Page 2 - Click here to return to Table of Contents
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 f...
Page 4 - How to return material for Repair or Exchange; Repair
How to return material for Repair or Exchange Before a product can be returned to Remote Automation Solutions (RAS) for repair, upgrade, exchange, or to verify proper operation, Form (GBU 13.01) must be completed in order to obtain a RA (Return Authorization) number and thus ensure an optimal lead t...
Page 6 - Emerson Process Management; Training; GET THE MOST FROM YOUR EMERSON; Avoid Delays and problems in getting your system on-line
Emerson Process Management Training GET THE MOST FROM YOUR EMERSON INSTRUMENT OR SYSTEM • Avoid Delays and problems in getting your system on-line • Minimize installation, start-up and maintenance costs. • Make the most effective use of our hardware and software. • Know your system. As you know, a w...
Page 7 - CI-ControlWave Express; Control; Express; Remote Terminal Unit; INSTALLATION FORWARD; NOTE for all Control; Wave; READ THIS SECTION FIRST!
CI-ControlWave Express - Installation Forward CI-ControlWave Express Control Wave Express Remote Terminal Unit INSTALLATION FORWARD NOTE for all Control Wave Express Installers: READ THIS SECTION FIRST! This manual has been designed for the following audience: • Customer Site Engineers, who must pla...
Page 8 - BLANK PAGE
BLANK PAGE Click here to return to Table of Contents
Page 9 - TABLE OF CONTENTS; Express INTRODUCTION
CI-ControlWave Express Contents / 0 - 1 CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - Control Wave Express INTRODUCTION 1.1 GENERAL DESCRIPTION .........................................................................................
Page 11 - Section 3 - ControlWave Express SERVICE; Express SPECIFICATIONS; APPENDICES/SUPPLEMENTAL INSTRUCTION
CI-ControlWave Express Contents / 0 - 3 CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # Section 3 - ControlWave Express SERVICE 3.1 SERVICE INTRODUCTION ........................................................................................ 3-...
Page 12 - REFERENCED Bristol CUSTOMER INSTRUCTION MANUALS
0 - 4 / Contents CI-ControlWave Express CI-ControlWave Express Control Wave Express Remote Terminal Unit TABLE OF CONTENTS SECTION TITLE PAGE # APPENDICES/SUPPLEMENTAL INSTRUCTION (Continued) Sources for Obtaining Material Safety Data Sheets ..................................... Appendix Z Site Cons...
Page 13 - Section 1; GENERAL DESCRIPTION; Firmware/Software Features
CI-ControlWave Express Introduction / 1-1 Section 1 ControlWave Express INTRODUCTION 1.1 GENERAL DESCRIPTION ControlWave Express remote terminal units (RTU) have been designed to perform as the ideal platform for remote site automation, measurement and data management in process control and manufact...
Page 14 - Figure 1-1 - ControlWave Express Component Identification
1-2 / Introduction CI-ControlWave Express microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC) is the core of the CPU/System Controller Board. In addition to the microprocessor and control logic, the CPU/System Controller Board includes two fixed RS-232 Communication Ports (CO...
Page 15 - ControlWave PROGRAMMING ENVIRONMENT; - Control Strategy Software Diagram; tools that make up the programming environment are:
CI-ControlWave Express Introduction / 1-3 1.2 ControlWave PROGRAMMING ENVIRONMENT The ControlWave programming environment uses industry-standard tools and protocols to provide a flexible, adaptable approach for various process control applications in the water treatment, wastewater treatment, and in...
Page 16 - PHYSICAL DESCRIPTION
1-4 / Introduction CI-ControlWave Express • ControlWave Designer programming package offers several different methods for generating and debugging control strategy programs including function blocks, ladder logic, structured languages, etc. The resulting programs are fully compatible with IEC 61131-...
Page 17 - Power Output
CI-ControlWave Express Introduction / 1-5 will remain on. When interfaced to a keypad, the operator may activate the display at any time by pressing the appropriate front panel button. 1.3.2 CPU/System Controller Board The multilayer CPU/System Controller Board provides ControlWave Express CPU, I/O ...
Page 18 - Figure 1-3 - ControlWave Express CPU/System Controller Board
1-6 / Introduction CI-ControlWave Express S1 1 2 34 12 3456 78 1 1 2 2 3 4 5 6 RJ-45 RJ-45 W3: 1-2 = Battery Enabled 2-3 = Battery Disabled W2: 1-2 = COM2 CTS from Port W5: 1-2 = 12/24V Power Supply Shut-down Hysterisis Shut-down Hysterisis 2-3 = 6V Power Supply W6: 1-2 = 12V Power Supply Shut-down ...
Page 19 - ControlWave Designer Programmer’s Handbook; are for factory use only.; Function; IOBUS
CI-ControlWave Express Introduction / 1-7 A supervisory circuit is used to switch to battery power when VCC falls out of specification. For maximum shelf life, the battery may be isolated from the circuit by removing the Backup Battery Jumper W3 from position 1 to 2 and then storing it in position 2...
Page 20 - Main Power Connector; A and a maximum input
1-8 / Introduction CI-ControlWave Express Table 1-1 - CPU/System Controller Board Connector Summary (Continued) Ref. # Pins Function Notes TB1 6-pin Solar Panel, Battery/Power Supply & Aux Out, Main Power Connector See Section 2.3.9 TB2 2-pin Secondary battery input TB3 8-pin Term. Block (COM2 -...
Page 21 - Boot/downloader FLASH; Note: Recovery Mode will also be initiated if CPU/System; FLASH Memory
CI-ControlWave Express Introduction / 1-9 • TB1-4 - Ground (GND) • TB1-5 - Auxiliary Power Out+: for an external radio/modem * • TB1-6 - Ground (GND) • TB2-1 - Secondary battery input • TB2-2 - Ground (GND) Note: * = Not available on units equipped with an Ethernet Port. Power may be provided by a u...
Page 23 - Recovery Mode/Local Mode Control; Switch
CI-ControlWave Express Introduction / 1-11 • W17 - Input Power Selection (Controls Solar Power Shunt Reg.) N/A for +24Vdc CPUs 1 to 2 = 6V Power 2 to 3 = 12V Power • W18 - COM1 Connector Selection 1 to 2 = Connector J4 (D connector) is active 2 to 3 = Alternate connector J11 is active 1.3.2.4 CPU/Sy...
Page 25 - Process I/O Board Configuration Jumpers and Switch SW1; JP3 - AO Power Source
CI-ControlWave Express Introduction / 1-13 • Two Non-Isolated Internally-Sourced High Speed Counter Inputs (or DI operation supported) • Three Non-Isolated Single-Ended 1-5V or 4 to 20mA Analog Inputs (Optional) • One Non-Isolated Externally-Powered 1-5V or 4 to 20mA Analog Output (Optional) 1.3.3.1...
Page 27 - High Speed Counter Input Interface; 5 millisecond input filtering protects
CI-ControlWave Express Introduction / 1-15 1.3.3.2 Process I/O Board Connectors Process I/O Boards are equipped with up to six (6) I/O interface connectors that function as follows (see Table 1-5): Table 1-5 - Process I/O Board Connector Summary Ref. # Pins Function Notes P1 20-Pin Bd. Power and I/O...
Page 28 - via ControlWave Designer.; Each HSC circuit has a maximum input frequency of 10 kHz.
1-16 / Introduction CI-ControlWave Express power is applied to the field device (controlled via jumper JP4) and can be supplied by the system battery or an external power source. Each AI channel can be individually configured for 4 to 20mA or 1-5V operation (via JP5 for AI1, JP6 for AI2 and JP7 for ...
Page 31 - Section 2; INSTALLATION IN HAZARDOUS AREAS; Express Component Identification; SITE LOCATION CONSIDERATIONS
CI-ControlWave Express Installation & Operation / 2-1 Section 2 ControlWave Express INSTALLATION & OPERATION 2.1 INSTALLATION IN HAZARDOUS AREAS Each ControlWave Express RTU is furnished in an enclosure/chassis that accommodates mounting to a Panel or a DIN-Rail and have been designed to ope...
Page 32 - Mounting the ControlWave; ControlWave Express INSTALLATION/CONIGURATION; Overview of Configuration; Step 1. Hardware Configuration
2-2 / Installation & Operation CI-ControlWave Express Chassis. Two Thumb Screws can be loosened to facilitate removal of the Card Edge Cover, and thus accommodating all instrument field wiring. Information on mounting the ControlWave Express assembly is provided in Section 2.3.1 Mounting the Con...
Page 33 - software must be installed on the PC. The completed project is
CI-ControlWave Express Installation & Operation / 2-3 5. Install I/O wiring to the Process I/O Board and to the CPU/System Controller Board if Pulse Inputs are present (see Section 2.3.4). Install a communications cable to a Model 3808 Transmitter if required (see Section 2.3.6). 6. Install a gr...
Page 34 - “PDD”
2-4 / Installation & Operation CI-ControlWave Express Detailed information on the Flash Configuration Utility, and LocalView is included in Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in Chapter 6 of that same manual. TechView is described in the TechView ...
Page 35 - ADD the ControlWave Express to an Existing Open BSI Network; If a Bristol network already exists:; Open BSI Utilities Manual; Mounting the ControlWave Express Enclosure/Chassis
CI-ControlWave Express Installation & Operation / 2-5 You can use whichever HTML creation package you want to create the pages, however, all ControlWave Express related web pages (whether standard or user-created) must be viewed within Microsoft® Internet Explorer. The web pages may reside eithe...
Page 36 - Figure 2-2 - ControlWave Express Dimensions
2-6 / Installation & Operation CI-ControlWave Express Figure 2-2 - ControlWave Express Dimensions - Power wiring should not be installed until the unit has been mounted and grounded at a designated work site. - I/O wiring, external power wiring, local comm. port, and network (RS-232 and RS-485) ...
Page 37 - Figure 2-3 - Process I/O Board Component Identification Diagram
CI-ControlWave Express Installation & Operation / 2-7 2.3.2 Process I/O Board Configuration I/O Board jumpers and Switch SW1 must be set to configure field I/O (see Figure 2-3). Figure 2-3 - Process I/O Board Component Identification Diagram Click here to return to Table of Contents
Page 40 - SWITCH
2-10 / Installation & Operation CI-ControlWave Express SW2-5 set OFF forces the ControlWave Express to reinitialize SRAM when the unit recovers from a low power or power outage condition. When set ON, the contents of SRAM will be retained and utilized when the system restarts. Note: If the Batte...
Page 45 - Looking into; Description; Not Connected
CI-ControlWave Express Installation & Operation / 2-15 1 8 Looking into receptacle Figure 2-6 - RJ-45 Connector (Ethernet Port) J1 on CPU/System Controller Board Figure 2-7 - Point-to-Point 10/100Base-T Ethernet Cable Figure 2-8 - Standard 10/100Base-T Ethernet Cable (CPU/System Controller Board...
Page 46 - RTUs utilize terminal blocks equipped with compression-type; CPU/System Controller Board I/O Connections; 5 millisecond input filtering protects against contact bounce.
2-16 / Installation & Operation CI-ControlWave Express 2.3.4 I/O Wiring ControlWave Express RTUs are provided with card edge terminal blocks that accommodate field wiring. Wiring is routed into the enclosure/chassis through a slot in the removable card edge cover. 2.3.4.1 I/O Wire Connections Co...
Page 48 - Note: When AI Field Power Jumper JP4 is set in
2-18 / Installation & Operation CI-ControlWave Express 2.3.4.4 Dedicated Non-isolated Digital Outputs Process I/O Board Terminal Block connector TB3 provides interface to 2 dedicated non-isolated Digital Outputs (DOs) and two selectable DI/Os. Digital Outputs have a 30V operating range and are d...
Page 49 - Table 2-7 - Analog Input Circuitry Jumper Assignments; AI Field Power; It should be noted that Analog Output; Power
CI-ControlWave Express Installation & Operation / 2-19 Note: Cable shields associated with AI wiring should be connected to the ControlWave Express Chassis Ground. Multiple shield terminations will require a user supplied copper ground bus. This ground bus must be connected to the ControlWave Ex...
Page 50 - Switches; Configures HSC1; Figure 2-10 - Pulse Input Wiring Diagram
2-20 / Installation & Operation CI-ControlWave Express 2.3.4.8 Non-isolated High Speed Counter/Digital Inputs Process I/O Board Terminal Block connector TB4 provides the interface to two internally-sourced single-ended High Speed Counter/Digital Inputs (HSC/DIs). All Input circuits have surge su...
Page 51 - Connector TB6 on the CPU/System Controller Board; TB6 Pin; EXC
CI-ControlWave Express Installation & Operation / 2-21 2.3.5 RTD Wiring A 3-wire RTD may be provided with the ControlWave Express (equipped with a 14MHz CPU/System Controller Board). Connector TB6 on the CPU/System Controller Board accommodates a removable three-wire Terminal Block (TB6). This c...
Page 52 - Figure 2-13 - 3808 Transmitter to ControlWave Express; Use SW3 on CPU/System Controller Board to configure COM3.
2-22 / Installation & Operation CI-ControlWave Express 2.3.6 Connection to a Model 3808 Transmitter A Model 3808 Transmitter (Digital) can be interfaced to a ControlWave Express via an RS-232 or an RS-485 communication scheme. Communication schemes and cable lengths determine the type of communi...
Page 53 - 4MHz Ultra Low Power CPU:
CI-ControlWave Express Installation & Operation / 2-23 Figure 2-15 - ControlWave Express to 3808s - RS-485 Network Diagram Figures 2-13 and 2-14 detail the RS-232 and RS-485 wiring connections required between the ControlWave Express and the Model 3808 Transmitter. Up to two Model 3808 Transmitt...
Page 54 - application loads. For 3808 power consumption refer to CI-3808.
2-24 / Installation & Operation CI-ControlWave Express • TB1-1 - Solar Power In + (TB1-2 = GND ) (GND = − ) • TB1-5 - Auxiliary Power Out + - for External Radio/Modem (TB1-6 = GND) (GND = − ) A secondary power input is available at connector TB2: • TB2-1 – Input • TB2-2 – Ground ControlWave Expr...
Page 55 - is used and that the length should be as short as possible.
CI-ControlWave Express Installation & Operation / 2-25 2.3.7.2 Power Wiring One Bulk DC supply can be connected to the ControlWave Express CPU/System Controller Board. The Bulk DC supply (nominally +6Vdc, +12Vdc or +24Vdc) connected to TB1-3 (Power In +) and TB1-4 (GND -) is converted, regulated...
Page 56 - OPERATIONAL DETAILS; Steps required to download system firmware.
2-26 / Installation & Operation CI-ControlWave Express 2.3.8 Operation of the Lithium Backup Coin-cell Battery CPU/System Controller Boards are equipped with a Coin-cell Socket (S1) that accommodates a 3.0V, 300 mA-hr lithium coin cell. A supervisory circuit on the CPU/System Controller Board is...
Page 57 - OFF; position and SW1-2 set to the; ON; Firmware; product code and; Using LocalView to Upgrade ControlWave Express Firmware
CI-ControlWave Express Installation & Operation / 2-27 familiar with the various programming tools. The following software user documentation is referenced: Getting Started with ControlWave Designer Manual - D5085 ControlWave Designer Reference Manual - D5088 Open BSI Utilities Manual - D5081 We...
Page 59 - Step 3 - Flash Data Setup; Click on
CI-ControlWave Express Installation & Operation / 2-29 Step 3 - Flash Data Setup Complete the following fields in the Flash Data Setup Wizard: "Please enter the name of the binary file to Flash" To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file on yo...
Page 61 - xxxx; Figure 2-21 - Local View Downloading System Firmware Menu
CI-ControlWave Express Installation & Operation / 2-31 Figure 2-20 - Flash Data Setup Menu (Note: Substitute \e1s xxxx bin or \e3s xxxx for cwe04...) Figure 2-21 - Local View Downloading System Firmware Menu Click here to return to Table of Contents
Page 62 - If not already running, apply power to the associated PC.
2-32 / Installation & Operation CI-ControlWave Express 2.4.2.2 Using HyperTerminal to Upgrade ControlWave Express Firmware A half-duplex null modem cable (see Figure 2-5) must be connected to COM1 of the ControlWave Express and to any RS-232 port on the associated PC. The PC’s RS-232 port used f...
Page 63 - xxxxx; Figure 2-23 - HyperTerminal FLASH Download Menu
CI-ControlWave Express Installation & Operation / 2-33 5. When the FLASH is ready for download the letter C will be displayed on the screen. In the HyperTerminal command bar click on Transfer and then Send File (see Figure 2-23). In the Send File Dialog Box (see Figure 2-24), select “1KXmodem” f...
Page 64 - Figure 2-25 - HyperTerminal FLASH Download
2-34 / Installation & Operation CI-ControlWave Express Figure 2-25 - HyperTerminal FLASH Download (Download in Process) (Note: Substitute \e1s xxxx bin or \e3s xxxx .bin for cwe04... ) Figure 2-26 - CPU/System Controller LEDs (See Figure 2-27 and Table 2-12 for Status LED Definitions) Click here...
Page 65 - Table 2-12 - System Status Codes on LCD Display; Indication
CI-ControlWave Express Installation & Operation / 2-35 Figure 2-27 - CPU/System Controller LED Board - LED Hexadecimal Codes (See Table 2-12 for Definitions) Table 2-12 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Display Board. LED 6 STA6 LED 5 STA5 LED 4...
Page 66 - Note: Remote upgrade of ControlWave; Soft Switch Configuration and Communication Ports; Note: By setting CPU/System Controller Board
2-36 / Installation & Operation CI-ControlWave Express 2.4.2.3 Remote Upgrade of ControlWave Express Firmware It is possible to download system firmware into an unattended remote ControlWave Express. This function can only be accomplished if CPU Board Switch SW2-6 (associated with the unit in qu...
Page 67 - WINDIAG program, it must not otherwise be in use.
CI-ControlWave Express Installation & Operation / 2-37 WINDIAG program, it must not otherwise be in use. Note: CPU Switch SW2-8 must be set OFF to run the WINDIAG program. COM3: RS-232/RS-485 Communications Port COM3 on the CPU/System Controller Board defaults to 9600 baud, 8-bits, no parity, 1 ...
Page 69 - User defined strings; List Selection Screen:; List
CI-ControlWave Express Installation & Operation / 2-39 Figure 2-29 - Dual-button Display/Keypad Assembly Installation Drawing Displays are organized into screens as follows: Opening Screen: User defined strings List Selection Screen: List Name List Number <Blank Line> <Blank Line> Th...
Page 70 - Display Element Screen:; Variable; Automatic Mode; and; Manual Mode
2-40 / Installation & Operation CI-ControlWave Express Figure 2-30 - 25-Button Display/Keypad Assembly Installation Drawing Display Element Screen: <Blank Line> <Blank Line> Variable Name Variable Name The Display Element screen is entered from the list selection screen by pressing t...
Page 73 - Section 3; SERVICE INTRODUCTION; PC with null modem interface cable & Bristol WINDIAG Software; Warning; COMPONENT REMOVAL/REPLACEMENT PROCEDURES; components for
CI-ControlWave Express Service / 3-1 Section 3 ControlWave Express SERVICE 3.1 SERVICE INTRODUCTION This section provides general, diagnostic and test information for the ControlWave Express. The service procedures described herein will require the following equipment: 1. PC with null modem interfac...
Page 74 - Carefully slide the boards out of the Enclosure/Mounting Chassis.; TROUBLESHOOTING TIPS
3-2 / Service CI-ControlWave Express 3.2.2 Removal/Replacement of the CPU/System Controller Board & the Process I/O Board 1. Loosen the two Thumb Screws and remove the Removable Card Edge Cover. 2. If the ControlWave Express is running, place any critical control processes under manual control a...
Page 76 - Table 3-1 - System Status Codes on LCD Display
3-4 / Service CI-ControlWave Express Figure 3-1 - CPU/System Controller LED Board – Status LED Hexadecimal Codes (See Table 3-1 for Definitions) Table 3-1 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Display Board. LED 6 STA6 LED 5 STA5 LED 4 STA4 LED 3 STA3 L...
Page 79 - Figure 3-3 - Process I/O Board Component Identification Diagram
CI-ControlWave Express Service / 3-7 Figure 3-3 - Process I/O Board Component Identification Diagram Click here to return to Table of Contents
Page 81 - Disconnecting RAM Battery; WINDIAG DIAGNOSTICS
CI-ControlWave Express Service / 3-9 Figure 3-5 - CPU/System Controller Board Field I/O Wiring Diagram 3.4.2 Disconnecting RAM Battery The ControlWave Express RTU Lithium RAM battery cannot be replaced while power is on. Once the RAM battery has been replaced, the unit will still execute its FLASH-b...
Page 82 - Note: Port COM1 will be configured for; Start
3-10 / Service CI-ControlWave Express • CPU/System Controller Board Switch SW2-8 must be OFF to run the WINDIAG program. Setting SW2-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode. • Any ControlWave Express communication port can be connected to the P...
Page 83 - Figure 3-6 – NetView - Example with Multiple Networks
CI-ControlWave Express Service / 3-11 Figure 3-6 – NetView - Example with Multiple Networks Figure 3-7 - WINDIAG Main Diagnostics Screen Click here to return to Table of Contents
Page 84 - Communications Diagnostic:
3-12 / Service CI-ControlWave Express 4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG will perform the diagnostics and display pass/fail results. 5. After all diagnostic testing has been performed, exit WINDIAG program and then exit the NetView. When you clos...
Page 85 - Click on RUN button next to External loop-back.
CI-ControlWave Express Service / 3-13 Figure 3-8 - COM1 & COM2 RS-232 Loop-back Plug/Wires Figure 3-9 - COM3 RS-232 & RS-485 Loop-back Wires Note: RS-485 Loopback can be achieved via CPU Switches SW3-1 & SW3-2 set ON 3.5.1.2 Serial Comm. Port External Loop-back Test Procedure Connect an ...
Page 86 - Figure 3-10 - WINDIAG’s Communications Diagnostic Menu
3-14 / Service CI-ControlWave Express Figure 3-10 - WINDIAG’s Communications Diagnostic Menu 3.6 CORE UPDUMP In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for evaluation by Emerson Remote Automation Solutions division engineers. This upload is referred to as a ‘Core ...
Page 87 - Note: The factory default; position or the; CALIBRATION CHECKS; TechView User’s Guide
CI-ControlWave Express Service / 3-15 1. Set CPU/System Controller Board Switch SW2-1 OFF (Disable Watchdog Timer). If Switch SW2-4 is ON, set it to OFF (Enable Core Updump). Note: The factory default setting for SW2-4 is OFF. 2. Wait for the error condition (typically 3F on CPU/System Controller Bo...
Page 89 - Section 4; Note: Voltages are dc unless otherwise specified.
CI-ControlWave Express Specifications / 4- 1 Section 4 ControlWave Express SPECIFICATIONS 4.1 CPU, MEMORY & PROGRAM INTERFACE Processor: Sharp’s LH7A400 32-bit System-on-Chip with 32-bit ARM9TDMI RISC Core Memory: 8 Mbytes of simultaneous read/write FLASH 2 Mbyte of on-board SRAM 512 Kbytes FLAS...
Page 92 - Figure 4-4 - Terminal Blocks TB1 and TB2; V Input Source Voltage
4-4 / Specifications CI-ControlWave Express Table 4-3 - RS-232/485 Port (COM3) Connector TB4 Pin Assignments Pin # Signal RS-232 Description: RS-232 Signals Signal RS-485 Description: RS-485 Signals 1 - - RXD+ Receive Data + Input 2 RXD Receive Data Input- RXD − Receive Data − Input 3 TXD Transmit D...
Page 93 - 0 microsecond Filtering.; Figure 4-5 - 4-Position Pulse Input Interface Terminal Block TB5
CI-ControlWave Express Specifications / 4- 5 Max. Input Frequency: 10 kHz Signal conditioning: 20 microsecond Filtering. Figure 4-5 - 4-Position Pulse Input Interface Terminal Block TB5 RTD Input Note: Only Available on 14MHz CPUs RTD Type: 100-ohm platinum bulb (using the DIN 43760 curve). Configur...
Page 95 - Non-isolated Digital Inputs
CI-ControlWave Express Specifications / 4- 7 4.3.2 Non-isolated Digital Input/Output Circuitry Specs. Non-isolated Digital Inputs Number of Inputs: 4 Fixed, 2 Selectable DI - Internally Sourced (Dry Contact) operation Input Filtering: 15 milliseconds Input Current: Switch Selectable (SW1-3) DI1 thro...
Page 96 - Non-isolated Analog Outputs; Note
4-8 / Specifications CI-ControlWave Express Input Impedance: 1 Meg ohm for 1-5V inputs 250 ohm for 4-20mA inputs Settling Time: 600 msec to within 0.1% of input signal Conversion Time: 20 usec Non-isolated Analog Outputs Number of Outputs: 1 AO (1-5V or 4-20mA) individually jumper configurable 4-20m...
Page 98 - Express Dimensions
4-10 / Specifications CI-ControlWave Express Figure 4-8 - Control Wave Express Dimensions Click here to return to Table of Contents
Page 99 - Table A1 -Module/Board Connector Customer Wiring Connectors; Module/Item Connector
Control Wave Express Special Instructions for Class I, Division 2 Hazardous Locations 04/24/2006 Appendix A, Document CI-ControlWave Express Page 1 of 2 1. Bristol’s Control Wave Express RTU is listed by Underwriters Laboratories (UL) as nonincendive and (when installed in a NEMA 1 or better enclosu...
Page 101 - Appendix C; Hardware Configuration
CI-ControlWave Express Appendix C - Hardware Installation Guide / C-1 Appendix C HARDWARE INSTALLATION GUIDE Hardware Configuration There are seven (7) main steps required to configure a ControlWave Express. This appendix provides an overview of these steps with an emphasis on the installation and c...
Page 103 - Figure C-3 – Process I/O Board Component Identification Diagram
CI-ControlWave Express Appendix C - Hardware Installation Guide / C-3 Figure C-3 – Process I/O Board Component Identification Diagram Click here to return to Table of Contents
Page 104 - Loopback & Termination Control for COM3
C-4 / Appendix C - Hardware Installation Guide CI-ControlWave Express Step 1. Hardware Configuration (Continued) 2. Remove the Process I/O Board and the CPU/System Controller Board (as one assembly). Table C-1 - CPU/System Controller Bd. Switch SW1 Recovery Mode/Local Mode Control SWITCH Function Se...
Page 105 - of connector determined by setting of jumper W18.)
CI-ControlWave Express Appendix C - Hardware Installation Guide / C-5 Step 1. Hardware Configuration (Continued) 3. Make sure that the Lithium Backup Battery has been enabled, i.e., Backup Battery Jumper W3 on the CPU/System Controller Assembly should be installed on jumper posts 1-2). Configure the...
Page 108 - Ethernet Port
C-8 / Appendix C - Hardware Installation Guide CI-ControlWave Express Step 1. Hardware Configuration (Continued) RS-485 Ports ControlWave Express RTUs can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for ne...
Page 110 - Figure C-8 - Model 3808 Transmitter to Control
C-10 / Appendix C - Hardware Installation Guide CI-ControlWave Express Step 1. Hardware Configuration (Continued) 5. Install I/O wiring to the Process I/O Board and CPU/System Controller Board (see Figures C-11 and C-12 and Section 2.3.4 if required). Install a communications cable between the Contr...
Page 113 - wire is used and that the length should be as short as possible.; Step 2. Software Installation on the PC Workstation; . For information on minimum system
CI-ControlWave Express Appendix C - Hardware Installation Guide / C-13 Step 1. Hardware Configuration (Continued) 6. Install a ground wire between the Enclosure/Chassis and a known good Earth Ground. ControlWave Express Enclosures are not provided with a Ground Lug. A ground wire (#4 AWG Max. wire s...
Page 114 - and Run the Flash Configuration Utility; Chapter 6 of that same manual. TechView is described in the; Step 4. Creation of the Application-Specific Control Strategy; example. Additional examples are included in the manual,
C-14 / Appendix C - Hardware Installation Guide CI-ControlWave Express subsequently start ControlWave Designer, it will operate only in ‘DEMO’ mode, and will limit the available system resources. IMPORTANT: When you start ControlWave Designer, you will be reminded to register the software. Unregiste...
Page 115 - Variables marked as OPC can be built into a text file by the
CI-ControlWave Express Appendix C - Hardware Installation Guide / C-15 On the variables declaration page(s) in ControlWave Designer, you will need to mark any variable you want to make accessible to external programs, such as Open BSI’s DataView utility, as “PDD” . Similarly, any variables which sho...
Page 116 - Downloading the Application; Getting Started with ControlWave Designer Manual; position and SW1-2 in the; LED & LCD Display Checks; CPU/System Controller Boards ONLY are also equipped with a
C-16 / Appendix C - Hardware Installation Guide CI-ControlWave Express the ControlWave Express is reset, or if there has been a failure of the backup battery, the control strategy can be restarted from the beginning, i.e. from the BOOT project in FLASH memory. Downloading the Application Any Control...
Page 118 - Table C-7 - System Status Codes on LCD Display
C-18 / Appendix C - Hardware Installation Guide CI-ControlWave Express (See Table C-7 for Definitions) Table C-7 - System Status Codes on LCD Display & LEDs on CPU/System Controller Board’s LED Board. LED 6 STA6 LED 5 STA5 LED 4 STA4 LED 3 STA3 LED 2 STA2 LED 1 STA1 Status In Hex LCD Disp. Indic...
Page 119 - Instruction Manual; Appendix E
www.EmersonProcess.com/Bristol Instruction Manual CI-ControlWave Express Oct., 2006 Control Wave Express ControlWave Express DISPLAY/KEYPAD ASSEMBLY - GUIDE Appendix E Click here to return to Table of Contents
Page 120 - APPENDIX E
CI-ControlWave Express Appendix E – Display/Keypad Contents / 0 - 1 APPENDIX E Control Wave Express Display/Keypad Assembly Guide TABLE OF CONTENTS SECTION TITLE PAGE # E1.1 OVERVIEW ................................................................................................................... E...
Page 121 - These assemblies allow an operator or engineer to view and modify
CI-ControlWave Express Appendix E - Display/Keypad / E - 1 Appendix E DISPLAY/KEYPAD ASSEMBLY GUIDE E1.1 OVERVIEW Bristol Display/Keypad assemblies provide a built-in, local, user interface for the Control Wave Express These assemblies allow an operator or engineer to view and modify variable values...
Page 122 - Display/Keypad Assemblies are supported by; Automatic Mode and Manual Mode; E2.1 DISPLAY FUNCTION BLOCK DESCRIPTION; E2.1.1 DISPLAY Function Block Parameters
E - 2 / Appendix E - Display/5x5Keypad CI-ControlWave Express Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode . Automatic Mode In Automatic Mode a set of screens (based on the application load) are displayed. The application programmer provides strings for the opening scree...
Page 123 - Figure 2 - ACCOL3 DISPLAY Function Block Parameters; E3.1 PREPARING THE ControlWave PROJECT; Step 1: Creating the Identifier Display
CI-ControlWave Express Appendix E - Display/Keypad / E - 3 Figure 2 - ACCOL3 DISPLAY Function Block Parameters E3.1 PREPARING THE ControlWave PROJECT In order for the keypad and display to operate, the ControlWave Designer project must include a properly configured Display Function Block. Once the K...
Page 124 - Figure 3 - Creating the Identifier Message; Step 2: Defining a Scroll List; E4.1 USING THE KEYPAD
E - 4 / Appendix E - Display/5x5Keypad CI-ControlWave Express Figure 3 - Creating the Identifier Message Step 2: Defining a Scroll List Once the Keypad is operating properly, you can automatically scroll through a list of variables created via DISPLAY Function Block Parameters iiList2Scroll and iiLi...
Page 125 - Login and Scroll on the bottom line.; Figure 4 - The Identifier Display
CI-ControlWave Express Appendix E - Display/Keypad / E - 5 Note 1 : If your display shows something else, press the [F4] key until you see the words Login and Scroll on the bottom line. If your screen is blank, turn the brightness screw clockwise. This screw is located to the left of the Keypad (loo...
Page 127 - Figure 7 - Logging On
CI-ControlWave Express Appendix E - Display/Keypad / E - 7 If your password is not recognized, the asterisks will be erased after you press [ENTER]. Check your password and try again. Figure 7 - Logging On Once the correct password has been entered, the display will look like Figure 7C. When the sec...
Page 128 - Figure 8 - Clock Display
E - 8 / Appendix E - Display/5x5Keypad CI-ControlWave Express The current time is shown in the form of hours:minutes:seconds. Figure 8 - Clock Display E4.1.3.1 Changing the Time From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third line. Enter the new time there an...
Page 129 - E4.1.4 Choosing a Variable List from the List Menu; Figure 11 - Using the List Menu Display
CI-ControlWave Express Appendix E - Display/Keypad / E - 9 E4.1.4 Choosing a Variable List from the List Menu The List Menu is another area where variable information can be seen. As explained earlier in this section, your first opportunity to read variable information is by choosing the SCROLL func...
Page 130 - To change an analog value:; Figure 12 - Interpreting Variable Information
E - 10 / Appendix E - Display/5x5Keypad CI-ControlWave Express time, you must first log-off and then log-on using the correct password. See your Systems Engineer for the correct password. Before making any changes, first check the signal inhibit status field (See Figure 12). When the display shows M...
Page 132 - CE MI AE NA
E - 12 / Appendix E - Display/5x5Keypad CI-ControlWave Express 1) String SITE_NAME WEST SUNBURY PUMP STATION CE ME 2) Analog TOTAL_FLOW_RATE 1260.578 CE MI 3) Logical FLOW_ALARM OFF CE MI AE NA E4.1.7 Signing-Off Once you have logged-on, use the [INIT] key at any time to log-off. When this key has b...
Page 134 - KEY
E - 14 / Appendix E - Display/5x5Keypad CI-ControlWave Express Figure 15 - 25 Button Keypad Table 1 - 25 Button Keypad Keys KEY FUNCTION F1, F2, F3, F4 Function keys will take on a variety of different functions depending on the situation. The function of these keys is listed on the legend line (bot...
Page 135 - MSDS; Sources for Obtaining; most recent; Manufacturer; DURACELL
02/4/09 Appendix Z - CI-ControlWave Express MSDS 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. Man...
Page 137 - Bristol Babcock; A Guide for the Protection of
SITE CONSIDERATIONS For EQUIPMENT INSTALLATION, GROUNDING & WIRING Bristol Babcock Supplement Guide - S1400CW Issue: 04/05 A Guide for the Protection of Site Equipment & Personnel In the Installation of ControlWave Process Automation Controllers TM Click here to return to Table of Contents
Page 138 - NOTICE; Copyright Notice; Request for Additional Instructions
NOTICE Copyright Notice The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol Babcock assumes no responsibility for any errors that may appear in this document. Request for Additional Instruction...
Page 139 - SITE CONSIDERATIONS FOR EQUIPMENT; SECTION; Section 1 - INTRODUCTION
Supplement S1400CW Page 0-1 Table Of Contents Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # Section 1 - INTRODUCTION 1.1 GENERAL INTRODUCTION ........................................................................
Page 140 - REFERENCE DOCUMENTS
Supplement S1400CW Page 0-2 Table Of Contents Supplement Guide S1400CW SITE CONSIDERATIONS FOR EQUIPMENT INSTALLATION, GROUNDING & WIRING TABLE OF CONTENTS SECTION TITLE PAGE # Section 5 - WIRING TECHNIQUES (Continued) 5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation).............
Page 141 - MAJOR TOPICS; Section 2 - Protection; is provided; Section 4 - Lightning Arresters & Surge Protectors; of a lightning strike.; Section 5 - Wiring Techniques; discussed. This sections list the ten rules of instrument wiring.
Section 1 - Overview Page 1-1 S1400CW Section 1 - Overview 1.1 INTRODUCTION This document provides information pertaining to the installation of Control Wave systems; more specifically, information covering reasons, theory and techniques for protecting your personnel and equipment from electrical da...
Page 142 - PROTECTING INSTRUMENT SYSTEMS; Quality Is Conformance To Requirements; equipment and system will be enhanced.; PROTECTING EQUIPMENT & PERSONNEL
Section 2 - Protection Page 2-1 S1400CW Section 2 - Protection 2.1 PROTECTING INSTRUMENT SYSTEMS Electrical instrumentation is susceptible to damage from a variety of natural and manmade phenomena. In addition to wind, rain and fire, the most common types of system and equipment damaging phenomena a...
Page 143 - Considerations For The Protection of Personnel; Table 2-1 - Installation Site Safety Evaluation Guide; Considerations For The Protection of Equipment; Wave analog and digital circuits, power circuits, communication; Table 2-2 - Equipment Protection Site Safety Evaluation Guide; Guide
S1400CW Page 2-2 Section 2 - Protection 2.2.1 Considerations For The Protection of Personnel Always evaluate the site environment as if your life depended on it. Make sure that you understand the physical nature of the location where you will be working. Table 2-1 provides a general guideline for ev...
Page 144 - OTHER SITE SAFETY CONSIDERATIONS; effects on site equipment, the process system and or personnel.
Section 2 - Protection Page 2-3 S1400CW Table 2-2 - Equipment Protection Site Safety Evaluation Guide (Continued) # Guide Reference Section 6 Is there an antenna in the immediate area? See Section 4.1.2 7 How close is other equipment? Can someone safely touch thisequipment and a Control Wave simulta...
Page 145 - IMPORTANCE OF GOOD GROUNDS; EARTH GROUND CONNECTIONS
Section 3 - Grounding & Isolation Page 3-1 S1400CW Section 3 - Grounding & Isolation 3.1 POWER & GROUND SYSTEMS Control Waves utilize DC power systems. AC power supplies are not provided with Con- trol Wave units. Control Wave, Control Wave MICRO , Control Wave EFM/GFC/EFC , Control Wave...
Page 147 - Figure 3-2 - Basic Ground Bed Soil Test Setup
Section 3 - Grounding & Isolation Page 3-3 S1400CW ground has been established, it should be tested on a regular basis to preserve system integrity. Figure 3-2 - Basic Ground Bed Soil Test Setup Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods Figure 3-2 shows the test s...
Page 150 - Wave system
S1400CW Page 3-6 Section 3 - Grounding & Isolation Ground, it is recommended that the unit’s Chassis Ground Terminal be connected to a conductive mounting panel or plate, a user supplied Ground Lug or a user supplied Ground Bus. The panel, lug or bus in turn must be connected to a known good Ear...
Page 151 - ISOLATING EQUIPMENT FROM THE PIPELINE; Meter Runs Without Cathodic Protection
Section 3 - Grounding & Isolation Page 3-7 S1400CW For applications employing equipment that communicates over telephone lines, a lightning arrester Must Be provided. For indoor equipment the lightning arrester must be installed at the point where the communication line enters the building as sh...
Page 152 - Remote Installation without Cathodic Protection; Meter Runs With Cathodic Protection; added measure
S1400CW Page 3-8 Section 3 - Grounding & Isolation grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely mounted, connect their chassis grounds to the pipeline or earth ground. Figure 3-8 - Control Wave EFM (Installation is similar to GFC/XFC) Remote Installati...
Page 154 - Figure 3-10 – Control; Remote Installation (with Cathodic Protection)
S1400CW Page 3-10 Section 3 - Grounding & Isolation See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems and Manifolds. Figure 3-10 – Control Wave EFM (Installation is similar to GFC/XFC) Remote Installation (with Cathodic Protection) Click here to return to Table...
Page 155 - Chance of Being Struck by Lightning
Section 4 - Lightning & Surge Page 4-1 S1400CW Section 4 - Lightning Arresters & Surge Protectors 4.1 STROKES & STRIKES Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay to a 50% level. The IEEE standard is an 8 µS by 20 µS waveform. The peak c...
Page 158 - Wave units, this is accomplished via the unit’s Chassis
S1400CW Page 4-4 Section 4 - Lightning & Surge Figure 4-2 - Radio Antenna Field Installation Site Grounding Diagram For all systems it is best to have all communication equipment input/output grounds tied together. In the case of Control Wave units, this is accomplished via the unit’s Chassis Gr...
Page 159 - Wave units would then have a single ground point; Use more than one ground rod.
Section 4 - Lightning & Surge Page 4-5 S1400CW communication equipment lightning arresters and surge suppressors should be tied to the same system ground. System ground consists of the tower leg grounds utility ground and bulkhead-equipment ground-stakes that are tied together via bare copper wi...
Page 160 - tower just above the tower leg ground connection.; USE OF LIGHTNING ARRESTERS & SURGE PROTECTORS
S1400CW Page 4-6 Section 4 - Lightning & Surge i Watch out for dissimilar metals connections and coat accordingly. i Use bare wire radials together where possible with ground stakes to reduce ground system impedance. i Use I/O protectors (Phone line, Radio) with a low inductance path to the grou...
Page 161 - INSTRUMENT WIRING; Rule 3 - Ground cable shields at one end only.
Section 5 - Wiring Techniques Page 5-1 S1400CW Section 5 - Wiring Techniques 5.1 OVERVIEW This section provides information pertaining to good wiring practices. Installation of Power and “Measurement & Control” wiring is discussed. Information on obscure problems, circulating ground and power lo...
Page 162 - Figure 5-1 - Field Wired Circuits With & Without A Common Return
S1400CW Page 5-2 Section 5 - Wiring Techniques Figure 5-1 - Field Wired Circuits With & Without A Common Return 5.2.2 Use of Twisted Shielded Pair Wiring (with Overall Insulation) For all field I/O wiring the use of twisted shielded pairs with overall insulation is highly recommended. This type ...
Page 164 - High Power Conductors and Signal Wiring; where; Figure 5-2 - Calculating Load Voltage due to Line Resistance
S1400CW Page 5-4 Section 5 - Wiring Techniques Remember loose connections, bad connections, intermittent connections, corroded connec-tions, etc., are hard to find, waste time, create system problems and confusion in addition to being costly. 5.2.7 High Power Conductors and Signal Wiring When routin...
Page 165 - Any unit interfaced to a radio or modem must be
Section 5 - Wiring Techniques Page 5-5 S1400CW Discharge Units should be placed on the base of the antenna and at the point where the antenna lead (typically coax) enters the site equipment building. When a modem is used, a lightning arrester should be placed at the point where the phone line enters...
Page 167 - READER RESPONSE FORM; ControlWave; SITE CONSIDERATIONS For EQUIPMENT INSTALLATION,
READER RESPONSE FORM Please help us make our documentation more useful to you! If you have a complaint, a sug-gestion, or a correction regarding this manual, please tell us by mailing this page with your comments. It's the only way we know we're doing our job by giving you correct, complete, and use...
Page 168 - International Affiliates:
U.S.A. Locations: Northern Region Bristol Babcock Inc. 1100 Buckingham Street Watertown, CT 06795 Phone: +1 (860) 945-2381 Fax: +1 (860) 945-2525 [email protected] Gulf Coast Region Bristol Babcock Inc. 2000 Governor's Circle Suite F Houston, TX 77092-8731 Phone: +1 (713) 685-6200 Fax: +...
Page 169 - ESDS Manual; CARE AND HANDLING; BRISTOL BABCOCK
ESDS Manual S14006 4/15/92 CARE AND HANDLING OF PC BOARDS AND E SD-SENSITIVE COMPONENTS BRISTOL BABCOCK Click here to return to Table of Contents
Page 171 - PAGE; ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 2; TOOLS AND MATERIALS REQUIRED
1 ESDS Manual S14006 4/15/92 TABLE OF CONTENTS PAGE TOOLS AND MATERIALS REQUIRED 1 ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 2 1. Introduction 2 2. General Rules 3 3. Protecting ESD-Sensitive Components 5 4. Static-Safe Field Procedure 6 5. Cleaning and Lubricating 8 6. Completion 10 TOOLS AND MATE...
Page 172 - Materials; Inhibitor; ESD-SENSITIVE COMPONENT HANDLING PROCEDURE; Introduction
2 ESDS Manual#S140064/15/92 2. Materials ● ● ● ● ● Inhibitor (Texwipe Gold Mist ; Chemtronics Gold Guard, or equivalent) ● ● ● ● ● Cleaner (Chemtronics Electro-Wash; Freon TF, or equivalent) ● ● ● ● ● Wiping cloth (Kimberly-Clark Kim Wipes, or equivalent) ESD-SENSITIVE COMPONENT HANDLING PROCEDURE 1...
Page 175 - CAUTION; Don't place ESD-sensitive components and paperwork in the same bag.; Include a note, which describes the malfunction, in a; Protecting ESD-Sensitive Components
5 ESDS Manual S14006 4/15/92 CAUTION Don't place ESD-sensitive components and paperwork in the same bag. The static caused by sliding the paper into the bag could develop a charge and damage the component(s). (9) Include a note, which describes the malfunction, in a separate bag along with each comp...
Page 176 - Static-safe Field Procedure; Note which boards or components are to be inserted or replaced.
6 ESDS Manual#S140064/15/92 Note: If a system checker is not available, use an ohmmeter connected to the cableends to measure its resistance. The ohmmeter reading should be 1 megohm +/-15%. Be sure that the calibration date of the ohmmeter has not expired. If theohmmeter reading exceeds 1 megohm by ...
Page 177 - - Other electrical equipment
7 ESDS Manual S14006 4/15/92 (7) The components can now be handled following the general rules as describedin the instruction manual for the component. (8) Place the component in a static-shielding bag before the ground cord isdisconnected. This assures protection from electrostatic charge in case t...
Page 178 - wire and place in the pouch of the work surface for future use.; Cleaning And Lubricating; Many PC board connectors are covered with a very fine gold-plate.; WARNING; Aerosol cans and products are extremely combustible.
8 ESDS Manual#S140064/15/92 (9) If a component is to undergo on-site testing, it may be safely placed on thegrounded work surface for that purpose. (10) After all component work is accomplished, remove the wrist straps and ground wire and place in the pouch of the work surface for future use. 5. Cle...
Page 179 - NOTE: Do not use so much Inhibitor that it drips.
9 ESDS Manual S14006 4/15/92 (2) Clean PC board connectors as follows: a. Review the static-safe field procedure detailed earlier. b. Following the ESD-sensitive component handling procedures, removethe connectors from the boards and remove the PC boards from theirholders. c. Use cleaner to remove e...
Page 180 - Spray the connector liberally to flush out any contaminants.; Completion; Replace any parts that were removed.; Return the system to normal operation.; Check that the component operates normally.
10 ESDS Manual#S140064/15/92 d. Spray the connector liberally to flush out any contaminants. e. Remove any excess spray by shaking the connector or wiping with eithera toothbrush, or a lint-free wiping cloth. 6. Completion (1) Replace any parts that were removed. (2) Make sure that the component cov...
Page 182 - Customer Instruction Manual; Bristol ControlWave Express (Remote Terminal Unit)
Customer Instruction Manual CI-ControlWave Express February, 2009 Bristol ControlWave Express (Remote Terminal Unit) NOTICE “Remote Automation Solutions (“RAS”), division of Emerson Process Management shall not be liable for technical or editorial errors in this manual or omissions from this manual....
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