Instruction Manual

Doc Number CI-ControlWave

Part Number D301381X012
May 2013

ControlWave®
Process Automation Controller

Remote Automation Solutions

www.EmersonProcess.com/Remote
 IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any operation is
attempted. Improper use of this device in some applications may result in damage or injury. The
user is urged to keep this book filed in a convenient location for future reference.

These instructions may not cover all details or variations in equipment or cover every possible
situation to be met in connection with installation, operation or maintenance. Should problems arise
that are not covered sufficiently in the text, the purchaser is advised to contact Emerson Process
Management, Remote Automation Solutions for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for whatever reason, may
leave an operating process without protection. Depending upon the application, this could result in
possible damage to property or injury to persons. It is suggested that the purchaser review the
need for additional backup equipment or provide alternate means of protection such as alarm
devices, output limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches,
etc. If additional information is required, the purchaser is advised to contact Remote Automation
Solutions.

RETURNED EQUIPMENT WARNING

When returning any equipment to Remote Automation Solutions for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure that the
materials returned to Remote Automation Solutions are clean to safe levels, as such levels are
defined and/or determined by applicable federal, state and/or local law regulations or codes. Such
party agrees to indemnify Remote Automation Solutions and save Remote Automation Solutions
harmless from any liability or damage which Remote Automation Solutions may incur or suffer due
to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be grounded in
accordance with OSHA rules and regulations pertaining to "Design Safety Standards for Electrical
Systems," 29 CFR, Part 1910, Subpart S, dated: April 16, 1981 (OSHA rulings are in agreement
with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic instruments that

include electrically operated devices such as lights, switches, relays, alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by exposure to an
electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this
can result in erratic operation or complete failure of the equipment. Read supplemental document
S14006 for proper care and handling of ESD-sensitive components.
 ControlWave Instruction Manual (CI-ControlWave)

Contents
Chapter 1 – Introduction 1-1
1.1 Scope of the Manual .................................................................................................................1-2
1.2 Physical Description ..................................................................................................................1-2
1.3 Housings ...................................................................................................................................1-3
1.4 CPU Module ..............................................................................................................................1-5
1.5 Power Supply/Sequencer Module (PSSM) ...............................................................................1-7
1.6 I/O Modules ...............................................................................................................................1-7
1.7 Software Tools ..........................................................................................................................1-8

Chapter 2 – Installation 2-1

2.1 Site Considerations ...................................................................................................................2-1
2.1.1 Class I, Div 2 Installation Considerations......................................................................2-2
2.2 Installation Overview .................................................................................................................2-2
2.2.1 Unpacking Components ................................................................................................2-3
2.2.2 Color Coding of Slot Connectors ..................................................................................2-4
2.2.3 Mounting the Housing ...................................................................................................2-4
2.2.4 Grounding the Housing .................................................................................................2-6
2.3 Power Supply/Sequencer Module (PSSM) ...............................................................................2-7
2.3.1 General Information about the PSSM ...........................................................................2-9
2.3.2 PSSM Installation Overview ..........................................................................................2-9
2.3.3 General Wiring Guidelines ..........................................................................................2-10
2.3.4 Wiring a Bulk DC Power Supply to the PSSM ............................................................2-10
2.3.5 Wiring an External Alarm or Annunciator to the Watchdog Connector and Wiring the
Redundancy Control Input (OPTIONAL) ................................................................................2-15
2.4 CPU Module ............................................................................................................................2-18
2.4.1 Setting DIP Switches on the CPU Module ..................................................................2-19
2.4.2 Connections to RS-232 Serial Port(s) .........................................................................2-22
2.4.3 Connections to RS-485 Serial Port(s) on the Secondary Communication Board (SCB)2-27
2.4.4 Connections to Ethernet Port(s) on the CPU Module .................................................2-29
2.5 Bezels......................................................................................................................................2-30

Chapter 3 – I/O Modules 3-1

3.1 Module Placement ....................................................................................................................3-3
3.2 Status LEDs ..............................................................................................................................3-4
3.3 Wiring ........................................................................................................................................3-4
3.2.1 Local Termination ..........................................................................................................3-5
3.2.2 Remote Termination......................................................................................................3-6
3.2.3 Shielding and Grounding...............................................................................................3-6
3.4 Digital Input (DI) Modules..........................................................................................................3-8
3.5 Digital Output (DO) Modules ...................................................................................................3-13
3.6 Analog Input (AI) Modules.......................................................................................................3-19
3.7 Analog Output (AO) Modules ..................................................................................................3-24
3.8 Universal Digital Input (UDI) Modules .....................................................................................3-29
3.9 Isolated Resistance Temperature Device (RTD) Input Module ..............................................3-35
3.10 Isolated Low Level Analog Input (LLAI) Module .....................................................................3-39

Chapter 4 – Operation 4-1

4.1 Powering Up/Powering Down the ControlWave .......................................................................4-1

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4.2 Setting the Operating Mode (Run/Remote/Local Switch) ......................................................... 4-1

4.3 Communicating with the ControlWave ...................................................................................... 4-2
4.3.1 Default Comm Port Settings ......................................................................................... 4-2
4.3.2 Changing Port Settings ................................................................................................. 4-3
4.3.3 Collecting Data from the ControlWave.......................................................................... 4-4
4.4 Creating and Downloading an Application (ControlWave Project) ........................................... 4-4
4.5 Creating and Maintaining Backups ........................................................................................... 4-5
4.5.1 Creating a Zipped Project File (*.ZWT) For Backup ..................................................... 4-5
4.5.2 Saving Flash Configuration Parameters (*.FCP) .......................................................... 4-7
4.5.3 Backing up Data ............................................................................................................ 4-8

Chapter 5 – Service and Troubleshooting 5-1

5.1 Upgrading Firmware.................................................................................................................. 5-2
5.2 Removing or Replacing Components ....................................................................................... 5-5
5.2.1 Accessing Modules for Testing ..................................................................................... 5-5
5.2.2 Removing/Replacing the Bezel ..................................................................................... 5-5
5.2.3 Removing/Replacing the CPU Module ......................................................................... 5-6
5.2.4 Removing/Replacing the PSSM.................................................................................... 5-6
5.2.5 Removing/Replacing an I/O Module (Hot Swapping) ................................................... 5-7
5.2.6 Removing/Replacing the Backup Battery ...................................................................5-12
5.3 General Troubleshooting Procedures ..................................................................................... 5-12
5.3.1 Common Communication Configuration Problems..................................................... 5-13
5.3.2 Checking LEDs ...........................................................................................................5-13
5.3.3 Checking Wiring/Signals ............................................................................................. 5-22
5.3.4 Port 80 Display Codes ................................................................................................ 5-23
5.3.5 Reset Switch ............................................................................................................... 5-26
5.4 WINDIAG Diagnostic Utility ..................................................................................................... 5-26
5.4.1 Available Diagnostics .................................................................................................. 5-29
5.5 Core Updump .......................................................................................................................... 5-33

Appendix A – Special Instructions for Class I, Division 2 Hazardous Locations A-1

Appendix P – Redundant Power Supply Sequencer Module (RPSSM) P-1

Appendix Z – Sources for Obtaining Material Safety Data Sheets Z-1

Index IND-1

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 ControlWave Instruction Manual (CI-ControlWave)

Chapter 1 – Introduction
This manual focuses on the hardware aspects of the ControlWave
Process Automation Controller (called the “ControlWave” throughout
the rest of this manual). For information about the software used with
the ControlWave, refer to the ControlWave Quick Setup Guide (D5084),
the ControlWave Designer Programmer’s Handbook (D5125), and the
online help in ControlWave Designer.
This chapter details the structure of this manual and provides an
overview of the ControlWave and its components.

In This Chapter

1.1 Scope of the Manual ........................................................................1-2

1.2 Physical Description ........................................................................1-2
1.3 Housings ..........................................................................................1-3
1.4 CPU Module ....................................................................................1-5
1.5 Power Supply/Sequencer Module (PSSM) .....................................1-7
1.6 I/O Modules......................................................................................1-7
1.7 Software Tools .................................................................................1-8

ControlWave products have been designed and integrated as a highly

adaptable, high performance distributed open controller family with
exceptional networking capability that provides a complete process
automation management solution for the natural gas, water, and
wastewater industries. The ControlWave was designed with an
emphasis on providing high performance with low power consumption,
scalability, and modularity.
Features ControlWave process automation controllers have the following key
features:
 Low power consumption
 Wide operating temperature range: (–40 to +70C) (–40 to 158F)
 Small size (enabling panel mount or 19 inch rack-mount
installations)
 Two RS-232 ports
 One 10/100 MB Ethernet port
 Optional secondary communication board (SCB) provides additional
options for RS-232, RS-485, and Ethernet communications
 Housings to support four or eight I/O modules
 Variety of I/O modules and support for hot swapping of I/O modules
 Support for redundant operation with another ControlWave process
automation controller
 LED status indicators on the CPU, PSSM, and certain I/O modules
 Port 80 display to present status codes

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 Battery backup for the real-time clock and the system’s static RAM
(SRAM)
 Class I, Division 2 Hazardous Location approvals

1.1 Scope of the Manual

This manual contains the following chapters:
Chapter 1 Provides an overview of the hardware and
Introduction general specifications for the ControlWave.
Chapter 2 Provides information on the housings, the
Installation Power Supply/Sequencer module (PSSM), and
the CPU module.
Chapter 3 Provides general information and wiring
I/O Modules diagrams for the I/O modules.
Chapter 4 Provides information on day-to-day operation of
Operation the ControlWave.
Chapter 5 Service and Provides information on service and
Troubleshooting troubleshooting procedures.

1.2 Physical Description

Each ControlWave has a printed circuit board (PCB) backplane
mounted in a stainless steel housing, a Power Supply/Sequencer Module
(PSSM), a CPU module which may include an optional Secondary
Communication Board (SCB) and—depending on the backplane and
housing size—up to eight I/O modules.

Figure 1-1. ControlWave with 8 I/O Modules

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Refer to the following sections in this chapter or to other chapters in this

manual for further information:
 Housings (chassis) with backplanes (see Section 1.3 and Chapter 2)
 Power Supply/Sequencer module (PSSM) (see Section 1.5 and
Chapter 2)
 CPU module (see Section 1.4 and Chapter 2)
 One or more I/O modules (see Section 1.6 and Chapter 3)

1.3 Housings
ControlWave housings are stainless steel designed for panel-mounting
or for some versions, for mounting in a 19-inch equipment rack. They
contain the printed circuit board (PCB) backplane into which you
connect the PSSM, the CPU module, and any I/O modules.
The following housings are available:
 6-slot backplane supports one PSSM, one CPU, and up to four I/O
modules.
 10-slot housing supports one PSSM, one CPU, and up to eight I/O
modules. The 10-slot housing is suitable for mounting in a 19-inch
equipment rack.

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Figure 1-2. ControlWave Housing Options

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Note: For detailed technical specifications, please see document

CWPAC available on our website
http://www.emersonprocess.com/remote.

1.4 CPU Module

The CPU (central processing unit) module houses the multi-layer PCB,
which contains the ControlWave CPU, I/O monitor/control, memory,
and communication functions. It also may include the optional
Secondary Communications Board (SCB).
The CPU module includes:
 AMD Elan SC520 microprocessor running at 100 MHz
 two RS-232 communication ports
 one 10/100baseT Ethernet port
 2 MB of battery backed Static RAM (SRAM)
 64 MB of Synchronous Dynamic RAM (SDRAM)
 512 KB boot/downloader FLASH
 32 MB simultaneous read/write FLASH memory
 transmit (TX) and receive (RX) LEDs for each communication port
 Keyed run/remote/local operation switch
 configuration DIP switches (described in Chapter 2)
 Port 80 display to show status codes
You can order the CPU module with the optional secondary
communication board (SCB) for additional communication ports. See
CPU Module Configurations.
CPU Module The CPU module has several basic configurations, all of which
Configurations have an on-board backup battery and different combinations of
communications ports.

Table 1-1. CPU Module Configurations

Number of RS-232 Number of Number of Notes

Ports RS-485 Ethernet
Ports Ports
2 0 1 No SCB.
3 1 2 For this port count, 1 RS-232, 1
RS-485, and 1 Ethernet port
reside on the SCB.
3 1 1 For this port count, 1 RS-232 and
1 RS-485 port reside on the
SCB.
2 2 1 For this port count, both RS-485
ports reside on the SCB.

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CPU Backup The CPU module includes a 3.6V, 950 mA-hr lithium ½
Battery AA battery. This battery provides backup power for the
real-time clock, CMOS RAM (within the microprocessor)
and the system’s Static RAM (SRAM).

CPU Memory There are several different types of memory used on the CPU module:
Boot/Downloader FLASH
Boot/download code is contained in a single 512 Kbyte FLASH chip.
Boot FLASH also holds the value of soft switches, audit/archive file
configurations, and user account and port information.

FLASH Memory
The CPU module contains 32 MB of FLASH memory. The FLASH
memory holds the system firmware and the boot project. Optionally
FLASH memory also stores the zipped ControlWave project (*.zwt),
user files, and historical data (audit/archive files).The FLASH does not
support hardware write protection.

System Memory (SRAM)

The CPU module has 2 MB of static random access memory (SRAM).
During power loss periods, SRAM enters data retention mode (powered
by the CPU backup battery). Critical system information that must be
retained during power outages or when the system has been disabled for
maintenance is stored here. This includes the last states of all I/O points,
audit/archive historical data (if not stored in FLASH), the values of any
variables marked RETAIN, the values of any variables assigned to the
static memory area, and any pending alarm messages not yet reported.

SDRAM
The CPU module contains 64MB of synchronous dynamic random
access memory (SDRAM). SDRAM holds the running application
(ControlWave project) as well as a copy of system firmware and the
current values of any variables not marked RETAIN or stored in the
static memory area. This allows the system to run faster than it will
from the SRAM memory. SDRAM is not battery-backed.

CMOS RAM
The Elan microprocessor includes 124 bytes of complementary metal
oxide semiconductor (CMOS) RAM to hold various internal
parameters.

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1.5 Power Supply/Sequencer Module (PSSM)

Note: If you need redundant power supply capabilities, you can install
a Redundant Power Supply/Sequencer Module (RPSSM) instead
of the PSSM. For details on the RPSSM, see Appendix P.
The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.
The PSSM operates from +22.2 to +30V (dc) and ships from the factory
with a nominal input supply configuration of 24V.
The PSSM includes:
 ON/OFF system power switch
 Pluggable terminal block to connect the external power supply
 Watchdog output connector to signal a watchdog failure to an
external device
 Status LEDs
Chapter 2 includes instructions for installing and configuring the PSSM.

1.6 I/O Modules

The ControlWave supports analog input, analog output, digital input,
digital output, universal digital input, isolated RTD, and isolated low
level analog input modules for either local or remote field device wiring
termination.
Refer to Chapter 3 for information on specific I/O modules. Figure 1-3
shows a typical I/O module housing.
Terminations are pluggable and accept a maximum wire size of #14
AWG. All I/O modules have surge protection that meets either C37.90-
1978 or 472-1978 IEEE specifications.
Each I/O module connects to the backplane using a 110-pin male
connector and to its associated terminal block assembly using a 44 pin
header.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 1-3. I/O Module (with door open)

1.7 Software Tools

The ControlWave programming environment consists of a set of
integrated software tools which allow you to create, test, implement,
and download complex control strategies for use with the ControlWave.
Figure 1-4 graphically presents the programming environment.

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 1-4. ControlWave Programming Environment

The tools which make up the programming environment include:

 ControlWave Designer is your load-building package. It offers
several different methods for you to create control strategy programs
that run in your ControlWave. You can use pre-made function
blocks, ladder logic, or structured languages. The resulting process
control strategy programs (called projects) are fully compatible
with IEC 61131 standards. For information on ControlWave
Designer, see the Getting Started with ControlWave Designer
manual (document D5085), the ControlWave Quick Setup Guide
(document D5084), and the ControlWave Designer Programmer’s
Handbook (document D5125).
 The I/O Configurator, accessible via a menu item in ControlWave
Designer, allows you to define process I/O modules in the
ControlWave and configure the individual mapping of I/O points for
digital and analog inputs and outputs. For information on the I/O
Configurator see the ControlWave Designer Programmer’s
Handbook (document D5125).

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 The ACCOL3 Firmware Library, available within ControlWave

Designer, includes a series of ControlWave-specific function blocks.
These pre-programmed function blocks let you accomplish various
tasks common to most user applications including alarming,
historical data storage, as well as process control algorithms such as
PID control. For information on individual function blocks, see the
online help within ControlWave Designer.
 OpenBSI Utilities provides a set of programs that allow you to
configure a communication network of ControlWave controllers,
download files to the controllers, and collect data from the network.
OpenBSI also exports data from the network to a SCADA/host
package, such as OpenEnterprise. For information on configuring
OpenBSI communications, see the OpenBSI Utilities Manual
(document D5081).
 OpenBSI Harvester is a special add-on package that allows
scheduled data collections from large networks. For information on
the Harvester, see the OpenBSI Harvester Manual (document
D5120).
 A series of web page controls are available for retrieval of real-time
data values and communication statistics. These controls utilize
ActiveX technology and are called through a set of fixed web pages,
compatible with Microsoft® Internet Explorer. Alternatively,
developers can place the controls in third-party ActiveX compatible
containers such as Visual BASIC or Microsoft® Excel. For
information on the ActiveX controls, see the Web_BSI Manual
(document D5087).
 User-defined web pages - If desired, you can use the ActiveX web
controls in your own user-defined web pages you can store at the PC
to provide a customized human-machine interface (HMI).
 Flash Configuration Utility – Parameters such as the BSAP local
address, IP address, etc. are set using the Flash Configuration
Utility, accessible via OpenBSI LocalView, NetView, or TechView.
For information on the Flash Configuration Utility, see Chapter 5 of
the OpenBSI Utilities Manual (document D5081).

Communication In addition to the Bristol Synchronous/Asynchronous Protocol

Protocols (BSAP), ControlWave supports communications using:
Internet Protocol (IP) - You can use an Ethernet port or use a serial
port using serial IP using Point-to-Point Protocol (PPP).
Other supported protocols include: Modbus, Allen-Bradley DF1, CIP,
DNP3, and Hex Repeater. See the ControlWave Designer online help
for details and restrictions.

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Chapter 2 – Installation
This chapter discusses the physical configuration of the ControlWave,
considerations for installation, wiring instructions for the PSSM
module, and instructions for setting switches and jumpers on the CPU
module. For instructions on I/O installation, see Chapter 3.
In This Chapter

2.1 Site Considerations..........................................................................2-1

2.1.1 Class I, Div 2 Installation Considerations .............................2-2
2.2 Installation Overview........................................................................2-2
2.2.1 Unpacking Components .......................................................2-3
2.2.2 Color Coding of Slot Connectors..........................................2-4
2.2.3 Mounting the Housing ..........................................................2-4
2.2.4 Grounding the Housing ........................................................2-6
2.3 Power Supply/Sequencer Module (PSSM) .....................................2-7
2.3.1 General Information about the PSSM ..................................2-9
2.3.2 PSSM Installation Overview .................................................2-9
2.3.3 General Wiring Guidelines .................................................2-10
2.3.4 Wiring a Bulk DC Power Supply to the PSSM ...................2-10
2.3.5 Wiring an External Alarm or Annunciator to the Watchdog
Connector and Wiring the Redundancy Control Input
(OPTIONAL) .....................................................................2-15
2.4 CPU Module ..................................................................................2-18
2.4.1 Setting DIP Switches on the CPU Module .........................2-19
2.4.2 Connections to RS-232 Serial Port(s) ................................2-22
2.4.3 Connections to RS-485 Serial Port(s) on the Secondary
Communication Board (SCB) ...........................................2-27
2.4.4 Connections to Ethernet Port(s) on the CPU Module ........2-29
2.5 Bezels ............................................................................................2-30

2.1 Site Considerations

When choosing an installation site, check all clearances. Ensure that the
ControlWave is accessible for wiring and service.
To ensure safe use of this product, please review and follow the
Caution instructions in the following supplemental documentation:
 Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
 ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)

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ControlWave Instruction Manual (CI-ControlWave)

Specifications  See document CWPAC available on our website for detailed

for Temperature, technical specifications for temperature, humidity, and vibration for
Humidity and the ControlWave. This document is available on our website at:
Vibration http://www.emersonprocess.com/remote.
 Ensure that the ambient temperature and humidity at the installation
site remains within these specifications. Operation beyond the
specified ranges could cause output errors and erratic performance.
Prolonged operation under extreme conditions could also result in
failure of the unit.
 Check the mounted enclosure, panel, or equipment rack for
mechanical vibrations. Make sure that the ControlWave is not
exposed to a level of vibration that exceeds that provided in the
technical specifications..

Caution Placement of the ControlWave in Class 1, Division 2 (Group A, B, C, and

D) hazardous locations requires that you select an appropriate
enclosure that meets NEMA Type 3X or 4X specifications.

2.1.1 Class I, Div 2 Installation Considerations

Underwriters Laboratories (UL) lists the ControlWave as non-incendive
and suitable only for use in Class I, Division 2, Group A, B, C, and D
hazardous locations and non-hazardous locations. Read this chapter and
Appendix A carefully before you install a ControlWave in a hazardous
location.
Perform all power and I/O wiring in accordance with Class I, Division 2
wiring methods as defined in Article 501-4 (b) of the National Electrical
Code, NFPA 70 (for installations within the United States) or as
specified in Section 18-152 of the Canadian Electrical Code (for
installation in Canada).

WARNING EXPLOSION HAZARD

Substitution of components may impair suitability for use in Class I,
Division 2 environments.
When the ControlWave is situated in a hazardous location, turn off
power before servicing or replacing the unit and before installing or
removing I/O wiring.
Do not connect or disconnect equipment unless the power is switched
off or the area is known to be non-hazardous.

2.2 Installation Overview

Installing a ControlWave involves several general steps:
1. Unpacking, assembling, and configuring the hardware
2. Installing PC-based software (ControlWave Designer)

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3. Establishing communications
4. Creating an application-specific control strategy (ControlWave
project).
5. Creating application-specific web pages (optional)
6. Adding the ControlWave to an OpenBSI network
7. Downloading the application-specific ControlWave project into the
ControlWave

Note: Steps 2 through 7 require that you install and use ControlWave
Designer software on your PC. This manual focuses on hardware
installation and preparation. Software installation and
configuration is beyond the scope of this manual. Refer to the
ControlWave Quick Setup Guide (D5084) for material related to
software installation and use.

2.2.1 Unpacking Components

Packaging Depending upon how you order it, the ControlWave Micro may arrive
pre-assembled, with all modules installed in the housing, or as
individual components in a number of separate boxes. In the latter case,
you must identify, unpack, and assemble the components. Unless
otherwise noted, you can place modules in any slot in a base or
expansion housing.

Note: Do not install modules in the housing until you have mounted
and grounded the housing at the designated installation site.
Delivered boxes may include:
 Housing assemblies
 Power Supply/Sequencer module (PSSM)

Note: The PSSM must reside in slot #1 in the base housing.

 CPU module

Note: The CPU module must reside in slot #2 in the base housing.

 I/O Modules
Notes:
 There are many different types of I/O modules available. Chapter
3 contains detailed instructions on each I/O module.
 Universal Digital Input (UDI) modules can only reside in the first
four I/O slots.
 One or more bezel assemblies; each bezel covers two I/O
modules.

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2.2.2 Color Coding of Slot Connectors

A color tab on each backplane connector matches the color on the
module which you can place in that slot.
 PSSM goes in the first slot (Yellow tab)
 CPU goes in the second slot (Blue tab)
 I/O modules go in any other slot (Green tab)

2.2.3 Mounting the Housing

You can install a ControlWave equipped with a 4-I/O module housing
on a wall or panel. See Figure 2-2 for mounting hole patterns for a 4-
I/O unit.
You can install a ControlWave equipped with an 8-I/O module housing
in a 19-inch equipment rack, a panel or a wall. These units ship from the
factory with the end plates configured for 19-inch rack mounting.
Remove the end plates, rotate them 180° and then reinstall them to
accommodate panel or wall mounting. See Figure 2-1 for hole patterns
and dimensions.
When you install any of these units on a panel or wall, position it
according to the following restrictions:
 Position the unit so that you can see the front of the assembly and so
it is accessible for service such as installing a module or replacing a
battery.
 Do not install ControlWave modules until you mount the housing
and ground it properly.

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Figure 2-1. 8-I/O Module ControlWave - Mounting Diagram

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ControlWave Instruction Manual (CI-ControlWave)

Figure 2-2. 4-I/O Module ControlWave - Mounting Diagram

2.2.4 Grounding the Housing

Caution Do not install any modules in the housing until you mount and ground
the housing at the designated installation site.

Housings have a ground lug that accommodates up to a #4 AWG wire

size. Once you install the housing, you must run a ground wire between
the housing ground lug and a known good earth ground.
When you install the various ControlWave modules into the housing
and secure them using the captured panel fasteners, this automatically
connects them to chassis ground.

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 ControlWave Instruction Manual (CI-ControlWave)

Note: After you install the PSSM in the housing, as an added

precaution we recommend that you run a #14 AWG wire from
the TB2-5 power connection (chassis ground) to the same known
good earth ground.
Additional grounding guidelines include:
 Use stranded copper wire (#4 AWG) for the housing to earth
ground, and keep the length as short as possible.
 Clamp or braze the ground wire to the ground bed conductor
(typically a stranded copper AWG 0000 cable installed vertically or
horizontally).
 Tin the wire ends with solder (using a high-wattage soldering iron)
prior to inserting the wire into the housing ground lug.
 Run the ground wire so that any routing bend in the cable has a
minimum radius of 12-inches below ground and 8-inches above
ground.

2.3 Power Supply/Sequencer Module (PSSM)

Before we actually install the PSSM it in the housing, we’re going to
discuss some general information about how it works.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 2-3. Power Supply/Sequencer Module (PSSM)

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 ControlWave Instruction Manual (CI-ControlWave)

2.3.1 General Information about the PSSM

The Power Supply/Sequencer module (PSSM) takes power from an
external bulk DC power supply and then provides power through the
ControlWave housing/backplane to all installed modules.
The Power Supply/Sequencer module (PSSM) plugs into slot #1 (first
slot from the left) on the ControlWave’s backplane using connector J1.
Power The PSSM ships from the factory configured for a nominal input supply
Supply of 24Vdc.

Hot Swap of I/O The PSSM supports “hot swapping” of I/O modules. This means you
Modules can insert or remove an I/O module from the chassis while power is
live. There is no support for “hot swapping” of the PSSM itself, or the
CPU module.

WARNING Do not perform “hot swapping” in a Class I, Division 2 hazardous

location.

Watchdog PSSMs include a watchdog metal oxide semiconductor field-effect

Switch transistor (MOSFET) switch connector. The purpose of the watchdog
connector is to trigger an external alarm or annunciator if the
ControlWave enters a “watchdog” condition in which the CPU cannot
control your process. This occurs on power-up before the ControlWave
project starts, if the unit is reset, if the ControlWave project “crashes”
or if the system loses power. See Section 2.3.5.
Redundancy The same terminal block (TB1) used for watchdog control also handles
Control Input a redundancy control line to a ControlWave Redundant I/O Switcher.
See Section 2.3.5.

2.3.2 PSSM Installation Overview

There are several steps you need to follow when you install the PSSM.
1. Identify the carton holding the PSSM and remove it from that carton.
See Section 2.2.1.
2. Slide the PSSM into slot #1 of the housing.
3. Tighten the captured panel fasteners to secure the PSSM in place.
4. Unplug terminal block connector TB2 from the PSSM and wire it to
an external bulk DC power supply. See Section 2.3.4.
5. If you want to use the watchdog connector TB1, or use this
ControlWave in a redundant system, unplug TB1 from the PSSM and
wire it to an external annunciator or similar device according to
instructions in Section 2.3.5 .
6. After you configure and install the CPU module in slot #2 re-connect

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ControlWave Instruction Manual (CI-ControlWave)

terminal blocks to their connectors to apply power to the unit.

2.3.3 General Wiring Guidelines

 ControlWave PSSMs use compression-type terminals that
accommodate up to #14 AWG wire.
 When making a connection, insert the bare end of the wire (approx
¼” max) into the clamp adjacent to the screw and secure the wire.
 To prevent shorts, ensure that no bare wire is exposed. If using
standard wire, tin the bare end with solder to prevent flattening and
improve conductivity.
 Allow some slack in the wire while making terminal connections.
Slack makes the wires more manageable and helps minimize
mechanical strain on the terminal blocks.

2.3.4 Wiring a Bulk DC Power Supply to the PSSM

Caution At this time you can also connect power and watchdog wiring. However;
for safety reasons and to prevent accidental damage to the your bulk DC
power supply, do not connect the pluggable terminal block connectors
TB1 and TB2 to the PSSM until after you install, wire, and configure the
CPU module.
Follow the instructions in Section 2.3.3 General Wiring Guidelines when
wiring connections.

Operating The ControlWave operates from +22.2 Vdc to +30.0 Vdc (with a
Range nominal +24Vdc input source).

One or Two You can connect one or two bulk DC power supplies (nominally +24
Power Vdc) to the PSSM.
Supplies The bulk DC supply you connect to terminal TB2-1 (+VIN) powers the
CPU, communications, and I/O logic circuits. The PSSM converts,
regulates, and filters the power to +5Vdc, +3.3Vdc, +12Vdc (optional)
and -12Vdc (optional). +3.3 Vdc. For safety, this circuit has a 3A fuse.
The bulk DC supply (+20.0 to +30Vdc) you connect to terminal TB2-2
(+VINF) powers the I/O field devices connected to the I/O modules. For
safety, this circuit has a 10A fuse.
Notes:
 When you require two bulk power supplies, the first supply (VIN)
must be rated to handle 2 amps.
 The fuses for the PSSM cannot be replaced in the field.

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Calculating the Use the following formula to determine the maximum current required
Maximum Current for the +24 Vdc bulk power used with a particular ControlWave:
Required

Max Bulk +24 Vdc Supply Current = CPUmax_current + Σ I/O Modulemax_current

where:
CPUmax_current refers to the maximum current required by the CPU (with or
without an SCB), backplane and the PSSM. This is 1A.

Σ I/O Modulemax_current refers to the sum of the maximum current required by each
and every I/O module installed in the unit. The amount per
I/O module varies as follows:
16 AI Module 2A per module

8 AI Module 1A per module

8 AO Module 1A per module

16 DI Module 1A per module

32 DI Module 1A per module

16 DO Module See table (no surge current)

32 DO Module See table (no surge current)

6 UDI Module See table (no surge current)

4 RTD Module See table (no surge current)

6 LLAI Module See table (no surge current)

So, for example, if you have a ControlWave with a 16AI module, an

8AO module, and a 32DI module, the maximum current draw is 1A for
the CPU plus 2A for the 16AI module plus 1A for the 8AO module and
1A for the 32DI module, for a total of 5A.

Note: This calculation covers current draw during normal operation

(steady state) as well as the current draw during power-up in-
rush when the unit is first powered on. Power up in-rush current
can last up to 100 milliseconds and is higher than the current
draw required during normal operation.
Refer to Table 2-1 for ControlWave steady state and loop current
requirements for bulk power supplies.

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ControlWave Instruction Manual (CI-ControlWave)

Table 2-1. Steady State Current Draw for Bulk Power Supplies

Component(s) System Current Field Current draw for Notes

draw for 24Vdc 24Vdc Power Supply
Power Supply
CPU (with Ethernet), 290 mA Not applicable
PSSM and backplane
CPU (with Ethernet), SCB 400 mA Not applicable
(with Ethernet), PSSM and
backplane
CPU (with Ethernet), SCB 310 mA Not applicable
(with 2 RS-232), PSSM
and backplane
Analog Input Module 16 40.5 mA 52.2 mA For 24Vdc supply add 25 mA per
points (4-20 mA) loop
Analog Input Module 8 36.1 mA 29.7 mA For 24Vdc supply add 25 mA per
points (4-20 mA) loop
Analog Output Module 8 20.0 mA 26.9 mA For 24Vdc supply add 23.6 mA
points (4-20 mA) per loop
Analog Output Module 8 20.0 mA 56.8 mA For 24Vdc supply add 26.1 mA
points (1-5V) per loop. Output at 5 mA
Digital Input Module 32 29.2 mA 29.7 mA For 24Vdc supply add 4.74 mA
points per loop – dry contact
Digital Input Module 16 15.8 mA 29.7 mA For 24Vdc supply add 4.74 mA
points per loop – dry contact
Digital Output Module 32 42.6 mA 0 mA
points
Digital Output Module 16 22.6 mA 0 mA
points
Universal Digital Input 16.7 mA 0 mA
(UDI) – 6 points
Isolated RTD 4 point 26.0 mA 0 mA
Isolated Low Level Analog 40.0 mA 0 mA
Input 6 points

Terminal Block Unplug removable connector TB2 from the PSSM and wire DC power
Connector TB2 to the connector. We recommend you do not plug the connector back
into the PSSM until the CPU module is already installed in the housing.
TB2 provides five input connections for bulk power:
 TB2-1: = (+VIN) (+22.2V to +30V dc for +24V supply)
 TB2-2 = (+VINF) Connected to TB2-1 or +20Vdc to +30Vdc
supply
 TB2-3 = (-VIN) 1st supply ground
 TB2-4 = (-VIN) 2nd supply ground internally connected to TB2-3
 TB2-5 = Chassis Ground - CHASSIS ( )

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 2-4 shows the typical wiring at the PSSM’s TB1 block.

Figure 2-4. PSSM Wire Routing Diagram

Note: As an added precaution, we recommend that you run a #14

AWG wire from the TB2-5 power connection (chassis ground)
to the same known good earth ground used for the housing.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 2-5. PSSM TB2 – Typical Wiring Schemes

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2.3.5 Wiring an External Alarm or Annunciator to the Watchdog

Connector and Wiring the Redundancy Control Input (OPTIONAL)

Caution At this time you can also connect power and watchdog wiring.
However; for safety reasons and to prevent accidental damage to the
your bulk DC power supply, do not connect the pluggable terminal
block connectors TB1 and TB2 to the PSSM until after you install, wire,
and configure the CPU module.
Follow the instructions in Section 2.3.3 General Wiring Guidelines when
wiring connections.

Watchdog The PSSM includes an optional watchdog connector TB1. The purpose
Condition of the watchdog connector is to trigger an external alarm or annunciator
if the ControlWave enters a “watchdog” condition in which the CPU
cannot control your process.
A watchdog condition occurs when:
 A watchdog timer expires. This happens if the ControlWave project
execution halts unexpectedly – “program crash.”
 The controller powers up but is not yet running the ControlWave
project.
 The CPU module detects that the regulated supplies are out of
specification.
A MOSFET switch activates the watchdog connector whenever a
watchdog condition occurs. If your ControlWave is part of a redundant
pair, the ControlWave Redundancy Switcher monitors the watchdog
switch to detect a failure of the ControlWave.

Redundancy The same TB1 connector includes an input from the ControlWave
Control Input Redundancy Switcher. If this ControlWave is part of a redundant pair,
and the ControlWave Redundancy Switcher detects a watchdog failure
in the other ControlWave, the redundancy control input sends signals to
this ControlWave that it must take control. For more information on
how this works, see the ControlWave Redundancy Setup Guide (D5123)
and the ControlWave Redundant I/O and Control Switch Unit Manual
(CI-ControlWave REDI/O).

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ControlWave Instruction Manual (CI-ControlWave)

Terminal Block You must power the watchdog connector (TB1) from an external power
Connector TB1 supply. Unplug removable connector TB1 from the PSSM and wire
power to the connector. We recommend you do not plug the connector
back into the PSSM until the CPU module is already installed in the
housing.
TB1 provides the following connections:
 TB1-1 = VO - Watchdog MOSFET Switch Output
 TB1-2 = VI - Watchdog MOSFET Switch Input
 TB1-3 = VR = Redundant Unit Control Input
The VI input on TB2 (TB1-2) powers the watchdog switch; its switched
output connects to the VO output on the same terminal block (TB1-1).
You must reference the external power source connected to the VI
terminal to the return point of the input source powering the PSSM
[which is either –VIN or PSGND (TB2-3)]. See Figure 2-6.

TB1-1

TB1-2

TB2-1
TB2-3

TB2-5

Figure 2-6. Watchdog MOSFET Switch Wiring

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Figure 2-7. ControlWave to ControlWave RED I/O Redundancy Field Wiring

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ControlWave Instruction Manual (CI-ControlWave)

2.4 CPU Module

The CPU module, which controls the ControlWave and handles memory
and communication functions, can only be installed in Slot #2 of the
ControlWave backplane.
Identify the carton holding the CPU module and remove it from that
carton. The CPU module has several different configurations, depending
upon whether or not you ordered the CPU with a secondary
communications board (SCB), and if you did order an SCB, which type:
 CPU with two RS-232 serial ports, and one Ethernet port. No SCB.
 CPU with two RS-232 serial ports, and one Ethernet port. SCB with
one additional RS-232 port, one RS-485 port, and two additional
Ethernet ports.
 CPU with two RS-232 serial ports, and one Ethernet port. SCB with
one additional RS-232 and an RS-485 port.
 CPU with two RS-232 serial ports, and one Ethernet port. SCB with
two RS-485 ports.
Set DIP switches on the CPU module according to the tables on the next
few pages. After you configure the DIP switches, slide the CPU module
into slot #2 (the second slot from the left) of the housing.

Figure 2-8. ControlWave CPU Module (without SCB)

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 2-9. ControlWave CPU Module (with SCB)

2.4.1 Setting DIP Switches on the CPU Module

Before you install the CPU module, you must determine the settings for
its DIP switches. Refer to Figure 2-8 for the location of the DIP switch
banks on the CPU board itself. If you have a secondary
communications board (SCB) you must also refer to Figure 2-9 for the
location of the DIP switch banks on the SCB. Refer to Tables 2-2
through 2-4 for DIP switch setting values.

Note: Examine each bank of DIP switches carefully to note the switch
direction for ON or OFF.

Table 2-2. CPU Module Switch SW1

SW1 Setting Function Mode

1 Watchdog Controls whether the system enters a watchdog state
Enable when a crash or system hangup occurs and automatically
restarts. Values are:
ON (Enables watchdog circuit; factory default)
OFF (Disables watchdog circuit and prevents automatic
restart)
2 Lock/Unlock Controls the ability to modify soft switches, other
Soft Switches configurations, and flash files. Values are:
ON (Unlocks soft switches and flash files; factory
default).
OFF (Locks soft switches, configurations, and flash files)

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ControlWave Instruction Manual (CI-ControlWave)

SW1 Setting Function Mode

3 Use/Ignore Controls the use of soft switches. Values are:
Soft Switches ON (Enable user-defined soft switches configured in flash
memory; factory default)
OFF (Disable soft switch configuration and use factory
defaults)
Note: Setting both switch 3 and switch 8 to OFF (closed)
sets all serial communication ports to 9600 bps
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.
4 Core Updump Causes the ControlWave to perform a core updump,
(see Section provided you have set the mode switch (SW3-3) to
3.6) Recovery mode or properly sequenced the Run / Remote /
Local switch on the PSSM. Values are:
ON (Disables core updump; factory default)
OFF (Core updump via PSSM Run/Remote/Local switch
or mode switch SW3-3)
5 SRAM Control Manages SRAM contents following a low power situation
or a power outage. Values are:
ON (Retain values in SRAM during restarts; factory
default)
OFF (Reinitialize SRAM) – Data in SRAM lost during
power outage or re-start.
6 Redundancy Specifies whether this ControlWave is part of a redundant
Enable / pair. Values are:
Disable ON (Redundancy Disabled. Not part of redundant pair;
factory default)
OFF (Redundancy Enabled. This ControlWave is one of
two in a redundant pair)
7 Unit A / Unit B Specifies whether this ControlWave is the “A” or “B” unit in
a redundant pair. Values are:
ON (“A” unit in the redundant pair; factory default)
OFF (“B” unit in the redundant pair)
Note: If SW1-6 is ON, the system ignores SW1-7.
8 Enable Suspends normal operation and allows diagnostic
WINDIAG routines. Values are:
ON (Permits normal system operation, including the boot
project, and disables the WINDIAG diagnostics from
running; factory default)
OFF (Allow WINDIAG to run test; disable boot project.)
Note: Setting both switch 8 and switch 3 to OFF (closed)
sets all serial communication ports to 9600 bps
operation. All serial communication ports must be
set at 9600 bps before WINDIAG can perform
communication tests.

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Table 2-3. CPU Module Switch SW3

SW3 Setting Function Mode

1 N/A Not currently used.
2 System Enables / disables remote system firmware upgrade via
Firmware load System Firmware Downloader:
control ON (disables remote system firmware upgrade)
OFF (enables remote system firmware upgrade; factory
default)
Note: Remote system firmware upgrade using System
Firmware Downloader requires boot PROM version 06
(or newer) and system PROM version 4.7 (or newer).
3 Force Enables recovery mode. This allows for system firmware
Recovery upgrades. Values are:
Mode ON (enables recovery mode)
OFF (disables recovery mode). – This is the factory
default.
4 Backup Battery Enables/disables the backup battery for SRAM and the
Enable/Disable real-time clock. Values are:
ON (enables backup battery)
OFF (disables backup battery). – This is the factory
default.
Note: The unit ships from the factory with the backup
battery disabled to conserve battery power. Set this to
ON when you install the CPU.

Notes:
 Table 2-4 describes switch settings for ports on the SCB board. You
may want to review Section 2.4.3 before you set these switches.
 Table 2-4 applies to the following switches:
o SW1 on the SCB board – controls COM3
o SW2 on the SCB board – controls COM4
 COM4 is always an RS-485 port.

Table 2-4. SCB Port Configuration Switches (For COM3 use SW1, for COM4 use SW2)

SCB Function if this is an RS-232 Function if this is an RS-485 Port

SW1 or SW2 Port
Switch
Number
1 ON DTR to DSR Loopback (Use ON TX+ to RX+ Loopback (Use for
for Diagnostics only) Diagnostics or 2-wire only)
OFF No loopback (factory OFF No loopback (factory default)
default)
2 ON TXD to RXD Loopback (Use ON TX- to RX- Loopback (Use for
for Diagnostics only) Diagnostics or 2-wire only)

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ControlWave Instruction Manual (CI-ControlWave)

SCB Function if this is an RS-232 Function if this is an RS-485 Port

SW1 or SW2 Port
Switch
Number
OFF No loopback (factory OFF No loopback (factory default)
default)
3 Not currently used ON 100 Ohm RX+ termination (end
node)
OFF Not an end node (factory
default)
4 Not currently used ON 100 Ohm RX- termination (end
node)
OFF Not an end node (factory
default)
5 ON RTS to CTS Loopback (Use Not currently used
for Diagnostics only)
OFF No loopback (factory
default)
6 Not currently used ON (Fast slew rate enabled)
OFF (Slow slew rate enabled) (factory
default)

7 Not currently used ON RX+ bias (end node)

OFF Not an end node (factory
default)
8 Not currently used ON RX- bias (end node)
OFF Not an end node (factory
default)

After you set the DIP switches and insert the CPU module in slot #2 of
the housing, you can connect communication ports.

2.4.2 Connections to RS-232 Serial Port(s)

An RS-232 port provides point-to-point, half-duplex and full-duplex
communications (for a maximum of 20 feet using data quality cable).
The standard CPU module includes two RS-232 ports. If you purchased
your CPU module with a secondary communication board (SCB) you
may have one additional RS-232 port, depending upon the type of SCB.

RS-232 COM RS-232 COM ports are assigned names based on their location in the
Port Names and ControlWave. The CPU board has two RS-232 ports (COM1 and
Connectors COM2). See Table 2-5.

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Table 2-5. RS-232 Connectors on CPU Board

Connector Name Function Notes

J2 COM1 9-pin male D-sub (RS-232) See Figure 2-10 & Table 2-7
J3 COM2 9-pin male D-sub (RS-232) See Figure 2-10 & Table 2-7

If you purchased an SCB board, it may include an RS-232 port. If

present, the RS-232 port on the SCB is COM3 and it has a different type
of connector than that used for COM1 or COM2.

Note: COM3 on the secondary communication board (SCB) can be

ordered as an RS-485 port, in which case it will not function as
an RS-232 port.

Table 2-6. RS-232 Connectors on Secondary Communications Board (SCB)

Connector Name Function Notes

J2 COM3 8-pin RJ-45 (RS-232) See Figure 2-11 & Table 2-8

RS-232 COM For the ControlWave, half-duplex communications use BSAP protocol
Port Cables or another protocol such as Modbus, while full-duplex communications
use point-to-point protocol (PPP). RS-232 ports use a “null modem”
cable (see Figure 2-12) to connect with other devices (such as a PC, a
printer, another ControlWave [except the CW_10/30/35]) when the
ControlWave uses the full-duplex PPP protocol.
If you don’t want to make your own cables, as described in this section,
you can purchase cables.
 You can purchase a null modem cable using part number 392843-
01-3.
 For RJ-45 connectors (for example COM3 on the SCB) you can
purchase RJ45 to DB9 Adapter cable(s) using part number 392844-
01-0 to use with the null modem cable.

Note: You can configure the ControlWave as either a master or slave

node on a BSAP network.
Figure 2-10 illustrates the CPU module’s male 9-pin D-type connector.
Use the content provided in Table 2-7 to determine pin assignments for
the COM1 and COM2 ports.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 2-10. Male DB9 9-Pin Connector

Table 2-7. COM1 & COM2 RS-232 Port Connector Pin Assignment

RS-232
Pin Signal RS-232 Description
1 DCD Data Carrier Detect Input
2 RXD Receive Data Input
3 TXD Transmit Data Output
4 DTR Data Terminal Ready Output
5 GND Signal/Power Ground
6 DSR Data Set Ready Input
7 RTS Request to Send Output
8 CTS Clear to Send Input
9 RI Ring Indicator

Figure 2-11 shows the RJ-45 connector used for COM3 on the SCB. If
you ordered COM3 as an RS-232 port, see Table 2-8 for pin
assignments.

Figure 2-11. RJ-45 Connector Associated with COM3 (SCB)

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 ControlWave Instruction Manual (CI-ControlWave)

Table 2-8. COM3 (on SCB) RS-232 Port Connector Pin Assignment

RS-232
Pin Signal RS-232 Description
1 DCD Data Carrier Detect Input
2 DSR Data Set Ready Input
3 RXD Receive Data input
4 RTS Request to Send Output
5 TXD Transmit Data Output
6 CTS Clear to Send Input
7 DTR Data Terminal Ready Output
8 GND Signal/Power Ground

Use the “null modem” cable for full-duplex (PPP protocol)

communications when connecting a ControlWave to a PC. (See top part
of Figure 2-12.)
CW or PC CW
9-Pin Female 9-Pin Female
“D” Connector “D” Connector
P1 P2 Full-duplex
5 = GND
To P2 Pin-5 1 = DCD (Null Modem)
6 = DSR
4 = DTR
To P2 Pin-6 2 = RXD
7 = RTS
Cable
8 = CTS
3 = TXD
7 = RTS
To P2 Pin-2 3 = TXD (PPP Protocol)
2 = RXD
To P2 Pin-1 or 8 = CTS
4 = DTR
To P2 Pin-3
6 = DSR
To P2 Pin-4 vice
1 = DCD
To P2 Pin-7 versa 5 = GND
P/N 392843-01-3

CW CW
9-Pin Female 9-Pin Female
“D” Connector “D” Connector
P1 P2
5 = GND 1 = DCD
To P2 Pin-5
6 = DSR
4 = DTR
8 = CTS
2 = RXD
7 = RTS Half-duplex
3 = TXD 3 = TXD
7 = RTS
To P2 Pin-2
or 8 = CTS Cable
2 = RXD 4 = DTR
6 = DSR
To P2 Pin-3
vice (for CW)
5 = GND
1 = DCD versa

Figure 2-12. Full-duplex and Half-duplex Cable

Use the half-duplex cable (shown in the bottom part of Figure 2-12)
when connecting the ControlWave to another ControlWave series unit
(again, with the exception of the CW_10/30/35 units).
When communicating with a Network 3000 series RTU 3305, RTU
3310, DPC 3330, or DPC 3335 or CW_10/30/35, you must use one of
the cables shown in Figure 2-13.

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ControlWave Instruction Manual (CI-ControlWave)

3305/3310/3330/3335/CW_10/30/35 CW
9-Pin Male 9-Pin Female
“D” Connector “D” Connector
P1 P2
1 = DTR 1 = DCD
To P2 Pin-1
6 = CTS
2 = TXD
7 = DCD
To P2 Pin-2 2 = RXD Full-duplex
To P2 Pin-4 7 = RTS
3 = TXD Cable
8 = CTS
4 = RXD
9= GND
To P2 Pin-3
To P2 Pin-5
4 = DTR
(PPP Protocol)
5 = RTS 5 = GND

3305/3310/3330/3335/CW_10/30/35 CW
9-Pin Male 9-Pin Female
“D” Connector “D” Connector
P1 P2
1 = DTR 1 = DCD
6 = CTS
2 = TXD 2 = RXD
To P2 Pin-2
7 = DCD
3 = TXD
7 = RTS Half-duplex
4 = RXD
9 = GND
To P2 Pin-3
8 = CTS
4 = DTR
Cable
To P2 Pin-5
5 = RTS 5 = GND

Figure 2-13. Full-duplex and Half-duplex Cable

To connect to a modem or radio, use the cable configuration shown in

Figure 2-14.
1 = DCD
To DCD
2 = RXD
PSTN Modem
To RXD
To/From 3 = TXD 7 = RTS Intf.
To TXD
MODEM 4 = DTR
8 = CTS Cable
To DTR

CW
5 = GND
To GND

9-Pin Female
“D” Connectors
1 = DCD

To/From
To RXD
To RTS
2 = RXD
7 = RTS PL Modem
3 = TXD
RADIO
To TXD
To CTS
8 = CTS or Radio
5 = GND
4 = DTR
Intf.
To GND
Cable

Figure 2-14. Connecting to a Modem or Radio

When COM3 on the secondary communications board (SCB) is an RS-

232 port, you use an RJ-45 connector to connect to other devices. See
Figure 2-15.
P2
P1 Pin 1 (Wht/Grn Stripe) to Pin 1 = DCD
CW Pin 2 (Wht/Blu Stripe) to Pin 6 =
Pin 3 (Blu/Wht Stripe) to Pin 2 =
DSR/RX+
RXD/RX-
(COM3) Pin 4 (Grn/Wht Stripe) to Pin 7 = RTS
Pin 5 (Wht/Org Stripe) to Pin 3 = TXD/TX-
Pin 6 (Wht/Brn Stripe) to Pin 8 = CTS
Pin 7 (Orn/Wht Stripe) to Pin 4 = DTR/TX+
8-Pin Pin 8 (Brn/Wht Stripe) to Pin 5 = GND
RJ45 9-Pin Male
Plug “D” Connector
(Looking into Connector Intf. Side of P1)
(Looking into Wire Terminal Side of P2)

Figure 2-15. COM3 (on SCB) RS-232 Cable Diagram (RJ-45 connector)

RS-232 Cable Observe the following guidelines when constructing RS-232

Guidelines communication cables:

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 ControlWave Instruction Manual (CI-ControlWave)

 Ensure that DCD is high to transmit

 Set CTS to high to transmit.
 If the port is set for full-duplex operation, RTS is always ON.
 Ensure that DTR is always high when port is active

Note: Control DTR using the PORTCONTROL function block and

the _Pn_AUTO_DTR system variable in your ControlWave
project. If you turn DTR off through these mechanisms, the
port remains off, even though hardware is fully configured.
 When port is set for half-duplex operation, CTS must go low after
RTS goes low.
 All RS-232 comm ports are protected by surge protectors (to 8KV
ESD).

2.4.3 Connections to RS-485 Serial Port(s) on the Secondary

Communication Board (SCB)
The RS-485 port supports local network communications to multiple
nodes up to 4000 feet away.
If you purchased your CPU module with a secondary communication
board (SCB) you may have either one or two RS-485 ports.
RS-485 COM RS-485 COM ports are assigned names based on their location in the
Port Names and ControlWave.
Connectors
 COM3 on the SCB board can be purchased as either an RS-232 port,
or as an RS-485 port.
 COM4 on the SCB board is always an RS-485 port.
Table 2-9. RS-485 Connectors on SCB

Connector Name Function Notes

J2 COM3 8-pin RJ-45 (RS-485) See Figure 2-11 & Table 2-10
J3 COM4 9-pin male D-sub (RS-485) See Figure 2-10 & Table 2-11

RS-485 COM Figure 2-10 illustrates the CPU module’s male 9-pin D-type connector.
Port Cables Use the content provided in Table 2-12 to determine pin assignments for
the COM3 port on the CPU, and COM5/9, COM6/10, and COM7/11
expansion communication ports.

Table 2-10. RS-485 COM3 Port (RJ-45) Connector Pin Assignment

RS-485
Pin Signal RS-485 Description
1
2 RXD+ Receive Data + Input

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ControlWave Instruction Manual (CI-ControlWave)

RS-485
Pin Signal RS-485 Description
3 RXD- Receive Data – Input
4
5 TXD- Transmit Data – Output
6
7 TXD+ Transmit Data + Output
8 ISOGND Isolated Ground

Table 2-11. RS-485 COM4 Port (Male DB9) Connector Pin Assignment

RS-485
Pin Signal RS-485 Description
1
2 RXD- Receive Data - Input
3 TXD- Transmit Data - Output
4 TXD+ Transmit Data + Output
5 ISOGND Isolated Ground
6 RXD+ Receive Data + Input
7
8
9

Since the RS-485 port is intended for network communications, refer to

Table 2-12 for the appropriate connections for wiring the master, first
slave, and nth slave.
Essentially, the master and the first slave transmit and receive data on
opposite lines; all slaves (from the first to the nth) are paralleled (daisy-
chained) across the same lines. Wire the master node to one end of the
RS-485 cable run using a 24-gauge paired conductor cable (such as a
Belden 9843).

Note: ControlWave only supports half-duplex RS-485 networks.

Table 2-12. RS-485 Network Connections

From Master To First Slave To nth Slave

TXD+ RXD+ RXD+
TXD– RXD– RXD–
RXD+ TXD+ TXD+
RXD– TXD– TXD–
ISOGND ISOGND ISOGND

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 ControlWave Instruction Manual (CI-ControlWave)

To ensure that the “Receive Data” lines are in a proper state during
inactive transmission periods, you must maintain certain bias voltage
levels at the master and most distant slave units (end nodes). These end
nodes also require the insertion of 100Ω terminating resistors to
properly balance the network.
You must also configure secondary communication board switches at
each node to establish proper network performance. Accomplish this by
configuring switches listed so that the 100Ω termination resistors and
biasing networks are installed at the end nodes and are removed at all
other nodes on the network. You enable receiver biasing and
termination using SCB switch SW1 (for COM3) and SCB switch SW2
(for COM4). See Table 2-4 in Section 2.4.1 Setting DIP Switches on the
CPU Modules for information on RS-485 termination and loopback
control switch settings.

2.4.4 Connections to Ethernet Port(s) on the CPU Module

The ControlWave can support from one to three Ethernet ports. These
use a 10/100Base-T RJ-45 modular connector that provides a shielded
twisted pair interface to an Ethernet hub. Two LEDs per port provide
transmit and receive status indications:
Table 2-13 shows port assignments for the Ethernet ports.

Table 2-13. Ethernet Ports

Connector Name Function Notes

J4 on CPU Ethernet Port 1 8-pin RJ-45 (RS-485) – Shielded Twisted
board Pair 10/100Base-T
J5 on SCB Ethernet Port 2 8-pin RJ-45 (RS-485) – Shielded Twisted Requires SCB board
board Pair 10/100Base-T
J6 on SCB Ethernet Port 3 8-pin RJ-45 (RS-485) – Shielded Twisted Requires SCB board
board Pair 10/100Base-T

A typical Ethernet hub provides eight 10/100Base-T RJ-45 ports (with

port 8 having the capability to link either to another hub or to an
Ethernet communications port). Both ends of the Ethernet twisted pair
cable are equipped with modular RJ-45 connectors.
1 8

Looking into
receptacle

Figure 2-16. RJ-45 Ethernet Connector

These cables have a one-to-one wiring configuration as shown in Figure

2-17. Table 2-14 provides the assignment and definitions of the 8-pin
Revised May-2013 Installation 2-29
ControlWave Instruction Manual (CI-ControlWave)

10/100Base-T connectors.

Figure 2-17. Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)

Table 2-14. Ethernet 10/100Base-T CPU Module Pin Assignments

Pin Description
1 Transmit Data+ (Output)
2 Transmit Data– (Output)
3 Receive Data+ (Input)
4 Not connected
5 Not connected
6 Receive Data– (Input)
7 Not connected
8 Not connected

Note: You can swap TX and RX at the hub.

You can connect two nodes in a point-to-point configuration without

using a hub. However, you must configure the cable so that the TX+/-
Data pins connect to the RX+/- Data pins (swapped) at the opposite
ends of the cable (see Figure 2-18).

Figure 2-18. Point-to-Point 10/100Base T Ethernet Cable

The maximum length of one segment (CPU to hub) is 100 meters (328
feet). The use of Category 5 shielded cable is recommended.

2.5 Bezels
The bezel is a blue plastic cover (see Figure 2-19) that protects the CPU
and PSSM modules. Another function of the bezel is to let you route
bundled wires and cables downward between the modules and the bezel.
The factory ships a version of the bezel appropriate to the options you
ordered.
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 ControlWave Instruction Manual (CI-ControlWave)

You should install the bezel whenever the ControlWave is operational.

The bezel includes a door you can open to access the PSSM and CPU
modules. If necessary, you can remove the bezel for maintenance
procedures.
To install the bezel, align the snaps on the bezel with the corresponding
holders on the chassis. Once you have it positioned, push gently and the
bezel snaps into place.
To remove the bezel, gently grasp its sides and pull out and away from
the chassis.

Figure 2-19. Bezel Assembly

Revised May-2013 Installation 2-31

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 ControlWave Instruction Manual (CI-ControlWave)

Chapter 3 – I/O Modules

This chapter discusses the placement and wiring for I/O modules in the
ControlWave. The chapter begins with some general instructions on
module installation and wiring guidelines that are common to most I/O
modules. The balance of the chapter includes specific details for
configuring and wiring each type of I/O module.
In This Chapter

3.1 Module Placement ...........................................................................3-3

3.2 Status LEDs .....................................................................................3-4
3.3 Wiring ...............................................................................................3-4
3.2.1 Local Termination .................................................................3-5
3.2.2 Remote Termination .............................................................3-6
3.2.3 Shielding and Grounding ......................................................3-6
3.4 Digital Input (DI) Modules ................................................................3-8
3.5 Digital Output (DO) Modules .........................................................3-13
3.6 Analog Input (AI) Modules .............................................................3-19
3.7 Analog Output (AO) Modules ........................................................3-24
3.8 Universal Digital Input (UDI) Modules ...........................................3-29
3.9 Isolated Resistance Temperature Device (RTD) Input Module.....3-35
3.10 Isolated Low Level Analog Input (LLAI) Module ............................3-39

Installation Installing any I/O module in the ControlWave involves the same basic
steps:
1. Remove the I/O module from the shipping carton. I/O modules
include a removable terminal housing assembly. This assembly has
a door that swings downward to provide access to the unit’s terminal
handle you can use to remove an installed I/O module once you
loosen the captured panel fasteners.

Note: Modules normally ship from the factory completely

assembled.
2. Turn the terminal block’s quarter turn fasteners (counterclockwise)
and remove the terminal housing assembly from the I/O module (see
Figure 3-1).
3. Wire the modules according to instructions for each individual
module, included later in this chapter. I/O modules support local
terminations (field wiring connected directly to the I/O module’s
terminal block PCB) or remote terminations (field wiring connected
to a remote DIN-rail mounted terminal block assembly). See Section
3.2.1 for information on local termination wiring and Section 3.2.2
for information on remote termination wiring.
4. Align the I/O module with the assigned I/O slot and gently push the
module into the chassis. When the assembly is fully seated, turn the
I/O module’s captured panel fasteners (clockwise) to secure the unit

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ControlWave Instruction Manual (CI-ControlWave)

to the chassis; this establishes a low resistance path between the I/O
module and chassis ground.
5. Install the local or remote terminal block assembly (with wiring
harness) onto the I/O module (turning the quarter turn fasteners
(clockwise)).
6. Replace the module’s terminal housing assembly.

Figure 3-1. Terminal Housing Assembly Removal

7. Using a PC running the ControlWave Designer and OpenBSI
software, configure the ControlWave to accept the new I/O modules
and download the revised ControlWave project.

Note: This step is beyond the scope of this manual. Refer to the
ControlWave Designer Programmer’s Handbook (D5125)
for further instructions.

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 ControlWave Instruction Manual (CI-ControlWave)

Caution The ControlWave process automation controller supports “hot

swapping” of I/O modules, but before any I/O modules can become
operational, you must use ControlWave Designer to configure the
project to accept the new I/O module, and then compile and download
the revised application (project).

Do not install any modules in the housing until you have mounted and
grounded the housing at the designated installation site.
To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:
 Supplement Guide - ControlWave Site Considerations for
Equipment Installation, Grounding, and Wiring (S1400CW)
 ESDS Manual – Care and Handling of PC Boards and ESD
Sensitive Components (S14006)

NEVER ATTEMPT “hot swapping” in a Class I, Division 2

WARNING hazardous location.

3.1 Module Placement

You can place I/O modules in the housing:
 6-slot housing: supports up to four I/O modules in slots 3 through 6.
 10 slot housing: supports up to eight I/O modules in slots 3 through
10.
Note: Interrupt driven I/O modules, such as the Universal Digital Input
(UDI) cannot reside in slots 7 through 10 of the 10 slot housing.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 3-2. ControlWave Chassis Slot Assignments (with/without bezel

shown)

3.2 Status LEDs

Most of the I/O modules include one or more light emitting diodes
(LEDs) to provide diagnostic or status indications.
See Chapter 5 for information on the different LEDs.

3.3 Wiring
With a few exceptions (noted in the module descriptions), I/O modules
support either “local termination” (field wiring connected directly to the

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 ControlWave Instruction Manual (CI-ControlWave)

module’s removable terminal blocks) or “remote termination” (field

wiring connected to the remote headers under the module’s cover and
routed to a DIN-rail mounted terminal assembly and then to field
devices).
ControlWave I/O modules use compression-type terminals that
accommodate up to #14 AWG wire. Insert the wire’s bared end (approx.
¼” max) into the clamp beneath the screw and secure the wire. To
prevent shorts, ensure that no bare wire is exposed. If using standard
wire, tin the bare end with solder to prevent flattening and improve
conductivity. Allow some slack in the wires when making terminal
connections. Slack makes the wires more manageable and helps
minimize mechanical strain on the terminal blocks.

3.2.1 Local Termination

For I/O modules equipped with local terminal blocks, install the field
wiring between the I/O module’s removable terminal block connectors
and field devices (see Figure 3-3). Use AWG 14 or smaller wire
(consult with the field device manufacturer for recommendations).
Leave some slack and plan for wire routing, identification, and
maintenance. Route the bundled wires out through the bottom of the I/O
module assembly between the terminal block and the terminal housing.

Figure 3-3. I/O Module (Local Termination) Wire Routing

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ControlWave Instruction Manual (CI-ControlWave)

3.2.2 Remote Termination

For I/O modules that support remote terminations, install cables
between the module’s remote headers and the remote DIN-rail mounted
terminal block assemblies (see Figure 3-4). Install field wiring between
the DIN-rail mounted terminal bock assembly and field devices (see the
wiring diagrams associated with each I/O module description).
Use AWG 14 or smaller wire (consult with the field device
manufacturer for recommendations) for remote terminations. Leave
some slack and plan for wire routing, identification, and maintenance.
Route the cables running between the I/O module and the DIN-rail
mounted terminal blocks out through the bottom of the I/O module
between the header block and the terminal housing assembly.
To provide access to the header block’s lower ¼ turn fastener use a
tie wrap to secure cables associated with connectors P3 and P4 to the
lower left side of the header block assembly. Use a second tie wrap to
secure cables for connectors P1 and P2 to the lower right side of the
header block assembly.

3.2.3 Shielding and Grounding

Use twisted-pair, shielded and insulated cable for I/O signal wiring to
minimize signal errors caused by electromagnetic interference (EMI),
radio frequency interference (RFI), and transients. When using shielded
cable, ground all shields at only one point in the appropriate system.
This prevents circulating ground current loops that can cause signal
errors.

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 3-4. I/O Module (Remote Termination) Wire Routing

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ControlWave Instruction Manual (CI-ControlWave)

3.4 Digital Input (DI) Modules

DI modules provide 16 or 32 digital inputs. Using jumpers, you can
individually configure each input as either externally sourced or
internally powered using an internal +21Vdc power supply (dry
contacts).

Note: Early versions of ControlWave DI modules required you to

specify either internal or external sourcing for all DIs when you
ordered the module; now you can set this yourself using jumpers
on a per DI basis.
Table 3-1 DI Module General Characteristics
Type Number Characteristics
Supported
Digital Inputs (DI) 16 or 32 Each DI supports/ includes:
 Nominal input voltage of 24Vdc at 5
mA.
 Jumper to configure choice of either:
externally sourced input - or -internally
powered dry contact using internal
+21 Vdc power supply.
 Nominal input current of 5 mA
 30 ms input filtering
 Dedicated LED on module turns ON
when DI is ON
A DI module consists of a digital input printed circuit board (PCB) with
either a terminal block assembly (for local termination) or a header
block assembly (for remote termination). Each DI module also includes
an LED board, as well as I/O assembly and mounting hardware. The DI
PCB connects to the backplane using a 110-pin connector.
Detailed Technical For detailed technical specifications, please see document CWPAC
Specifications available on our website http://www.emersonprocess.com/remote.

Configurations DI modules (general part number 396357-XX-X) come in several

different configurations. See Table 3-2 to see the variations.

Table 3-2 DI Module Configurations

Part Number Number of DIs Termination Connector
396357-01-6 32 Local
396357-02-4 16 Local
396357-11-3: 32 Remote
396357-12-1 16 Remote

Isolation Surge suppressors and optocouplers electrically isolate the DI field

circuitry from the module’s bus interface circuitry. Inputs configured

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 ControlWave Instruction Manual (CI-ControlWave)

for use in dry contact applications contain a +21 Vdc isolated power
supply powered through an output of the hot swap circuitry which
receives power originating on the backplane.

Setting Jumpers You must set configuration jumpers for each DI. according to Table 3-
3. For a 16DI module, use W1 through W16, for a 32DI module, use
W1 through W32.

Figure 3-5. DI Module -Right Side View - Jumper Locations

Table 3-3. Jumper Assignments: DI Module
Jumper Purpose Description
WI Configures DI1 Pins 2-3 & 4-5 installed = External Power DI
Pins 1-2 & 3-4 installed = Internal Source DI
W2-W32 Configures DI2 through DI32 (respectively) Same as W1

Wiring the Module Figure 3-6 shows field wiring assignments associated with locally
terminated DI modules; Figure 3-9 shows field wiring assignments
associated with remotely terminated DI modules. Figure 3-10 shows
an optional remote termination module with built-in discrete relay
module that supports input from 120 Vac DIs. The special remote
termination module (with built-in discrete relay module) interfaces
with an externally sourced DI module.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 3-6. DI Module - Local Terminal Block Assembly Assignments

Figure 3-7. Internally Sourced DI Module - Wiring Diagram

Figure 3-8. Externally Powered DI Module - Wiring Diagram

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 ControlWave Instruction Manual (CI-ControlWave)

FUSES: F0 to F7: 1/8A, F+: 2A

Figure 3-9. Remote DIN-Rail Mountable Terminal Block Assembly
Assignments
Software Configuration To use data from any ControlWave DI module you must add a
CW_DI32 board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for this module.

Revised May-2013 I/O Modules 3-11

ControlWave Instruction Manual (CI-ControlWave)

Figure 3-10. Remote DIN-Rail Mountable Terminal Block Assembly

Assignments for Relay Isolated 120Vac DI Operation

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 ControlWave Instruction Manual (CI-ControlWave)

3.5 Digital Output (DO) Modules

DO modules provide 32 or 16 DOs to control signaling functions.
DO modules consist of a DO PCB with either a terminal block assembly
(for local termination) or a header block assembly (for remote
termination). DO modules also include an LED board, a terminal
housing assembly, as well as I/O assembly and mounting hardware.
Table 3-4 DO Module General Characteristics
Type Number Characteristics
Supported
Digital Outputs 32 or 16 Each DO supports/ includes:
(DO)  Optically isolated open source
MOSFET with surge suppression that
is capable of handling 500mA at 31V.
 Maximum operating frequency of 20
Hz.
 Dedicated LED on module turns ON
when DO is ON.

Detailed Technical For detailed technical specifications, please see document CWPAC
Specifications available on our website http://www.emersonprocess.com/remote.

Configurations The DO module (general part number 396358-XX-X) comes in several

possible configurations, see Table 3-5:
Table 3-5. Isolated DO Module Configurations
Part Number Number of Termination Notes
DOs Connector
396358-01-2 32 Local
396358-02-0 16 Local
396358-11-0 32 Remote
396358-12-8 16 Remote
396358-20-9 16 Remote DO with read-back

Outputs set OFF on An on-board DO load register stores output data. At power-up the load
power-up register clears and sets all outputs to “OFF.”

Digital Output with Newer digital output modules with 16 outputs support read-back
Readback capability for use in redundant systems. A DO with read-back module
operating in online mode monitors the DO values of its standby
counterpart in order to verify that standby DO values are consistent
should a failover occur. Depending upon software configuration
settings; a failover can be prevented if they are inconsistent. A
standard DO module used in a redundant system does not perform this
monitoring; therefore the potential exists to failover to a backup DO

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ControlWave Instruction Manual (CI-ControlWave)

module with failed hardware. For critical processes, the redundant DO

with read-back capability is recommended.
Use the same DO module type in any redundant pair; do not install a
DO with read-back module in the primary controller and a standard
DO module as its redundant counterpart in the backup controller, or
vice versa.
See Software Configuration later in this section for details on setting
up DO with readback.
Wiring the Module Figure 3-11 shows field wiring assignments associated with a locally
terminated DO module; Figure 3-12 shows a wiring diagram for the
DO. Field wiring assignments associated with remotely terminated DO
modules. Figure 3-13 shows field wiring assignments for a remotely
terminated DO module. Figure 3-14 shows a special remote
termination module with built-in discrete relay modules.

Figure 3-11. Local Terminal Block Assembly Assignments for Open

Source Isolated DO Operation

Figure 3-12. Open Source Isolated DO Module - Wiring Diagram

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 ControlWave Instruction Manual (CI-ControlWave)

FUSES: F0 to F7: 1A, F+: 2A

Figure 3-13. Remote DIN-Rail Mountable Terminal Block Assembly
Assignments for Open Source Isolated DO Operation

Revised May-2013 I/O Modules 3-15

ControlWave Instruction Manual (CI-ControlWave)

Figure 3-14. Remote DIN-Rail Mountable Terminal Block Assembly

Assignments for Relay Isolated 24Vdc DO Operation

Software Configuration To use data from any ControlWave DO module you must add a
CW_DO32 board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
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 ControlWave Instruction Manual (CI-ControlWave)

Handbook (D5125) for more information. That same manual includes

an I/O Mapping section that describes, for advanced users, the I/O map
for this module.

DO with Readback in a Redundant System

Variables in the ControlWave project govern how inconsistencies
between the online DO module and the standby DO module are
handled in redundant systems with DO readback. Information on
configuring system variables is included in the ControlWave Designer
Programmer’s Handbook (D5125).
If there is a discrepancy between the value of the online and standby
DOs, the system sets a status variable to TRUE. For local I/O boards,
this is a system variable that follows the format:
_RDN_IO_n_ERR
where n is the I/O slot number of the DO module in the backup unit
that has a failure.
For boards residing in an I/O expansion rack, instead of a system
variable, a variable mapped by the _ER_STAT virtual status board
provides this indication. By default, the name of the variable follows
one of two possible formats.
ERSTAT_n_RDN_IO_x_ERR
ERST_n_RDN_IO_x_ERR
where n is the I/O slot number of the virtual ER_STAT board, and x is
the I/O slot number of the digital output module. See the I/O
Configurator and I/O Mapping sections of the ControlWave Designer
Programmer's Handbook (D5125) for more information. You can
optionally rename these variables.
You should configure these variables as alarms so you receive
notification of a failure of the backup DO module. See the
ControlWave Designer online help for information on alarm
configuration.
When a read-back failure occurs, the FAIL LED remains RED until the
unit reboots, either through a sideload, forced redundant switchover, or
power-down and restart, or you remove and replace the board (hot card
replacement). Each of these operations momentarily turns the FAIL
LED to GREEN (and the associated _ERR error variable to FALSE)
until a new readback failure occurs, which changes the LED back to
RED, and the associated _ERR error variable back to TRUE.
For boards installed locally in the controller (local I/O), another system
variable (_RDN_IOERR_WARN) determines whether a failure of the
standby DO (as indicated by the LED and associated _ERR error
variable) should only be treated as a warning condition, which would
still allow a failover to occur, or as an error which would prevent a

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ControlWave Instruction Manual (CI-ControlWave)

failover to the standby.

When you set this system variable to FALSE, the system treats a DO
readback failure in the associated device as an error; failover is
inhibited. When you set this variable to TRUE, the system treats a DO
readback failure in the associated device as a warning that does not
prevent a failover, and the only reporting is via the _RDN_IO_x_ERR
system variables and LEDs discussed, above.
For boards residing in an I/O expansion rack, instead of a system
variable for this purpose, you must map a variable from the
_ER_STAT virtual status board named either
ERSTAT_RDN_IOERR_WARN (or ERST_RDN_IOERR_WARN).
NOTE: Those are the default names, you can change them as needed.

Note: In the I/O Configurator, you must associate these boards with a
cyclic task, and the task must not run faster than 10
milliseconds.

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 ControlWave Instruction Manual (CI-ControlWave)

3.6 Analog Input (AI) Modules

AI modules support either 16 or eight 4–20 mA or 1–5 Vdc analog
inputs.
AI modules consist of an AI PCB with either a terminal block assembly
(for local termination) or a header block assembly (for remote
termination). AI modules also include an LED board, a terminal housing
assembly, as well as I/O assembly and mounting hardware.

Table 3-6 Analog Input (AI) Module General Characteristics

Type Number Characteristics
Supported
Analog Inputs 16 or 8 Each AI supports:
(AI)  Either 4–20mA internally sourced input
or 1–5Vdc isolated input operation.
Choice for whether the module
supports 4-20mA or 1-5Vdc is set at
the factory.
 1-5Vdc AIs have a common mode
range of 31Vdc.
 4-20mA inputs reference –VFxx of the
module.
 Analog input circuitry isolated from bus
interface.
 Surge suppression and signal
conditioning.

Cable Shields Connect cable shields associated with AI wiring to the ControlWave
housing ground. Multiple shield terminations require that you supply a
copper ground bus (up to a #4 AWG wire size) and connect it to the
housing’s ground lug.
This ground bus must accommodate a connection to a known good earth
ground (in lieu of a direct connection from the ground lug) and to all AI
cable shields. Shield wires should use an appropriate terminal lug.
Secure them to the copper bus using industry rugged hardware
(screw/bolt, lock washer, and nuts).
Detailed Technical For detailed technical specifications, please see document CWPAC
Specifications available on our website http://www.emersonprocess.com/remote.

Configurations The AI module (general part number 396352-XX-X) has the following
configurations:

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ControlWave Instruction Manual (CI-ControlWave)

Table 3-7 Analog Input Module Configurations

Part Number Number of AIs Termination Notes

Connector
396352-01-4 16 Local 4-20 mA
396352-03-0 8 Local 4-20 mA
396352-11-1 16 Remote 4-20 mA
396352-13-8 8 Remote 4-20 mA
396352-14-6 8 Remote 1-5 Vdc

Wiring the Module Figure 3-18 shows terminal assignments for a locally terminated AI
module; Figure 3-19 and Figure 3-20 show terminal assignments for a
4-20mA and a 1-5Vdc remotely terminated AI, respectively.

Figure 3-15. Internally Sourced 4-20mA Current Loop AI - Wiring

Diagram

Figure 3-16. Externally Powered 4-20mA Current Loop AI - Wiring Diagram

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 3-17. Externally Powered Isolated 1-5 Volt AI - Wiring Diagram

Figure 3-18. Local AI Module Terminal Blocks Assembly Assignments

Software Configuration To use data from any ControlWave analog input module you must add
a CW_AI16 board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for this module.

Revised May-2013 I/O Modules 3-21

ControlWave Instruction Manual (CI-ControlWave)

FUSES: F0, F2, F4, F6: 1/8A

Figure 3-19. Remote DIN-Rail Mountable Terminal Block Assembly Assignments for 4-20 mA AI
Operation

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 ControlWave Instruction Manual (CI-ControlWave)

FUSES: F0, F2, F4, F6: 1/8A

Figure 3-20. Remote DIN-Rail Mountable Terminal Block Assembly Assignments for 1-5V AI
Operation

Revised May-2013 I/O Modules 3-23

ControlWave Instruction Manual (CI-ControlWave)

3.7 Analog Output (AO) Modules

AO modules support eight 4–20 mA analog outputs. AO modules
consist of an AO PCB (with a daughter board when configured for read-
back) an LED board, a terminal housing assembly, as well as I/O
assembly and mounting hardware.

Table 3-8 Analog Output (AO) Module General Characteristics

Type Number Characteristics
Supported
Analog Outputs 8 Each AO supports:
(AO)  4–20mA output with a maximum
external load of 650 ohms.
 Analog output circuitry isolated from
bus interface
 Surge suppression

Analog Output with Analog output modules with eight outputs are available in two versions
Read-back – standard AO, or AO with read-back capability for use in redundant
systems. Both versions may be used in redundant systems; however,
they operate differently.
An AO with read-back module operating in online mode monitors the
AO values of its standby counterpart in order to verify that standby AO
values are consistent should a failover occur. Depending upon software
configuration settings; a failover can be prevented if they are
inconsistent. A standard AO module used in a redundant system does
not perform this monitoring; therefore the potential exists to failover to
a backup AO module with failed hardware. For critical processes, the
redundant AO with read-back capability is recommended.
Use the same AO module type in any redundant pair – i.e. do not
install an AO with read-back module in the primary controller and a
standard AO module as its redundant counterpart in the backup
controller, or vice versa.
See Software Configuration later in this section for details on setting
up AO with readback.

Detailed Technical For detailed technical specifications, please see document CWPAC
Specifications available on our website http://www.emersonprocess.com/remote.

Configurations The isolated AO module (general part number 396353-XX-X) has the
following configurations:

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 ControlWave Instruction Manual (CI-ControlWave)

Table 3-9. Analog Output Module Configurations

Part Number Number of Termination Notes
AOs Connector
396353-01-0 8 local 4-20mA
396353-11-8 8 remote 4-20mA
396353-20-7 8 remote 4-20mA AO Readback
on this module

Wiring the Module Figure 3-21 shows field wiring assignments for a locally terminated
AO module. Figure 3-22 shows field wiring assignments for a
remotely terminated AO module.

Figure 3-21. Local AO Module Terminal Blocks Assembly Assignments

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ControlWave Instruction Manual (CI-ControlWave)

FUSES: F0, F2, F4, F6: 1/8A

Figure 3-22. Remote DIN-Rail Mountable Terminal Block Assembly Assignments for AO 4-20mA
Operation

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 3-23. 4-20mA Current Loop AO - Wiring Diagrams

Software Configuration To use data from any ControlWave analog output module you must
add a CW_AO8 board in ControlWave Designer’s I/O Configurator,
and then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for this module.
AO with Readback in a Redundant System
Variables in the ControlWave project govern how inconsistencies
between the online AO module and the standby AO module are
handled in redundant systems with AO readback. Information on
configuring system variables is included in the ControlWave Designer
Programmer’s Handbook (D5125).
If there is a difference of more than 0.5% (of span) between the value
of the online and standby AO values, a variable will be set TRUE. For
local I/O boards, this is a system variable that follows the format:

_RDN_IO_n_ERR
where n is the I/O slot number of the AO module.

For boards residing in an I/O expansion rack, instead of a system

variable, this indication is provided by a variable mapped by the
_ER_STAT virtual status board. By default, the name of the variable
follows one of two possible formats.
ERSTAT_n_RDN_IO_x_ERR
ERST_n_RDN_IO_x_ERR
where n is the I/O slot number of the virtual ER_STAT board, and x is
the I/O slot number of the analog output module. See the I/O
Configurator and I/O Mapping sections of the ControlWave Designer
Revised May-2013 I/O Modules 3-27
ControlWave Instruction Manual (CI-ControlWave)

Programmer's Handbook (D5125) for more information. You can

optionally rename these variables.
You should configure these variables as alarms so you receive
notification of a failure of the backup AO module. See the
ControlWave Designer online help for information on alarm
configuration.
When a read-back failure occurs, the FAIL LED remains RED until the
unit is rebooted, either through a sideload, forced redundant
switchover, or power-down and restart, or you remove and replace the
board (hot card replacement). Each of these operations momentarily
turns the FAIL LED to GREEN (and the associated _ERR error
variable to FALSE) until a new readback failure occurs, which will
change the LED back to RED, and the associated _ERR error variable
back to TRUE.
For boards installed locally in the controller (local I/O) another system
variable (_RDN_IOERR_WARN) determines whether a failure of the
standby AO (as indicated by the LED and associated _ERR error
variable) should only be treated as a warning condition, which would
still allow a failover to occur, or as an error which would prevent a
failover to the standby.
When you set this system variable to FALSE, an AO readback failure
in the associated device is treated as an error; failover is inhibited.
When you set this variable to TRUE, an AO readback failure in the
associated device is treated as a warning that does not prevent a
failover, and the only reporting is via the _RDN_IO_x_ERR system
variables and LEDs discussed, above.
For boards residing in an I/O expansion rack, instead of a system
variable for this purpose, you must have mapped a variable from the
_ER_STAT virtual status board named either
ERSTAT_RDN_IOERR_WARN (or ERST_RDN_IOERR_WARN).
NOTE: Those are the default names, you can change them as needed.

Note: In the I/O Configurator, you must associate these boards with a
cyclic task, and the task must not run faster than 10
milliseconds.

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3.8 Universal Digital Input (UDI) Modules

Universal Digital Input (UDI) modules include six inputs which you can
individually configure as high speed counters or polled inputs.
UDI modules consist of a UDI PCB, either a terminal board assembly
for local termination or a header block assembly for remote termination,
a terminal housing assembly, an LED board, as well as I/O assembly
and mounting hardware.

Note: Because UDI modules are interrupt driven, you can only install
them in the first four I/O slots.
Table 3-10. UDI Module General Characteristics

Type Number Characteristics

Supported
Universal Digital 6 Each UDI supports/includes:
Inputs (UDI)  Field input can be a driven signal, an
open collector output, or a relay
contact. Inputs handle 24V
 Jumper to configure point for debounce
enable or debounce disable.
 Software configures point as a polled
input with a 30 millisecond filter or as a
16-bit high speed counter (totalizer)
with a 20 microsecond filter.
 Maximum input frequency of 10 KHz
with a nominal input current of 5mA.
 16 bit counter.
 Signal conditioning circuitry and
bandwidth limiting circuitry. Software
selectable delays for signal
conditioning.
 Each input is optically isolated from the
field device.
 Each input has an electrical isolation of
500Vdc to chassis and 1500Vdc to
system logic.
 Surge protection. Protection from a
31dc transorb (across input and to
field common) that meets ANSI/IEEE
standard C37.90-1978.

Additional For additional technical specifications, please see document CWPAC

Technical available on our website http://www.emersonprocess.com/remote.
Specifications

Revised May-2013 I/O Modules 3-29

ControlWave Instruction Manual (CI-ControlWave)

Configurations The UDI module (general part number 396362-XX-X) has the following
configurations:

Table 3-11. UDI Module Configurations

Part Number Number of UDIs Termination Connector
396362-02-8 6 local
396362-12-5 6 remote

Setting Jumpers Each input has a jumper to enable/disable debounce. Enabling debounce
activates filters that reduce spurious pulses caused by relay contact bounce.
Figure 3-24 shows the location of jumpers on the module.
Jumper
1.820“ 6.457“ locations
6.970“

1 1
W5 W1
W6 W2
W7 W3
W8 W4
1 1

1 W9
W12
W11 W10
1 1

Terminal
Front Housing Ass’y. Right Side

Figure 3-24. - UDI Module -Right Side View -Jumper Locations

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 ControlWave Instruction Manual (CI-ControlWave)

Table 3-12. Jumper Assignments: UDI Module

Jumper Purpose Description
W1 Configures UDI1 Pins 1-2 installed = Enable Debounce (Factory default). A
change of state on both the SET and RST (reset) field
inputs is required to accumulate counts.
Pins 2-3 installed = Disable Debounce. A change of state
on the SET field input is required to accumulate counts.
W2 through Configures UDI 2 through UDI6 Pins 1-2 installed = Enable Debounce (Factory default). A
W6 change of state on both the SET and RST (reset) field
inputs is required to accumulate counts.
Pins 2-3 installed = Disable Debounce. A change of state
on the SET field input is required to accumulate counts.

Wiring the Module Figure 3-27 shows field wiring assignments for the locally terminated
UDI module. It also includes examples for relay contact and open
collector applications. Figure 3-28 shows field wiring assignments for
the remotely terminated UDI module.

Figure 3-25. UDI (Debounce Enabled) Wiring Diagram

Figure 3-26. UDI (Debounce Disabled) Wiring Diagram

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ControlWave Instruction Manual (CI-ControlWave)

Terminal Block Assembly Assignments

for FIELD Field
UDI Operation CIRCUITRY TB
HSCSET
1

+HSCSET1 +HSCSET2 HSCCOM

HSCCOM1 HSCCOM2
3
+HSCRST1 +HSCRST2 HSCRST
+HSCSET3 +HSCSET4 5
HSCCOM3 HSCCOM4
+HSCRST3
+HSCSET5
HSCCOM5
+HSCRST4
+HSCSET6
HSCCOM6
Relay Contact ‘A’
+HSCRST5 +HSCRST6
FIELD Field
CIRCUITRY TB
HSCSET
1
HSCCOM
3

Open Collector
or ‘B’
Relay Contact

Figure 3-27. Local UDI Terminal Block/Configuration Diagram

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 ControlWave Instruction Manual (CI-ControlWave)

Cable Assembly
(One of 2 Cables)
End of cable that interfaces with
Remote UDI Module’s
Header Block Assembly

End of cable that interfaces with

Remote UDI Module’s
DIN-Rail Mountable
Terminal Block Assembly

From P1 From P2

UDI1 - UDI3 UDI4 - UDI6

FUSE FUSE
F2 F6

FUSE FUSE
F0 F4

+ .0 .2 .4 .6 + 0 2 4 6 +

+ .1 .3 .5 .7 1 3 5 7

12/24V UDI 12/24V UDI

(without fuses) (with fuses)
A = Top TB A = Top TB
+ = N/A + = N/A
.0 = UDISET1 0 = UDISET4
.2 = UDIRST1 2 = UDIRST4
.4 = UDICOM2 4 = UDICOM5
.6 = UDISET3 6 = UDISET6
_
= UDIRST3 + = N/A
B = Bottom TB B = Bottom TB
+ = N/A _ = UDIRST6
.1 = UDICOM1 1 = UDICOM4
.3 = UDISET2 3 = UDISET5
.5 = UDIRST2 5 = UDIRST5
.7 = UDICOM3 7 = UDICOM6
_ _
= UDIRST3 = UDIRST6

FUSES: F0, F2, F4, F6: 1/8A

Figure 3-28. Remote DIN-Rail Mountable Terminal Block Assembly Assignments for UDI Operation

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ControlWave Instruction Manual (CI-ControlWave)

Software Configuration To use data from a UDI module you must add a CW_HSC12 board in
ControlWave Designer’s I/O Configurator, and then configure it.
The I/O Configurator is where you specify the usage for each input
using the Select Filter list box.

Figure 3-29. Selecting Input Type in ControlWave Designer I/O

Configurator
Choose one of the following:

“HSC Channel” to select a 20 microsecond delay for 10 kHz high

speed counter applications.
“1 MS” to select a 1 millisecond delay for a low speed
counter application.
“30 MS” to select a 30 millisecond delay for a polled
input. This is for general purpose inputs or
contacts where contact bounce may apply.

See the ControlWave Designer Programmer's Handbook (D5125) for

more information. That same manual includes an I/O Mapping section
that describes, for advanced users, the I/O map for this module.

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3.9 Isolated Resistance Temperature Device (RTD) Input Module

RTD Input modules provide a total of four inputs. Firmware detects the
RTD type (2-, 3- or 4 wire) via the installation of jumper wires on the
terminal block for 2-wire and 3-wire RTDs (see Figure 3-30).
Table 3-13. Isolated RTD Input Module General Characteristics
Type Number Characteristics
Supported
Isolated RTD 4 Each isolated RTD input
Input supports/includes:
 Signal conditioning circuitry
 Surge protection with a 25V transorb
that meets IEEE standard 472-1978
 Current limiting for over voltage
protection
 24-bit analog to digital converter (ADC)
 Common mode range of 500V with
respect to chassis
 Electrical isolation of 500Vdc (channel
to channel/system bus)
 Source current to RTD limited to 330
uA

The RTD Input Module consists of an isolated RTD input board, a

terminal board assembly (for local termination) or a header block
assembly (for remote termination), an LED board, a terminal housing
assembly, as well as I/O assembly and mounting hardware.
Detailed Technical For additional technical specifications, please see document CWPAC
Specifications available on our website http://www.emersonprocess.com/remote.

Configuration The isolated RTD module (general part number 396878-XX-X) has the
following configurations
Table 3-14. Isolated RTD Input Module Configurations
Part Number Termination Connector Notes
396878-01-6 local
396878-02-4 remote

Enabling/Disabling The Isolated RTD Module includes a jumper (W1) to enable/disable

LEDs using jumper LEDs on the module. Normally, you should keep the LEDs enabled,
but if power conservation is an issue, you could disable the LEDs.

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Table 3-15. Jumper Assignments: Non-isolated HSC Module

Jumper Purpose Description
W1 Enables/disables LEDs on Pins 1-2 installed = Enable LEDs (Factory default).
module Pins 2-3 installed = Disable LEDs

Wiring the Module Figure 3-31 shows field wiring assignments for locally terminated
isolated RTD modules. Figure 3-32 shows field wiring assignments for
remotely terminated isolated RTD modules.
Figure 3-30 provides wiring diagrams for 2-wire, 3-wire, and 4-wire
RTDs to the local RTD module terminal blocks; wiring assignments,
such as +RTD#_3/4W, -RTD#_4W, +RTD# and –RTD# are similar to
those assigned to the Remote DIN-rail mountable terminal blocks.

Note: To maintain specified accuracy with a 3-wire RTD, you must

match the two field wires that source and sink the RTD current
within 0.01 ohms (matched in length and matched in wire type)
and the ambient temperature on these wires must be the same.

Figure 3-30. Isolated RTD Module - 2-Wire, 3-Wire & 4-Wire Wiring Diagram

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 3-31. Local Isolated RTD Module Terminal Block Assembly Assignments

Software Configuration To use data from an Isolated RTD Input module you must add a
CWM_RTD8 board in ControlWave Designer’s I/O Configurator, and
then configure it. See the ControlWave Designer Programmer's
Handbook (D5125) for more information. That same manual includes
an I/O Mapping section that describes, for advanced users, the I/O map
for this module.

Revised May-2013 I/O Modules 3-37

ControlWave Instruction Manual (CI-ControlWave)

Figure 3-32. Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Isolated RTD
Module Operation

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3.10 Isolated Low Level Analog Input (LLAI) Module

Low Level Analog Input (LLAI) modules provide six individually
isolated differential inputs for thermocouples or 10mV inputs plus one
cold junction compensation (CJC) input for temperature compensation
at the terminal block.
Table 3-16. Isolated Low Level Analog Input (LLAI) Module General
Characteristics
Type Number Characteristics
Supported
Isolated Low 6 Each isolated LLAI supports/includes:
Level Analog  Signal conditioning circuitry including a
Input (LLAI) 2.5V reference
 Surge suppression with a 188V
Transorb that meets IEEE standard
472-1978.
 Over voltage protection
 Common mode range for each channel
is 500Vdc with respect to chassis.
 24-bit analog to digital converter (ADC)

Detailed Technical For additional technical specifications, please see document CWPAC
Specifications available on our website http://www.emersonprocess.com/remote.

Configuration The isolated LLAI module (general part number 396877-XX-X) has
the following configurations:
Table 3-17. Isolated Low Level Analog Input (LLAI) Module
Configurations
Part Number Termination Connector Notes
396877-01-0 local
396877-02-8 remote

Enabling/Disabling The Isolated LLAI Module includes a jumper (W2) to enable/disable

LEDs using jumper LEDs on the module. Normally, you should keep the LEDs enabled,
but if power conservation is an issue, you could disable the LEDs.

Table 3-18. Jumper Assignments: Isolated LLAI Module

Jumper Purpose Description
W2 Enables/disables LEDs on Pins 1-2 installed = Enable LEDs (Factory default).
module Pins 2-3 installed = Disable LEDs

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ControlWave Instruction Manual (CI-ControlWave)

Wiring the Module Figure 3-34 shows field wiring for locally terminated isolated LLAI
modules. Figure 3-35 shows field wiring for remotely terminated
isolated LLAI modules.
The cold junction compensation (CJC) with a built-in RTD provides
thermocouple temperature compensation at the terminal block and is
electrically isolated. Pins 8, 9 and 10 of the local terminal block source
and sink the CJC’s RTD.
Figure 3-35 also provides diagrams showing the wiring for
thermocouples and the 3-wire RTDs to a locally terminated LLAI
module. Wiring assignments (that is, +AI#, -AI#, +CJC (Sense), -CJC
(Return) & +CJC (Reference) are similar to those assigned to the remote
DIN-rail mountable terminal blocks. A small CJC PCB is factory-
installed to the terminal block.

Figure 3-33. Isolated LLAI Module - Thermocouple Wiring Diagram

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 3-34. Local Isolated LLAI Module Terminal Block Assembly Assignments

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ControlWave Instruction Manual (CI-ControlWave)

Figure 3-35. Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Isolated LLAI
Module Operation

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 ControlWave Instruction Manual (CI-ControlWave)

Ranges & Table 3-19 provides the accuracy, resolution and temperature range for
Errors the various thermocouples and 10mV LLAI inputs. Table 3-20 lists the
RTD error with the CJC.
Table 3-19. LLAI Module Input Accuracy and Resolution
Input Type Accuracy/Range Resolution 25C –20C to +70C
B – Thermocouple 100C to 200C 2.00C  8C  16C
200C to 390C 1.00C  4C  8C
390C to 840C 0.50C  2C  4C
840C to 1820C 0.20C  1C  2C
R – Thermocouple –50C to +50C 0.40C  2C  4C
+50C to 1720C 0.17C  1C  2C
S – Thermocouple – 50C to +50C 0.37C  2C  4C
+50C to 1760C 0.18C  1C  2C
C – Thermocouple 0C to 2315C 0.16C  0.75C  1.5C
N – Thermocouple – 270C to – 260C 1.50C  8C  10C
– 260C to – 250C 0.75C  4C  8C
– 250C to – 230C 0.50C  2C  4C
– 230C to – 150C 0.25C  1C  2C
– 150C to 1300C 0.09C  0.500C  1C
J – Thermocouple – 210C to 191C 0.08C  0.750C  1.5C
190C to 1200C 0.11C  0.500C  1C
E – Thermocouple – 270C to – 260C 1.00C  3C  6C
– 260C to – 225C 0.25C  1C  2C
– 225C to – 200C 0.08C  0.750C  1.5C
– 200C to 1000C 0.09C  0.500C  1C
K – Thermocouple – 270C to – 261C 2.00C  5C  10C
– 260C to – 246C 0.56C  2C  4C
– 245C to – 180C 0.25C  1C  2C
– 179C to – 145C 0.08C  0.750C  1.5C
– 145C to 1372C 0.14C  0.500C  1C
T – Thermocouple – 270C to – 261C 1.50C  4C  8C
– 260C to – 251C 0.38C  2C  4C
– 250C to – 181C 0.18C  1C  2C
– 180C to – 136C 0.08C  0.750C  1.5C
– 135C to – 400C 0.06C  0.500C  1C
 10mV  10mV 1.2V  0.25%  0.05%
Note: The CJC RTD adds an additional error (see Table 3-20)

Table 3-20. LLAI Module RTD Error with CJC at 25C

Thermocouple Process Temperature RTD Error with CJC
Type Range @ 25C
B 100C to 1820C  0.30C
R – 50C to +50C  0.49C
+50C to 1720C  0.30C
S – 50C to +50C  0.45C
+50C to 1760C  0.30C

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Thermocouple Process Temperature RTD Error with CJC

Type Range @ 25C
C 0C to 2315C  0.30C
N – 270C to – 261C  20.50C
– 260C to – 251C  5.00C
– 250C to – 231C  2.70C
– 230C to – 189C  1.40C
– 188C to – 70C  0.70C
– 70C to + 25C  0.35C
+25C to 1300C  0.30C
J – 210C to – 111C  0.80C
– 110C to +25C  0.40C
+25C to 1200C  0.30C
E – 270C to – 261C  10C
– 260C to – 245C  3C
– 244C to – 200C  1.50C
– 200C to – 87C  0.75C
– 86C to +25C  0.39C
+25C to 100C  0.30C
K – 270C to – 261C  15.00C
– 260C to – 247C  4.50C
– 246C to – 222C  2.20C
– 220C to – 160C  1.10C
– 159C to +25C  0.55C
+25C to 1372C  0.30C
T – 270C to – 261C  10.30C
– 260C to – 243C  3.00C
– 242C to – 196C  1.50C
– 195C to – 61C  0.75C
– 60C to +25C  0.375C
+25C to 400C  0.30C
Note: Use straight-line approximation to calculate approximate error between
end points.

Software Configuration To use data from an Isolated Low Level Analog Input module you
must add a CW_TC12 board in ControlWave Designer’s I/O
Configurator, and then configure it. See the ControlWave Designer
Programmer's Handbook (D5125) for more information. That same
manual includes an I/O Mapping section that describes, for advanced
users, the I/O map for this module.

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Chapter 4 – Operation
This chapter provides general operational details for using the
ControlWave.
In This Chapter

4.1 Powering Up/Powering Down the ControlWave ..............................4-1

4.2 Setting the Operating Mode (Run/Remote/Local Switch) ...............4-1
4.3 Communicating with the ControlWave ............................................4-2
4.3.1 Default Comm Port Settings .................................................4-2
4.3.2 Changing Port Settings ........................................................4-3
4.3.3 Collecting Data from the ControlWave .................................4-4
4.4 Creating and Downloading an Application (ControlWave Project) ..4-4
4.5 Creating and Maintaining Backups ..................................................4-5
4.5.1 Creating a Zipped Project File (*.ZWT) For Backup ............4-5
4.5.2 Saving Flash Configuration Parameters (*.FCP) .................4-7
4.5.3 Backing up Data ...................................................................4-8

4.1 Powering Up/Powering Down the ControlWave

Open the bezel door on the PSSM and use the power switch to turn the
ControlWave ON or OFF.

Power switch
1 = ON
O = OFF

Figure 4-1. Power Switch on PSSM

4.2 Setting the Operating Mode (Run/Remote/Local Switch)

Run/Remote/ You set the PSSM’s Run/Remote/Local switch using a removable key.
Local Switch You can remove this key when the switch is in any position to prevent
an unauthorized person from changing the operating mode.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 4-2. Run/Remote/Local Key Switch

Run prevents you from performing any ControlWave Designer debug

or program functions (start/stop, application downloads, etc.). Remote
and Local functions depend on how you configured the communication
port in ControlWave Designer (serial, IP, or OpenBSI).
 IP/OpenBSI (BSAP): If you configure the communication port for
either of these choices in ControlWave Designer it becomes a
remote port: set the Run/Remote/Local switch to Remote for
downloads.
 Serial: If you configure the communication port for serial in
ControlWave Designer, it becomes a local port: set the
Run/Remote/Local switch to Local for downloads.

Note: Setting the Run/Remote/Local switch to Local enables

communications through any comm port. However, if you
set the switch to Remote, that restricts communications only
to comm ports configured as remote comm ports.

4.3 Communicating with the ControlWave

You communicate to the ControlWave by connecting a cable between a
port on your PC workstation and one of the ControlWave ports. See
Section 2.4 for more information on communications.
The port at the PC workstation must match the configuration of the
ControlWave port.

4.3.1 Default Comm Port Settings

As delivered from the factory, ControlWave communication ports have
default settings. Table 4-1 details these defaults.

Table 4-1. Default Comm Port Settings (by PCB)

Port PCB Default Configuration

COM1 CPU Ships from factory at RS-232; 115.2 Kbps using BSAP. Once
the default switch is OFF, a factory default of IP Point-to-Point
protocol (PPP) at 115,200 applies.

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Port PCB Default Configuration

COM2 CPU RS-232; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol
COM3 SCB RS-485 or RS-232 depending upon factory order; 9600 baud,
8 bits, no parity, 1 stop bit, BSAP or ControlWave Designer
protocol
COM4 SCB RS-485; 9600 baud, 8 bits, no parity, 1 stop bit, BSAP or
ControlWave Designer protocol

Note: You can re-enable the factory comm settings at any time by
setting switch 3 on the CPU module’s SW1 to “OFF.”
Ethernet The ControlWave can include from one to three Ethernet ports. You
can connect directly or through a network to a PC equipped with an
Ethernet port.
The default IP addresses and masks for these are:
 ETH1 IP Address: 10.0.1.1 IP Mask: 255.255.255.0
 ETH2 IP Address: 10.0.2.1 IP Mask: 255.255.255.0
 ETH3 IP Address: 10.0.3.1 IP Mask: 255.255.255.0

4.3.2 Changing Port Settings

You change port settings (baud rate, port type, IP address, and so on)
using the Flash Configuration utility.
You must establish communications with the ControlWave Micro using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.

Note: For detailed information on using the Flash Configuration utility,

see Chapter 5 of the OpenBSI Utilities Manual (D5081).

Caution When you change the baud rate for a port, the baud rate changes as
soon as you write the flash file changes to the RTU, and do not require
a reset. For this reason, you should not change baud rate for the active
port on which you are communicating, or communications will
immediately stop due to the baud rate mismatch between the PC port
and the controller port. If this happens accidentally, you can use CPU
switch settings as discussed in the notes in Section 4.3.1 to restore
defaults and re-establish communications.

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ControlWave Instruction Manual (CI-ControlWave)

4.3.3 Collecting Data from the ControlWave

OpenBSI utilities such as DataView, Data Array Save/Restore and
Harvester allow you to collect real time data (values of variables, array
values, alarm messages) and historical data (audit records, archive files)
from the ControlWave. See the OpenBSI Utilities Manual (D5081) for
details. SCADA software such as OpenEnterprise can then present this
data to an operator in the form of graphical displays and reports.

4.4 Creating and Downloading an Application (ControlWave Project)

Your ControlWave executes an application called a ControlWave
project. You create the project using PC-based ControlWave Designer
software. Instructions for creating a ControlWave project are beyond the
scope of this manual. Please refer to the following sources for
information:
 Getting Started with ControlWave Designer (D5085)
 ControlWave Quick Setup Guide (D5084)
 ControlWave Designer Programmer’s Handbook (D5125)
 ControlWave Designer online help
You must connect the ControlWave to a PC running ControlWave
Designer software and OpenBSI software.

Note: You can download an application either from ControlWave

Designer or from the OpenBSI 1131 Downloader.
1. Set the PSSM’s Run/Remote/Local (key-operated) switch:
 If the PC is connected to a comm port configured as an IP or
OpenBSI Network port set the PSSM’s Run/Remote/Local
switch to Remote
 If the PC is connected to a comm port configured as a serial
port set the PSSM’s Run/Remote/Local switch to Local
Note: COM1 has a factory default of 115.2 Kps (RS-232) using the
Internet Point-to-Point Protocol (PPP). Do not connect COM1 to
a PC unless you configure that PC’s RS-232 port for PPP.
2. Define the project, setting communication and configuration
parameters.
3. Download the project according to instructions in the
Downloading section of the ControlWave Designer
Programmer's Manual (D5125).
4. After the download completes successfully, restore the PSSM
switch settings:
 Turn Run/Remote/Local to Run

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4.5 Creating and Maintaining Backups

You should always maintain a current backup of each ControlWave
project and keep it in a safe place, preferably in a location physically
separate from the controller.
The reason we recommend you keep a backup files is that if a disaster
occurs that damages or destroys your ControlWave hardware (flood,
lightning strike, etc.) you don’t want to also lose its control strategy
software programs. Otherwise, when the unit is repaired or replaced,
you’d have to create a new ControlWave project from scratch, which
might take a lot longer than replacing a few damaged modules.

Caution Always maintain a backup copy of your ControlWave project in a safe

place.

Anytime you modify your ControlWave project, be sure to create a new

backup of the new project.

Notes:
 You may find it useful to maintain more than one backup copy in
case the backup media itself fails, for example, a CD-ROM becomes
unreadable because it melted in the sun or a thumb drive fails
because someone spilled coffee on it.
 If you don’t keep more than one backup copy, it’s a good idea to
periodically test your backup copy to verify that the media has not
failed.

4.5.1 Creating a Zipped Project File (*.ZWT) For Backup

Note: The .zwt file is a complete backup of your entire project
including code, comments and graphics. It may be stored on your
PC or removable storage media. It may also be downloaded and
archived to ControlWave Flash memory where it may be
uploaded at a later time for editing.
With your current ControlWave project open in ControlWave Designer,
perform the following steps:
1. Click File > Save Project As / Zip Project As.

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ControlWave Instruction Manual (CI-ControlWave)

Figure 4-3. Saving a Backup of Your Project

2. In the “Save/Zip project as” dialog box, specify a project name in

the File name field. In Figure 4-3 we chose the name mynewproj.
3. In the Save as type field, choose Zipped Project Files (*.zwt).
4. In the Zip Options area, select which additional files you want to
include in the zwt file. Other than increasing the file size of the zwt,
it doesn’t hurt to check any or all of these options.
Zip Option Description
Zip User-Libraries If you created your own user-defined
functions or function blocks, you must
select this to preserve them.
Zip Frontend-Code If you selected Zip User-Libraries you
should also select this option to include
compiled code for libraries in your zip file.
Otherwise, you need to re-compile your
user libraries with the project when you
unzip the zwt.
Zip FW-Libraries This includes firmware libraries, such as
ACCOL3.FWL in your zwt.
Zip Pagelayouts This includes pagelayout information for
printing your project, as well as graphical
elements used in certain 1131 languages.

5. Click Zip and a progress bar displays the percent complete of the
zipping process.

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6. When the zip process completes, you’ll see a message box reporting
successful completion. Click OK.
7. Copy the resulting zwt file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the project, just open the zwt
file in ControlWave Designer, load libraries as needed, then compile
the project and download it into the ControlWave.

4.5.2 Saving Flash Configuration Parameters (*.FCP)

You must establish communications with the ControlWave using
NetView, LocalView, or TechView before you can run the Flash
Configuration utility.
Note: For detailed information on using the Flash Configuration utility,
see Chapter 5 of the OpenBSI Utilities Manual (D5081).
1. Start the Flash Configuration utility. To do this in NetView or
LocalView, right-click on the icon for this ControlWave and
choose RTU > RTU Configuration Parameters.

To do this in TechView, click Operations > Access Flash

Parameters or click the Access Flash icon .

2. Depending upon how your system is configured, the Flash

Configuration – Loading Options dialog box may open. If it
does, choose Load from device and wait for the utility to
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ControlWave Instruction Manual (CI-ControlWave)

retrieve all parameters from the ControlWave, then skip to step

4, otherwise, just proceed to step 3.

3. Click and wait for the utility to retrieve all

parameters from the ControlWave.

4. Click and specify a name for your FCP file,

then click Save. When the status line indicates successful
completion, your FCP file in done.
5. Copy the resulting FCP file to backup media (CD-ROM, thumb
drive, etc.) If you ever need to restore the FCP parameters to the
controller, establish communications with the unit, start the
Flash Configuration utility, and load the FCP file using the Read
from FCP button, then choose the Write to RTU button.

4.5.3 Backing up Data

You can back up certain types of data and restore it if needed. There are
other types of data that you can only collect, but you cannot restore.
 If you have certain variables that represent tuning parameters
(setpoints, for example) you can use tools such as the OpenBSI
DataView recipe feature to save those values to a recipe file on the
PC, and then restore them at a later time. See Chapter 8 of the
OpenBSI Utilities Manual (D5081).
 You can store the contents of read/write data arrays using the
OpenBSI Data Array Save/Restore utility. See Chapter 13 of the
OpenBSI Utilities Manual (D5081).
 You can collect alarms, and historical data (audit records, archive
files) but you cannot restore alarms or historical data.

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Chapter 5 – Service and Troubleshooting

This chapter provides general diagnostic and test information for the
ControlWave.
In This Chapter

5.1 Upgrading Firmware ........................................................................5-2

5.2 Removing or Replacing Components ..............................................5-5
5.2.1 Accessing Modules for Testing ............................................5-5
5.2.2 Removing/Replacing the Bezel ............................................5-5
5.2.3 Removing/Replacing the CPU Module.................................5-6
5.2.4 Removing/Replacing the PSSM ...........................................5-6
5.2.5 Removing/Replacing an I/O Module (Hot Swapping) ..........5-7
5.2.6 Removing/Replacing the Backup Battery ..........................5-12
5.3 General Troubleshooting Procedures ...........................................5-12
5.3.1 Common Communication Configuration Problems ............5-13
5.3.2 Checking LEDs...................................................................5-13
5.3.3 Checking Wiring/Signals ....................................................5-22
5.3.4 Port 80 Display Codes........................................................5-23
5.3.5 Reset Switch ......................................................................5-26
5.4 WINDIAG Diagnostic Utility ...........................................................5-26
5.4.1 Available Diagnostics .........................................................5-29
5.5 Core Updump ................................................................................5-33

Equipment You need the following equipment to perform the procedures described
in this chapter:
To run diagnostics software:
 PC with WINDIAG software, and either OpenBSI LocalView,
NetView, or TechView for communications.
 Null modem interface cable
 Loop-back plug for RS-232 port (see Figure 5-21)
 Loop-back plug for RS-485 port (see Figure 5-22)
 Loop-back plug, 8-pin RJ-45 male (for twisted pair Ethernet) (see
Figure 5-24)
To perform firmware upgrades:
 Null modem interface cable
 PC with the following software:
o OpenBSI System Firmware Downloader and either NetView,
LocalView, or TechView for communications.
o HyperTerminal (included in Windows® XP)
Note: When you service a ControlWave on site, we recommend that
you close down (or place under manual control) any associated
processes. This precaution prevents any processes from
accidentally running out of control when you conduct tests.

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Caution Harmful electrical potentials may still exist at the field wiring terminals
even though the ControlWave power source may be turned off or
disconnected. Do not attempt to unplug termination connectors or
perform any wiring operations until you verify that all associated power
supply sources are turned off and/or disconnected.
Always turn off any external supply sources for externally powered I.O
circuits before you change any modules.

5.1 Upgrading Firmware

The ControlWave CPU ships from the factory with system firmware
already installed. If you need to upgrade the system firmware (stored in
Flash memory) to acquire new functionality or restore firmware, you
can use one of several methods.
System Use this tool to download system firmware to an unattended remote
Firmware ControlWave controller. To use this utility, you must set CPU module
Downloader switch SW3-2 OFF (the factory default position).

Note: For further information and detailed use instructions, refer to

Appendix J of the OpenBSI Utilities Manual (D5081).

LocalView One of the standard OpenBSI utilities, LocalView requires OpenBSI

version 5.1 (or newer). If you have an older version of OpenBSI, use
HyperTerminal.

Note: For further information and detailed use instructions, refer to the
Flash Mode section of Chapter 5 of the OpenBSI Utilities
Manual (D5081).
HyperTerminal HyperTerminal is a communications utility program included with
Microsoft® Windows®.XP
Notes:
 If you are using a version of OpenBSI older than 5.1, or do not have
OpenBSI software, you can only perform a firmware upgrade using
HyperTerminal.
 While HyperTerminal is included in Microsoft® Window® XP,
some newer versions of Window® do not include it.
 HyperTerminal requires *.BIN files; newer ControlWave firmware
upgrade files use *.CAB files. In cases such as those, you should use
the Remote System Firmware Downloader.
1. Connect a null modem cable between COM1 of the
ControlWave and any RS-232 port on the associated PC.
2. Click Start > Programs > Accessories > Communications >
HyperTerminal
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3. If using HyperTerminal for the first time, set the communication

properties (for the PC port) via the Properties Menu as follows:
Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop
bits: = 1, and Flow control: = None and then click OK.
4. Set CPU switch SW3-3 to ON (Force Recovery Mode).
5. Apply power; to the ControlWave. The resident BIOS initializes
and tests the hardware, this process is referred to as POST
(Power On Self Test). Unless there is a problem, you should see
the code “86” on the Port 80 display. If you see a different status
code, see Section 5.3.4.
6. From the HyperTerminal Mode menu (Figure 5-1), press the F
key to enter FLASH download. A message warns that the
FLASH is about to be erased; press the Y key at the prompt. The
screen displays dots as the system erases the flash memory; this
could take a few minutes.

Figure 5-1. HyperTerminal Mode Menu

7. When the FLASH is ready for download, HyperTerminal

repeatedly displays the letter C on the screen. In the
HyperTerminal menu bar click Transfer > Send File (see
Figure 5-2).

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ControlWave Instruction Manual (CI-ControlWave)

Figure 5-2. HyperTerminal (Ready to Download)

8. In the Send File dialog box (see Figure 5-3), select 1KXmodem
for the protocol, enter the filename of the appropriate .bin file in
the format “CWPxxxxx.bin” (where xxxxx varies from release to
release) and click Send to start the flash upgrade (see Figure 5-
4). When you see the HyperTerminal Mode Menu again, it
means the download has completed.
9. Exit HyperTerminal and power down the ControlWave. If
desired, you can disconnect the null modem cable between the
ControlWave and the PC.
10. Set CPU switch SW3-3 to OFF (Recovery Mode Disabled).
11. Restore power to the ControlWave.

Figure 5-3. Send File dialog box

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Figure 5-4. HyperTerminal (Download in Process)

5.2 Removing or Replacing Components

This section provides information on accessing ControlWave modules
for testing, as well as removal/replacement procedures.
Field repairs to ControlWave process automation controllers are strictly
Caution limited to the replacement of complete modules. All modules (CPU,
PSSM, and I/O) are factory sealed to prevent tampering. Breaking the
seal and/or replacing module components constitutes tampering and
voids the product warranty. Return defective modules or housings to
the factory for authorized service.

5.2.1 Accessing Modules for Testing

Only technically qualified personnel should test and/or replace
ControlWave modules. Read completely the disassembly and test
procedures described in this manual before starting. Any damage to the
ControlWave resulting from improper handling or incorrect service
procedures is not covered under the product warranty agreement. If you
cannot properly perform these procedures, obtain authorization and then
return the device to the factory for evaluation and repairs.

5.2.2 Removing/Replacing the Bezel

Before you can remove the CPU module or the PSSM module you must
remove the bezel.

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ControlWave Instruction Manual (CI-ControlWave)

1. Remove any cables and or the Run/Remote/Local key from their

connectors; make sure you label the cables so you can replace them
later.
2. Grasp the sides of the bezel assembly and gently pull it off the
chassis.
3. To replace the bezel, align the bezel’s two snaps (one near the top
and one near the bottom) with the associated holes on the chassis.
(These holes are centered between the PSSM and CPU captured
panel fastener holes.)
4. Press the bezel in gently until it snaps into place.
5. Reconnect the cables and reinsert the key, if necessary.

5.2.3 Removing/Replacing the CPU Module

Use this procedure to remove or replace the CPU module.
1. If the ControlWave is running, place any critical control
processes under manual control.
2. Shut down the ControlWave by disconnecting the power.
3. Disconnect any CPU module communication cables. Label or
otherwise identify them so you can easily return them to their
assigned communication ports. .
4. Remove the bezel. (See Section 5.2.2.)
5. Loosen the two captured panel fasteners that secure the CPU
module to the chassis and carefully slide it out the front of the
chassis. You may need to rock the board back and forth gently to
do this.
6. To replace a CPU module, the PSSM must already reside in slot
1, but power must be off. Carefully align the CPU module with
the guides for slot 2 and insert the CPU module into the housing.
When the module correctly seats in the backplane, turn the
module’s captured panel fasteners clockwise to secure the CPU
module; this establishes a low resistance path between the CPU
module and chassis ground. Make sure the fasteners are tight,
but don’t over-tighten them.
7. Replace any communication cables, apply power, and test the
module.

5.2.4 Removing/Replacing the PSSM

Note: If you have a redundant power supply sequencer module, please
see Appendix P.
Use this procedure to remove or replace the PSSM module.

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1. If the ControlWave is running, place any critical control processes

under manual control.
2. Shut down the unit by turning off the power.
3. Unplug the cables and PSSM modular connectors for power (TB2)
and watchdog (TB1).
4. Remove the bezel assembly. See Section 5.2.2.
5. Remove the CPU module. See Section 5.2.3. You must remove the
CPU module in order to remove the PSSM.
6. Loosen the two captured panel fasteners that secure the PSSM
module to the chassis and carefully slide it out the front of the
chassis.
7. To replace a PSSM module, power must be off and the CPU
module must be removed. Carefully align the PSSM module with
the guides for slot 1 and insert the module into the housing. When
the module correctly seats in the backplane, turn the module’s
captured panel fasteners clockwise to secure the PSSM module;
this establishes a low resistance path between the PSSM module
and chassis ground. Make sure the fasteners are tight, but don’t
over-tighten them.
8. Replace the CPU module.
9. Replace power and watchdog cables and then apply power and test
the unit.

5.2.5 Removing/Replacing an I/O Module (Hot Swapping)

DO NOT ATTEMPT hot swapping in a Class I, Division 2 hazardous
WARNING location.

The ControlWave process automation controller supports removal of

any or all I/O modules from the housing while the application is
running. This is called “hot swapping.” When you initially remove or
replace any I/O module, the ControlWave halts operation for 300
milliseconds before resuming operation from where it halted. During
this momentary halt, the Port 80 display shows “CA” on its screen.

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ControlWave Instruction Manual (CI-ControlWave)

Never try to “hot swap” more than one I/O module simultaneously. You
Caution can remove or replace multiple modules sequentially, but not at the
same time.

1. If the ControlWave is running, place any critical control

processes that use this I/O module under manual control.
2. Loosen the capture fasteners at the top and bottom of the module
by turning them counter-clockwise.

Loosen the
capture
fasteners at the
top and bottom
of the module.

Figure 5-5. I/O Module to Be Replaced

3. Open the bezel door and grasp the handle. Pull the entire module
out of the chassis.

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Figure 5-6. Pulling the I/O Module Out of the Housing

4. If you plan to replace this module with a new module, but want
to retain all your existing I/O wiring to the terminal blocks, you
need to disconnect the terminal block board from the rest of the
module. To do that, loosen the screws at the top and bottom of
the terminal block board. Then grab the handle and pull the
terminal block board along with the terminal housing assembly
off of the front of the module.

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ControlWave Instruction Manual (CI-ControlWave)

Loosen the
fasteners at the
top and bottom
of the terminal
board.

Figure 5-7. Loosening the Top Fastener

Figure 5-8. Terminal Block Board and Terminal Housing Assembly Separated from the Rest of the
Module

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5. Again, assuming you want to preserve your existing wiring to

the terminal blocks, because you haven’t wired to the terminal
blocks on the replacement module, remove the terminal block
board and terminal housing assembly from the new replacement
module.
6. Carefully slide the new module into the same I/O slot in the
housing and tighten the top and bottom capture fasteners, but not
too tight.

Figure 5-9. New I/O Module in Place Prior to Attaching Terminal Board and Terminal Housing
Assembly

7. Take the terminal block board and terminal housing assembly,

with all the I/O wiring, that you removed in step 4, and line up
its fasteners with the holes on the module, now seated in the
housing, and gently push the terminal block board and terminal
housing assembly into the module and tighten the fasteners.
8. When the new board starts, and is functioning properly, return
any processes you put into manual control to automatic control.

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5.2.6 Removing/Replacing the Backup Battery

Note: For the backup battery to function, CPU switch SW3-4 must be
ON. See Section 2.4.1 for information on setting CPU module
switches.
The CPU module includes a backup battery that sits in front of the
PSSM module as you face the ControlWave. The battery provides
backup power for the real-time clock (RTC), CMOS RAM, and the
system SRAM on the CPU module. The CPU module backup battery is
a 3.6V, 950 mA-hr ½ AA lithium cell battery.

Note: The CPU module draws power from the battery only if the
module loses power. The system SRAM has a standby current
draw of 50 uA maximum for each part. For a ControlWave
containing 2MB of SRAM, a worst-case current draw of 110 uA
allows a battery life of approximately 8,636 hours. This means
you should not need to replace a battery until the ControlWave
has been in service for an extended period (normally many
years).

Caution You lose SRAM contents when you remove the backup battery or its
assembly from the CPU module.

If you replace a backup battery or its assembly, wait at least one minute
before re-powering the system. This enables the SRAM to completely
discharge.

Removing / 1. If the ControlWave is running, place any critical control processes

Replacing the under manual control.
Battery 2. Remove the bezel that covers the PSSM and CPU modules.
3. Grasp the battery retaining clip and gently pull it up and away from
the backup battery assembly to release the top of the retaining clip.
4. Pull the retaining clip down and outward to remove it.
5. Remove the battery. Wait at least one minute for SRAM to fully de-
charge.
6. Put in the replacement battery.
7. Snap the retaining clip back into place.
8. Put the bezel back in place.

5.3 General Troubleshooting Procedures

This section presents some procedures to troubleshoot problems with
the ControlWave.

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 ControlWave Instruction Manual (CI-ControlWave)

5.3.1 Common Communication Configuration Problems

If serial communications do not function, it is often due to one of the
following issues:
 Baud rate mismatch – the baud rate at both ends of the
communication line must match. If communications fail during a
download of a new flash configuration profile (FCP) file, you may
have changed the baud rate of the active communication line, since
baud rate changes occur immediately on FCP download. You can
always re-establish factory default baud rates for communication
ports by powering down the unit, and then setting CPU switch SW1-
3 to OFF and restoring power.
 Incorrect BSAP local address – this address must be an integer from
1 to 127 and must be unique on this particular BSAP communication
line. You set the BSAP local address using the flash configuration
utility. If this ControlWave is a BSAP slave node, and the range of
addresses defined for the BSAP master port end of the
communication line does not encompass the local BSAP address
defined for this ControlWave, BSAP communications will not
function.
 Incorrect EBSAP Group number – if you use expanded BSAP the
EBSAP group number must be correct; if you are not using EBSAP,
the group number must be 0.

If IP communications do not function, it is often due to incorrect IP

addresses or masks. Check to see that the IP address you defined for the
ControlWave is compatible with the range of IP addresses defined for
the communication line on which the unit resides. Also check that the IP
address of the default gateway is correct.

5.3.2 Checking LEDs

ControlWave modules contain light emitting diodes (LEDs) that provide
operational and diagnostic functions.
Table 5-1 shows LED assignments on modules.

Table 5-1. LED Assignments on Modules

Module / LED Name LED Color Function and Location

Board
PSSM MC Red Master Clear; ON 2msec after PWR FAIL goes
low. See Figure 5-10.
PSSM PWRFAIL Red ON = Bulk or regulated power out of
specification. See Figure 5-10.
PSSM PWRGOOD Green ON = Normal operation; all power supplies
okay. See Figure 5-10.

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ControlWave Instruction Manual (CI-ControlWave)

Module / LED Name LED Color Function and Location

Board
CPU CR1 – WATCHDOG Red ON = Watchdog condition. See Section 2.3.5
for a description of what causes a watchdog.
See Figure 5-11.
CPU CR2 – IDLE Red ON = CPU idle. The CPU should show idle
most of the time. If this light goes OFF and
stays OFF, the CPU is overloaded. See Figure
5-11.
CPU CR3 – COMM 1 RX Red ON = RX (receive activity) on COMM1. See
top-left of LED cluster in Figure 5-11.
CPU CR3 – COMM 1 TX Red ON = TX (transmit activity) on COMM1. See
top-right of LED cluster in Figure 5-11.
CPU CR3 – COMM 2 RX Red ON = RX (receive activity) on COMM2. See
bottom-left of LED cluster in Figure 5-11.
CPU CR3 – COMM 2 TX Red ON = TX (transmit activity) on COMM2. See
bottom-right of LED cluster in Figure 5-11.
CPU CR8 – ENET Port 1 Red/Green ON RED = Data Collision (Left – see Figure 5-
11.)
CPU CR8 – ENET Port 1 Red/Green ON GREEN = Receiving data (Left – see
Figure 5-11.)
CPU CR8 – ENET Port 1 Red/Green ON RED = Transmitting data (Right – see
Figure 5-11.)
CPU CR8 – ENET Port 1 Red/Green ON GREEN = Link O.K. (Right – see Figure 5-
11.)
SCB CR2 – COMM 3 RX Red ON = RX (receive activity) on COMM3. See
top-left of LED cluster in Figure 5-11.
SCB CR2 – COMM 3 TX Red ON = TX (transmit activity) on COMM3. See
top-right of LED cluster in Figure 5-11.
SCB CR2 – COMM 4 RX Red ON = RX (receive activity) on COMM4. See
bottom-left of LED cluster in Figure 5-11.
SCB CR2 – COMM 4 TX Red ON = TX (transmit activity) on COMM4. See
bottom-right of LED cluster in Figure 5-11.
SCB CR4 – ENET Port 2 Red/Green ON RED = Data Collision (Left – see Figure 5-
11.)
SCB CR4 – ENET Port 2 Red/Green ON GREEN = Receiving data (Left – see
Figure 5-11.)
SCB CR4 – ENET Port 2 Red/Green ON RED = Transmitting data (Right – see
Figure 5-11.)
SCB CR4 – ENET Port 2 Red/Green ON GREEN = Link O.K. (Right – see Figure 5-
11.)
SCB CR5 – ENET Port 3 Red/Green ON RED = Data Collision (Left – see Figure 5-
11.)
SCB CR5 – ENET Port 3 Red/Green ON GREEN = Receiving data (Left – see
Figure 5-11.)
SCB CR5 – ENET Port 3 Red/Green ON RED = Transmitting data (Right – see
Figure 5-11.)
SCB CR5 – ENET Port 3 Red/Green ON GREEN = Link O.K. (Right – see Figure 5-
11.)

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Module / LED Name LED Color Function and Location

Board
CPU PORT 80 DISPLAY Red LEDs LED Matrix displays status codes. See Figure
5-11. See Table 5-3 & 5-4.
AI AI Board Status Red/Green ON RED = Fail state/ board not recognized
ON GREEN = Normal state. See Figure 5-12
AI Range (16 LEDs – one per Red LED ON = AI over-range or AI under-range
point) condition. See Figure 5-12
AI Range (16 LEDs – one per Green LED ON = AI in range. See Figure 5-12
point)
AO AO Board status fail Red LED ON = AO board fail state / board not
recognized. See Figure 5-13.
AO AO Board status pass Green LED ON = AO board normal or O.K. state.
Figure 5-13.
DI DI Board status Red/Green ON RED = DI board fail state; board not
recognized.
ON GREEN = DI board normal state. See
Figure 5-14.
DI DI board inputs (32 LEDs – 1 Red LED ON = Input is present.
per point) LED OFF = Input is not present. See Figure 5-
14.
DO DO Board status Red/Green ON RED = DO board fail state; board not
recognized.
ON GREEN = DO board normal state. See
Figure 5-15.
DO DO board outputs (32 LEDs – Red LED ON = Output is ON. See Figure 5-15.
1 per point)
UDI UDI Board Status Fail Red LED ON = UDI board fail state/board not
recognized. See Figure 5-16.
UDI UDI Board Status Pass Green LED ON = UDI board normal or O.K. state.
See Figure 5-16.
UDI UDI Input (12 LEDs – 1 per Red LED ON = UDI input activity.
point) LED OFF= no UDI input activity. See Figure 5-
16.
RTD RTD Board Status Red/Green ON RED = Fail state/board not recognized.
ON GREEN = Normal state. See Figure 5-17.
RTD Range (8 LEDs – 1 per point) Red LED ON = RTD over-range or RTD under-
range condition. See Figure 5-17.
RTD Range (8 LEDs – 1 per point) Green LED ON = RTD in range. See Figure 5-17.
LLAI LLAI Board Status Red/Green ON RED = Fail state/board not recognized.
ON GREEN = Normal state. See Figure 5-18.
LLAI Range (12 LEDs – 1 per point) Red LED ON = LLAI over-range or LLAI under-
range condition. See Figure 5-18.
LLAI Range (12 LEDs – 1 per point) Green LED ON = LLAI in range. See Figure 5-18.

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ControlWave Instruction Manual (CI-ControlWave)

Captured Panel Fastener

O I

I Pressed = Power ON
POWER SWITCH O Pressed = Power OFF

(Red) MC LED = Master Clear is active asserted 2msc after

PWR_FAIL has been asserted.
(Red) PWRFAIL LED = Bulk or Regulated Power Out Of Spec.
(Green)
PWRGOOD LED = Regulated +3.3Vdc, +5vdc, +12Vdc (Optional), & -12Vdc (Optional)
Supplies are above minimum acceptable limits.
1 1 +VIN (+22.2Vdc to +30Vdc for +24V supply)
(+VINF) Connected to TB2-1 (or separate +20.0Vdc to +30Vdc supply)
TB2 (-VIN) (1st Supply Ground)
Input Power (-VINF) (2nd Supply Ground) Internally connected to TB2-3
5 Connector 5 Chassis Ground (CHASSIS)
1 TB1 Redundancy Connections: TB1 MOSFET Connections:
TB1 1 VO - WD MOSFET Switch Output VO - WD MOSFET Switch Output
3 Watchdog VI - Relay Power (+24Vdc) VI - WD MOSFET Switch Input
Connector 3 VR - Redundant Unit Control Input Not Used

Captured Panel Fastener

Figure 5-10. Power Supply/Sequencer Module’s TB1, TB2 & LED Designations

Figure 5-11. CPU Module (CPU & SCB boards) Port & LED Designations

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 5-12. Analog Input (AI) Module LED Designations

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ControlWave Instruction Manual (CI-ControlWave)

Figure 5-13. Analog Output (AO) Module LED Designations

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Figure 5-14. Digital Input (DI) Module LED Designations

Figure 5-15. Digital Output (DO) Module LED Designations

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ControlWave Instruction Manual (CI-ControlWave)

UDI Bd. Status LED (Red) = UDI Bd. not recognized or failed.
UDI Bd. Status LED (Green) = UDI Bd. recognized and normal.
ON UDIXX = Input is present. Note: The Status LED will turn ON (Red)
whenever power is initially applied to
OFF UDIXX = Input is not present. the UDI Module. It will remain Red until
the CPU has recognized the UDI Module
and then it will turn Green and should
UDI LED Board remain ON.
LED Assignments
for UDI1 - UDI6
UNIVERSAL DIGITAL INPUT

UNIVERSAL DIGITAL INPUT

FAIL (Red) UDI Bd. Status LED

PASS (Green) UDI Bd. Status LED

Figure 5-16. Universal Digital Input (UDI) Module LED Designations

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 5-17. RTD Module LED Designations

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ControlWave Instruction Manual (CI-ControlWave)

Figure 5-18. Low Level Analog Input (LLAI) Module LED Designations

5.3.3 Checking Wiring/Signals

Check I/O field wiring at the terminal blocks and at the field device.
Inspect the wiring for continuity, shorts, and opens. Check I/O signals at
their respective terminal blocks (see Table 5-2).

Table 5-2. I/O Field Wiring - Terminal Block Reference

I/O Module or sub-system Notes

Digital Input Modules See Section 3.4
Digital Output Modules See Section 3.5
Analog Input Modules See Section 3.6
Analog Output Modules See Section 3.7
Universal Digital Input (UDI) Modules See Section 3.8
RTD Input Modules See Section 3.9
Low Level Analog Input Modules See Section 3.10
Watchdog Circuit See Section 2.3.5

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5.3.4 Port 80 Display Codes

The Port 80 Display shows two different types of codes. POST codes,
and run-time status codes.
Power-On-Self-
Test (POST)
When you first power up the ControlWave, or if you reset it using the
Codes reset switch, the BIOS runs a power-on-self-test (POST) to test the
hardware. Normally, the POST codes pass by too quickly for you to see
them, and the system enters normal run time, or if the CPU is set for
force recovery mode, you see the code “86.” If there is a fault during the
POST process, see Table 5-3 for the 2-digit failure code.

Table 5-3. Port 80 POST Status Codes

HEX Code Definition

00 POST beginning.
01 CPU register test about to start.
02 NMIs are disabled; delay starts.
03 power-on delay finished.
04 kbd BAT done; reading kbd SYS bit.
05 disabling shadowing & cache.
06 calcing ROM cksum, wait kbd ctrllr.
07 cksum okay, kbd ctrllr free.
08 verifying BAT cmd to kbd ctrllr.
09 issuing kbd ctrllr cmd byte.
0A issuing kbd ctrllr data byte.
0B issuing pin 23, 24 blocking & unblocking.
0C issuing kbd ctrllr NOP cmd next.
0D testing CMOS RAM shutdown register.
0E checking CMOS cksum, updating DIAG byte.
0F initializing CMOS (if req’d every boot).
10 Init. CMOS status reg. for date/time.
11 disabling DMA, interrupt ctrllrs.
12 disabling Port B, disabling video display.
13 Init. board, start auto-mem detect.
14 starting timer tests.
15 testing 8254 T2, for spkr, part B.
16 testing 8254 T1, for refresh.
17 testing 8254 To, for 18.2 Hz.
18 starting memory refresh.
19 testing memory refresh.
1A testing 15usec refresh ON/OFF time.
1B testing base 64KB memory.
1C testing data lines.
1D currently loading the Boot Project.
20 testing address lines.
21 testing parity (toggling).
22 base 64KB mem read/write test.
23 system init before vector table init.
24 init vector table.
25 reading 8042 for turbo switch setting.
26 initiating turbo data.
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ControlWave Instruction Manual (CI-ControlWave)

HEX Code Definition

27 any init after vector table init is next.
28 setting monochrome mode.
29 setting color mode.
2A toggle parity before optional video ROM.
2B init before video ROM check.
2C control passed to video ROM.
2D video ROM returned control.
2E checking for EGA/VGA adapter found.
2F no EGA/VGA found, r/w test of video.
30 looking for video retrace signal.
31 retrace failed, checking alt. Display.
32 alt found, checking video retrace signal.
33 compare switches w/actual adapter type.
34 setting display mode.
35 check ROM BIOS data area at seg 40h.
36 setting cursor for power-on msg.
37 displaying power-on message.
38 save cursor position.
39 display BIOS ident. String.
3A display “Hit <DEL> to …” msg.
40 preparing vm test. vrfy from display.
41 preparing descriptor tables.
42 enter virtual mode for memory test.
43 enable inits for diagnostics mode.
44 init data for checking wraparound at 0:0.
45 checking for wrap, find total memory size.
46 write extended memory test patterns.
47 write conventional memory test patterns.
48 finding low memory size from patterns.
49 finding high memory size from patterns.
4A check ROM BIOS data area again.
4B check for <DEL>, clear low mem for soft reset.
4C clearing ext mem for soft reset.
4D saving memory size.
4E on cold boot, display 1st 64KB memtest.
4F on cold boot, test all of low memory.
50 adjust memsize for 1K usage.
51 system initialization in progress.
52 prepare for shutdown to real-mode.
53 saved regs & memsize, entering real-mode.
54 shutdown successful, restoring codepath.
55 disabling A20 line.
56 checking ROM BIOS data area again.
57 checking ROM BIOS data area some more.
58 clear the “Hit <DEL>” message.
59 test DMA page register.
60 verify from display memory (???).
61 test DMA0 base register.
62 test DMA1 base register.
63 checking ROM BIOS data area again.
64 checking ROM BIOS data area some more.
65 programming DMA ctrllrs 0 & 1
66 initializing INT ctrllrs 0 & 1.
67 starting keyboard test.
80 issuing reset cmd & clring output buffer

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HEX Code Definition

81 check for stuck keys & issue test cmd.
82 initializing circular buffer.
83 check for locked keys.
84 check for memsize mismatch.
85 check for pswd or bypass setup.
86 pswd checked. Do pgming before setup.
87 call the setup module.
88 back from setup, clr screen.
89 display power-on screen message.
8A display “Wait…” message.
8B do system & video BIOS shadowing.
8C load standard setup params into BIOSDATA.
8D check and initialize mouse.
8E check floppy disks.
8F configure floppy drives.
90 check hard disks.
91 configure IDE drives.
92 checking ROM BIOS data area again.
93 checking ROM BIOS data area some more.
94 setting base & ext mem sizes.
95 memsize adjusted for 1K, verifying disp mem.
96 initialization before calling C800h.
97 call ROM BIOS extension at C800h.
98 processing after extension returns.
99 configuring timer data area, printer base addr.
9A configuring serial port base addrs.
9B initialization before coprocessor test.
9C initializing the coprocessor.
9D processing after coprocessor initialized.
9E check ext kbd, kbdID, numlock settings.
9F issue keyboard ID command next.
A0 kbd ID flag reset.
A1 do cache memory test.
A2 display any soft errors.
A3 set keyboard typematic rate.
A4 program memory wait states.
A5 clear screen.
A6 enable parity and NMIs.
A7 initialization before calling E000h.
A8 call ROM BIOS extension at E000h.
A9 processing after extension returns.
B0 display system config. Box.
B1 test low memory exhaustively.
B2 test extended memory exhaustively.
B3 enumerate PCI space.

Run Time Once your ControlWave project is normally running, the Port 80 display
Status Codes is usually blank to conserve power. Table 5-4 shows status codes you
may see during run-time.

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ControlWave Instruction Manual (CI-ControlWave)

Table 5-4. Port 80 Run Time Status Codes

HEX Definition Notes

Code
00 No Application
01 Application Loaded
10 Application Loaded - BPTs Set Break Point(s) Set
11 Application Running Display Blank
12 Running with BPT Break Point in Debug
1D Currently Loading the Boot Project
51 System Initialization in Progress
86 Recovery Mode SW3-3 = ON; during
normal runtime operation
you should set SW3-3 to
OFF.
BA Standby (redundant systems only) Valid Standby
(can take over)
BC Standby (redundant systems only) Connected to Master
BD Standby (redundant systems only) Not Connected to
Master
BF Battery Fail Check S3-4
CA Hot Card Replacement in Progress
CF Invalid Checksum Detected Unit Stopped
D0 Diagnostic Mode SW1-8 =OFF
D1 Running Diagnostic
DE User Application has failed to start Invalid I/O Card
configuration
F0 NPX Error Unit Stopped
F1 Waiting for Power-down After NMI
FA CPU Bd. Switch SW1-3 Set OFF Flashes for 1 second
Ignore Soft Switch Configuration - Use At startup
factory defaults
FC Waiting for Alt. Watchdog Timer Unit Stopped
FD Waiting for Updump Core Dump in process or
waiting to start
FE FLASH Programming Error
FF Unit Crashed Unit Stopped

5.3.5 Reset Switch

The reset switch (SW4) is a momentary button that lets you reset (stop
and restart) the ControlWave while you test the unit using WINDIAG
diagnostic software.

Caution Never use the reset switch during normal operation.

5.4 WINDIAG Diagnostic Utility

WINDIAG is a software-based diagnostic tool you use to test the
performance of I/O modules, CPU memory, communication ports, and
other system components. .

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 ControlWave Instruction Manual (CI-ControlWave)

WINDIAG is a PC-based program, so the ControlWave must be

attached to and communicating with a PC running WINDIAG. Set
configuration switch SW1-8 OFF (closed) on the CPU module to
enable the diagnostic routines.
Establish communication between the ControlWave (with/without an
application loaded) and the PC with a local or network port under the
following conditions:
 Turn CPU module switches SW1-3 and SW1-8 OFF to run the
WINDIAG program. Setting SW1-8 off prevents the boot project
from running and places the ControlWave in diagnostic mode.
Setting SW1-3 off causes the ControlWave to ignore soft switch
settings and use factory defaults; this sets all serial ports to 9600
baud in preparation for the diagnostic tests.
 Use a null modem cable to connect RS-232 ports between the
ControlWave and the PC. Use an RS-485 cable to connect the RS-
485 ports of the ControlWave and the PC.
Note: For information on port connections and cabling, please see
Chapter 2. See Section 4.3.1 for information on communication
port defaults.
 Reserve the port running a diagnostic test for exclusive use; you
cannot use that port for any other purpose during testing.
Before starting the WINDIAG program, place any critical processes the
ControlWave is handling under manual control. You cannot run
WINDIAG while the ControlWave is running applications. Set the CPU
modules switches SW2-3 and SW2-8 to OFF, and perform the
following steps:
1. Start the NetView program in OpenBSI with your current
network NETDEF file. A menu displays (similar to the one in
Figure 5-19):

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ControlWave Instruction Manual (CI-ControlWave)

Figure 5-19. NetView

2. Select Start >Programs > OpenBSI Tools >Common Tools >

Diagnostics. The Main Diagnostics menu (Figure 5-20)
displays.

Figure 5-20. WINDIAG Main Diagnostics Menu

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 ControlWave Instruction Manual (CI-ControlWave)

3. Select the module to be tested. Enter any prompted parameters

(slot #, etc.). WINDIAG performs the diagnostics and displays
pass/fail results.
4. After performing all diagnostic testing, exit WINDIAG and then
exit the NetView if you don’t have any other ControlWave units
to test.
When you close NetView, the system asks whether you want to
close OpenBSI. Select Yes.
5. Set switch SW1-8 on the CPU module to ON (open). The
ControlWave should resume normal operation.

5.4.1 Available Diagnostics

Using WINDIAG, you can test all ControlWave modules with the
exception of the PSSM. WINDIAG’s Main Diagnostics Menu (see
Figure 5-20) provides the following diagnostic selections:
Option Tests
CPU & Peripherals Checks the CPU module (except for RAM &
PROM).
Analog Output Checks AOs on the Analog Output module.
High Speed Counter Checks the Universal Digital Input (UDI) module.
Prom/Ram Checks the CPU’s RAM and PROM hardware.
Analog Input Checks AIs on the Analog Input module.
Communications Checks Communication ports 1 through 4. The
loop-back tests require the use of a loop-back
plug.
Discrete I/O Checks DIs on Digital Input Module, DOs on
Digital Output Modules.
Ethernet Checks Ethernet Ports 1, 2, or 3. The loop-back
tests require the use of a loop-back plug.
Low Level AI Checks LLAI modules and RTD modules.
EEPROM Checks the EEPROM.
Keyboard & Display Not applicable.

Port Loop-back WINDIAG allows you to select the communication port (1 through 4)
Test to test. Depending on the type of network (RS-232 or RS-485) and the
port in question, a special loop-back plug is required:
 Ports 1 and 2 (RS-232) use a 9-pin female D-type loop-back plug
(shown in the right side of Figure 5-21).

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ControlWave Instruction Manual (CI-ControlWave)

Figure 5-21. RS-232 Loop-back Plugs

 Port 3 (RS-232) use an 8-pin male RJ-45 loop-back plug (shown in

left side of Figure 5-21).

Figure 5-22. RS-485 Loop-back Plugs

 Port 3 (RS-485) use an 8-pin male RJ-45 loop-back plug (shown in

left side of Figure 5-22).

 Port 4 (RS-485) use a 9-pin female D-type loop-back plug (shown in

right side of Figure 5-22).
These tests verify the correct operation of the communication interface
on ports COM1 through COM4.

Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct

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 ControlWave Instruction Manual (CI-ControlWave)

functioning), you must reconnect (using a now validated port)

and test the remaining untested port.
Test Procedure Use this procedure to test the comm ports.
1. Connect an external loop-back plug to the port on the CPU or
SCB port you want to test. Valid ports are:
J2 of CPU board for COM1
J3 of CPU board for COM2
J2 of SCB board for COM3
J3 of SCB board for COM4
2. Select Communications on the WINDIAG Main Diagnostics
Menu. The Communications Diagnostic screen opens:

Figure 5-23. Communications Diagnostic Menu

3. Enter 5 in the Number of Passes field.

4. Select a port to test (click  to display all available ports).

Note: The port you select must correlate to the port on which you
placed the loop-back plug in step 1.
5. Select 115200 or ALL ASYNC as the baud rate (click  to
display all available rates).
6. Click RUN to start the test. At the completion of the test (which
generally takes about 5 seconds), any failed results appear in the
Status field to the right of the RUN button:
 TXD RXD Failure
 CTS RTS Failure

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ControlWave Instruction Manual (CI-ControlWave)

7. Click Return to Menu to display the WINDIAG Main Menu.

Ethernet Port The Ethernet option on the WINDIAG Main Menu allows you to
Loop-back Test select the Ethernet communication port (1 through 3) to test.
This test configures the Ethernet port’s ability to transmit and receive
via the twisted pair. The text transmits frames and compares them
against received frames. You need a special loop-back plug (shown in
Figure 5-24) to perform the Ethernet loop-back test:

Figure 5-24. RJ-45 Ethernet Loop-back Plug

Note: You cannot test a communications port while you are using it.
You can only test currently unused ports. After you complete
testing on all other communication ports (and verify their correct
functioning), you must reconnect (using a now validated port)
and test the remaining untested port.
Test Procedure Use this procedure to test the Ethernet port.
1. Connect an external Ethernet loop-back plug (see Figure 5-24)
to the Ethernet port on the CPU module to be tested.
2. Select Ethernet on the WINDIAG Main Diagnostics Menu.
The Ethernet Diagnostic screen opens:

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 ControlWave Instruction Manual (CI-ControlWave)

Figure 5-25. Ethernet Diagnostic Menu

3. Enter 1 in the Number of Passes field.

4. Enter 1, 2, or 3 in the Ethernet Port to Test field.
5. Click RUN next to the Loop-back out twisted pair field to start
the test. At the completion of the test, any failed results appear in
the Status field next to the Loop-back out twisted pair label:
 No Hardware Present
 Loop-back Send Failed
 Loop-back Receive Failed
 Loop-back Compare Failed
 Error Information Returned
6. Disconnect the loop-back plug and reconnect the Ethernet cable
to the ControlWave and the Ethernet hub.
7. Click Return to Menu to display the WINDIAG Main Menu.

5.5 Core Updump

In some cases—such as when a ControlWave fails for no apparent
reason—you can upload a copy of the contents of SRAM and SDRAM
to a PC for support personnel and service engineers to evaluate. This
upload is called a “core updump.”
A core updump may be required if the ControlWave spontaneously
enters a watchdog state that affects all system operation. This occurs
when the system crashes as a result of a CPU timeout (resulting from
improper software operation, a firmware glitch, and so on). In some

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ControlWave Instruction Manual (CI-ControlWave)

cases, the watchdog state can recur but you cannot logically reproduce
the conditions.
The CPU module’s RAM contains “crash blocks,” a firmware function
provided specifically for watchdog troubleshooting. You can view and
save the crash blocks by viewing the Crash Block Statistic Web Page
(see the Web_BSI Manual, D5087). On request, you can forward crash
block files to our technical support personnel. If they need additional
information to evaluate the condition, the technical support group may
request a core updump. Once the core updump process generates a file,
you can forward that file to the support personnel for evaluation and
resolution.
Use the following steps to preserve the “failed state” condition at a
system crash and perform a core updump:
1. Set switch SW1-1 on the CPU module to OFF (Disable
Watchdog Timer). Set switch SW1-4 to OFF (Enable Core
Updump).
2. Wait for the error condition (typically FF on the Port 80
display).
3. Connect the ControlWave Comm Port 1 to a PC using a null
modem cable.
4. Operate the Run/Remote/Local switch as follows:
Note: You must perform each step in less that one second.
a. Set Run/Remote/Local switch to Run
b. Set Run/Remote/Local switch to Remote
c. Set Run/Remote/Local switch to Local
d. Set Run/Remote/Local switch back to Remote
e. Set Run/Remote/Local switch back to Local
5. Start the PC’s HyperTerminal program (at 115.2 kbaud) and
generate a receive using the 1KX-Modem protocol. Save the
resulting core updump in a file so you can forward it later to the
technical support group.
By setting the CPU module switches SW1-1 and SW1-4 both off before
the ControlWave fails, you prevent the ControlWave from automatically
recovering from the failure and enable it to wait for you to take a core
updump.
Once you complete the core updump, set the CPU module’s switch
SW1-1 to ON (Watchdog Enabled) and SW1-4 to ON (Normal Run).
With these switches set, power up the ControlWave and recommence
standard operations.
When the “active” unit of a ControlWave Redundant Controller fails, it
does not recover but forces the watchdog relay so the “standby” unit

5-34 Service & Troubleshooting Revised May-2013

 ControlWave Instruction Manual (CI-ControlWave)

takes over. Once the core updump completes, set the failed unit’s CPU
switch SW1-1 to ON and SW1-4 to ON, if required, and then power
cycle the failed unit to receive the sideload to become a valid standby
unit. This applies to the ControlWave REDIO as well.

Revised May-2013 Service & Troubleshooting 5-35

This page is intentionally left blank
 ControlWave Instruction Manual (CI-ControlWave)

Appendix A – ControlWave Process Automation

Controller – Special Instructions for
Class I, Division 2 Hazardous Locations
1. The ControlWave Process Automation Controller is listed by
Underwriters Laboratories (UL) as nonincendive and is suitable for
use in Class I, Division 2, Groups A, B, C and D hazardous
locations and non-hazardous locations only. Read this appendix
carefully before installing a nonincendive ControlWave Process
Automation Controller. In the event of a conflict between the main
body of this manual and this appendix, always follow the
instructions in this appendix.
2. All power and I/O wiring must be performed in accordance with
Class I, Division 2 wiring methods as defined in Article 501-4 (b) of
the National Electrical Code, NFPA 70, for installations within the
United States, or as specified in Section 18-152 of the Canadian
Electrical Code for installation in Canada.

WARNING EXPLOSION HAZARD

Substitution of components may impair
suitability for use in Class I, Division 2
environments.

WARNING EXPLOSION HAZARD

When situated in a hazardous location, turn off
power before servicing / replacing the unit and
before installing or removing I/O wiring.

WARNING EXPLOSION HAZARD

Do NOT disconnect equipment unless the
power has been switched off or the area is
known to be non-hazardous.

Revised May-2013 Appendix A A-1

This page is intentionally left blank
 Redundant Power Supply Sequencer Module (RPSSM)

Appendix P – Redundant Power Supply Sequencer

Module (RPSSM)
The Redundant Power Supply Sequencer Module (RPSSM) provides
your ControlWave with dual power supplies for operational redundancy.
You can use the RPSSM in place of the standard power supply sequencer
module (PSSM) in the following ControlWave models:
 ControlWave Process Automation Controller
 ControlWave I/O Expansion Rack
 ControlWave Redundant Controller
The RPSSM includes two independent power supplies. Should either
power supply fail, operations automatically continue using the second
supply, and you can “hot-swap” the failed power supply with a spare unit
without interrupting control operations. The RPSSM also supports hot
swapping of I/O modules. However, you cannot replace the RPSSM itself
without first turning off power to the ControlWave.
When used as part of a redundant system, the failure of one of the two
power supplies in a redundant power supply sequencer module would not
force a failover to the other controller. Only the loss of both power
supplies on the redundant power supply sequencer module would trigger
a failover.

Installing the RPSSM

To ensure safe use of this product, please review and follow the
instructions in the following supplemental documentation:
 Supplement Guide - ControlWave Site Considerations for Equipment
Installation, Grounding, and Wiring (S1400CW)
 ESDS Manual – Care and Handling of PC Boards and ESD Sensitive
Components (S14006)
If needed, first adjust jumpers as described in Setting Jumpers.
Slide the RPSSM into slot 1 (see Figure P-1) prior to installing the CPU
module. You can wire power and watchdog connections at this time.
However, for safety reasons and to prevent accidental damage to your
bulk DC power supply, we recommend you do not connect pluggable
terminal block connectors TB1, TB2, and TB3 to the RPSSM until you
have installed, wired, and configured the CPU module.

Revised May-2013 Installation and Use P-1

Redundant Power Supply Sequencer Module (RPSSM)

Slot 1

TB2

Power Supply
Module 1
Pin 7
TB3
Pin 1
Power Supply
Module 2

TB1

Figure P-1. RPSSM Installed in ControlWave Slot #1 of a ControlWave Controller

Setting Jumpers
Depending upon how you are using the RPSSM, you may have to change
one or more jumpers from their factor default positions. See Table P-1 for
a list of the jumpers and their functions; see Figure P-3 for jumper
locations.
Table P-1. RPSSM Jumpers
Jumper Position Description
JP1 1-2 Enables the watchdog circuitry.
This is the default. Watchdog wiring is discussed later in this document.
2-3 Disables the watchdog circuitry.
JP2 1-2 Sets the RPSSM as always the on-line unit.
This is the default. Use this setting if the RPSSM is not installed in a redundant system.
2-3 Specifies that the RPSSM is part of a redundant system.
Choose this position if the RPSSM is installed:
 In a ControlWave Redundant Controller or
 In a ControlWave Controller that is part of a redundant pair or
 In a ControlWave I/O Expansion Rack that is part of a redundant pair.
JP3 1-2 Enables the 12V monitor.
This is the default. When enabled, the RPSSM reports a failure when voltage falls
below 12V and lights the PWR Down LED to indicate the failure.
2-3 Disables the 12V monitor.
When disabled, the RPSSM does not report a failure if voltage falls below 12V.

If you need to change the jumper positions, unscrew the protective case
from the RPSSM using a Phillips screwdriver (see Figure P-2).

P-2 Installation and Use Revised May-2013

 Redundant Power Supply Sequencer Module (RPSSM)

screws
Figure P-2. Removing the Protective Case from the RPSSM

Figure P-3. Jumper Locations

Revised May-2013 Installation and Use P-3
Redundant Power Supply Sequencer Module (RPSSM)

Make the necessary adjustments to the jumpers according to Table P-1.

When finished, re-attach the case by first aligning the protective case with
the screw holes, then inserting and tightening each screw.

Wiring Power Connections

Use terminal blocks TB1 and TB2 to connect an external bulk power
supply to the RPSSM. An external 24V power supply (22.2 to 30V)
connected to TB1 provides system power to the ControlWave including
the CPU boards and I/O boards (see Figure P-4).
Note: Be sure you route wires to the terminal block connectors so they
do not interfere with removal/replacement of the power supply
modules.

Figure P-4. Wiring System Power to the RPSSM

An external power supply (22.2 to 30V) connected to TB2 provides field
power to I/O boards, and any field devices (switches, relays, etc.)
powered through the I/O boards (see Figure P-5).

Figure P-5. Wiring Field Power to the RPSSM

Wiring Watchdog Circuitry and Redundancy Connections

When the CPU’s hardware detects improper software operation, it
triggers a watchdog condition. If you have enabled the watchdog
hardware using jumper JP1, the watchdog condition triggers a failure to
the redundant unit and resets the CPU.
The circuit that drives the watchdog switch is on the secondary side of the
power supply. A solid state relay actuates the watchdog hardware and is
factory enabled or disabled via jumper JP1 (see Setting Jumpers).

P-4 Installation and Use Revised May-2013

 Redundant Power Supply Sequencer Module (RPSSM)

Figure P-6. Watchdog Switch Field Wiring

The VI input of the terminal block (TB3-6) powers the watchdog switch.
Its switched output connects to the VO output of the terminal block (TB3-
5). Reference the external power source connected to the VI terminal to
the return point of the input source that powers the RPSSM [-VIN (TB1-
2)].
RPSSM connector TB3 provides watchdog switch and redundancy
control connections as follows:
Connections TB3-5 = VO - Watchdog switch output
TB3-6 = VI - Watchdog switch input
TB3-7 = VR - Redundant unit control input (Used with ControlWave
RED I/O)

When using a pair of ControlWave I/O expansion racks, each with an

RPSSM, and a ControlWave Redundant I/O and Communications Switch
Unit (the redundant I/O switcher), the choice of which unit is “online”
and which unit is “backup” is determined by redundancy control line
wiring between the ControlWave I/O redundancy control module
(IORCM) on the I/O switcher, and each I/O expansion rack (See Figure
P-7).

Wire terminal block connector TB3-7 on the “A” I/O expansion rack
RPSSM to TB2-1 on the IORCM, and TB2-2 on the IORCOM to 24V.

Similarly, wire terminal block connector TB3-7 on the “B” I/O expansion
rack RPSSM to TB2-3 on the IORCM, and TB2-4 on the IORCOM must
to 24V.

Figure P-8 shows the location of the IORCM connectors on the

ControlWave I/O Switcher.

Revised May-2013 Installation and Use P-5

Redundant Power Supply Sequencer Module (RPSSM)

Figure P-7. – ControlWave to ControlWave REDI/O - Redundancy Field Wiring

Figure P-8. – Location of TB2 on ControlWave I/O Switcher

P-6 Installation and Use Revised May-2013

 Redundant Power Supply Sequencer Module (RPSSM)

Wiring Digital Inputs to indicate Power Supply Failure

Each power supply on the RPSSM drives a solid state relay contact
closed during normal operation. In a failure, this contact opens. You can
optionally wire the contact to a digital input (either externally or
internally sourced) to provide indication of a power supply failure. You
must wire the contact differently depending upon whether the digital
input supports internally sourced or externally sourced power. See Table
P-2 for details.

Table P-2. Wiring a Digital Input to Indicate Power Supply Failure

Power Supply Digital Input (Internally Sourced) Digital Input (Externally Sourced)
1 TB3-3 SYSTEM GND TB3-3 SYSTEM PWR
TB3-4 DIGITAL INPUT TB3-4 DIGITAL INPUT
2 TB3-1 SYSTEM GND TB3-1 SYSTEM PWR
TB3-2 DIGITAL INPUT TB3-2 DIGITAL INPUT

Hot-swapping a Power Supply

DO NOT ATTEMPT hot swapping in a Class I, Division 2 hazardous
WARNING location.
Each power supply has a Power Good indication LED (see Figure P-10).
If this light goes out while the power supply is on, the power supply’s
output voltage is out of specification. This could occur if the supply is not
properly seated in the slot or if its fuse has blown. Remove the power
supply to check for these conditions. If neither condition has occurred,
you may need to replace the power supply.

To remove one of the power supplies, first turn the power supply’s
ON/OFF switch off (the down position, as shown in Figure P-9). Loosen
the plastic screw either by hand or with a Phillips screwdriver. Grasp the
bracket and gently pull the power supply straight out of the assembly.

Revised May-2013 Installation and Use P-7

Redundant Power Supply Sequencer Module (RPSSM)

ON/OFF switch for power

supply
OFF = down position (shown)
ON = up position

Bracket

Screw

Loosen the screw and grasp

the bracket to slide the
power supply out of the
RPSSM.

Figure P-9. Hot Swapping a Power Supply

To re-insert the power supply, grasp the bracket and line up the board
with the grooves in the assembly. Gently slide the card into the RPSSM
until it inserts into the connector. Gently tighten the screw either by hand
or with a Phillips screwdriver. Now turn the On/Off switch on (the up
position).

P-8 Installation and Use Revised May-2013

 Redundant Power Supply Sequencer Module (RPSSM)

LED Indicators on the RPSSM

Three light emitting diodes (LEDs) are visible through the front cover of
the RPSSM (see Figure P-10). Table P-3 describes their functions.
Table P-3. LED Descriptions
Color
LED label (when lit) Meaning
PWR GOOD Green Lights when power is within correct range,
and remains on as long as power to unit
remains within normal operating ranges.
MC (Master Clear) Red Lights when the CPU is not running, and
I/O has been reset to 0. This lights
momentarily when the unit first powers on
or when the unit resets.
PWR DOWN Red Lights when power has fallen below
acceptable levels.

PWR GOOD (POWER GOOD)

MC (MASTER CLEAR)
PWR DOWN (POWER DOWN)
PWR GOOD (POWER GOOD)
PWR GOOD (POWER GOOD) For this power supply
For this power supply Pin 1 Pin 7

Figure P-10. LED Locations

Each power supply on the RPSSM also has an LED which lights when
power is good. If this LED does not light, remove the power supply and
check the fuse. Then ensure that the board is fully inserted.

Specifications
Redundant Power Supply Sequencer Module
Input Range: 22.2 to 30V DC (24V input supply, nominal)
Shutdown occurs at 22.2 nominal for 24V
input supply systems, respectively.
Temperature Range: Operating: -40 to 70 o C
Revised May-2013 Installation and Use P-9
Redundant Power Supply Sequencer Module (RPSSM)

Storage: -40 to 85 o C
Relative Humidity: 15 to 95% non-condensing
Vibration: 1G for 10-150 Hz
0.5 G for 150 Hz to 2000 Hz
RFI Susceptibility 3V/m 80 MHz to 1000 MHz per EN50082-2
Watchdog MOSFET 1A

Power Supplies (1 or 2 on the RPSSM)

Input Range 20 to 30Vdc (24V input supply, nominal)
Output Voltage 5V ± 2%, 3.3V ± 2%
Output Current 1A @ 3.3V, 2A @5V
Efficiency 75% at full load
Fusing 7x2 mm fuse 3A fast acting

Field Supply Power

VINF Input Range 20V to 30V
Fusing 5x20 mm fuse 10A slow blow

P-10 Installation and Use Revised May-2013

 ControlWave Instruction Manual (CI-ControlWave)

Appendix Z – Sources for Obtaining Material Safety Data

Sheets
This device includes certain components or materials which may be
hazardous if misused. For details on these hazards, please contact the
manufacturer for the most recent material safety data sheet.
Manufacturer General Emerson Part
Description Number & Media
Notes

Eagle Picher Lithium Thionyl 395600-01-4

Chloride Battery
Eagle Picher P/N
http://www.eaglepicher.com (1/2 AA, 3.6V, 950 LTC-9C
mAh - On-board)

Lithium Thionyl 395600-01-4

SAFT America
Chloride Battery SAFT P/N LS-
(1/2 AA, 3.6V, 950 14250
http://www.saftbatteries.com
mAh - On-board)

Revised May-2013 Appendix Z Z-1

This page is intentionally left blank
 ControlWave Instruction Manual (CI-ControlWave)

Index
Communication Ports
A defaults .....................................4-2
ACCOL3 Firmware Library ......... 1-10 Ethernet ..................................2-29
Analog Input (AI) Module ........... 3-19 Loop-back Test .... 5-29, 5-31, 5-32
Wiring ..................................... 3-20 RS-232 ...................................2-22
Analog Output (AO) Module ....... 3-24 RS-485 ...................................2-27
Wiring ..................................... 3-25 Communications
with readback ................ 3-24, 3-27 protocols supported ................1-10
ControlWave project
B downloading .............................4-4
Core Updump ............... See Updump
Backplanes .................................. 1-3 CPU Module .................................1-5
color code of connectors .......... 2-4 description ................................1-5
Backups ....................................... 4-5 Installation ..............................2-18
Battery Lithium battery backup............5-12
Disconnecting ......................... 5-12 Removing .................................5-6
enable switch.......................... 2-21 Replacing ..................................5-6
Lithium backup ....................... 5-12 switches ..................................2-19
replacing ................................. 5-12 Current
Bezel .......................................... 2-30 calculating maximum required 2-10
Removing ................................. 5-5
Replacing ................................. 5-5 D
Boot FLASH memory
amount ..................................... 1-6 Defaults
Bulk power ................................. 2-10 Comm Ports ..............................4-2
Diagnostic software ....................5-26
C Digital Input (DI) Module...............3-8
Jumpers ....................................3-9
Cables Wiring .......................................3-9
for Ethernet ports.................... 2-30 Digital Output (DO) Module ........3-13
RS-232 ................................... 2-23 Wiring .....................................3-14
RS-485 ................................... 2-27 with readback ............... 3-13, 3-17
shields .................................... 3-19 Disconnecting SRAM Battery .....5-12
Checking Downloading
LEDs ...................................... 5-13 the ControlWave project ...........4-4
Wiring ..................................... 5-22
CJC Error E
LLAI Module ........................... 3-43
Class I, Division 2 ........................ 2-2 Environmental specifications ........2-2
CMOS RAM memory Error codes .................................5-23
amount ..................................... 1-6 Ethernet ports .............................2-29
color code of connectors .............. 2-4 cables for ................................2-30
Communication problems Loop-back Test .......................5-32
common reasons for............... 5-13

Revised: May-2013 Index IND-1

ControlWave Instruction Manual (CI-ControlWave)

F 2-17. Standard 10/100Base-T

Ethernet Cable (CPU Module to
Features ....................................... 1-1
Hub) ....................................2-30
Field repair ................................... 5-5
2-18. Point-to-Point 10/100Base T
Figures
Ethernet Cable ....................2-30
1-1. ControlWave with 8 I/O
2-19 Bezel Assembly ..............2-31
modules ................................ 1-2
3-1. Terminal housing assembly
1-2. ControlWave Housing Options
removal .................................3-2
.............................................. 1-5
3-2. ControlWave Chassis Slot
1-3. I/O Modules ....................... 1-8
Assignments .........................3-4
1-4. ControlWave Programming
3-3. I/O Module (local termination)
Environment.......................... 1-9
wire routing ...........................3-5
2-1. 8 I/O module ControlWave -
3-4. I/O Module Remote
mounting diagram ................. 2-5
Termination Wiring ................3-7
2-2. 4 I/O module ControlWave -
3-5. DI Module – right side view –
mounting diagram ................. 2-6
jumper locations ....................3-9
2-3. Power Supply/Sequencer
3-6. DI Module – Local Terminal
Module (PSSM) .................... 2-8
block assembly assignments ..3-
2-4. PSSM Wire Routing Diagram
10
............................................ 2-13
3-7. Internally sourced DI Module
2-5. PSSM TB2 Typical wiring
– wiring diagram ..................3-10
schemes ............................. 2-14
3-8. Externally powered DI module
2-6. Watchdog MOSFET Switch
wiring diagram .....................3-10
Wiring ................................. 2-16
3-9. Remote DIN rail mountable
2-7. ControlWave to ControlWave
terminal block assembly
RED I/O Redundancy Field
assignments ........................3-11
Wiring ................................. 2-17
3-10. Remote DIN-rail mountable
2-8. ControlWave CPU module
without SCB ........................ 2-18 terminal block assembly
2-9. ControlWave CPU module assignments for relay isolated
with SCB ............................. 2-19 120Vac DI operation ...........3-12
2-10. Male DB9 9-Pin Connector 2- 3-11. Local terminal block
24 assembly assignments for open
2-11. RJ-45 Connector associated source isolated DO..............3-14
with COM3 (SCB) ............... 2-24 3-12. Open source isolated DO
2-12. Full-duplex and Half-duplex module wiring diagram ........3-14
Cable .................................. 2-25 3-13. Remote DIN-rail mountable
2-13. Full-duplex and Half-duplex terminal block assembly
Cable .................................. 2-26 assignments for open source
2-14. Connecting to a Modem or isolated DO .........................3-15
Radio .................................. 2-26 3-14. Remote DIN-rail mountable
2-15. COM3 (on SCB) RS-232 terminal block assembly
Cable Diagram (RJ-45 assignments for relay isolated
connector) ........................... 2-26 DO.......................................3-16
2-16. RJ-45 Ethernet Connector. 2- 3-15. Internally sourced 4-20mA
29 current loop AI wiring diagram 3-
20

IND-2 Index Revised: May-2013

 ControlWave Instruction Manual (CI-ControlWave)

3-16. Externally powered 4-20mA 3-34. Local isolated LLAI module

current loop AI – wiring diagram terminal block assy.
............................................ 3-20 assignments ........................3-41
3-17. Externally powered isolated 3-35. Remote DIN-rail mountable
1-5V AI wiring diagram ....... 3-21 terminal block assy.
3-18. Local AI module terminal assignments ........................3-42
block assembly ................... 3-21 4-1. Power Switch on PSSM .....4-1
3-19. Remote DIN-rail mountable 4-2. Run/Remote/Local Key
terminal block assembly Switch ...................................4-2
assignments for 4-20mA AI. 3-22 4-3. Saving a Backup of Your
3-20. Remote DIN-rail mountable Project ...................................4-6
terminal block assembly 5-1. HyperTerminal Mode Menu .5-
assignments for 1-5V AI ..... 3-23 3
3-21. Local AO module terminal 5-2. HyperTerminal (Ready to
block assembly assignments .. 3- Download) .............................5-4
25 5-3. Send File dialog box ..........5-4
3-22. Remote DIN-rail mountable 5-4. HyperTerminal (Download in
terminal block assembly progress) ...............................5-5
assignments for AO ............ 3-26 5-5 I/O Module to Be Replaced 5-8
3-23. 4-20mA current loop AO 5-6. Pulling the I/O Module Out of
wiring diagram .................... 3-27 the Housing ...........................5-9
3-24. UDI module – right side view 5-7. I/O Loosening the Top
– jumper locations ............... 3-30 Fastener ..............................5-10
3-25. UDI (debounce enabled) 5-8. I/O Terminal Block Board and
wiring diagram .................... 3-31 Terminal Housing Assembly
3-26. UDI debounce disabled Separated from the Rest of the
wiring diagram .................... 3-31 Module ................................5-10
3-27. Local UDI terminal block 5-9. New I/O Module in Place Prior
configuration/diagram ......... 3-32 to Attaching Terminal Board and
3-28. Remote DIN-rail mountable Terminal Housing Assembly5-11
terminal block assy. 5-10. Power Supply Sequencer
Assignments for UDI ........... 3-33 Module LEDs.......................5-16
3-29. Selecting Input Type in 5-11. CPU Module ports and LEDs
ControlWave Designer I/O ............................................5-16
Configurator ........................ 3-34 5-12. Analog Input (AI) module
3-30. Isolated RTD module wiring LEDs ...................................5-17
diagram ............................... 3-36 5-13. Analog output (AO) Module
3-31. Local isolated RTD module LEDs ...................................5-18
terminal block assy. 5-14. Digital Input (DI) Module
assignments........................ 3-37 LEDs ...................................5-19
3-32. Remote DIN-rail mountable 5-15. Digital Output Module LEDs
terminal block assy. ............................................5-20
assignments........................ 3-38 5-16. Universal Digital Input (UDI)
3-33. Isolated LLAI Module – Module LEDs.......................5-20
Thermocouple wiring diagram. 3- 5-17. RTD Module LEDs .........5-21
40

Revised: May-2013 Index IND-3

ControlWave Instruction Manual (CI-ControlWave)

5-18. Low Level Analog Input Placement in housings..............3-3

Module LEDs ...................... 5-22 Removing .................................5-7
5-19. NetView ......................... 5-28 Replacing ..................................5-7
5-20. WINDIAG Main Diagnostics RTD ........................................3-35
Menu ................................... 5-28 UDI .........................................3-29
5-21. RS-232 Loop-back plugs ... 5- Wiring .......................................3-5
30 Input Accuracy and Resolution
5-22. RS-485 Loop-back plugs ... 5- LLAI Module ...........................3-43
30 Installation ............................ 2-1, 3-6
5-23. Communications Diagnostic Class 1, Div 2 ...........................2-2
menu ................................... 5-31 CPU ........................................2-18
5-24. RJ-45 Ethernet Loop-back I/O Modules ..............................3-3
plug ..................................... 5-32 Overview ...................................2-2
5-25. Ethernet Diagnostic Menu . 5- PSSM .......................................2-7
33
Firmware upgrade ........................ 5-2 J
HyperTerminal .......................... 5-2 Jumpers
LocalView ................................. 5-2 DI ..............................................3-9
System Firmware Downloader . 5-2 LLAI ........................................3-39
FLASH memory RPSSM .................................... P-2
amount ..................................... 1-6 RTD ........................................3-35
Force recovery mode switch ...... 2-21 UDI .........................................3-30
G L
Grounding ............................. 2-6, 3-6 LEDs
Checking .................................5-13
H on RPSSM ............................... P-9
Hot swapping Local termination ..........................3-5
I/O module ................................ 5-7 LocalView .....................................5-2
power supply on an RPSSM ....P-7 Loop-back Test ................ 5-29, 5-31
Housings ...................................... 1-3 Low Level Analog Input (LLAI)
mounting .................................. 2-4 Module ....................................3-39
Humidity CJC Error ................................3-43
specifications ............................ 2-2 Input Accuracy and Resolution ...3-
HyperTerminal ............................. 5-2 43
LLAI ranges ............................3-43
I wiring ......................................3-40
I/O Configurator ........................... 1-9
I/O Modules ................................. 3-1 M
AI 3-19 Memory
AO .......................................... 3-24 Boot FLASH ..............................1-6
DI.............................................. 3-8 CMOS RAM
DO .......................................... 3-13 amount ..................................1-6
general information about ......... 1-7 FLASH
Installation (General) ................ 3-1 amount ..................................1-6
LLAI ........................................ 3-39 SDRAM

IND-4 Index Revised: May-2013

 ControlWave Instruction Manual (CI-ControlWave)

amount .................................. 1-6 Enable/Disable switch.............2-20

SRAM wiring ......................................2-15
amount .................................. 1-6 Redundant Power Supply Sequencer
Modules (RPSSM) Module ..................... P-1
AI 3-19 Remote termination ......................3-6
AO .......................................... 3-24 Repair in field ...............................5-5
CPU .......................... 1-5, 2-18, 5-6 Reset switch ...............................5-26
DI.............................................. 3-8 Resistance Temperature Device
DO .......................................... 3-13 (RTD) Input Module ................3-35
I/O Wiring .....................................3-36
general information about ..... 1-7 RPSSM Module ........................... P-1
LLAI ........................................ 3-39 RS-232 ports ..............................2-22
PSSM ......................... 1-7, 2-7, 5-6 cables for ................................2-23
RPSSM ....................................P-1 configuration switches ............2-21
RTD ........................................ 3-35 RS-485 ports ..............................2-27
steady state current draw of ... 2-12 cables for ................................2-27
UDI ......................................... 3-29 configuration switches ............2-21
RTD .... See Resistance Temperature
P Device (RTD) Input Module
Packaging Run/Remote/Local switch.............4-1
modules .................................... 2-3 Running diagnostic software ......5-26
Port 80 display
POST codes ........................... 5-23 S
run time status codes ............. 5-25 SDRAM memory
Port Configuration switches amount......................................1-6
for SCB ................................... 2-21 Service .........................................5-1
Power Supply Sequencer (PSSM) Shielding ......................................3-6
Module Site Considerations ......................2-1
description ................................ 1-7 Soft Switches
installation ................................ 2-7 Lock & unlock .........................2-19
Removing .......................... 2-7, 5-6 Software
Replacing ................................. 5-6 used with the ControlWave .......1-8
Run/Remote/Local switch ......... 4-1 Specifications
TB1 Connectors ..................... 2-16 for temperature, humidty, vibration
TB2 Connectors ..................... 2-12 ..............................................2-2
Wiring ..................................... 2-10 SRAM Battery
Power switch ................................ 4-1 Disconnecting .........................5-12
Protocols SRAM control switch ..................2-20
supported in ControlWave ...... 1-10 SRAM memory
PSSM See Power Supply Sequencer amount......................................1-6
(PSSM) Module Status codes ..............................5-23
Switches
R CPU Module ...........................2-19
Ranges power switch .............................4-1
Isolated LLAI .......................... 3-43 Reset switch ...........................5-26
Redundancy Run/Remote/Local switch .........4-1

Revised: May-2013 Index IND-5

ControlWave Instruction Manual (CI-ControlWave)

System Firmware Downloader ..... 5-2 3-9. AO Module Configurations ..3-

25
T 3-10. UDI Module General
Tables Characteristics ....................3-29
1-1. CPU Module Configurations 1- 3-11. UDI Module Configurations3-
5 30
2-1. Steady State Current Draw for 3-12. Jumper Assignments – UDI
Bulk Power Supplies ........... 2-12 Module ................................3-31
2-2. CPU Module Switch SW1 2-19 3-13. Isolated RTD Input Module
2-3. CPU Module Switch SW3 2-21 General Characteristics .......3-35
2-4. SCB Port Configuration 3-14. Isolated RTD Input Module
Switches ............................. 2-21 Configurations .....................3-35
2-5. RS-232 Connectors on CPU2- 3-15. Jumper Assignments - Non-
23 isolated HSC Module ..........3-36
2-6. RS-232 Connectors on SCB 2- 3-16. Isolated LLAI Module
23 General Characteristics .......3-39
2-7. RS-232 Port Connector Pin 3-17. Isolated LLAI Module
Assignment ......................... 2-24 Configurations .....................3-39
2-8. COM3 (on SCB) RS-232 Port 3-18. Jumper Assignments -
Connector Pin Assignment . 2-25 Isolated LLAI Module ..........3-39
2-9. RS-485 Connectors on SCB 2- 3-19. LLAI Module Input Accuracy
27 and Resolution ....................3-43
2-10. RS-485 COM3 Port 3-20. LLAI Module RTD Error with
Connector Pin Assignment . 2-27 CJC at 25C ........................3-43
2-11. RS-485 COM4 Port 4-1. Default Comm Port Settings
Connector Pin Assignment . 2-28 (by PCB) ...............................4-2
2-12. RS-485 Network 5-1. LED Assignments on Modules
Connections ........................ 2-28 ............................................5-13
2-13. Ethernet Ports ............... 2-29 5-2. I/O Field Wiring – Terminal
2-14. Ethernet 10/100Base-T CPU Block Reference ..................5-22
Module Pin Assignments .... 2-30 5-3. Port 80 POST status codes .5-
3-1. DI Module General 23
Characteristics ...................... 3-8 5-4. Port 80 Run Time Status
3-2. DI Module Configurations .. 3-8 Codes ..................................5-25
3-3. Jumper Assignments - DI TB1 Connector
Module .................................. 3-9 PSSM .....................................2-16
3-4. DO Module General TB2 Connector
Characteristics .................... 3-13 PSSM .....................................2-12
3-5. Isolated DO Module General Temperature
Characteristics .................... 3-13 specifications ............................2-2
3-6. AI Module General termination
Characteristics .................... 3-19 local ..........................................3-5
3-7. AI Module Configurations 3-20 remote ......................................3-6
3-8. AO Module General Troubleshooting ................. 5-1, 5-12
Characteristics .................... 3-24 common communication
configuration problems ........5-13

IND-6 Index Revised: May-2013

 ControlWave Instruction Manual (CI-ControlWave)

U Wiring, DC ..............................2-16
WINDIAG ...................................5-26
Universal Digital Input (UDI) Module
Wiring
............................................... 3-29
AI 3-20
Wiring ..................................... 3-31
AO ..........................................3-25
Unpacking components ............... 2-3
Checking .................................5-22
Updump
DI ..............................................3-9
procedure ............................... 5-33
DO ..........................................3-14
switch ..................................... 2-20
for redundancy ........................2-15
Upgrading firmware...................... 5-2
I/O Modules ..............................3-5
V LLAI ........................................3-40
PSSM .....................................2-10
Vibration RPSSM .................................... P-4
specifications ............................ 2-2 RTD ........................................3-36
UDI .........................................3-31
W watchdog circuit ............ 2-15, 2-16
Watchdog
and RPSSM .............................P-4
CPU switch ............................. 2-19

Revised: May-2013 Index IND-7

ControlWave Instruction Manual
CI-ControlWave May 2013

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