-7).
3.
From the Diagnostic Test Category Menu (see Figure 1-7) highlight the "High Speed
Counter" selection and then click on the "Run" button at the bottom of the screen. The
PC will proceed to the High Speed Counters Diagnostic Menu (see Figure 6-24).
4.
Set the "Number of Passes" to "Continuous/Stop after Error" and then click on the
"RUN" button adjacent to the "High Speed Counters Display" selection. Run this test for a minimum of 50 pulses. The High Speed Counters Diagnostic Menu will post
Board Number Returned (1), the Board Type Returned (HSC4) and the Number of
Failures. The Status: should change from IDLE to WORKING while the test is running. Verify that the count is displayed both at the totalizer and on the High Speed
Counters Diagnostics Menu (see Figure 6-24).
5.
Repeat steps 2 through 4 for each of the remaining High Speed Counter circuits.
6.
To End the HSC Counters Test, click on the "ABORT Counter Test" button.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-32
Figure 6-26 - High Speed Counters Display Test (Counter - 1 Test Completed)
Table 6-7 - High Speed Counter Terminal Block TB4 Pin Assignments
Block
Label
Pin #
(Label)
HSC-B 1 (1)
HSC-A 2 (1)
HSC-B 3 (1)
HSC-A 4 (S)
HSC Name
1COM
1SET
1RESET
Shield
Pin #
(Label)
5 (2)
6 (2)
7 (2)
8 (S)
HSC
Name
Pin
(Label)
2COM
2SET
9 (3)
10 (3)
2RESET 11 (3)
Shield 12 (S)
HSC
Name
Pin
(Label)
3COM
3SET
13 (4)
14 (4)
3RESET 15 (4)
Shield 16 (S)
HSC
Name
4COM
4SET
4RESET
Shield
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-33
Figure 6-27 - HSC Test Circuit - Debounce Disabled
D4041A
Figure 6-28 - HSC Test Circuit - Debounce Enabled
ControlWaveLP Process Automation Controller Diagnostics / 6-34
Figure 6-29 - HSC Input Terminal Block TB4 - LEDs & Configuration Jumpers
6.9.3
HSC Circuit Internally Sourced Mode Verification Test
1.
Configure Jumpers W33, W35, W37 and W39 for field powered operation, i.e., Jumpers in positions 1 to 2 and 3 to 4 (see Figure 6-29).
2.
Measure for 24Vdc (± 5%) between TB4-2 and TB4-1; TB4-3 and TB4-1; TB4-6 and
TB4-5; TB4-7 and TB4-5; TB4-10 and TB4-9; TB4-11 and TB4-9; TB4-14 and TB4-13;
TB4-15 and TB4-13 (see Table 6-7).
6.10 Control
Wave
LP Power Supply Test
To test the Control Wave LP’s Power Supply circuitry follow steps 1 and 2 below:
1.
From the Diagnostic Test Category Menu (see Figure 1-7) highlight the "CPU &
Peripherals" selection and then click on the "Run" button at the bottom of the screen.
The PC will proceed to the CPU And Peripherals Diagnostic Menu (see Figure 6-5).
2.
On the CPU And Peripherals Diagnostic Menu (Figure 6-5) click on the "RUN Power
Supply (CWaveLP)" Button. A value from 9 to 30 Vdc should be displayed in the Status column next to the "RUN Power Supply (CWaveLP)" Button.
D4041A ControlWaveLP Process Automation Controller Diagnostics / 6-35
BLANK PAGE
Chapter 7
ControlWave Process Automation Controller
& ControlWave I/O Expansion Rack
Diagnostics
7.1 Control
Wave
DIAGNOSTICS INTRODUCTION
This chapter describes the diagnostic testing for Control Wave Process Automation
Controllers, Control Wave I/O Expansion Racks and Control Wave Redundant I/O
Communications Switch Units (CWREDIO). Various elements to be tested (CPU memory, communication ports, I/O Modules, etc.) are individually accessed from the Diagnostic Test
Category Menu described in chapter 1 (see Figure 1-7). Control Wave diagnostic tests provide pass/fail indications to assist the service technician in determining if a module requires further service. Note: The term Control Wave as used in this chapter implies either a Control Wave Process Automation Controller or a Control Wave I/O Expansion
Rack unless specifically connoted as Control Wave PAC or Control Wave EXP .
Communications between the Control Wave and the PC (equipped with BBI’s DIAG program) can be made via a Local or Network Port with the following restrictions:
• CPU Board Switch SW1-8 must be OFF to run the DIAG program. Setting it OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode.
• Any Wave communication port can be connected to the PC provided their port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to 9600 bps operation).
• For a Wave PAC , Communication port COM1 is only forced to 9600 bps operation when CPU Switches SW1-3 and SW1-8 have both been set OFF. COM1 can also be set to 9600 bps operation via user defined Soft Switches. In the case of a
Control Wave EXP COM1 defaults to 9600 bps.
• Setting CPU Board Switches SW1-3 and SW1-8 OFF prevents the ‘Boot Project’ from running, places the unit into diagnostic mode and forces communication ports COM1 through COM6 to operate at 9600 baud. Note COM5 and COM6 are only available on Control Wave EXPs and require Open BSI version 5.0 or higher to run.
COM1: From the factory, COM1 defaults to 115.2 kbd (9600 baud for a Control Wave EXP )
(RS-232) using the Internet Point to Point Protocol (PPP). Note: Control Wave Port
COM1 will be configured for RS-232 operation (at 9600 bps) by setting CPU
Switches SW1-3 and SW1-8 OFF. To test COM1 using the DIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. Connection to a
PC requires the use of an RS-232 "Null Modem" cable (see Figure 7-1). COM1 utilizes a 9-pin D-type male connector.
COM2: From the factory, COM2 on the CPU Board defaults to 9600 baud, 8-bits, no parity,
1 stop bit, BSAP/ Control Wave Designer protocol operation. To test COM2 using the DIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. It is recommended that an RS-232 "Null Modem" cable be connected between COM2 and the PC (typically COM1) (see Figure 7-1). COM2 can be
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-1
configured for RS-485 operation on 386EX CPUs that don’t have a
Secondary Comm. Board.
COM2 utilizes a 9-pin D-type male connector.
Figure 7-1 - Comm. Port RS-232 Cable Wiring Diagram for Connection to a PC
COM3: When factory set for RS-232 or RS-485 operation, COM3 on the SCB Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. This port utilizes an RJ-45 female connector (see Figures 7-3 and Table 7-2). To test COM3 using the DIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. Connection to a PC depends on the type of communications port jack utilized by the PC. For 386EX CPU Modules,
COM3 is factory configured for RS-485 operation.
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 7-1, or use Bristol "Null Modem" cable P/N 392843-01-
3 connected to two Bristol "RJ45 to DB9 Adapter" cables P/N 392844-01-0 (see
Figure 7-1), to interconnect the PC to COM3.
If the PC’s RS-232 Port utilizes the standard 9-pin D-type male connector, the use of the Bristol "Null Modem" cable P/N 392843-01-3 (see Figure 7-1) and one Bristol
"RJ45 to DB9 Adapter" cable P/N 392844-01-0 (see Figure 7-1) will be required.
This RS-232 network, consisting of two cables, connects to COM3 of the
Control Wave with an 8-pin RJ-45 male connector and to the PC (typically COM1) with a 9-pin D-type female connector.
If RS-485 communications is required an RS-485 cable can be assembled using the connections provided in Table 7-3.
COM4: When factory set for RS-232 or RS-485 operation, COM4 on the SCB Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To test COM4 using the DIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. In lieu of COM2, either an RS-
232 "Null Modem" cable (see Figure 7-1) can be connected between COM4 and the
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-2
PC (typically COM1) or an RS-485 cable (see Tables 7-1 & 7-3) can be connected between COM4 and the PC’s RS-485 Port. For 386EX CPU Modules, COM4 is factory configured for RS-485 operation. COM4 utilizes a 9-pin D-type male connector.
COM5: Factory set for RS-232 operation, COM5 on the 386EX CPU Module’s SCB Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. This port utilizes an RJ-45 female connector (see Figure 7-3 and Table 7-2). To test COM5 using the DIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. Connection to a PC depends on the type of communications port jack utilized by the PC. 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 7-1, or use Bristol "Null Modem" cable P/N 392843-01-3 connected to two Bristol "RJ45 to DB9 Adapter" cables P/N 392844-01-0 (see Figure 7-1), to interconnect the PC to
COM5.
If the PC’s RS-232 Port utilizes the standard 9-pin D-type male connector, the use of the BBI "Null Modem" cable P/N 392843-01-3 (see Figure 7-1) and one Bristol
"RJ45 to DB9 Adapter" cable P/N 392844-01-0 (see Figure 7-1) will be required.
This RS-232 network, consisting of two cables, connects to COM5 of the
Control Wave with an 8-pin RJ-45 male connector and to the PC (typically COM1) with a 9-pin D-type female connector. Note COM5 is only available on a
Control Wave EXP and requires Open BSI version 5.0 or higher to run.
COM6: Factory set for RS-232 operation, COM6 on the 386EX CPU Module’s SCB Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. This port utilizes an RJ-45 female connector (see Figure 7-3 and Table 7-2). To test COM6 using the DIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. Connection to a PC depends on the type of communications port jack utilized by the PC. 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 7-1, or use Bristol "Null Modem" cable P/N 392843-01-3 connected to two Bristol "RJ45 to DB9 Adapter" cables P/N 392844-01-0 (see Figure 7-1), to interconnect the PC to
COM6.
If the PC’s RS-232 Port utilizes the standard 9-pin D-type male connector, the use of the Bristol "Null Modem" cable P/N 392843-01-3 (see Figure 7-1) and one Bristol
"RJ45 to DB9 Adapter" cable P/N 392844-01-0 (see Figure 7-1) will be required.
This RS-232 network, consisting of two cables, connects to COM6 of the
Control Wave with an 8-pin RJ-45 male connector and to the PC (typically COM1) with a 9-pin D-type female connector. Note COM6 is only available on a
Control Wave EXP and requires Open BSI version 5.0 or higher to run.
Others: Any of the three optional Ethernet Ports can be connected directly or via a network to a PC equipped with an Ethernet Port (see Figures 7-5, 7-12 and 7-13. If not configured with an address, the Control Wave uses DHCP (by default) to obtain an
IP address.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-3
Figure 7-2 - Male DB9 9-Pin Connector Associated with COM1, COM2 & COM4
Table 7-1 - COM1, COM2 & COM4 (SCB) Connector Pin Assignment
Pin
#
Signal
RS-232
Description:
RS-232 Signals
Signal
RS-485
Description:
RS-485 Signals
1 DCD * Data Carrier Detect Input
2 RXD Receive Data Input
3 TXD
4 DTR
Transmit Data Output
RXD-
TXD-
Data Terminal Ready Output TXD+
5 GND Signal/Power Ground
6 DSR * Data Set Ready Input
N/A
Receive Data - Input
Transmit Data - Output
Transmit Data + Output
ISOGND Isolated Ground
RXD+ Receive Data + Input
7 RTS Request To Send Output
8 CTS * Clear To Send Input
9 RI * Ring Indicator
N/A
N/A
N/A
Note: RS-485 Signals in Table 7-1 are only available on COM2 of 386EX CPUs (without an
SCB) or COM 4 of SC520 or 386EX CPUs. RI not present on 386EX CPU
Modules. * = Not used on COM1 of 386EX CPUs.
Table 7-2 - SCB Connectors COM3, COM5 & COM6 Pin Assignment
Pin
#
Signal
RS-232
Description:
RS-232 Signals
Signal
RS-485
Description:
RS-485 Signals (COM3)
1 DCD
2 DSR
3 RXD
4 RTS
5 TXD
6 CTS
7 DTR
8 GND
Data Carrier Detect Input
Data Set Ready Input
Receive Data Input
Request To Send Output
Transmit Data Output
Clear To Send
TXD-
RXD+
RXD-
N/A
Receive Data + Input
Receive Data - Input
N/A
Transmit Data - Output
N/A
Data Terminal Ready Output TXD+
Signal/Power Ground ISOGND
Transmit Data + Output
Isolated Ground
1 8
D4041A
Looking into receptacle
Figure 7-3 - RJ-45 Connector J2 (SCB) Associated with COM3 (SCB)
ControlWavePAC & ControlWaveEXP Diagnostics / 7-4
Table 7-3 - RS-485 Network Connections
(see Tables 7-1 & 7-2 for Control Wave RS-485 Port Pin # Assignments)
From
Master
To 1st
Slave
To nth
Slave
TXD+ RXD+ RXD+
TXD- RXD- RXD-
RXD+ TXD+ TXD+
RXD- TXD- TXD-
ISOGND ISOGND ISOGND
Figure 7-4 - Control Wave CPU Board Switches SW1 & SW3
7.1.1
Overview of WINDIAG Testing
To use the WINDIAG program place any critical process (associated with the Control Wave unit in question) under manual control. WINDIAG cannot be run while the Control Wave application is running. Set the CPU Modules Switch SW1-8 to the OFF (closed) position (see
Figure 7-4). Perform steps 1 through 6 below.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-5
Figure 7-5 - Control Wave Diagnostic Component Identification Diagram
1.
Before you begin, either LocalView (see Section 1.7.1) or NetView (see Section 1.7.2) must be running.
2.
To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-6
3.
Once WINDIAG has been entered (and the unit to be tested has been selected on the initial WINDIAG entry menu), the Diagnostic Test Category Menu (Figure 1-7) 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.
6.
Set the Control Wave CPU Switch SW1-8 (SW3-8 for a Control Wave EXP ) to the ON
(Open) position and then restart the unit via the Power Switch. The Control Wave should resume normal operation.
7.1.2 Diagnostics Using WINDIAG
All Controllers Modules except the Power Supply/Sequencer Module can be tested using the
WINDIAG program. From the Diagnostic Test Category Menu (see Figure 1-7) the following diagnostic tests can be performed:
CPU & Peripherals Diagnostic: See Section 7.2
Checks the CPU Module (except for RAM & PROM).
PROM/RAM Diagnostic:
Communications Diagnostic:
See Section 7.3
Checks the CPU’s RAM and PROM hardware.
See Section 7.4
Checks Comm. Ports 1 through 6 - The External loopback tests require the use of a loop-back plug. Note:
COM5 & COM6 require Open BSI version 5.0 or higher.
Ethernet Diagnostic: See Section 7.5
Checks Ethernet Ports 1 through 3 - The Loop-back Out
Twisted Pair tests require the use of a loop-back plug.
Analog Output Diagnostic:
Analog Input Diagnostic:
Discrete I/O Diagnostic:
See Section 7.6
Checks the Analog Output Module.
See Section 7.7
Checks the Analog Input Module.
See Section 7.8 for DO & Section 7.9 for DI
Checks the DI Module and/or the DO Module.
High Speed Counter Diagnostic: See Section 7.10
Checks the Universal Digital Input Module
Low Level AI Diagnostic: Sec 7.11
Checks RTD and LLAI Modules
EEPROM See
Checks I/O Module EEPROM Circuitry
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-7
Analog Output Diagnostic, Analog Input Diagnostic, Discrete Input/Output Diagnostic, and the High-speed Counter Diagnostic and the Low Level Analog Input Diagnostic menus discussed in this chapter contain the following entry and display fields:
Number of Passes
Enter the number of test cycles you want to execute (1 to 256), or enter one of the Continuous Modes (see Section 1.9.2 of Chapter 1).
Board Number to Test
Enter a number from 1 to 8 representing the slot assignment of the I/O Module to be tested.
Note: On secondary or "Display" menus, the "Board Number Returned" should match the
"Board Number to Test."
Board Type Returned
This field displays the type of board being tested. It provides you with a verification of the board type selected for the slot position being tested by posting one of the following board types: AI8 or AI16, DO16 or DO32, DI16 or DI32, HSC6, HSC12, LLAI6 or RTD4. "AO
Point to Test" is posted on the Analog Output Linearity Calibration Menu instead of "Board
Number Returned." The "AO Point to Test" adjustment point represents the AO circuit number to be tested (1 to 4 or 8).
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays ‘Working’ or ‘Idle’ to indicate if a test is in process or not.
7.1.3 Diagnostics Test Equipment
The test detailed in this chapter require the use of the following external test equipment:
C Digital Multimeter (DMM), 1 ohm to 10 M ohm (45 PPM or better accuracy)
C DC Voltage Source, Variable to 31 V dc ( ± 10 microvolt resolution)
C Precision Current Source, 1 mA to 20 mA ( ± 1 microamp resolution)
C One 50-ohm, (50-watt) ± 5% resistor (used as the 500mA load for DO testing - see
Figure 7-26)
C One NPN Transistor (2N2222) (used in UDI HSC Test Circuit - see Figures 7-36 &
7-37)
C One 1 k ohm ± 1% resistor (used in UDI HSC Test Circuit - see Figures 7-36 & 7-37)
C One 12/24V Form C Relay (used in UDI HSC Test Circuit - see Figure 7-37)
C Pulse Generator, adjustable offset, adjustable amplitude to 24 V, and adjustable frequency to 10 kHz (with totalizer/accumulator function) - see Figures 7-36 & 7-37)
C Accumulator (Totalizer) - Required if Pulse Gen. doesn’t have totalizer function.
C RS-232 Loop-back Plugs (see Figure 7-10)
C RS-485 Loop-back Plugs (see Figure 7-11)
C Ethernet Loop-back Plug (see Figure 7-13)
7.2 TESTING CPU & PERIPHERALS
These tests do not require removal of any board or any special external equipment. At the
Diagnostic Test Category Menu (see Figure 1-7), highlight the "CPU And Peripherals"
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-8
selection and then click on the "Run" button at the bottom of the screen. Figure 7-6 will be invoked.
The following tests aren’t applicable to ControlWave units: RUN Pic, RUN Dma, RUN
Timers, RUN Floating Point Coprocessor, & RUN Power Supply (CWaveLP).
7.2.1 RUN LEDs
Click on the "RUN LEDs" button. The RUN LEDs test provide pass/fail status indications as follows: RUN LEDs - Pass = X (--- No Return Status---) where x = the number of the pass. For this test, no messages are reported at the PC.
While the test is running observe the Port 80 Display on the CPU Module. The Display codes should come on with 00 and proceed to 11, 22, 33, 44, 55, 66, 77, 88, 99, AA, BB, CC,
DD, EE and FF and then count down to 00, i.e., EE, DD, etc.
D4041A
Figure 7-6 - CPU and PERIPHERALS Diagnostic Menu
ControlWavePAC & ControlWaveEXP Diagnostics / 7-9
7.2.2 RUN Lithium
This test checks the status of the on-board battery that maintains the data in the system
RAM if power is lost. When the battery(s) are functioning properly, the controller can lose power but still retain its application load and continue running from the point of power loss when power is restored.
Click on "RUN Lithium" button. The STATUS column will show either "SUCCESS" or
"Lithium Battery Fail" (if the test fails or the Lithium Battery Enable Switch (SW3-4) on the CPU Board hasn’t been set ON.
7.2.3 Real Time Clock (RTC)
Click on the "RTC Diagnostic" button. The PC will proceed to the RTC Diagnostic Menu shown in Figure 7-7.
Figure 7-7 - Real Time Clock Diagnostic Menu
This set of tests will determine if the RTC chip is fully functional. This menu has its own
Number of Passes field that is independent of what is set at the CPU and Peripherals
Diagnostic Menu (Figure 7-6). Individual selections are made by positioning the cursor at the appropriate selection point and clicking the left mouse button.
Time Registers Test
This test checks the RTC registers and will display either "SUCCESS" or "FAILURE - RTC" under the STATUS column.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-10
Alarm Registers Test
This test checks the RTC Alarm Registers and will display either "SUCCESS" or
"FAILURE - RTC Alarm" under the STATUS column.
Set Time: 01-JAN-87 00:00:00
For this function, the Number of Passes should be set to 1. This function sets the RTC to the date and the time shown and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Set Time from PEI (see note 1)
For this function the Number of Passes should be set to 1. This function sets the RTC using the date and time from the PC clock and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Note 1: Only the date and time (down to minutes) will be used from the PC. The seconds at the RTC will ALWAYS be initialized at 30.
Read Time
This function reads the date and time from the RTC and displays it in the STATUS column at the PC. To set the RTC to a known starting point, use one of the SET TIME functions.
Then set the Number of Passes to continuous (CR or CS) and activate the READ TIME function to visually monitor the accuracy of the RTC.
When finished, return to the CPU and Peripherals Diagnostic Menu by clicking on the
"Return To Menu" button.
7.3 PROM / RAM DIAGNOSTIC TESTING
Each Control Wave Process Automation Controller has a mixture of PROM and RAM memory to support both the firmware and the software load. The PROM/RAM Diagnostic
Menu shown in Figure 7-8 is accessed from the Diagnostic Test Category Menu described in
Chapter 1 (Figure 1-7).
7.3.1 PROM Diagnostic Test
PROM diagnostic testing is done by calculating a checksum on the FLASH memory contents and comparing it against a checksum stored in FLASH memory when they were programmed. The PROM diagnostic is designed to test both the firmware FLASH memory and the load FLASH memory in a single execution of the test.
After setting the Number of Passes, click on the "RUN PROM Diagnostic" button to begin the test. After the test is completed, one of the following responses will be displayed under the STATUS column.
Success
Fail - System PROM Failure
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-11
Figure 7-8 - PROM/RAM Diagnostic Menu (see notes 2 & 3)
Note 2: The Note: The RAM test is a destructive test…doesn’t apply to Control Wave units.
Note 3: The Error Status: If rtu was not reset automatically,…doesn’t apply to Control Wave units.
7.3.2 RAM Diagnostic Test
This test verifies that each bit of read/write memory can be written and read correctly and that each memory location can be addressed without adversely affecting another memory location. This test checks all RAM memory installed in the Control Wave Process
Automation Controller. Any failures are reported by giving the full address of the failing location which enables isolating the failure to the board and chip level.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-12
Set the "Number of Passes" field to a number from 1 to 256 or to either "Continuous/Repeat
After Error" or "Continuous/Stop After Error." If a "Continuous" selection is made, the test will run continuously until it is stopped by selecting "ABORT Diagnostic Test."
To start the test, click on the "RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
Pass is indicated by: Size X.XMB where X.X is the size of RAM given in MB.
Failure is indicated by: Fail - YYYYYYYY where YYYYYYYY is the address that failed.
At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, click on the "ABORT RAM
Diagnostic" button. Return to the PROM/RAM Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first click on the "Return to Menu" button before it will exit from the
PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the
Control Wave.
7.4 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 7-9) verify the operation of the Universal Asynchronous Receiver Transmitter (UART) and associated interfaces for the Control Wave serial communications ports. Testing is done in both a polled environment (where the UART is interrogated for event status), and in an interruptdriven environment (where the UART presents an interruption to the firmware to report events).
7.4.1 Hardware Setup and Testing of Serial Comm. Ports
These tests use a loop-back technique to verify correct operation of the port being tested.
For loop-back mode an external loop-back plug is required as detailed.
Note: COM5 & COM6 require Open BSI version 5.0 or higher to run.
1.
Connect the appropriate loop-back plug (see Figure 7-10 for RS-232 or Figure 7-11 for
RS-485) to the port to be tested. Remember that the port connected to the PC cannot be tested.
2.
Access the Communications Diagnostic Menu. The Communications Diagnostic Menu
(see Figure 7-9) is accessed from the Diagnostic Test Category Menu (Figure 1-7) by
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-13
highlighting the "Communications" selection and then clicking on the "Run" button at the bottom of the screen.
Figure 7-9 - Communications Diagnostic Menu
3.
Select the port to be tested, i.e., COM1, COM2, COM3, COM4, COM5 or COM6 at the
"Port to Test" field of the Communications Diagnostic Menu (Figure 7-9) (also see
Figure 7-5).
4.
Set the "Baud Rate to Test" field to 115200 baud or ALL ASYNC.
5.
Set the "Number of Passes" to any number from 1 to 256, or select "Continuous/Repeat after Error," or "Continuous/Stop after Error" via one of the three "Radio" buttons located near the top of the menu.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-14
Figure 7-10 - RS-232 Loop-back Plugs
Figure 7-11 - RS-485 Loop-back Plugs
6.
Click on the "RUN External Loop-back" Test button. The Status: indication will switch from "IDLE" to "Working." If an incorrect baud rate has been set, or a port without a loopback plug has been selected, the test will fail and the message "Time Out Waiting
For Response" will be posted next to "Error Status:".
The test will proceed and return one of the following responses under the STATUS column:
Success
Fail - Polling Asynch Failure
- Interrupt Asynch Failure
- Sync
- RTS/CTS
Error
If the "RTS/CTS Failure" message is displayed, ensure that the loop-back plug is correctly configured and installed.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-15
When you have finished with communications port testing, be sure to remove the loop-back plug.
7.5 ETHERNET PORT DIAGNOSTICS
The Ethernet Diagnostic menu of Figure 7-12 is entered from the Diagnostic Test Category
Menu (Figure 1-7). This menu provides four poke points (three associated with Ethernet circuitry test and one that provides the Return Hardware Address [which resides in
FLASH]). These tests verify the operation and integrity of the PCNET (Ethernet)
Controller and the Ethernet port hardware on the CPU Board and SCB Board.
Figure 7-12 - Ethernet Diagnostic Menu
7.5.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup
The 10Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub. To configure the system for the Loop-Back Out Twisted Pair diagnostic test either remove the standard R-J45 cable from the CPU Board's R-J45 connector and replace it with an R-J45
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-16
cable configured for loop-back, or remove the R-J45 cable associated with the port in question from the hub and install the unterminated end into an RJ-45 Jack configured for loop-back. Table 7-4 provides the pin identification and description for the RJ-45 port. Pin-1
(TX+) must be connected to Pin-3 (RX+) and Pin-2 (TX-) must be connected to Pin-6 (RX-) for proper loop-back test configuration (see Figure 7-13).
If the "Loop-Back Out Twisted Pair" Test RUN button is selected while the port is attached to an Ethernet Hub, a Failures Status will be posted.
Table 7-4 - Ethernet 10Base-T (RJ45) Connector Pin Assignments
Pin # Pneumonic Description
1 TX+
2 TX-
3 RX+
4 -
5 -
6 RX-
7 & 8 - Not Connected
Figure 7-13 - RJ-45 Ethernet Loop-back Plug
7
.5.2 Ethernet Port Diagnostic Test Execution
There are four unique test buttons provided on the Ethernet Diagnostic Menu. Note: Only the "RUN Loop-back out twisted pair" and "RUN Return hardware address" tests are
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-17
applicable to Control Wave units, i.e., the "RUN Chip internal loop-back" and "RUN Loopback out AUI port" tests aren’t applicable. The applicable tests are discussed below.
7.5.2.1 Loop-back Out Twisted Pair Test RUN Button
Set the Number of Passes. Make sure that the port is properly configured with a cable or jack for loop-back testing (see Section 7.5.1). Click on the "RUN Loop-back out twisted pair"
Test button. The test will proceed and return either 'Success' or one of the following responses under the STATUS column:
Fail - No Hardware Present
- Loop-back
- Loop-back
- Loop-back Failed
-
Error Information Returned
When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jackplug and reconnect the Ethernet cable to both the Control Wave port in question and the
Ethernet Hub.
7.5.2.2 Return Hardware Address Test RUN Button
Set the Number of Passes. Click on the "Return hardware address" Test button. The test will proceed and if successful the hardware address will be displayed. The hardware address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all Bristol
Ethernet Comm. ports. The remainder of the hardware address is unique for each board manufactured and is stored in EEPROM. If the error message "Error Information
Returned" is displayed instead of the hardware address, and the unit has been programmed with a proper hardware address, the CPU Module should be replaced.
7.5.3 Ethernet Port Diagnostic Error/Failure Messages
If either a "No Hardware Present" or "Error Information Returned" message is displayed, ensure that the loop-back test requirements have been properly established (see Section
7.5.1). If test requirements have been met and the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare
Failed" message, check the cable in question. If the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
7.6 ANALOG OUTPUT (AO) TESTS
The AO tests are used to check Analog Output Modules to ensure they are fully operational.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Output" selection and then click on the “Run” button at the bottom of the screen.
The PC will proceed to the Analog Output Linearity Calibration Menu (see Figure 7-14).
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-18
Figure 7-14 - Analog Output Linearity Calibration Menu
WARNING
Only the "RUN Set 0% (after Cal)", "RUN Set 100% (after Cal)", "RUN Set Output to
UnderRange" and the "RUN Set Output to OverRange" Tests buttons are to be utilized by other than factory personnel. DO NOT initiate any other tests. The
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-19
tests discussed herein provide for testing Analog Output Modules; calibration is not covered. DO NOT attempt to calibrate an Analog Output Module.
7.6.1 Analog Output Circuitry Calibration Verification
For this procedure the following items are required:
A Digital Multimeter (DMM) (see Chapter 1).
Wiring terminals for local and remote terminal blocks are identified in Figures 7-15 & 7-16 respectively.
D4041A
Figure 7-15 - Local AO Module Terminal Block Assembly Assignments
ControlWavePAC & ControlWaveEXP Diagnostics / 7-20
Figure 7-16 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
For AO 4-20mA & 1-5V Operation.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-21
7.6.1.1 4-20 mA Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 7-14) provides for test setup configuration of the Analog Output Module to be tested.
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until stopped by clicking on the appropriate “ABORT” button.
2.
The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Output Module being tested (1 to 2, 4 or 8). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message
" Invalid Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the menu.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1 to 4 or 8). Set the value accordingly.
4.
Connect the Digital Multimeter (in current Mode) (+) lead to the +AO#I terminal and the (-) lead to the -AO# terminal of the local or remote AO Module Terminal Block
Assembly (see Figures 7-15 & 7-16).
5.
Click on "RUN Set 0% (after Cal)" Test button. Verify that the DMM displays 4.000 mA
( ± .0043 mA). The AO Module’s green LED (GOOD) should be ON and the red LED
(FAIL) should dim until the "ABORT" selection has been activated. Once the test has been aborted, the red LED (FAIL) should be ON.
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the DMM displays 20.000 mA ( ± .0043 mA). The AO Module’s green LED (GOOD) should be ON and the red LED
(FAIL) should dim until the "ABORT" selection has been activated. Once the test has been aborted, the red LED (FAIL) should be ON.
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 3.200 mA ( ± .129 mA). The AO Module’s green LED (GOOD) should be ON
(the red LED (FAIL) should remain ON) until the "ABORT" button has been activated.
Once the test has been aborted, the red LED (FAIL) should be ON.
8.
Click on "RUN Set Output to OverRange" Test button. Verify that the DMM displays
20.800 mA ( ± .129 mA). The AO Module’s green LED (GOOD) should be ON (the red
LED (FAIL) should remain ON) until the "ABORT" button has been activated. Once the test has been aborted, the red LED (FAIL) should be ON.
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
10.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-9) by selecting the Return to Menu button at the bottom of the Analog Output
Linearity Calibration Menu (Figure 7-14).
7.6.1.2 1-5V Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 7-14) provides for test setup configuration of the Analog Output Module to be tested.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-22
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until it is stopped by clicking on the appropriate “ABORT” button.
2.
The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Output Module being tested (1 to 2, 4 or 8). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message
" Invalid Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the menu.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1 to 4 or 8). Set the value accordingly.
4.
Connect the Digital Multimeter (in voltage Mode) (+) lead to the +AO#V terminal and the (-) lead to the -AO# terminal of the local or remote AO Module Terminal Block
Assembly (see Figures 7-15 & 7-16).
5.
Click on the "RUN Set 0% (after Cal)" Test button. Verify that the meter displays 1.000
Vdc ( ± .001 V). The AO Module’s green LED (GOOD) should be ON and the red LED
(FAIL) should dim until the "ABORT" button has been activated. Once the test has been aborted, the red LED (FAIL) should be ON.
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the meter displays 5.000
Vdc ( ± .001 V). The AO Module’s green LED (GOOD) should be ON and the red LED
(FAIL) should dim until the "ABORT" button has been activated. Once the test has been aborted, the red LED (FAIL) should be ON.
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 0.800 Vdc ( ± .030 V). The AO Module’s green LED (GOOD) should be ON (the red LED (FAIL) should remain ON) until the "ABORT" button has been activated.
Once the test has been aborted, the red LED (FAIL) should be ON.
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
10.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by clicking on the "Return to Menu" button at the bottom of the Analog
Output Linearity Calibration Menu (Figure 7-14).
8.
Click on the "RUN Set Output to OverRange" Test button. Verify that the DMM displays 5.200 Vdc ( ± .030 V). The AO Module’s green LED (GOOD) should be ON (the red LED (FAIL) should remain ON) until the "ABORT" button has been activated.
Once the test has been aborted, the red LED (FAIL) should be ON.
7.7 ANALOG INPUT (AI) TESTS
The AI tests are used to check Analog Input Modules to ensure they are fully operational. A
Precision Current Source is required for 4-20mA AI testing and a Variable dc Voltage
Source is required for 1-5V AI testing.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-23
Figure 7-17 - Analog Input Diagnostic Menu
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Input" selection and then click on the “Run” button at the bottom of the screen. The PC will proceed to the Analog Input Diagnostic Menu (see Figure 7-17).
The Analog Input Diagnostic Menu (Figure 7-17) provides for test setup configuration of the
Analog Input Module to be tested. Only the "Analog Input Display" button is utilized. If the
"RUN 0% of AI", "RUN 100% of AI" or "RUN Verify Amplifier Calibration" button is activated, the following message will posted (in red) adjacent to Error Status: near the bottom of the menu: " Invalid Diagnostic Test Code ."
7.7.1 4-20 mA Analog Input Channel Test
A Precision Current Source capable of providing 20 mA with 1 uA resolution will be required to perform AI testing of a 4-20mA AI Module.
1. The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Input Module being tested (1 to 2, 4 or 8). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Display menu (see Figure 7-18).
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-24
2.
On the Analog Input Diagnostic Menu (Figure 7-17) click on the "Analog Input
Display" button. The Analog Input Display menu (Figure 7-18) will appear.
Figure 7-18 - Analog Input Display Menu
The test will proceed until it is stopped by clicking on the “End Test” button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI
Values should be either 8 or 16 (depending on the type of AI Module). The Board
Number Returned should be the same as the Board Number to Test assigned on the
Analog Input Diagnostic Menu and the Board Type Returned should be either AI8 or
AI16.
Verify that the AI Module’s Status LED turns Green for the duration of testing. Zeros
(0) should be displayed for all AIs on the Analog Input Display Menu (Figure 7-18).
Verify that in addition to an Analog Input Display "GND-Ref" value = 0, the values of the 1V-REF and 5V-REF are within specification as follows:
1V-REF Hex Reading = 0333 ± 0010 (0323 to 0343)
5V-REF Hex Reading = 3CCC ± 0010 (3CBC to 3CDC)
3. Click on the "End Test" button and return to the Analog Input Diagnostic menu
(Figure 7-17).
4.
Connect the positive output of the Precision Current Source to the (-) input AI channel
# (e.g., for AI1 = Pin 2 of the local Term. Block). Connect the negative output of the
Precision Current Source to the (ISOGND) associated with the AI channel # in
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-25
question (e.g., for AI1 through AI4 = -VF1-4 of the local Term. Block). (See Figures 7-19 and 7-20 for local and remote AI Term. Block assignments respectively).
Figure 7-19 - Analog Input Module - Local Terminal Blocks
5. Apply 3.111 mA to the Analog Input being tested. Click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (Figure 7-17). Vary the input current from 3.111 mA to 20.898 mA and verify that the hex values provided below are displayed accordingly for the AI channel being tested.
Input
Current
HEX
Reading
3.111 mA 0000 to 0018
4.000 mA 0333 ± 0010 (0323 to 0343)
8.000 mA 1199 ± 0010 (1189 to 01A9)
12.000 mA 2000 ± 0010 (1FEO to 2010)
Red
LED
Green
LED
ON OFF
ON/OFF ON/OFF
OFF ON
OFF ON
16.000 mA 2E66 ± 0010 (2E56 to 2E76) OFF ON
20.000 mA 3CCC ± 0010 (3CBC to 3CDC) ON/OFF ON/OFF
20.889 mA 3FEF to 3FFF ON OFF
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-26
Figure 7-20 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
For 4-20 mA AI Operation
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-27
6. Set the Precision Current Source output to zero and remove it from the AI Module’s
Term. Block. Reconnect it to the next AI on TB2 and repeat Steps 4 through 5 for each of the eight/sixteen analog inputs, checking the hex reading under the appropriate AI channel.
WARNING
Be sure to set the current source to zero before removing it after each input is tested.
7.7.2 1-5V Analog Input Channel Test
A Variable dc Voltage Source capable of outputting 5.000V with 10uV resolution will be required to perform AI testing of a 1-5V AI Module.
1. The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Input Module being tested (1 to 2, 4 or 8). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Display menu (see Figure 7-18).
2.
On the Analog Input Diagnostic Menu (Figure 7-17) click on the "Analog Input
Display" button. The Analog Input Display menu (Figure 7-18) will appear.
The test will proceed until it is stopped by clicking on the "End Test" button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI
Values should be either 8 or 16 (depending on the type of AI Module). The Board
Number Returned should be the same as the Board Number to Test assigned on the
Analog Input Diagnostic Menu and the Board Type Returned should be either AI8 or
AI16.
Verify that the AI Modules Status LED turns Green for the duration of testing. Zeros
(0) should be displayed for all AIs on the Analog Input Display Menu (Figure 7-18).
Verify that in addition to an Analog Input Display "GND-Ref" value = 0, the values of the 1V-REF and 5V-REF are within specification as follows:
1V-REF Hex Reading = 0333 ± 0010 (0323 to 0343)
5V-REF Hex Reading = 3CCC ± 0010 (3CBC to 3CDC)
3.
Click on the "End Test" button and return to the Analog Input Diagnostic menu
(Figure 7-17).
4.
Connect the positive output of the Variable dc Voltage Source to the (+) input AI channel # (e.g., for AI1 = Pin 1 of the local Term. Block). Connect the negative output of the Variable dc Voltage Source to the (-) input AI channel # in question (e.g., for AI1 =
Pin 2 of the local Term. Block). (See Figures 7-19 and 7-21 for local and remote AI
Term. Block assignments respectively).
5. Apply 0.778 Vdc to the Analog Input being tested. Click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (Figure 7-17). Vary the input voltage from
0.778 Vdc to 5.222 Vdc and verify that the hex values provided below are displayed accordingly for the AI channel being tested.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-28
D4041A
Figure 7-21 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
For 1-5V AI Operation
ControlWavePAC & ControlWaveEXP Diagnostics / 7-29
Input
Voltage
0.778 Vdc 0000 to 0018
HEX
Reading
Red
LED
ON
Green
LED
OFF
1.000 Vdc 0333 ± 0010 (0323 to 0343)
2.000 Vdc 1199 ± 0010 (1189 to 01A9)
3.000 Vdc 2000 ± 0010 (1FE0 to 2010)
4.000 Vdc 2E66 ± 0010 (2E56 to 2E76)
5.000 Vdc 3CCC ± 0010 (3CBC to 3CDC
5.222 Vdc 3FEF to 3FFF
ON/OFF ON/OFF
OFF ON
OFF ON
OFF ON
ON/OFF ON/OFF
ON OFF
6. Set the Variable dc Voltage Source to zero and remove it from the AO Module’s Term.
Block. Reconnect it to the next AI on the appropriate Term. Block and repeat Steps 4 and 5 for each of the eight/sixteen analog inputs, checking the hex reading under the appropriate AI channel.
WARNING
Be sure to set the voltage source to zero before removing it after each input is tested.
7.8 DISCRETE OUTPUT (DO) TESTS
These tests check the discrete output circuitry of a Control Wave DO Module, including the output registers and the output paths to the terminal block.
For the tests in this chapter, you will need the DMM and Variable dc Voltage Source described in Chapter 1. You will also need a 50-ohm, 30-watt resistor required to provide a
500mA DO load from the 10 to 31 Vdc source (see Section 7.8.3).
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the “Run” button at the bottom of the screen. The PC will proceed to the menu shown in Figure 7-22.
7.
8.1 Automatic Discrete Output Test
All of the DOs will be automatically sequenced for this test. Each DO will be enabled in turn for approximately 0.2 seconds. Be sure to set the Number of Passes to
"Continuous/Stop after Error" to provide a continuous test cycle.
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7-22), set the Board
Number to Test to match DO Module’s ControlWave Slot # (1 to 8). Set the Number of
Passes to "Continuous/Stop after Error" and then click on the "RUN Discrete Output
Sequence" Test button. NOTE: No test information will be displayed on the menu.
2.
The DO Bd. Status LED should turn GREEN and the DO status LEDs should sequence in a rotating pattern (see Figure 7-23). Each DO should turn on for approximately 200 msec. When the test has completed, the DO Bd. Status LED will turn RED.
Additionally, the Board Type Returned should match the DO Module configuration, i.e., DO16 or DO32. Proceed to Section 7.8.2 for the Discrete Output Display Test.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-30
Figure 7-22 - Discrete Input/Output Diagnostic Menu - DO Sequence
7.8.2 Discrete Output Display Test
These tests check the DO Modules LEDs.
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7-22), set the "Board
Number to Test" to match DO Module’s ControlWave Slot # (1 to 8). Set the "Number of
Passes" to 10 and then click on the "Discrete Output Display" Test button. The Discrete
Output Display Menu (Figure 7-24) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-31
Figure 7-23 - Digital Output Module LED Designations
2.
On the Discrete Output Display Menu (see Figure 7-24), the Status: indication will change from IDLE to WORKING once "Start Test" has been selected. When the Status: indication changes back to IDLE, it will appear similar to the Discrete Output Display
Menu of Figure 7-25.
The Discrete Output Display menu will display DOs numbers (16 or 32) and will post the Number of Valid DO Values (16 or 32), the Board Number Returned (1 to 8 representing the DO Module’s Slot #), the Board Type Returned (DO16 or DO32).
Observe the DO Module’s LED Board. DO LED 1 should be ON and all other DO LEDs should be OFF.
3.
Change the Drive DO: number to 2 and click on the "Start Test" button. Observe the
DO Module’s LED Board. DO LED 2 should be ON and all other DO LEDs should be
OFF.
4.
Repeat step 3 until all DOs have been tested. Note: The LED associated with the last DO tested will remain ON until the unit has been reset.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-32
Figure 7-24 - Discrete Output Display - Initial Entry
Figure 5-10 - 3305 DO Test – Test Setup
Figure 7-25 - Discrete Output Display - Tests in Progress
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-33
7.8.3
Manual Discrete Output Load Test
This test checks each DOs output circuitry. You will need the Digital Multimeter (DMM), the Variable dc Voltage Source and a 50-ohm, 30-watt resistor (required to provide a
500mA DO load from the 10 to 31 Vdc source).
1.
Shut off the Control Wave.
2.
Construct the test circuit of Figure 7-26 (DO1 example) (for Remote Termination
Modules see Figure 7-27). The test circuit of Figure 7-26 provides a 500mA load with the power supply providing from 10 to 31 Vdc. Turn on Control Wave power.
D4041A
Figure 7-26 - DO Module Local Term. Block & Load Test Circuit
ControlWavePAC & ControlWaveEXP Diagnostics / 7-34
Figure 7-27 - Remote DIN-Rail Mountable DO Term. Block Assembly Assignments
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-35
3.
On the Discrete Input/Output Diagnostic Menu (see Figure 7-22), set the "Board
Number to Test" to match DO Module’s Control Wave Slot # (1 to 8). Set the "Number of Passes" to 1 and then click on the "Discrete Output Display" button. The Discrete
Output Display Menu (Figure 7-24) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
4.
On the Discrete Output Display Menu (see Figure 7-24), the Status: indication will change from IDLE to WORKING once "Start Test" has been selected. When the Status: indication changes back to IDLE, it will appear similar to the Discrete Output Display
Menu of Figure 7-25.
The Discrete Output Display menu will display DOs numbers (16 or 32) and will post the Number of Valid DO Values (16 or 32), the Board Number Returned (1 to 8 representing the DO Module’s Slot #), the Board Type Returned (DO16 or DO32).
Observe the DO Module’s LED Board. DO LED 1 should be ON and all other DO LEDs should be OFF.
5.
On the Discrete Output Display Menu, set the Drive DO: for the desired DO channel number (1 to 16 or 1 to 32) (see Figures 7-26 & 7-27). Measure the voltage drop between the ISOPWR# terminal and the DO output terminal (with the output in question turned ON) (ISOPWR1 = Pin 9 and +DO1 = Pin 1 - see Figure 7-26). The output will be turned ON once the “Start Test” button has been selected. The DO voltage drop should not exceed 0.25V. Shut off the Control Wave Process Automation
Controller and the test circuit’s power source.
6.
Move the test circuit to the next DO to be tested. Reapply power to the Control Wave and the test circuit. Repeat step 5 for each channel to be tested.
7.9 DISCRETE INPUT (DI) TESTS
These tests check the discrete input circuitry of a Control Wave DI Module to ensure a complete and fully operational DI Module.
For the Digital Input Display Test (see Section 7.9.2), you will need the Variable dc Voltage
Source described in Chapter 1 and a short jumper wire (3” long).
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the
Discrete Input/Output Diagnostic Menu (see Figure 7-28).
7
.9.1 Automatic Discrete Input Test
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7-28), set the "Board
Number to Test" to match the DI Module’s Control Wave Slot # (1 to 8). Set the
"Number of Passes" field to "Continuous/Stop after Error" and then click on the "RUN
Discrete Input Circuitry" Test button.
2.
The DI Bd. Status LED should turn GREEN and the DI status LEDs should remain
OFF. When the test has completed (via “ABORT”), the DI Bd. Status LED will turn
RED. Additionally, the Board Type Returned should match the DI Module con-
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-36
figuration, i.e., DI16 or DI32. Proceed to Section 7.9.2 for the Discrete Input Display
Test.
Figure 7-28 - Discrete Input/Output Diagnostic Menu - DI Circuitry
7.9.2 Discrete Input Display Test
These tests check the DI Modules LEDs and field input circuitry.
1. On the Discrete Input/Output Diagnostic Menu (see Figure 7-28), set the "Board
Number to Test" to match DI Module’s Control Wave Slot # (1 to 8). Set the "Number of Passes" to "Continuous/Repeat after Error" and then click on the "Discrete Input
Display" Test button. The Discrete Input Display Menu (Figure 7-31) will appear. The
DIs should not be highlighted (in RED) and the module’s DI LEDs should be OFF. The
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-37
Discrete Input Display Menu will display DIs numbers (16 or 32) and will post the
Number of Valid DI Values (16 or 32), the Board Number Returned (1 to 8 representing the DI Module’s Slot #), the Board Type Returned (DI16 or DI32). Observe the DI
Module’s LED Board. All DI Module channel LEDs, i.e., DI1 through DI16/32 should be
OFF. The DI Module LED Boards Status LED should be GREEN when the test is running and should return to RED when the test is ended.
2. Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Display Menu.
3. Shut off the Control Wave Process Automation Controller. Set up a test circuit for the type of DI Module being tested, i.e., Internally Sourced DIs or Externally Powered DIs
(see Figures 7-29 & 7-30). For an Internally Sourced DI Module the individual inputs to be tested must be shorted (e.g., +DI1 to ISOGND1, +DI3 to ISOGND1, etc.). For an
Externally Powered DI Modules, 24Vdc must be placed across the inputs to be tested
(e.g., +24Vdc to +DI1 and 24V Common to ISOGND1, +24Vdc to +3DI and 24V
Common to ISOGND1, etc). Any or all inputs can be tested. It is recommended that odd
DIs (1 through 15/31) be tested and then even DIs (2 through 16/32).
Figure 7-29 - Local Terminal Block Assembly Assignments and Test Examples for
Internally Sourced DI Operation or Externally Powered DI Operation
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-38
4. Apply power to the Control Wave unit. On the Discrete Input/Output Diagnostic Menu
(see Figure 7-28), click on the "Discrete Input Display" button.
Figure 7-30 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Internally Sourced DI Operation or Externally Powered DI Operation
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-39
The Discrete Input Display menu will display DIs numbers (16 or 32) and will post the
Number of Valid DI Values (16 or 32), the Board Number Returned (1 to 8 representing the DI Module’s Slot #), the Board Type Returned (DI16 or DI32). Any DI being tested should be highlighted in RED (see Figure 7-32). Observe the DI Module’s LED Board.
DI Channel LEDs associated with DI Channels configured for testing should be ON and all other DI Channel LEDs should be OFF. The DI Module LED Boards Status
LED should be GREEN when the test is running and should return to RED when the test is ended.
Figure 7-31 - Discrete Input Display Menu - No Inputs
D4041A
Figure 7-32 - Discrete Input Display Menu - DIs 1, 3, 5 & 7 ON
ControlWavePAC & ControlWaveEXP Diagnostics / 7-40
5.
Repeat steps 2 through 4 configuring the DIs to be tested until all DIs have been tested. Select the "End Test" button at the bottom of the screen to return to the
Discrete Input/Output Diagnostic Menu. On the Discrete Input/Output Diagnostic
Menu select the "Return to Menu" button or the X (in the upper right corner) to return to the Diagnostic Test Category Menu. When testing has been completed, shut off power to the Control Wave and remove any test hardware.
7.10 UNIVERSAL DIGITAL INPUT (UDI) TESTS
These tests check the universal digital input circuitry of a Control Wave UDI Module to ensure a complete and fully operational UDI Module. These modules are factory configured with all inputs set with debounce enabled or with all inputs set with debounce disabled.
Individual UDI inputs can be customer configured for polled input, interrupt on change of state (COS) or totalizer operations. The maximum input frequency is 10 kHz. Note: The
Counters Test is not applicable to the Control Wave UDI Module.
To perform the High Speed Counters Display Tests (see Section 7.10.1), the test setup of
Figure 7-36 is required for UDI Modules with Debounce Disabled and the test setup of
Figure 7-37 is required for UDI Modules with Debounce Enabled.
Figure 7-33 - High Speed Counters Diagnostic Menu
In addition to the equipment shown in Figures 7-36 and 7-37 you will need a dual trace oscilloscope to calibrate the square wave produced by the Pulse Generator. Note: If the
Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-41
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the "High Speed Counter" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the High Speed Counters Diagnostic Menu (see Figure 7-33).
est
7.10.1 High Speed Counter Display T
Selecting "High Speed Counter Display" will test the UDI input path from the termination blocks. In this test the totalizers for each input are continually polled and the accumulated count for each input is displayed. A signal is forced at the universal input terminal block and the state of that UDI is updated on the screen.
The 24V or 12V UDI may be tested in debounced or non-debounced configurations. For the non-debounced configuration, connect a pulse generator that can drive a 5 mA load at 24V or 12V to the UDISETX terminal and the return to the UDICOMX terminal. All inputs can be driven simultaneously. The pulse generator should generate a predetermined number of pulses. After the pulses are applied to the UDI input/s the count displayed in the totalizer/s for the counters should match the predetermined number pulses generated by the pulse generator.
For the debounced configuration, a 24V or 12V signal must be alternately applied to the
UDISETX and UDIRSTX terminals. The return for the 24V or 12V signal is connected to the UDICOMX terminal.
1.
Set the output of the Pulse Generator to 5 V at 10 kHz, 50% duty cycle.
2.
Connect the channel 1 probe of the oscilloscope to the output of the pulse generator and offset the output wave as shown in Figure 7-34. Remove the oscilloscope connections when calibration is completed. Turn the Pulse Generator OFF.
3.
Construct the test circuit for debounce disabled or debounce enabled (see Figures 7-36 and 7-37). If the Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
4.
On the High Speed Counters Diagnostic Menu (see Figure 7-33), set the "Board
Number to Test" to match UDI Module’s ControlWave Slot # (1 to 8). Set the "Number of Passes" to "Continuous/Stop after Error."
Figure 7-34 - Square Wave (50% Duty Cycle)
5.
Apply the test circuit for debounce disabled (see Figure 7-36) or the test circuit for debounce enabled (see Figure 7-37) to the UDI Module input/s to be tested. See Figures
7-38 and 7-39 for terminal block assembly input assignments. See Figure 3-43 for local terminal block assembly input assignments associated with a CWREDIO UDI
Redundancy Switch Module (UDIRSM).
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-42
6.
Click on the "RUN High Speed Counter Display" button.
7.
Turn the Pulse Generator ON. The High Speed Counters Diagnostic Menu will display the UDI accumulated counts for inputs UDI1 through UDI12 (Counter - 1 through
Counter - 12). The UDI Module LED Board’s Status LED should be GREEN when the test is running and should return to RED when the test is ended.
Figure 7-35 - High Speed Counters Display Test Completed
8. Verify that the count in the totalizer/s match the number of pulses generated by the pulse generator. Verify that the appropriate LED is ON for each UDI channel connected to the test circuit (see Figure 7-40).
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-43
Figure 7-36 - HSC Test Circuit - Debounce Disabled
D4041A
Figure 7-37 - HSC Test Circuit - Debounce Enabled
ControlWavePAC & ControlWaveEXP Diagnostics / 7-44
Figure 7-38 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments
For UDI Operation
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-45
Note: See Figure 7-43 for Local UDI Term. Block used with CWREDIO
Figure 7-39 - Local UDI Terminal Block Assembly Assignments
D4041A
Figure 7-40 - UDI Module LED Designations
ControlWavePAC & ControlWaveEXP Diagnostics / 7-46
7.11 LOW LEVEL ANALOG INPUT SETUP
These tests check either the Low Level Analog Input (LLAI) Module or the RTD Module to ensure that the module tested is complete and fully operational. Table 7-5A summarizes the types of signals that can be accepted by these modules; resistance temperature devices
(RTD) are associated with the RTD Module and thermocouples, and voltage inputs are associated with the LLAI Module.
7.11.1 Hardware Configuration
RTD Modules and LLAI Modules cannot be calibrated in the field. Therefore, there is no need for external test equipment or for removal of the field wiring from their termination blocks. Off-line diagnostics are intended for checking purposes only. If they indicate problems, the LLAI or RTD Module is question should be returned to the factory for calibration or repair.
7.11.2 Menu Access
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the “Low Level Analog
Input” selection and then click on the RUN button at the bottom of the screen. Figure 7-41 will be invoked.
D4041A
Figure 7-41 - Low Level Analog Input Diagnostic Menu
ControlWavePAC & ControlWaveEXP Diagnostics / 7-47
Figure 7-42 - Local Terminal Block Assembly Assignments for LLAI Module
Figure 7-43 - Local Isolated RTD Module Terminal Block Assembly Assignments
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-48
Figure 7-44 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Isolated LLAI Module Operation
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-49
Figure 7-45 - Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Isolated RTD Module Operation
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-50
7.11.3 Low Level Analog Input & RTD Tests
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the
“
Low Level Analog
Input
”
selection and then click on the RUN button at the bottom of the screen. Figure 7-41 will be invoked.
LLAI Display tests will vary depending on the type of input module, i.e., Therocouple/10mV or RTD. Follow the appropriate instructions below.
Tests for the LLAI Module will vary depending on your type of controller. Follow the appropriate instructions below.
Note: 0 Percent of AI and Self Test buttons aren’t available. Ambient Temp, ZERO
Reference, and GAIN Reference fields are not used during diagnostic testing.
7.11.4 Low Level Analog Input Display
A Low Level Analog Input Display screen will be evoked when "Low Level Analog Input
Display" button on the Low Level Analog Input Diagnostic Menu (see Figure 7-41) has been selected. If the "Point Type" column shows the correct input for your controller, click on the
"Activate Display" button. The diagnostics program will gather data from the Low Level AI
Module or the RTD Module based on the signal types defined there. After the diagnostic program has tested the applicable Module, a menu similar to Figure 7-46 or 7-47 will be posted.
Figure 7-46 - Low Level Analog Input Display (Thermocouple Testing)
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-51
Figure 7-47- Low Level Analog Input Display (RTD Testing)
If the test is successful and the reading is in range, the status column will show "OK." You should also check the "Scaled Value" column to ensure the reading there is reasonable.
If you wish to change the input type, place the cursor in the appropriate "Point Type" column and select the down pointer (click on the up/down selection until the correct type is visible). At this time, the screen is not being refreshed with new data. Next, select the "Stop
Test" button and then the "Send Input Types" button. Wait for a success message at the bottom of the screen. When you're ready to begin the test again, use the "Activate Display" button. To obtain meaningful results, the "Point Type" should show the actual input signals to the board.
If necessary, repeat the tests of this chapter for any other LLAI Modules included in the controller.
Table 7-5A LLAI Module Input Accuracy & Resolution
Input Type Accuracy/Range Resolution
B - Thermocouple 100 ° C to 200 ° C
200 ° C to 390 ° C
390 ° C to 840 ° C
840 ° C to 1820 ° C
2.00
° C
1.00
° C
0.50
° C
0.20
° C
R - Thermocouple -50 ° C to +50 ° C
+50 ° C to 1720 ° C
S - Thermocouple -50 ° C to +50 ° C
+50 ° C to 1760 ° C
0.40
0.17
0.37
0.18
°
°
°
°
C
C
C
C
C - Thermocouple 0 ° C to 2315 ° C 0.16
° C
25 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± 2 ° C
± 1 ° C
± 2 ° C
± 1 ° C
± 0.75
° C
-20 ° C to +70 ° C
± 16 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 4 ° C
± 2 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-52
Table 7-5A LLAI Module Input Accuracy & Resolution (Continued)
Input Type Accuracy/Range Resolution
N - Thermocouple -270 ° C to -260 ° C
-260 ° C to -250 ° C
-250 ° C to -230 ° C
-230 ° C to -150 ° C
-150 ° C to 1300 ° C
J - Thermocouple -210 ° C to 191 ° C
190 ° C to 1200 ° C
E - Thermocouple -270 ° C to -260 ° C
-260 ° C to -225 ° C
-225 ° C to -200 ° C
-200 ° C to 1000 ° C
K - Thermocouple -270 ° C to -261 ° C
-260 ° C to -246 ° C
-245 ° C to -180 ° C
-179 ° C to -145 ° C
-145 ° C to 1372 ° C
T - Thermocouple -270 ° C to -261 ° C
-260 ° C to -251 ° C
-250 ° C to -181 ° C
-180 ° C to -136 ° C
-135 ° C to -400 ° C
Input Type
1.50
0.38
0.18
0.08
0.06
°
°
°
°
°
C
C
C
C
C
Accuracy/Range Resolution
1.50
° C
0.75
° C
0.50
° C
0.25
° C
0.09
° C
0.08
° C
0.11
° C
1.00
° C
0.25
° C
0.08
° C
0.09
° C
2.00
° C
0.56
° C
0.25
° C
0.08
° C
0.14
° C
25 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± .500
° C
± .750
° C
± .500
° C
± 3 ° C
± 1 ° C
± .750
° C
± .500
° C
± 5 ° C
± 2 ° C
± 1 ° C
± .750
° C
± .500
° C
± 4 ° C
± 2 ° C
± 1 ° C
± .750
° C
± .500
° C
25 ° C
± .025%
± .500
° C
-20 ° C to +70 ° C
± 10 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± 1.5
° C
± 1 ° C
± 6 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
± 10 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
-20 ° C to +70 ° C
± 0.05%
± 1 ° C
± 10mV ± 10mV -1.2
μ V
RTD -210 ° C to 850 ° C 0.09
° C
RTD Error: The CJC RTD adds an additional error (see Table 7-5B)
Note: Use straight line approximation to calculate approximate error between end points.
Table 7-5B - LLAI Module – RTD Error with CJC @ 25°C
THERMOCOUPLE
Process
Temp. Range
RTD Error
With CJC
@ 25°C
B 100 ° C to 1820 ° C ± .30
° C
R
S - Thermocouple
-50 ° C to +50 ° C
+50 ° C to 1720 ° C
-50 ° C to +50 ° C
+50 ° C to 1760 ° C
±
±
±
±
.49
.30
.45
.30
°
°
°
°
C
C
C
C
C - Thermocouple 0 ° C to 2315 ° C ± .30
° C
N - Thermocouple
-270 ° C to -261 ° C
-260 ° C to -251 ° C
-250 ° C to -231 ° C
-230 ° C to -189 ° C
-188 ° C to -70 ° C
-70 ° C to +25 ° C
+25 ° C to 1300 ° C
± 20.50
° C
± 5.00
° C
± 2.70
° C
± 1.40
° C
± .70
° C
± .35
° C
± .30
° C
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-53
Table 7-5B - LLAI Module – RTD Error with CJC @ 25°C (Continued)
THERMOCOUPLE
J - Thermocouple
E - Thermocouple
K - Thermocouple
T - Thermocouple
Process
Temp. Range
-210 ° C to -111 ° C
-110 ° C to +25 ° C
+25 ° C to 1200 ° C
-270 ° C to -261 ° C
-260 ° C to -245 ° C
-244 ° C to -200 ° C
-200 ° C to -87 ° C
-86 ° C to +25 ° C
+25 ° C to 100 ° C
-270 ° C to -261 ° C
-260 ° C to -247 ° C
-246 ° C to -221 ° C
-220 ° C to -160 ° C
-159 ° C to +25 ° C
+25 ° C to 1372 ° C
-270 ° C to -261 ° C
-260 ° C to -243 ° C
-242 ° C to -196 ° C
-195 ° C to -61 ° C
-60 ° C to +25 ° C
+25 ° C to 400 ° C
RTD Error
With CJC
@ 25°C
± .80
° C
± .40
° C
± .30
° C
± 10 ° C
± 3 ° C
± 1.50
° C
± .75
° C
± .39
° C
± .30
° C
± 15.00
° C
± 4.50
° C
± 2.20
° C
± 1.10
° C
± .55
° C
± .30
° C
± 10.30
° C
± 3.00
° C
± 1.50
° C
± .75
° C
± .375
° C
± .30
° C
7.12 Control
Wave
I/O MODULE EEPROM TEST
Control Wave I/O Modules are equipped with EEPROM memory. All I/O module memory
(EEPROM) circuitry is tested when the EEPROM test function is initiated from the
Diagnostic Test Category Menu (Figure 1-7).
D4041A
Figure 7-48 - EEPROM Menu
ControlWavePAC & ControlWaveEXP Diagnostics / 7-54
The resulting EEPROM Menu (Figure 7-48) will display the Slot Number, Serial Number,
Module Description, Module Part Number and Module Revision of each I/O Module installed in the Control Wave Process Automation Controller.
To run the EEPROM test, highlight the EEPROM selection on the Diagnostic Test
Category Menu (Figure 1-7) and then click on the Run button at the bottom of the screen.
Click on the OK button at the bottom of the EEPROM Menu (Figure 7-48) to end the test and return to the Diagnostic Test Category (Figure 1-7).
7.13 TESTING CWs & CWEXPs VIA A CWREDIO
A diagnostic load doesn’t exist for a Control Wave Redundant I/O and Communications
Switch Unit (CWREDIO). However the Control Waves or Control Wave EXP s associated with a CWREDIO system can receive a diagnostic load and can be tested discretely as any other CW or CWEXP unit described in this chapter. Control Wave or Control Wave EXP s associated with a CWREDIO system may also be tested through the CWREDIO’s I/O
Redundancy Control Module (IORCM).
7.13.1 Considerations for WINDIAG Tests Associated with a CWREDIO
• Redundant Waves or Control Wave EXP s can be disconnected from the
CWREDIO and tested discretely or may be tested still connected to the CWREDIO.
• CWREDIO Ports:
-
Any IORCM Comm Port connected to a PC’s RS-232 Comm. Port must utilize the
Null Modem Cable (P/N 392843-01-3) shown in Figure 7-1.
-
IORCM Comm. Ports 1 and 2 are always RS-232 Ports, while Comm Ports 3 and 4 are individually factory configured per order for RS-232 or RS-485 operation.
-
To test the CW or CWEXP Comm. Port in question through the IORCM, an appropriate loopback plug must be installed at the IORCM Port to be tested. IORCM
Comm. Port assignments are provided in Figure 7-49.
• I/O Modules
-
Diagnostics can be performed at the I/O Redundancy Switch Module’s (IORSM)
Terminal Block.
-
The Local Termination Block utilized in conjunction with the UDI Redundancy
Switch Module is different from the one used at a Control Wave or Control Wave
EXP (see Figure 7-50).
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-55
D4041A
Figure 7-49
CWREDIO I/O Redundancy Control Module
Component Identification Diagram (Front)
ControlWavePAC & ControlWaveEXP Diagnostics / 7-56
Figure 7-50
Local UDI Terminal Block Assembly Assignments for CWREDIO UDIRSM
D4041A ControlWavePAC & ControlWaveEXP Diagnostics / 7-57
BLANK PAGE
Chapter 7A
ControlWaveRED
Redundant Controller Diagnostics
7A.1 Control
Wave
RED DIAGNOSTICS INTRODUCTION
This chapter describes the diagnostic testing for Control Wave RED Redundant Controllers. The various elements to be tested (CPU memory, communication ports, etc.) are individually accessed from the Diagnostic Test Category Menu described in chapter 1 (see
Figure 1-7). Control Wave RED diagnostic tests provide pass/fail indications to assist the service technician in determining if a module requires further service.
Communications between the Control Wave RED and the PC (equipped with BBI’s
WINDIAG program) can be made via a Local or Network Port with the following restrictions:
• CPU Board Switch SW1-8 (of the CPU being tested) must be OFF to run the DIAG program. Setting this switch OFF will prevent the
‘
Boot Project
’
from running and will place the unit into diagnostic mode.
• Any Wave RED communication port can be connected to the PC provided their port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to 9600 bps operation). The Control Wave RED communication port connected to the PC
(running the DIAG program) must be configured for 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. This can be accomplished via user defined Soft Switches, or for ports COM2, COM3 and COM4, by setting CPU Board
Switch SW1-3 (SW3-3 for a Control Wave EXP ) OFF .
• For a Wave RED , Communication port COM1 is only forced to 9600 bps operation when CPU Switches SW1-3 and SW1-8 have both been set OFF. COM1 can also be set to 9600 bps operation via user defined Soft Switches.
• Setting CPU Board Switches SW1-3 and SW1-8 OFF prevents the
‘
Boot Project
’
from running, places the unit into diagnostic mode and forces communication ports COM1 through COM4 to operate at 9600 baud.
COM1: From the factory, COM1 defaults to 115.2 kbd (RS-232) using the Internet Point to
Point Protocol (PPP). Note: Control Wave RED Port COM1 will be configured for
RS-232 operation (at 9600 bps) by setting CPU switches SW1-3 and SW1-8 OFF.
This will prevent the boot project from running and places the unit into diagnostic mode.
To test COM1 using the WINDIAG program, it must not otherwise be in use and SPU Switch SW1-8 must be set OFF. Connection to a PC requires the use of an RS-232 "Null Modem" cable (see Figure 7A-1).
COM2: From the factory, COM2 on the CPU Board defaults to 9600 baud, 8-bits, no parity,
1 stop bit, BSAP/ Control Wave 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 OFF. It is recommended that an RS-232 "Null Modem" cable be connected between COM2 and the PC (typically COM1) (see Figure 7A-1).
D4041A ControlWaveRED Diagnostics / 7A-1
Figure 7A-1 - Comm. Port RS-232 Cable Wiring Diagram for Connection to a PC
COM3: When factory set for RS-232 or RS-485 operation, COM3 on the SCB Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. This port utilizes an RJ-45 female connector (see Figures 7A-1,
7A-2 and Table 7A-2). To test COM3 using the WINDIAG program, it must not otherwise be in use and CPU Switch SW1-8 must be set OFF. Connection to a PC depends on the type of communications port jack utilized by the PC.
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 7A-1, or use BBI "Null Modem" cable P/N 392843-01-3 connected to two BBI "RJ45 to DB9 Adapter" cables P/N 392844-01-0 (see Figure
7A-1), to interconnect the PC to COM3.
If the PC’s RS-232 Port utilizes the standard 9-pin D-type male connector, the use of the BBI "Null Modem" cable P/N 392843-01-3 (see Figure 7A-1) and one BBI
"RJ45 to DB9 Adapter" cable P/N 392844-01-0 (see Figure 7A-1) will be required.
This RS-232 network, consisting of two cables, connects to COM3 of the
Control Wave RED with an 8-pin RJ-45 male connector and to the PC (typically
COM1) with a 9-pin D-type female connector.
If RS-485 communications is required an RS-485 cable can be assembled using the connections provided in Table 7A-3.
COM4: When factory set for RS-232 or RS-485 operation, COM4 on the SCB Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave 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 OFF. In lieu of COM2, either an RS-232 "Null Modem" cable (see Figure 7A-1) can be connected between
COM4 and the PC (typically COM1) or an RS-485 cable (see Tables 7A-1 & 7A-3) can be connected between COM4 and the PC’s RS-485 Port.
D4041A ControlWaveRED Diagnostics / 7A-2
Others: Any of the three optional Ethernet Ports can be connected directly or via a network to a PC equipped with an Ethernet Port (see Figures 7A-5, 7A-10 and 7A-11). If not configured with an address, the Control Wave RED uses DHCP (by default) to obtain an IP address.
Figure 7A-2 - Male DB9 9-Pin Connector Associated with COM1, COM2 & COM4
Table 7A-1 - Connector Pin Assignment
COM1 (CPU), COM2 (CPU), & COM4 (SCB)
COM1, COM2, COM3 & COM4 of CCRS Module
Pin
#
Signal
RS-232
1 DCD
Description:
RS-232 Signals
Data Carrier Detect Input
Signal
RS-485
N/A
Description:
RS-485 Signals
COM2 of CWEXP
COM4 of CWPAC
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
Receive Data Input
Transmit Data Output
RXD-
TXD-
Receive Data - Input
Transmit Data - Output
Data Terminal Ready Output TXD+
Signal/Power Ground ISOGND
Transmit Data + Output
Isolated Ground
Data Set Ready Input
Request To Send Output
Clear To Send Input
RXD+ Receive Data + Input
N/A
N/A
9 RI Ring N/A
Note: RS-485 Signals in Table 7-1 are available as follows:
COM 4 of SCB or COM3 & 4 of CCRSM
Table 7A-2 - SCB Connectors J2 (COM3) Pin Assignment
Pin
#
Signal
RS-232
Description:
RS-232 Signals
Signal
RS-485
Description:
RS-485 Signals
1 DCD
2 DSR
3 RXD
4 RTS
5 TXD
6 CTS
7 DTR
8 GND
Data Carrier Detect Input
Data Set Ready Input
Receive Data Input
Request To Send Output
RXD+
RXD-
Transmit Data Output
Clear To Send
TXD-
Data Terminal Ready Output TXD+
Signal/Power Ground
N/A
Receive Data + Input
Receive Data - Input
N/A
Transmit Data - Output
N/A
Transmit Data + Output
ISOGND Isolated Ground
D4041A ControlWaveRED Diagnostics / 7A-3
1 8
Looking into receptacle
Figure 7A-3 - RJ-45 Connector J2 (SCB) Associated with COM3 (SCB)
Table 7A-3 - RS-485 Network Connections
(see Tables 7A-1 & 7A-2 for Control Wave RED RS-485 Port Pin # Assignments)
From
Master
To 1st
Slave
To nth
Slave
TXD+ RXD+ RXD+
TXD- RXD- RXD-
RXD+ TXD+ TXD+
RXD- TXD- TXD-
ISOGND ISOGND ISOGND
D4041A
Figure 7A-4 - Control Wave RED CPU Board Switches SW1 & SW3
ControlWaveRED Diagnostics / 7A-4
7A.1.1 Overview of WINDIAG Testing
To use the WINDIAG program place any critical process (associated with the Control -
Wave RED unit in question) under manual control. WINDIAG cannot be run while the
Control Wave RED application is running.
Control Wave RED CPU Modules can be tested while connected to the CCRS Module or they may be tested independently (by removing the associated CCRS Module communication cable from the Comm. Ports on the CPU Module in question). If testing through the CCRS Module, set the 3-position A/B Enabled Mode Select Switch to either the
‘
A
’ or ‘
B
’
position as required. Set the associated CPU Module’s Switch SW1-8 to the OFF
(closed) position (see Figure 7A-4). Perform steps 1 through 6 below.
1.
Before you begin, either LocalView (see Section 1.7.1) or NetView (see Section 1.7.2) must be running.
2.
To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
Figure 7A-5 - Control Wave RED Diagnostic Component Identification Diagram
D4041A ControlWaveRED Diagnostics / 7A-5
3.
Once WINDIAG has been entered (and the unit to be tested has been selected on the initial WINDIAG entry menu), the Diagnostic Test Category Menu (Figure 1-7) 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.
6.
If the CPU Module was tested independently, i.e., disconnected from the CCRS Module, reconnect the associated CCRS Module communication cable to the Comm. Ports on the
CPU Module in question. Set the 3-position A/B Enabled Mode Select Switch to its center position. Set the Control Wave RED CPU Switch SW1-8 to the ON (Open) position and then restart the unit via the Power Switch. The Control Wave RED should resume normal operation.
7A.1.2 Diagnostics Using WINDIAG
All Controllers Modules except the Power Supply/Sequencer Module can be tested using the
WINDIAG program. From the Diagnostic Test Category Menu (see Figure 1-7) the following diagnostic tests can be performed:
CPU & Peripherals Diagnostic: See Section 7A.2
Checks the CPU Module (except for RAM & PROM).
PROM/RAM Diagnostic:
Communications Diagnostic:
See Section 7A.3
Checks the CPU’s RAM and PROM hardware.
See Section 7A.4
Checks Comm. Ports 1 through 4 - The External loopback tests require the use of a loop-back plug.
Ethernet Diagnostic: See Section 7A.5
Checks Ethernet Ports 1 through 3 - The Loop-back Out
Twisted Pair tests require the use of a loop-back plug.
7A.1.3 Diagnostics Test Equipment
The test detailed in this chapter require the use of the following external test equipment:
C RS-232 Loop-back Plugs (see Figure 7A-11)
C RS-485 Loop-back Plugs (see Figure 7A-12)
C Ethernet Loop-back Plug (see Figure 7A-14)
7A.2 TESTING CPU & PERIPHERALS
These tests do not require removal of any board or any special external equipment. At the
Diagnostic Test Category Menu (see Figure 1-7), highlight the "CPU And Peripherals" selection and then click on the "Run" button at the bottom of the screen. Figure 7A-6 will be invoked.
D4041A ControlWaveRED Diagnostics / 7A-6
The following tests aren’t applicable to Control Wave RED units: RUN Pic, RUN Dma,
RUN Timers, RUN Floating Point Coprocessor, and RUN Power Supply).
7A.2.1 RUN LEDs
Click on the "RUN LEDs" button. The RUN LEDs test provide pass/fail status indications as follows: RUN LEDs - Pass = X (--- No Return Status---) where x = the number of the pass. For this test, no messages are reported at the PC.
While the test is running observe the Port 80 Display on the CPU Module. The Display codes should come on with 00 and proceed to 11, 22, 33, 44, 55, 66, 77, 88, 99, AA, BB, CC,
DD, EE and FF and then count down to 00, i.e., EE, DD, etc.
D4041A
Figure 7A-6 - CPU and PERIPHERALS Diagnostic Menu
ControlWaveRED Diagnostics / 7A-7
7A.2.2 RUN Lithium
This test checks the status of the on-board battery that maintains the data in the system
RAM if power is lost. When the battery(s) are functioning properly, the controller can lose power but still retain its application load and continue running from the point of power loss when power is restored.
Click on "RUN Lithium" button. The STATUS column will show either "SUCCESS" or
"Lithium Battery Fail" (if the test fails or the Lithium Battery Enable Switch (SW3-4) on the CPU Board hasn’t been set ON.
7A.2.3 Real Time Clock (RTC)
Click on the "RTC Diagnostic" button. The PC will proceed to the RTC Diagnostic Menu shown in Figure 7A-7.
Figure 7A-7 - Real Time Clock Diagnostic Menu
This set of tests will determine if the RTC chip is fully functional. This menu has its own
Number of Passes field that is independent of what is set at the CPU and Peripherals
Diagnostic Menu (Figure 7A-6). Individual selections are made by positioning the cursor at the appropriate selection point and clicking the left mouse button.
D4041A ControlWaveRED Diagnostics / 7A-8
Time Registers Test
This test checks the RTC registers and will display either "SUCCESS" or "FAILURE - RTC" under the STATUS column.
Alarm Registers Test
This test checks the RTC Alarm Registers and will display either "SUCCESS" or
"FAILURE - RTC Alarm" under the STATUS column.
Set Time: 01-JAN-87 00:00:00
For this function, the Number of Passes should be set to 1. This function sets the RTC to the date and the time shown and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Set Time from PEI (see note 1)
For this function the Number of Passes should be set to 1. This function sets the RTC using the date and time from the PC clock and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Note 1: Only the date and time (down to minutes) will be used from the PC. The seconds at the RTC will ALWAYS be initialized at 30.
Read Time
This function reads the date and time from the RTC and displays it in the STATUS column at the PC. To set the RTC to a known starting point, use one of the SET TIME functions.
Then set the Number of Passes to continuous (CR or CS) and activate the READ TIME function to visually monitor the accuracy of the RTC.
When finished, return to the CPU and Peripherals Diagnostic Menu by clicking on the
"Return To Menu" button.
7A.3 PROM / RAM DIAGNOSTIC TESTING
Each Control Wave RED Redundant Controller has a mixture of PROM and RAM memory to support both the firmware and the software load. The PROM/RAM Diagnostic Menu shown in Figure 7A-8 is accessed from the Diagnostic Test Category Menu described in
Chapter 1 (Figure 1-7).
7A.3.1 PROM Diagnostic Test
PROM diagnostic testing is done by calculating a checksum on the FLASH memory contents and comparing it against a checksum stored in FLASH memory when they were programmed. The PROM diagnostic is designed to test both the firmware FLASH memory and the load FLASH memory in a single execution of the test.
After setting the Number of Passes, click on the "RUN PROM Diagnostic" button to begin the test. After the test is completed, one of the following responses will be displayed under the STATUS column.
Success
Fail - System PROM Failure
D4041A ControlWaveRED Diagnostics / 7A-9
Figure 7A-8 - PROM/RAM Diagnostic Menu (see notes 2 & 3)
Note 2: The Note: The RAM test is a destructive test…doesn’t apply to Control Wave RED units.
Note 3: The Error Status: If rtu was not reset automatically,…doesn’t apply to Control Wave RED units.
7A.3.2 RAM Diagnostic Test
This test verifies that each bit of read/write memory can be written and read correctly and that each memory location can be addressed without adversely affecting another memory location. This test checks all RAM memory installed in the Control Wave RED . Any failures are reported by giving the full address of the failing location which enables isolating the failure to the board and chip level.
Set the "Number of Passes" field to a number from 1 to 256 or to either "Continuous/Repeat
After Error" or "Continuous/Stop After Error." If a "Continuous" selection is made, the test will run continuously until it is stopped by selecting "ABORT Diagnostic Test."
D4041A ControlWaveRED Diagnostics / 7A-10
To start the test, click on the "RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
Pass is indicated by: Size X.XMB where X.X is the size of RAM given in MB.
Failure is indicated by: Fail - YYYYYYYY where YYYYYYYY is the address that failed.
At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, click on the "ABORT RAM
Diagnostic" button. Return to the PROM/RAM Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first click on the "Return to Menu" button before it will exit from the
PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the
Control Wave RED .
7A.4 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 7A-9) verify the operation of the Universal Asynchronous Receiver Transmitter (UART) and associated interfaces for the Control Wave serial communications ports. Testing is done in both a polled environment (where the UART is interrogated for event status) and in an interruptdriven environment (where the UART presents an interruption to the firmware to report events). Each UART can control two ports. The ports are paired as follows:
A/B CPU Peripheral UART on CPU Board (A = COM1, B = COM2)
C/D UART Chip on Secondary Comm. Board (SCB) (C = COM3, 4 = COM4)
7A.4.1 Hardware Setup and Testing of Serial Comm. Ports
Control Wave RED CPU Module Comm. Ports can be tested while connected to the CCRS
Module or they may be tested independently (by removing the associated CCRS Module communication cable from the Comm. Ports on the CPU Module in question). If testing through the CCRS Module, set the 3-position A/B Enabled Mode Select Switch to either the
‘
A
’ or ‘
B
’
position as required. Set the associated CPU Module’s Switch SW1-8 to the OFF
(closed) position (see Figure 7A-4).
These tests use a loop-back technique to verify correct operation of the port being tested.
For loop-back mode an external loop-back plug is required as detailed. Testing of a
Control Wave RED serial communications port can be made with the following restrictions:
D4041A ControlWaveRED Diagnostics / 7A-11
Figure 7A-9 - Communications Diagnostic Menu
D4041A
Figure 7A-10 - CPU Module Component Identification Diagram
ControlWaveRED Diagnostics / 7A-12
• The Control Wave RED communication port connected to the PC (running the
WINDIAG program) can be configured for 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. This can be accomplished via user defined Soft Switches, or for ports COM2, COM3 and COM4, by setting CPU Board
Switch SW1-3 OFF.
• Communication port COM1 is only forced to 9600 bps operation when CPU Switches
SW1-3 and SW1-8 have both been set OFF. COM1 can also be set to 9600 bps operation via user defined Soft Switches.
• Communication ports COM1 through COM4 can be tested at speeds up to 115.2 kbd.
1.
Connect the appropriate loop-back plug (see Figure 7A-11 for RS-232 or Figure 7A-12 for RS-485) to the port to be tested. Remember that the port connected to the PC cannot be tested.
2.
Access the Communications Diagnostic Menu. The Communications Diagnostic Menu
(see Figure 7A-9) is accessed from the Diagnostic Test Category Menu (Figure 1-7) by highlighting the "Communications" selection and then clicking on the "Run" button at the bottom of the screen.
Figure 7A-11 - RS-232 Loop-back Plugs
Figure 7A-12 - RS-485 Loop-back Plugs
3.
Select the port to be tested, i.e., COM1, COM2, COM3 or COM4 at the "Port to Test" field of the Communications Diagnostic Menu (Figure 7A-9) (see Figures 7A-5 & 7A-
10).
4.
Set the "Baud Rate to Test" field to 115200 baud or ALL ASYNC.
D4041A ControlWaveRED Diagnostics / 7A-13
5.
Set the "Number of Passes" to any number from 1 to 256, or select "Continuous/Repeat after Error," or "Continuous/Stop after Error" via one of the three "Radio" buttons located near the top of the menu.
6.
Click on the "RUN External Loop-back" Test button. The Status: indication will switch from "IDLE" to "Working." If an incorrect baud rate has been set, or a port without a loopback plug has been selected, the test will fail and the message "Time Out Waiting
For Response" will be posted next to "Error Status:"
.
The test will proceed and return one of the following responses under the STATUS column:
Success
Fail - Polling Asynch Failure
- Interrupt Asynch Failure
Failure
- RTS/CTS
Error
If the "RTS/CTS Failure" message is displayed, ensure that the loop-back plug is correctly configured and installed.
When you have finished with communications port testing, be sure to remove the loop-back plug.
7A.5 ETHERNET PORT DIAGNOSTICS
The Ethernet Diagnostic menu of Figure 7A-13 is entered from the Diagnostic Test
Category Menu (Figure 1-7). This menu provides four poke points (three associated with
Ethernet circuitry test and one that provides the Return Hardware Address [which resides in FLASH]). These tests verify the operation and integrity of the PCNET (Ethernet)
Controller and the Ethernet port hardware on the CPU Board and SCB Board.
7A.5.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup
The 10Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub. To configure the system for the Loop-Back Out Twisted Pair diagnostic test either remove the standard R-J45 cable from the CPU Board's R-J45 connector and replace it with an R-J45 cable configured for loop-back, or remove the R-J45 cable associated with the port in question from the hub and install the unterminated end into an RJ-45 Jack configured for loop-back. Table 7A-4 provides the pin identification and description for the RJ-45 port.
Pin-1 (TX+) must be connected to Pin-3 (RX+) and Pin-2 (TX-) must be connected to Pin-6
(RX-) for proper loop-back test configuration (see Figure 7A-14).
If the "Loop-Back Out Twisted Pair" Test RUN button is selected while the port is attached to an Ethernet Hub, a Failures Status will be posted.
D4041A ControlWaveRED Diagnostics / 7A-14
Table 7A-4 - Ethernet 10Base-T (RJ45) Connector Pin Assignments
Pin # Pneumonic Description
1 TX+
2 TX-
3 RX+
4 -
5 -
6 RX-
7 & 8 - Not Connected
D4041A
Figure 7A-13 - Ethernet Diagnostic Menu
ControlWaveRED Diagnostics / 7A-15
Figure 7A-14 - RJ-45 Ethernet Loop-back Plug
7A
.5.2 Ethernet Port Diagnostic Test Execution
There are four unique test buttons provided on the Ethernet Diagnostic Menu. Note: Only the "RUN Loop-back out twisted pair" and "RUN Return hardware address" tests are applicable to Control Wave units, i.e., the "RUN Chip internal loop-back" and "RUN Loopback out AUI port" tests aren’t applicable. The applicable tests are discussed below.
7A.5.2.1 Loop-back Out Twisted Pair Test RUN Button
Set the Number of Passes. Make sure that the port is properly configured with a cable or jack for loop-back testing (see Section 7A.5.1). Click on the "RUN Loop-back out twisted pair" Test button. The test will proceed and return either 'Success' or one of the following responses under the STATUS column:
Fail - No Hardware Present
- Loop-back
- Loop-back Receive
- Loop-back Failed
- Error Information Returned
When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jackplug and reconnect the Ethernet cable to both the Control Wave RED port in question and the Ethernet Hub.
7A.5.2.2 Return Hardware Address Test RUN Button
Set the Number of Passes. Click on the "Return hardware address" Test button. The test will proceed and if successful the hardware address will be displayed. The hardware address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all BBI
Ethernet Comm. ports. The remainder of the hardware address is unique for each board manufactured and is stored in EEPROM. If the error message "Error Information
Returned" is displayed instead of the hardware address, and the unit has been programmed with a proper hardware address, the CPU Module should be replaced.
D4041A ControlWaveRED Diagnostics / 7A-16
7A.5.3 Ethernet Port Diagnostic Error/Failure Messages
If either a "No Hardware Present" or "Error Information Returned" message is displayed, ensure that the loop-back test requirements have been properly established (see Section
7.5.1). If test requirements have been met and the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare
Failed" message, check the cable in question. If the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
D4041A ControlWaveRED Diagnostics / 7A-17
BLANK PAGE
Chapter 7B
ControlWave MICRO/EFM
Process Automation Controller &
Electronic Flow Meter Diagnostics
7B.1 Control
Wave
MICRO/EFM DIAG. INTRODUCTION
Diagnostic testing for Control Wave MICRO Process Automation Controllers including
Control Wave EFM (Electronic Flow Meters) is described in this chapter. Various elements to be tested (CPU memory, communication ports, I/O Modules, etc.) are individually accessed from the Diagnostic Test Category Menu described in chapter 1 (see
Figure 1-7). Control Wave MICRO diagnostic tests provide pass/fail indications to assist the service technician in determining if a module requires further service. The term
Control Wave MICRO will be used herein generically and pertains to either the Process
Automation Controller or the Electronic Flow Meters (unless otherwise specified).
Communications between the Control Wave MICRO and the PC (equipped with Bristol
WINDIAG program) can be made via a Local or Network Port with the following restrictions:
• CPU Board Switch SW2-8 must be OFF to run the DIAG program. Setting this switch
OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic
• mode.
Any Wave MICRO communication port can be connected to the PC provided their port speeds match. Most PCs have a COM1 port (typically RS-232 and defaulted to
9600 bps operation). The Control Wave MICRO communication port connected to the
PC (running the DIAG program) must be configured for 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. This can be accomplished via user defined Soft Switches, or for all serial communication ports (except COM1), by
• setting CPU Board Switch SW2-3 OFF.
For Wave MICRO , Communication port COM1 is only forced to 9600 bps operation when CPU Switches SW2-3 and SW2-8 have both been set OFF. COM1 can also be set to 9600 bps operation via user defined Soft Switches.
• Setting CPU Board Switches SW2-3 and SW2-8 OFF prevents the ‘Boot Project’ from running, places the unit into diagnostic mode and forces all serial communication ports to operate at 9600 baud.
COM1: From the factory, RS-232 Communications Port COM1 defaults to 115.2 kbd (RS-
232) using the Internet Point to Point Protocol (PPP). Note: Port COM1 will be configured for RS-232 operation (at 9600 baud) by setting CPU Switches SW2-3 and SW2-8 OFF. This will prevent the boot project from running and places the unit into diagnostic mode. CPU Switch SW2-8 must be set OFF to run the
WINDIAG program.
To utilize COM1 as the PC to Control Wave MICRO/EFM interface for WINDIAG communications, it must be configured to match the PC port to witch it is connected and it must not otherwise be in use. Connection to a
PC requires the use of an RS-232 “Null Modem” cable that in the case of the
Control Wave EFM , is typically connected to the Local Port on the bottom of the
Instrument (see Figure 7B-1).
D4041A ControlWave MICRO/EFM Diagnostics / 7B-1
Figure 7B-1 - Comm. Port RS-232 Cable Wiring Diagram for Connection to a PC
COM2: From the factory, RS-232 Communications Port COM2 on the CPU Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To utilize COM2 as the PC to Control Wave MICRO/EFM interface for
WINDIAG communications, it must be configured to match the PC port to witch it is connected and it must not be in use. To test COM2 using the WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set
OFF to run the WINDIAG program.
In lieu of COM1, an RS-232 “Null Modem” cable can be connected between COM2 and the PC (typically COM1). It is recommended that an RS-232 “Null Modem” cable be connected between COM2 and the PC when it is desired to test ControlWave MICRO/EFM Comm. Port 1
(COM1) via WINDIAG.
COM3: RS-485 Communications Port COM3 on the CPU Board defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To test
COM3 using the WINDIAG program, it must not otherwise be in use. Note: CPU
Switch SW2-8 must be set OFF to run the WINDIAG program.
In lieu of the use of an RS-232 Port, an RS-485 cable (see Tables 7B-1 & 7B-2) can be connected between COM3 and the PC’s RS-485 Port.
COM4: From the factory, RS-232 Communications Port COM4 on the first optional
Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To test COM4 using the
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program.
When required, an RS-232 “Null
Modem” cable be connected between COM4 and the PC (typically COM1) (see
Figure 7B-1).
COM5 RS-485 Communications Port COM5 on the first optional Expansion
Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. To test COM5 using the
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program.
In lieu of the use of an RS-232
Port, an RS-485 cable (see Tables 7B-1 & 7B-2) can be connected between COM5 and the PC’s RS-485 Port.
COM8: From the factory, RS-232 Communications Port COM8 on the second optional
Expansion Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To test COM8 using the
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program.
When required, an RS-232 “Null
Modem” cable be connected between COM8 and the PC (typically COM1) (see
Figure 7B-1).
D4041A ControlWave MICRO/EFM Diagnostics / 7B-2
COM9 RS-485 Communications Port COM9 on the second optional Expansion
Communications Module defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. To test COM9 using the
WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program.
In lieu of the use of an RS-232
Port, an RS-485 cable (see Tables 7B-1 & 7B-2) can be connected between COM9 and the PC’s RS-485 Port.
Others: An optional Ethernet Port (situated on the CPU Module) can be connected directly or via a network to a PC equipped with an Ethernet Port (see Figures 7B-5 through 7B-7). If not configured with an address, the Control Wave MICRO uses
DHCP (by default) to obtain an IP address.
Figure 7B-2 - Male DB9 9-Pin Connector
(Associated with COM1, COM2, COM3, COM4, COM5, COM8 & COM9)
Table 7B-1 - RS-232 Ports COM1/2/4/8 and RS-485 Ports COM3/5/9
Connector Pin Assignment
Pin
#
Signal
RS-232
1 DCD
Description:
RS-232 Signals
Data Carrier Detect Input
Signal
RS-485
N/A
Description:
RS-485 Signals
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
Receive Data Input
Transmit Data Output
RXD-
TXD-
Receive Data - Input
Transmit Data - Output
Data Terminal Ready Output TXD+
Signal/Power Ground
Transmit Data + Output
GND/ISOGND* Ground/Isolated Ground
Data Set Ready Input
Request To Send Output
RXD+ Receive Data + Input
N/A
8 CTS
9
Clear To Send Input N/A
N/A
* ISOGND on Isolated RS-485 Ports ONLY!
Table 7B-2 - RS-485 Network Connections
(see Tables 7B-1 for Control Wave MICRO/EFM RS-485 Port Pin # Assignments)
From
Master
To 1st
Slave
To nth
Slave
TXD+ RXD+ RXD+
TXD- RXD- RXD-
RXD+ TXD+ TXD+
RXD- TXD- TXD-
ISOGND ISOGND ISOGND
D4041A ControlWave MICRO/EFM Diagnostics / 7B-3
D4041A
Figure 7B-3A - Control Wave MICRO CPU Board Switches & Jumpers
(with Optional Ethernet Port – System Battery on PSSM)
ControlWave MICRO/EFM Diagnostics / 7B-4
D4041A
Figure 7B-3B - Control Wave MICRO CPU Board Switches & Jumpers
(with System Battery – shown without Ethernet Port)
ControlWave MICRO/EFM Diagnostics / 7B-5
D4041A
Figure 7B-3C – Control Wave Micro CPU Board Switches & Jumpers
(with two Optional Ethernet Ports)
ControlWave MICRO/EFM Diagnostics / 7B-6
D4041A
Figure 7B-3D - Control Wave EFM (Electronic Flow Meter)
CPU Board Switches & Jumpers
ControlWave MICRO/EFM Diagnostics / 7B-7
7B.1.1 Overview of WINDIAG Testing
To use the WINDIAG program place any critical process (associated with the Control -
Wave MICRO/EFM unit in question) under manual control. WINDIAG cannot be run while the Control Wave MICRO/EFM ’s application is running. Set the CPU Modules
Switch SW2-8 to the OFF (closed) position (see Figure 7B-3A or 7B-3B). Perform steps 1 through 6 below.
D4041A
Figure 7B-4A - Control Wave EFM
Diagnostic Component Identification Diagram
ControlWave MICRO/EFM Diagnostics / 7B-8
Figure 7B-4B - Control Wave MICRO Diagnostic Component ID Diagram
(8-Slot Base Housing Shown)
D4041A ControlWave MICRO/EFM Diagnostics / 7B-9
Figure 7B-4C - Control Wave MICRO Diagnostic Component ID Diagram
(8-Slot Expansion Housing Shown)
1.
Before you begin, either LocalView (see Section 1.7.1) or NetView (see Section 1.7.2) must be running.
2.
To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
3.
Once WINDIAG has been entered (and the unit to be tested has been selected on the initial WINDIAG entry menu), the Diagnostic Test Category Menu (Figure 1-7) 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.
6.
Set the Control Wave MICRO/EFM CPU Switch SW2-8 to the ON position and then restart the unit via the Power Switch. The Control Wave MICRO/EFM should resume normal operation.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-10
7B.1.2 Diagnostics Using WINDIAG
All Controller Modules except the Power Supply/Sequencer Module (System Controller
Module in the case of the Control Wave EFM ) can be tested using the WINDIAG program.
From the Diagnostic Test Category Menu (see Figure 1-7) the following diagnostic tests can be performed:
CPU & Peripherals Diagnostic: See Section 7B.2
Checks the CPU Module (except for RAM & PROM).
PROM/RAM Diagnostic:
Communications Diagnostic:
See Section 7B.3
Checks the CPU’s RAM and PROM hardware.
See Section 7B.4
Checks Comm. Ports 1, 2, 3, 4, 5, 8 and 9 - The External loop-back tests require the use of a loop-back plug.
Ethernet Diagnostic: See Section 7B.5 - (not applicable to Control Wave EFM )
Checks Ethernet Ports 1 through 3 - The Loop-back Out
Twisted Pair tests require the use of a loop-back plug.
Analog Output Diagnostic:
Analog Input Diagnostic:
See Section 7B.6
Checks Analog Output Circuitry.
See Section 7B.7
Checks Analog Input Circuitry.
Discrete I/O Diagnostic: See Section 7B.8 for DO & Section 7B.9 for DI
Checks DI and/or the DO Circuitry.
High Speed Counter Diagnostic: See Section 7B.10
Checks High Speed Counter Circuitry
Low Level AI Diagnostic: Sec 7B.11
Checks RTD and LLAI Modules
EEPROM See
Checks I/O Module EEPROM Circuitry
Analog Output Diagnostic, Analog Input Diagnostic, Discrete Input/Output Diagnostic, and the High-speed Counter Diagnostic menus discussed in this chapter contain the following entry and display fields:
Number of Passes
Enter the number of test cycles you want to execute (1 to 256), or enter one of the Continuous Modes (see Section 1.9.2 of Chapter 1).
Board Number to Test
Enter a number from 1 to 14 representing the slot assignment of the I/O Module to be tested (1 to 2 for C W MICRO/EFM ). Note: On secondary or "Display" menus, the "Board
Number Returned" should match the "Board Number to Test."
D4041A ControlWave MICRO/EFM Diagnostics / 7B-11
Board Type Returned
This field displays the type of board being tested. It provides you with a verification of the board type selected for the slot position being tested by posting one of the following board types: MA (AI/O Modules), MD (DI/O Modules), MIX (Mixed I/O Modules), DO16 (DO
Modules), DI16 (DI Modules), HSC4 (HSC Modules), LLAI6 (LLAI Modules) or RTD4 (RTD
Modules). "AO Point to Test" is posted on the Analog Output Linearity Calibration Menu instead of "Board Number Returned." The "AO Point to Test" adjustment point represents the AO circuit number to be tested (1 to 2).
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays ‘Working’ or ‘Idle’ to indicate if a test is in process or not.
7B.1.3 Diagnostics Test Equipment
The tests detailed in this chapter require the use of the following external test equipment:
C Digital Multimeter (DMM), 1 ohm to 10 M ohm (45 PPM or better accuracy)
C DC Voltage Source, Variable to 31 V dc ( ± 10 microvolt accuracy)
C Precision Current Source, 1 mA to 20 mA ( ± 1 microamp accuracy)
C One 250-ohm, (30-watt) ± 5% resistor (100mA load - Non-isolated DO testing - see Fig.
7B-24A/B)
C One 50-ohm, (50-watt) ± 5% resistor (500mA load - Isolated DO testing - see Fig. 7B-25)
C One NPN Transistor (2N2222) (used in HSC Test Circuit - see Figures 7B-35 & 7B-36)
C One 1 k ohm ± 1% resistor (used in HSC Test Circuit - see Figures 7B-35 & 7B-36)
C One 12/24V Form C Relay (used in HSC Test Circuit - see Figure 7B-36)
C Pulse Generator, adjustable offset, adjustable amplitude to 24 V, and adjustable frequency to 10 kHz (with totalizer/accumulator function) - see Figures 7B-35 & 7B-36)
C Accumulator (Totalizer) - Required if Pulse Gen. doesn’t have totalizer function.
C RS-232 Loop-back Plugs (see Figure 7B-10)
C RS-485 Loop-back Plugs (see Figure 7B-11)
C Ethernet Loop-back Plug (see Figure 7B-13)
7B.2 TESTING CPU & PERIPHERALS
These tests do not require removal of any board or any special external equipment. At the
Diagnostic Test Category Menu (see Figure 1-7), highlight the "CPU And Peripherals" selection and then click on the "Run" button at the bottom of the screen. Figure 7B-5 will be invoked.
The following tests aren’t applicable to Control Wave MICRO/EFM units: RUN Pic, RUN
Dma, RUN Timers and RUN Floating Point Coprocessor.
7B.2.1 RUN LEDs
Click on the "RUN LEDs" button. The RUN LEDs test provide pass/fail status indications as follows: RUN LEDs - Pass = X (--- No Return Status---) where x = the number of the pass. For this test, no messages are reported at the PC. While the test is running observe the 6 Status LEDs on the PSSM/SCM. The LEDs will initially all go off and then will
D4041A ControlWave MICRO/EFM Diagnostics / 7B-12
individually come on stating with Status LED1 and sequencing through Status LED6 and then count down again ending with Status LED1 ON.
7B.2.2 RUN Lithium
This test checks the status of the PSSM’s or SCM’s on-board battery that maintains the data in the system RAM if power is lost. When the battery(s) are functioning properly, the controller can lose power but still retain its application load and continue running from the point of power loss when power is restored.
Click on "RUN Lithium" button. The STATUS column will show either "SUCCESS" or
"Lithium Battery Fail" (if the test fails or the Lithium Battery Enable Jumper (JP5) on the
Power Supply/Sequencer Module or (JP1) on the System Controller Module’s Battery
Backup Board isn’t installed.
Figure 7B-5 - CPU and PERIPHERALS Diagnostic Menu
7B.2.3 RUN Power Supply
Click on the "RUN Power Supply (CWLP, CWM)" button. The Control Wave
MICRO/EFM ’s bulk power level will be posted to the CPU and Peripherals Diagnostic
Menu shown in Figure 7B-6.
7B.2.4 Real Time Clock (RTC)
Click on the "RTC Diagnostic" button. The PC will proceed to the RTC Diagnostic Menu shown in Figure 7B-7.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-13
This set of tests will determine if the RTC chip is fully functional. This menu has its own
Number of Passes field that is independent of what is set at the CPU and Peripherals
Diagnostic Menu (Figure 7B-5). Individual selections are made by positioning the cursor at the appropriate selection point and clicking the left mouse button.
Figure 7B-6 - CPU and PERIPHERALS Diagnostic Menu
(Bulk 24V Supply Level Posted)
Time Registers Test
This test checks the RTC registers and will display either "SUCCESS" or "FAILURE - RTC" under the STATUS column.
Set Time: 01-JAN-87 00:00:00
For this function, the Number of Passes should be set to 1. This function sets the RTC to the date and the time shown and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Set Time from PEI (see note 1)
For this function the Number of Passes should be set to 1. This function sets the RTC using the date and time from the PC clock and displays "SUCCESS" under the STATUS column.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-14
The user should verify that the function worked by using the Read Time selection.
Note 1: Only the date and time (down to minutes) will be used from the PC. The seconds at the RTC will ALWAYS be initialized at 30.
Figure 7B-7 - Real Time Clock Diagnostic Menu
Read Time
This function reads the date and time from the RTC and displays it in the STATUS column at the PC. To set the RTC to a known starting point, use one of the SET TIME functions.
Then set the Number of Passes to continuous (CR or CS) and activate the READ TIME function to visually monitor the accuracy of the RTC.
When finished, return to the CPU and Peripherals Diagnostic Menu by clicking on the
"Return To Menu" button.
7B.3 PROM / RAM DIAGNOSTIC TESTING
Each Control Wave MICRO/EFM has a mixture of PROM and RAM memory to support both the firmware and the software load. The PROM/RAM Diagnostic Menu shown in
Figure 7B-8 is accessed from the Diagnostic Test Category Menu described in Chapter 1
(Figure 1-7).
7B.3.1 PROM Diagnostic Test
PROM diagnostic testing is done by calculating a checksum on the FLASH memory contents and comparing it against a checksum stored in FLASH memory when they were
D4041A ControlWave MICRO/EFM Diagnostics / 7B-15
programmed. The PROM diagnostic is designed to test both the firmware FLASH memory and the load FLASH memory in a single execution of the test.
After setting the Number of Passes, click on the "RUN PROM Diagnostic" button to begin the test. After the test is completed, one of the following responses will be displayed under the STATUS column: Success or Fail - System PROM Failure.
Figure 7B-8 - PROM/RAM Diagnostic Menu (see notes 2 & 3)
Note 2: The Note: The RAM test is a destructive test…doesn’t apply to Control Wave MICRO or
Control Wave EFM units.
Note 3: The Error Status: If rtu was not reset automatically,…doesn’t apply to Control Wave MICRO or Control Wave EFM units.
7B.3.2 RAM Diagnostic Test
This test verifies that each bit of read/write memory can be written and read correctly and that each memory location can be addressed without adversely affecting another memory location. This test checks all RAM memory installed in the Control Wave MICRO/EFM .
Any failures are reported by giving the full address of the failing location which enables isolating the failure to the board and chip level.
Set the "Number of Passes" field to a number from 1 to 256 or to either "Continuous/Repeat
After Error" or "Continuous/Stop After Error." If a "Continuous" selection is made, the test will run continuously until it is stopped by selecting "ABORT Diagnostic Test."
To start the test, click on the "RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
D4041A ControlWave MICRO/EFM Diagnostics / 7B-16
Pass is indicated by: Size X.XMB
Current where X.X is the size of RAM given in MB.
Failure is indicated by: Fail - YYYYYYYY where YYYYYYYY is the address that failed.
At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, click on the "ABORT RAM
Diagnostic" button. Return to the PROM/RAM Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first click on the "Return to Menu" button before it will exit from the
PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the
Control Wave MICRO/EFM .
7B.4 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 7B-9) verify the operation of the Universal Asynchronous Receiver Transmitters (UARTs) and associated interfaces for the Control Wave MICRO/EFM serial communications ports. Testing is done in both a polled environment (where the UART is interrogated for event status), and in an in-terrupt-driven environment (where the UART presents an interruption to the firmware to report events).
7B.4.1 Hardware Setup and Testing of Serial Comm. Ports
These tests use a loop-back technique to verify correct operation of the port being tested.
For loop-back mode an external loop-back plug is required as detailed. Testing of a
Control Wave MICRO/EFM serial communications port can be made with the following restrictions:
• The Wave MICRO/EFM communication port connected to the PC (running the
DIAG program) must be configured for 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. This can be accomplished via user defined Soft Switches, or for all serial communication ports (except COM1), by setting
CPU Board Switch SW2-3 OFF.
• Communication port COM1 is only forced to 9600 bps operation when CPU Switches
SW2-3 and SW2-8 have both been set OFF. COM1 can also be set to 9600 bps operation via user defined Soft Switches.
1.
Connect the appropriate loop-back plug (see Figure 7B-10 for RS-232 or Figure 7B-11 for RS-485) to the port to be tested. Remember that the port connected to the PC cannot be tested.
2.
Access the Communications Diagnostic Menu. The Communications Diagnostic Menu
(see Figure 7B-9) is accessed from the Diagnostic Test Category Menu (Figure 1-7) by
D4041A ControlWave MICRO/EFM Diagnostics / 7B-17
highlighting the "Communications" selection and then clicking on the "Run" button at the bottom of the screen.
3.
Select the port to be tested, i.e., COM1, COM2, COM3, COM4, COM5, COM6, COM8 or COM9 at the "Port to Test" field of the Communications Diagnostic Menu (Figure
7B-9) (also see Figure 7B-4A/B).
4.
Set the "Baud Rate to Test" field to 115200 baud or ALL ASYNC.
5.
Set the "Number of Passes" to any number from 1 to 256, or select "Continuous/Repeat after Error," or "Continuous/Stop after Error" via one of the three "Radio" buttons located near the top of the menu.
Figure 7B-9 - Communications Diagnostic Menu
6.
Click on the "RUN External Loop-back" Test button. The Status: indication will switch from "IDLE" to "Working." If an incorrect baud rate has been set, or a port without a loopback plug has been selected, the test will fail and the message "Time Out Waiting
For Response" will be posted next to "Error Status:".
The test will proceed and return one of the following responses under the STATUS column:
Success
Fail - Polling Asynch Failure
- Interrupt Asynch Failure
- Sync
- RTS/CTS
-
Configuration Error
D4041A ControlWave MICRO/EFM Diagnostics / 7B-18
If the "RTS/CTS Failure" message is displayed, ensure that the loop-back plug is correctly configured and installed.
When you have finished with communications port testing, be sure to remove the loop-back plug.
Figure 7B-10 - RS-232 Loop-back Plug
Figure 7B-11 - RS-485 Loop-back Plug
7B.5 ETHERNET PORT DIAGNOSTICS
The Ethernet Diagnostic menu of Figure 7B-12 is entered from the Diagnostic Test
Category Menu (Figure 1-7). This menu provides four poke points (three associated with
Ethernet circuitry test and one that provides the Return Hardware Address [which resides in FLASH]). These tests verify the operation and integrity of the PCNET (Ethernet)
Controller and the Ethernet port hardware on the CPU Board and SCB Board.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-19
7B.5.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup
The 10Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub. To configure the system for the Loop-Back Out Twisted Pair diagnostic test either remove the standard R-J45 cable from the CPU Board's R-J45 connector and replace it with an R-J45 cable configured for loop-back, or remove the R-J45 cable associated with the port in question from the hub and install the unterminated end into an RJ-45 Jack configured for loop-back. Table 7-4 provides the pin identification and description for the RJ-45 port. Pin-1
(TX+) must be connected to Pin-3 (RX+) and Pin-2 (TX-) must be connected to Pin-6 (RX-) for proper loop-back test configuration (see Figure 7B-13).
If the "Loop-Back Out Twisted Pair" Test RUN button is selected while the port is attached to an Ethernet Hub, a Failures Status will be posted.
D4041A
Figure 7B-12 - Ethernet Diagnostic Menu
Table 7B-4 - Ethernet 10Base-T (RJ45) Connector Pin Assignments
Pin # Pneumonic Description
1 TX+
2 TX-
3 RX+
4 -
5 -
6 RX-
7 & 8 - Not Connected
ControlWave MICRO/EFM Diagnostics / 7B-20
Figure 7B-13 - RJ-45 Ethernet Loop-back Plug
7B
.5.2 Ethernet Port Diagnostic Test Execution
There are four unique test buttons provided on the Ethernet Diagnostic Menu. Note: Only the "RUN Loop-back out twisted pair" and "RUN Return hardware address" tests are applicable to Control Wave MICRO units, i.e., the "RUN Chip internal loop-back" and
"RUN Loop-back out AUI port" tests aren’t applicable. The applicable tests are discussed below.
7B.5.2.1 Loop-back Out Twisted Pair Test RUN Button
Set the Number of Passes. Make sure that the port is properly configured with a cable or jack for loop-back testing (see Section 7.5.1). Click on the "RUN Loop-back out twisted pair"
Test button. The test will proceed and return either 'Success' or one of the following responses under the STATUS column:
Fail - No Hardware Present
- Loop-back Send
- Loop-back
- Loop-back Failed
-
Error Information Returned
When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jackplug and reconnect the Ethernet cable to both the Control Wave MICRO Ethernet port and the Ethernet Hub.
7B.5.2.2 Return Hardware Address Test RUN Button
Set the Number of Passes. Click on the "Return hardware address" Test button. The test will proceed and if successful the hardware address will be displayed. The hardware address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all Bristol
Ethernet Comm. ports. The remainder of the hardware address is unique for each board manufactured and is stored in EEPROM. If the error message "Error Information
D4041A ControlWave MICRO/EFM Diagnostics / 7B-21
Returned" is displayed instead of the hardware address, and the unit has been programmed with a proper hardware address, the CPU Module should be replaced.
7B.5.3 Ethernet Port Diagnostic Error/Failure Messages
If either a "No Hardware Present" or "Error Information Returned" message is displayed, ensure that the loop-back test requirements have been properly established (see Section
7.5.1). If test requirements have been met and the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare
Failed" message, check the cable in question. If the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
7B.6 ANALOG OUTPUT (AO) TESTS
The AO tests are used to check Analog Output circuitry on Analog I/O Modules and Mixed
I/O Modules to ensure they are fully operational.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Output" selection and then click on the “Run” button at the bottom of the screen.
The PC will proceed to the Analog Output Linearity Calibration Menu (see Figure 7B-14).
7B.6.1 Analog Output Circuitry Calibration Verification
For this procedure the following items are required:
A Digital Multimeter (DMM) (see Chapter 1).
AO Wiring terminals for local and remote terminations are identified in Figure 7B-15A/B/C.
7B.6.1.1 4-20 mA Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 7B-14) provides for test setup configuration of the Analog Output circuitry on the Analog I/O Module or Mixed I/O Module to be tested.
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until stopped by clicking on the appropriate “ABORT” button.
2.
The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Output Module being tested (1 to 14). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the menu.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1 or 2). Set the value accordingly.
4.
Connect the Digital Multimeter (in current Mode) (+) lead to the +AO#I terminal and the (-) lead to the -AO# terminal of the local or remote AO Module Terminal Block
D4041A ControlWave MICRO/EFM Diagnostics / 7B-22
Assembly (see Figure 7B-15A/B). Connect a +24Vdc Supply between the VEXT
Terminal and GND (GNDDIGITAL).
5.
Click on "RUN Set 0% (after Cal)" Test button. Verify that the DMM displays 4.000 mA
( ± .0172 mA) @ 23°C (73.4°F).
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the DMM displays 20.000 mA ( ± .0172 mA) @ 23°C (73.4°F).
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 3.200 mA ( ± .129 mA).
Figure 7B-14 - Analog Output Linearity Calibration Menu
WARNING
Only the "RUN Set 0% (after Cal)", "RUN Set 100% (after Cal)", "RUN Set Output to
UnderRange" and the "RUN Set Output to OverRange" Tests buttons are to be utilized by other than factory personnel. DO NOT initiate any other tests. The
D4041A ControlWave MICRO/EFM Diagnostics / 7B-23
tests discussed herein provide for testing Analog Output Modules; calibration is not covered. DO NOT attempt to calibrate an Analog Output Module.
D4041A
Figure 7B-15A – Isolated AO Module Assembly AO Assignments
ControlWave MICRO/EFM Diagnostics / 7B-24
D4041A
Figure 7B-15B - AI/O Module Assembly AO Assignments
ControlWave MICRO/EFM Diagnostics / 7B-25
Figure 7B-15C - Non-isolated Mixed I/O Module Assembly AO Assignments
8.
Click on "RUN Set Output to OverRange" Test button. Verify that the DMM displays
20.800 mA ( ± .129 mA).
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
10.
11.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by selecting the Return to Menu button at the bottom of the Analog Output
Linearity Calibration Menu (Figure 7B-14).
7B.6.1.2 1-5V Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 7B-14) provides for test setup configuration of the Analog Output circuitry on the Analog I/O Module or Mixed I/O Module to be tested.
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until it is stopped by clicking on the appropriate “ABORT” button.
2.
The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Output Module being tested (1 to 14). Set the value accordingly. Note: If an
D4041A ControlWave MICRO/EFM Diagnostics / 7B-26
invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the menu.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1 or 2). Set the value accordingly.
4.
Connect the Digital Multimeter (in voltage Mode) (+) lead to the +AO#V terminal and the (-) lead to the -AO# terminal of the local or remote AO Module Terminal Block
Assembly (see Figure 7B-15A/B). Connect a +24Vdc Supply between the VEXT
Terminal and GND (GNDDIGITAL).
5.
Click on the "RUN Set 0% (after Cal)" Test button. Verify that the meter displays 1.000
Vdc ( ± .004 V) @ 23°C (73.4°F).
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the meter displays 5.000
Vdc ( ± .004 V) @ 23°C (73.4°F).
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 0.800 Vdc ( ± .030 V).
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
10.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by clicking on the "Return to Menu" button at the bottom of the Analog
Output Linearity Calibration Menu (Figure 7B-14).
8.
Click on the "RUN Set Output to OverRange" Test button. Verify that the DMM displays 5.200 Vdc ( ± .030 V).
7B.7 ANALOG INPUT (AI) TESTS
The AI tests are used to check Analog Input circuitry to ensure they are fully operational. A
Precision Current Source is required for 4-20mA AI testing and a Variable dc Voltage
Source is required for 1-5V AI testing.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Input" selection and then click on the “Run” button at the bottom of the screen. The PC will proceed to the Analog Input Diagnostic Menu (see Figure 7B-16).
The Analog Input Diagnostic Menu (Figure 7B-16) provides for test setup configuration of the Analog Input circuitry on the Analog I/O Module or Mixed I/O Module to be tested.
7B.7.1 4-20 mA Analog Input Channel Test
A Precision Current Source capable of providing 20 mA with 1 uA resolution will be required to perform AI testing of a 4-20mA AI Module.
1.
The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Input Module being tested (1 to 14). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Diagnostic Menu (see Figure 7B-16).
D4041A ControlWave MICRO/EFM Diagnostics / 7B-27
Figure 7B-16 - Analog Input Diagnostic Menu (Number of Passes set Continuous)
2. On the Analog Input Diagnostic Menu (Figure 7B-16) click on the "Analog Input
Display" button. The Analog Input Display Menu (Figure 7B-17) will appear.
The test will proceed until it is stopped by clicking on the “End Test” button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI
Values should be 6 (4 for Control Wave EFM units). The Board Number Returned should be the same as the Board Number to Test assigned on the Analog Input
Diagnostic Menu and the Board Type Returned should be MA for AI/O Modules or MIX for Mixed I/O Modules.
3. Click on the "End Test" button and return to the Analog Input Diagnostic Menu
(Figure 7B-16).
4.
Connect the positive output of the Precision Current Source to the (-) input AI channel
# (e.g., for AI1 = Pin 1 of local Term. Block TB1. Connect the negative output of the
Precision Current Source to the (GND) associated with the AI channel # in question
(e.g., for AI1 = Pin 2 of local Term. Block TB1). (See Figures 7B-18A/B/C for local and remote AI Term. Block assignments).
D4041A ControlWave MICRO/EFM Diagnostics / 7B-28
Figure 7B-17 - Analog Input Display Menu (shown for AI/O Module)
(Mixed I/O Module will show AI-01 through AI-04 - Number of Valid AI Values will be 4)
5.
Apply 3.111 mA to the Analog Input being tested. Click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (Figure 7B-16). Vary the input current from 3.111 mA to 20.898 mA and verify that the values provided below are displayed accordingly for the AI channel being tested.
Input
Current
Reading
3.111 mA 778 (+30 -50) = 728 to 828
4.000 mA 10000 (+30 -50) = 9950 to 10030
8.000 mA 20000 (+30 -50) = 19950 to 20030
12.000 mA 30000 (+30 -50) = 29950 to 30030
16.000 mA 40000 (+30 -50) = 39950 to 40030
20.000 mA 50000 (+30 -50) = 49950 to 50030
20.889 mA 52220 (+30 -50) = 52170 to 52250
6. Set the Precision Current Source output to zero and remove it from the AI Module’s
Term. Block. Reconnect it to the next AI on TB1 or TB2 and repeat Steps 4 through 5 for each of the remaining five analog inputs, checking the reading under the appropriate AI channel.
WARNING
Be sure to set the current source to zero before removing it after each input is tested.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-29
D4041A
Figure 7B-18A - Non-isolated AI/O Module Assembly AI Assignments
ControlWave MICRO/EFM Diagnostics / 7B-30
Figure 7B-18B - Non-isolated Mixed I/O Module Assembly AI Assignments
7B.7.2 1-5V Analog Input Channel Test
A Variable dc Voltage Source capable of outputting 5.000V with 10uV resolution will be required to perform AI testing of a 1-5V AI Module.
1. The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Input Module being tested (1 to 14). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Diagnostic Menu (see Figure 7B-16).
2.
On the Analog Input Diagnostic Menu (Figure 7B-16) click on the "Analog Input
Display" button. The Analog Input Display Menu (Figure 7B-17) will appear.
The test will proceed until it is stopped by clicking on the "End Test" button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI
Values should be 6 (4 for Control Wave EFM units). The Board Number Returned, should be the same as the Board Number to Test assigned on the Analog Input
Diagnostic Menu and the Board Type Returned should be MA for AI/O Modules or MIX for Control Wave EFM units.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-31
3.
Click on the "End Test" button and return to the Analog Input Diagnostic menu
(Figure 7B-16).
Figure 7B-18C - Isolated Analog Input Module Assembly AI Assignments
D4041A ControlWave MICRO/EFM Diagnostics / 7B-32
4.
Connect the positive output of the Variable dc Voltage Source to the (+) input AI channel # (e.g., for AI1 = Pin 1 of local Term. Block TB1). Connect the negative output of the Variable dc Voltage Source to the (-) input AI channel # in question (e.g., for AI1
= Pin 2 of local Term. Block TB1). (See Fig. 7B-18A for AI Term. Block assignments on the AI/O Module) (See Fig. 7B-18B for Mixed I/O Module AI Term. Block assignments)
(See Fig. 7B-18C for Isolated AI Module AI Term. Block assignments.
5. Apply 0.778 Vdc to the Analog Input being tested. Click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (Figure 7B-16). Vary the input voltage from 0.778 Vdc to 5.222 Vdc and verify that the values provided below are displayed accordingly for the AI channel being tested.
Input
Voltage
Reading
0.778 Vdc 778 ± 40 (738 to 818)
1.000 Vdc 10000 ± 40 (9960 to 10040)
2.000 Vdc 20000 ± 40 (19960 to 20040)
3.000 Vdc 30000 ± 40 (29960 to 30040)
4.000 Vdc 40000 ± 40 (39960 to 40040)
5.000 Vdc 50000 ± 40 (49960 to 50040)
5.222 Vdc 52220 ± 40 (52180 to 52260)
6. Set the Variable dc Voltage Source to zero and remove it from the AI/O Module’s Term.
Block. Reconnect it to the next AI on the appropriate Term. Block and repeat Steps 4 and 5 for each of the remaining five analog inputs, checking the reading under the appropriate AI channel.
WARNING
Be sure to set the voltage source to zero before removing it, after each input is tested.
7B.7.3 Analog Input Calibration Routine
A Variable dc Voltage Source capable of outputting 5.000V with 10uV resolution will be required to perform AI calibration of a 1-5V AI Input. A Precision Current Source capable of providing 20 mA with 1 uA resolution will be required to perform AI calibration of a 4-
20mA AI Input.
1.
The "Board Number to Test" adjustment point represents the I/O slot number of the
Analog Input Module being tested (1 to 14). Set the value accordingly. Note: If an invalid board number is entered (empty slot or wrong module type) the message " Invalid
Board Number Selected " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Diagnostic Menu (see Figure 7B-16).
2.
Set the AI channel to be calibrated for either 1-to-5 V or 4-to-20 mA operation via appropriate jumpers on the Analog I/O Module (see Figure 7B-18A) or the Mixed I/O
Module (see Figure 7B-18B).
3.
Apply a 0% input (1V or 4mA) to the analog input in question and press the RUN button adjacent to the Read Input 0% field. The resulting 0% Cal. Value: will be posted.
4.
Apply a 25% input 2V or 8mA) to analog input in question and press the RUN button adjacent to the Read Input 25% field. The resulting 25% Cal. Value: will be posted.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-33
Figure 7B-19 - Analog Input Diagnostic Menu - AI Calibration
(for AI/O Module) (Board Type Returned = MIX for Mixed I/O Module)
5.
Apply a 50% input 3V or 12mA) to analog input in question and press the RUN button adjacent to the Read Input 50% field. The resulting 50% Cal. Value: will be posted.
6.
Apply a 75% input 4V or 16mA) to analog input in question and press the RUN button adjacent to the Read Input 75% field. The resulting 75% Cal. Value: will be posted.
7.
Apply a 100% input 5V or 20mA) to analog input in question and press the RUN button adjacent to the Read Input 100% field. The resulting 100% Cal. Value: will be posted.
8.
Press the RUN button adjacent to the Read Cal Values field. The stored EEPROM values and the difference of the Stored EEPROM Values and the input Cal. Values
(obtained in steps 3 through 7) will be displayed (see Figure 7B-19). The difference between the Cal. Value: and the Stored EEPROM Value must be within the following parameters: For 0% & 100% - ± 218 counts - For 25%, 50% and 75% - ± 6 counts
9.
If the calibration data appears good, press the RUN button adjacent to Write
Calibration Values. New EEPROM data should be stored. Note: If there is a problem with the calibration data, the message " Calibration Linear Failure " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Diagnostic Menu.
10. Repeat Steps 1 through 9 above for each of the remaining five AI channels.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-34
7B.8 DISCRETE OUTPUT (DO) TESTS
These tests check the discrete output circuitry of a Control Wave MICRO/EFM DO
Module, including the output registers and the output paths to the terminal block.
For the tests in this chapter, you will need the DMM and Variable dc Voltage Source described in Chapter 1. You will also need a 50-ohm, 50-watt resistor required to provide a
500mA Isolated DO load from the 10 to 31 Vdc source and/or a 250-ohm, 30-watt resistor required to provide a 100mA Non-isolated DO load from the 10 to 31 Vdc source (see
Section 7B.8.3).
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the “Run” button at the bottom of the screen. The PC will proceed to the menu shown in Figure 7B-20.
7B.
8.1 Automatic Discrete Output Test
All of the DOs will be automatically sequenced for this test. Each DO will be enabled in turn for approximately 0.2 seconds. Be sure to set the Number of Passes to
"Continuous/Stop after Error" to provide a continuous test cycle.
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7B-20), set the Board
Number to Test to match DO Module’s Control Wave MICRO/EFM Slot # (1 to 14).
Set the Number of Passes to "Continuous/Stop after Error" and then click on the "RUN
Discrete Output Sequence" Test button. NOTE: No test information will be displayed on the menu.
2.
The DO status LEDs should sequence in a rotating pattern. Each DO should turn on for approximately 200 msec. The Board Type Returned should match the DO Module configuration, i.e., DO16 for Isolated DO Modules, MD for DI/O Modules, MIX for
Mixed I/O Modules or DO16 for Isolated VAC/VDC DO Modules (see Figure 7B-21).
Proceed to Section 7B.8.2 for the Discrete Output Display Test.
7B.8.2 Discrete Output Display Test
These tests check the DO Modules LEDs.
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7B-20), set the "Board
Number to Test" to match DO Module’s Control Wave MICRO/EFM Slot # (1 to 14).
Set the "Number of Passes" to 10 and then click on the "Discrete Output Display" Test button. The Discrete Output Display Menu (similar to Figure 7B-22 or 7B-23) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
2.
On the Discrete Output Display Menu, the Status: indication will change from IDLE to
WORKING once "Start Test" has been selected. When the Status: indication changes back to IDLE, it will appear similar to the Discrete Output Display Menu of Figure 7B-
22 or 7B-23.
The Discrete Output Display menu will display DOs numbers (16, 4 or 8) and will post the Number of Valid DO Values (16, 4 or 8), the Board Number Returned (1 to 14 representing the DO Module’s Slot #), the Board Type Returned (DO16 for Isolated DO
Module, MD for Non-isolated DI/O Module or DO16 for Isolated VAC/VDC DO Module).
D4041A ControlWave MICRO/EFM Diagnostics / 7B-35
Observe the DO Module’s LED Board. DO LED 1 should be ON and all other DO LEDs should be OFF.
Figure 7B-20 - Discrete I/O Diagnostic Menu - Initial Entry
3.
Change the Drive DO: number to 2 and click on the "Start Test" button. Observe the
DO Module’s LED Board. DO LED 2 should be ON and all other DO LEDs should be
OFF.
4.
Repeat step 3 until all DOs have been tested. Note: The LED associated with the last DO tested will remain ON until the unit has been reset.
The Discrete Output Display menu will display DOs numbers (16, 4, 6 or 8 for Isolated
DOs, Non-isolated DI/Os, Mixed I/Os and Isolated VAC/VDC DOs respectively) and will post the Number of Valid DO Values (16, 4, 6 or 8), the Board Number Returned (1 to
D4041A ControlWave MICRO/EFM Diagnostics / 7B-36
14) representing the DO Module’s Slot #), the Board Type Returned (DO16 for Isolated
DO Modules, MD for Non-isolated DI/O Modules, MIX for Mixed I/O Modules or DO8 for Isolated VAC/VDC DO Modules). Observe the Module’s LED Board. DO LED 1 should be ON and all other DO LEDs should be OFF.
Figure 7B-21 - Discrete I/O Diagnostic Menu - DO Sequence
(shown for Isolated DO Module)
7B.8.3 Manual Discrete Output Load Test
This test checks each DOs output circuitry. You will need the Digital Multimeter (DMM), the Variable dc Voltage Source and either a 50-ohm, 50-watt resistor (required to provide a
500mA Isolated DO load from the 10 to 31 Vdc source) or a 250-ohm, 30-watt resistor
(required to provide a 100mA Non-isolated DO load from the 10 to 31 Vdc source. For
Isolated VAC/VDC DO Modules the output circuitry will be tested open (measuring resistance).
1.
Shut off the Control Wave MICRO/EFM .
2.
For Non-Isolated DOs, construct the test circuit of Figure 7B-24A/B (DO1 example) using a 250-ohm 30-watt resistor for the load. For Isolated DOs, (except VAC/VDC
DOs) construct the test circuit of Figure 7B-25 (DO1 example) using a 500-ohm 50-watt resistor for the load. The test circuit of Figure 7B-24A/B provides a 100mA load with
D4041A ControlWave MICRO/EFM Diagnostics / 7B-37
the power supply providing from 10 to 31 Vdc. The test circuit of Figure 7B-25 provides a 500mA load with the power supply providing from 10 to 31 Vdc. For Isolated
VAC/VDC DO Modules the output circuitry will be tested open (measuring resistance).
Turn on Control Wave MICRO/EFM power.
Figure 7B-22 - Isolated DI/O Module - Discrete Output Display Menu - Idle
Figure 7B-23 - Non-isolated DI/O Module Discrete Output Display Menu – Idle
(Mixed I/O Module will show six DOs and will have a Board Type Returned of MIX)
D4041A ControlWave MICRO/EFM Diagnostics / 7B-38
3.
On the Discrete Input/Output Diagnostic Menu (see Figure 7B-20), set the "Board
Number to Test" to match DO Module’s Control Wave MICRO/EFM Slot # (1 to 14).
Set the "Number of Passes" to 1 and then click on the "Discrete Output Display" button. The Discrete Output Display Menu (Figure 7B-22 or 7B-23) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
4.
On the Discrete Output Display Menu (see Figure 7B-22 or 7B-23), the Status: indication will change from IDLE to WORKING once "Start Test" has been selected.
D4041A
Figure 7B-24A - Non-isolated DI/O Module Assembly DO Assignments
ControlWave MICRO/EFM Diagnostics / 7B-39
Figure 7B-24B - Non-isolated Mixed I/O Module Assembly DO Assignments
D4041A ControlWave MICRO/EFM Diagnostics / 7B-40
Figure 7B-25A - Isolated DO Module Assembly DO Assignments
D4041A ControlWave MICRO/EFM Diagnostics / 7B-41
LED Board
Connector
1 2
P2
39
TB1
1
W1
LED Enable
1-2 = Enable LEDs Manually
2-3 = Enable LEDs via Software
DO1 DO2 DO3 DO4
DO1 DO2 DO3 DO4
DO5 DO6 DO7 DO8
AC/DC
DO Module
LED
Assignments
DO5 DO6 DO7 DO8
P1
NO_IN1
NO_OUT1
NO_IN2
NO_OUT2
N/C
N/C
NO_IN3
NO_OUT3
NO_IN4
NO_OUT4
NO_IN5
NO_OUT5
NO_IN6
NO_OUT6
N/C
N/C
NO_IN7
NO_OUT7
NO_IN8
NO_OUT8
TB2
FIELD
CIRCUITRY
AC/DC DO MODULE
1
NO_IN1
NO_OUT1
Field
TB
2
Figure 7B-25B - Isolated VAC/VDC DO Module Assembly DO Assignments
4
5
6
1
2
3
7
8
9
10
4
5
6
7
8
1
2
3
9
10
TB1
TB2
D4041A ControlWave MICRO/EFM Diagnostics / 7B-42
DI1 DI2 DI3 DI4
TB2
10
1
1
1
1
1
1
1
1
1
1
1
1
1
LED Board
Connector
1 2
P2
39
1
(For DIs) W15
1-2 = One or More DIs Internally Powered
2-3 = All DIs Externally Powered
1
(For LEDs) W13 1
1-2 = Enable LEDs Manually
2-3 = Enable LEDs via Software
W15
P1
TB1
10
W1 (for DI1)
W2 (for DI2)
W3 (for DI3)
W4 (for DI4)
W5 (for DI5)
W6 (for DI6)
W7 (for DI7)
W8 (for DI8)
W9 (for DI9)
W10 (for DI10)
W11 (for DI11)
W12 (for DI12)
1
W14
Factory Use
W1 through W12
1-2 & 3-4 = Internally Sourced Input
2-3 & 4-5 = Driven, Single-ended Input
DI5 DI6 DI7 DI8
DI/O Module
LED
Assignments
DI9 DI10 DI11 DI12
DO1 DO2 DO3 DO4
+DI1
+DI2
+DI3
+DI4
+DI5
+DI6
+DI7
+DI8
+DI9
ISOGND
+DI10
+DI11
+DI12
ISOGND
+DO1
+DO2
+DO3
+DO4
DOEXTPWR
ISOGND
3
4
5
1
2
6
7
8
9
10
1
2
7
8
9
10
3
4
5
6
TB1
TB2
FIELD
CIRCUITRY
Field
TB#2
500mA Load
Max.
+DO1
DOEXTPWR
5
9
_
24Vdc
Pwr. Supply
+
ISOGND
4 or 10
DO#1 (Example)
Ext. Powered DO
Wiring Diagram
Figure 7B-25C - Isolated Digital I/O Module Assembly DO Assignments
5.
Discrete Outputs other than VAC/VDC Type
On the Discrete Output Display Menu (Figure 7B-22 or 7B23), set the Drive DO: for the desired DO channel number (1 to 16, 1 to 4, 1 to 6 or 1 to 8). Measure the voltage drop across the output terminals (+DO# to GND for Non-isolated modules) (ISOVFLD# to +DO# for Isolated modules) (with the output in question turned ON) - (see Figures
D4041A ControlWave MICRO/EFM Diagnostics / 7B-43
7B-24A/B & 7B-25A/C). The output will be turned ON once the “Start Test” button has been selected. The DO voltage drop should not exceed 0.25V. Shut off the
Control Wave MICRO/EFM and the test circuit’s power source.
VAC/VDC Discrete Outputs
On the Discrete Output Display Menu (see Figure 7B-22 or 7B23), set the Drive DO: for the desired DO channel number (1 to 8). Measure the resistance across the NO_IN# and NO_OUT# terminals, i.e., the DO output terminals (with the output in question turned ON) (NO_IN1 = Pin 1 and NO_OUT1 = Pin 2 - (see Figure 7B-25B). The output will be turned ON once the “Start Test” button has been selected. The DO’s output relay will be energized and the output contact resistance should approximate a short, i.e., not to exceed 100 milliohms. Shut off the Control Wave MICRO and test the DO circuit in question for an open state.
6. Move the test circuit to the next DO to be tested. Reapply power to the Control Wave
MICRO/EFM and the test circuit. Repeat step 5 for each channel to be tested
7B.9 DISCRETE INPUT (DI) TESTS
These tests check the discrete input circuitry of a Control Wave MICRO/EFM DI Module,
DI/O Modules, Mixed I/O Module or Isolated VAC DI Module to ensure complete and fully operational DI circuitry.
D4041A
Figure 7B-26 - Discrete Input/Output Diagnostic Menu - DI Circuitry
(Shown for Isolated DI Module)
ControlWave MICRO/EFM Diagnostics / 7B-44
For the Digital Input Display Test (see Section 7B.9.2), you will need the Variable dc
Voltage Source described in Chapter 1 and a short jumper wire (3” long).
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the
Discrete Input/Output Diagnostic Menu (see Figure 7B-26).
7B
.9.1 Automatic Discrete Input Test
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7B-26), set the "Board
Number to Test" to match the Module’s Control Wave MICRO/EFM Slot # (1 to 14).
Set the "Number of Passes" field to "Continuous/Stop after Error" and then click on the
"RUN Discrete Input Circuitry" Test button.
2.
The Module’s DI Status LEDs should remain OFF. When the test has completed (via
“ABORT”), the Module’s DI Status LEDs will turn RED. Additionally, the Board Type
Returned should match the Module configuration, i.e., DI16 (for Isolated DC DIs), MD
(for Non-isolated DIs on the DI/O Module, MIX for Non-isolated DIs on the Mixed I/O
Module) or DI16 for DIs on the VAC DI Module. Proceed to Section 7.9.2 for the
Discrete Input Display Test.
7B.9.2 Discrete Input Display Test
These tests check the DI Modules LEDs and field input circuitry.
1. On the Discrete Input/Output Diagnostic Menu (see Figure 7B-26), set the "Board
Number to Test" to match DI Module’s Control Wave Slot # (1 to 14). Set the "Number of Passes" to "Continuous/Repeat after Error" and then click on the "Discrete Input
Display" Test button. The Discrete Input Display Menu (similar to Figure 7B-27) will appear. The DIs should not be highlighted (in RED) and the module’s DI LEDs should be OFF. The Discrete Input Display Menu will display DIs numbers (16, 12, 6 or 8) and will post the Number of Valid DI Values (16, 12, 6 or 8), the Board Number Returned (1 to 14 representing the DI Module’s Slot #), and the Board Type Returned (DI16 for
Isolated DI Modules, MD for Non-isolated DI/O Modules, MIX for Non-isolated Mixed
I/O Modules or DI16 for Isolated VAC DI Modules). Observe the Module’s LED Board.
All DI channel LEDs, i.e., DI1 through DI16/12/6/8 should be OFF.
D4041A
Figure 7B-27 - Discrete Input Display Menu
(Shown for Non-isolated DI/O Modules)
ControlWave MICRO/EFM Diagnostics / 7B-45
2. Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Display Menu.
Figure 7B-28A - Isolated DI Module Assembly DI Assignments & Test Circuits
D4041A ControlWave MICRO/EFM Diagnostics / 7B-46
LED Board
Connector
1 2
P2
39
TB1
1
W13
LED Enable
1-2 = Enable LEDs Manually
2-3 = Enable LEDs via Software
P1
DI1 DI2 DI3 DI4
DI1 DI2 DI3 DI4
DI5 DI6 DI7 DI8
AC/DC
DI Module
LED
Assignments
DI5 DI6 DI7 DI8
TB2
FIELD
CIRCUITRY
AC DI MODULE
1
Field
TB
2
Figure 7B-28B - Isolated VAC DI Module Assembly DI Assignments & Test Circuits
3. Discrete Inputs other than VAC Type
Shut off the Control Wave MICRO/EFM . Set up a test circuit for the type of DI
Module being tested, i.e., Internally Sourced DIs or Externally Powered DIs (see
Figures 7B-28A/C & 7B-29A/B). For Internally Sourced DIs the individual inputs to be tested must be shorted (e.g., +DI1 to ISOGND/GND, +DI3 to ISOGND/GND, etc.). For
Externally Powered DIs, 24Vdc must be placed across the inputs to be tested (e.g.,
+24Vdc to +DI1 and 24V Common to ISOGND/GND, +24Vdc to +3DI and 24V Common
D4041A ControlWave MICRO/EFM Diagnostics / 7B-47
to ISOGND/GND, etc). Any or all inputs can be tested. It is recommended that odd DIs
(1 through 15/11/5) be tested and then even DIs (2 through 16/12/6). Note: DIs associated with the Non-isolated DI/O Module are internally sourced ONLY, i.e., they can’t be externally powered.
Figure 7B-28C - Isolated DI/O Module Assembly DI Assignments & Test Circuits
VAC Discrete Inputs
Shut off the Control Wave MICRO . Place 110Vac across the inputs to be tested (e.g.,
ACL1_1 and ACL2_1 for DI1) (see Figure 7B-28B). Any or all inputs can be tested. It is recommended that odd DIs (1 through 7) be tested and then even DIs (2 through 8).
D4041A ControlWave MICRO/EFM Diagnostics / 7B-48
4. Apply power to the Control Wave MICRO/EFM unit. On the Discrete Input/Output
Diagnostic Menu (see Figure 7B-26), click on the "Discrete Input Display" button.
The Discrete Input Display menu will display DIs numbers (16, 12, 6 or 8) and will post the Number of Valid DI Values (16, 12 or 6), the Board Number Returned (1 to 14 representing the DI Module’s Slot #), the Board Type Returned (DI16 for Non-isolated
DI Modules, MD for Non-isolated DI/O Modules, MIX for Non-isolated Mixed I/O
Modules or DI8 for Isolated VAC DI Modules). Any DI being tested should be highlighted in RED (see Figures 7B30 or 7B-31). Observe the DI Module’s LED Board.
DI Channel LEDs associated with DI Channels configured for testing should be ON and all other DI Channel LEDs should be OFF. The DI Module LED Boards Status
LED should be GREEN when the test is running and should return to RED when the test is ended.
Figure 7B-29A - Non-isolated DI Module Assembly DI Assignments & Test Circuit
D4041A ControlWave MICRO/EFM Diagnostics / 7B-49
5.
Repeat steps 2 through 4 configuring the DIs to be tested until all DIs have been tested.
Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Diagnostic Menu. On the Discrete Input/Output Diagnostic Menu select the "Return to Menu" button or the X (in the upper right corner) to return to the
Diagnostic Test Category Menu. When testing has been completed, shut off power to the
Control Wave MICRO/EFM and remove any test hardware.
D4041A
Figure 7B-29B - Non-isolated Mixed I/O Module Assembly
DI Assignments & Test Circuit
ControlWave MICRO/EFM Diagnostics / 7B-50
Figure 7B-30 - Discrete Input Display Menu - DIs 1, 3 & 5 ON
(for Isolated DI Module) (Similar to Mixed I/O Module - Board Type MIX)
Figure 7B-31 - Discrete Input Display Menu - DI#1 ON
(Non-isolated DI/O Module) (Similar to Mixed I/O Module - Board Type MIX)
D4041A ControlWave MICRO/EFM Diagnostics / 7B-51
7B.10 HIGH SPEED COUNTER TESTS
These tests check the non-isolated high speed counter input circuitry on the Control Wave
MICRO/EFM HSC Module and Mixed I/O Module to ensure a complete and fully operational HSC circuitry. These modules are factory configured with all inputs set with debounce enabled or with all inputs set with debounce disabled; however, the HSC inputs can be individually customer configured via suit-case jumpers. The maximum input frequency is 10 kHz. Note: The HSC Counter Test is not applicable to HSC Module or the Mixed I /O Module.
To perform the High Speed Counters Display Tests (see Section 7B.10.1), the test setup of
Figure 7B-35 is required for HSC circuits with Debounce Disabled and the test setup of
Figure 7B-36 is required for UDI circuits with Debounce Enabled.
In addition to the equipment shown in Figures 7B-35 and 7B-36 you will need a dual trace oscilloscope to calibrate the square wave produced by the Pulse Generator. Note: If the
Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the "High Speed Counter" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the High Speed Counters Diagnostic Menu (see Figure 7B-32).
7B.10.1 High Speed Counter Display Test
Selecting "High Speed Counter Display" will test the HSC input path from the termination blocks. In this test the totalizers for each input are continually polled and the accumulated count for each input is displayed. A signal is forced at the universal input terminal block and the state of that HSC is updated on the screen.
The 24V or 12V HSC may be tested in debounced or non-debounced configurations. For the non-debounced configuration, connect a pulse generator that can drive a 5 mA load at 24V or 12V to the HSC#SET terminal and the return to the GND terminal. All inputs can be driven simultaneously. The pulse generator should generate a predetermined number of pulses. After the pulses are applied to the HSC input/s the count displayed in the totalizer/s for the counters should match the predetermined number pulses generated by the pulse generator.
For the debounced configuration, a 24V or 12V signal must be alternately applied to the
HSC#SET and HSC#RST terminals. The return for the 24V or 12V signal is connected to the GND terminal.
1.
Set the output of the Pulse Generator to 5 V at 10 kHz, 50% duty cycle.
2.
Connect the channel 1 probe of the oscilloscope to the output of the pulse generator and offset the output wave as shown in Figure 7B-33. Remove the oscilloscope connections when calibration is completed. Turn the Pulse Generator OFF.
3.
Construct the test circuit for debounce disabled or debounce enabled (see Figures 7B-35 and 7B-36). If the Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-52
4.
On the High Speed Counters Diagnostic Menu (see Figure 7-32), set the "Board
Number to Test" to match HSC Module’s Control Wave MICRO/EFM Slot # (1 to 14).
Set the "Number of Passes" to "Continuous/Stop after Error."
Figure 7B-32 - High Speed Counters Diagnostic Menu - Counters Test Running
(for HSC Module) (Similar to Mixed I/O Module - Board Type MIX - 2 Counters)
D4041A
Figure 7B-33 - Square Wave (50% Duty Cycle)
ControlWave MICRO/EFM Diagnostics / 7B-53
Figure 7B-34A - Non-isolated HSC Module Assembly HSC Assignments
5.
Apply the test circuit for debounce disabled (see Figure 3B-35) or the test circuit for debounce enabled (see Figure 3B-36) to the HSC Module input/s to be tested. See
Figure 7B-34A/B for terminal block assembly input assignments.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-54
Figure 7B-34B - Non-isolated Mixed I/O Module Assembly HSC Assignments
D4041A
Figure 7B-35 - HSC Test Circuit - Debounce Disabled
ControlWave MICRO/EFM Diagnostics / 7B-55
Figure 7B-36 - HSC Test Circuit - Debounce Enabled
6.
Click on the "RUN High Speed Counter Display" button.
7.
Turn the Pulse Generator ON. The High Speed Counters Diagnostic Menu will display the HSC accumulated counts for inputs HSC1 through HSC4 (Counter #1 through
Counter #4).
8. Verify that the count in the totalizer/s match the number of pulses generated by the pulse generator. Verify that the appropriate LED is ON for each HSC channel connected to the test circuit (see Figure 7B-34A/B)
7B.11 LOW LEVEL ANALOG INPUT SETUP
These tests check either the Low Level Analog Input (LLAI) Module or the RTD Module to ensure that the module tested is complete and fully operational. Table 7B-5A summarizes the types of signals that can be accepted by these modules; resistance temperature devices
(RTD) are associated with the RTD Module and thermocouples, and voltage inputs are associated with the LLAI Module.
7B.11.1 Hardware Configuration
RTD Modules and LLAI Modules cannot be calibrated in the field. Therefore, there is no need for external test equipment or for removal of the field wiring from their termination blocks. Off-line diagnostics are intended for checking purposes only. If they indicate problems, the LLAI or RTD Module is question should be returned to the factory for calibration or repair.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-56
7B.11.2 Menu Access
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the “Low Level Analog
Input” selection and then click on the RUN button at the bottom of the screen. Figure 7B-37 will be invoked.
D4041A
Figure 7B-37 - Low Level Analog Input Diagnostic Menu
ControlWave MICRO/EFM Diagnostics / 7B-57
Figure 7B-38 - Local Isolated LLAI Module Configuration Diagram
D4041A ControlWave MICRO/EFM Diagnostics / 7B-58
D4041A
Figure 7B-39 - Local Isolated RTD Module Configuration Diagram
ControlWave MICRO/EFM Diagnostics / 7B-59
D4041A
Figure 7B-40 - Remote DIN-Rail Mountable Terminal Block Assembly
Assignments for Isolated LLAI Module Operation
ControlWave MICRO/EFM Diagnostics / 7B-60
Figure 7B-41 - Remote DIN-Rail Mountable Terminal Block Assembly
Assignments for Isolated RTD Module Operation
7B.11.3 Low Level Analog Input & RTD Tests
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the
“
Low Level Analog
Input
”
selection and then click on the RUN button at the bottom of the screen. Figure 7B-37 will be invoked.
D4041A ControlWave MICRO/EFM Diagnostics / 7B-61
LLAI Display tests will vary depending on the type of input module, i.e., Therocouple/10mV or RTD. Follow the appropriate instructions below.
Note: 0 Percent of AI and Self Test buttons aren’t available. Ambient Temp, ZERO
Reference, and GAIN Reference fields are not used during diagnostic testing.
7B.11.4 Low Level Analog Input Display
A Low Level Analog Input Display screen will be evoked when "Low Level Analog Input
Display" button on the Low Level Analog Input Diagnostic Menu (see Figure 7B-37) has been selected. If the "Point Type" column shows the correct input for your controller, click on the "Activate Display" button. The diagnostics program will gather data from the Low
Level AI Module or the RTD Module based on the signal types defined there. After the diagnostic program has tested the applicable Module, a menu similar to Figure 7B-42 or
7B-43 will be posted.
If the test is successful and the reading is in range, the status column will show "OK." You should also check the "Scaled Value" column to ensure the reading there is reasonable.
If you wish to change the input type, place the cursor in the appropriate "Point Type" column and select the down pointer (click on the up/down selection until the correct type is visible). At this time, the screen is not being refreshed with new data. Next, select the "Stop
Test" button and then the "Send Input Types" button. Wait for a success message at the bottom of the screen. When you're ready to begin the test again, use the "Activate Display" button. To obtain meaningful results, the "Point Type" should show the actual input signals to the board.
If necessary, repeat the tests for any other LLAI Modules included in the controller.
Figure 7B-42 - Low Level Analog Input Display (Thermocouple Testing)
D4041A ControlWave MICRO/EFM Diagnostics / 7B-62
Figure 7B-43 - Low Level Analog Input Display (RTD Testing)
Table 7B-5A LLAI Module Input Accuracy & Resolution
Input Type Accuracy/Range Resolution
B - Thermocouple 100 ° C to 200 ° C
200 ° C to 390 ° C
390 ° C to 840 ° C
840 ° C to 1820 ° C
2.00
° C
1.00
° C
0.50
° C
0.20
° C
R - Thermocouple -50 ° C to +50 ° C
+50 ° C to 1720 ° C
S - Thermocouple -50 ° C to +50 ° C
+50 ° C to 1760 ° C
0.40
0.17
0.37
0.18
°
°
°
°
C
C
C
C
C - Thermocouple 0 ° C to 2315 ° C 0.16
° C
N - Thermocouple -270 ° C to -260 ° C
-260 ° C to -250 ° C
-250 ° C to -230 ° C
-230 ° C to -150 ° C
-150 ° C to 1300 ° C
J - Thermocouple -210 ° C to 191 ° C
190 ° C to 1200 ° C
E - Thermocouple -270 ° C to -260 ° C
-260 ° C to -225 ° C
-225 ° C to -200 ° C
-200 ° C to 1000 ° C
K - Thermocouple -270 ° C to -261 ° C
-260 ° C to -246 ° C
-245 ° C to -180 ° C
-179 ° C to -145 ° C
-145 ° C to 1372 ° C
1.50
° C
0.75
° C
0.50
° C
0.25
° C
0.09
° C
0.08
° C
0.11
° C
1.00
° C
0.25
° C
0.08
° C
0.09
° C
2.00
° C
0.56
° C
0.25
° C
0.08
° C
0.14
° C
25 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± 2 ° C
± 1 ° C
± 2 ° C
± 1 ° C
± 0.75
° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± .500
° C
± .750
° C
± .500
° C
± 3 ° C
± 1 ° C
± .750
° C
± .500
° C
± 5 ° C
± 2 ° C
± 1 ° C
± .750
° C
± .500
° C
D4041A
-20 ° C to +70 ° C
± 16 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 4 ° C
± 2 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 10 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± 1.5
° C
± 1 ° C
± 6 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
± 10 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
ControlWave MICRO/EFM Diagnostics / 7B-63
Table 7B-5A LLAI Module Input Accuracy & Resolution (Continued)
Input Type Accuracy/Range Resolution
T - Thermocouple -270 ° C to -261 ° C
-260 ° C to -251 ° C
-250 ° C to -181 ° C
-180 ° C to -136 ° C
-135 ° C to -400 ° C
Input Type
1.50
0.38
0.18
0.08
0.06
°
°
°
°
°
C
C
C
C
C
Accuracy/Range Resolution
25 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± .750
° C
± .500
° C
25 ° C
± .025%
± .500
° C
-20 ° C to +70 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
-20 ° C to +70 ° C
± 0.05%
± 1 ° C
± 10mV ± 10mV -1.2
μ V
RTD -210 ° C to 850 ° C 0.09
° C
RTD Error: The CJC RTD adds an additional error (see Table 7B-5B)
Note: Use straight line approximation to calculate approximate error between end points.
Table 7B-5B - LLAI Module – RTD Error with CJC @ 25°C
THERMOCOUPLE
Process
Temp. Range
RTD Error
With CJC
@ 25°C
B 100 ° C to 1820 ° C ± .30
° C
R
S - Thermocouple
-50 ° C to +50 ° C
+50 ° C to 1720 ° C
-50 ° C to +50 ° C
+50 ° C to 1760 ° C
±
±
±
±
.49
.30
.45
.30
°
°
°
°
C
C
C
C
C - Thermocouple 0 ° C to 2315 ° C ± .30
° C
N - Thermocouple
J - Thermocouple
E - Thermocouple
K - Thermocouple
-270 ° C to -261 ° C
-260 ° C to -251 ° C
-250 ° C to -231 ° C
-230 ° C to -189 ° C
-188 ° C to -70 ° C
-70 ° C to +25 ° C
+25 ° C to 1300 ° C
-210 ° C to -111 ° C
-110 ° C to +25 ° C
+25 ° C to 1200 ° C
-270 ° C to -261 ° C
-260 ° C to -245 ° C
-244 ° C to -200 ° C
-200 ° C to -87 ° C
-86 ° C to +25 ° C
+25 ° C to 100 ° C
-270 ° C to -261 ° C
-260 ° C to -247 ° C
-246 ° C to -221 ° C
-220 ° C to -160 ° C
-159 ° C to +25 ° C
+25 ° C to 1372 ° C
± 20.50
° C
± 5.00
° C
± 2.70
° C
± 1.40
° C
± .70
° C
± .35
° C
± .30
° C
± .80
° C
± .40
° C
± .30
° C
± 10 ° C
± 3 ° C
± 1.50
° C
± .75
° C
± .39
° C
± .30
° C
± 15.00
° C
± 4.50
° C
± 2.20
° C
± 1.10
° C
± .55
° C
± .30
° C
D4041A ControlWave MICRO/EFM Diagnostics / 7B-64
Table 7B-5B - LLAI Module – RTD Error with CJC @ 25°C (Continued)
THERMOCOUPLE
T - Thermocouple
Process
Temp. Range
-270 ° C to -261 ° C
-260 ° C to -243 ° C
-242 ° C to -196 ° C
-195 ° C to -61 ° C
-60 ° C to +25 ° C
+25 ° C to 400 ° C
RTD Error
With CJC
@ 25°C
± 10.30
° C
± 3.00
° C
± 1.50
° C
± .75
° C
± .375
° C
± .30
° C
7B.12 Control
Wave
MICRO/EFM I/O MODULE EEPROM TEST
Control Wave MICRO/EFM I/O Modules are equipped with EEPROM memory. All I/O module memory (EEPROM) circuitry is tested when the EEPROM test function is initiated from the Diagnostic Test Category Menu (Figure 1-7).
The resulting EEPROM Menu (Figure 7B-44 will display the Slot Number, Serial Number,
Module Description, Module Part Number and Module Revision of each I/O Module installed in the Control Wave MICRO/EFM .
To run the EEPROM test, highlight the EEPROM selection on the Diagnostic Test
Category Menu (Figure 1-7) and then click on the Run button at the bottom of the screen.
Click on the OK button at the bottom of the EEPROM Menu (Figure 7B-44) to end the test and return to the Diagnostic Test Category (Figure 1-7).
D4041A
Figure 7B-44 - EEPROM Menu
ControlWave MICRO/EFM Diagnostics / 7B-65
BLANK PAGE
Chapter 7C
ControlWave GFC/GFC-CL/XFC, ControlWave
Express/ExpressPAC and
ControlWave Corrector Diagnostics
7C.1 Control
Wave
GFC/GFC-CL/XFC/Express/ExpressPAC and
Corrector DIAGNOSTICS INTRODUCTION
Diagnostic testing for Control Wave GFC-CL/GFC/XFC Gas Flow Computers,
Control Wave Express/ExpressPAC Remote Terminal Units and Control Wave Corrector Electronic Meter Correctors are described in this chapter. Various elements to be tested
(CPU memory, communication ports, I/O Modules, etc.) are individually accessed from the
Diagnostic Test Category Menu described in chapter 1 (see Figure 1-7). Control Wave
GFC-CL/GFC/XFC/Express/ExpressPAC/Corrector diagnostic tests provide pass/fail indications to assist the service technician in determining if a module requires further service.
Note: For the remainder of this chapter, the term ‘EXPRESS’ (upper case) will be used (for the most part) to generically refer to Control Wave GFC GFCs, Control Wave Express
RTUs, Control Wave ExpressPAC RTUs, and Control Wave Correctors (EMCs). These products utilize the same diagnostic menus and are based upon relatively similar
CPU/System Controller Boards and Process I/O Boards.
Communications between Control Wave GFC-CL//XFC/EXPRESS units and the PC
(equipped with Bristol’s DIAG program) can be made via a Local or Network Port with the following restrictions:
• Control Wave GFC-CL/EXPRESS CPU/System Controller Board Switch SW2-8 or
Control Wave XFC CPU Board Switch SW1-8 must be OFF to run the DIAG program.
Setting the ‘switch OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode.
• Any Wave GFC-CL/XFC/EXPRESS communication port can be connected to
• the PC provided their port speeds match.
Setting Wave GFC-CL/EXPRESS CPU/System Controller Board Switches
SW2-3 and SW2-8 or Control Wave XFC CPU Board Switches SW1-3 and SW1-8 OFF prevents the ‘Boot Project’ from running, places the unit into diagnostic mode and forces all serial communication ports to operate at 9600 baud. COM1/2/3 can also be set to
9600 bps operation via user defined Soft Switches.
Control Wave GFC-CL/XFC/EXPRESS Communication Port 1:
COM1: From the factory, RS-232 Communications Port COM1 defaults to 115.2 kbd (RS-
232) using the BSAP Protocol. Note: By setting CPU Switch (GFC = SW2-8), (XFC =
SW1-8) OFF, the ‘Boot Project’ will be prevented from running and the unit will be placed into diagnostic mode.
To utilize COM1 as the PC to Control Wave GFC-
CL/XFC/EXPRESS interface for WINDIAG communications, it must be configured to match the PC serial port to which it is connected and it must not be in use. In the case of the Control Wave GFC-CL/GFC/ ExpressPAC or the
Control Wave Corrector , connection to a PC requires the use of an RS-232 “Null
Modem” cable that may be connected to the Local Port (on the bottom of the
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-1
instrument for the Control Wave GFC-CL / GFC / ExpressPAC/Corrector ) or directly to COM1 on the CPU/system Controller Board (see Figure 7C-1A). For A
Control Wave XFC connection between COM1 (Local Port) and a PC requires the use of a three-wire cable (see Figure 7C-1B). In the case of the Control Wave
Express , connection to a PC requires the use of the COM1 on the CPU/System
Controller Board via the Null Modem cable of Figure 7C-1A.
Figure 7C-1A - Control Wave GFC-CL/EXPRESS (COM1) to PC - RS-232 Cable
Figure 7C-1B - Control Wave XFC (COM1) to PC - RS-232 Cable
Control Wave GFC-CL Communication Port 2
Figure 7C-1C - Control Wave GFC-CL/EXPRESS (COM2) to PC - RS-232 Cable
COM2: From the factory, Network Communications Port COM2 (RS-232/485) on the
CPU/System Controller Board defaults to RS-232 at 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To utilize COM2 as the
PC to Control Wave GFC-CL interface for WINDIAG communications, it must be configured to match the PC port to which it is connected and it must not be in use.
Note: Switch (SW2-8 on GFC) must be set OFF to run the WINDIAG program.
In lieu of COM1, an RS-232 “Null Modem” cable can be connected between COM2 on the CPU/system Controller Board (see Figure 7C-1C) or via the Local Port. (on the bottom of the Instrument Front Cover) and the PC. Note: To physically connect the
Control Wave GFC-CL ’s Local Port to COM2, you will have to disconnect the internal communication cable from CPU/System Controller Board connector TB1 and install it into TB2. Control Wave GFC-CL CPU/System Controller Board.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-2
Connector TB2 must be configured for RS-232 operation by setting CPU/System
Controller Board Jumpers as follows: W19 pins 2 to 3 and W21 pins 1 to 2.
Control Wave EXPRESS Communication Port 2:
COM2: From the factory, Network Communications Port COM2 (RS-232) on the
CPU/System Controller Board defaults to RS-232 at 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To utilize COM2 (TB3) as the PC to Control Wave EXPRESS interface for WINDIAG communications, it must be configured to match the PC port to which it is connected and it must not be in use. In lieu of COM1, an RS-232 “Null Modem” cable can be connected between COM2 and the PC (see Figure 7C-1C).
Control Wave XFC Communication Port 2:
COM2: From the factory, Network Communications Port COM2 (RS-232) on the
Control Wave XFC Termination Plate defaults to RS-232 at 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. To utilize
COM2 as the PC to Control Wave XFC interface for WINDIAG communications, it must be configured to match the PC port to which it is connected and it must not be in use. Note: Switch SW1-8 must be set OFF to run the WINDIAG program.
In lieu of COM1, an RS-232 “Null Modem” cable can be connected between COM2 and the PC (see Figure 7C-1D & 7C-2).
Figure 7C-1D - Control Wave XFC (COM2) to PC RS-232 Cable Wiring Diagram
Figure 7C-2 - Control Wave XFC - Terminal Plate 14-Pin Comm. Port Connector
Control Wave GFC-CL/XFC Communication Port 3:
COM3: RS-485 Communications Port COM3 ( Control Wave GFC-CL CPU/System
Controller Board, Control Wave XFC Termination Plate) defaults to 9600 baud, 8bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. It is not recom-mended that COM3 be used as the PC to Control Wave GFC-CL / XFC interface for WINDIAG communications. However, if COM3 must be used as the
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-3
Control Wave GFC-CL / XFC to PC communication link for WINDIAG program communications, it must be configured to match the PC port to which it is connected (either via Soft Switch configuration, or for 9600 bps operation, by setting (GFC-CL CPU Switch SW2-3, XFC CPU Switch SW1-3) OFF and it must not otherwise be in use. Note: (GFC CPU Switch SW2-8, XFC CPU Switch SW1-8) must be set OFF to run the WINDIAG program.
In lieu of the use of an RS-232
Port, an RS-485 cable (see Tables 7C-2A and 7C-2B) can be connected between
COM3 and the PC’s RS-485 Port (if available).
Control Wave EXPRESS Communication Port 3:
COM3: RS-232/485 Communications Port COM3 on the CPU/System Controller Board defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control Wave Designer protocol operation. It is not recommended that COM3 be used as the PC to
Control Wave EXPRESS interface for WINDIAG communications. However, if
COM3 must be used as the Control Wave EXPRESS to PC communication link for WINDIAG program communications, it must be configured to match the PC port to which it is connected (either via Soft Switch configuration, or for 9600 bps operation, by setting CPU/System Controller Board Switch SW2-3, OFF and it must not otherwise be in use. Note: CPU/System Controller Board Switch SW2-8 must be set OFF to run the WINDIAG program.
In lieu of the use of an RS-232
Port, an RS-485 cable (see Table 7C-2A) can be connected between COM3 and the
PC’s RS-485 Port (if available). CPU/System Controller Board Jumpers W12 through W16 must be set as follows: RS-232 Operation = Jumper Positions 1 to 2,
RS-485 Operation = Jumper Positions 2 to 3.
Table 7C-1A - ControlWave GFC/EXPRESS RS-232 Ports COM1 & COM2 and ControlWave GFC RS-485 Port COM2 Connector Pin Assignments
(CW GFC-CL COM1 - Local Port, J19 or TB1 & COM2 - TB2)
(CW EXPRESS COM1 - Local Port or J4 & COM2 - TB3)
1
2
DCD
RXD
Description:
RS-232 Signals
Data Carrier Detect Input
Receive Data Input
Signal
RS-485
RXD+
TXD+
Description:
CW GFC COM2
RS-485 Signals
Receive Data + Input
Transmit Data + Output
3
4
6
7
8
TXD
DTR
DSR
Transmit Data Output
Data Terminal Ready Output
Data Set Ready Input
GND Ground
RXD − Receive − Input
RTS
CTS
Request To Send Output
Clear To Send Input
TXD − Transmit − Output
N/A
Table 7C-1B - ControlWave XFC RS-232 Port COM2
Terminal Plate Connector J2 Pin Assignments
Pin # Signal RS-232 Description: RS-232 Signals
8 TXD Transmit Data Output
9
10
11
RXD
RTS
CTS
Receive Data Input
Request To Send Output
Clear To Send Input
12
13
DTR
DCD
Data Terminal Ready Output
Data Carrier Detect Input
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-4
Table 7C-1C - ControlWave XFC RS-232 Port COM1
Terminal Plate Connector J2 Pin Assignments
Pin
#
Signal
RS-232
5 RXD
6 TXD
Description:
RS-232 Signals
Receive Data Input
Transmit Data Output
Table 7C-2A - Control Wave GFC-CL RS-485 Port COM3 (TB3)
Control Wave EXPRESS RS232/485 Port COM3 (TB4)
Connector Pin Assignments
Pin
#
Signal
RS-232/485
Description:
RS-485 Signals
1 RXD+ Receive Data + Input
2 RXD/RXD − − Input
Description:
CW EXPRESS COM3
RS-232 Signals
-
Receive Date Input
3 TXD/TXD − − Output Transmit Data Output
4 TXD+ Transmit Data + Output -
5 Power Ground Ground Ground
Table 7C-2B - ControlWave XFC RS-485 Port COM3
Terminal Plate Connector J2 Pin Assignments
Pin
#
Signal
RS-485
Description:
RS-485 Signals
2 TR − Transmit/Receive − I/O
3 TR+
4 +V
Transmit/Receive Data +I/O
Optional Power Out to Slave(s)
Table 7C-3A - Control Wave GFC-CL/EXPRESS RS-485 Port Network Connections
(see Table 7C-2A)
From
Master
To 1st
Slave
To nth
Slave
TXD+ RXD+ RXD+
TXD − RXD − RXD −
RXD+ TXD+ TXD+
RXD − TXD − TXD −
ISOGND ISOGND ISOGND
Table 7C-3B - Control Wave XFC RS-485 Port Network Connections
(see Table 7C-2B)
From
Master
To 1st
Slave
To nth
Slave
TR+ TR++ TR+
TR − TR − - TR −
GND GND GND
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-5
Figure 7C-3A - Control Wave GFC-CL - CPU/System Controller Bd. Component I.D.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-6
Figure 7C-3B - Control Wave EXPRESS - CPU/System Controller Bd. Component I.D.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-7
Figure 7C-3C - Control Wave XFC - CPU Bd. Component Identification
7C.1.1 Overview of WINDIAG Testing
To use the WINDIAG program place any critical process (associated with the Control -
Wave GFC-CL/XFC/EXPRESS unit in question) under manual control. WINDIAG cannot be run while the Control Wave GFC-CL/XFC/EXPRESS ’s application is running. Set
(GFC-CL/EXPRESS CPU/System Controller Bd. Switch SW2-8), (XFC CPU Bd. Switch SW1-
8) to the OFF position (see Figure 7C-3A/B). Perform steps 1 through 6 below.
1.
Before you begin, either LocalView (see Section 1.7.1) or NetView (see Section 1.7.2) must be running.
2.
To start the WINDIAG program, go to the Start Programs menu, select OpenBSI Tools, select Utility Programs and then select Diagnostics.
3.
Once WINDIAG has been entered (and the unit to be tested has been selected on the initial WINDIAG entry menu), the Diagnostic Test Category Menu (Figure 1-7) will appear.
4.
Select the category to be tested. Enter any prompted parameters (Number of Passes).
WINDIAG will perform the diagnostics and display pass/fail results.
5. After all diagnostic testing has been performed, exit the WINDIAG program.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-8
6.
Set (GFC-CL/EXPRESS CPU/System Controller Bd. Switch SW2-8), (XFC CPU Bd.
Switch SW1-8) to the ON position and then restart the unit via the Power Switch. The
Control Wave GFC-CL/XFC/EXPRESS should resume normal operation.
7C.1.2 Diagnostics Using WINDIAG
From the Diagnostic Test Category Menu (Fig. 1-7) the following WINDIAG tests can be performed:
CPU & Peripherals Diagnostic: See Section 7C.2
(GFC-CL/EXPRESS CPU/System Controller
Bd.), (XFC CPU Bd.) (except for RAM & PROM).
PROM/RAM Diagnostic: See Section 7C.3
(GFC-CL/EXPRESS CPU/System Controller
Bd.) (XFC CPU Bd.) RAM and PROM hardware.
Communications Diagnostic: See Section 7C.4
Checks Comm. Ports 1, 2 and 3 - The External loop-back tests require the use of a loop-back plug or loop-back wires.
Analog Output Diagnostic:
Analog Input Diagnostic:
Discrete I/O Diagnostic:
See Section 7C.5
Checks Analog Output Circuitry.
See Section 7C.6
Checks Analog Input Circuitry.
See Section 7C.7 for DO & Section 7C.8 for DI
Checks DI and/or the DO Circuitry.
High Speed Counter Diagnostic: See Section 7C.9
Checks High Speed Counter and Pulse Counter Circuitry
Diagnostic: See
Checks I/O Circuitry EEPRPM
Analog Output Diagnostic, Analog Input Diagnostic, Discrete Input/Output Diagnostic, and the High-speed Counter Diagnostic menus discussed in this chapter contain the following entry and display fields:
Number of Passes
Enter the number of test cycles you want to execute (1 to 256), or enter one of the Continuous Modes (see Section 1.9.2 of Chapter 1).
Board Number to Test
This field is not applicable to ControlWave GFC/XFC testing.
Board Type Returned
This field will display FIX for ControlWave GFC/XFC circuitry that is recognized.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-9
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays ‘Working’ or ‘Idle’ to indicate if a test is in process or not.
7C.1.3 Diagnostics Test Equipment
The test detailed in this chapter require the use of the following external test equipment:
C Digital Multimeter (DMM), 1 ohm to 10 M ohm (45 PPM or better accuracy)
C DC Voltage Source, Variable to 31 V dc ( ± 10 microvolt accuracy)
C Precision Current Source, 1 mA to 20 mA ( ± 1 microamp accuracy)
C One 510-ohm, (30-watt) ± 5% resistor (10mA load - Non-isolated 6V DO testing ( GFC-
CL / EXPRESS s)
C One 1K-ohm, (30-watt) ± 5% resistor (10mA load - Non-isolated 12V DO testing ( GFC-
CL s, XFC s and EXPRESS s)
C One LED (rated for 10mA) – Non-isolated DO Testing
C One 250-ohm, (30-watt) ± 5% resistor (100mA load - Non-isolated DO testing for
Control Wave GFC-CL - see Fig. 7C-19A)
C One 75-ohm, (30-watt) ± 5% resistor (400mA load - Non-isolated DO testing for
Control Wave XFC & Control Wave EXPRESS units - see Fig. 7C-19B)
C One NPN Transistor (2N2222) (used in HSC Test Circuit - see Figures 7C-24A/B)
C One 1 k ohm ± 1% resistor (used in HSC Test Circuit - see Figures 7C-24A/B & 7C-25)
C One 12/24V Form C Relay (used in HSC Test Circuit - see Figure 7C-25)
C Pulse Generator, adjustable offset, adjustable amplitude to 24 V, and adjustable frequency to 10 kHz (with totalizer/accumulator function) - see Figures 7C-24 & 7C-25)
C Accumulator (Totalizer) - Required if Pulse Gen. doesn’t have totalizer function.
C RS-232 Loop-back Plug (for GFC-CL see Figure 7C-9A) (for EXPRESS see Figure 7C-
9B)
C RS-232 Loop-back Wires (see Figures 7C-9A, 7C-9B, 7C-9C & 7C-10B)
C RS-485 Loop-back Wires (see Figures 7C-10A & 7C-10B)
7C.2 TESTING CPU & PERIPHERALS
These tests do not require removal of any board or any special external equipment. At the
Diagnostic Test Category Menu (see Figure 1-7), highlight the "CPU And Peripherals" selection and then click on the "Run" button at the bottom of the screen. Figure 7C-4 will be invoked.
The following tests aren’t applicable to Control Wave GFC-CL/XFC/EXPRESS units:
RUN Pic, RUN Dma, RUN Timers and RUN Floating Point Coprocessor. Note: Run LEDs is not applicable to Control Wave XFC units.
7C.2.1 RUN LEDs (ControlWave GFC-CL only)
Click on the "RUN LEDs" button. The RUN LEDs test provides pass/fail status indications as follows: RUN LEDs - Pass = X (--- No Return Status---) where x = the number of the pass. For this test, no messages are reported at the PC.
While the test is running observe the 6 Status LEDs on the CPU/System Controller Board.
The LEDs will initially all go off and then will individually come on stating with Status
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-10
LED1 and sequencing through Status LED6 and then count down again ending with Status
LED1 ON.
7C.2.2 RUN Lithium
This test checks the status of the ( Control Wave GFC-CL/EXPRESS CPU/System
Controller Board’s), ( Control Wave XFC CPU Board’s) on-board battery that maintains the data in the system RAM if power is lost. When the battery(s) are functioning properly, the unit can lose power but still retain its application load and continue running from the point of power loss when power is restored.
Click on "RUN Lithium" button. The STATUS column will show either "SUCCESS" or
"Lithium Battery Fail" if the test fails or the Lithium Battery Enable Jumper (W3) on the
Control Wave GFC-CL CPU/System Controller Board or (JP1) on the Control Wave XFC
CPU Board isn’t installed, or, in the case of the Control Wave EXPRESS CPU/System
Controller Board, W3 isn’t installed in position 1 to 2.
Figure 7C-4 - CPU and PERIPHERALS Diagnostic Menu
7C.2.3 RUN Power Supply
Click on the "RUN Power Supply (CWLP, CWM)" button. The Control Wave GFC-
CL/XFC/EXPRESS ’s bulk power level will be posted to the CPU and Peripherals
Diagnostic Menu shown in Figure 7C-5.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-11
7C.2.4 Real Time Clock (RTC)
Click on the "RTC Diagnostic" button. The PC will proceed to the RTC Diagnostic Menu shown in Figure 7C-6.
This set of tests will determine if the RTC chip is fully functional. This menu has its own
Number of Passes field that is independent of what is set at the CPU and Peripherals
Diagnostic Menu (Figure 7C-4/5). Individual selections are made by positioning the cursor at the appropriate selection point and clicking the left mouse button.
Time Registers Test
This test checks the RTC registers and will display either "SUCCESS" or "FAILURE - RTC" under the STATUS column.
Figure 7C-5 - CPU and PERIPHERALS Diagnostic Menu
(Bulk 12V Supply Level Posted)
Set Time: 01-JAN-87 00:00:00
For this function, the Number of Passes should be set to 1. This function sets the RTC to the date and the time shown and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-12
Set Time from PEI (see note 1)
For this function the Number of Passes should be set to 1. This function sets the RTC using the date and time from the PC clock and displays "SUCCESS" under the STATUS column.
The user should verify that the function worked by using the Read Time selection.
Note 1: Only the date and time (down to minutes) will be used from the PC. The seconds at the RTC will ALWAYS be initialized at 30.
Read Time
This function reads the date and time from the RTC and displays it in the STATUS column at the PC. To set the RTC to a known starting point, use one of the SET TIME functions.
Then set the Number of Passes to continuous (CR or CS) and activate the READ TIME function to visually monitor the accuracy of the RTC.
When finished, return to the CPU and Peripherals Diagnostic Menu by clicking on the
"Return To Menu" button.
Figure 7C-6 - Real Time Clock Diagnostic Menu
7C.3 PROM / RAM DIAGNOSTIC TESTING
Each Control Wave GFC-CL/XFC GFC or EXPRESS RTU has a mixture of PROM and
RAM memory to support both the firmware and the software load. The PROM/RAM
Diagnostic Menu shown in Figure 7C-7 is accessed from the Diagnostic Test Category Menu described in Chapter 1 (Figure 1-7).
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-13
7C.3.1 PROM Diagnostic Test
PROM diagnostic testing is done by calculating a checksum on the FLASH memory contents and comparing it against a checksum stored in FLASH memory when they were programmed. The PROM diagnostic is designed to test both the firmware FLASH memory and the load FLASH memory in a single execution of the test.
After setting the Number of Passes, click on the "RUN PROM Diagnostic" button to begin the test. After the test is completed, one of the following responses will be displayed under the STATUS column: Success or Fail - System PROM Failure
Note 2: The Note: The RAM test is a destructive test…doesn’t apply to Control Wave GFC-CL / XFC/-
EXPRESS units.
Note 3: The Error Status: If rtu was not reset automatically,…doesn’t apply to Control Wave GFC-
CL / XFC/EXPRESS units.
Figure 7C-7 - PROM/RAM Diagnostic Menu (see notes 2 & 3)
7C.3.2 RAM Diagnostic Test
This test verifies that each bit of read/write memory can be written and read correctly and that each memory location can be addressed without adversely affecting another memory location. This test checks all RAM memory installed in the Control Wave GFC-CL/XFC/-
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-14
EXPRESS . Any failures are reported by giving the full address of the failing location which enables isolating the failure to the board and chip level.
Set the "Number of Passes" field to a number from 1 to 256 or to either "Continuous/Repeat
After Error" or "Continuous/Stop After Error." If a "Continuous" selection is made, the test will run continuously until it is stopped by selecting "ABORT Diagnostic Test."
To start the test, click on the "RAM Diagnostic" button. The test will proceed and return one of the following responses under the status column:
Pass is indicated by: Size 2.0MB
Current FFFFFFFF
Failure is indicated by: Fail - YYYYYYYY where YYYYYYYY is the address that failed.
At the end of each complete cycle of the RAM diagnostic, status is returned to the PC.
Complete analysis of the failing address to isolate the failure to a specific RAM component is beyond the scope of this document.
When you decide to terminate the RAM Diagnostic test, click on the "ABORT RAM
Diagnostic" button. Return to the PROM/RAM Diagnostic Menu at the PC by clicking on the "Return to Menu" button at the bottom of the screen. You will have to wait for the PC to timeout when you first click on the "Return to Menu" button before it will exit from the
PROM/RAM Diagnostic Menu due to the disruption of the normal communications with the
Control Wave GFC-CL/XFC/EXPRESS .
7C.4 SERIAL COMMUNICATION PORT DIAGNOSTICS
Tests associated with the Communication Diagnostic Menu (Figure 7C-8) verify the operation of the Universal Asynchronous Receiver Transmitters (UARTs) and associated interfaces for the Control Wave GFC-CL / XFC / EXPRESS serial communications ports.
Testing is done in both a polled environment (where the UART is interrogated for event status), and in an interrupt-driven environment (where the UART presents an interruption to the firmware to report events).
7C.4.1 Hardware Setup and Testing of Serial Comm. Ports
These tests use a loop-back technique to verify correct operation of the port being tested.
For loop-back mode an external loop-back plug or wires is required as detailed. Testing of a
Control Wave GFC-CL / XFC / EXPRESS serial communications port can be made with the following restrictions:
• The Wave GFC-CL / XFC / EXPRESS communication port connected to the PC
(running the DIAG program) must be configured for 8-bits, no parity, 1 stop bit,
BSAP/ Control Wave Designer protocol operation. This can be accomplished via user defined Soft Switches.
• Communication port COM1 is only forced to 9600 bps operation when ( Control Wave
GFC-CL / EXPRESS CPU Switches SW2-3 and SW2-8), ( Control Wave XFC CPU
Switches SW1-3 and SW1-8) have both been set OFF. If required, COM1 can also be set to 9600 bps operation via user defined Soft Switches.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-15
1.
Connect the appropriate loop-back plug/wires (see Figure 7C-9A/B/C for RS-232 or
Figure 7C-10A/B for RS-485) to the port to be tested. Remember that the port connected to the PC cannot be tested. Note: Control Wave XFC RS-485 Comm. Port 3
(COM3) doesn’t require loopback wires.
2.
Access the Communications Diagnostic Menu. The Communications Diagnostic Menu
(see Figure 7C-8) is accessed from the Diagnostic Test Category Menu (Figure 1-7) by highlighting the "Communications" selection and then clicking on the "Run" button at the bottom of the screen.
3.
Select the port to be tested, i.e., COM1, COM2 or COM3 at the "Port to Test" field of the Communications Diagnostic Menu (Figure 7C-8) (also see Figure 7C-3).
4.
Set the "Baud Rate to Test" field to 115200 baud or ALL ASYNC.
Figure 7C-8 - Communications Diagnostic Menu
5.
Set the "Number of Passes" to any number from 1 to 256, or select "Continuous/Repeat after Error," or "Continuous/Stop after Error" via one of the three "Radio" buttons located near the top of the menu.
6.
Click on the "RUN External Loop-back" Test button. The Status: indication will switch from "IDLE" to "Working." If an incorrect baud rate has been set, or a port without a loopback plug has been selected, the test will fail and the message "Time Out Waiting
For Response" will be posted next to "Error Status:".
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-16
The test will proceed and return one of the following responses under the STATUS column:
Success
Fail - Polling Asynch Failure
- Interrupt Asynch Failure
- Sync
Failure
-
Configuration Error
-
Failure
- RTS/CTS
If the "RTS/CTS Failure" message is displayed, make sure that the loop-back plug is correctly configured and installed.
When you have finished with communications port testing, be sure to remove the loop-back plug.
1 DCD
RXD
TXD
DTR
4 = DTR
8 = CTS
3 = TXD
7 = RTS
2 = RXD
RTS
CTS
1 = DCD
TB1/TB2
COM1/COM2 COM1
Shown with RS-232 RS-232
Loop-back Wires Loop-back Plug
Figure 7C-9A - Control Wave GFC-CL (COM1/2) RS-232 Loop-back Test Plug/Wiring
D4041A
Figure 7C-9B - Control Wave EXPRESS COM1/2) RS-232
Loop-back Test Plug/Wiring
ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-17
Figure 7C-9C - Control Wave XFC RS-232 Loop-back Test Wiring
RXD+
TXD+
1
RXD-
TXD-
RXD+
RXD-
TXD-
TXD+
1
TB2
COM2
Shown with RS-485
Loop-back Wires
TB3
COM3
RS-485
Loop-back Wires
Figure 7C-10A - ControlWave GFC-CL (COM2/3) RS-485 Loop-back Plug/Wiring
Figure 7C-10B - ControlWave EXPRESS (COM3) RS-232/485 Loop-back Wiring
7C.5 ANALOG OUTPUT (AO) TESTS
The AO tests are used to check Analog Output circuitry on Analog I/O Modules and Mixed
I/O Modules to ensure they are fully operational.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Output" selection and then click on the “Run” button at the bottom of the screen.
The PC will proceed to the Analog Output Linearity Calibration Menu (see Figure 7C-12).
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-18
7C.5.1 Analog Output Circuitry Calibration Verification
For this procedure the following items are required:
A Digital Multimeter (DMM) (see Chapter 1).
Wiring terminals for local terminations are identified as follows:
- for Control Wave GFC-CL , see in Figure 7C-11A
- for Control Wave XFC , see Figure 7C-11B
- for Control Wave EXPRESS , see in Figure 7C-11C
7C.5.1.1 4-20 mA Analog Output Calibration Verification
The Analog Output Linearity Calibration Menu (Figure 7C-12) provides for test setup configuration of the Analog Output circuitry to be tested on the Control Wave GFC-CL
Analog I/O Module or Mixed I/O Module, Control Wave XFC I/O Board, via the Term. Plate or the Control Wave EXPRESS Process I/O Board via Terminal Block TB7.
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until stopped by clicking on the appropriate “ABORT” button.
2.
The "Board Number to Test" field is disabled.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1).
4.
For Control Wave GFC-CL s: Make sure that Battery Charger & I/O Board Jumpers
JP4 and JP5 are set in positions 1-2 and that JP6 is set in position 2-3. Connect the
Digital Multimeter (in current Mode) (+) lead to the AO terminal and the ( − ) lead to the
DGND terminal of Terminal Block TB9 on the Battery Charger & I/O Board assembly
(see Figure 7C-11A). Connect a +24Vdc Supply between the EXTPWR Terminal and
DGND (GNDDIGITAL).
For Control Wave EXPRESS s: Make sure that Process I/O Board Jumper JP1 is set in positions 1-2, Jumper JP3 is set in position 2-3 and that Switch SW1-4 is set OFF.
Connect the Digital Multimeter (in current Mode) (+) lead to the AO terminal (TB7-1) and the ( − ) lead to the DGND terminal (TB7-2) on the Process I/O Board assembly (see
Figure 7C-11C). Connect a +24Vdc Supply between the EXTPWR Terminal (TB7-3) and DGND (TB7-4).
For Wave XFC ’s: Connect the Digital Multimeter (in current Mode) with ( − ) lead to AO terminal (J4-10) and (+) lead to AO terminal (J4-11) on the Terminal Plate assembly (see Figure 7C-11B).
5.
Click on "RUN Set 0% (after Cal)" Test button. Verify that the DMM displays 4.000 mA
[ ± .0172 mA @ 23°C (73.4°F)].
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the DMM displays 20.000 mA [ ± .0172 mA @ 23°C (73.4°F)].
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-19
Figure 7C-11A - ControlWave GFC-CL Battery Charger and I/O Board Component
I.D. & Power and I/O Assignments
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-20
Figure 7C-11B - ControlWave XFC Terminal Plate Component Identification and Power & I/O Assignments
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-21
Figure 7C-11C - ControlWave EXPRESS Process I/O Board Component I..D.
& I/O Assignments
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-22
Figure 7C-12 - Analog Output Linearity Calibration Menu
WARNING
Only the "RUN Set 0% (after Cal)", "RUN Set 100% (after Cal)", "RUN Set Output to
UnderRange" and the "RUN Set Output to OverRange" Tests buttons are to be utilized by other than factory personnel. DO NOT initiate any other tests. The tests discussed herein provide for testing Analog Output Modules; calibration is not covered. DO NOT attempt to calibrate an Analog Output Module.
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 3.200 mA ( ± .129 mA).
8.
Click on "RUN Set Output to OverRange" Test button. Verify that the DMM displays
20.800 mA ( ± .129 mA).
9.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by selecting the Return to Menu button at the bottom of the Analog Output
Linearity Calibration Menu (Figure 7C-12).
7C.5.1.2 1-5V Analog Output Cal. Verification (CW GFC-CL/EXPRESS only)
The Analog Output Linearity Calibration Menu (Figure 7C-14) provides for test setup configuration of Analog Output circuitry.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-23
1. Set the "Number of Passes" field to either "Continuous/Repeat after Error" or "Continuos/Stop after Error." Once initiated, the test will run continuously until it is stopped by clicking on the appropriate “ABORT” button.
2.
"Board Number to Test" field is disabled.
3.
The "AO Point to Test" adjustment point represents the AO circuit number being tested (1).
4.
For Control Wave GFC-CL s: Make sure that Battery Charger & I/O Board Jumpers
JP4 and JP5 are set in positions 2-3 and that JP6 is set in position 2-3. Connect the
Digital Multimeter (in voltage Mode) (+) lead to the AO terminal and the (-) lead to the
DGND terminal of Terminal Block TB9 on the Battery Charger & I/O Board assembly
(see Figure 7C-11A). Connect a +24Vdc Supply between the EXTPWR Terminal and
DGND (GNDDIGITAL).
For Control Wave EXPRESS s: Make sure that Process I/O Board Jumper1 JP1 is set in position 2-3 and that JP3 is set in position 2-3. Connect the Digital Multimeter (in voltage Mode) (+) lead to the AO terminal (TB7-1) and the (-) lead to the DGND terminal (TB7-2) on the Process I/O Board assembly (see Figure 7C-11C). Connect a
+24Vdc Supply between the EXTPWR Terminal (TB7-3) and DGND (TB7-4)).
5.
Click on the "RUN Set 0% (after Cal)" Test button. Verify that the meter displays 1.000
Vdc [ ± .004 V @ 23°C (73.4°F)].
6.
Click on "RUN Set 100% (after Cal)" Test button. Verify that the meter displays 5.000
Vdc [ ± .004 V @ 23°C (73.4°F)].
7.
Click on the "RUN Set Output to UnderRange" Test button. Verify that the DMM displays 0.800 Vdc ( ± .030 V).
8.
Click on the "RUN Set Output to OverRange" Test button. Verify that the DMM displays 5.200 Vdc ( ± .030 V).
9.
Repeat steps 3 through 8 for all remaining AO circuits to be tested.
10.
When testing is complete you can return to the Diagnostic Test Category Menu (see
Figure 1-7) by clicking on the "Return to Menu" button at the bottom of the Analog
Output Linearity Calibration Menu (Figure 7C-12).
7C.6 ANALOG INPUT (AI) TESTS
The AI tests are used to check Analog Input circuitry to ensure they are fully operational. A
Precision Current Source is required for 4-20mA AI testing and a Variable dc Voltage
Source is required for 1-5V AI testing.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Input" selection and then click on the “Run” button at the bottom of the screen. The PC will proceed to the Analog Input Diagnostic Menu (see Figure 7C-13).
The Analog Input Diagnostic Menu (Figure 7C-13) provides for test setup configuration of
Analog Input circuitry.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-24
7C.6.1 4-20 mA AI Channel Test (Control Wave GFC-CL/EXPRESS only)
A Precision Current Source capable of providing 20 mA with 1 uA accuracy will be required to perform AI testing of a 4-20mA AI Module.
1.
The "Board Number to Test" field is disabled .
2. On the Analog Input Diagnostic Menu (Figure 7C-13) click on the "Analog Input
Display" button. The Analog Input Display Menu (Figure 7C-14) will appear.
The test will proceed until it is stopped by clicking on the “End Test” button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI
Values should be 3. The Board Number Returned should be blank and the Board Type
Returned should be FIX.
Figure 7C-13 - Analog Input Diagnostic Menu (Number of Passes set Continuous)
3. Click on the "End Test" button and return to the Analog Input Diagnostic Menu
(Figure 7C-13).
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-25
4. For Control Wave GFC-CL s: Connect the positive output of the Precision Current
Source to the (+) input AI channel # (e.g., for AI1 = Pin 2 of Term. Block TB8 on the
Battery Charger & I/O Board. Connect the negative output of the Precision Current
Source to the (GND) associated with the AI channel # in question (e.g., for AI1 = Pin 3 of Term. Block TB8). (See Figures 7C-11A for AI Terminal Block assignments).
For Wave EXPRESS s: Connect the positive output of the Precision Current
Source to the (+) input AI channel # (e.g., for AI1 = Pin 2 of Term. Block TB6 on the
Process I/O Board. Connect the negative output of the Precision Current Source to the
(GND) associated with the AI channel # in question (e.g., for AI1 = Pin 3 of Term. Block
TB6). (See Figures 7C-11C for AI Terminal Block assignments).
Input
Current
Reading
3.111 mA 778 (+30 -50) = 728 to 828
4.000 mA 10000 (+30 -50) = 9950 to 10030
8.000 mA 20000 (+30 -50) = 19950 to 20030
12.000 mA 30000 (+30 -50) = 29950 to 30030
16.000 mA 40000 (+30 -50) = 39950 to 40030
20.000 mA 50000 (+30 -50) = 49950 to 50030
20.889 mA 52220 (+30 -50) = 52170 to 52250
Figure 7C-14 - Analog Input Display Menu
5.
Apply 3.111 mA to the Analog Input being tested. Click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (Figure 7C-13). Vary the input current from 3.111 mA to 20.898 mA and verify that the values provided below are displayed accordingly for the AI channel being tested.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-26
6. Set the Precision Current Source output to zero and remove it from the AI‘s Term.
Block. Reconnect it to the next AI (on TB8 of the GFC-CL’s Battery Charger & I/O
Board or TB6 of the EXPRESS ‘s Process I/O Board) and repeat Steps 4 through 5 for each of the remaining two analog inputs, checking the reading under the appropriate
AI channel.
WARNING:
Be sure to set the current source to zero before removing it after each input is tested
7C.6.2 1-5V Analog Input Channel Test
A Variable dc Voltage Source capable of outputting 5.000V with 10uV accuracy will be required to perform AI testing of a 1-5V Control Wave GFC-CL / XFC / EXPRESS circuit.
1. The "Board Number to Test" field is disabled.
2.
On the Analog Input Diagnostic Menu (Figure 7C-13) click on the "Analog Input
Display" button. The Analog Input Display Menu (Figure 7C-14) will appear. The test will proceed until it is stopped by clicking on the "End Test" button at the bottom of the menu or the X at the top right corner of the menu. The Number of Valid AI Values should be 3. The "Board Number Returned" should be blank and the "Board Type
Returned" should be FIX.
NOTE:
The Analog Input Display Menu is only available after all AI and AO have been initially calibrated by the factory.
3.
Click on the "End Test" button and return to the Analog Input Diagnostic menu
(Figure 7C-13).
4.
Connect the positive output of the Variable dc Voltage Source to the (+) input AI channel. Connect the negative output of the Variable dc Voltage Source to the (-) input
AI channel # in question (see Figure 7C-11A/B/C).
5. Apply 0.778 Vdc to the Analog Input being tested. Click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (Figure 7C-13). Vary the input voltage from 0.778 Vdc to 5.222 Vdc and verify that the values provided below are displayed accordingly for the AI channel being tested.
Input
Voltage
Reading
0.778 Vdc 778 ± 40 (738 to 818)
1.000 Vdc 10000 ± 40 (9960 to 10040)
2.000 Vdc 20000 ± 40 (19960 to 20040)
3.000 Vdc 30000 ± 40 (29960 to 30040)
4.000 Vdc 40000 ± 40 (39960 to 40040)
5.000 Vdc 50000 ± 40 (49960 to 50040)
5.222 Vdc 52220 ± 40 (52180 to 52260)
6. Set the Variable dc Voltage Source to zero and remove it from the AI’s Term. Block.
Reconnect it to the next AI on the appropriate Term. Block and repeat Steps 4 and 5 for each of the remaining five analog inputs, checking the reading under the appropriate
AI channel.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-27
WARNING
Be sure to set the voltage source to zero before removing it, after each input is tested.
7C.6.3 Analog Input Calibration Routine
A Variable dc Voltage Source capable of outputting 5.000V with 10uV accuracy will be required to perform AI calibration of a 1-5V AI Input.
1. The "Board Number to Test" field is disabled.
2.
Set the AI channel to be calibrated for 1-to-5 V operation via appropriate jumpers on the Analog I/O Module (see Figure 7C-11A/B/C).
3.
Apply a 0% input (1V) to the analog input in question and press the RUN button adjacent to the Read Input 0% field. The resulting 0% Cal. Value: will be posted.
4.
Apply a 25% input (2V) to analog input in question and press the RUN button adjacent to the Read Input 25% field. The resulting 25% Cal. Value: will be posted.
5.
Apply a 50% input (3V) to analog input in question and press the RUN button adjacent to the Read Input 50% field. The resulting 50% Cal. Value: will be posted.
6.
Apply a 75% input (4V) to analog input in question and press the RUN button adjacent to the Read Input 75% field. The resulting 75% Cal. Value: will be posted.
7.
Apply a 100% input (5V) to analog input in question and press the RUN button adjacent to the Read Input 100% field. The resulting 100% Cal. Value: will be posted.
8.
Set the Number of Passes to 1. Press the RUN button adjacent to the Read Cal Values field. The stored EEPROM values and the difference of the Stored EEPROM Values and the input Cal. Values (obtained in steps 3 through 7) will be displayed (see Figure
7C-15). The difference between the Cal. Value: and the Stored EEPROM Value must be within the following parameters: For 0% & 100% (of the nominal values 3128 & 15640)
± 218 counts respectively - For 25%, 50% and 75%,verify that the span is within ± 6 decimal counts of the calculated value for the applied voltage. To calculate the span, subtract the 1V reading from the 5V reading and then use the result to calculate the
.778V, 2V, 3V, 4V and 5.222V ± .0001V readings via the following formula:
(Voltage - 1V) / 4V x (span in decimal) + (decimal value for 1V)
9. If the calibration data appears good, press the RUN button adjacent to Write
Calibration Values. New EEPROM data should be stored. Note: If there is a problem with the calibration data, the message " Calibration Linear Failure " will be posted (in red) adjacent to Error Status: at the bottom of the Analog Input Diagnostic Menu.
10. Repeat Steps 1 through 9 above for each of the remaining two AI channels.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-28
Figure 7C-15 - Analog Input Diagnostic Menu - AI Calibration
(Board Type Returned = FIX for GFC-CL/XFC/EXPRESS)
7C.7 DISCRETE OUTPUT (DO) TESTS
These tests check the discrete output circuitry of a Control Wave GFC-CL / XFC /-
EXPRESS , including the output registers and the output paths to the terminal block.
For the tests in this section, you will need the DMM and Variable dc Voltage Source described in Chapter 1. For the Discrete Output Display test you will need either a 510 ohm resistor (for 6V GFC-CL s) or a 1K ohm resistor (for 12V GFC-CL / EXPRESS s and for
XFCs) in series with an LED rated for 10mA. For the Manual Discrete Output Load test, the resistor you need depends on the type of GFC/RTU you are testing as follows:
for Control Wave GFC-CL s, you will need a 250-ohm, 30-watt resistor that is required to provide a 100mA Non-isolated DO load from the 10 to 31 Vdc source (see Section
7C.7.3).
- for Wave XFC s or resistor that is required to provide a 400mA Non-isolated DO load from the 24 to 31 Vdc source (see Section 7C.7.3).
Control Wave EXPRESS s, you will need a 75-ohm, 30-watt
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-29
Figure 7C-16 - Discrete I/O Diagnostic Menu - Initial Entry
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the “Run” button at the bottom of the screen. The PC will proceed to the menu shown in Figure 7C-16.
7C.7.1 Automatic Discrete Output Test
Two DOs on the Control Wave GFC-CL will be automatically sequenced for this test (four on Control Wave XFC ) (two to four on the Control Wave EXPRESS) . Each DO will be enabled in turn for approximately 1 second. Be sure to set the Number of Passes to
"Continuous/Stop after Error" to provide a continuous test cycle.
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7C-16), set the Number of
Passes to "Continuous/Stop after Error" and then click on the "RUN Discrete Output
Sequence" Test button. NOTE: No test information will be displayed on the menu.
2.
Each DO should turn on for approximately 1 second. The Board Type Returned should be FIX. Proceed to Section 7C.7.2 for the Discrete Output Display Test.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-30
Figure 7C-17 – Discrete I/O Diagnostics Menu - DO Sequence
7C.7.2 Discrete Output Display Test
These tests check the DO output circuitry.
1. Place a 510 ohm resistor (for 6V GFC-CL s) or a 1K ohm resistor (for a 12V GFC-CL ,
EXPRESS or XFC ) in series with an LED rated for 10mA across the Discrete Output circuit (DO# to DGND) to be tested. In the case of the Control Wave GFC-CL , start with DO1 and then test DO2. In the case of the Control Wave XFC , start with DO1 and then test DO2, DO3 & DO4 in order. In the case of the Control Wave EXPRESS , start with DO1 and then test DO2, DO3 & DO4 in order.
2. On the Discrete Input/Output Diagnostic Menu (see Figure 7C-17), set the "Number of
Passes" to 10 and then click on the "Discrete Output Display" Test button. The Discrete
Output Display Menu (similar to Figure 7C-18) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
3. On the Discrete Output Display Menu, the Status: indication will change from IDLE to
WORKING once "Start Test" has been selected. When the Status: indication changes back to IDLE, it will appear similar to the Discrete Output Display Menu of Figure 7C-
18.
The Discrete Output Display menu will display DOs numbers (2 or 4, for Control Wave
GFC-CL or Control Wave XFC respectively or 2 to 4 for Control Wave EXPRESS ) and will post the Number of Valid DO Values (2/4) and the Board Type Returned (FIX).
Observe the test LED associated with DO1; it should be ON.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-31
Figure 7C-18 - Discrete Output Display Menu - Idle
4. After moving the test circuit to DO2, change the Drive DO: number to 2 and click on the "Start Test" button. Observe the test LED associated with DO2; it should be ON.
Note: The LED associated with the last DO tested (DO2) will remain ON until the unit has been reset
7C.7.3 Manual Discrete Output Load Test
This test checks each DOs output circuitry. You will need the Digital Multimeter (DMM), the Variable dc Voltage Source and depending on the unit, i.e., Control Wave GFC-CL ,
EXPRESS or XFC , the following resistor:
- for Wave GFC-CL s: a 250-ohm, 30-watt resistor (required to provide a 100mA
Non-isolated DO load from the 10 to 31 Vdc source.
- for Control Wave XFC s and Control Wave EXPRESS s: a 75-ohm, 30-watt resistor
(required to provide a 400mA Non-isolated DO load from the 24 to 31 Vdc source.
1.
Shut off the Control Wave GFC-CL / XFC / EXPRESS .
2.
For Control Wave GFC-CL s, construct the test circuit of Figure 7C-19A (DO1 example) using a 250-ohm 30-watt resistor for the load. The test circuit of Figure 7C-
19A provides a 40 to 124mA load with the power supply providing from 10 to 31 Vdc
(respectively). Set the power supply for 12V for a 6V system or 24V for a 12V system.
Turn on Control Wave GFC-CL power.
For Control Wave XFC s, construct the test circuit of Figure 7C-19B (DO1 example) using a 75-ohm 30-watt resistor for the load. Foe Control Wave EXPRESS s construct a test circuit similar to that of Figure 7C-19 connecting to Terminal Block TB3 of the
Process I/O Board (see Figure 7C-11C). The test circuit of Figure 7C-19B provides a
320 to 413mA load with the power supply providing from 24 to 31 Vdc (respectively).
Set the power supply for 24Vdc. Turn on Control Wave XFC/EXPRESS power.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-32
Figure 7C-19A - Control Wave GFC-CL Discrete Output Term. Block & DO Circuit
Use a 75-Ohm (30 Watt) Resistor to simulate the Load.
Ext. Powered DO
400mA
Max. Load
30Vdc
(Max.)
+
J5
Figure 7C-19B - Control Wave XFC Discrete Output Term. Block (J5) & DO Circuit
3.
On the Discrete Input/Output Diagnostic Menu (see Figure 7C-16), set the "Number of
Passes" to 1 and then click on the "Discrete Output Display" button. The Discrete
Output Display Menu (Figure 7C-18) will appear. The initial version of this menu will be blank (except for posting Drive DO: 1).
4.
On the Discrete Output Display Menu (see Figure 7C-18), the Status: indication will change from IDLE to WORKING once "Start Test" has been selected.
The Discrete Output Display menu will post the Number of Valid DO Values (2) and the Board Type Returned (FIX).
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-33
5. On the Discrete Output Display Menu (Figure 7C-18), set the Drive DO: for the desired
DO channel number (1 or 2 for GFC) (1, 2, 3 or 4 for XFC). Measure the voltage drop across the output terminals (+DO# to GND for Non-isolated modules) (with the output in question turned ON) - (see Figures 7C-19A/B). The output will be turned ON once the “Start Test” button has been selected. The DO voltage drop should not exceed
0.25V. Shut off the Control Wave GFC-CL / XFC / EXPRESS and the test circuit’s power source.
6. Move the test circuit to the next DO to be tested. Reapply power to the Control Wave
GFC-CL / XFC / EXPRESS and the test circuit. Repeat step 5 for each channel to be tested.
7C.8 DISCRETE INPUT (DI) TESTS
These tests check the discrete input circuitry of a Control Wave GFC-CL Battery Charger
& I/O Board, a Control Wave XFC I/O Board (via the Terminal Plate), or a Control Wave
EXPRESS Process I/O Board (via the Terminal Block TB2) to ensure complete and fully operational DI circuitry.
For the Digital Input Display Test (see Section 7C.8.2), you will need a short jumper wire
(3” long).
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the
Discrete Input/Output Diagnostic Menu (see Figure 7C-16).
7C
.8.1 Automatic Discrete Input Test
1.
On the Discrete Input/Output Diagnostic Menu (see Figure 7C-16), set the "Number of
Passes" field to "Continuous/Stop after Error" and then click on the "RUN Discrete
Input Circuitry" Test button.
2.
When the test has completed (via “ABORT”), the Board Type Returned should be FIX.
Proceed to Section 7C.8.2 for the Discrete Input Display Test.
7C.8.2 Discrete Input Display Test
These tests check the DIs field input circuitry.
1. On the Discrete Input/Output Diagnostic Menu (see Figure 7C-20), set the "Number of
Passes" to "Continuous/Repeat after Error" and then click on the "Discrete Input
Display" Test button. The Discrete Input Display Menu (similar to Figure 7B-21) will appear. DI1and DI2 (for GFC-CL s and XFC s) or DI1 through DI6 (for EXPRESS s) should be highlighted (in Gray). The Discrete Input Display Menu will display DIs numbers (2 or 6) and will post the Number of Valid DI Values (2 or 6), the Board
Number Returned (1), and the Board Type Returned (FIX).
2. Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Display Menu.
3. Shut off the Control Wave GFC-CL / XFC / EXPRESS . Place a jumper wire across the
DI channel to be tested. Test DI1 and then DI2, etc. Note: DIs are internally sourced ONLY, i.e., they can’t be externally powered.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-34
Figure 7C-20 - Discrete Input/Output Diagnostic Menu - DI Circuitry
D4041A
Figure 7C-21 - Discrete Input Display Menu
ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-35
4. Apply power to the Control Wave GFC-CL / XFC / EXPRESS unit. On the Discrete Input/Output Diagnostic Menu (see Figure 7C-20), click on the “Discrete Input Display” button.
The Discrete Input Display menu (Figure 7C-21) will display DIs numbers (2/6) and will post the Number of Valid DI Values (2/6), the Board Number Returned (1) and the
Board Type Returned (FIX). Any DI being tested should be highlighted in RED (see
Figure 7C-21).
5.
Repeat steps 2 through 4 configuring the DI to be tested until all DIs have been tested.
Select the "End Test" button at the bottom of the screen to return to the Discrete
Input/Output Diagnostic Menu. On the Discrete Input/Output Diagnostic Menu select the "Return to Menu" button or the X (in the upper right corner) to return to the
Diagnostic Test Category Menu. When testing has been completed, shut off power to the Control Wave GFC-CL / XFC / EXPRESS and remove any test hardware.
7C.9 HIGH SPEED COUNTER TESTS
These tests check the non-isolated high speed counter input circuitry on the Control Wave
GFC-CL Battery Charger & I/O Board, a Control Wave XFC I/O Board (via the Terminal
Plate), a Control Wave EXPRESS Process I/O Board (via Term. Block TB4) or the Pulse
Counter input circuitry on the Control Wave EXPRESS CPU/System Controller I/O Board
(via Term. Block TB5) to ensure a complete and fully operational HSC or Pulse Counter input circuitry. Control Wave GFC-CL Battery Charger I/O Boards and Control Wave
EXPRESS Process I/O Boards support Internally Sourced with an external Dry Contact
(debounce enabled) or Internally Sourced with an External Signal Generator (debounce disabled) operation. Control Wave XFC I/O Boards and Control Wave EXPRESS
CPU/System Controller Boards (Pulse Inputs on TB5) support Internally Sourced with an
External Signal Generator (debounce disabled) operation only. The maximum input frequency for either unit is 10 kHz.
To perform the High Speed Counters Display Tests (see Section 7C.9.1), the test setup of
Figure 7C-24A/B is required for HSC circuits with Debounce Disabled and the test setup of
Figure 7C-25 is required for HSC circuits with Debounce Enabled.
In addition to the equipment shown in Figures 7C-24A/B and 7C-25, you will need a dual trace oscilloscope to calibrate the square wave produced by the Pulse Generator. Note: If the
Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the "High Speed Counter" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the High Speed Counters Diagnostic Menu (see Figure 7C-22).
7C.9.1 High Speed Counter Display Test
Selecting "High Speed Counter Display" will test the HSC input path from the termination block. In this test the totalizers for each input are continually polled and the accumulated count for each input is displayed. A signal is forced at the HSC input terminal block and the state of that HSC is updated on the screen.
Control Wave GFC-CL 12V or 6V HSCs or Control Wave EXPRESS (HSCs 3 & 4 on the
Process I/O Board) may be tested in debounced or non-debounced configurations.
Control Wave XFC HSCs and Control Wave EXPRESS CPU/System Controller Board’
Pulse Inputs (HSCs 1 & 2) can be tested in non-debounced configuration only. For the non-
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-36
debounced configuration, connect a pulse generator that can drive the HSC Test Circuit shown in Figure 7C-24A, 7C-24B or 7C-25 to the HSCSET# terminal (P terminal for XFC s) and the return to the GND terminal (G terminal for XFC s). All inputs can be driven simultaneously. The pulse generator should generate a predetermined number of pulses.
After the pulses are applied to the HSC input/s the count displayed in the totalizer/s for the counters should match the predetermined number pulses generated by the pulse generator.
Figure 7C-22 - High Speed Counters Diagnostic Menu - Counters Test Running
1.
Set the output of the Pulse Generator to 5 V at 10 kHz, 50% duty cycle.
2.
Connect the channel 1 probe of the oscilloscope to the output of the pulse generator and offset the output wave as shown in Figure 7C-23. Remove the oscilloscope connections when calibration is completed. Turn the Pulse Generator OFF.
3.
Construct the test circuit for debounce disabled or debounce enabled (see Figures 7C-
24A/B and 7C-25). If the Pulse Generator has a built-in "Totalizer," the "Accumulator" won’t be required.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-37
Figure 7C-23 - Square Wave (50% Duty Cycle)
Figure 7C-24A - Control Wave GFC-CL (or Control Wave EXPRESS Process I/O Bd.)
HSC Test Circuit - Debounce Disabled
4.
On the High Speed Counters Diagnostic Menu (see Figure 7C-22), set the "Number of
Passes" to "Continuous/Stop after Error."
5. Apply the test circuit for debounce disabled (see Figure 3C-24A/B) or the test circuit for debounce enabled (see Figure 3C-25) to the HSC input/s to be tested. See Figures 7C-
11A/B/C and 7C-3B for terminal block assembly input assignments and Jumper settings .
5V
HSC#
(P1 or P2)
2N2222
1K
GND
(G)
Pulse Generator
Totalizer
(Accumulator) +
D4041A
Figure 7C-24B – Control Wave XFC (or Control Wave EXPRESS CPU Board.)
HSC Test Circuit - Debounce Disabled
ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-38
Form 'C' Relay
GND
HSCSET#
24V
+
24V
Coil
K1
C
NO
K1
NC
SPDT
5V
1K
2N2222
HSCRST#
Pulse Generator
Set no faster than
Max. Frequency of Relay
Totalizer
(Accumulator) +
Figure 7C-25 - Control Wave GFC-CL (or Control Wave EXPRESS Process I/O Bd.)
HSC Test Circuit - Debounce Enabled
6.
Click on the "RUN High Speed Counter Display" button.
7.
Turn the Pulse Generator ON. The High Speed Counters Diagnostic Menu will display the HSC accumulated counts for inputs HSC1 and HSC2 (Counter #1 through Counter
#4).
8. Verify that the count in the totalizer matches the number of pulses generated by the pulse generator.
7C.10 Control
Wave
GFC-CL/XFC/EXPRESS I/O EEPROM TEST
ControlWave GFC-CL Battery Charger I/O Boards, ControlWave EXPRESS Process
I/O Boards and Control Wave XFC I/O Boards are equipped with EEPROM memory. I/O memory (EEPROM) circuitry is tested when the EEPROM test function is initiated from the Diagnostic Test Category Menu (Figure 1-7).
The resulting EEPROM Menu provides the I/O EEPROM firmware version (line 1) and the
LCD Display firmware version (line 2) under Module Description.
To run the EEPROM test, highlight the EEPROM selection on the Diagnostic Test
Category Menu (Figure 1-7) and then click on the Run button at the bottom of the screen.
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-39
Figure 7C-26 – EEPROM Test Page (XFC Test Page shown)
Click on the OK button at the bottom of the EEPROM Test Page to end the test and return to the Diagnostic Test Category (Figure 1-7).
D4041A ControlWave GFC-CL/EXPRESS/XFC Diagnostics / 7C-40
Chapter 8
33XX Low Level Analog Input Modules
8.1 LOW LEVEL ANALOG INPUT SETUP
Bristol Babcock process controllers can contain one or more Low Level Analog Input Boards
(LLAI Boards) and corresponding Low Level Analog Termination Boards. The RTU 3310 can have up to four board sets and the DPC 3330 and DPC 3335 can have up to 10 board sets.
Table 8-1 summarizes the types of signals that can be accepted by the Low Level AI Board.
These include a resistance temperature device (RTD), thermocouples, and voltage inputs.
8.1.1 Hardware Configuration
The Low Level Analog Input (LLAI) Module cannot be calibrated in the field. Therefore, there is no need for external test equipment or for removal of the field wiring from the termination board. The off-line diagnostics are intended for checking purposes only. If they indicate problems, the LLAI Module should be returned to the factory for calibration or repair. Set up the LLAI Module as follows:
For the DPC 3330/3335 and RTU 3310 only:
For thermocouple and voltage-type inputs, jumpers W1 to W4 on the isolation board must be strapped. These jumpers are not necessary for RTD inputs.
8.1.2 Menu Access
At the Diagnostic Test Category Menu (see Figure 1-7), highlight the “ Low Level Analog
Input ” selection and then click on the RUN button at the bottom of the screen. Figure 8-1 will be invoked.
8.1.3 Entry/Display Fields
Menus contained in this chapter will use the following entry and display fields.
Number of Passes
Enter the number of test cycles you want to execute, or enter one of the Continuous Modes
(see Section 1.9.2 of Chapter 1). Some of the LLAI diagnostic functions default to continuous mode and are so noted in the text.
Board Number to Test
Enter the slot position of the LLAI Modules you are testing. A valid entry is a number from
1 to 12, depending on your type of controller. Enter 1 if the board is in the first slot; 2 if the board is in the second slot, and so forth.
D4041A 33XX Low Level Analog Input Boards / 8-1
Figure 8-1 Low Level Analog Input Diagnostic Menu DPC 3330
Board Type Returned
This field displays the type of the board being tested based on information returned from the controller. It provides you with verification that the correct board is being tested. This field should indicate "LAI" after you have begun testing.
Board Version
This field displays the EPROM code revision level of the LLAI Module. In Figure 8-1, the revision level is 1.2.
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
D4041A 33XX Low Level Analog Input Boards / 8-2
Status
This field displays ‘ Working ’ or ‘ Idle ’ to indicate if a test is in process or not.
D4041A
Figure 8-2 - Low level Analog Input Modules
33XX Low Level Analog Input Boards / 8-3
8.2 LOW LEVEL ANALOG INPUT TESTS
The first Low Level Analog Input Diagnostic display looks like Figure 8-1. The tests for the
LLAI Module will vary depending on your type of controller. Follow the appropriate instructions below.
8.2.1 0 Percent of AI
This function is only applicable for factory use and should not be used in the field. If you choose the "RUN" button (adjacent to "0 Percent of AI" Test ) and the message "Calibration
Mode Not Active" appears on the screen (under the status column), exit the calibration mode by pressing the "ABORT" button (adjacent to ” 0 Percent of AI ” Test ).
This mode can also be set by on-board jumpers. In this case the mode cannot be cleared by the PC and the Low Level Analog Input Display Menu (see Figure 8-3) cannot be executed.
8.2.2 Self Test (DPC 3330)
This test will verify the on board EPROM, internal registers, internal RAM, external RAM, ambient temperature sensor (ATS), ATS gain reference, and ATS zero reference. If a failure occurs, a failure message indicating the failed function will be displayed in the Status column.
8.2.3 Ambient Temperature, Zero & Gain Reference (DPC3330/3335 and RTU 3310)
The Ambient Temp, ZERO Reference, and GAIN Reference fields on the DPC 3330 display are only used during calibration at the factory. These fields are not used during diagnostic testing.
8.3 LOW LEVEL ANALOG INPUT DISPLAY
- DPC 3330/3335 and RTU 3310
For the DPC 3330/3335 and RTU 3310 the screen for the LLAI Diagnostic test will look like
Figure 8-3. If the "Point Type" column shows the correct input for your controller, click on the "Activate Display" button. The diagnostics program will gather data from the Low Level
AI Board based on the signal types defined there. After the diagnostic program has tested the HSAI Module, a menu similar to Figure 8-4 will be posted. These signal types will be displayed in the lower part of the screen. If you're using less than four channels, the default signal, Type K, will be displayed.
If the test is successful, the zero and gain columns will show "OK. " You should also check the "Scaled Value" column to ensure the reading there is reasonable.
If you wish to change the input type, place the cursor in the appropriate "TYPE" column and select the down pointer (click on the up/down selection until the correct type is visible).
At this time, the screen is not being refreshed with new data. Next, select the "Send Input
Types" button. Wait for a success message at the bottom of the screen. When you're ready to begin the test again, use the "Activate Display" button. To obtain meaningful results, the signal type should show the actual input signals to the board.
D4041A 33XX Low Level Analog Input Boards / 8-4
Figure 8-3 - Low Level Analog Input Display (Before Testing)
D4041A
Figure 8-4 - Low Level Analog Input Display DPC 3330 (After Testing)
33XX Low Level Analog Input Boards / 8-5
If Calibration Mode is active the input readings cannot be obtained. The types will be displayed and the message "Calibration Active" will appear in the center of the display. This condition could indicate that Calibration Mode is set via the on-board jumpers.
8.4 COMPLETING TESTING
At the conclusion of the LLAI tests, turn the power switch to OFF. If you changed the LLAI
Board address jumper settings, be sure to return them to their original positions. If necessary, repeat the tests of this chapter for any other LLAI Modules included in the controller.
Table 8-1 Input Accuracy & Resolution
Input Type Accuracy
B - Thermocouple 100 ° C to 200 ° C
200 ° C to 390 ° C
390 ° C to 840 ° C
840 ° C to 1800 ° C
R - Thermocouple -50 ° C to +50 ° C
+50 ° C to 1720 ° C
S - Thermocouple -50 ° C to +50 ° C
+50 ° C to 1760 ° C
J - Thermocouple -210 ° C to 191 ° C
190 ° C to 1200 ° C
E - Thermocouple -270 ° C to -260 ° C
-260 ° C to -225 ° C
-225 ° C to -200 ° C
-200 ° C to 1000 ° C
K - Thermocouple -270 ° C to -261 ° C
-260 ° C to -246 ° C
-245 ° C to -180 ° C
-179 ° C to -145 ° C
-145 ° C to 1372 ° C
T - Thermocouple -270 ° C to -261 ° C
-260 ° C to -251 ° C
-180 ° C to -136 ° C
-135 ° C to -400 ° C
Input Type Accuracy
RTD
± 10mV -
-220 ° C to 850 ° C
-
Resolution
2.00
° C
1.00
° C
0.50
° C
0.20
° C
0.40
° C
0.17
° C
0.37
° C
0.18
° C
0.08
° C
0.11
° C
1.00
° C
0.25
° C
0.08
° C
0.09
° C
2.00
° C
0.56
° C
0.25
° C
0.08
° C
0.14
° C
1.50
° C
0.38
° C
0.08
° C
0.06
° C
Resolution
0.09
° C
25 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 1 ° C
± 2 ° C
± 1 ° C
± 2 ° C
± 1 ° C
± .750
° C
± .500
° C
± 3 ° C
± 1 ° C
± .750
° C
± .500
° C
± 5 ° C
± 2 ° C
± 1 ° C
± .750
° C
± .500
° C
± 4 ° C
± 2 ° C
± .750
° C
± .500
° C
25 ° C
± .500
° C
± .025%
0 ° C to +70 ° C
± 16 ° C
± 8 ° C
± 4 ° C
± 2 ° C
± 4 ° C
± 2 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
± 6 ° C
± 2 ° C
± .5
° C
± 1 ° C
± 10 ° C
± 4 ° C
± 2 ° C
± 1.5
° C
± 1 ° C
± 8 ° C
± 4 ° C
± 1.5
° C
± 1 ° C
-20 ° C to +70 ° C
± 1 ° C
± 0.05%
D4041A 33XX Low Level Analog Input Boards / 8-6
INPUT
TYPE
TYPE-B
TYPE-R
TYPE-S
TYPE-J
TYPE-E
TYPE-K
TYPE-T
RTD
10mV
100mV
1V
10V
1-5V
Table 8-2 - LLAI Hex Reading Correlation’s
0%
0BA
100 E C
-50 E C
-50 E C
-210 E C
-270 E C
-270 E C
-270 E C
-220 E C
-10mV
-100mV
-1V
-10V
1V
PERCENT OF SCALE HEX READING
25%
45D
50%
800
75%
BA3
393 E C
402 E C
142 E C
47 E C
140 E C
-103 E C
47 E C
-5mV
-50mV
-0.5V
-5V
2V
835 E C
855 E C
495 E C
365 E C
550 E C
65 E C
315 E C
0
0
0
0
3V
1277 E C
1307 E C
848 E C
682 E C
960 E C
233 E C
582 E C
+5mV
+50mV
+0.5V
+5V
4V
100%
F46
1820 E C
1720 E C
1760 E C
1200 E C
1000 E C
1370 E C
400 E C
850 E C
+10mV
+100mV
+1V
+10V
5V
D4041A 33XX Low Level Analog Input Boards / 8-7
BLANK PAGE
Chapter 9
33XX Analog Output & Analog Input Modules
9.1 ANALOG I/O SETUP
The 33XX units (3310/30/31/35) can contain one or more Analog Output (AO2 ) and Analog
Input (AI3) Boards (see Notes 1, 2 & 3). These boards handle only analog signals. The maximum number of I/O boards you can have per 33XX unit is shown in Table 9-1 below:
UNIT
TYPE
3310
3330
3331
3335
MAXIMUM NUMBER
OF I/O BOARDS
4
6 or 12 (Depending on the 3330 Model)
10
9 or 10 (Depending on the 3335 Model)
Table 9-1 - Maximum Number of I/O Boards Per 33XX Unit
The tests in this chapter are intended for 33XX units furnished with Analog Input or
Analog Output Boards. If your unit is not equipped with Analog Input or Analog Output
Boards, you can skip this chapter.
Note 1: 33XX includes RTU 3310, DPC 3330, RIO 3331, and DPC 3335.
Note 2: There are two types of AO boards - 2 point AO board (AO2), 4 point AO board
(AO4).
Note 3: There are two types of AI boards - 4 point AI board (AI4), 8 point AI board (AI8).
9.1.1 Hardware Configuration
For the tests in this chapter, you will need the Digital Multimeter (DMM), the dc Voltage
Source and the Precision Current Source described in Chapter 1. Set up for testing as follows:
1. Turn the 33XX unit's power switch to OFF.
2. Make sure that all analog signal wiring is disconnected from the field wiring terminals.
3. Remove the board to be tested from its slot.
4. You can determine the type of board you have by referring to the part number that appears on a label on the board. The following part numbers are supported:
D4041A 33XX Analog Output & Analog Input Modules / 9-1
RTU 3310 :
PART NUMBER
392005-XX-X, 392080-XX-X
392007-XX-X, 392027-XX-X
392004-XX-X, 392086-XX-X
392009-XX-X, 392029-XX-X
395317-XX-X
395315-XX-X, 395316-XX-X
392544-XX-X
392547-XX-X
DPC 3330 :
PART NUMBER
BOARD TYPE
AO2 Board 1-5V/4-20mA
AO2 Board 0-10V
AI4 Board 1-5V/4-20mA
AI4 Board 0-10V
AO4 Board 1-5V/4-20mA
AI8 Board 1-5V/4-20mA
AI4/8 Board 1-5V/4-20mA
AO2/4 Board 1-5V/4-20mA
392005-XX-X, 392080-XX-X
392007-XX-X, 392027-XX-X
392004-XX-X, 392086-XX-X
392009-XX-X, 392029-XX-X
395317-XX-X
395315-XX-X, 395316-XX-X
392544-XX-X
392547-XX-X
RIO 3331/DPC 3335 :
PART NUMBER
BOARD TYPE
AO2 Board 1-5V/4-20mA
AO2 Board 0-10V
AI4 Board 1-5V/4-20mA
AI4 Board 0-10V
AO4 Board 1-5V/4-20mA
AI8 Board 1-5V/4-20mA
AI4/8 Board 1-5V/4-20mA
AO2/4 Board 1-5V/4-20mA
BOARD TYPE
392080-XX-X
392027-XX-X
392086-XX-X
392029-XX-X
395317-XX-X
395315-XX-X, 395316-XX-X
392544-XX-X
392547-XX-X
AO2 1-5V/4-20mA
AO2 0-10V
AI4 Board 1-5V/4-20mA
AI4 Board 0-10V
AO4 Board 1-5V/4-20mA (see note 4 below)
AI8 Board 1-5V/4-20mA (see note 4 below)
AI4/8 Board 1-5V/4-20mA
AO2/4 Board 1-5V/4-20mA
Note 4: These AI8 and AO4 do NOT apply to RIO 3331
Each test procedure in this chapter identifies the board type to which it applies. Make sure you are using the correct procedure.
Information is provided within this chapter for configuring switch and jumper settings for various tests. If necessary, refer to the appropriate section of the controller hardware manual for information on specific AI/AO Boards (see Table 9-2 for controller hardware manual, document numbers and applicable chapters).
D4041A 33XX Analog Output & Analog Input Modules / 9-2
UNIT
TYPE
3310
3330
3331
3335
DOCUMENT
NUMBER
CI-3310
CI-3330
CI-3335
CI-3335
CHAPTER
AI Modules
3D, 3DA & 3DB
3D, 3DA & 3DB
3D, 3DA & 3DB
3D, 3DA & 3DB
CHAPTER
AO Modules
3E & 3EA
3E & 3EA
3E & 3EA
3E & 3EA
Table 9-2 - Hardware Manual Reference
5. Plug the board into any I/O slot in the 33XX unit.
6. Reapply power. If the 33XX unit was executing the DIAG load when you powered down, there is no need to reset and reload it; simply continue with proper menu selection at the PC. If you have not previously downloaded the DIAG file, refer to
Chapter 1 for the recommended procedures.
7. You are now ready to begin testing. If you are testing an Analog Output Board, refer to Section 9.2. For Analog Input Board testing, refer to Section 9.3.
9.1.2 Menu Access
The test procedures in this chapter begin with the Diagnostic Test Category Menu (Figure
1-7). From that display, you will be asked to select from one of the following test categories:
ANALOG OUTPUT Diagnostic
ANALOG INPUT Diagnostic
(If you need help with this menu, see Sections 1.7.4 through 1.8.)
9.1.3 Entry/Display Fields
Each of the menus used in this chapter contain the following entry and display fields:
Number of Passes
Enter the number of test cycles you want to execute, or enter one of the Continuous Modes
(see Section 1.9.2 of Chapter 1).
Board Number to Test
Enter the slot position of the Analog Output or Analog Input Board you are testing. A valid entry for RTU 3310 is a number from 1 through 4. A valid entry for a 6-slot DPC 3330 is a number 1 through 6. For a 12-slot DPC 3330, enter a number from 1 through 12. For a 9- or
10-slot DPC 3335, enter a number from 1 through 9 or 10. For RIO 3331, enter a number from 1 through 10.
Board Type Returned
This field displays the type of the board being tested based on information returned from the controller. It provides verification that the correct board is being tested. This field
D4041A 33XX Analog Output & Analog Input Modules / 9-3
should indicate "AO", or "AO4", "AI", or "AI8", based on the board being tested, after you have initiated testing.
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays ‘Working’ or ‘Idle’ to indicate if a test is in process or not.
Number of Valid AI Values
This display field only appears on the Analog Input Display screen. It indicates the maximum number of AIs that the board supports. For an AI4 Board this number will be 4 and for AI8 Board this number will be 8.
9.2 ANALOG OUTPUT (AO) TESTS
The AO tests are used to calibrate the analog outputs on the AO2 and AO4 Boards, check for linearity in the Analog-to-Digital conversion, and check for AO channel interference.
D4041A
Figure 9-1 - Analog Output Diagnostic Menu
33XX Analog Output & Analog Input Modules / 9-4
You will need the Digital Multimeter (DMM) described in Chapter 1.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Analog Output" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu of Figure 9-1. Set the Number of Passes to Continuous (CR or CS) and enter the number of the board to be tested (slot position).
9.2.1 Calibration
Depending on your type of Analog Output Board, choose the appropriate calibration procedure listed below.
Adjustments and test points are identified in Figures 9-2 through 9-4.
1-5V/4-20 mA AO2 Board
In this procedure you will be calibrating the base voltages for the 1-5V/4-20 mA AO2
Boards. The procedures are performed with the board configured for 1-5 V outputs, and serve to calibrate and test both modes.
1. In this step, both outputs are set for 1-5 V operation. Note the switch settings before you change them, since you will need to restore them to their original settings later when testing is complete.
Set Switch S1 positions 1 and 2 (AO1) and 5 and 6 (AO2) to ON. Set positions 3 and
7 to OFF (see Figures 9-2 through 9-4).
D4041A
Figure 9-2 - 1-5V & 1-10V (AO Modules)
33XX Analog Output & Analog Input Modules / 9-5
D4041A
Figure 9-3 - Two AO Type Modules (1-10 V Types Shown)
33XX Analog Output & Analog Input Modules / 9-6
Older 1-5V
HDAO-4 Module
No
Longer
Available
392547-01-5
Older Units
392547-03-1
D4041A
AO1+ = Pin 1
AO1- = Pin 2
AO2+ = Pin 3
AO2- = Pin 4
AO3+ = Pin 5
AO3- = Pin 6
AO4+ = Pin 7
AO4- = Pin 8
AO1+ = Pin 29
AO1- = Pin 30
AO2+ = Pin 25
AO2- = Pin 26
AO3+ = Pin 17
AO3- = Pin 18
AO4+ = Pin 13
AO4- = Pin 14
Figure 9-4 - 2/4 High Density AO Type Modules
33XX Analog Output & Analog Input Modules / 9-7
2. On the Analog Output Diagnostic Menu (Figure 9-1), click on the "RUN Signal Cond.
Zero" Test button.
3. Use the DMM to measure across the field terminals indicated below. If necessary, adjust the respective potentiometer for +1.000V dc 0.001V.
Analog
Output
AO1
AO2
DMM Connection
TB1
(+) (-)
AO1-A AO1-B
AO2-A AO2-B
Adjustment
R37
R14
4.
Click on the "RUN Signal Cond. Span" Test button.
5. Use the DMM to measure across the field terminals indicated below. If necessary, adjust the respective potentiometer for +5.000Vdc ±0.001V.
Analog
Output
AO1
AO2
DMM Connection
TB1
(+) (-)
AO1-A AO1-B
AO2-A AO2-B
Adjustment
R10
R11
6.
Repeat steps 2 through 5 until both outputs are within specification. The 1-5V-
/4-20mA calibration is now complete.
7. Leave the S1 switches in the 1-5 V positions and proceed to Section 9.2.2 for calibration verification.
1-5V/4-20 mA AO4 Board
In this procedure you will be calibrating the base voltages for the 1-5V/4-20mA AO4 Boards.
The procedures are performed with the board configured for 1-5 V outputs, and serve to calibrate and test both modes.
1. In this step, all four outputs are set for 1-5 V operation. Note the switch settings before you change them, since you will need to restore them to their original settings later when testing is complete. Set Switch S1 positions 1 and 2 (AO1), 4 and 5 (AO2),
7 and 8 (AO3), 10 and 11 (AO4) to ON. Set positions 3, 6, 9 and 12 to OFF (See
Figure 9-4).
2. On the Analog Output Diagnostic Menu (Figure 9-1), click on the "RUN Signal Cond.
Zero" Test button.
3. Use the DMM to measure across the field terminals indicated below. If necessary, adjust the respective potentiometer for +1.000Vdc ±0.001V.
Analog
Output
AO1
AO2
DMM Connection
TB1
(+) (-)
AO1-A AO1-B
AO2-A AO2-B
Adjustment
R7
R20
D4041A 33XX Analog Output & Analog Input Modules / 9-8
AO3
AO4
AO3-A AO3-B
AO4-A AO4-B
R31
R45
4. Click on the "RUN Signal Cond. Span" Test button.
5.
Use the DMM to measure across the field terminals indicated below. If necessary, adjust the respective potentiometer for +5.000Vdc ±0.001V.
Analog
Output
AO1
AO2
AO3
AO4
DMM Connection
TB1
(+) (-)
AO1-A AO1-B
AO2-A AO2-B
AO3-A AO3-B
AO4-A AO4-B
Adjustment
R2
R12
R24
R35
6. Repeat steps 2 through 5 until all four outputs are within specification. The 1-5V/-
4-20mA calibration is now complete.
7. Leave the S1 switches in the 1-5 V positions and proceed to Section 9.2.2 for calibration verification.
0-10V AO2 Board
In this procedure you will be calibrating the base voltages for the 0-10 V AO2 Board.
1. On the Analog Output Diagnostic Menu (Figure 9-1), click on the "RUN Signal Cond.
Zero" Test button.
2. Use the DMM to measure across the field terminals indicated below. If necessary, adjust the respective potentiometer to 0.0Vdc ±±0.001V (see Figures 9-2 through 9-
4).
Analog
Output
AO1
AO2
DMM Connection
TB1
(+) (-)
AO1-A AO1-B
AO2-A AO2-B
Adjustment
R37
R14
3. Click on the "RUN Signal Cond. Span" Test button.
4. Use the DMM to measure across the field terminals indicated below. If necessary, adjust the respective potentiometer for +10Vdc ±0.001V.
Analog
Output
AO1
AO2
DMM Connection
TB1
(+) (-)
AO1-A AO1-B
AO2-A AO2-B
Adjustment
R10
R11
5. Repeat steps 1 through 4 until both outputs are within specification. The 0-10 V calibration is now complete.
D4041A 33XX Analog Output & Analog Input Modules / 9-9
6. Proceed to Section 9.2.2 for calibration verification.
9.2.2 Calibration Verification
Once the base voltage calibration has been done, the following procedure determines if the
DAC is working linearly throughout the specification range.
At the PC, the "RUN Calibration" Test allows you to select one of seven points to test relative to the voltage range of the analog outputs. Position the cursor at the jog point just to the right of "RUN Calibration." As you click on the jog point, the seven options are displayed in turn. The option on the screen will become active when you select the "RUN
Calibration" Test button.
1-5V/4-20mA AO2 Board
In this step, both analog outputs must be set for 1-5 V operation. For Switch S1 set switch positions 1, 2, 5 and 6 to ON, and positions 3 and 7 to OFF.
1. With the "UNDERRANGE" option on the screen click on the "RUN Calibration" Test button.
2. The DMM connection points for the calibration procedures are the same as described in Step 3 of Section 9.2.1 for this board type. Verify that the DMM reads +0.800Vdc
±0.004V.
3. At the PC, bring up the next option and click on the "RUN Calibration" Test button.
Verify that the DMM reads the appropriate voltage level. The following list shows the expected voltage readings for each of the seven test settings for 1-5 V outputs.
UNDERRANGE +0.800V ±4mV
0% +1V
25% +2V
50% +3V
75% +4V
100% +5V
OVERRANGE +5.2V
±4mV
±4mV
±4mV
±4mV
±4mV
±4mV
4. Repeat Step 3 for each of the test settings.
5.
If ANY of the voltages are not within tolerance the board is in need of repair or recalibration.
6. If all measurements are within tolerance, proceed to 9.2.3 for interference testing.
1-5V/4-20mA AO4 Board
In this step, all four analog outputs must be set for 1-5 V operation. For Switch S1 set switch positions 1, 2, 4, 5, 7, 8, 10, and 11 to ON, and positions 3, 6, 9, and 12 to OFF.
1. With the "UNDERRANGE" option on the screen click on "RUN Calibration" Test button.
D4041A 33XX Analog Output & Analog Input Modules / 9-10
2. The DMM connection points for the calibration procedures are the same as described in Step 3 of Section 9.2.1 for this board type. Verify that the DMM reads +0.800Vdc
±0.004V.
3. At the PC, bring up the next option, click on the "RUN Calibration" Test button.
Verify that the DMM reads the appropriate voltage level. The following list shows the expected voltage readings for each of the seven test settings for 1-5 V outputs.
UNDERRANGE +0.800V ±4mV
0% +1V
25% +2V
50% +3V
75% +4V
100% +5V
OVERRANGE +5.2V
±4mV
±4mV
±4mV
±4mV
±4mV
±4mV
4. Repeat Step 3 for each of the test settings.
5. If ANY of the voltages are not within tolerance the board is in need of repair or recalibration.
6. If all measurements are within tolerance, proceed to 9.2.3 for interference testing.
0-10 V AO2 Board
1. With the "UNDERRANGE" option on the screen click on the "RUN Calibration" Test button.
2. DMM connection points for the calibration procedures are the same as described in
Step 2 of Section 9.2.1 for this board type. The DMM should read -0.5Vdc ±0.010V.
3. At the PC, bring up the next option, click on the "RUN Calibration" Test button.
Verify that the DMM reads the appropriate voltage level. The following list shows the expected voltage readings for each of the seven test settings for 0-10 V outputs.
UNDERRANGE -0.5V
0% 0.0V
25% +2.5V
50% +5.0V
±10mV
±10mV
±10mV
±10mV
75% +7.5V
±10mV
100% +10.0V
±10mV
OVERRANGE +10.497V ±10mV
4. Repeat Step 3 for each of the test settings.
5. If ANY of the voltages are not within tolerance the board is in need of repair or recalibration.
6. If all measurements are within tolerance, proceed to 9.2.3 for interference testing.
D4041A 33XX Analog Output & Analog Input Modules / 9-11
9.2.3 Interference Test
This test helps to determine if there is interference between adjacent output channels. The same procedure applies to all board types.
1. On the Analog Output Diagnostic Menu (Figure 9-1), click on the "RUN Interference
Test" Test button.
2. The status of the test will be displayed as follows: for AO2/4 board: Channel 1/3 - 0% Channel 2/4 - 100%
This indicates that AO1 and AO3 have been set for a 0% output and AO2 and AO4 have been set for a 100% output. Note: For AO2 boards, /3 and /4 have no meaning.
3. Using the DMM across the terminal points as described in 9.2.1 for the board type being tested, verify that the 0% channel(s) and the 100% channel(s) read as indicated below, based on the output type:
1-5V/4-20mA Output 0-10 V Output
0% - +1V ±4mV
100% - +5V ±4mV
0% - 0.0 V ±10mV
100% - +10.0 V ±10mV
4. At the PC, click on the "RUN Interference Test" Test button. The loading of the
(two/four) channels will be interchanged and the display will indicate: for both AO2 and AO4 boards: Channel 1/3 - 100% Channel 2/4 - 0%
This indicates that for an AO2 board Channels 1 and 2 are applicable, and for an
AO4 board Channels 1, 2, 3, and 4 are applicable.
5.
Repeat Step 3. Any variance from the specified readings indicates interference between the adjacent outputs. The board should be repaired or replaced.
6. If your application uses the 4-20 mA option on either AO channel, be sure to return the S1 switches on the AO Board to their original positions.
9.3 ANALOG INPUT (AI) TESTS
The AI tests are used to calibrate reference voltages, to calibrate and verify the instrumentation amplifier and to verify correct operation of the analog inputs on both
Analog Input (AI4/AI84 ) boards (see Note 4).
For these tests, you will need the Digital Multimeter (DMM), dc Voltage Source and the
Precision Current Source described in Chapter 1.
D4041A 33XX Analog Output & Analog Input Modules / 9-12
Figure 9-5 - 33XX Analog Input Diagnostic Menu
From the Diagnostic Test Category Menu (Figure 1-7), click on the "Analog Input Display" button. The PC will proceed to the menu of Figure 9-5. Set the Number of Passes to Continuous (CR or CS) and enter the number of the board to be tested (slot position).
9.3.1 Reference Voltage Calibration
Depending on the type of your analog input board, choose one of the appropriate calibration procedures listed below.
1-5V/4-20mA AI4 Boards - 392004-XX-X & 392086-XX-X
Set the 5 V and 1 V reference voltages as follows:
D4041A 33XX Analog Output & Analog Input Modules / 9-13
1.
Connect the DMM (+) to TP1-1 and DMM (-) to TP1-2. TP1 is a 3-pin header located beside potentiometers R13 and R14 (See Figure 9-6).
2. Adjust R13 until the DMM displays +5.0V ±0.001V
Figure 9-6 - Discontinued 4AI Modules (1-5V/4-20mA) - 392086-XX-X Shown
D4041A 33XX Analog Output & Analog Input Modules / 9-14
D4041A
Figure 9-7 - 4AI Modules (0-10 V Types) - 392009-XX-X Shown
33XX Analog Output & Analog Input Modules / 9-15
Figure 9-8 - 4AI Modules (0-10 V Types - 392029-XX-X With Common Mode)
D4041A 33XX Analog Output & Analog Input Modules / 9-16
Figure 9-9 - 4AI Modules (0-10 V Types - 392029-XX-X Without Common Mode)
D4041A 33XX Analog Output & Analog Input Modules / 9-17
Figure 9-10 - Discontinued 8AI Modules (1-5V/4-20mA) - (395315-XX-X/395316-XX-X)
3. Connect the DMM (+) to TP1-3.
4.
Adjust R14 until the DMM displays +1.0V ±0.001V.
1-5V/4-20mA AI4/8 Boards - 392544-XX-X, 395315-XX-XS & 395316-XX-X
Set the 5 V and 1 V reference voltages as follows:
1. Connect the DMM (+) to TP1-1 and DMM (-) to TP1-2. TP1 is a 3-pin header located beside potentiometers R23 and R25 (See Figures 9-10 & 9-11).
2.
Adjust R23 until the DMM displays +5.0 V ±0.001 V.
3. Connect the DMM (+) to TP1-3.
4. Adjust R25 until the DMM displays +1.0 V ±0.001 V.
D4041A 33XX Analog Output & Analog Input Modules / 9-18
Note:
These
Components
Are
Only
Available
On
High
Common
Mode
(HCM)
Units
Older Units
Figure 9-11 - 4/8HDAI Modules (1-5V/4-20mA) - (392554-XX-X) (HCM-HDAI Shown)
D4041A 33XX Analog Output & Analog Input Modules / 9-19
0-10V AI4 Boards - 392009-XX-X & 392029-XX-X
Set the 5 V and 10 V reference voltages as follows:
1. Connect the DMM (+) to TP1-1 and DMM (-) to TP1-2. TP1 is a 3-pin header located beside potentiometers R9 and R10 (see Figures 9-7, 9-8 & 9-9).
2. Adjust R9 until the DMM displays +5.0V ±0.001V.
3. Connect the DMM (+) to TP1-3.
4. Adjust R10 until the DMM displays +10.0V ±0.001V.
9.3.2 Instrumentation Amplifier Calibration
This test channels the 0% reference voltage or the 100% reference voltage to the instrumentation amplifier. The resultant readings from the analog-to-digital converter are displayed at the PC. Choose the appropriate procedure below based on your board type.
1-5V/4-20mA AI4 Boards - 392004-XX-X & 392086-XX-X
1. Click on the "RUN 0 percent of AI" Test button.
2. Verify that the hex value 0BA ±1 count (0B9 - 0BB) is displayed under the STATUS column. Adjust R15 if necessary (see Figure 9-6).
3.
Click on "RUN 100 percent of AI" Test button.
4. Verify that the hex value F46 ±1 count (F45 - F47) is displayed under the STATUS column. Adjust R16 if necessary (see Figure 9-6).
5. Because steps 2 and 4 may affect each other, repeat steps 1-4 until further adjustments are not required and the hex readings are stable within the tolerance.
1-5V/4-20mA AI4/8 Boards - 392544-XX-X, 395315-XX-XS & 395316-XX-X
1. Click on the "RUN 0 percent of AI" Test button.
2. Verify that the hex value 0BA ±1 count (0B9 - 0BB) is displayed under the STATUS column. Adjust R21 if necessary (see Figures 9-10 & 9-11).
3. Click on the "RUN 100 percent of AI" Test button.
4. Verify that the hex value F46 ±1 count (F45 - F47) is displayed under the STATUS column. Adjust R22 if necessary (see Figures 9-10 & 9-11).
5. Because steps 2 and 4 may affect each other, repeat steps 1-4 until further adjustments are not required and the hex readings are stable within the tolerance.
D4041A 33XX Analog Output & Analog Input Modules / 9-20
0-10 V AI4 Boards - 392009-XX-X & 392029-XX-X
1. Click on the "RUN 0 percent of AI" Test button.
2. Verify that the hex value 0BA ±1 count (0B9 - 0BB) is displayed under the STATUS column. Adjust R6 if necessary (see Figures 9-7, 9-8 & 9-9).
3. Click on the "RUN 100 percent of AI" Test button.
4. Verify that the hex value F46 ±1 count (F45 - F47) is displayed under the STATUS column. Adjust R7 if necessary (see Figures 9-7, 9-8 & 9-9).
5. Because steps 2 and 4 may affect each other, repeat steps 1-4 until further adjustments are not required and the hex readings are stable within the tolerance.
9.3.3 Calibration Verification
This test applies to all analog input board types. The 0% and 100% reference voltages are processed and checked to be within ±0.2% of the nominal value ( 8 counts).
1. Click on the "RUN Verify Amplifier Calibration" Test button.
2. The results of the test are displayed under the STATUS column as follows:
Success
Fail
Fail
0% AI
100% AI
9.3.4 Analog Input Termination Test
These procedures check the analog input values at the Analog Input terminal block (TB1) for all modes supported by the board. On a 1-5V/4-20mA Analog Input (AI4/AI8) Board, each input can be individually configured; on a 0-10 V Analog Input (AI4) Board all inputs are fixed. The procedures include all four/eight AIs in each test, however you may select only those tests for specific input types based on your actual configuration.
1-5V Isolated Analog Inputs
1.
Verify that jumpers W1-4 for AI4 board (see Figure 9-6) and W1-8 for AI8 board (see
Figures 9-10 & 9-11) are correctly configured (see Figure 9-12).
2.
From the Analog Input Diagnostic Display (Figure 9-5), click on the "Analog Input
Display" button. The Analog Input Display Menu will appear (see Figure 9-13).
3. Connect the dc Voltage Source (+) to AI1-A and the Voltage Source (-) to AI1-B at
TB1 (see Figures 9-6, 9-10 or 9-11).
4. For the input voltages shown below, the associated hex value should appear under the AI-01 heading on the display.
D4041A 33XX Analog Output & Analog Input Modules / 9-21
INPUT VOLTAGE
+0.8V ±0.001V
+1.0V ±0.001V
+3.0V ±0.001V
+5.0V ±0.001V
+5.2V ±0.001V
HEX READING
000 ±4 = (000 - 004)
0BA ±4 = (0B6 - 0BE)
800 ±4 = (7FB - 804)
F46 ±4 = (F42 - F4A)
FFF ±4 = (FFB - FFF)
Figure - 9-12 - AI Board Input Range Jumper Assignments
D4041A
Figure 9-13 - 33XX Analog Input Display Menu
33XX Analog Output & Analog Input Modules / 9-22
After each input voltage value (.8V, 1V, etc.) click on the "End Test" button at the bottom of the screen. Adjust the dc Voltage Source to the next value and then click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (see
Figure 9-5).
5. Move the dc Voltage Source to the next AI on TB1 and repeat Step 4 for each of the four/eight analog inputs, checking the hex reading under the appropriate heading.
4-20mA Isolated Analog Inputs
1. Verify that jumpers W1-4 for AI4 board (see Figures 9-6 & 9-11) and W1-8 for AI8 board (see Figures 9-10 & 9-11) are correctly configured (see Figure 9-12).
2. Click on the "Analog Input Display" button. The Analog Input Display Menu will appear (see Figure 9-13).
3. Connect the Precision Current Source output to AI1-A and the return to AI1-B at
TB1 (see Figures 9-6, 9-10 or 9-11).
4. For the input currents shown below, the associated hex value should appear under the AI-01 heading on the display.
INPUT CURRENT
4mA ±0.004mA
20mA ±0.004mA
HEX READINGS
0BA ±4 = (0B6 - 0BE)
F46 ±4 = (F42 - F4A)
5. Set the Precision Current Source output to zero and remove it from TB1. Reconnect it to the next AI on TB1 and repeat Step 4 for each of the four/eight analog inputs, checking the hex reading under the appropriate heading.
WARNING
Be sure to set the current source to zero before removing it after each input is tested.
4-20mA Internally Sourced Analog Inputs
Note
This option is only applicable to 33XX units that operate from +24V dc power sources.
1.
Verify that jumpers W1-4 for AI4 board (see Figure 9-6 or 9-11) and W1-8 for AI8 board (see Figure 9-10 or 9-11) are correctly configured (see Figure 9-12).
2. Using the DMM, measure between AI1-A and AI1-B at TB1. The DMM should read
+24 volts (see Figure 9-6, 9-10 or 9-11).
3. Move the DMM to the next AI on TB1 and repeat Step 2 for each of the four/eight analog inputs.
D4041A 33XX Analog Output & Analog Input Modules / 9-23
0-10 Volt Analog Inputs
Note
This test is only applicable to the AI4 board. These boards don’t have Input Range Jumpers
1. Click on the "Analog Input Display" button. The Analog Input Display Menu will appear (see Figure 9-13).
2. Connect the dc Voltage Source (+) to AI1-A and the Voltage Source (-) to AI1-B at
TB1 (see Figures 9-7 through 9-9).
3. For the input voltages shown below, the associated hex value should appear under the AI-01 heading on the display.
INPUT VOLTAGE
- 0.5V ±0.001V
0.0V ±0.001V
+5.0V ±0.001V
+10.0V ±0.001V
+10.497V ±0.001V
HEX READING
000 ±4 = (000 - 004)
0BA ±4 = (0B6 - 0BE)
800 ±4 = (7FB - 804)
F46 ±4 = (F42 -F4A)
FFF ±4 = (FFB - FFF)
After each input voltage value (.8V, 1V, etc.) click on the "End Test" button. Adjust the dc Voltage Source to the next value and then click on the "Analog Input Display" button on the Analog Input Diagnostic Menu (see Figure 9-5).
4. Move the dc Voltage Source to the next AI on TB1 and repeat Step 3 for each of the four analog inputs, checking the hex reading under the appropriate heading.
9.4 COMPLETING TESTING
At the conclusion of the AO and/or AI tests, turn the 33XX unit's power switch to OFF.
Turn all test equipment off and remove it from the I/O board terminals. Return all switch and jumper settings to their original positions. If necessary, repeat the tests of this chapter for any other AO2/AO4 or AI4/AI8 Boards included in the 33XX controller. When all boards have been tested, reconnect field wiring and restore operation as required.
D4041A 33XX Analog Output & Analog Input Modules / 9-24
Chapter 10
33XX Discrete Output/Discrete Input Modules
10.1 DISCRETE I/O SETUP
DPC 3330, RIO 3331, DPC 3335, or RTU 3310 controllers may contain one or more Discrete
Output and Discrete Input Boards (DO or DI Boards). These boards handle discrete signals exclusively.
The tests in this chapter are intended only for 3310/30/31/35 controllers that contain Discrete Input or Discrete Output Boards. If your unit is not a DPC 3330, RIO 3331, DPC
3335, or RTU 3310, or if it does not contain Discrete Input or Discrete Output Boards, you can skip this chapter.
10.1.1 Hardware Configuration
For the tests in this chapter, you will need the Digital Multimeter (DMM), the dc Voltage
Source (variable to 31 V dc), the 2.2 k ohm (1/2 watt, 5% resistor) and the Power Supply
(variable to 120 V dc ± 0.200 mV dc, 100mA) described in Chapter 1. Set up for testing as follows:
1. Turn the 3310/30/31/35 power switch to OFF.
2. Make sure that all discrete signal wiring is disconnected from the field wiring terminals.
3. Remove the board to be tested from its slot.
4. Determine the type of board to be tested by referring to the part number that appears on a label on the board.
#392000-XX-X DI Board, 5/12/24 V ac/dc (8 DIs)
#392006-XX-X D0 Board, Open Collector or Relay (4/8 DOs)
#392010-XX-X DI Board, 120 V ac/dc (4 DIs)
#392030-XX-X DI Board, 5/12/24 V ac/dc (8 DIs), 120 V ac/dc (4 DIs)
#392076-XX-X D0 Board, Open Collector or Relay (4/8 DOs)
#392087-XX-X DI Board, 5/12/24 V ac/dc (8 DIs)
#392502-XX-X DI Board, 120 V ac/dc (4 DIs)
#392557-XX-X DI Board, 12/24 V ac/dc (8/16 DIs)
#392567-XX-X Solid State DC Relay DO Board, 3A @ 38 Vdc Max. (8 DOs)
#392586-XX-X DO Board, Open Drain (8/16 DOs)
Information is provided within this chapter for configuring jumper settings for various tests. If necessary, refer to the appropriate section of the controller hardware manual for information on specific DI/DO Boards (see Tables 10-1 & 10-2 for part numbers, controller hardware manual and applicable chapters). This information will be needed in order to select the appropriate diagnostic tests. Verify that the board is correctly configured.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-1
NOTE:
There are no address switches or jumpers for a DPC 3330, RIO 3331, DPC 3335 or RTU
3310 Process I/O Board.
5. Plug the board into any I/O slot in the 33XX unit.
6. Reapply power. If the controller was executing the DIAG load when you powered down, there is no need to reset and reload it; simply continue with proper menu selection at the PC. If you have not previously downloaded the DIAG file, refer to
Chapter 1 for the recommended procedures.
7. You are now ready to begin testing. If you are testing a Discrete Output Board, the procedures start with Section 10.2. For Discrete Input Board testing, procedures are contained in Section 10.3.
10.1.2 Menu Access
The test procedures in this chapter begin with the Diagnostic Test Category Menu (Figure
1-7). From that display, you will be asked to choose the "Discrete I/O" Test. (If you need help with this menu, see Sections 1.7.4 through 1.8).
10.1.3 Entry/Display Fields
The menus used in this chapter contain the following entry and display fields listed below:
Number of Passes
Enter the number of test cycles you want to execute, or enter one of the Continuous Modes
(see Section 1.9.2 of Chapter 1).
Board Number to Test
Enter the slot position of the Discrete Output or Discrete Input Board you are testing. A valid entry for a 6-slot DPC 3330, is a number from 1 to 6. For a 12-slot DPC 3330, enter a number from 1 to 12. For a 9- or 10-slot DPC 3335, enter a number from 1 to 9 or 10. For an RTU 3310, enter a number from 1 to 4. For the RIO 3331, enter a number from 1 through 10.
Board Type Returned
This field displays the type of the board being tested based on information returned from the controller. It provides verification that the correct board is being tested. This field should indicate "DO" or "DI", based on the board being tested, after you have initiated testing.
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays ‘Working’ or ‘Idle’ to indicate if a test is in process or not.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-2
Number of Valid DO Values
This display field only appears on the Discrete Output Display menu (see Figure 10-3). It indicates the maximum number of DOs that the board supports. For an ‘open collector’ or
‘solid state relay’ DO Boards this number will be 8; for a ‘relay contact’ DO Board it will be
4 and for an ‘open drain’ DO Board it will be 8 or 16.
Number of Valid DI Values
This display field only appears on the Discrete Input Display menu. It indicates the maximum number of DIs that the board supports. For a 12/24 V DI Board, this number will be 8; for a 120 V DI Board, it will be 4 and for a 24 V, 16 DI Board, it will be 16.
D4041A
Figure 10-1 - 3310/30/31/35 Discrete Input/Output Diagnostic Menu
33XX Discrete Output/Discrete Input Modules / 10-3
10.2 DISCRETE OUTPUT (DO) TESTS
These tests check the discrete output circuitry of a 3310/30/31/35 DO Board, including the output registers and the output paths to the terminal block.
For the tests in this chapter, you will need the DMM, dc Voltage Source (variable to 31 V dc), and 2.2K ohm resistor described in Chapter 1.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Discrete I/O" selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu shown in Figure 10-1. Enter the Board Number to Test and set the Number of Passes field to "CR" for continuous mode.
Table 10-1 - Discrete Output Modules
Output
Type
Open Collector
Relay Contact
Relay Contact
Open Collector
Open Collector
Relay Contact
SSDC Relay Contact
SSDC Relay Contact
Open Drain
Open Drain
Open Drain
Open Drain
No.
D0s
8
4
8
8
8
4
4
8
8
8
16
16
Part
Number
392006-02-2
392006-04-9
392006-05-7
392076-12-8*
392076-02-0 1
392076-04-7 1
392567-01-6
392567-02-4 1
392586-03-7
392586-04-5*
392586-01-0
392586-02-9*
33XX
Use
10/30
10/30
10/30
30/31/35
31/35
31/35
10/30
31/35
10/30/31/35
30/31/35
10/30/31/35
30/31/35
Manual
Chapter
CI-3310/30 (Chapter 3G)
CI-3310/30 (Chapter 3G)
CI-3310/30 (Chapter 3G)
CI-3330/35 (Chapter 3G)
CI-3335 (Chapter 3G)
CI-3310/30 (Chapter 3GA)
CI-3310/30 (Chapter 3GA)
CI-3335 (Chapter 3GA)
CI-3310/30/35 (Chapter 3GB)
CI-3330/35 (Chapter 3GB)
CI-3310/30/35 (Chapter 3GB)
CI-3330/35 (Chapter 3GB)
* = Remote, Mass Termination, Non-Isolated, Without Termination Module
1 = Right Angle Term. Block
10.2.1 Automatic Discrete Output Test
This test applies to all types of DO Boards. All of the DOs will be automatically sequenced for this test. Each DO will be enabled in turn for approximately 0.2 seconds. Be sure to set the Number of Passes to "CR" to provide a continuous test cycle.
1. On the DO Board, verify that jumper W1 (W9 for HDDO or SSDCRDO) is installed.
This enables the status LEDs.
2.
On the Discrete Input/Output Diagnostic Menu (see Figure 10-1), click on the "RUN
Discrete Output Sequence" Test button. NOTE: No test information will be displayed on the menu.
3. The status LEDs should sequence in a rotating pattern. Each DO should turn on for approximately 200 msec. Go to Section 10.2.2 for the Manual Discrete Output Test.
10.2.2 Manual Discrete Output Test
This procedure applies to all DO Board types and uses the same test setup shown in Figure
10-2. Be sure to install jumper W1 (W9 for HDDO or SSDCRDO Boards) to enable the status LEDs. Construct the test jig shown in Figure 10-2. This provides a supply source and load for the DOs.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-4
Figure 10-2 - Test Setup - DO Test
Figure 10-3 - 3310/30/31/35 Discrete Output Display Menu
From the Discrete Input/Output Diagnostic Menu (Figure 10-1), click on the "Discrete
Output Display" button. The Discrete Output Display (Figure 10-3) will appear.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-5
This screen shows the number of DOs being tested (8 for open collector and Solid State
Relay DOs and 4 for relay contact DOs). For each DO position an ON/OFF status is indicated. A zero means OFF and one means the DO is ON.
Note:
No information will be displayed until a DO number is entered in the "Drive DO:" field and you press [ENTER].
1.
On the Discrete Output Display (Figure 10-3), set the cursor at the "Drive DO:" input field, type the number "1" (for DO1), and press [Start Test].
2. With the test setup (see Figure 10-2) connected to DO1, verify that the DMM reads
+24 V (nominal), that the status LED (DS1) is ON and that the DO1 display is a "1".
NOTE: For relay option DOs (W4, W7, W10, W13 in the "B" position), when the status LED is ON and the display is a "1", the DMM measures 0 V.
3. On the PC, change the "Drive DO:" input field to the next DO and press [Start Test].
4. Verify that the DMM reads 0.0 V, that the status LED is OFF and that the DO1 display is a "0". NOTE: For relay option DOs (W4, W7, W10, W13 in the "B" position), when the status LED is OFF and the display is a "0", the DMM measures 24 V
(nominal).
5. Connect the test setup to each DO in turn, and repeat Steps 2-4. Note that as each
DO is turned on, all other DOs will be off. The status of the DO that was on will return from "1" to "0" and the associated LED will go off.
6.
At the PC, press [End Test] to return to the Discrete Input/Output Diagnostic Menu
(Figure 10-1).
7. Turn off and remove all test equipment. If the status LEDs aren’t normally enabled, remove the appropriate jumper, i.e., W1 or W9.
10.3 DISCRETE INPUT (DI) TESTS
These tests check the DI Board including the interrupt circuitry and the input paths from the termination block.
For this test, you will need the Variable 120 V dc Power Supply described in Chapter 1.
At the PC, highlight the "Discrete I/O" Test selection from the Diagnostic Test Category
Menu (Figure 1-7) and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu shown in Figure 10-1. Enter the Board Number to Test.
10.3.1 DI Circuitry Test
This test applies to all DI Board types. It verifies that all discrete inputs can be turned on and that all can be turned off. An internal DI Pattern Register (DIPR) is connected to the
DIs using special hardware test circuitry. A sequence of test values is written to the DIPR and the values read from the DIs are compared with the known values written. A polling failure is reported when the values do not match.
If the above test is successful, the diagnostic program then verifies that all of the DI
Interrupt Mask Register bits can be turned on and off and that each DI generates an inter-
D4041A 33XX Discrete Output/Discrete Input Modules / 10-6
rupt when it changes state if the corresponding mask register bit is on. An interrupt failure is reported when an expected interrupt does not occur or when an unexpected interrupt does occur.
D4041A
Figure 10-4 - Series 392006-XX-X & 392076-XX-X - 4/8 DO Boards
33XX Discrete Output/Discrete Input Modules / 10-7
Figure 10-5 - Series 392567-XX-X Solid State DC Relay - 8 SSDCRDO Boards
D4041A 33XX Discrete Output/Discrete Input Modules / 10-8
* *
Older Unit
* *
16-DO HDDO
392586-01-0
(Local Term.)
*
#
1
#
3
*
#
5
#
7
*
#
9
#
11
*
#
13
#
15
DO01 through DO08 are applicable for 8-DO HDDOs
1 3 5 7
2 4 6 8
*
#
2
#
4
*
#
6
#
8
*
8-DO HDDO
392586-03-7
(Local Term.)
DO01+ = Pin 30
DO02+ = Pin 29
DO03+ = Pin 27
DO04+ = Pin 25
DO05+ = Pin 23
DO06+ = Pin 21
DO07+ = Pin 19
DO08+ = Pin 17
DO09+ = Pin 15
DO10+ = Pin 13
DO11+ = Pin 11
DO12+ = Pin 09
DO13+ = Pin 07
DO14+ = Pin 05
DO15+ = Pin 03
DO16+ = Pin 01
J1
PCOM (DO-)
Pin #s =
02
04
06
08
10
12
14
16
18
20
22
24
26
28
LEDs
DS#
8-DO HDDO
392586-04-5
(Remote Term.)
16-DO HDDO
392586-02-9
(Remote Term.)
*
#
1
#
3
*
#
5
#
7
*
To Disable LEDs
Unplug Jumper W9
1 3 5 7 9 11 13 15
2 4 6 8
*
#
2
#
4
*
#
6
#
8
10 12 14 16
*
#
10
#
12
*
#
14
#
16
DO#s
(* = PCOM)
*
#
1
#
3
*
#
5
#
7
*
#
9
#
11
*
#
13
#
15
Figure 10-6 - Series 392586-XX-X - High Density - 8/16 HDDO Boards
At the Discrete Input/Output Diagnostic Menu (Figure 10-1), set the desired Number of
Passes, click on the "RUN Discrete Input Circuitry" Test button. The test will automatically progress through all the DI circuitry and display one of the following messages:
Success
Fail - Polling
Fail - Interrupt
Interrupt
Failure
Fail - Unexpected
10.3.2 DI Termination Tests
Before starting, you must know the voltage input range of the board being tested and the operation mode of each DI. The voltage range of the board can be determined from its part number. Refer to Table 10-2 for details.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-9
Table 10-2 - Discrete Input Modules
Input
Range
5 V ac/dc
12 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
120 V ac/dc
5 V ac/dc
12 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
120 V ac/dc
5 V ac/dc
12 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
No.
DIs
8
8
8
8
8
8
8
8
4
8
4
8
8
8
8
8
8
Part
Number
392000-07-5
392000-08-3
392000-01-6
392000-02-4
392000-03-2
392010-02-0
392087-07-3
392087-08-1
392087-01-4
392087-02-2
392087-03-0
392502-01-1
392087-17-0*
392087-18-9*
392087-11-1*
392087-12-0*
392087-13-8*
33XX
Use
10/30
10/30
10/30
10/30
10/30
10/30
31/35
31/35
31/35
31/35
31/35
31/35
30/31/35
30/31/35
30/31/35
30/31/35
30/31/35
Manual
Chapter
CI-3310/30 (Chapter 3F)
CI-3310/30 (Chapter 3F)
CI-3310/30 (Chapter 3F)
CI-3310/30 (Chapter 3F)
CI-3310/30 (Chapter 3F)
CI-3310/30 (Chapter 3F)
CI-3335 (Chapter 3F)
CI-3335 (Chapter 3F)
CI-3335 (Chapter 3F)
CI-3335 (Chapter 3F)
CI-3335 (Chapter 3F)
CI-3335 (Chapter 3F)
CI-3330/35 (Chapter 3F)
CI-3330/35 (Chapter 3F)
CI-3330/35 (Chapter 3F)
CI-3330/35 (Chapter 3F)
CI-3330/35 (Chapter 3F)
12 V ac/dc
24 V ac/dc
24 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
5 V ac/dc
5 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
5 V ac/dc
5 V ac/dc
120 V ac/dc
120 V ac/dc
120 V ac/dc
120 V ac/dc
8
8
8
8
8
8
8
8
4
4
4
4
8
8
8
8
8
8
8
8
392030-01-2
392030-02-0
392030-03-9
392030-04-7
392030-05-5
392030-06-3
392030-07-1
392030-08-0
392030-11-0*
392030-12-8*
392030-13-6*
392030-14-4*
392030-15-2*
392030-16-0*
392030-17-9*
392030-18-7*
392030-21-7
392030-22-5
392030-31-4*
392030-32-2*
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
31/35
CI-3335 (2/94) (Chapter 3F)
CI-3335 (2/94) (Chapter 3F)
CI-3335 (2/94) (Chapter 3F)
None
None
None
CI-3335 (2/94) (Chapter 3F)
None
CI-3335 (2/94) (Chapter 3F)
CI-3335 (2/94) (Chapter 3F)
CI-3335 (2/94) (Chapter 3F)
None
None
None
CI-3335 (2/94) (Chapter 3F)
None
None
CI-3335 (2/94) (Chapter 3F)
None
CI-3335 (2/94) (Chapter 3F)
24 V ac/dc
24 V ac/dc
24 V ac/dc
24 V ac/dc
24V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
24 V ac/dc
12 V ac/dc
16
16
16
16
16
16
8
8
8
8
392557-01-0
392557-02-9
392557-03-7*
392557-04-5*
392557-06-1*
392557-11-8
392557-22-3
392557-23-1
392557-24-0*
392557-25-8
10/30/31/35
10/30/ 31/35
30
30
30
30
10/30/31/35
10/30/ 31/35
30
30
CI-3310/30/35 (Chapter 3FA)
CI-3310/30/35 (Chapter 3FA)
CI-3330 (Chapter 3FA)
CI-3330 (Chapter 3FA)
CI-3330 (Chapter 3FA)
CI-3330 (Chapter 3FA)
CI-3310/30/35 (Chapter 3FA)
CI-3310/30/35 (Chapter 3FA)
CI-3330 (Chapter 3FA)
CI-3330 (Chapter 3FA)
* = Remote, Mass Termination, Non-Isolated, Without Termination Module.
Note: HDDI Modules with 16 inputs must not be located in slot 10 of a DPC 3335.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-10
D4041A
Figure 10-7 - 4 & 8 Discrete Input - DI Modules
33XX Discrete Output/Discrete Input Modules / 10-11
Figure 10-8 - 16 Discrete Input - HDDI Modules (see Fifures 10-9A and 10-9B)
If the board is a 120 V DI Board, all 4 DIs are factory configured for isolated 120 V inputs.
For the 12/24 V DI Boards, each input can be independently configured via jumpers W1-8
(W1-16 on the 16 DI board) for either external isolated input or internally powered input for dry contact actuation. Select the "Isolated Inputs" or "Internally Powered Dry Contact
Input" tests as required from the paragraphs that follow.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-12
WARNING
High voltage levels may be present for some tests. Mishandling these voltages can result in shock or injury, and damage to equipment. Please exercise caution.
For Externally Powered (Isolated) & 120V Discrete Inputs
1. Be sure you know the correct voltage range for the board being tested. Install resistor pack R4 (for DI boards) or install jumper W17 for HDDI boards) to enable the status LEDs.
2. From the Discrete Input/Output Diagnostic Menu (Figure 10-1), click on the
"Discrete Input Display" button. The Discrete Input Display Menu (Figure 10-10) will appear.
3. Connect the Variable 120 V dc Power Supply (+) to DI1-A and the power supply (-) to
DI1-B at TB1 (or (+) to TB2-2 and (-) to TB2-1 for HDDI) (see Figures 10-7, 10-8 10-
9A & 10-9B). Set the power supply voltage for the DI application voltage (12, 24 or
120 V dc).
Figure 10-9A - 16-DI HDDI Terminal Block Labels
D4041A
Figure 10-9B - 8-DI HDDI Terminal Block Labels
33XX Discrete Output/Discrete Input Modules / 10-13
4. Check that the STATUS value of DI1 on the Discrete Input Display Menu (Figure
10-10) changes from "0" to "1" and that the associated status LED (DS1) is ON.
Figure 10-10 - 3330/3335/3310 - Discrete Input Display Menu
5. Move the power supply output connections to the (+) and (-) terminals of each successive DI and verify that the STATUS of each selected DI changes from "0" to
"1" and its status LED turns ON. Verify that each DI STATUS returns to "0" and the status LED turns OFF following removal of the input voltage.
6. Drive multiple DIs using test patterns with alternate DIs in the ON and OFF state, e.g. DI1,3,5,7 etc. ON and DI2,4,6,8 etc. OFF. Verify that the correct status of each is displayed in the status LEDs and on the Discrete Input Display Menu (Figure 10-
10). This verifies that individual DIs are not affected by the state of other positions.
7. At the completion of the test, turn the power supply off and disconnect it from the DI
Board.
8. At the PC, press [End Test] to return to the Discrete Input/Output Diagnostic Menu
(Figure 10-1).
For Internally Powered Discrete Inputs
1. On the DI Board, install resistor pack R4 (for DI boards) or install W17 (for HDDI boards) to enable the status LEDs.
2. On the Diagnostic Input/Output Diagnostic Display (Figure 10-1), click on the "Discrete Input Display" button. The Discrete Input Display Menu (Figure 10-10) will appear.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-14
3. Connect a jumper wire across the DI1 terminals at TB1 (DI1-A and DI1-B) (or (+) to
TB2-2 and (-) to TB2-1 for HDDI) (see Figures 10-7, 10-8, 10-9A & 10-9B).
4. Check that the STATUS value of DI1 on the Discrete Input Display Menu changes from "0" to "1" and that the associated status LED (DS1) turns ON.
5. Move the jumper wire to the (+) and (-) terminals of each successive DI and verify that the STATUS of each selected DI changes from "0" to "1" and that its status LED turns ON. Verify that each DI "ON/OFF" status returns to "0" and the status LED turns OFF following removal of the jumper.
6. Drive multiple DIs using test patterns with alternate DIs in the ON and OFF state, e.g. DI1,3,5,7 etc. ON and DI2,4,6, etc. OFF. Verify that the correct status of each is displayed in the status LEDs and on the Discrete Input Display. This verifies that individual DIs are not affected by the state of other positions.
7. At the completion of the test remove all input jumper wires from the DI Board.
8. At the PC, press [End Test] to return to the Discrete Input/Output Diagnostic Menu
(Figure 10-1).
10.4 COMPLETING TESTING
At the conclusion of the DO and/or DI tests, turn the 33XX power switch to OFF. Turn all test equipment off and remove it from the I/O board terminals. Return all jumper positions to their original positions. If necessary, repeat the tests of this chapter for any other DO or
DI Boards included in the 33XX controller. When all boards have been tested, reconnect field wiring and restore operation as required.
D4041A 33XX Discrete Output/Discrete Input Modules / 10-15
BLANK PAGE
Chapter 11
33XX High Speed Counter Module
11.1 HIGH SPEED COUNTER (HSC) SETUP
The DPC 3330, RIO 3331, DPC 3335 and RTU 3310 controllers may contain one or more
High Speed Counter (HSC) Boards. These boards handle High Speed Counter devices exclusively. Depending on the DPC model, you can have up to six or twelve I/O boards.
The tests in this chapter are intended only for 3310/30/31/35 controllers that contain HSC
Modules. If your unit is not a DPC 3330, RIO 3331, DPC 3335 or RTU 3310, or if it is not equipped with a High Speed Counter Module, you can skip this chapter.
11.1.1 Hardware Configuration
For the tests in this chapter, you will need the Square Wave Generator, Frequency
Counter, Form C Relay (12/24V), Variable Power Supply, and the Dual Channel Oscilloscope described in Chapter 1. Set up for testing as follows:
1. Turn the 3310/30/31/35 power switch to OFF.
2. Make sure that all field wiring is disconnected from the HSC Board.
3. Remove the module to be tested from its slot.
4. Determine the type of module to be tested by referring to the part number that appears on a label on the non-component side of the module (see Table 11-1).
Table 11-1 - HSC MODULE TYPES
Input
Range
24 Vdc
24 Vdc
12 Vdc
12 Vdc
5 Vdc
5 Vdc
#
HSCs
4
4
4
4
4
4
Surge
Suppression
30 V rms
30 V rms
10 V rms
10 V rms
5 V rms
5 V rms
Part Number
(Local Term.)
392008-04-1
392028-04-2
392008-02-5
392028-02-6
392008-05-0
392028-05-0
33XX
Use
10/30
31/35
10/30
31/35
10/30
31/35
Part Number*
(Remote Term.)
392028-14-0
392028-14-0
392028-12-3
392028-12-3
392028-15-8
392028-15-8
24 Vdc
12 Vdc
5 Vdc
24 Vdc
12 Vdc
5 Vdc
8
4
8
8
4
4
30 V rms
10 V rms
5 V rms
30 V rms
10 V rms
5 V rms
400018-01-2
400018-03-9
400018-05-5
400018-02-0
400018-04-7
400018-06-3
10/30/31/35
10/30/31/35
10/30/31/35
10/30/31/35
10/30/31/35
10/30/31/35
N/A
N/A
N/A
400018-12-8
400018-13-6
400018-14-4
* = Remote, Mass Termination, Non-Isolated, Without Termination Module
N/A
N/A
N/A
30/31
30/31
30/31
33XX
Use
30
31/35
30
31/35
30
31/35
D4041A 33XX High Speed Counter Module / 11-1
NOTE
There are no address switches or jumpers for DPC 3330, RIO 3331, DPC 3335 or RTU 3310 Process I/O Modules.
5.
Plug the module into any I/O slot in the 33XX unit.
Figure 11-1A - High Speed Counter Module (Series 392008-XX-X & 392028-XX-X)
D4041A 33XX High Speed Counter Module / 11-2
Series 400018-XX-X
Older Unit
P1
1 1
1 1
W1
1
1
W18
W2
1
W4
W3
1
1
1 1
1 1 1
W17
W5
W6
1
1
W7
W8
1
1
A B C D A B C D
LED Disable
Jumper
W17
Pin 29 = HSCRESET1
Pin 27 = GROUND
Pin 25 = HSCSET1
Pin 23 = GROUND
Pin 21 = HSCRESET2
Pin 19 = +24V
Pin 17 = HSCSET2
Pin 15 = +24V
Pin 13 = HSCRESET3
Pin 11 = N/A
Pin 09 = HSCSET3
Pin 07 = N/A
Pin 05 = HSCRESET4
Pin 03 = N/A
Pin 01 = HSCSET4
Pin 30 = COMMON1
Pin 28 = GROUND
Pin 26 = SHIELD
Pin 24 = GROUND
Pin 22 = COMMON2
Pin 20 = +24V
Pin 18 = SHIELD
Pin 16 = +24V
Pin 14 = COMMON3
Pin 12 = N/A
Pin 10 = SHIELD
Pin 08 = N/A
Pin 06 = COMMON4
Pin 04 = N/A
Pin 02 = SHIELD
Mode Jumper - W1 W2 W3 W4 W5 W6 W7 W8
HSC # - 1 2 3 4 5 6 7 8
Debounce Jumper - W9 W10 W11 W12 W14 W13 W16 W15
Shield
Jumper
W18
TB1
TB2
Figure 11-1B - High Speed Counter Module (Series 400018-XX-X)
6. Reapply power. If the DPC/RTU was executing the IAG load when you powered down, there is no need to reset and reload it; simply continue with proper menu
D4041A 33XX High Speed Counter Module / 11-3
selection at the PC. If you have not previously downloaded the DIAG file, refer to
Chapter 1 for the recommended procedures.
7. You are now ready to begin diagnostic testing.
11.1.2 Menu Access
The test procedures in this chapter begin with the Diagnostic Test Category Menu (Figure
1-7). From that display, you will be asked to choose the "High Speed Counter" Test selection. (If you need help with this menu, see Sections 1.7.4 through 1.8.)
11.1.3 Entry/Display Fields
The menus used in this chapter contain the following entry and display fields listed below:
Number of Passes
Enter the number of test cycles you want to execute, or enter one of the Continuous Modes
(see Section 1.9.2 of Chapter 1).
Board Number to Test
Enter the slot position of the High-Speed Counter Module you are testing. A valid entry for a 6-slot DPC 3330 is a number from 1 through 6. For a 12-slot DPC 3330, enter a number from 1 through 12. For a DPC 3335, enter a number from 1 through 9 or 10. For a RTU
3310, enter a number from 1 through 4. For the RIO 3331, enter a number from 1 to 10.
Board Type Returned
This field displays the type of the board being tested based on information returned from the DPC/RIO/RTU. It provides verification that the correct board is being accessed. This field should indicate "HSC" after you have initiated testing.
Number of Failures
This field displays the number of test failures that occurred for the number of specified passes. (See Chapter 1 for details.)
Status
This field displays "Working" or "Idle" to indicate if a test is in process or not.
11.2 HIGH SPEED COUNTER (HSC) TESTS
These tests check the circuitry of a DPC 3330/3335, RIO 3331 or RTU 3310 HSC Module, including the diagnostic loopback circuitry, the one-shot pulse width, the individual counters, the isolated and internally powered input circuitry, and the debouncing circuitry.
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "High Speed Counter"
Test selection and then click on the "Run" button at the bottom of the screen. The PC will proceed to the menu shown in Figure 11-2. Enter the Board Number to Test.
D4041A 33XX High Speed Counter Module / 11-4
11.2.1 Counter Test
This test automatically checks the following circuitry on the HSC Board. First, the diagnostic test counter is checked to verify that it counts properly and that it activates the proper output signal when the counter expires. If this test is successful, the diagnostic then checks that the diagnostic one-shot timer is operating correctly and that the width of the output of the one-shot logic for each pair of high-speed counters is within specification. If successful, each of the four high-speed counters is checked for proper operation, using the test counter to drive the inputs via diagnostic loopback hardware. Whenever a failure is detected, the test is exited and an error is reported.
Figure 11-2 - DPC 3330/3335 & RTU 3310 High Speed Counter Diagnostic Menu
(for Unit with 4 High Speed Counters)
1. At the High Speed Counter Diagnostic Menu (Figure 11-2), enter the desired
Number of Passes. Each pass of this test takes approximately 10 seconds.
D4041A 33XX High Speed Counter Module / 11-5
2. Click on the "RUN Counter Test" Test button.
3. One of the following messages will be displayed in the STATUS column:
Success
Fail Test Counter
Fail One-Shot Timer
Fail One-Shot Pulse Width HSC 1/2
Fail One-Shot Pulse Width HSC 3/4
Fail One-Shot Pulse Width HSC 5/6 - ( Series 400018-XX-X only )
Fail One-Shot Pulse Width HSC 7/8 - ( Series 400018-XX-X only )
Fail HSC 1/2
Fail HSC 3/4
Fail HSC 5/6 - ( Series 400018-XX-X only )
Fail HSC 7/8 - ( Series 400018-XX-X only )
The designation "1/2", "3/4", "5/6" or "7/8" indicates that the failure is associated with the logic for High-Speed Counters 1 and 2 or with the logic for the appropriate set of counters, i.e., High-Speed Counters 3 and 4, 5 and 6 or 7 and 8.
Any of the above failures indicate component failure on the HSC Board. The board must be repaired or replaced.
11.2.2 Input Circuitry Test
This test applies to both +12V and +24V HSC Board types and is done with the module configured for isolated inputs with debouncing circuitry disabled. If any of the inputs on the module to be tested are configured differently, it will be necessary to temporarily change the jumper settings. Be sure to record the original jumper positions so that they can be restored after testing is complete.
1.
On the Series 392008 or 392028 HSC Module verify that Mode Jumpers W2 (HSC1),
W4 (HSC2), W6 (HSC3) and W8 (HSC4) are in the position shown below and that
Debounce Jumpers W1, W3, W5 and W7 are removed.
D4041A
Figure 11-3 - HSC Jumpers Set for Isolated Input and Debounce Disabled
33XX High Speed Counter Module / 11-6
On the Series 400018 HSC Module verify that Mode Jumpers W1 (HSC1), W2
(HSC2), W3 (HSC3), W4 (HSC4), W5 (HSC5), W6 (HSC6), W7 (HSC7) and W8
(HSC8) are installed in position 2 to 3 shown below and that Debounce Jumpers W9 through W16 are installed in position 2 to 3 or removed.
2. For Series 392008 or 392028 HSC Modules, verify that jumper W9 is installed to enable the status LEDs. For Series 400018 HSC Modules, verify that jumper W17 is installed in position 1 to 2 to enable the Status LEDs.
3. Set the output of the square wave generator to the input voltage for the module type you are testing (+12 V or +24 V), at 10 kHz, 50% duty cycle.
WARNING
Connecting 24 volts to a module designed for 12 volts may cause equipment damage. Be sure you have correctly identified the module type.
4. Connect the channel 1 probe of the oscilloscope to the output of the square wave generator and offset the output wave as shown below. Remove the connection when calibration is complete.
Figure 11-4 - Square Wave (50% Duty Cycle)
5. Connect the frequency counter across the square wave generator output. Set it to totalizer mode.
6. Turn the square wave generator OFF and connect its (+) output to HSC1-A2 (Set) and its (-) output to HSC1-B1 (Com) at TB1 on the HSC Module (see Figure 11-5).
Figure 11-5 - HSC Test Circuit - Debounce Disabled
7.
On the High Speed Counter Diagnostic Menu (Figure 11-2), click on the "RUN High
Speed Counters Display" button.
D4041A 33XX High Speed Counter Module / 11-7
8.
Turn the square wave generator output ON. Verify that status LED DS1 on the HSC module is "ON" when the generator is enabled. The High-Speed Counter Diagnostic
Menu will display the accumulated counts for the input selected (in this case
Counter - 1).
9. Turn the generator OFF. At the PC, verify that the count displayed for Counter - 1 matches the total count displayed on the frequency counter. Verify that status LED
DS1 is "OFF".
10. At the PC, click on the "ABORT High Speed Counters Display" button.
11. Check channels HSC2 through HSC4/8 by connecting the square wave generator to each successive HSC position. Repeat steps 6 through 10, verifying that the associated display and status LED are correct for each channel.
12. Turn all equipment off and disconnect all test equipment. Return the HSC Module jumpers to their original positions. If the normal use of any of the HSC inputs has the debouncing circuitry enabled, proceed to section 11.2.3 to check the debouncing circuitry.
11.2.3 Debouncing Circuitry Test
The following procedures are based on configuration for isolated inputs or for internally powered inputs. Note that in order to use internally powered mode, the voltage range of the
HSC Module (+12 V or +24 V) must be matched with the voltage of the DPC/RIO/RTU, otherwise equipment malfunction or damage may occur. It is important that you return the mode jumpers to their original positions and then choose the correct procedure from the subtopics that follow based on that configuration. Note that the procedures are written assuming all four counters have the same configuration. You may choose to execute the appropriate procedure on individual inputs if they vary.
Isolated Inputs Debouncing Circuitry Test
1. On the HSC Module, verify that jumpers W1 through W8/W16 are set as follows and that W9/W17 is installed to enable the status LEDs.
Figure 11-6 HSC Mode Jumpers Set for Isolated Inputs with Debounce Enabled
D4041A 33XX High Speed Counter Module / 11-8
Figure 11-7 - HSC Test Circuit - Isolated Inputs - Debounce Enabled
2. Connect the coil of a Form C relay to the square wave generator output and connect the relay contacts at the HSC Module TB1 terminal and external power supply as illustrated in Figure 11-7.
3. Set the output of the square wave generator to the required coil voltage. Set the frequency of the generator equal to the maximum frequency of the relay.
4. Connect the frequency counter across the square wave generator output and set it for totalizer mode.
5.
At the High Speed Counter Diagnostic Menu (Figure 11-2), click on the "RUN High
Speed Counters Display" button.
6. Set the external power supply to the application voltage (+12 V or +24 V). Turn the power supply on and enable the generator output. Verify that status LED DS1 on the HSC Module blinks when the generator is enabled.
WARNING
Connecting 24 volts to a board designed for 12 volts may cause equipment damage. Be sure you have correctly identified the module type.
7. Turn the square wave generator off. The count displayed for COUNTER-1 at the PC should match the total displayed at the frequency counter. Also, verify that status
LED DS1 is "OFF" when the generator is off.
8. At the PC, click on the "ABORT High Speed Counters Display" button.
D4041A 33XX High Speed Counter Module / 11-9
9. Check channels HSC2, HSC3, etc. by turning off the power supply and connecting the test setup to each successive HSC. Repeat steps 5 through 8, verifying that the count displayed at the PC and the associated status LED are correct for each channel.
10. Turn off all equipment and disconnect all test equipment.
Internally Powered Inputs Debouncing Circuitry Test
1. On the HSC Module, verify that jumpers W1 through W8/W16 are set as follows and that W9/W17 is installed to enable the status LEDs.
Figure 11-8
HSC Mode Jumpers Set for Internally Powered Inputs with Debounce Enabled
WARNING
The input voltage rating of the HSC Module must match the voltage rating of the DPC/RIO/RTU. Failure to observe this requirement may result in equipment malfunction or damage. Be sure you have correctly identified the module and system types.
2. Connect the coil of a Form C relay to the square wave generator output and connect the relay contacts at the HSC Module TB1 terminal as illustrated in Figure 11-9.
3. Set the output of the square wave generator to the required coil voltage. Set the frequency of the generator equal to the maximum frequency of the relay.
4. Connect the frequency counter across the square wave generator output and set it for totalizer mode.
5. At the High Speed Counter Diagnostic Menu (Figure 11-2), click on the "RUN High
Speed Counters Display" button.
6. Turn the square wave generator on. Verify that status LED DS1 blinks when the generator is enabled.
D4041A 33XX High Speed Counter Module / 11-10
Figure 11-9 - HSC Test Circuit - Internally Powered Inputs - Debounce Enabled
7. Turn the square wave generator off. Verify that the count displayed for COUNTER-1 at the PC matches the totalizer count. Also, verify that the status LED DS1 is "OFF" when the generator is off
8. At the PC, click on the "ABORT High Speed Counters Display" button.
9. Check channels HSC2, HSC3, etc. by connecting the test setup to each successive
HSC. Repeat steps 5 through 8, verifying that the count displayed at the PC and the associated status LED are correct for each channel.
10.
Turn off all equipment and disconnect all test equipment.
11.3 COMPLETING TESTING
At the conclusion of the HSC tests, turn the DPC/RIO/RTU power switch to OFF. Turn all test equipment off and remove it from the HSC Module terminals. Return all jumper positions to their original positions. If necessary, repeat the tests in this chapter for any other HSC Modules included in the DPC/RIO/RTU controller. When all modules have been tested, reconnect field wiring and restore operation as required.
D4041A 33XX High Speed Counter Module / 11-11
BLANK PAGE
Chapter 12
33XX High Speed Analog Input Modules
12.1 HIGH SPEED ANALOG INPUT SETUP
DPC 3330, RIO 3331, DPC 3335 and RTU 3310 controllers may contain one or more High
Speed Analog Input Module Assemblies (HSAI Modules). These modules handle analog signals exclusively. Depending on the DPC model, you can have up to four, six, ten or twelve I/O HSAI Modules, i.e., 4 for a 3310, 6 or 12 for a 3330 and 10 for a DPC 3335.
The tests in this chapter are intended only for 3310/30/31/35 controllers furnished with
High Speed Analog Input Modules. If your unit is not a DPC 3330, RIO 3331, DPC 3335 or
RTU 3310, or if it is not equipped with HSAI Module, you can skip this chapter.
12.1.1 Hardware Configuration
For the tests in this chapter, you will need the Digital Multimeter (DMM), the dc Voltage
Source (Variable to 31 V dc), the Precision Current Source and the Square Wave Generator described in Chapter 1. Set up for testing as follows:
1. Turn the controller power switch to OFF.
2. Make sure that all analog signal wiring is disconnected from the field wiring terminals.
3. Remove the module to be tested from its slot.
4. You can determine the type of HSAI Module that you have by referring to the part number that appears on a label on the non-component side of the module’s Acquisition Board.
#390827-01-0 (3310/3330) HSAI Module 1-5V/4-20mA
#390827-02-9 (3335) HSAI Module 1-5V/4-20mA
Each test procedure in this chapter identifies the module type to which it applies.
Make sure you are using the correct procedure.
Verify that the HSAI Module is correctly configured by referring to Figure 12-2.
Additional information on jumper settings, etc. can be found in Chapter 3J of the
DPC/RTU user manual CI-3330, CI-3335 or CI-3310.
NOTE:
There are no address switches or jumpers for a DPC 3330, RIO 3331, DPC 3335 or RTU 3310 Process
I/O Module.
5. Plug the module into any I/O slot in the controller.
6.
Reapply power. If the controller was executing the DIAG load when you powered down, there is no need to reset and reload it; simply continue with proper menu
D4041A 33XX High Speed Analog Input Modules / 12-1
selection at the PC. If you have not previously downloaded the DIAG file, refer to
Chapter 1 for the recommended procedures.
7. You are now ready to begin testing.
12.1.2 Menu Access
The test procedures in this chapter begin with the Diagnostic Test Category Menu (Figure
1-7). From that display, you will select the following test category:
High Speed Analog Input Diagnostic
(If you need help with this menu, see Sections 1.7.4 through 1.8.)
12.1.3 Entry/Display Fields
Each of the menus used in this chapter contain the following entry and display fields listed below:
Number of Passes
Enter the number of test cycles you want to execute, or enter one of the Continuous Modes
(see Section 1.9.2 of Chapter 1).
Board Number to Test
Enter the slot position of the High Speed Analog Input Module you are testing. A valid entry for a 6-slot DPC 3330 is a number 1 through 6. For a 12-slot DPC 3330, enter a number from 1 through 12. For a DPC 3335, enter a number from 1 through 10. For a RTU
3310, enter a number from 1 through 4. For a RIO 3331, enter a number from 1 through 10.
Board Type Returned
This field displays the type of the module being tested based on information returned from the controller. It provides verification that the correct module is being tested. This field should indicate "HSAI", based on the module being tested, after you have initiated testing.
Status
This field displays "Working" or "Idle" to indicate if a test is in process or not.
12.2 HIGH SPEED ANALOG INPUT (HSAI) TESTS
The HSAI test are used to calibrate reference voltages, to calibrate and verify the instrumentation amplifier, to null the offset of the HSAI channels, verify correct operation of the four analog inputs and check the engine speed discrete input circuitry on a
3310/30/31/35 High Speed Analog Input Module.
For these tests, you will need the Digital Multimeter (DMM), dc Voltage Source (variable to
31 V dc) the Precision Current Source and the Square Wave Generator described in
Chapter 1.
D4041A 33XX High Speed Analog Input Modules / 12-2
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "High Speed Analog
Input" Test selection and click on the "Run" button at the bottom of the screen. The PC will proceed to the menu of Figure 12-1. Set the Number of Passes to Continuous (CR or CS) and enter the number of the board to be tested (slot position).
Figure 12-1 - High Speed Analog Input Diagnostic Menu
12.2.1 Reference Voltage Calibration
Adjustments and test points are identified in Figure 12-2.
Set the 5 V and 1 V reference voltages as follows:
1. Connect the DMM (+) to TP1-1 and DMM (-) to TP1-2. TP1 is a 3-pin header located below potentiometer R14 (see Figures 12-2 & 12-3).
2. Adjust R13 until the DMM displays +5.0 V ± 0.001 V (see Figures 12-2 & 12-3).
3.
Connect the DMM (+) to TP1-3 (see Figures 12-2 & 12-3).
4. Adjust R14 until the DMM displays +1.0 V ± 0.001 V (see Figures 12-2 & 12-3).
D4041A 33XX High Speed Analog Input Modules / 12-3
Figure 12-2 - High Speed Analog Input Module Configuration Diagram
12.2.2 Instrumentation Amplifier Calibration
This test channels the 0% reference voltage or the 100% reference voltage to the instrumentation amplifier. The resultant readings from the analog-to-digital converter are displayed at the PC.
D4041A 33XX High Speed Analog Input Modules / 12-4
1. Click on the "RUN 0 Percent of AI" Test button.
2. Verify that the hex value BA ± 1 count (B9 to BB) is displayed under the status column. Adjust R11 if necessary (see Figures 12-2 & 12-3).
3.
Click on the "RUN 100 Percent of AI" Test button.
4. Verify that the hex value F46 ± 1 count (F45 to F47) is displayed under the status column. Adjust R15 if necessary (see Figures 12-2 & 12-3).
5. Repeat steps 1 through 4 until further adjustments are not required.
12.2.3 Calibration Verification
The 0% and 100% reference voltages are processed and checked to be within ± 0.2% of the nominal value (± 8 counts).
1.
Click on the "RUN Verify Amplifier Calibration" Test button.
2. The results of the test are displayed under the STATUS column as follows:
Success
Fail 0 percent AI
Fail 100 percent AI
The total number of failed passes will be displayed under the "FAILURE" column.
12.2.4 Self Test
This test will force the HSAI board to test its digital and analog circuitry. The CPU, RAM and EPROM memory is tested as well as the calibration of the analog-to-digital converter.
1. Click on the "RUN Self-Test" Test button.
2. The results of the test are displayed under the STATUS column as follows:
Success
Fail
Fail
Fail
Fail
Fail
Fail
Fail
Fail
Fail
Timeout
Register Failure
Eprom Failure
Internal Ram Failure
External Ram Failure
Zero Reference Failure
Gain Reference Failure
DAC Failure
Calibration Failure
12.2.5 Analog Channel Offset Adjustment
This procedure is used to null the input offset of each AI channel.
D4041A 33XX High Speed Analog Input Modules / 12-5
1. Verify that HSAI channels 1-4 are configured for Isolated Inputs. See Figure 12-2
(Jumper W1 - W4 "B" Configuration) for the proper jumper configurations of W1-W4.
2.
Click on the "RUN HSAI Input Display" Test button.
Figure 12-3 - HSAI Assembly
Analog Isolation Board (Mounted on the Acquisition Board)
3. Connect the voltage source (+) to HSAI1-A and the Voltage Source (-) to HSAI1-B at
TB1 (see Figure 12-2).
4.
Set the dc Voltage Source to 1.0 V ± 0.001 V.
5. Adjust R17 until BA ± 1 count (B9 to BB) is displayed under AI-01.
6.
Move the dc Voltage Source to the next HSAI on TB1 and repeat step 5 adjusting
R18 for HSAI2, R19 for HSAI3 and R20 for HSAI4.
D4041A 33XX High Speed Analog Input Modules / 12-6
12.2.6 Analog Input Termination Test
These procedures check the analog input values at the High Speed Analog Input terminal block (TB1) for all modes supported by the board. On a High Speed Analog Input Module, each input can be individually configured. The procedures include all four AIs in each test, however you may select only those tests for specific input types based on your actual configuration.
1-5V Isolated Analog Inputs
1. Verify that HSAI channels 1-4 are configured for Isolated Inputs. See Figure 12-2
(Jumper W1 - W4 "B" Configuration) for the proper jumper configurations of W1-W4.
2. From the High Speed Analog Input Diagnostic Display (Figure 12-1), click on the
"RUN HSA Input Display" Test button.
3. Connect the dc Voltage Source (+) to HSAI1-A and the Voltage Source (-) to HSAI1-B at TB1.
4. For the input voltages shown below, the associated hex value should appear under the AI-01 heading on the display.
INPUT VOLTAGE HEX READING
+0.8V " 0.001V
+1.0V " 0.001V
+3.0V " 0.001V
+5.0V " 0.001V
+5.2V " 0.001V
000
0BA
800
F46
FFF
"
"
"
"
"
4 = (000 - 004)
4 = (0B6 - 0BE)
4 = (7FB - 804)
4 = (F42 - F4A)
4 = (FFB - FFF)
5. Move the dc Voltage Source to the next AI on TB1 and repeat Step 4 for each of the four analog inputs, checking the hex reading under the appropriate heading.
4-20mA Isolated Analog Inputs
1. Verify that HSAI channels 1-4 are configured for Isolated Inputs. See Figure 12-2
(Jumper W1 - W4 " C " Configuration) for the proper jumper configurations of W1-W4.
2. Click on the "RUN HSA Input Display" Test button.
3. Connect the Precision Current Source output to HSAI1-A and the return to HSAI1-B at TB1.
4. For the input currents shown below, the associated hex value should appear under the AI-01 heading on the display.
INPUT CURRENT HEX READINGS
4mA " 0.004mA
20mA " 0.004mA
0BA ±4 = (0B6 - 0BE)
F46 " 4 = (F42 - F4A)
D4041A 33XX High Speed Analog Input Modules / 12-7
5. Set the Precision Current Source output to zero and remove it from TB1.
Reconnect it to the next HSAI on TB1 and repeat Step 4 for each of the four analog inputs, checking the hex reading under the appropriate heading.
Be sure to set the Current Source to zero before removing it, after each input has been tested.
4-20mA Internally Sourced Analog Inputs
Note
This option is only applicable to DPC 3330/3335s & RTU 3310s which operate from +24V dc power sources.
1. Verify that HSAI channels 1-4 are configured for Isolated Inputs. See Figure 12-2
(Jumper W1 - W4 " A " Configuration) for the proper jumper configurations of W1-W4.
2. Using the DMM, measure between HSAI1-A and HSAI1-B at TB1. The DMM should read +24 volts.
3. Move the DMM to the next HSAI on TB1 and repeat Step 2 for each of the four analog inputs.
12.2.7 Engine Speed Input Test
1. Set the output of the Square Wave Generator to 5V, at 10 Hz, with a 1/360 duty cycle.
2. Connect the output of the square wave generator (+) to HSAIT-A and (-) to HSAIT-B.
3. On the High Speed Analog Input Diagnostic Menu (Figure 12-1), click on the "RUN
Engine Speed" Test button.
4. Verify under the RATE column that 600 ± 1 count (5FF - 601) is displayed.
12.3 COMPLETING TESTING
At the conclusion of the HSAI tests, turn the DPC/RIO/RTU power switch to OFF. Turn all test equipment off and remove it from the I/O module terminals. Return all switch and jumper settings to their original positions. If necessary, repeat the tests of this chapter for any other HSAI Modules included in the controller. When all modules have been tested, reconnect field wiring and restore operation as required.
D4041A 33XX High Speed Analog Input Modules / 12-8
Chapter 13
3330 Redundant System
13.1 3330 REDUNDANT SYSTEM INTRODUCTION
This chapter describes the procedures for checking out a 3330 redundant system using the
33XX Off-Line Diagnostics. These procedures directly exercise and test the hardware which enables redundant units to communicate and which provides for switching of control, including standard port communications, on a manual switchover or automatic fail-over to the back-up unit.
Prior to executing the tests of this chapter, it is recommended that each individual 3330 controller be tested as a stand-alone unit as described in Chapters 1 through 4. In this way, any individual unit problems can be isolated and corrected prior to verifying the redundancy system. To test a redundant unit as a stand-alone unit, simply have the second unit powered off. The standard diagnostic load file should be used (DIAGXRM for 386EX-
Real Mode units, DIAGXPM for 386EX-Protected Mode units or DIAG530 for 186-based units).
13.2 REDUNDANT SYSTEM SETUP
13.2.1 Hardware Configuration
A redundant DPC 3330 controller will be connected through a 3332 Redundancy Switch
Panel (RSP) which provides status indicators and manual control for selecting which unit will be On-line and which will be Back-up.
A redundant system can have up to five (5) serial communications ports through the RSP
(Ports A through D for the 186-based 3330 or any five selected from BIP1, BIP2 and A-D for the 386EX Real Mode units). For redundancy diagnostic testing, the PEI communicates with the redundant units on Port A, therefore Port A must be connected via the RSP and it must be configured for RS-423. In addition, for 386EX Real Mode units, or for 186-based units having AG.00 or later firmware, Switch 8 of Switch Block 1 (SW1) on the CPU engine must be set to the right or ON position for normal slave port operation on Port A. Please refer to Chapter 1 of this manual and to the CI-3330 hardware manual for details on jumper and switch settings and cable connections to meet the above requirements.
If meeting these requirements means that you must change your normal redundant system configuration in any way, be sure to record the original switch and/or jumper settings, and cable connections, so that they can be restored when testing is completed.
WARNING
BE SURE THAT THE 3330 IS POWERED OFF PRIOR TO REMOVING
OR INSERTING ANY PC BOARD.
In summary, the hardware setup for redundancy diagnostics should be as follows:
D4041A 3330 Redundant System / 13-1
1. Turn the power off at both 3330 units. The Fail indicator should be lit for both units on the RSP.
2. Select Unit A as the On-Line unit using the On-Line Selector switch and press the
Manual Reset switch on the RSP.
3. Verify Port A from each unit is connected at the RSP. A typical setup is provided as follows: Your configuration may differ, but must include Port A.
Port Unit A Unit B External
A
B
C
D
RSP Connector
From From To
J1A
J2A
J3A
J4A
J1B J1C
J2B J2C
J3B J3C
J4B J4C
4. Verify Port A, including connections through the RSP, is set for RS-423 operation, and that switch 8 of switch block 1 on the CPU engine is set to ON.
5. Connect the PC to Port A at the RSP (J1C).
13.2.2 Downloading and Preliminary Testing
The special redundancy diagnostic load file DIAGXRMR (386EX Real Mode), DIAGXPMR
(386EX Protected Mode) or DIAG30R (186-based units) must be loaded to both redundant units following the steps outlined below. Individual preliminary testing is also performed to verify each unit before actual redundancy testing is started.
1. Power on and reset Unit A. Observe the LEDs for proper completion of Self-Test diagnostics. (See the hardware manual for your unit for details on any failure indications.) Note: It takes approximately 25 seconds to complete the Self-Test.
2. At the PC, open the OpenBSI Tools LocalView or NetView program. Follow the appropriate steps for establishing communications via NetView or Local View (see
Chapter 1). Right click on the appropriate RTU ICON in the OpenBSI Network
Tree. Choose "Properties" from the pop-up menu. Use the "Browse…" button to specify the name of the diagnostic file to be entered into the "Control Strategy File: " field. Select the appropriate ".acc" file from the "Select ACCOL Load File Name" menu and then click on "Open. " Click on "OK" in the "RTU Properties Dialog Box."
Right click on the appropriate RTU Icon in the OpenBSI Tree. Choose "RTU à " and then "Download. " Enter the password for the RTU and then click on the "Begin" button.
3. After you have successfully downloaded the file, return to the "Diagnostic Test
Category Menu" (Figure 1-7), highlight the "Redundancy" Test selection and then click on the "Run" button at the bottom of the menu. The Redundancy Diagnostic
Menu shown in Figure 13-1 will appear.
Set the Number of Passes to "CR" for continuous mode and click on the "RUN
Register Diagnostic" Test button. Verify that the Idle LED is OFF. The Idle LED
D4041A 3330 Redundant System / 13-2
remains off until the test is completed when it is turned back on. (Note: one test pass takes approximately six seconds).
Figure 13-1 - 3330 Redundancy Diagnostic Menu
This test verifies the following functions:
· Hardware checksum generator.
· Buffer pointer register load and auto increment operations.
· Status register read and write operations.
· Parity error detection mechanism.
· Redundancy RAM tests.
D4041A 3330 Redundant System / 13-3
Verify that the count indicates several passes successfully completed with no failure indications.
Possible failure messages include:
Fail Redundancy not Detected
Fail Buffer Pntr. Load Fail
Fail Checksum Reg. Failure
Fail Status Register Failure
Fail Buffer
Fail Redundancy RAM Failure
Fail Redundancy Parity Failure
"Redundancy not Detected" indicates that the Enhanced Communication Board
(ECB) or the associated redundancy hardware is not detected by the firmware.
Verify that both the ECB and Redundancy Module are correct and the connector between these boards is properly seated.
Any of the other failures indicate that the basic redundancy hardware is malfunctioning. The ECB and/or Redundancy Module should be repaired or replaced. There is no point in proceeding any further with redundancy testing.
4. After successful execution of the Register Diagnostic, click on the "Return to Menu" button at the bottom of the screen to terminate the test and return to the
"Diagnostic Test Category" Menu (Figure 1-7). Highlight the "CPU and Peripherals"
Test selection and click on the "Run" button at the bottom of the screen. At the "CPU and Peripherals Diagnostic" Menu (Figure 2-1), set the Number of Passes to 2 or more and then click on the "RUN LEDs" (External Peripherals) button. Observe the failure LEDs on the 3330. For each pass, they will turn on in sequence, then go off in sequence. Power down Unit A while the LED test is still executing.
5. At the RSP set the selector switch and press Manual Reset to place Unit B on-line.
Power on and reset Unit B. Observe the LEDs for completion of Self-Test.
6. Click on the "Return to Menu" button at the bottom of the screen to return to the
"Diagnostic Test Category" Menu (Figure 1-7) and repeat Steps 3 through 4. While the LED test is still running at Unit B, power on Unit A.
7. Wait for the LED test to finish at both units.
8. At the RSP, set the selector switch to place unit A on-line. Press the Manual Reset switch to effect the online selection. Both units should now be running with Unit A indicated as the On-Line unit. You are now ready to begin redundancy testing.
13.3 REDUNDANCY TESTS
In order to do the following tests, you must have already completed the procedures in section 13.1.2.
It is important that the state of the running units not be changed during testing except as specifically directed. During this testing, both units are executing in parallel based on
D4041A 3330 Redundant System / 13-4
commands issued from the PC. YOU WILL HAVE TO OBSERVE THE IDLE AND
FAILURE LEDS TO VERIFY THAT THE UNITS ARE SYNCHRONIZED PROPERLY.
THE IDLE LED MUST BE ON AT BOTH UNITS BEFORE A NEW TEST IS STARTED.
Still it is possible that the backup unit may not see the test start-up message from the PC.
In this case you will see the test timed out error at the PC. This is not an indication of a failure, but is due to timing differences in the communications as seen at the back-up unit.
In a situation like this it may be necessary to repeat an action at the PC in order to synchronize the back-up unit.
13.3.1 Redundancy Control Test
This test verifies that all the redundancy interrupt control and status lines between the two units are functioning correctly.
1. Verify that both units have the Idle LED ON and all Failure LEDs OFF. The Idle
LED should be faintly flickering.
2. From the "Redundancy Diagnostic" Menu (Figure 13-1), click on the "RUN Control
Diagnostic" Test button.
3. Verify that the Idle LED is OFF at both units, three of the Failure LEDs at unit A
(the primary unit) are blinking and all of the Failure LEDs at unit B (the back-up unit) are always OFF. The three Failure LEDs at the primary unit are turned on for the duration of each pass of the test and are turned off at the conclusion of each pass, thus presenting a blinking pattern.
One of the following messages will be displayed at the PEI under the STATUS column:
Success
Fail Status Failure
Fail Timeout Failure
Fail Redundancy not Detected
A Status Failure indicates that the status register used to communicate between the units is not transferring status information accurately. A Timeout Failure indicates a problem with the interruption circuitry between the units or that the back-up unit is not executing the diagnostic test. Be sure that Port A is properly connected from each unit to the RSP and that the PC is connected to Port A at the RSP. During these tests, both units are monitoring the messages from the PC. If the back-up unit does not receive the proper diagnostic commands, it will not be coordinated with the primary unit.
13.3.2 Redundancy Channel Test
This test verifies that the data lines between the two units, the integrated DMA on both sides, and the checksum hardware are functioning correctly. This test also uses the status and interrupt circuitry previously tested.
1. Press the "ABORT Control Diagnostic" Test button to stop execution of the previous test (Redundancy Control Test).
D4041A 3330 Redundant System / 13-5
2. Verify that both units now have the Idle LED ON and all Failure LEDs OFF. The
Idle LED should be faintly flickering.
3. Click on the "RUN Channel Diagnostics" Test button.
4. Verify that the Idle LED is off at both units and three of the Failure LEDs at the primary unit starts blinking. The Failure LEDs at the back-up unit should always be OFF. During this test, the Data Copy Pass LED at the RSP should also blink.
One of the following messages will be displayed at the PC under the STATUS column:
Success
Fail Data Transfer Failure
Fail Receive Checksum Failure
Fail Transmit Checksum Failure
Fail TRX & RCV Checksum Failure
Fail Status Failure
Fail Redundancy Parity Failure
Fail Timeout Failure
Fail Redundancy not Detected
A Data Transfer Failure indicates that the data received at the back-up unit did not match the expected test pattern. The test data transmitted is copied from the EPROM of the primary unit and compared against the same address space in the back-up unit.
Note
If both units are not equipped with the same revision level of firmware, this could cause a failure to occur here, even though the transfer hardware is functioning correctly Redundant units should always be equipped with matching sets of firmware in either EPROM or Flash EPROM. To verify your system, check the labels on the EPROMs which are on the CPU Engine, or check the revision and date information displayed at the top of the screen by the Toolkit.
If the transferred test data matches, a software calculated checksum is then compared to the checksums generated by the hardware in each unit. A Receive Checksum Failure indicates that the software-generated checksum matched the hardware checksum in the primary unit, but did not match the hardware checksum in the back-up unit. This indicates a possible problem with the checksum hardware in the back-up unit. A Transmit Checksum
Failure indicates that the software-generated checksum matched the hardware checksum in the back-up unit, but did not match the hardware checksum in the primary unit. This indicates a possible problem with the checksum hardware in the primary unit. TRX & RCV
Checksum Failure indicates that the software-generated checksum did not match either hardware checksum.
The Status and Timeout failures are the same as those described under the Redundancy
Control test.
D4041A 3330 Redundant System / 13-6
13.3.3 Redundancy Failover Test
This test exercises the hardware that places the back-up unit on-line if the primary unit fails or if a manual switchover is done. It also verifies the functionality of the various switches and LEDs on the RSP panel.
While this test is active, three of the Failure LEDs of the on-line unit will blink every three seconds, while the back-up unit will have all of its Failure LEDs OFF. On any switchover this LED pattern also switches and the blinking LEDs should follow the current on-line unit; also communication with the PEI is switched as evidenced by update of the Pass
Count, and the LEDs at the RSP will indicate On-Line and Fail status for the appropriate units. Unit A should still be the primary unit.
1. At the PC, click on the "ABORT Channel Diagnostic" Test selection to terminate the previous test. Verify that both units have the Idle LED ON and all Failure LEDs
OFF.
2. Click on the "RUN Fail-Over Diagnostic" Test selection.
3. Verify that the Failure LEDs at Unit A are ON (they will blink approximately every three seconds), while those at Unit B are OFF. Verify that the Pass Count at the PC is incrementing (approximately every three seconds).
Manual Switchover
4. At the RSP, set the selector switch to make Unit B on-line. Verify that the RSP indicates Unit B as On-Line, and the Failure LEDs at Unit B are ON (blink every three seconds). The Failure LEDs at Unit A should now be OFF. The Pass Count at the PC should continue to increment. You may see a "Timeout this Transmission" error at the PC if a message is lost during the switchover, but the Pass Count should then continue to be updated as the new on-line unit takes over.
Automatic Failover - B to A
5. Set the Unit B power switch to OFF. The system should fail-over to Unit A.
6. At the RSP, verify the status indicators are On-Line for Unit A and Fail for Unit B, and that the Manual Select Disable indicator is ON.
7. Verify that Unit A Failure LEDs are ON (blink every three seconds) and that the
Pass Count at the PEI is still incrementing.
8. Set the Unit B power switch to ON. The Failure LEDs should be off.
Automatic Fail-Over - A to B
9. Set the Unit A power switch to OFF. The system should fail-over to Unit B.
10. At the RSP, verify that Unit B is indicated as On-Line, Unit A as Fail, and that the
Manual Select Disable indicator is still ON.
D4041A 3330 Redundant System / 13-7
11.
Verify that Unit B Failure LEDs are ON (blink every three seconds) and that the
Pass Count at the PEI is still incrementing.
12. Set the Unit A power switch to ON. The Failure LEDs should be OFF.
13. At the RSP, set the selector switch to make Unit A on-line. (It may be necessary to press the Manual Reset switch at the RSP to re-enable manual selection. The
Manual Select Disable indicator should go OFF.) Unit A should now be On-line.
14. Verify correct LED status at both units and on the RSP, and continued update of the
Pass Count at the PC.
15. Click on the "ABORT Fail-Over Diagnostic" Test selection to terminate the redundancy fail-over test. Both units should now have the Idle LED ON and all
Failure LEDs OFF. Click on the “ Return to Menu ” button at the bottom of the
"Redundancy Diagnostic Menu" to return to the "Diagnostic Test Category" Menu
(Figure 1-7).
13.3.4 Redundancy Communications Tests
These procedures are designed to test the hardware that switches communications control to the new on-line unit following a switchover event.
Standard Serial Port Switching
Up to five (5) of the standard serial ports can be connected via the RSP for automatic switching. Port A which is used to communicate with the PEI during diagnostics is verified in the course of the previous testing. The other ports, (B,C, and D) and BIP1 and BIP2, are verified using the following procedures:
1. Construct a 9-pin test plug (D-type male plug P/N 310670-05-5 with the following pins jumpered: 1 to 3, 2 to 4, 5 to 6, 7 to 8) (see Figure 4-1). Plug the loop-back plug into the connector on the RSP for the first port to be tested. For the suggested setup, this would be the J2C connector which tests Port B.
Caution
Do not connect the test plug to the Port A connection or designate
Port A as the port to be tested. This will disrupt communications with the PC.
2. Power off Unit B while testing Unit A communications ports. Both units cannot run these tests simultaneously since only the on-line unit controls the communications hardware.
3. On the Diagnostic Test Category Menu (Figure 1-7), highlight the "Communications" Test selection and then click on the "Run" button at the bottom of the screen to invoke the Communications Diagnostic Menu (Figure 4-2). Set the Number of Passes to "CR" for continuous mode and enter the Port to Test.
D4041A 3330 Redundant System / 13-8
4. Set Baud Rate to Test to "ALL ASYNC" which tests all available asynchronous baud rates and can be executed on any port. Each pass takes approximately 25-30 seconds.
5. Click on the "RUN External loop-back" Test button to start test execution. The following test status will be displayed at the PC:
Success
Fail Clear/Request to Send Fail
Fail Polling Asynch Failure
Fail Interrupt Asynch Failure
Fail Sync Failure (Synchronous Test only)
Fail Comm.Engine 2 not Detected (Ports C & D only)
Fail Configuration Error
6. After several successful passes, if the port being tested is normally used for synchronous communications, change the Baud Rate to Test to "SYNC" and repeat
Step 5. See the Communications chapter (4) for details on loop-back switch settings required, in addition to the loopback plug, when testing RS-485 ports.
7. After several successful passes, click on the "ABORT External loop-back" Test button to stop the test.
8. Move the test plug to the next port to be tested and enter the port designation at the
Port to Test field. Repeat steps 4 through 7.
9. After testing all ports on Unit A, power up Unit B and set the selector switch at the
RSP to make Unit B on-line. Verify correct status indications at the RSP.
10. Power off Unit A and repeat Steps 4 through 8 to execute the same testing at Unit B.
13.4 COMPLETING TESTING
When all redundancy testing is complete, reset both units and power them off. Restore all board positions and any communications port jumpers, switches, and cable connections to their original configuration. Restore any RIO, and process I/O connections as appropriate.
Restore the normal redundant load at the redundant units.
D4041A 3330 Redundant System / 13-9
BLANK PAGE
Chapter 14
LCDs & LCDs with 4 X 20 Display&25-Button Keyboard
This chapter is intended for the following units:
C DPC 3330 units that contain the optional 4 X 20 LCD Display/Keyboard System.
C RTU 3305 units that contain either a 2 X 16 LCD Display or a 4 X 20 LCD Display/-
Keyboard System.
C Control Wave MICRO , Control Wave EFM , Control Wave GFC-CL , Control Wave-
GFC , Control Wave Express , Control Wave ExpressPAC , CW_10 or CW_30 units that contain an optional 4 X 20 LCD Display/Keyboard System.
C Control Wave XFC , Control Wave GFC , Control Wave Express , or Control-
Wave ExpressPAC units that contain an optional 2-Row LCD Display Only assembly.
14.1 MENU ACCESS
From the Diagnostic Test Category Menu (Figure 1-7), highlight the "Keyboard & Display"
Test selection and then click on the "Run" button at the bottom of the screen. The screen will look like Figure 14-1. You may enter a number in the "Number of Passes" field if you want to execute more than one test cycle. The Status field for each test contains the message "No Return Status" to remind you that you must look at the keypad display to verify proper operation and test results.
D4041A
Figure 14-1 - LCD Pixel Test
2 X 16 LCD & 4 X 20 Display/Keyboard / 14-1
14.2 LCD PIXEL TEST
LCD Pixel Test for 4 X 20 LCD Display Assemblies
This test will turn on every pixel on the Display. When this test executes, four rows of black matrix blocks will appear. Each row contains 20 matrix blocks and each block contains a 5 by 8 matrix of pixels. After you verify that each pixel is lit, click on the "RUN Keyboard
Test" "Test" button; this will clear the display.
Figure 14-2A - LCD Pixel Test (4 X 20 LCD Display Shown)
LCD Pixel Test for 2 X 16 LCD Display Assemblies
This test will turn on every pixel on the Display. When this test executes, two rows of black matrix blocks will appear. Each row contains 16 matrix blocks and each block contains a 5 by 8 matrix of pixels. After you verify that each pixel is lit, click on the "RUN Keyboard
Test" "Test" button; this will clear the display.
Figure 14-2B - LCD Pixel Test (2 X 16 LCD Display Shown)
LCD Pixel Test for Control Wave Series 2-Row LCD Display Assembly
This test will turn on (black) every segment off each LCD matrix group on the LCD assembly. When this test executes, two rows of black LCD matrix groups will appear; the top row will contain the minus ( − ) character as well as nine 7-segment LCD matrix groups
(each with a decimal point); the bottom row contains six 14-segment LCD matrix groups.
After you verify that each segment of all LCD matrix groups are lit, click on the "RUN
Keyboard Test" "Test" button; this will clear the display. The display will then post DIAG utilizing the first four LCDs matrix groups of the bottom row.
Figure 14-2C - LCD Pixel Test (Control Wave Series - 2-Row LCD Display Shown)
D4041A 2 X 16 LCD & 4 X 20 Display/Keyboard / 14-2
14.3 LCD MOVING PIXEL TEST
LCD Moving Pixel Test for 4 X 20 and 2 X 16 LCD Displays
In this test, only one 5 by 8 matrix block of pixels will be lit at one time. Click on the "RUN
Keyboard Test" "Test" button; this will clear the display. Next, click on the "RUN LCD
Moving Pixel Test" Test button. The first matrix block in the upper left-hand corner will be turned on. When the number of passes is 1, each time the "RUN LCD Moving Pixel Test"
Test button is pressed, the matrix block of pixels will turn off and the next one to the right will turn on. When the right-most block in the row has been lit, selection of the "RUN LCD
Moving Pixel Test" will turn on the left-most matrix block in another row. In the case of the
4 X 20 LCD Display, the test sequence will first move through the first line, then to line 3, then line 2, and finally to line 4.
If you enter a number greater than 1 in the 'Number of Passes' field and press select "RUN
LCD Moving Pixel Test," you will see the test sequence repeated that number of times.
After you're finished with this test, click on the 'RUN Keyboard Test' "Test" button to clear the display.
LCD Moving Pixel Test for Control Wave Series 2-Row LCD Display Assembly
In this test, the LCD matrix groups [nine 7-Segment (plus decimal point) groups on the top row and six 14-segment groups on the bottom row] are tested sequentially from left to right for the first six of nine test periods. The three remaining test periods check the last three
LCD matrix groups on the top row, again, from left to right. Click on the "RUN Keyboard
Test" "Test" button; this will clear the display. Next, click on the "RUN LCD Moving Pixel
Test" "Test" button. In the first test period the minus (-) character and the top left 7segment LCD matrix group is displayed along with the bottom left 14-segment LCD matrix group. When the number of passes is 1, each time the "RUN LCD Moving Pixel Test" "Test" button is pressed, the matrix groups of segmented LCDs (top and bottom row pair for first of six test periods) will turn off and the next one to the right will turn on. When the rightmost LCD matrix group in the top row has been lit, selection of the "RUN LCD Moving
Pixel Test" will turn on the left-most top and bottom LCD matrix groups again.
If you enter a number greater than 1 in the 'Number of Passes' field and select "RUN LCD
Moving Pixel Test", you will see the test sequence repeated that number of times.
After you're finished with this test, click on the 'RUN Keyboard Test' "Test" button to clear the display. The display will post DIAG utilizing the first four LCDs of the bottom row.
14.4 LCD CHARACTER ROM TEST
Note: The LCD Character ROM Test is not applicable to Control Wave series RTUs that are equipped with a 2-Row LCD Display Only assembly.
LCD Character Rom Test for 4 X 20 and 2 X 16 LCD Displays
When the LCD Character ROM Test executes, the pixels, associated with the 4 X 20 LCD
Display’s 80 matrix blocks, will display the characters shown in Figure 14-3 or in the case
D4041A 2 X 16 LCD & 4 X 20 Display/Keyboard / 14-3
of the 2 X 16 LCD Display, the test sequence will cause the three consecutive displays of the
32 matrix blocks to appear as shown in Figure 14-4.
In either case, a different character will appear in each matrix block position with the exception of the first matrix block position (upper left) which will be blank.
Figure 14-3 - LCD Character Test (For 4 X 20 LCD Display)
Figure 14-4 - 2 X 16 LCD Display - LCD Character Test
14.5 KEYBOARD TEST
Note: The Keyboard Test is not applicable to Control Wave series RTUs that are equipped with a 2-Row LCD Display Only assembly.
Choosing the "RUN Keyboard Test" "Test" button will clear the screen initially. As you press the keys on the keypad, you will see a character on the associated display screen.
Pressing a key associated with numbers 0 through 9 as well as either the minus or period key will result in that key’s character being posted on the display. Pressing one of the 13 special function keys (see Figures 14-5 & 14-6) should result in the display connoted in
Table 14-1.
Table 14-1 - Keyboard Test – Special Function Key/LCD Assignments
When this key is pressed:
The 4 x 20 LCD Display
will show this character:
F1 A
F2 B
F3 C
D4041A 2 X 16 LCD & 4 X 20 Display/Keyboard / 14-4
Table 14-1 - Keyboard Test – Special Function Key/LCD Assignments (Continued)
When this key is pressed:
The 4 x 20 LCD Display
will show this character:
F4 D
INIT E
Up Arrow
Down Arrow
ALM I/E
F
D
H
ALM ACK J
A/M K
OPER I/E L
DEL M
ENT N
Figure 14-5 - 5 X 5 Membrane Keyboard
D4041A
Figure 14-6 – 25-Button Membrane Keyboard
2 X 16 LCD & 4 X 20 Display/Keyboard / 14-5
BLANK PAGE
Chapter 15
Check Before Operate System
15.1 GENERAL
The Check Before Operate (CBO) System sets and checks the output status of eight, relayoperated discrete outputs (DOs). The system consists of a CBO I/O Module that plugs into a
3310 or 3330 or 3335 I/O slot, a CBO Relay Board that mounts in an external DIN rail, and a cable that connects the two assemblies. The diagnostic tests that follow check the operating capabilities of all three assemblies. These tests are performed with the DPC operating in an "off-line" condition as described in Chapter 1, Section 1.7.
15.2 TEST SETUP
The DPC may contain one or more CBO Modules. These modules will not require any special hardware configuration to run diagnostic tests. However, be sure to perform these preliminary steps.
1. Turn the DPC/RTU power switch to OFF.
2. Make sure that all DO relay wiring is disconnected from the field wiring terminals of the CBO Relay Board. This step is necessary to prevent any accidental damage to a controlled load during testing.
3. Reapply power. If the DPC/RTU was executing the DIAG load when it was powered down, it will not be necessary to reset and reload it. Simply continue with the proper menu selection at the PC. If the DIAG file was not previously downloaded, do it now as described in Chapter 1.
15.3 FUNCTIONS OF DIAGNOSTIC MENU
The CBO tests are initiated by highlighting the "Check Before Operate" Test selection on the Test Category Menu of Figure 1-7 and then clicking on the Run button at the bottom of the screen. This selection brings up the CBO Diagnostic Menu of Figure 15-1. The CBO
Diagnostic Menu provides the following utilities:
Number of Passes
The entry in this field determines the number of times the DOs will be tested. This field accepts a numerical entry (1-256) or CR (Continuous with repeat after error) or CS
(Continuous with stop on error) (see Section 1.9.2 for details).
Board Number to Test
This field requires the slot position of the CBO Module to be tested. A valid entry for a 12slot DPC would be 1 to 12.
D4041A Check Before Operate System / 15-1
Figure 15-1 - CBO Diagnostic Menu
Relay Delay
The entry for this field is the desired relay delay time in milliseconds (ms). The default value for this field is 25 ms. An entry of 1000 ms is recommended for testing since it will slow down tests so that the results can be observed on the screen.
Board Type Returned
Once testing is initiated, this field displays the type of board under test based on information returned from the DPC. This field will display CBO as the board type.
Number of Failures
During testing, this field displays the number of test failures that occurred for the number of specified passes. See section 1.7.6 for details.
D4041A Check Before Operate System / 15-2
Status
This field displays "Working" or "Idle" to indicate if a test is in process or not.
RUN CBO Sequence
This test button, when selected, initiates the diagnostic test cycle.
Error Status
Shown on the lower half of the menu, (just below the "RUN CBO Sequence" Test button) this field displays dynamic test results for eight CBO points (1-8). The field lists three tests labeled Test Value, Select Value, and Output Value. Blank rows or a row of zeroes (0) indicates the test named at the left has passed for all eight points. A one (1) in any row signifies a mismatch between select or output values when they were compared to the test values; this indicates a failure.
15.4 INITIATING BOARD TESTS
These tests check the DO circuitry of the CBO Module including the output registers and the output paths to the terminal block of the CBO Relay Board. To start the test sequence, type in the module I/O slot number in the "Board Number to Test" field and along with a numerical or mode entry in the "Number of Passes" field.
These tests are initiated by clicking on the "RUN CBO Sequence" test button. During these tests, the DO LEDs on the I/O Module will turn on and off in a sequential pattern provided jumper W9 on the CBO Relay Board enabled them.
A complete test pass starts by sequentially turning each DO "ON," going from DO1 to DO8, then simultaneously turning all DOs "OFF" and "ON," and finally turning them all "OFF."
At the end of each test pass, a "pass" or "fail" status is returned. If there are no errors, the data for the test table display will be blank. If errors are present, the three rows of the test table will indicate:
Test Value The value written to the hardware (0 = OFF; 1 = ON)
Select Value The value read back from the Select Latch
Output Value The value read back from the Relay Feedback
A mismatch of the Select Values or Output Values, when compared to the Test Value, indicates the point(s) of failure. For example, assume that DO3 turned "ON" and it passed the Select Check but failed the Output Check. If no other points were in error, the test table would look like this:
CBO Point
Test Value
Select Value
Output Value
1 2 3 4 5 6 7 8
0 0 1 0 0 0 0 0
0 0 1 0 0 0 0 0
0 0 0 0 0 0 0 0
D4041A Check Before Operate System / 15-3
If a large number was entered in the "Number of Passes" field along with a small time period in the "Relay Delay" field, the STATUS field readout may sequence too fast to observe the results. By increasing the "Relay Delay" time, the display time will be lengthened for each test. Alternately, setting the "Number of Passes" to "1" will freeze the test results after one pass so that they can be studied. Also, by entering "CS" in this field, the test cycle will stop when an error is detected.
To halt an in process test, select the "ABORT CBO Sequence" Test button.
When testing is completed, press the "RETURN TO MENU" button to return to the
Diagnostic Test Category Menu (Figure 1-7). Then turn off the DPC/RTU, reconnect the DO power/loads to the CBO-DO Relay Board, and restore power.
D4041A Check Before Operate System / 15-4
Chapter 16
Honeywell Smartline Transmitter Interface
Module
16.1 GENERAL
The Honeywell Smartline Transmitter Interface (HWSTI) permits a maximum of eight
Smartline Transmitters to communicate with an RTU 3310, a DPC 3330 or a DPC 3335.
The complete package consists of an HWSTI Module that plugs into a I/O slot, a Field
Termination Assembly (FTA) Board that mounts in an external DIN rail, and a ribbon cable connects that the two assemblies. These tests are performed with the controller operating in an "off-line" condition as described in Chapter 1, Section 1.7.
16.2 PRELIMINARY TEST SETUP
The test selections shown on the menu of Figure 16-1 (excluding the Loopback Test Menu button) do not require any special test equipment or cables. These tests exercise the module's I/O processor (IP) and its associated PROM and RAM memory, as well as the control logic between the 33XX unit and the IP, including the IP and communications processor (DE) on the HWSTI Module. The Loopback Test Menu button is intended as a factory communications loopback test that checks the DE processor-to-transmitter interface by transmitting and receiving messages between two HWSTI Modules. One module, known to be good, functions as a control board while the other functions as the test board .
These tests will require a user-fabricated loopback test cable having three module connectors wired in parallel as shown in Figure 16-3.
Perform the following steps:
1. Turn the controller power switch to OFF.
2. Make sure that all transmitters wired to the FTA Board are disconnected from the field wiring terminals. This step is necessary to prevent any accidental damage to a controlled load during testing.
3. If you intend to perform loopback testing, connect the loopback cable between the control and test board as shown in Figure 16-3.
4. Reapply power. If the controller was executing the DIAG load when it was powered down, it will not be necessary to reset and reload it. Simply continue with the proper menu selection at the PC. If the DIAG file was not previously installed, do it now as described in Chapter 1.
16.3 FUNCTIONS OF HONEYWELL DIAGNOSTIC MENU
The HWSTI tests are implemented from the Test Category Menu of Figure 1-7 by highlighting the "Honeywell Transmitter" Test selection and then clicking on the Run button at the bottom of the screen. Entering this selection brings up the HWSTI Diagnostic
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-1
Menu of Figure 16-1. This menu consists of two screens. Screen 1, shown in Figure 16-1, provides a selection of eight tests plus the Loopback Menu, while Screen 2, shown in Figure
16-2, provides for loopback testing.
Figure 16-1 - Honeywell Transmitter Diagnostic Menu - (Screen 1)
16.3.1 Screen 1 Tests
Screen 1 of the Diagnostic Menu appears as shown in Figure 16-1. The menu entries and poke point selections are described as follows:
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-2
· Number of Passes
Type into this field the number of times that you want the test to be cycled. This field accepts a numerical entry (1-256), or CR (Continuous with repeat after error) or CS
(Continuous with stop on error) (see Section 1.9.2 for details).
· Board Number to Test
For this field type in the I/O slot number of the module you want to test (refer to Figure
16-3 to identify the test and control boards). Valid entries for a 12-slot DPC would be 1 to 12.
· Board Type Returned
This field will display the acronym of the board type under test. In this case it will read
HTI.
· HSTI IP Version
This field will display the version of the firmware EPROM chip installed on the HSTI
IP. For example: A.0/1
· Status
This field displays "Working" or "Idle" to indicate if a test is in process or not.
· Pass, Failures & Status Columns
The lower half of this menu allows you to select eight poke point tests ranging from "IP
REGISTERS/INTERNAL RAM" to "DE PROCESSOR CONTROL LINES." The PASS column keeps count of the test cycles, while the FAILURES column displays the number of failures, if any, that occurred during testing. The STATUS field will display a pass or fail-type message at the conclusion of the test.
· RUN IP Registers/Internal RAM Test
This test button, when entered, checks the HWSTI module's I/O processor (IP) registers and the internal RAM circuitry. When tests are completed, the text "Success" or "IP
Chip Test Fail" will be displayed in the STATUS column. If the text reads "fail," it will be appended with one of the following fault codes:
01 Program Status Word
02 Accumulator
03 B reg (multiplication)
04 DPL
05 DPH
06 R0/
07 Internal RAM
08 Timer0//Interrupt
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-3
· RUN IP PROM Checksum Test
This test button performs a checksum of the IP's firmware in EPROM and compares it against the embedded checksum. A "Success" or "Bad Checksum xxxx" message will be displayed in the STATUS column where xxxx is the numerical value of the returned checksum.
· RUN IP Local RAM Test
This test button verifies the ability of the IP local RAM to maintain a specified value in each RAM cell. Either "Success" or "Address Failure xxxx <-> yyyy" will be displayed where: xxxx = The numerical value of the Test Address yyyy = The numerical value of the Control Address
If the text "Contents Failure xxxx" is displayed, "xxxx" will indicate the memory address where the failure occurred.
· RUN Dual Port RAM Test
This test button verifies the ability of the IP to access the Dual Port RAM. When the test is complete, the STATUS column will show "Success" or "Address Failure xxxx <-> yyyy" where xxxx and yyyy represent the same values described above for the IP Local
RAM Test. If the text "Contents Failure xxxx" is displayed, "xxxx" will indicate the memory address where the failure occurred.
· RUN Shared RAM Test
This test button verifies the ability of the IP to access the shared RAM on the DE Board.
The STATUS column will show "Success" or "Address Failure xxxx <-> yyyy" where xxxx and yyyy represent the same values described above for the IP Local RAM Test. If the text "Contents Failure xxxx" is displayed, "xxxx" will indicate the memory address where the failure occurred.
· RUN Dual Port Semaphores
This test button checks the ability of the IP and the 33XX CPU to set and reset the Dual
Port RAM semaphores. The STATUS column will return either of the following messages: "Success," or "Lock Failed On xx," or "Unlock Failed On xx" where xx is a semaphore number 01 to 08.
· RUN Shared RAM CTRL Lines Test
The ability of the IP to switch the shared RAM to the DE processor is checked by this test button. A "Success" or "RAM Control Failure xx message will be returned under
STATUS where xx is one of the following error values:
10H = IP cannot access RAM
11H = IP cannot give RAM to DE
12H = RAM not returned in timeout period
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-4
· RUN DE Processor Control Lines Test
This test button verifies the functionality of the control lines to the DE processor. The
STATUS column will return "Success" or "DE CTRL" Failure xx" where xx is a numerical value such that:
01 = DE will not start/run
02 = DE will not go to reset state
16.3.2 Screen 2 - RUN Loopback Tests
This test is primarily intended for factory use. It requires a second HWSTI Module known to be good for use as a control board plugged into another I/O slot, and a special loopback test cable connected as shown in Figure 16-3. If the status of both HWSTI Modules is unknown, it may not be possible to isolate a test failure to a particular module.
Figure 16-2 - Honeywell Transmitter Loopback Diagnostic Menu - Screen 2
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-5
Figure 16-3 - Connections for Loopback Testing
When you click on the "Loopback Test Menu" button on Screen 1 of the HWSTI Diagnostic
Menu (Figure 16-1), Screen 2 of this menu will be displayed as shown in Figure 16-2. The upper part of Screen 2 is used in the same way as described for Screen 1 in section 16.3.1.
The remaining functions of Screen 2 are as follows:
· Control Board Number
This field will automatically default to the next higher slot number from the "Board
Number to Test" entry made on Screen 1 (or default to slot 1 if slot 12 was entered on
Screen 1). However, any slots in the 33XX unit may be used for the two modules in a loopback test by entering the slot numbers in their respective fields. If you enter the same slot designation for both, an error message will be displayed.
· RUN Loopback Test
Clicking on this test button will initiate loopback testing.
· Channel Failure History
This table displays dynamic failure counts for the eight communication channels (1-8) on the board under test. A "0" in this table indicates no failures, while non-zero values indicate the number of failures. A "receive" failure indicates that the test board failed to receive a message transmitted from the control board on the indicated channel. A
"transmit" failure indicates that the test board failed to transmit a message to the control board on the indicated channel.
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-6
NOTE
If the control board is defective, test failures may be misleading. For example, a "receive" failure might be caused by failure of the control board to transmit correctly.
· Passes, Failures, and Status
During testing, the PASSES column will count the number of test passes, the
FAILURES column will count the number of failures occurring during the test passes, and the STATUS column will show one of the following messages:
Success
No errors detected. The "Channel Failure History" will remain unchanged.
Loopback Failure
One or more channels have failed. The "Channel Failure History" for the failed channels is incremented for each failed category.
Loopback, Board Failure xx
Testing of all eight channels was not completed because of a module failure. The slot number of the board that failed is indicated by xx (this can be either the control board or the test board). The "Channel Failure History" is updated to include any detected channel failures.
The following status conditions will prevent the channel testing from being executed; therefore, the "Channel Failure History" is updated to include any detected channel failures.
Invalid HSTI IP firmware
IP firmware revision level on the test module is not correct.
Second loopback board invalid
This occurs when the second loopback board is the control board. For example: no board, wrong board type, or a board with an incorrect revision level is in the control board slot.
IP xx Failed to Start Test where xx is the slot number of the board that failed. This can be either the control board or the test board.
IP xx Failed to Complete Test where xx is the slot number of the board that failed. This can be either the control board or the test board.
16.4 INITIATING BOARD TESTS
1. The HWSTI tests are implemented from the Test Category Menu of Figure 1-7 by highlighting the "Honeywell Transmitter" Test selection and then clicking on the
Run button at the bottom of the screen.
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-7
2. Enter the necessary test information such as "Number of Passes" and "Board Number to test." Make all the necessary board entries.
3. Select the desired test under the Test column by clicking on the appropriate Test button. Details on each test selection are provided in Section 16.3.1. Interpret any test messages as noted in the text.
4. To perform loopback tests, a second HWSTI Module known to be good and a test cable will be required as previously noted. The connections for this setup are shown in Figure 16-3. Be sure to turn off power to the controller before connecting or disconnecting any wiring!
5. Click on the "Loopback Test Menu" button shown in Figure 16-1. Screen 2 of the
HWSTI Diagnostic Menu will now be displayed (Figure 16-2).
6. Type in the required loopback test information and then click on the "RUN Loopback
Test" test button. Details on the menu test entries and parameters are described in section 16.3.2.
7. When tests are complete, press the Return to Menu button at the bottom of the screen to return to the Diagnostic Test Category Menu (Figure 1-9). Then turn off controller power and remove the test cable (if used). Reconnect the transmitters to the Field Termination Board and restore power to the controller.
D4041A Honeywell Smartline Transmitter Inte rface Module / 16-8
Chapter 17
Bristol Teletrans Interface (BTI) Board
17.1 GENERAL
The B ristol T eletrans I nterface ( BTI ) board provides the interface to the DPC-33XX
(3310/3330/3335) line of controllers for simultaneous communication with up to eight 3508
Teletrans Transmitters. The complete package consists of a BTI board that plugs into a
3310/3330/3335 I/O slot, Modem Field Termination (MFT) Board (1 MFT board can handle up to four transmitters) that mounts in an external DIN rail, and a ribbon cable connecting the two assemblies. These tests are performed with the DPC operating in an "off-line" condition as described in Chapter 1, Section 1.7.
17.2 PRELIMINARY TEST SETUP
The test selections are shown on the menu of Figure 17-1. These tests exercise the board's processor (MCU) and its associated PROM and RAM memory, as well as the control logic between the 33XX unit and the MCU. The last Test Button of Figure 17-1 is intended as a factory communications loopback test that checks the Board-to-MCU and MCU-to-transmitter interface by transmitting and receiving messages between two BTI channels on the same board. This test will require the connectors on the MFT board(s) to be jumper configured as shown in Figure 17-2, also shown is the dual MFT cable (Bristol Part No.
395335-XX-X) that connects the BTI board to the MFT board(s).
Perform the following steps:
1. Turn the DPC power switch to OFF.
2. Make sure that all transmitters wired to the MFT Board are disconnected from the field wiring terminals. This step is necessary to prevent any accidental damage to a controlled environment during testing.
3. If you intend to perform loopback testing, setup the BTI and the MFT board(s) as shown in Figure 17-2.
4. Reapply power. If the DPC was executing the DIAG load when it was powered down, it will not be necessary to reset and reload it. Simply continue with the proper menu selection at the PC. If the DIAG file was not previously installed, do it now as described in Chapter 1 Preparation.
17.3 MENU ACCESS
The menu for BTI board is accessed from the Diagnostic Test Category Menu of Figure 1-7 by highlighting the "BBTI" Test selection and the clicking on the "Run" button at the bottom of the screen. Entering this selection brings up the BTI Board Diagnostic Menu of
Figure 17-1. The menu entries and poke point selections are described as follows:
D4041A Bristol Teletrans Interface (BTI) / 17-1
o Number of Passes
Type into this field the number of times that you want the test to be cycled. This field accepts a numerical entry (1-256), or CR (Continuous with repeat after error) or CS
(Continuous with stop on error) (see Section 1.9.2 for details). o Board Number to Test
For this field type in the I/O slot number of the board you want to test. A valid entry for
RTU 3310 is a number from 1 through 4. A valid entry for a 6-slot DPC 3330 is a number 1 through 6. For a 12-slot DPC 3330, enter a number from 1 through 12. For a
9- or 10-slot DPC 3335, enter a number from 1 through 9 or 10. o Board Type Returned
This field will display the acronym of the board type under test. In this case it will read
BTI. o BBTI Version
This field will display the version of the firmware EPROM chip installed on the BTI board. For example: A.0/2.0.
The lower half of the BTI board Diagnostic menu allows you to select six tests ranging from "RUN MCU Processor" to "RUN Loopback Test". The PASS column keeps count of the test cycles, while the FAILURES column displays the number of failures, if any, that occurred during testing. The STATUS field will display a SUCCESS or a failure message at the conclusion of the test.
The following status messages will prevent any off-line tests from being executed:
Invalid MCU Firmware Version indicating an incompatibility between the 33XX and BTI board's MCU firmware version (the MCU firmware version will be displayed at the "BBTI Version" field.)
Board Failed to Start Test indicating a bad board
Board Failed to Complete Test indicating a bad board.
Board Halted: XX indicating that the board is halted due to internal problems. XX is the fault code which represents the following (internal) problems:
07 - Task's stack ptr = 0
08 - This Timer block already in chain
09 - This block already hooked
10 - Attempt to hook a timer block located at 0
11 - Unknown external interrupt
D4041A Bristol Teletrans Interface (BTI) / 17-2
o RUN MCU Processor
Figure 17-1 - BTI Board Diagnostic Menu
This test button, when selected, checks the BTI board's processor (MCU) internal RAM circuitry and internal timer. At the completion of this test either, "Success" or "MCU chip test fail" will be displayed in the STATUS column. If a failure message is displayed it will be appended with one of the following fault codes:
01 Internal RAM
02 Timer
D4041A Bristol Teletrans Interface (BTI) / 17-3
o RUN PROM Checksum
This test button, when selected, calculates the checksum of the board processor (MCU) firmware (resident in a on board EPROM) and compares it against the embedded checksum. A "Success" or "Bad Checksum xxxx" message will be displayed in the
STATUS column where, xxxx is the numerical value of the returned checksum. o RUN Local RAM
This test button verifies the ability of the local RAM to maintain a specified value in each RAM cell and checks for any address line crosstalk. Either "Success" or "Address
Failure xxxx <-> yyyy" will be displayed where, xxxx = The numerical value of the Test Address yyyy = The numerical value of the Control Address
If the text "Contents Failure xxxx" is displayed, "xxxx" will indicate the memory address where the failure occurred. o RUN Dual Port RAM
Dual Port RAM is located on the BBTI board and can be accessed by both the 33XX
CPU and the BTI MCU (processor). This test button verifies the ability of the BTI board processor and the DPC 33XX CPU to access the Dual Port RAM and checks for any address line crosstalk. When the test is complete, the STATUS column will show
"Success" or one of the following failure messages: a. "Address Failure xxxx <-> yyyy" where, xxxx and yyyy is the numerical value of the Test address and Control address respectively. This failure is applicable when the on board processor is accessing the Dual Port RAM. b. "Contents Failure xxxx" where, xxxx will indicate the memory address where the failure occurred. This failure is applicable when the on board processor is accessing the Dual Port RAM. c. "RTU-DPR Address failure xxxx <-> yyyy" where, xxxx and yyyy is the numerical value of the Test address and Control address respectively. This failure is applicable when the DPC 33XX CPU is accessing the Dual Port RAM. d. "RTU-DPR Contents Failure xxxx" where, xxxx will indicate the memory address where the failure occurred. This failure is applicable when the DPC 33XX CPU is accessing the Dual Port RAM. o RUN Dual Port RAM Semaphores
This test button checks the ability of the MCU and the DPC 33XX CPU to set and reset the Dual Port RAM semaphores. The STATUS column will return either of the following messages: "Success," or "Lock Failed On xx," or "Unlock Failed On xx" where xx is a semaphore number 01 to 08.
D4041A Bristol Teletrans Interface (BTI) / 17-4
o RUN Loopback Test
This test button checks the interface between the BTI board and the MFT board, and the path through the modems on the MFT board. Test setup is shown in Figure 17-2.
The Channel Failure History matrix shown in Figure 17-1, displays dynamic failure counts for the eight channels on the board. A 0 (zero) in the table indicates no failures, while non-zero values indicate the number of failures. Some types of failure cannot be isolated to the failing channel, e.g. a failure to receive on a particular channel could indicate a receive problem on that channel, a transmit problem on the connected channel, or both.
After the completion of at least one full cycle of the loopback test one of the following messages will appear on the BBTI diagnostics menu:
Success
No errors detected. The Channel Failure History matrix will contain all zeros.
Loopback Failure
One or more channels have failed. The Channel Failure History matrix will be updated to contain non-zero values indicating the failing positions and number of failures.
Figure 17-2 - Connections for Loopback Testing
When tests are complete, press the Return to Menu button (at the bottom of the screen) to return to the Diagnostic Test Category Menu (Figure 1-7). Then turn off DPC power and remove the jumpers on the MFT board connectors (if used). Reconnect the transmitters to the MFT Board and restore DPC power.
D4041A Bristol Teletrans Interface (BTI) / 17-5
BLANK PAGE
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WINDIAG –
Windows Diagnostics for Bristol Controllers
Customer Instruction Manual
D4041A
Mar., 2007
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.
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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
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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Key features
Comprehensive diagnostics for Bristol controllers.
Tests for CPU, memory, and communication ports.
Analog and discrete I/O module testing.
Support for various ControlWave series controllers.
Ethernet port diagnostics with loop-back capabilities.
Frequently asked questions
The manual provides instructions for establishing communication using LocalView or NetView.
WINDIAG allows you to test CPU & Peripherals, PROM/RAM, Serial & Ethernet Communications, Analog and Discrete I/O, and other modules.
You can contact Bristol's Application Support Group by phone or email ([email protected]).
