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Emerson ControlWave User Manual
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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.
5-34
Service & Troubleshooting
Revised Nov-2010
133
135
Table of Contents
Default Chapter
5
Table of Contents
5
I/O Modules
5
Wiring
5
Service
6
Chapter 1 - Introduction
7
Housing
7
Scope of the Manual
8
Physical Description
8
Controlwave with 8 I/O Modules
8
Housings
9
Controlwave Housing Options
10
CPU Module
11
CPU Module Configurations
11
Power Supply/Sequencer Module (PSSM)
13
I/O Modules
13
Software Tools
14
Controlwave Programming Environment
15
Chapter 2 - Installation
17
Site Considerations
17
Installation
17
Class I, DIV 2 Installation Considerations
18
Installation Overview
18
Unpacking Components
19
Power Supply/Sequencer Module
19
Color Coding of Slot Connectors
20
Mounting the Housing
20
Grounding the Housing
22
Power Supply/Sequencer Module (PSSM)
23
General Information about the PSSM
25
PSSM Installation Overview
25
General Wiring Guidelines
26
Wiring a Bulk DC Power Supply to the PSSM
26
Steady State Current Draw for Bulk Power Supplies
28
Pssm
28
Wiring an External Alarm or Annunciator to the Watchdog Connector and Wiring the Redundancy Control Input (OPTIONAL)
31
Watchdog MOSFET Switch Wiring
32
Controlwave to Controlwave RED I/O Redundancy Field Wiring
33
CPU Module
34
Controlwave CPU Module
34
CPU Module Switch SW1
35
Setting DIP Switches on the CPU Module
35
Soft Switches
36
CPU Module Switch SW3
37
SCB Port Configuration Switches
37
Connections to RS-232 Serial Port(S)
38
Connector Associated with COM3 (SCB)
40
Male DB9 9-Pin Connector
40
Cable
41
COM3 (on SCB) RS-232 Port Connector Pin Assignment
41
Description
41
Full-Duplex and Half-Duplex Cable
41
COM3 (on SCB) RS-232 Cable Diagram (RJ-45 Connector)
42
Connecting to a Modem or Radio
42
Connections to RS-485 Serial Port(S) on Secondary Communication Board (SCB)
43
Connections to RS-485 Serial Port(S) on the Secondary Communication Board (SCB)
43
Connections to Ethernet Port(S) on the CPU Module
45
Bezels
46
Standard 10/100Base-T Ethernet Cable (CPU Module to Hub)
46
Point-To-Point 10/100Base T Ethernet Cable
46
Ethernet 10/100Base-T CPU Module Pin Assignments
46
Bezel Assembly
47
Chapter 3 - I/O Modules
49
Assembly
49
Terminal Housing Assembly
49
Modules
49
Terminal Housing Assembly Removal
50
Module Placement
51
Status Leds
52
Wiring
52
Controlwave Chassis Slot
52
I/O Module (Local Termination) Wire Routing
53
Local Termination
53
Remote Termination
54
Shielding and Grounding
54
Wiring Diagram
54
Digital Input (DI) Modules
56
DI Module General
56
DI Module - Local Terminal Block Assembly Assignments
58
Internally Sourced DI Module - Wiring Diagram
58
Externally Powered DI Module
58
Remote DIN-Rail Mountable
59
Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Relay Isolated 120Vac DI Operation
60
Digital Output (DO) Modules
61
DO Module General
61
Local Terminal Block Assembly
62
Open Source Isolated DO
62
Assignments for Open Source
63
Remote DIN-Rail Mountable Terminal Block Assembly Assignments for Open Source Isolated DO
63
Analog Input (AI) Modules
67
Internally Sourced 4-20Ma
68
Externally Powered 4-20Ma Current Loop AI - Wiring Diagram
68
Externally Powered Isolated
69
Local AI Module Terminal Block
69
Analog Output (AO) Modules
72
Universal Digital Input (UDI) Modules
77
UDI Module General
77
Jumper Locations
78
Terminal Block Assembly
80
Terminal Block Assembly
81
Remote
81
Selecting Input Type in
82
Isolated Resistance Temperature Device (RTD) Input Module
83
Isolated RTD Input Module General Characteristics
83
Isolated RTD Input Module
83
Local Isolated RTD Module
85
Isolated Low Level Analog Input (LLAI) Module
87
Isolated LLAI Module
88
LLAI Module
91
Chapter 4 - Operation
93
Powering Up/Powering down the Controlwave
93
Setting the Operating Mode (Run/Remote/Local Switch)
93
Power Switch on PSSM
93
Run/Remote/Local Switch
93
Power Switch
93
Default Comm Port Settings
93
Communicating with the Controlwave
94
Default Comm Port Settings
94
Run/Remote/Local Key Switch
94
Run/Remote/Local Switch
94
Collecting Data from the Controlwave
95
Creating and Downloading an Application (Controlwave Project)
95
Creating and Maintaining Backups
96
Creating a Zipped Project File (*.ZWT) for Backup
97
Saving a Backup of Your Project
97
Saving Flash Configuration Parameters (*.FCP)
98
Backing up Data
100
Chapter 5 - Service and Troubleshooting
101
Hyperterminal
101
Upgrading Firmware
102
Hyperterminal Mode Menu
103
Send File Dialog Box
104
Removing or Replacing Components
105
Accessing Modules for Testing
105
Removing/Replacing the Bezel
105
Removing/Replacing the CPU Module
106
Removing/Replacing the PSSM
106
Removing/Replacing an I/O Module (Hot Swapping)
107
CPU Module
107
I/O Module to be Replaced
108
Removing/Replacing the Backup Battery
112
General Troubleshooting Procedures
112
Checking Leds
113
Scb
113
LED Assignments on Modules
113
Port 80 Display
114
Module
114
Power Switch
115
Analog Output (AO) Module
117
For UDI
119
Universal Digital Input (UDI)
119
Checking Wiring/Signals
121
Low Level Analog Input
121
(RTD) Input Module
121
I/O Field Wiring - Terminal Block Reference
121
Port 80 Display Codes
122
Reset Switch
122
Status Codes
124
Reset Switch
125
WINDIAG Diagnostic Utility
125
Available Diagnostics
128
Communications Diagnostic
130
Core Updump
132
Appendix A - Special Instructions for Class I, Division 2 Hazardous Locations
135
Jumper Locations
140
Redundant Power Supply Sequencer
146
Appendix P - Redundant Power Supply Sequencer Module (RPSSM)
149
Appendix Z - Sources for Obtaining Material Safety Data Sheets (MSDS)
149
Index
149
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Emerson ControlWave Specifications
General
Brand
Emerson
Model
ControlWave
Category
I/O Systems
Language
English
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